SERVICE MANUAL SERVICE MANUAL - Gas Gas

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- If the straight portion of a course is longer, the secondary reduction ratio should be reduced so that the machine speed can be increased. - When the course has many corners or uphills or is wet, the secondary reduction rario should be increased so that gear shifting is possible with smooth acceleration. - Actually, the speed must be changed depending on the ground condition on the day of race and therefore, be sure to run through the racing circuit prior to a race and set the machine suitable for the entire course. - If the straight portion of a course on which the machine can be run at maximum speed is longer, the machine should be set so that the maximum machine speed can be developed toward the end of the straight course, but care should be taken not to over-rev the engine. - It is difficult to set the machine to be best suited for all portions of the circuit. Therefore, determine which circuit portions will have the greatest effect on lap time. Set the machine for these portions. Confirm your settings by recording lap times after each change. In this way the machine will deliver best performance for the entire circuit. Special Care According to Track Conditions. 1. In dry, dusty conditions (such as volcanic ash or fine powdery dust) special care must be given to keep the air cleaner element clean. 2. When riding on wet heavy clay the mud adheres to the tires and other parts of the vehicle. The mud can add significantly to the weight of the vehicle and therefore reduce performance. Take care to remove built-up mud from the tires and chassis after each ride, before drying occurs. EC FSE 2003 -52- 3. The engine works hardest in muddy conditions and the radiator can become clogged with mud. Take care not to overheat the engine in these conditions. The engine also works very hard when ridden in deep sand. 4. In muddy or sandy conditions adjust the chain looser than in other conditions as the chain and sprockets will pack with mud/sand and reduce chain slack. 5. Check chain and sprocket wear frequently when riding in mud or sand since wear is increased in these conditions. 6. In dusty conditions as the air cleaner collects dust, the engine runs richer. Therefore it may be advisable to run slightly leaner jetting (main jet) in very dusty conditions. SPARE PARTS carburation front sprocket rear sprocket front suspension springs rear suspension spring
PREPARATION FOR COMPETITION (1). Check: 1. Front axle shaft and nut, or axle clamp nut tightness 2. Front fork clamp bolt tightness 3. Handlebar clamp bolt tightness 4. Throttle grip screw tightness 5. Throttle grip operation 6. Front and rear brake hose installation 7. Front and rear brake fluid level 8. Front and rear brake disc and caliper installation 9. Front and rear brake function 10. Fuel tank installation 11. Shift pedal bolt tightness 12. Engine mounting bolt tightness 13. Engine sprocket installation 14. Brake pedal bolt tightness 15. Transmission oil level 16. Carburetor clamp screw tightness 17. Carburetor top cap tightness 18. Linkage tie rod mounting bolt tightness 19. Linkage rocker arm mounting bolt tightness 20. Rear shock absorber bolt tightness 21. Swing arm pivot shaft nut tightness 22. Rear axle shaft nut tightness 23. Rear sprocket bolts or nuts tightness 24. Rear brake pedal operation 25. Seat installation 26. Front and rear wheel sproke tightness 27. Front and rear tire air pressure 28. Drive chain slack 29. Coolant level EC FSE 2003 -53- (2). After first race maintenance 1. Air cleaner element 2. Drive chain slack 3. Rear sprocket nuts 4. Sprockets 5. Front and rear tire air pressure 6. Front and rear axle shaft nuts 7. Pivot shaft nut 8. Muffler, silencer bolts or nuts 9. Front, rear fender mounting bolts or nuts 10. Fuel tank, seat mounting bolts or nuts 11. Front and rear brakes 12. Steering play 13. Fuel tank fill 14. Coolant level check (3) Maintenance notice for after riding on dusty course If dirt or dust gets through into the engine, the crankshaft big end will wear excessively. After riding, inspect the crankshaft big end. If the crankshaft big end is worn past the service limit, replace the crankshaft big end with a new one. (4) Maintenance notice for after riding in rain on muddy course 1. Apply grease to swing arm pivot and rear suspension system 2. Inspect the drive chain and rear sprocket wear 3. Clean the air cleaner element 4. Check the cylinder and crankshaft big end bearing 5. Grease the throttle grip and cable (5) Suggest spare parts Look service manual
Page 1 and 2: SERVICE MANUAL ENGLISH
Page 3 and 4: Important notice Whenever you see t
Page 5 and 6: SPECIFICATIONS: ENGINE Engine 4 cyc
Page 7 and 8: Location of Components GAS GAS EC F
Page 9 and 10: SIDE STAND To operate the side stan
Page 11 and 12: START THE ENGINE - You have to assu
Page 13 and 14: STOPPING THE MOTORCYCLE For maximum
Page 15 and 16: BATTERY This battery is maintenance
Page 17 and 18: CAUTION Use of incorrect coolant so
Page 19 and 20: - Visually inspect the old coolant.
Page 21 and 22: (D) 5. Remove the tank rubber (D).
Page 23 and 24: - Clean the element in a bath of a
Page 25 and 26: - Remove the inner pipe mounting ri
Page 27 and 28: NOTA: For maximum strech resistance
Page 29 and 30: Front Brake Lever Play Adjust the f
Page 31 and 32: To check the steering adjustment, u
Page 33 and 34: CAUTION The left and right fork tub
Page 35 and 36: (1) REAR SUSPENSION (1). Fork tube
Page 37 and 38: WARINING Improper removal of the sp
Page 39 and 40: Bolt and Nut Tightening Every day b
Page 41 and 42: LUBRICATION Lubricate the points sh
Page 43 and 44: The oil is pumped from the oil rese
Page 45 and 46: WARNING Using a filter with an inco
Page 47 and 48: Troubleshooting Improper Settings L
Page 49: Front fork doesn´t respond to smal
Page 53 and 54: To change the time: - Press mode un
Page 55 and 56: 4 5 6 7 8 9 10 TROUBLE CAUSE REMEDY
Page 57 and 58: 17 18 19 20 TROUBLE CAUSE REMEDY Sh
Page 59 and 60: WARRANTY REGULATIONS Manufacturer's

SERVICE MANUAL SERVICE MANUAL - Gas Gas

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