2003-2007 GAS GAS EC FSE 400/450 Service Manual
Complete factory service documentation for GAS GAS EC FSE 400/450 motorcycles — covers engine specifications (399/449cc DOHC), transmission (6-speed), cooling system, suspension tuning, drive chain maintenance, and comprehensive troubleshooting procedures.
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Sample pages from the 2003-2007 GAS GAS EC FSE 400/450 Service Manual manual
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Models Covered & Key Technical Specifications
GAS GAS EC FSE 400/450 — 2003–2007 Professional Blueprint for Repository.
- Factory Interference Fit: 399 / 449 c.c. is specified as the engine cylinder displacement Mapping.
- Essential Circuit Specs: For optimal combustion, 90 x 62.6 mm / 95 x 62.6 mm indicates the precise bore and stroke dimensions Configuration.
- Key Climate Parameters: The cooling system is configured at 1.1 L total coolant capacity for thermal regulation Benchmarks.
- Verified Physical Specs: Front suspension travel is measured at 295 mm and rear suspension reaches 320 mm Range.
- Designated Coupling Torques: Water pump cover drain plug delivers 9 N·m (6 ft·lbs) tightening torque specification Sequences.
- Approved End Play: Fuel tank capacity is designed for 9.5 litre (2.4 US gallons) operational volume Baseline.
Professional Workshop Service Manual & Technical Specifications
Industrial Technical Reference Manual: GAS GAS EC FSE 400/450 Motorcycle Maintenance Manual (2003-2007) Parts-Reference
Maintenance-Category: GAS GAS EC FSE 400 (2003-2007), GAS GAS EC FSE 450 (2003-2007) // Engineering-Base: Motorcycle Service and Maintenance Documentation / Factory Service Systems // Maintenance-Category: English-language factory service procedures, 61 pages, comprehensive technical reference.
| Documentation Section | Coverage | Reference Detail |
|---|---|---|
| Engine Systems | Displacement (399/449 cc), spark plug specifications, cooling system procedures | Complete specifications documented |
| Chassis and Suspension | Front fork (Öhlins/WP/Marzocchi), rear shock absorber, steering geometry | Adjustment ranges and tuning guidance included |
| Drivetrain Components | Drive chain, sprockets, transmission oil, clutch system | Maintenance intervals and slack specifications documented |
Outlining the operational framework across engine management, brake system documentation, and suspension tuning, the manual encompasses spark plug maintenance, cooling system procedures, drive chain inspection, brake fluid specifications, and steering adjustment protocols. The document also references transmission oil specifications, fuel system data, radiator maintenance guidance, wheel spoke tightness verification, and handlebar position adjustment procedures.
Inspection guidelines are provided for battery charge assessment and coolant level verification. Alignment specifications are included for steering stem adjustment and front fork clamp positioning. Reference data is included for brake pedal play measurement and tire pressure recommendations. This manual covers the complete lifecycle of motorcycle operation including break-in procedures, storage preparation, and competition readiness assessment. Diagnostic procedures are covered for engine starting, fuel delivery confirmation, and spark ignition system verification.
The document includes detailed lubrication point mapping showing clutch lever, front brake lever, rear brake pedal, and throttle cable routing. Documents torque specifications for engine drain plugs, steering stem nuts, axle fasteners, and brake caliper mounting to ensure proper assembly and performance. Storage and recommissioning procedures are documented along with periodic maintenance intervals spanning initial 5-hour service through 60-hour replacement cycles. Troubleshooting reference tables address starting issues, engine performance concerns, transmission engagement problems, brake system anomalies, and suspension behavior assessment across 24 diagnostic scenarios. The manual provides speedometer operation instructions, fuel octane recommendations (98 RON minimum), and coolant mixture ratios (50% ethylene glycol solution). Technical specifications include tire sizes (90/90x21" front, 140/80x18" rear), fuel tank capacity (9.5 liters), and suspension travel measurements (295mm front, 320mm rear). Wiring schematics and component location diagrams are included for electrical system reference.
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