GAS GAS EC FSE 400 450 Service Repair Manual 2003-2005

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This manual covers the EC FSE models, including the 400cc and 450cc variants, produced between 2003 and 2005. The EC FSE line exemplifies a heritage of agile and performance-oriented off-road...

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Type: Motorcycle

Vendor:

Sku: 137355

Tags: 2003 2004 2005 EC FSE 400 EC FSE 450 EC Models Gas Gas Motorcycle Motorcycles

Product variants

Description

This manual covers the EC FSE models, including the 400cc and 450cc variants, produced between 2003 and 2005. The EC FSE line exemplifies a heritage of agile and performance-oriented off-road motorcycles, often built upon trial bike platforms with adaptations for enduro and supermoto riding. These models were known for their competitive performance within their classes during a period of significant growth for the brand, offering riders a capable machine for various off-road disciplines. This comprehensive A-Z Service Repair Workshop Manual provides detailed information essential for the maintenance and repair of all EC FSE 400 and 450 models from the specified years. It covers a wide array of systems including the engine and clutch, transmission, cooling, fuel and exhaust, ignition and electrical systems, brakes, wheels, tires, steering, suspension, and frame. The manual offers extensive guidance on routine maintenance, fault finding, troubleshooting, engine rebuilds, suspension overhauls, and electrical diagnosis, supported by numerous high-quality pictures and diagrams. It is intended for professional mechanics and knowledgeable DIY enthusiasts seeking professional-quality information for immediate repairs and ongoing upkeep.

🏷️ Basic Information

Identification

Make:

Gas Gas

Model:

EC FSE

Engine Options:

400cc, 450cc

Codes

Model Years Covered:

2003, 2004, 2005

👋 Introduction

Market Position

Target User:

Professional mechanics and knowledgeable DIY enthusiasts

Value Proposition:

Provides professional-quality information for immediate repairs and maintenance

Competitive Analysis

Advantage:

Instant download availability, comprehensive coverage comparable to OEM manuals

Key Features

Delivery Method:

Instant Download

📋 Manual Details

Coverage Areas

Manual Scope:

Comprehensive A-Z Service Repair Workshop Manual

Model Coverage:

All EC FSE 400 and 450 models within the specified years

Page Count

Estimated Page Count:

Estimated 500-800+ pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Engine And Clutch:

Complete overhaul, diagnosis, repair of engine components, cylinder head, piston, crankshaft, clutch system (friction plates, pressure plates, springs)

Transmissions:

Gearbox inspection, disassembly, assembly, gear selection mechanism, lubrication

Cooling Systems:

Radiator, water pump, coolant circulation, thermostat, hoses, fan operation

Fuel And Exhaust:

Carburetor (if applicable) or fuel injection system, fuel pump, fuel filter, fuel lines, exhaust system components, emissions control

Ignition And Electrical:

Ignition system components (coil, CDI unit, spark plug), battery, charging system, starter motor, lighting, switches, fuses, diagnostic connectors

Brakes And Brake Assembly:

Hydraulic brake systems (front and rear), calipers, master cylinders, brake lines, brake pads, brake discs, bleeding procedures

Wheels And Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing, rim specifications

Steering And Suspension:

Front fork (inner workings, seals, oil changes), rear shock absorber, linkage systems, steering head bearings, handlebar controls

Frame And Bodywork:

Frame integrity checks, subframe, plastics, seat, fuel tank, fender replacement

Wiring Diagrams:

Detailed electrical schematics for all systems, component identification, troubleshooting pathways

Procedures Included

Maintenance And Servicing:

Routine inspections, oil changes, filter replacements, chain adjustment, spark plug checks, valve clearance adjustments

Fault Finding Troubleshooting:

Diagnostic flowcharts, common problem identification, solutions for electrical, mechanical, and fuel system issues

Engine Rebuild:

Complete engine disassembly, inspection, part replacement, and reassembly procedures

Suspension Overhaul:

Front fork seal replacement, damper rod service, rear shock absorber rebuild guidance

Electrical Diagnosis:

Testing of sensors, actuators, charging system, starter circuit, ignition system

Technical Depth

Repair Coverage:

All major repair topics covered in great detail, from basic adjustments to complete overhauls

Diagnostic Capabilities:

Advanced troubleshooting guidance for complex issues

Visual Aids:

Numerous high-quality pictures and diagrams to illustrate procedures and components

📊 Manual Specifications

File Format

File Type:

Compatibility:

All operating systems (Windows 95/98/2000/Me/XP/Vista/7/8+, macOS, Linux)

Print Quality

Image Resolution:

High resolution for clear viewing and printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke (typical for EC FSE models)

Bore X Stroke 400:

Approx. 89mm x 71mm (estimated for 400cc variant)

Bore X Stroke 450:

Approx. 95mm x 71mm (estimated for 450cc variant)

Displacement 400:

Approx. 397cc

Displacement 450:

Approx. 449cc

Cooling Method:

Liquid-cooled

Valve Train:

DOHC, 4 valves per cylinder (typical)

Performance

Estimated Horsepower 400:

Approx. 35-40 HP (stock, depends on market tune)

Estimated Horsepower 450:

Approx. 40-45 HP (stock, depends on market tune)

Fuel System

Fuel Delivery:

Carburetor (Keihin FCR likely) or Fuel Injection depending on specific sub-model/market

Fuel Type:

Unleaded Gasoline (95 RON recommended)

Lubrication

Oil Capacity Engine:

Refer to manual for specific oil capacity (typically around 1.2-1.5 liters for this class)

Recommended Oil Viscosity:

SAE 10W-40 or 15W-50 (API SG or higher, JASO MA)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh manual gearbox

Features

Clutch Type:

Wet multi-plate clutch

Transmission Oil Capacity:

Refer to manual for specific capacity (often shares oil with engine)

📐 Dimensions

Exterior

Wheelbase:

Refer to manual for exact specifications (typically around 1470-1490mm)

Seat Height:

Refer to manual for exact specifications (typically around 900-920mm)

Weights

Dry Weight:

Refer to manual for exact specifications (typically around 120-130 kg)

Fuel Tank Capacity:

Refer to manual for exact specifications (typically around 9-10 liters)

🛡️ Safety Features

Ratings

Safety Standards:

Designed to meet relevant motorcycle safety standards for its production era

Active Features

Braking System:

Hydraulic disc brakes front and rear

Lighting:

Headlight, taillight, brake light, turn signals (depending on road legality specifications)

💡 Technology Features

Infotainment

Infotainment System:

N/A (Performance off-road motorcycle, no infotainment features)

Driver Assistance

Driver Assistance Features:

N/A (Performance off-road motorcycle, no electronic rider aids beyond basic engine management)

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 20-30 operating hours or annually (refer to manual for precise recommendations)

Air Filter Cleaning:

Frequent checks and cleaning, especially in dusty conditions (e.g., every 5-10 operating hours)

Spark Plug Inspection:

Every 20-40 operating hours

Valve Clearance Check:

Every 50-100 operating hours (critical for engine longevity)

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors (50% mixture with distilled water)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Known Issues

Typical Wear Items:

Clutch plates, fork seals, wheel bearings, chain and sprockets are common wear items in off-road motorcycles.

Electrical Connections:

Corrosion or loose connections in off-road environments can lead to intermittent electrical faults.

📚 Vehicle History

Brand Heritage

Brand Origin:

Gas Gas is a Spanish motorcycle manufacturer known for off-road and trial bikes.

Model Evolution

Ec Fse Line:

The EC FSE line represented Gas Gas's foray into the enduro and supermoto segments, often based on their trial bike platforms with modifications for broader off-road use.

Production

Manufacturing Era:

Early to mid-2000s, a period of growth and diversification for Gas Gas.

🏆 Awards & Recognition

Recognitions

Model Recognition:

Gas Gas motorcycles of this era were generally well-regarded within the off-road community for their agility and performance, often competing favorably in their respective classes.