Market Segment:
Dual-sport / Enduro motorcycle segment, targeting riders seeking off-road capability with street legality.
Key Competitors Era:
Competed against models from KTM (e.g., EXC series), Husqvarna, Honda (e.g., XR series), Yamaha (e.g., WR series), and Suzuki (e.g., DR-Z series) in the mid-2000s dual-sport market.
Distinguishing Features:
Known for robust construction, capable off-road performance, and a strong engine for its displacement. GASGAS historically focused on competitive off-road machines.
Primary Coverage:
Service, Repair, Maintenance, Rebuilding, Refurbishing, Restoration
Estimated Page Count:
High (typically 300-600+ pages for comprehensive factory service manuals)
Manual Type:
Workshop Service Repair Manual
Language:
English (presumed based on product description)
Engine Systems:
Engine assembly, disassembly, lubrication, cooling, fuel delivery, ignition, exhaust, emissions control, electrical components (starter, alternator), internal engine components (pistons, rings, valves, camshafts, crankshaft).
Transmission Systems:
Gearbox operation, disassembly, assembly, clutch, shift mechanism, lubrication, component wear analysis.
Chassis Systems:
Frame inspection and repair, suspension (forks, shock absorber), steering system, wheel bearing maintenance, brake system overhaul (master cylinders, calipers, lines, pads, rotors), wheel and tire specifications.
Electrical Systems:
Wiring diagrams, lighting system, battery management, charging system, ignition system components, diagnostic connector locations, troubleshooting electrical faults.
Bodywork And Controls:
Body panel removal and installation, seat, handlebars, footpegs, levers, cables (throttle, clutch), linkage adjustments.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, brake fluid checks and replacement, coolant checks and replacement, spark plug inspection and replacement, air filter cleaning/replacement.
Major Repairs:
Engine top-end overhaul (cylinder, piston, valves), engine bottom-end rebuild (crankshaft, connecting rod), transmission rebuild, fork seal replacement, shock absorber service, brake caliper rebuild, carburetor cleaning and adjustment.
Troubleshooting:
Diagnostic procedures for common starting issues, running problems, electrical faults, braking issues, and performance degradation.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Depth Of Coverage:
Comprehensive: Covers everything from basic fluid checks and adjustments to complete engine and transmission overhauls, including detailed torque specifications, component tolerances, and diagnostic flowcharts.
Engine Type:
Single-cylinder, four-stroke
Displacement:
Approximately 450cc (specific bore and stroke would be detailed in the manual)
Cooling System:
Liquid-cooled (radiator and fan assembly likely present)
Valve Train:
DOHC (Double Overhead Camshaft) or SOHC (Single Overhead Camshaft) configuration, with specific valve count (e.g., 4 valves).
Horsepower Estimate:
Estimated 40-50+ HP at peak, depending on specific tuning and state of tune. Exact figures would be in the manual.
Torque Estimate:
Torque figures would be detailed, contributing to strong off-road pulling power.
Fuel Delivery:
Carburetor (likely a Keihin FCR or similar performance carburetor). Specific model and jetting details would be covered.
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with electronic timing.
Wheelbase:
Typical for dual-sport/enduro, around 57-59 inches. Precise measurement in manual.
Seat Height:
High seat height, common for off-road motorcycles. Specific range will be in manual.
Dry Weight:
Likely in the range of 250-280 lbs (113-127 kg). Manual will provide exact spec.
Fuel Tank Capacity:
Typically 2.5-3.5 gallons (9.5-13 liters). Manual will confirm.
Crash Test Ratings:
Not applicable for this type of motorcycle as per automotive industry standards.
Braking System:
Hydraulic disc brakes front and rear. Manual details caliper, rotor, and master cylinder service.
Suspension Features:
Adjustable front forks and rear shock absorber (rebound, compression damping). Manual covers service and tuning.
Lighting System:
Headlight, taillight, brake light, turn signals (depending on street legality). Manual covers bulb replacement and wiring.
Oil Change Interval:
Typically every 15-25 hours of riding or annually, whichever comes first. Specifics in manual.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Daily or every few rides.
Chain Maintenance:
Lubrication and adjustment every 500-750 miles or more frequently based on conditions.
Valve Adjustment:
Typically every 5,000-10,000 miles or as per manual recommendations. Crucial for engine health.
Engine Oil Type:
JASO MA certified motorcycle oil, typically SAE 10W-40 or 15W-50. Manual will specify exact viscosity and API rating.
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture, typically 50/50. Manual will specify compatibility.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid. Manual will specify precise type.
Transmission Oil Type:
Dedicated transmission oil or specific engine oil depending on gearbox design. Manual will specify.
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings, chain and sprockets are common wear items requiring periodic replacement.
Potential Engine Concerns:
For this era, potential concerns might include valve guide wear, camshaft lobe wear if lubrication is neglected, and occasional carburetor jetting issues.
Electrical Quirks:
Wiring harness integrity, especially at stress points, and battery terminal corrosion can be common in off-road environments.
