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Table of Contents
Related Manuals for GAS GAS EC 125 Racing 2013
Summary of Contents for GAS GAS EC 125 Racing 2013
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Page 3: Foreword
Foreword GAS GAS thanks you for the trust you have placed in us. By choosing the new GAS GAS EC 2013 you have become part of the great GAS GAS family and, as a user of the number one manufacturer of off-road motorbikes, you deserve the distinguished treatment that we wish to offer to you both in our after-sale relationship and in the explanations that we provide in this manual. -
Page 4: How To Use This Manual
HOW TO USE THIS MANUAL Motorcycle riding, if improverly conducted, has the potential to cause environmental problems as well as conflicts with other people. Responsible riding use of your motorcycle will ensure that these Read this Manual carefully. You will find it contains all the necessary problems and conflicts do not develop. -
Page 5: Table Of Contents
TABLE OF CONTENTS Foreword...................3 Exhaust System ................24 How to use this manual..............4 Drive Chain Guide................25 Table of contents................5 Handlebar ..................27 Specifications..................6 Brakes.....................28 Location of components..............8 Steering...................29 Side Stand ..................10 Steering blockage ................30 Fuel ....................10 Front Fork ..................31 Serial Number .................12 Rear suspension ................34 Homologation Plate.................12 Wheels ....................36... -
Page 6: Specifications
SPECIFICATIONS ENGINE 2 cycles, single cylinder, crankcase intake, liquid cooled 125 cc Engine Bore and stroke 54 x 54.5 mm Displacement 124 cc Carburettor, diameter of diffusor Lubrication system Mixture 100% Synthetic Oil 50:1 = 2% Mineral Oil (Only USA) 32:1 = 3% Starting system Starting lever... - Page 7 Primary reduction 3,32 (63/19) Final reduction 4,17 (50/12) Transmission oil Capacity 750 cc Type 10W30 API SF or SG CHASSIS Type Tubular, semi-double cradle Tire size Front EC - 90/90 x 21 Rear EC - 140/80 x 18 Suspension Front Inverted telescopic fork ø...
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Page 8: Location Of Components
LOCATION OF COMPONENTS GAS GAS EC Front Brake fluid reservoir Clutch lever Throttle grip Starter lever Clutch fluid reservoir Front brake lever Multifunction scoreboard Steering, lights, horn and headlamp controls Fuel tank cap Burglar by locking direction - 8 -... - Page 9 GAS GAS EC 17- Shift pedal 25- Kick-start pedal 9- Brake disc 18- Muffler 26- Exhaust 10- Front suspension 19- Seat 27- CDI switch 11- Fuel tank 20- Gas reservoir 28- Front axe puller 12- Carburetor 21- Chain guide 29- Skid plate 13- Rear shock absorber 22- Chain 30- Rear brake pump intercooler...
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Page 10: Side Stand
SIDE STAND FUEL To set the side stand only turn it until it contacts the stopper, then The GAS GAS EC models have 2-cycle engines that require a the side stand will be parallel to the ground and rest securely. mixture of gasoline and oil. - Page 11 RECOMMENDED FUEL Recommended oil: Use gasoline with an octane rating equal to or higher than that shown 2-CYCLE SYNTHETIC in the table. NOTE If the recommended oil is not available, use only oil designed OCTANE RATING METHOD MINIUM for racing with 2-cycle engines. RATING Antiknock Index (RON+MON)/2...
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Page 12: Serial Number
STARTING THE ENGINE SERIAL NUMBER (A) It is stamped on the steering pipe. It indicates the frame number 1. Make sure the motorcycle is in the neutral position. 2. Turn the gasoline cock (A) clockwise to the "ON" position. registered for this motorcycle. HOMOLOGATION PLATE (B) This motorcycle carries its corresponding homologation plate where Open... -
Page 13: Shifting Gears
NOTE SHIFTING GEARS - When the engine is already warm or on hot days, open the throttle instead of using the choke knob. The transmission is a 6-speed, of the return shift type. A return shift - If the engine is flooded, kick with the throttle fully open. means that to go from first gear to third gear it must go first through - If the clutch lever is pulled, the motorcycle can be the second gear, that is to say that it upshifts gears one by one. -
Page 14: Stopping The Motorcycle
STOPPING THE MOTORCYCLE inspection of the spark plug shows this to be the case, replace the standard spark plug with another of a higher heat range. For maximum deceleration, close the throttle (A) and apply both front and rear brakes. Disengage the clutch as the motorcycle comes Perform the break-in period following these steps: to a stop. -
Page 15: Maintenance Schedule
MANTENANCE SCHEDULE Check / Inspect Adjust Change / Replace Clean Apply grease / Item Lubricate Clutch At each fill up At each fill up At each fill up* At each fill up Discs 3 fill ups 3 fill ups* 3 fill ups* Throttle cable 1 fill up Spark plug... - Page 16 MANTENANCE SCHEDULE Check / Inspect Adjust Change / Replace Clean Apply grease / Item Lubricate Brake caliper piston seal & dust seal Every 2 years Brake hose and pipe Every 4 years Spoke tightness and rim runout 1 fill up 1 fill up* 1 fill up* Lubricate drive chain...
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Page 17: Electronic Ignition
ELECTRONIC IGNITION - If the marks are not aligned, loosen the magnetic inertia wheel screws and turn it. - Tighten the screws securely. This motorcycle uses a capacitor discharge ignition system (CDI). - Install the magnetic flywheel cover. The ignition system should never require adjustment unless the stator of the magnetic flywheel was incorrectly installed during engine NOTE reassembly. - Page 18 CAUTION If the lowest ambient temperature encountered falls below the freezing If high water pressure is used the radiator fins could be damaged point of water, protect the cooling system. Use a permanent type of and impair the radiator effectiveness. antifreeze in the cooling system (distilled water and ethylene glycol Do not obstruct or deflect airflow through the radiator by installing and corrossion inhibitors for aluminium engines and radiators).
- Page 19 WARNING Total quantity To prevent severe scalding do not remove the radiator cap or try to Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze change liquid, when the engine is still hot. Wait until it cools. 50%). Capacity: 1.1 L Coolant Replacement Coolant level Coolant should be changed periodically to ensure long engine life.
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Page 20: Spark Plug
Standard Spark Plug WARNING 125 cc Denso W27ESR-U 0.7-0.8 mm OR NGK BR9EG If coolant gets on the tires will make them very slippery and can cause an accident. The spark plug should be removed periodically to check its gap. If the plug is oily or has carbon deposits, clean it with a sandblaster. - Page 21 Oil level inspection Oil change - Wait a few minutes if the motorcycle has been operating. NOTE The engine must be completely cool and then warm up the engine again for a few minutes to normal operating temperature, to register the correct engine oil temperature and to obtain an accurate oil level measurement.
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Page 22: Air Cleaner
- Place a lint-free towel in the intake port of the carburetor so no AIR CLEANER dirt is allowed to enter the carburetor. A clogged air cleaner restricts the engine air intake, increasing fuel CAUTION consumption, reducing engine power, and causing spark plug fouling. Do not turn the filter since it can be easily damaged or torn. -
Page 23: Throttle Cable
- Inspect the filter for damage such as tears, hardening, or shrinkage. - If the free play cannot be set by adjusting the cable, remove the If damaged, replace it or it will allow dirt into the carburetor. cable protector in the throttle body. Make the necessary free play - Apply grease to all connections and screws in the air cleaner and adjustments with the tensor at the end of the cable, tighten the intake ports. -
Page 24: Clutch
WARNING EXHAUST SYSTEM Riding with a damaged throttle cable could be dangerous. The exhaust and the muffler reduce the noise and send gases away from the rider. CLUTCH If the exhaust is badly damaged, dented, cracked or rusted, replace it with a new one. Replace the muffler fibre if the exhaust noise The clutch lever should have a maximum play of 3 mm. -
Page 25: Drive Chain Guide
Changing the silencer packing - Remove all cover rivets with a drill. - Remove the inside core of the muffler. - Replace the muffler fibre by wraping it around the inner tube. - Reinstall the assembly. -(A). Screw. -(B). Silencer. -(C). - Page 26 Drive Chain Slack Adjustment - Tighten the chain tensor nuts (B). - Tighten rear axle nut to 98 Nm. - Loosen the rear axle nut (A). - Rotate the wheel, measure the chain slack again at the tightest - Turn the nuts on the chain adjusting tensors (B) until the drive position, and readjust if necessary.
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Page 27: Handlebar
Chain Guide Slider Apply oil to the sides of the chain rollers for better oil penetration. Wipe off any excess oil. Visually inspect the upper and lower chain slider at the location of the swingarm. If damaged or worn, replace it with a new part. (A). -
Page 28: Brakes
Rear brake pedal position Tighten the bolts, front first and then the rear, to 25 Nm of torque. When the brake pedal is in rest position, there should be a free play of 10 mm. Check the brake for good braking power and no brake drag. If the handlebar is installed correctly, there will be an... -
Page 29: Steering
Brake fluid CAUTION Inspect the brake fluid level and change it periodically. The brake Do not spill brake fluid onto any painted surface. Do not use fluid fluid should also be changed if it becomes contaminated with dirt or from a container that has been left open or that has been unsealed water for a long time. -
Page 30: Steering Blockage
To check the steering adjustment use a stand under the chassis, - Install the suspension top bridge (D). and lift the motorcycle off the ground. Move the handlebar lightly to - Tighten the steering stem nut, and front fork washers and screws. either side;... -
Page 31: Front Fork
- Using a stand under the frame, and stabilize the motorcycle. CAUTION - Place a support under the engine so that the front wheel is raised Never leave the key in the latch. If the steering is turned to the left off the ground. - Page 32 - Remove the suspension srping guide. Use the standard settings to adjust the rebound (turn it 11 positions - Use a wrench to remove the fork springs. counterclockwise. - Put the oil level gauge on the upper portion of the fork tube, and measure the distance from the top of the fork tube to the oil level COMFORT: 24 CLICKS STANDARD: 20 CLICKS...
- Page 33 - Pull the hydraulic rod out slowly. Suspension tube spring - At this time, the fork oil pours out of the hydraulic Different springs are available in accordance with the rider´s weight rod hole, keep it raised to let it drain until it stops. or the road conditions.
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Page 34: Rear Suspension
Shock absorber extension adjustment To adjust, turn by hand the extension adjuster in the lower part of the shock absorber until a “CLICK” is heard. COMFORT: 26 CLICKS STANDARD: 24 CLICKS SPORT: 22 CLICKS (Counterclockwise from fully closed position). (1). Suspension top bridge position. (A). - Page 35 (A). Nut. (B). Spring. (C). Locknut. - Tighten the locknut securely. - After adjustment, move the spring up and down to make sure that the spring is fully seated. - Install the parts removed. Spring adjustment Rear shock absorber spring replacement - Remove the seat and side covers.
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Page 36: Wheels
Wheel rim runout WARNING Improper installation of the rear shock absorber spring may cause Place a dial indicator at the rim side, and spin the wheel by hand the spring and any of its related parts to be ejected at high velocity. to measure the axial runout. -
Page 37: Cleaning
CLEANING CAUTION To avoid excessive ageing of the plastic parts and other washable pieces of the motorcycle, it is suggested that these items must be 1- Preparation for washing washed carefully. If the washer applies water at high pressure and/or Before washing the motorcycle, precautions must be taken to prevent temperature, take the precaution of maintaining the washer outlet gun at a distance of 30 centimeters minimum, this will ensure the... -
Page 38: Bolts And Nuts Tightening
BOLTS AND NUTS TIGHTENING Every day before riding, check the tighteness of the bolts and nuts described here. Also check that all other fasteners are in place and in good condition. 30,31 9- Trailing plate bolts. 17- Chain guide bolts. 1- Front and rear wheel. - Page 39 Torque Values Table Tighten all bolts and nuts to the proper torque using an adequate wrench. A bolt or nut loose might damage the motorcycle or even cause an accident. PART NAME PART NAME Brake caliper mounting bolt Cylinder head screws Disc mounting screw Cylinder nut Engine mounting bolt...
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Page 40: Lubrication
LUBRICATION Lubricate the points shown here, apply either engine oil or grease, periodically or whenever the vehicle has been operated under wet or rainy conditions, and especially after using high water pressure. Before lubricating each part, remove any rusty spots with rust remover and wipe off any grease, oil, or dirt. -
Page 41: Tunning (Carburetor And Suspension)
Drive Chain Lubrication NOTE The main jet should be increased or decreased 1 to 5 sizes and Lubricate the drive chain after driving on wet terrein or when the tested until the engine gives maximum power. chain looks dry. A high viscosity oil is preferred rather than a lower viscosity because it will stick to the chain longer and lubricate the chain better. - Page 42 Idling nozzle and mixture adjustment screw Carburetor jet needle Controls the mixture from the closed position to an opening of 1/8 The jet needle and jet needle hole together have their greatest effect of throttle range, but has little effect on full throttle. To adjust the in the one-half throttle range.
- Page 43 Check the condition of the spark plug, make sure the ingnition timing Correction factors: is correct, service the air cleaner element, decarbonize the exhaust tube (For altitude or temperature changes). If you machine has run properly up to this point, it is possible that the problem is elsewhere;...
- Page 44 ALTITUDE ALTITUD (104) (86) (68) (ºC) (50) (ºF) °C (32) (°F) (14) 0.86 0.88 0.90 0.92 0.94 0.96 0.98 1.00 1.02 1.04 1.06 CORRECTION FACTOR FACTOR DE CORRECCIÓN NEEDLE POSITION / AIR SCREW OPENING CORRECTION FACTOR 1.06 or HIGHER 1.06 - 1.02 1.02 - 0.98 0.98 - 0.94 0.94 or LOWER...
- Page 45 2. SUSPENSION TUNE-UP - When the oil level is raised: The spring effects become more progressive, and the front fork This adjustment is very critical because if an improperly tuned action feels harder at the end of travel. suspension will keep even the best rider from attaining the full benefit If the front suspension is making jounce stops, raise the oil level 10 of his machine´s ability.
- Page 46 Troubleshooting Improper Settings Symptoms of the rear shock absorber: Listed below are some symptoms of improper suspension settings - Too hard: and the most likely means of correcting them. 1. The suspension is too stiff • Compression damping is too high. The proper settings can be achieved by applying the information in •...
- Page 47 Riding experience Front and rear compatibility: Beginner: Soft spring with rebound. Use this procedure to determine if the suspension is balanced. Place Experienced: Harder spring. the motorcycle upright. While standing next to the right side of the motorcycle, hold the front brake and press the rear brake pedal firmly. If the motorcycle maintains its level attitude as the suspension is Rider's weight compressed, the spring rates are well balanced.
- Page 48 Does the front fork fails to respond to small potholes while Adjustments that depend on the conditions of the jounce stops managing wide turns? (rear shock absorber). Front Fork is hard: 1. Decrease the compression or rebound damping. - Suspension jounce stops at low speed, increase the spring preload 2.
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Page 49: Final Recommendatios
- Actually, the speed can be changed depending on the terrain FINAL RECOMMENDATIONS conditions on the day of the race and therefore, be sure to run through the racing circuit prior to a race and set the machine PREVENTIVE ADVICE suitable for the entire course. -
Page 50: Homologation
HOMOLOGATION: (NOT APPLICABLE TO CROSS COUNTRY MODELS) The vehicle you have just acquired has been homologated under the directives of the EU and complies with all the homologation requirements demanded. Compulsory homologation elements required, among others, when travelling on a public road and to meet periodical vehicle inspection approval at state controlled plants are listed below. -
Page 51: Preparation For Competition
PREPARATION FOR COMPETITION (2). After 1 day of racing competition: (1). Check: 1. Clean the air cleaner element. 2. Adjust drive chain slack. 1. Front axle and bridges nuts tightness. 3. Tighten rear sprocket nuts. 2. Front fork clamp bolts tightness. 4. -
Page 52: Storage
STORAGE For extended storage of the motorcycle, you must do the following: - Clean the motorcycle thoroughly. - Start the engine for about 5 minutes to warm up the transmission oil and then drain it (refer to the transmission section). - Fill with new transmission oil. -
Page 53: Gas Gas Multifunction Instructions
MULTIFUNCTION GAUGE The multifunction device is water resistant, has 3 buttons, 2 LEDs. And a brightly lit LCD. Amber warning led Red warning led LCD screen Left button Middle button or MODE Right button Remote Switch It provides information about the speed, average speed, maximum speed, covered distance, total covered distance, operation time, total operation time, environmental temperature, engine temperature, battery voltage, time and maintenance. - Page 54 QUICK GUIDE NORMAL MODE TEMPORAL DATA RESET Enable the screen backlight for 3 seconds, if the icon Resets temporal data (MS, LO is displayed on the screen or the temperature is TT, DST y RT) below -5ºC will not turn on. Switch between screens in normal mode.
- Page 55 SPECIFICATIONS Operating temperatura: 0ºC to 60ºC (32ºF to 140ºF) Storage temperature: -20ºC to 80ºC (-4ºF to 176ºF) Battery: 3V CR2032 (About 1 year life )
- Page 56 CONFIGURATION Enter Configuration Mode Set Clock Format To enter the configuration mode, To switch between 12h and 24h press the 3 front buttons for 3 format use the left button seconds, release them to continue. To confirm press the button Set Speed Units Set Time To switch between Km/h and MPH...
- Page 57 CONFIGURATION Set High Temperature Warning Set Maintenance Reminder When programmed engine When programmed kilometers or temperature is reached, the amber miles are reached, the maintenance warning led will turn on. reminder icon will turn on. The warning will be disabled if the Change the blinking digit with the value is 0.
- Page 58 MEASURE OF THE WHEEL CIRCUMFERENCE SCREENS IN NORMAL MODE Screen 1 The following information is displayed: Actual speed (SPD) Distance (DST) Engine Temperature (ºC) Ride time (RT) Voltage (V) Clock Diameter (mm) Screen 2 The following informations is displayed: Medium speed (AS) Total Distance (DST) Ambient Temperature (ºC) Method 1...
- Page 59 SCREENS IN NORMAL MODE SLEEP MODE Screen 3 The following information is displayed: Maximum speed (MS) Odometer (ODO) Maximum EngineTemperature Accumulated ride time (ART) Maximum Voltage (MAX V) and Minimum Voltage (MIN V) Aternately displays min/max If the device is not used for 5 minutes, it will be automatically voltage and avg/max speed every into sleep mode to save battery.
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Page 60: Troubleshooting
MALFUNCTION POSSIBLE CAUSE REMEDY The engine operates irregularly - Ignition rotor damaged. - Replace the rotor. - Water in fuel. - Drain the fuel tank and fill up with new fuel. Engine lacks power or poor - Fuel supply defective. - Clean the fuel system and verify its operation. - Page 61 MALFUNCTION POSSIBLE CAUSE REMEDY Gears do not engage correctly - Clutch does not disengage. - Go to a specialized workshop. - Bent or seized shift fork. - Replace the shift fork. - Gear seized at the transmission. - Go to a specialized workshop. - Damaged gearshift lever.
- Page 62 MALFUNCTION POSSIBLE CAUSE REMEDY Shock absorber set too hard - Excessive front fork oil. - Pour excess oil until reaching the correct oil level. - Front fork oil viscosity too high. - Drain fork oil and fill with correct fork oil viscosity. - Bent front fork.
- Page 63 MALFUNCTION POSSIBLE CAUSE REMEDY Handlebar vibration - Excessive steering axles tolerances. - Tighten steering bracket and steering stem locknut to the correct torque values. - Loose handlebar bracket, and loose - Tighten steering bracket and steering stem locknut to the handlebar stem locknut.
- Page 64 (According to Law decree 23/2003 on the 10th of July, covering Warranties on Consumer Item Sales) Warranty terms of the manufacturer GASGAS Motos, S.A. The company GAS GAS MOTOS, S.A. (hereafter referred to as “GG”), with this present document guarantees the consumer, the purchaser of a vehicle manufactured by GG, that both the materials and the manufacturing are free of defects in accordance with the highest standards of quality.
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Page 65: Electric Schemas
Obligation of the purchaser GG will have the right to reject any claims under Warranty in the event that: a) The purchaser has failed to submit the vehicle to any of the inspections and/or maintenance work required in the Users’ Manual, or has exceeded the date set for such inspections or maintenance work. -
Page 66: Warranty Manual
e) Any damages caused as a result of the defects, as well as any expenses incurred either directly or indirectly as a consequence of the defects (for example, communication costs, accommodation expenses, car hire costs, public transport costs, breakdown truck fees,, courier costs, etc.), as well as other financial losses (for example, those caused by the loss of the use of the vehicle, loss of income, time lost, etc.) f) Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle (for example, small or hidden imperfections, noise or vibrations that are normal in use, etc.)