GAS GAS ENDURO 4T EC 2014 Owner's Manual
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GAS GAS ENDURO 4T EC 2014 Owner's Manual

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  • Page 2 2013 GAS GAS Motos, S.A. All rights reserved. The reproduction, distribution, public communication and transformation, totally or partially, is prohibited wi- thout the express authorization of the copyright owner. The Company has the right, without prior notice, to change the technical content of the products.

  • Page 3: Table Of Contents

    Owner´s manual CContents Contents GENERAL INFORMATION ................................. 7 INTRODUCTION ....................................8 LEGAL NOTICES ....................................8 NOTICES AND WARNINGS................................8 PRELIMINARY WARNINGS ................................9 CONTROLS ANS COMPONENTS LOCATION ..........................10 EC 4T 250/300/450cc RACING ............................. 10 XC 4T 250/300/450cc RACING (USA) ...........................12 IDENTIFICATION ....................................
  • Page 4 Owner´s manual Contents 17.-Radiator hose and connections ............................. 52 18.-Brakes adjustment ................................ 52 19.-Brake wear ..................................53 20.-Brake fluid ..................................55 21.-Brake fluid level................................55 22.-Pump piston and dust cover (front and rear) ........................56 23.-Caliper piston and dust cover (all calipers) ........................56 24.-Brake hoses ...................................

  • Page 5: General Information

    Owner´s manual GENERAL INFORMATION...

  • Page 6: Introduction

    GAS GAS Motos, S.A. thanks you for your confidence. With the choose of your new GAS GAS EC 2014 or XC 2014 you just entered the great GAS GAS team and, as a user of the brand number one on off-road motorcycles, deserves distinguished treatment that we want to offer both our relationship after the acquisition of your GAS GAS and in the explanations that you are in this manual.

  • Page 7: Preliminary Warnings

    GAS GAS Motorcycles, S.A. It is an essential condition for maintaining the warranty. Your GAS GAS has been designed for off-road use, not designed for long travel on highways. Such use could lead to engine damages be- cause it maintained high revolutions.
  • Page 8 Owner´s manual Ubicazione dei componenti EC 4T 250/300/450cc * Image taken from the EC 4T 450F RACING.. Number Name Number Name Headlamp with position, low beam and high beam lamps Front fork Front turn signals Engine start Fuel tank Gear shift pedal Rear shock Carburetor Air filter...
  • Page 9 Owner´s manual Ubicazione dei componenti EC 4T 250/300/450cc *Image taken from the EC 4T 450F RACING. Number Name Number Name License plate light Muffler Brake light Rear brake disc Seat Rear brake caliper Rear shock gas reservoir Rear brake master cylinder Kick-starter Suspension linkage Fuel valve...
  • Page 10 Owner´s manual Controls and components location XC 4T 250/300/450cc * Image taken from the XC 4T 450F RACING Number Name Number Name Headlamp with position, low beam and high beam lamps Front fork Fuel tank Engine start Rear shock Gear shift pedal Air filter Carburetor Side stand...
  • Page 11 Owner´s manual Controls and components location XC 4T 250/300/450cc * Image taken from the XC 4T 450F RACING Number Name Number Name Brake light Rear brake disc Seat Rear brake caliper Rear shock gas reservoir Rear brake master cylinder Kick-starter Suspension linkage Fuel valve Rear brake pedal...
  • Page 12 Owner´s manual Controls and components location EC 4T Number Name Number Name Clutch lever Front brake master cylinder Choke lever Throttle Multifunction gauge Front brake lever Fuel tank cap Turn signals, lights, horn and engine stop controls Ignition key Steering lock Only XC models.

  • Page 13: Identification

    The chassis number is also stamped in the right side of the steering column. Steering lock Your GAS GAS has a steering lock. It’s found on the right side of the steering column. To lock the steering: Turn the handlebar fully to the right.

  • Page 14: Specifications

    Owner´s manual Specifications Comercial model EC250F EC300F EC450F Cycle 4 strokes Cylinder number Monocylinder Refrigeration Liquid cooled Capacity 249,6 cc 290,0 cc 449,0 cc Bore 77,0 mm 83,0 mm 95,0 mm Stroke 53,6 mm 53,6 mm 63,4 mm Carburetor Keihin FCR JUM6 37MX Keihin FCR 5TJ 39MX Distribution DOHC 5 valve...
  • Page 15 Owner´s manual Specifications EC250F EC300F EC450F Front Brake disc, with Nissin floating 2 piston caliper Brakes Rear Brake disc, with Nissin floating 1 piston caliper Front Disco Galfer “wave” Ø260 mm Brake disc Rear Disco Galfer “wave” Ø220 mm Total height 1260 mm Total length 2200 mm...

  • Page 16: Electrical Diagram

    Owner´s manual Electrical diagram -16-...

  • Page 17: Torque Values

    Owner´s manual Torque Values GENERAL Size Torque (Nm) M4 nuts and bolts M5 nuts and bolts M6 nuts and bolts M8 nuts and bolts M10 nuts and bolts CHASSIS Nº Name Size Torque(Nm) Steering nut Rear shock bolt M10x50 Swingarm bolt Brake disc bolt M6x14 Front axle bolt...
  • Page 18 Owner´s manual Torque Values Nº Name Size Torque(Nm) Subframe bolt M8x50 Brake banjo bolt Upper clamp bolt M7x30 Spokes Rear axle nut Linkage bolt M14x110 Rear brake pedal bolt M8x45 -18-...

  • Page 19: Engine

    Owner´s manual Coppie di serraggio Torque Values ENGINE Nº Name Size Torque (Nm) Gearshift pedal bolt Kick-starter bolt Kick-starter bolt M6x20 Crankcase bolt -19-...
  • Page 20 Owner´s manual Coppie di serraggio Torque Values Nº Nome parte Misura Torque (Nm) Cylinder head bolt M6x1.0 Cylinder bolt M6x1.0 Ignition cover bolt M6x1.0 Screw inlet duct M6x1.0 Spark plug M10Sx1.0 Engine drain plug M10x1.25 Engine drain plug (left side) M6x1.0 Water pump drain bolt M6x1.0...

  • Page 21: Multifunction Gauge

    Owner´s manual Multifunction gauge (Only on certain models and markets) The multifunction device is water resistant, has 3 buttons with a brightly lit LCD. • Current speed • Backlight Full time • Average speed • Maximum speed • Two independent tripmeters •...

  • Page 22: Screens In Normal Mode

    Owner´s manual Multifunction gauge (Only on certain models and markets) Adjust the clock format: Select the desired format using the buttons 1 or 2 (12H or 24H). Setting the time: Set the clock to the desired time by pressing 1 to 2. Setting the maintenance reminder method: Select the desired maintenance reminder method using the buttons 1 or 2.

  • Page 23: Measure Of The Wheel Circumference

    Owner´s manual Multifunction gauge (Only on certain models and markets) Screen 3: ODP ODO (odómeter), is the kilometers totality which has been traveled , is the total sum. Press and hold buttons 1 and 2 for three seconds to reset the maximum speed. To see the remaining time until the next maintenance, hold button 3 for 3 se- conds.

  • Page 24: Homologation

    Anti-theft lock Air filter restriction Throttle opening limiter Each component of type-approval must be a part of your GAS GAS and in case of breakage, loss or malfunction you must go to your official GAS GAS service to repair it. -24-...
  • Page 25 Owner´s manual -25-...

  • Page 26: Operating Instructions

    Owner´s manual This page is intentionally left blank. OPERATING INSTRUCTIONS -26-...

  • Page 27: Starting Procedure

    Break-in procedure It is important to respect the break-in procedure, with this you will ensure the duration and correct function of your GAS GAS in the long term. Intervals to res- pect are as follows: From 0 to 200 Km.: Ride between 50% and 75% of load (throttle opening), alternatively, without continued use of the 75% load.

  • Page 28: Daily Inspection

    Owner´s manual Daily inspection Prior to use your GAS GAS, it is necessary to carry out the following checks: Is there enough fuel? Open the fuel tank plug and, moving the motorcycle la- terally with the handlebar, you can see and hear fuel level, so that you can know the approximate content.
  • Page 29 The correct level is 6~8 mm from upper edge of the tank. If you have any doubt go to your GAS GAS official service.
  • Page 30 You know your motorcycle, any change that you appreciate will make you immediately go to your GAS GAS official service. Your GAS GAS official service will be happy to assist you and ensure your safety.
  • Page 31 GAS GAS service, this affects your safety. Is the seat properly fixed? This is a point of vital importance for your safety, if you have some doubt about this fixation you must go to your GAS GAS official service. Is there some element with risk to fly-off when the motorcycle is running? Fenders, side covers, fuel tank, coveralls, etc.

  • Page 32: Cleaning

    The respect of this set of controls means greater safe- ty for you and, sure, a cheaper and better maintenance for your GAS GAS. Cleaning To clean your GAS GAS follow these steps: Put a plug in the exhaust system to prevent water entry.

  • Page 33: Storage

    Owner´s manual Storage When you need to store the bike for a period of time must: • Clean the bike thoroughly. • Start the engine for about 5 minutes to warm the transmission oil and then drain it (see maintenance). •...

  • Page 34: Service And Maintenance

    Owner´s manual This page is intentionally left blank. SERVICE AND MAINTENANCE -34-...
  • Page 35 Owner´s manual Maintenance table The maintenance requirements exposed in this table are simple and are required for a good maintenance of your motorcycle. Check / Replace / Grease / Element Adjust Clean Inspect Change Lubricate 1.-Clutch 10 hours 20 hours When necessary 10 hours 2.-Clutch discs...

  • Page 36: Clutch

    If the dead play is not correct, loose the lock nut at the end of the throttle cable, rotate de adjuster until its correct. • Tighten the lock nut. 2.-CLUTCH DISCS For this check, adjustment, or change, you must go to your GAS GAS official service. 3.-THROTTLE CABLE • Check that the throttle rotates smoothly.

  • Page 37: Air Filter

    Owner´s manual Maintenance 5.- AIR FILTER Removing the filter To access the air filter must remove the seat and the battery box. Loosen the screw of the seat. Remove the seat by pulling it back. Remove the filter fixing. Remove the air filter. -37-...
  • Page 38 Owner´s manual Maintenance Air filter cleaning Clean inside the filter box with a damp cloth. Remove the cage (2) of the air filter (3). Clean the filter using a soft brush in a bath of filter cleaning liquid. Squeeze it and dry with a clean cloth. Do not blow the filter as it may be damaged.

  • Page 39: Carburetor

    Owner´s manual Maintenance 6.-CARBURETOR Idling adjustment It is carried out by adjusting the iddlescrew (1) Warm up the engine. Turn the free closing screw to adjust the idling speed. If you don’t have references turn screw until the engine stops. Tighten slightly the idle screw.

  • Page 40: Piston And Ring

    10. Screw the oil filling plug. 11. Check the oil level, after powering the kick-starter for 3 or 4 times. 8.-PISTON AND RING For this check, adjustment, or change, you must go to your GAS GAS official service. 9.-CYLINDER HEAD, CYLINDER, EX. VALVE For this check, adjustment, or change, you must go to your GAS GAS official service.

  • Page 41: Exhaust System

    Change the silencer fiber if the noise is becoming too high or the engine perfor- mance decreases. Exhaust cleaning For the cleaning of the exhaust pipe you must go to your GAS GAS official ser- vice. Muffler change Remove the bolt (1,2) of the left fairing.

  • Page 42: Connecting Rod And Bearings

    Owner´s manual Maintenance 12.-CONNECTING ROD AND BEARINGS For this check, adjustment, or change, you must go to your GAS GAS official service. 13.-KICK-STARTER AND GEAR SHIFT PEDAL Lubricate articulated and mobile parts with oil or grease. Lubrication excess can cause slip of your boots on the pedals.
  • Page 43 Owner´s manual Maintenance Coolant change It must be changed periodically to ensure long engine life. Allow the engine to cool completely. Put the bike in position for use. Remove the radiator cap. Place a pan under drain plug which is located at the bottom of the top of the water pump (2).

  • Page 44: Radiator Hose And Connections

    Is dangerous to ride in these terms and conditions, check the brake system im- mediately, so we recommend you go to your GAS GAS official service. -44-...

  • Page 45: Brake Wear

    Verify that the thickness of the brake discs is at least 3 mm in the front and 3,5 mm in the rear. WARNING For this change, we recommend strongly that you go to your GAS GAS official service who, in addition, will verify a possible wear and damages on your brake discs.
  • Page 46 Owner´s manual Maintenance Changing the rear brake pads To change the rear pads follow these steps: Remove the pin protector (1). Loosen and remove the pin (2). Remove the pads (3). Keep the metal plate (4) and the fiber plate (5) if the new pads does not have them.

  • Page 47: Brake Fluid

    Do not pour brake fluid on painted surfaces. DANGER Check for fluid leakage through the joints. Check possible damage to the brake hoses. 22.-PUMP PISTON AND DUST COVER (FRONT AND REAR) For this check, adjustment, or change, you must go to your GAS GAS official service. -47-...

  • Page 48: Caliper Piston And Dust Cover (All Calipers)

    Owner´s manual Maintenance 23.-CALIPER PISTON AND DUST COVER (ALL CALIPERS) For this check, adjustment, or change, you must go to your GAS GAS official service. 24.-BRAKE HOSES For this check, adjustment, or change, you must go to your GAS GAS official service.

  • Page 49: Front Suspension

    Owner´s manual Maintenance 30.-FRONT SUSPENSION Front suspension air purge To purge air from the front suspension follow these steps: Place the bike on a stand or support. The front fork must be fully extended. Remove purge bolts (1). When purging is complete, replace the purge bolts. Changing the fork spring In case you need to change the front fork spring, follow these steps: Place the bike on a stand or support.

  • Page 50: Front Suspension Oil

    DANGER Riding with a damaged gas tube, or simply starting the engine, can cause a fire and subsequent crash (and related injuries) Always use the original gas tube, your GAS GAS official service will provide it to you. -50-...

  • Page 51: Fuel System

    Owner´s manual Maintenance 34.-FUEL SYSTEM Check the status of: fuel tank rubber plug, fuel tank plug, the fuel tank respira- tor and the fuel tank. 35.-STEERING HEAD ADJUSTMENT The steering should always be kept adjusted so that the turn freely and without play.

  • Page 52: General Lubrication

    It is necessary after driving on wet ground when the chain looks dry. The chain is an o-ring chain, therefore a specific lubricant should be used for this type of chains. Your GAS GAS official service will be pleasured to provide it. 37.-STEERING BEARINGS For this check, adjustment, or change, you must go to your GAS GAS official service.
  • Page 53 Owner´s manual Maintenance Removing the rear shock To remove the rear shock from the frame follow these steps: Stabilize the bike with a stand or a support. Keep the rear wheel off the ground. Loosen the seat clamping screw (1) and remove it by pulling it back. Remove the silencer (see “Silencer change”...
  • Page 54 Owner´s manual Maintenance Loosen only, top screws that fastening subframe, in both sides (6) Loosen the link suspension system (7) to have access to and remove the screw connection between the connecting rod and shock (8). Loosen and remove the shock top mounting screw (9). Turn up the subframe rotating on his top anchor.

  • Page 55: Chain

    In the medium and long term the most economic is to change the complete transmission kit at each chain change. Your GAS GAS official service will provide it. Lubrication: The chain is the type with o-rings, this requires a special lubricant, use the same lubricant in the guide and the chain guide shoe, front and rear sproc- kets.

  • Page 56: Battery Charge

    Owner´s manual Maintenance 43.-BATTERY CHARGE The Furukawa FTZ7S 12V and 7Ah battery, without maintence battery. Change of battery The battery is located under the seat inside the battery box. To change it, follow these steps: Loosen the subjection seat screw (1) and remove it by pulling it back slightly.

  • Page 57: Adjustments

    Owner´s manual ADJUSTMENTS -57-...

  • Page 58: Introduction

    Owner´s manual Introduction This chapter is for users with high mechanical knowledge and experience. Otherwise these adjustments, must be carrie by your GAS GAS official service.. Carburetor setting THROTTLE VALVE OPENING INFLUENCES The elements of the carburetor that alters the composition of the mixture ba- sed on the opening of the throttle valve (load) depends on the openness of it: •...

  • Page 59: Needle

    Owner´s manual Carburetor setting NEEDLE The needle and the main jet together have an effect ranging from 25% to 75% load. The needle moves into the main jet, when the needle narrows, changes from cylindrical (1) to conical (2), its position determines the amount of fuel passing. At the top of the needle are five slots (3) which sets the clip.

  • Page 60: Correction Factors

    Owner´s manual Carburetor setting CORRECTION FACTORS (For temperature or altitude changes). Needle position / Mixture screw opening Correction factor 1,06 o higher 1,06~1,02 1,02~0,98 0,98~0,94 0,94 or lower Needle position Lower clip 1 position Same Same Same Raise clip 1 position Mixture screw opening Tighten 1 turn Tighten ½...

  • Page 61: Symptoms Of Improper Settings

    Rear: 39, 40, 42, 44, 46, 47, 48, 49, 50, 51, 52, 53, 54 teeth. Front: 12, 13, 14 teeth. If you shorten the ratio, your GAS GAS will lose top speed but will gain in acce- leration and low speeds, will be more manageable in difficult terrain.
  • Page 62 Owner´s manual Suspension settings Front Fork (Marzocchi 48) MARZOCCHI 48 • Rebound (3) - located at the bottom of the fork. • Compression (1) - located at the top of the fork. • Spring Preload (2) - by the PFP system (Progressive Floating Piston) located in the upper part of the fork, each turn equals approx.
  • Page 63 Owner´s manual Suspension settings SUSPENSION SETTINGS Front Fork MARZOCCHI 48 ÖHLINS RXF 250/300cc 450cc 250/300cc 450cc 65 - 75kg. 4,0 N/mm 4,2 N/mm 4,1 N/mm 4,2 N/mm 75 - 85kg. 4,2 N/mm 4,4 N/mm 4,3 N/mm 4,5 N/mm (STD) (STD) (STD) (STD) 85 - 95kg.
  • Page 64 Owner´s manual Suspension settings Rear Shock (Reiger). Racing models • Rebound (1) - located at the bottom of the shock. • Low speed compression (2) - located at the top of the shock. • Standard spring preload (3) - 256 mm, adjustable between 251 and 261 mm between planes of support.

  • Page 65: Static Sag

    Owner´s manual Suspension settings STATIC SAG To adjust the SAG of the suspension, follow these steps: Put the bike on a stand that allows you to leave the rear wheel in the air in a stable manner. Measure the vertical distance (1) between the rear axle nut and the bolt clamping the muffler.
  • Page 66 Owner´s manual Suspension setting Rebound • If the motorcycle feels unstable or soft, easily losses the path or oscillates widely, although the speed and the obstacles are small. You must tighten the adjustment in rebound in both the fork and the shock. The failure to correct may be indicative of a too soft or fatigued spring, and low SAE or insufficient oil level.
  • Page 67 Owner´s manual Footpegs Settings FOOTPEGS HEIGHT SETTING Your GAS GAS has height adjustable footpegs to suit your needs, in particular has two positions. Position 1 is the standard regulation that is delivered with your motorcycle. Position 2 gets lower the height of the footpegs at 12mm.

  • Page 68: Troubleshooting

    Owner´s manual This page is intentionally left blank. TROUBLESHOOTING -68-...
  • Page 69 Fault Cause Solution The engine does not crank. Seized crankshaft. Go to your GAS GAS official service. Seized cylinder, piston, etc. Go to your GAS GAS official service. Seized transmission assembly. Go to your GAS GAS official service. The electric starter motor does...
  • Page 70 Getto principale ostruito. Scendere il carburatore e pulire. Andare al vostro servizio ufficiale GAS GAS. Cuscinetti albero a gomiti consumati o danneg- giati. Il motore emette strane sonori´ta. Problemi nell’accensione.
  • Page 71 Owner´s manual Troubleshooting Le marce slatano. Forcella del cambio consumata sugli ingranaggi. Andare al vostro servizio ufficiale GAS GAS. Scanalatura marce consumata. Andare al vostro servizio ufficiale GAS GAS. Marce rotta. Andare al vostro servizio ufficiale GAS GAS. Sedi (guide) marce rovinate.
  • Page 72 Il manubrio vibra. Pneumatico consumato. Cambio pneumatici. Basculante o i suoi cuscinetti ad ago consumati. Andare al vostro servizio ufficiale GAS GAS. Cerchione scentrato. Andare al vostro servizio ufficiale GAS GAS. Ruota non allineata. Controllare la tensione dei raggi del cerchione.
  • Page 73 Owner´s manual -73-...

  • Page 74: Warranty Manual

    Owner´s manual This page is intentionally left blank. WARRANTY MANUAL -74-...
  • Page 75 Warranty terms of the manufacturer GAS GAS 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.
  • Page 76 Owner´s manual Warranty manual Warranty exclusions The following items are not covered by this Warranty: a.) Worn parts, including, without any limitation, spark plugs, batteries, petrol filters, oil filter elements, (secondary) chains, engine output pinions, rear sprockets, air filters, brake discs, brake pads, clutch plates and discs, bulbs, fuses, carbon brushes, footrest rub- bers, tyres, inner tubes, cables and other rubber components.

This manual is also suitable for:

Enduro 4t xc 2014

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