Related Manuals for GAS GAS EC - 2004
Summary of Contents for GAS GAS EC - 2004
- Page 1 MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D’ENTRETIEN MANUEL D’ENTRETIEN LIBRETTO USO E MANUTENZIONE LIBRETTO USO E MANUTENZIONE Compuesta...
- Page 3 SERVICE MANUAL SERVICE MANUAL...
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Page 5: Foreword
GAS GAS thank you for your confidence By choosing the new GAS GAS EC 2004 you have just entered the great GAS GAS family and, as a user of the number one off-road motorbike manufacturer, 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 6: Common Notice
COMMON NOTICE Whenever you see the symbols shown below, heed their instructions! TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE Always follow safe operating and maintenance practices. YOU USE YOUR BIKE LEGALLY, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE. -
Page 7: Table Of Contents
Bolt and nut tightening ..............99 Ignition timing ..................78 Lubrication..................101 Cooling system................78 Tunning (Carburetor and suspension) ..........102 Spark plug ..................81 Preparation check................111 Transmission ...................81 Storage..................112 Air cleaner ..................83 Gas Gas speedo instructions ............112 Throtlle cable...................84 Troubleshooting................114 Carburetor ..................84 Warranty regulations ..............118 EC 2004 -... -
Page 8: Specifications
SPECIFICATIONS ENGINE 2 cycle, single cylinder, crank case induction, liquid cooled Engine 125 cc. Bore and stroke 54 x 54.5 mm. Displacement in cubic centimeters 124 cc. Engine 200 cc. Bore and stroke 62.5 x 65 mm. Displacement in cubic centimeters 199,4 cc. - Page 9 Overall drive ratio 8.149 (6th gear) Transmission oil Capacity 1800 cc. Type 5W50 API SF o SG CHASSIS Type Chromolly tubular semi double cradle Tires Front 80/100 x 21 Rear 120/90 x 18 Suspension Front Upside-down telescopic ø 43mm WP fork. Upside-down telescopic ø...
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Page 10: Location Of Components
LOCATION OF COMPONENTS GAS GAS EC 2004 cc. 1- Clutch lever 2- Engine Stop Button 3- Fuel Tank Fill Cap 4- Front Brake Fluid Reservoir 5- Front Brake lever 6- Throttle Twist-Grip EC 2004 -... - Page 11 24 25 7- Brake Disc, front 17- Air Cleaner 8- Front Suspension 18- Silencer 9- Brake fluid reservoir, rear 19- Seat 10- Fuel Tank 20- Nitrogen Reservoir 11- Carburetor 21- Chain Guide 12- Rear shock absorber 22- Drive chain 13- Brake Caliper, front 23- Rear Suspension Linkage 14- Radiator 24- Rear Brake Pedal...
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Page 12: Side Stand
SIDE STAND FUEL To operate the side stand: The GAS GAS FSE 400 cc has a four stroke engine and requires 95 octane, unleaded gasoline Release the security strap (B), the sidestand is held in the down position by the weight of the motorcycle. Thes sidestand automatically Gas Tank Capacity retracts when the motorcycle is placed in the upright position. - Page 13 RECOMENDED FUEL Use premium gasoline with an octane rating equal to or higher than Recomended Oil: that shown in the table. OIL 2T SINTETIC OCTANE RATING METHOD MINIUM NOTE RATING If recommended oil is not available, use only synthetic oil designed for use in racing 2 cycle engines.
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Page 14: Serial Number
START THE ENGINE SERIAL NUMBER This number allows the motorcycle to be registered. The serial 1. You have to assure the motorcycle to the neutral position. number (or V.I.N.) is located on the steering stem of the frame. 2. Turn right the key of fuel tank (A). Official approval plate Open This motorcycle has an official approval plate. -
Page 15: Shifting Gears
SHIFTING GEARS NOTE - When the engine is already warm or on hot days, open The transmission is a 6 speed, return shift type with neutral halfaway the throttle part way instead of using the choke knob. - If the engine is flooded, kick with the throttle fully open. between 1st and 2nd gears. -
Page 16: Stopping The Motorcycle
STOPPING THE MOTORCYCLE SPARK PLUG Standard Plug Hotter Plug For maximum deceleration, close the throttle (A) and apply both NGK BR8EG front and rear brakes. Disengage the clutch as the motorcycle comes to a stop. Independent use of the front or rear brake may be advantageous under certain conditions. -
Page 17: Table Of Maintenance
MAINTENANCE AND ADJUSTMENT Check / Adjust Replace / Clean Grease / Part inspect Change Lubricate Clutch Each race Each race Each race* Each race Friction plates 3 races 3 races* 3 races* Throttle cable Each race Spark plug 1 race Air cleaner element 1 race If it's damaged... - Page 18 MAINTENANCE AND ADJUSTMENT Check / Adjust Replace / Clean Grease / Part inspect Change Lubricate Brake caliper pisto seal & dust seal Every 2 years Brake hose and pipe Every 4 years Spoke tightness and rim runout 1 race 1 race* 1 race* Lubricate drive chain 1 race...
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Page 19: Ignition Timing
IGNITION TIMING - If the marks are not aligned, loosen the magneto stator screws and turn the magneto stator. - Tighten the screws securely. Because a capacitor discharge ignition (CDI) system is used on this - Install the magneto cover. motorcycle, the ignition timing should never require adjustment unless the magneto stator is incorrectly installed during engine NOTE... - Page 20 CAUTION Using high-pressure water, as from a car wash facility, could damage If the lowest ambient temperature encountered falls below the freezing the radiator fins and impair the radiator´s effectiveness. point of water, protect the cooling system against engine and radiator Do not obstruct or deflect airflow through the radiator by installing freeze-up.
- Page 21 Coolant level Recommended coolant - Situate the motorcycle so that it is perpendicular to the ground. Permanent type of antifreeze (soft water and ethylene glycol plus - Remove the radiator (A) cap in two steps. First turn the cap corrosion and rust inhibitor chemicals for aluminum engines and counterclockwise to the first stop and wait there for a few seconds.
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Page 22: Spark Plug
Standard Spark Plug WARNING NGK CR8 E o DENSO U24ESR-N 0.7-0.8 mm. Coolant on tires will make them slippery and can cause an accident and injury. The spark plug should be taken out periodically to check its gap and ceramic insulator. If the plug is oily or has carbon build up on it, clean it (preferably with a (sandblaster) and then clean off any - Visually inspect the old coolant. - Page 23 Oil level Transmission oil type - Stand the motorcycle upright and level allow a few minutes for the oil to settle. Viscosity: SAE 10W30. Capacity: 1000 cc. Oil Change - The transmission oil should be changed periodically to assure long engine life.
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Page 24: Air Cleaner
AIR CLEANER - Stuff a clean, lint-free towel into the carburetor so no dirt is allowed to enter the carburetor. A clogged air cleaner restricts the engine´s air intake, increasing fuel consumption, reducing engine power, and causing spark plug CAUTION fouling. -
Page 25: Throtlle Cable
- Inspect the element for damage such as tears, hardening, or - If the free play cannot beset by adjusting the upper cable adjuster, shrinkage. If damaged, replace it or it will allow dirt into the carburetor. pull the rubber boot off of the carburetor top. Make the necessary - Apply grease to all connections and srew hole in the air cleaner free play adjustment at the lower cable adjuster, tighten the locknut, housing and intake tract. -
Page 26: Clutch
EXHAUST SYSTEM WARNING The muffler and silencer reduce exhaust noise and conduct the Operation with a damaged cable could result in an unsafe riding exhaust gases back away from the rider. condition. If the muffler is badly damaged, dented, cracked or rusted, replace it with a new one. -
Page 27: Drive Chain
(A). Rivots. (B). Inner Pipe. 30-50 mm. In addition to checking the slack, rotate the rear wheel to inspect DRIVE CHAIN the drive chain and sprockets for damaged rollers, loose pin and links, unevenly or excessively worn teet, and damaged teeth. The drive chain must be checked, adjusted, and lubricated in accordance with the Periodic Maintenance table. - Page 28 NOTE master link clip must be installed with the closed end of the Wheel alignment can also be checked using the straightedge «U» points in the direction of chain rotation. or string metod. WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition.
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Page 29: Handlebar
Cain Slider Wear Apply oil to the side of the rollers so that it will penetrate to the rollers and bushings. Wipe off any excess oil. Visually inspect the upper and lower chain sliders. (A). Apply oil. HANDLEBAR To suit various riding positions, the handlebar position can be adjusted front to rear. -
Page 30: Brakes
Tighten the clamp bolts, front first and then the rear, to 25 Nm of Rear brake pedal position torque (18 ft.lbs). When the brake pedal is in rest position, there should be a play of 10 mm. If not, adjust the pedal position. Check the brake for good braking power and no brake drag. -
Page 31: Steering
1 mm, replace both pads in the caliper as a set Pad replacement should be done by an authorized GAS GAS dealer. Steering The steering should always be kept adjusted so that the handlebar will turn freely but have no excessive play. -
Page 32: Steering Blocade
To check the steering adjustment, using a stand under the frame, - Tighten the steering stem head nut (B), and front fork upper or raise the wheel off the ground. Push the handlebar lightly to either lower clamp bolts to the specified torque. side;... -
Page 33: Front Fork
- Air pressure: Air pressure acts as a progressive spring and affects the entire range of fork travel. The air pressure in the fork increases as the fork heats up, so the fork action on your GAS GAS will get stiffer as the race progresses. Because of this, we don´t recommend using air pressure for additional springing. - Page 34 Stand oil level CAUTION The left and right fork tubes must bealigned (level) at the top clamps. Marzocchi: 110 mm. (see the illustration). WP: 120 mm. Öhlins: 110 mm. Compression Dampening Adjustment - To adjust, turn the knob located at the top of the fork. Adjust to rider preferance.
- Page 35 (1). Spring (2). Locknut (3). Suspension cap (4). Cap Wrench (5). Lock nut wrench Fork Springs Different fork springs are available to achieve suitable front fork action in accordance with the rider´s weight and track conditions. - Harder springs make the fork stiffer, and rebound action quicker. (A).
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Page 36: Rear Suspension
Shock Rebound Dampening Adjustment Rear shock Absorber o adjust shock rebound dampening, turn the rebound dampening adjuster on the rear shock absorber lower end until you feel a click. The total number of adjustments is: 60 ¨CLICKS¨. The standard setting is: 25 ¨CLICKS¨. (Counterclockwise from fully closed). - Page 37 Suspension spring The standard spring is a 4.0. The standard spring preload length is 258 mm (A). Compression dampening adjuster Adjusting the spring (A). Adjusting - Remove the seat, right and left side number plates. (B). Spring - Loosen the air cleaner duct clamp screw. (C).
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Page 38: Wheel
(A). Llave tensador radios WARINING Improper removal of the spring from the rear shock absorber body may cause the spring and associated parts to be ejected at high velocity. Always wear eye and face protection. Removal and installation of spring should be performed by an person or company. WHEELS Tires (A). -
Page 39: Cleaning
CLEANING 3- After washing: - Remove the plastic bags, and clean the air cleaner intake. 1- Preparation for washing - Lubricate the points listed in the lubrication section. - Start the engine and run for 5 minutes. Before washing, precautions must be taken to keep water off the - Dry the brakes before operating the motorcycle. -
Page 40: Bolt And Nut Tightening
BOLT AND NUT TIGHTENING Every day before riding, check without fail the tighteness of the bolts and nuts described here. Also, check to see whether or not each cotter pin is in place and in good condition. 5,6,7 21 22 23,24,25 13 14 28,29... - Page 41 Torque Table Tighten all bolts and nuts to the proper torque using an accurate torque wrench. A bolt or nut if insufficiently tightened may become damaged or fall out, possibly resulting in damage to the motorcycle and injury to the rider. PART NAME N-m / FT.LBS.
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Page 42: Lubrication
LUBRICATION Lubricate the points shown here, with either motor oil or regular grease, in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions, and especially after using a high pressure spray washer. Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. -
Page 43: Tunning (Carburetor And Suspension)
Chain lubrication NOTE The main jet should be increased or decreased one to five sizes Lubricate the chain after drive over wet places or when the chain and tested until the engine gives maximum power. looks dry. It's better a high viscosity oil than a small viscosity oil because it will stay a long time in chain. - Page 44 Slow Jet (piltot jet) and air screw Jet needle The slow jet and air srew controls the mixture in the closed to 1/8 The jet needle and jet needle hole together have their greatest effect throttle range, but has little effect on up to full throttle. To adjust the in the 1/4 to 3/4 throttle range.
- Page 45 Check the condition of the spark plug, make sure the ingnition timing Correction factors: is correct, service the air cleaner element, decarbonize the muffler If you machine has run properly at a certain track in the past and (For changes in altitude and temperature). then starts running poorly with the same carb settings, the problem is almost certain to be elsewhere;...
- Page 46 ALTITUDE (104) (86) (68) (ºC) (50) (ºF) (32) (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 JET NEEDLE/ AIR SCREW CHART CORRECTION FACTORS 1,06 or ABOVE 1,06 - 1,02 1,02 - 0,98 0,98 - 0,94 0,94 or BELOW JET NEEDLE LOWER CLIP...
- Page 47 2. SUSPENSION TUNING Front fork No area of machine adjustment is more critical than proper suspension The fork oil level in the fork tube is adjustable. A change in the fork tuning. An improperly tuned suspension will keep even the best rider oil level will not affect the spring force much at the top of fork travel, from attaining the full benefit of his machine´s ability.
- Page 48 5. Rebound or compression damping adjusting incorrect. Troubleshooting Improper Settings Listed below are some symptoms of improper suspension settings Symptoms of the rear shok: and the most likely means of correcting them. Too hard The proper settings can be achieved by applying the information - The suspension is too stiff in this chapter in a scientific, methodical manner;...
- Page 49 Riding experience Front and rear compability: Beginner Softer: spring with more rebound damping. Use this procedure to determine if the suspension is balanced Experienced: Harder spring. reasonably well: Hold the bike upright (retract the side stand). While standing next to the machine, lightly pull on the front brake, place one foot on the footpeg closest to you, and push down hard.
- Page 50 Adjustment depending on bottoming condition:(rear shock absorber). Front fork doesn´t respond to small bumps in sweeping turns: - Front Fork is too hard: - Bottoms at low speed. 1. Decrease the compression damping or rebound damping. - Increase spring preload until maximum preload is achieved. 2.
- Page 51 - If the straight portion of a course is longer, the secondary reduction 3. The engine works hardest in muddy conditions and the radiator ratio should be reduced so that the machine speed can be increased. can become clogged with mud. Take care not to overheat the engine in these conditions.
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Page 52: Preparation Check
PREPARATION FOR COMPETITION (2). After first race maintenance: 1. Air cleaner element (1). Check: 2. Drive chain slack 3. Rear sprocket nuts 1. Front axle shaft and nut, or axle clamp nut tightness 4. Sprockets 2. Front fork clamp bolt tightness 5. -
Page 53: Storage
STORAGE GAS GAS SPEEDO INSTRUCTIONS When the motorcycle is to be stored for any lenght of time, it should The top button is the reset button. be prepared for storage as follows: The bottom button is the mode button. - Clean the entire vehicle thoroughly. - Page 54 met -- for km/h mil --- for mp/h 0000 - The white plastic block connector on the speedo is for the display backlight. - The red wire is positve. - The black wire is negative. Total distance Trip distance - Warning; your speedo is set for the diameter of your front wheel To change the time: enduro 21"...
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Page 55: Troubleshooting
TROUBLESHOOTING NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. CAUSE REMEDY TROUBLE Engine doesn't crank - Crankshaft seizure. - Page 56 TROUBLE CAUSE REMEDY Engine flooded - Water in fuel. - Empty fuel tank and fill up with new one. Engine does not rev high, will - Fuel supply partically interrupted or - Clean and check fuel system as well as carburettor. not reach full power carburettor dirty.
- Page 57 TROUBLE CAUSE REMEDY Clutch not disengaging properly - Clutch hub or housing unevenly worn. - Change clutch hub. Jumps out of gear - Shift fork worn, gear worn. - Change it and go to specialized garage. - Gear dogs and/or dog holes worn. - Change it and go to specialized garage.
- Page 58 TROUBLE CAUSE REMEDY Abnormal train noise - Rear and/or engine sprocket worn. - Change it. - Chain lubrication insufficient. - Lubricate with apropiate chain oil. - Rear wheel misaligned. - Align rear wheel. - Oil front fork insufficient or too thin. - Add oil until correct level.
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Page 59: Warranty Regulations
The Company GAS GAS Motos S.A. hereby warrants to the final purchaser of a vehicle manufactured by GG that both materials and maintenance work performed not at all or performed only after the prescribed date. - Page 60 b) Lubricants (e.g. oil, grease, etc.) and operating fluids (e.g. battery 3.- If it turns out that any defect cannot be removed, the warranty fluid, cooling liquid, etc.). shall be entitled to demand termination of the contract (payment of c) Inspection, adjusting and other periodical maintenance work as a compensation) or partial reimbursement for the purchasing price well as all kinds of cleaning work.
- Page 61 RECOMIENDA EL USO DE ACEITE: JULIO / JULY 2003 C/ UNICEF nº 17 · Poligon Industrial Torremirona · 17190 Salt (Girona) SPAIN · Tel: +34 902 47 62 54 Fax: +34 902 47 61 60 E-mail: officegg @ gasgasmotos.es / partsgg @ gasgasmotos.es · Web: www.gasgasmotos.es Compuesta...
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