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Related Manuals for GAS GAS EC 2T 20012501300cc RACING
Summary of Contents for GAS GAS EC 2T 20012501300cc RACING
- Page 2 2012 GAS GAS Motos, S.A. All rights reserved. The reproduction, distribution, public communication and transformation, totally or partially, is prohibited without the express authorization of the copyright owner. The company has the right, whithout notice, to change technical content of products.
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Page 3: Table Of Contents
Owner’s manual Contents GENERAL INFORMATION ................................. 7 INTRODUCTION ....................................8 LEGAL NOTICES ....................................8 NOTICES AND WARNINGS................................8 PRELIMINARY WARNINGS ................................9 CONTROLS ANS COMPONENTS LOCATION ..........................10 EC 2T 200cc/250cc/300cc RACING //250cc/300cc Replica Factory..................10 EC 2T 250cc/300cc RACING E-START ........................... 12 EC 2T 200cc/250cc/300cc RACING “Cross Country”... - Page 4 Owner’s manual Contents Measure of the wheel circumference ..........................47 Method 1 ................................47 Method 2 ................................47 Screens in normal mode ..............................48 Screen 1 .................................. 48 Screen 2 .................................. 48 Screen 3 .................................. 48 Sleep mode ..................................48 HOMOLOGATION ..................................
- Page 5 Contents 28.-Chain guide wear ................................76 29.-Chain guide shoe................................76 30.-Front suspension................................77 31.-Front suspension oil ..............................78 32.-Bolts, nuts and fasteners............................... 78 33.-Gas tube..................................78 34.-Fuel system ................................... 79 35.-Steering head adjustment ............................. 79 36.-General lubrication ............................... 80 37.-Steering bearings ................................80 38.-Wheel bearing ................................
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Page 7: General Information
Owner’s manual GENERAL INFORMATION... -
Page 8: Introduction
Owner’s manual Introduction GAS GAS Motos, S.A. thanks you for your confidence. With the choose of your new GAS GAS EC 2013 or XC 2013 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 9: Preliminary Warnings
Owner’s manual Preliminary warnings DANGER Three of each four fatal accidents are due to head injuries. The risk of brain injury is three times higher if you don’t use a helmet. Always take a helmet approved, the probability of leaving unharmed in an accident increases by 20%. It also recommends the use of eye protection and gloves, boots and other items for protection that are in perfect condition. -
Page 10: Controls Ans Components Location
Owner’s manual Components location EC 2T 200cc/250cc/300cc RACING// EC 2T 250cc/300cc/ REPLICA FACTORY Number Name Number Name Headlamp with position, low beam and high beam lamps Front brake caliper Front turn signals Front fork Fuel tank CDI switch Fuel valve Gear shift pedal Rear shock Carburetor... - Page 11 Owner’s manual Components location EC 2T 200cc/250cc/300cc RACING// EC 2T 250cc/300cc/ REPLICA FACTORY 12 13 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 Manufacturer’s identification plate...
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Page 12: Ec 2T 250Cc/300Cc Racing E-Start
Owner’s manual Components location EC 2T 250cc/300cc RACING E-START Number Name Number Name Headlamp with position, low beam and high beam lamps Front brake caliper Front turn signals Front fork Fuel tank CDI switch Fuel valve Electric Starter Rear shock Gear shift pedal Air filter Carburetor... - Page 13 Owner’s manual Components location EC 2T 250cc/300cc RACING E-START 12 13 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 Manufacturer’s identification plate Rear brake pedal Radiator Sump guard...
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Page 14: Ec 2T 200Cc/250Cc/300Cc Racing "Cross Country
Owner’s manual Components location EC 2T 200cc/250cc/300cc RACING “Cross Country” Number Name Number Name Headlamp with position, low beam and high beam lamps Front fork Fuel tank CDI switch Fuel valve Gear shift pedal Rear shock Carburetor Air filter Secondary transmission chain Side stand Chain guide Front brake disc... - Page 15 Owner’s manual Components location EC 2T 200cc/250cc/300cc RACING “Cross Country” 12 13 Number Name Number Name License plate light (available in certain countries) Muffler Brake light Rear brake disc Seat Rear brake caliper Rear shock gas reservoir Rear brake master cylinder Kick-starter Suspension linkage Manufacturer’s identification plate...
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Page 16: Ec 2T 250Cc/300Cc Racing E-Start "Cross Country
Owner’s manual Components location EC 2T 250cc/300cc RACING E-START “Cross Country” Number Name Number Name Headlamp with position, low beam and high beam lamps CDI switch Fuel tank Electric Starter Fuel valve Gear shift pedal Rear shock Carburetor Air filter Secondary transmission chain Side stand Chain guide... - Page 17 Owner’s manual Components location EC 2T 250cc/300cc RACING E-START “Cross Country” 12 13 Number Name Number Name License plate light (available in certain countries) Muffler Brake light Rear brake disc Seat Rear brake caliper Rear shock gas reservoir Rear brake master cylinder Kick-starter Suspension linkage Manufacturer’s identification plate...
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Page 18: Xc 2T 200Cc/250Cc/300Cc Racing (Usa)
Owner’s manual Components location XC 2T 200cc/250cc/300cc RACING (USA) Number Name Number Name Headlamp with position, low beam and high beam lamps Front brake caliper Fuel tank Front fork Fuel valve CDI switch Rear shock Gear shift pedal Air filter Carburetor Side stand Secondary transmission chain... - Page 19 Owner’s manual Components location XC 2T 200cc/250cc/300cc RACING (USA) 12 1 13 2 14 3 1 1 5 4 1 1 6 5 11 0 11 12 1 9 0 Number Name Number Name Brake light Rear brake disc Seat Rear brake caliper Rear shock gas reservoir Rear brake master cylinder...
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Page 20: Xc 2T 250Cc/300Cc Racing E-Start (Usa)
Owner’s manual Components location XC 2T 250cc/300cc RACING E-START (USA) Number Name Number Name Headlamp with position, low beam and high beam lamps Front fork Fuel tank CDI switch Fuel valve Electric Starter Rear shock Gear shift pedal Air filter Carburetor Side stand Secondary transmission chain... - Page 21 Owner’s manual Components location XC 2T 250cc/300cc RACING E-START (USA) 12 1 13 2 14 3 1 1 5 4 1 1 6 5 11 0 11 12 1 9 0 Number Name Number Name Brake light Rear brake disc Seat Rear brake caliper Rear shock gas reservoir...
- Page 22 Owner’s manual Controls location EC RACING & E-START Number Name Number Name Clutch lever Front brake master cylinder Choke lever Throttle Clutch fluid reservoir Front brake lever Multifunction gauge Turn signals, lights, horn and engine start/stop controls Fuel tank cap Steering lock Ignition key Only models EC Racing E-START.
- Page 23 Owner’s manual Controls location EC RACING & E-START “Cross Country” Number Name Number Name Clutch lever Throttle Choke lever Front brake lever Clutch fluid reservoir Lights switch “ON-OFF” Fuel tank cap Engine stop Ignition key Steering lock Front brake master cylinder Starter Switch Only models EC Racing E-START “CrossCountry”.
- Page 24 Owner’s manual Controls location XC RACING & E-START (USA) Number Name Number Name Clutch lever Throttle Choke lever Front brake lever Clutch fluid reservoir Lights switch “ON-OFF” Fuel tank cap Engine stop Ignition key Steering lock Front brake master cylinder Starter Switch Only models XC Racing E-START.
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Page 25: Identification
Owner’s manual Identification Your GAS GAS has a manufacturer’s identification plate (1) in which details are: manufacturer, chassis number, homologation number and noise level. The chassis number is also stamped in the right side of the steering column (2). Steering lock Your GAS GAS has a steering lock. -
Page 26: Specifications
Owner’s manual Specifications EC 2T 200cc/250cc/300cc RACING & “Cross Country” Code GG-E2013-R GG-E2513-R GG-E3013-R Comercial model EC200 RACING EC250 RACING EC300 RACING Cycle 2 strokes Cylinder number Monocylinder Refrigeration Liquid cooled Capacity 199,4 cc 249,3 cc 294,7 cc Bore 62,5 mm 66,4 mm 72,0 mm Stroke... - Page 27 Owner’s manual Specifications EC 2T 200cc/250cc/300cc RACING & “Cross Country” EC200 RACING EC250 RACING EC300 RACING Front fork oil level MARZOCCHI 320 ml. each bottle ÖHLINS 300 ml. each bottle Brakes Front Brake disc, with 2 parallel floating piston caliper Rear Brake disc, with 1 floating piston caliper Brake disc...
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Page 28: Ec 2T 250Cc/300Cc Racing & "Cross Country" E-Start
Owner’s manual Specifications EC 2T 250cc/300cc RACING & “Cross Country” E-START Code GG-E2513-RE GG-E3013-RE Comercial model EC250-RE EC300-RE Cycle 2 strokes Cylinder number Monocylinder Refrigeration Liquid cooled Capacity 249,3 cc 294,7 cc Bore 66,4 mm 72,0 mm Stroke 72,0 mm 72,0 mm Carburetor Keihin PWKS 38... - Page 29 Owner’s manual Specifications EC 2T 250cc/300cc RACING & “Cross Country” E-START EC250-RE EC300-RE Front fork oil level MARZOCCHI 320 ml. each bottle ÖHLINS 300 ml. each bottle Brakes Front Brake disc, with 2 parallel floating piston caliper Rear Brake disc, with 1 floating piston caliper Brake disc Front Ø260 mm...
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Page 30: Xc 2T 200Cc/250Cc/300Cc Racing (Usa)
Owner’s manual Specifications XC 2T 200cc/250cc/300cc RACING (USA) Code GG-E2013-USA GG-E2513-USA GG-E3013-USA Comercial model XC200 RACING XC250 RACING XC300 RACING Cycle 2 strokes Cylinder number Monocylinder Refrigeration Liquid cooled Capacity 199,4 cc 249,3 cc 294,7 cc Bore 62,5 mm 66,4 mm 72,0 mm Stroke 65,0 mm... - Page 31 Owner’s manual Specifications XC 2T 200cc/250cc/300cc RACING (USA) XC200 RACING XC250 RACING XC300 RACING Front fork oil level MARZOCCHI 320 ml. each bottle Brakes Front Brake disc, with 2 parallel floating piston caliper Rear Brake disc, with 1 floating piston caliper Brake disc Front Ø260 mm...
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Page 32: Xc 2T 250Cc/300Cc Racing E-Start (Usa)
Owner’s manual Specifications XC 2T 250cc/300cc RACING E-START (USA) Code GG-E2513-E USA GG-E3013-E USA Comercial model XC250-RE XC300-RE Cycle 2 strokes Cylinder number Monocylinder Refrigeration Liquid cooled Capacity 249,3 cc 294,7 cc Bore 66,4 mm 72,0 mm Stroke 72,0 mm 72,0 mm Carburetor Keihin PWKS 38... - Page 33 Owner’s manual Specifications XC 2T 250cc/300cc RACING E-START (USA) XC250-RE XC300-RE Front fork oil level MARZOCCHI 320 ml. each bottle Brakes Front Brake disc, with 2 parallel floating piston caliper Rear Brake disc, with 1 floating piston caliper Brake disc Front Ø260 mm Rear...
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Page 34: Electrical Diagrams
Owner’s manual EC Racing / EC Replica Factory electrical diagram -34-... -
Page 35: Ec Racing "Crosscountry" & Xc Racing (Usa)
Owner’s manual EC Racing CrossCountry & XC Racing (USA) electrical diagram -35-... -
Page 36: Ec Racing "E-Start
Owner’s manual EC Racing “E-START” electrical diagram -36-... -
Page 37: Ec Racing Crosscountry "E-Start" & Xc Racing "E-Start" (Usa)
Owner’s manual EC Racing CrossCountry “E-START” & XC Racing “E-START” (USA) electrical diagram -37-... -
Page 38: 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 M6x15 Front axle bolt... - Page 39 Owner’s manual Torque Values Nº Name Size Torque(Nm) Subframe bolt M8x25 Brake banjo bolt Upper clamp bolt M8x35 Spokes Rear axle nut Linkage bolt M14x115 Rear brake pedal bolt M8x45 -39-...
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Page 40: Engine
Owner’s manual Torque Values ENGINE Nº Name Size Torque (Nm) Valve cover bolt M6x15 Gearshift pedal bolt M6x20 Kick-starter bolt M6x10 Kick-starter bolt M6x20 Crankcase bolt M6x65 -40-... - Page 41 Owner’s manual Torque Values Nº Name Size Torque (Nm) Cylinder head bolt M8x40 Cylinder nut Ignition cover bolt M6x40 Reed block bolt M6x30 Spark plug Engine drain plug Clutch cover bolt M6x75 Water pump drain bolt M6x10 Starter pedal plate bolt Ignition motor stator bolt Ignition motor coil nut Selector spring fixing bolt...
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Page 42: E-Start" Engine
Owner’s manual “E-START” Torque Values ENGINE Nº Name Size Torque (Nm) Valve cover bolt M6x15 Gearshift pedal bolt M6x20 Kick-starter bolt M6x10 Kick-starter bolt M6x20 Crankcase bolt M6x65 -42-... - Page 43 Owner’s manual “E-START” Torque Values Nº Name Size Torque (Nm) Cylinder head bolt M8x40 Cylinder nut Ignition cover bolt M6x40 Reed block bolt M6x30 Spark plug Engine drain plug Clutch cover bolt M6x75 Water pump drain bolt M6x10 Starter pedal plate bolt Ignition motor stator bolt Ignition motor coil nut Selector spring fixing bolt...
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Page 44: Multifunction Gauge
Owner’s manual Multifunction gauge (Only on certain models and markets) The multifunction device is water resistant, has 3 buttons, 2 LEDs. And a brigthly 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, co-... -
Page 45: Temporal Data Reset
Owner’s manual Quick guide TEMPORAL DATA RESET + 3 seg. Resets temporal data (MS, TT, DST and RT) TRIP ADJUST Enter/exit the trip adjustment mode + 3 seg. Change distance value Reset and change of battery When the device turns on the LO icon, indicates that the battery charge is low and should be changed. -
Page 46: Configuration
Owner’s manual Configuration ENTER CONFIGURATION MODE To enter the configuration mode press the three front buttons for three seconds, release them to continue. SET SPEED UNITS To switch between Km/h and MPH use the left button. To confirm press the button SET WHEEL SIZE The multifunction gauge needs to know the wheel circumference for the correct measurement of the distance and speed, makes this measure as precise as possi-... -
Page 47: Set High Temperature Warning
Owner’s manual Configuration SET HIGH TEMPERATURE WARNING When programmed engine temperature is reached, the amber warning led will turn on. The warning will be disabled if the value is 0. Change the blinking digit with the left button. Change to next digit using the button To confirm press the button NOTE: engine temperature sensor is optional and is not available in GAS GAS. -
Page 48: Screens In Normal Mode
Owner’s manual Screens in normal mode SCREEN 1 The following information is displayed: • Actual speed (SPD) • Distance (DST) • Engine temperature • Ride time (RT) • Voltage (V) • Clock SCREEN 2 The following information is displayed: • Average speed (AS) •... -
Page 49: Homologation
Owner’s manual Homologation NOTE: This chapter is not valid on CrossCountry and XC models. The vehicle just acquired is a vehicle approved under the EU directives and comply with all the requirements for type-approval. The components of approval required to ride on public roads and to pass technical legislative inspections, which are detailed below. The components of type-approval are identified with a determined and registered stamp Component list Amount/moto... - Page 50 Owner’s manual This page is intentionally left blank -50-...
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Page 51: Operating Instructions
Owner’s manual OPERATING INSTRUCTIONS -51-... -
Page 52: Starting Procedure
Owner’s manual Starting procedure To start your GAS GAS with the kickstarter follow this steps: Open the fuel tap. Deploy the kickstarter. Give the throttle two energic strokes. Pull the choke lever (1). Push the kickstarter vigorously. NOTE: With the motor at the operating temperature it will not be necessary to pull the choke lever. -
Page 53: 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 54 Owner’s manual Daily inspection Is the brake fluid level correct? Front and rear brake fluid tanks have a viewfin- der (1 and 2) to check its level. DANGER The brake fluid level must be in the center of the viewfinder, as a minimum, in both tanks, verify the thickness of brake pads and to ensure that they have not reached its limit of use.
- Page 55 Owner’s manual Daily inspection Are the brake pads correct? We can visually check the thickness of the lining (1) that remains, we know if are in function or we must change quickly, the thickness of the lining must be 1 mm as a minimum. Does the controls have good touch? Front brake lever, rear brake pedal, clutch lever, gearbox pedal, starter lever, lights switches, engine stop switch, horn and lighters switches, gas command, kick starter.
- Page 56 Owner’s manual Daily inspection Does the wheel spokes have a properly tightness? Pressing with the fingers, we can know the possible lack of tension. In case of excessive lax in some wheel spiders, we must review all wheel spiders in both wheels, it’s a work for experts, go to your GAS GAS official service.
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Page 57: Cleaning
Owner’s manual Daily inspection Is there any leakage? Visually check the possible existence of leaks, assess them in function of their location, amount, or escaped product (attention to the fire danger). Always go as soon as possible to your GAS GAS official service. DANGER These controls are really very easy to make, it is a matter of habit, the rider knows the use that has undergone the motorcycle in its last use and knows where... -
Page 58: 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 59: Service And Maintenance
Owner’s manual SERVICE AND MAINTENANCE -59-... -
Page 60: Maintenance Schedule
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 61: Maintenance
Owner’s manual Maintenance 1.-CLUTCH The clutch lever can be adjusted for your comfort. To adjust it, act as described: • With the wheel (1) adjust the distance between the lever and the handle- bar. The assembly is designed so that the lever position can’t change when you ride. DANGER •... -
Page 62: Air Filter
Owner’s manual Maintenance 5.1-”EC RACING” / “EC REPLICA FACTORY” AIR FILTER Removing the filter To access the air filter must remove the seat and the battery box. Loosen the screw of the seat (1). Remove the seat by pulling it back (2). Remove the filter fixing (3). -
Page 63: Ec Racing E-Start" Air Filter
Owner’s manual Maintenance 5.2- “EC RACING E-START” AIR FILTER Removing the filter To access the air filter must remove the seat and the battery box. Loosen the screw of the seat (1). Remove the seat by pulling it back (2). Leave it hanging from the left side (3). -
Page 64: Xc Racing (Usa)" Air Filter
Owner’s manual Maintenance 5.3-”XC RACING (USA)” AIR FILTER Removing the filter To access the air filter must remove the seat and the battery box. Loosen the screw of the seat (1). Remove the seat by pulling it back (2). Remove the filter fixing (3). Remove the air filter (4). -
Page 65: Xc Racing E-Start (Usa)" Air Filter
Owner’s manual Maintenance 5.4- “XC RACING E-START (USA)” AIR FILTER Removing the filter To access the air filter must remove the seat and the battery box. Loosen the screw of the seat (1). Remove the seat by pulling it back (2). Leave it hanging from the left side (3). -
Page 66: Air Filter Cleaning
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 67: Carburetor
Owner’s manual Maintenance 6.-CARBURETOR Idling adjustment It is carried out by adjusting the air screw (1) and the idling screw (2). Turn the air screw clockwise until you reach the top of its travel and open 1 turn. 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. -
Page 68: Piston And Ring
Owner’s manual Maintenance Transmission oil change The transmission oil should be changed periodically to ensure engine life. Heat the engine for 5 minutes, in order to lift all sediments. Stop the engine and put a container under the motorcycle. Remove the emptying screw (see “Checking the oil level”) and put the bike in the use position to allow the complete oil drain. -
Page 69: Muffler Fiber
Owner’s manual Maintenance 11.-MUFFLEER FIBER The Muffler on your GAS GAS is a silencer of absorption. The absorbent element is the silencer fiber. If you notice an increase in exhaust noise should proceed to change the Muffler fiber. Muffler fiber change Once dismantled the silencer, (see “Muffler change”). -
Page 70: 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. 14.-RUBBER JOINT EXHAUST/SILENCER For this check, adjustment, or change, you must go to your GAS GAS official service. -
Page 71: Coolant Change
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 (3) which is located at the bottom of the top of the water pump (2). -
Page 72: Radiator Hose And Connections
Owner’s manual Maintenance 17.-RADIATOR HOSE AND CONNECTIONS Radiator hoses Check for cuts or damages on the radiator hoses and connections losses. Radiator Check if radiator fins (1) are blocked (insects or mud). For clearing obstructions use a low pressure water jet. WARNING Using a high pressure water jet can damage the radiator fins and detract its effectiveness. -
Page 73: Brake Wear
Owner’s manual Maintenance 19.-BRAKE WEAR If the thickness of the front or rear brake pads is less than 1 mm, shall be to complete change of the affected pads set. DANGER Verify that the thickness of the brake discs is at least 3 mm in the front and 3,5 mm in the rear. - Page 74 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.
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Page 75: Brake Fluid
Owner’s manual Maintenance 20.-BRAKE FLUID Inspect the brake fluid and change it periodically. It should also be changed if it becomes contaminated with dirt or water. Recommended fluid: GRO Brake Fluid DOT-4. DANGER Do not mix different types of brake fluid. The liquid used to fill or renew your cir- cuit must meet the standard specified in the fluid reservoir each circuit. -
Page 76: 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 77: 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 78: Front Suspension Oil
Owner’s manual Maintenance 31.-FRONT SUSPENSION OIL Adjust the oil level To adjust the oil level you must first remove the spring, follow the steps descri- bed in “Changing the fork spring” to do so. Get a liquid graduated cylinder in which you must fill the indicated volume of the recommended oil (each bottle). -
Page 79: 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 80: General Lubrication
Owner’s manual Maintenance 36.-GENERAL LUBRICATION Lubricate the parts shown periodically or when the vehicle is wet, especially af- ter using high pressure water. Before lubricating each part, clean rusty spots with rust remover and clean any grease, oil or dirt. General lubrication •... - Page 81 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 82 Owner’s manual Maintenance Loosen only, top screws that fastening subframe, in both sides (6) 10. Loosen the link suspension system (7) to have access to and remove the screw connection between the connecting rod and shock (8). 11. Loosen and remove the shock top mounting screw (9). 12.
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Page 83: Chain
Owner’s manual Maintenance 41.-CHAIN The secondary transmission (chain, sprockets, guide, etc.) supports your motor- cycle hard work. It is also one of the most important assemblies for your SAFETY. It requires constant maintenance and obviously, correct. Chain tension Motorcycle without load and the sidestand position: It must be a space of 35 ~ 60 mm between the chain and the swingarm at the rear of the guide. -
Page 84: Battery Load
Owner’s manual Maintenance 43.-BATTERY CHARGE The Furukawa FTZ7S 12V and 7Ah battery, is without maintence. 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 85: Settings
Owner’s manual SETTINGS -85-... -
Page 86: 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 settings 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 87: Needle
Owner’s manual Carburetor settings 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 88: Correction Factors
Owner’s manual Carburetor settings CORRECTION FACTORS (For temperature or altitude changes). Needle position / Mixture screw opening Correction factor 1,06 o higher 1 , 0 6 ~ 1 , 0 2 1 , 0 2 ~ 0 , 9 8 0 , 9 8 ~ 0 , 9 4 0 , 9 4 o r l o w e r Needle position... -
Page 89: Symptoms Of Improper Settings
Owner’s manual Carburetor settings SYMPTOMS OF IMPROPER SETTINGS If your bike has one of the following symptoms the changes must be adjusted. Before attempting any change make sure everything else is working properly. Check the condition of the spark plug, make sure the ignition timing is correct, clean the air filter, decarbonize the exhaust pipe. -
Page 90: Cdi Map
Owner’s manual CDI map Your GAS GAS has an ignition map switch with two positions. In position 1 the behavior and engine power delivery is more aggressive, suita- ble for terrains with good grip and / or experienced riders. In position 2 the performance and power delivery are more progressive, suita- ble for slippery surfaces and / or inexperienced riders. -
Page 91: Suspension Settings
Owner’s manual Suspension settings AVAILABLE SETTINGS Your motorcycle has adjustable suspension, these regulations are: Front Fork (Marzocchi 48) MARZOCCHI 48 • Rebound (3) - n/d clicks, located at the bottom of the fork. • Compression (1) - n/d clicks, located at the top of the fork. •... -
Page 92: Standard Settings
Owner’s manual Suspension settings Rear Shock (Öhlins 888) • Rebound (1) - total 35 clicks, located at the bottom of the shock. • Low speed compression (2) - total 24 clicks, located at the top of the shock. • Standard spring preload (3) - 258 mm, adjustable between 253 and 263 mm between planes of support (K spring: 52N/m - ideal pilot weight 75-85 kg). -
Page 93: 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 94 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.
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Page 95: Footpegs Set Tings
Owner’s manual Footpegs Settings (Only EC Racing models) FOOTPEGS HEIGHT SETTING Your GAS GAS EC Racing 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 96 Owner’s manual This page is intentionally left blank -96-...
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Page 97: Troubleshooting
Owner’s manual TROUBLESHOOTING -97-... - Page 98 Owner’s manual Troubleshooting 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 The fusible of starter relay is fuse Remove the seat and check the fusible...
- Page 99 Owner’s manual Troubleshooting The engine operates irregularly Spark plug dirrty or misadjusted. Verify the spark plug condition and clean, tighten or replace it. Poor contact between spark plug and spark plug Verify the spark plug condition. Replace if dete- cap. riorated.
- Page 100 Owner’s manual Troubleshooting Clutch slips. Excessive clutch fluid level. Verify the clutch fluid level and adjust. Worn clutch friction plate. Go to your GAS GAS official service. Broken or weak clutch springs. Go to your GAS GAS official service. The motorcycle is unstable. Cable interfereswith handlebar turns.
- Page 101 Owner’s manual Troubleshooting Brakes do not operate correctly Worn brake discs. Replace brake discs. Brake fluid leakage. Go to your GAS GAS official service. Deteriorated brake fluid. Go to your GAS GAS official service. Broken pump piston. Go to your GAS GAS official service. Worn brake pads.
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Page 103: Warranty Manual
Owner’s manual WARRANTY MANUAL -103-... - Page 104 Owner’s manual Warranty manual (According to Law decree 23/2003 on the 10th of July, covering Warranties on Consumer Item Sales) 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 105 Owner’s manual Warranty manual a.) Inspection, adjustments and other maintenance tasks, as well as all kinds of cleaning work. b.) Damage to the paint-work and consequent corrosion due to external causes, such as stones, salt, industrial fumes and other envi- ronmental impact, or inadequate cleaning with inappropiate products.