GAS GAS EC250E 2012 Owner's Manual
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GAS GAS EC250E 2012 Owner's Manual

Ec 2t 250c.c/300c.c e-start
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  • Page 2 2011 GAS GAS Motos, S.A. All rights reserved. The reproducti on, distributi on, public communicati on and transformati on, totally or parti ally, is prohibited without the express authorizati on of the copyright owner. Manual made by: Automoti ve Technical Projects, S.L.

  • 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 IDENTIFICATION ....................................13 STEERING LOCK ....................................13 SPECIFICATIONS ....................................14 EC MODELS ELECTRICAL DIAGRAM ..............................16 CROSSCOUNTRY MODELS ELECTRICAL DIAGRAM ...........................17 TORQUE VALUES .....................................18 General ....................................18 Chassis ....................................18...
  • Page 4 Owner’s manual Contents STORAGE ......................................36 SERVICE AND MAINTENANCE ................................ 37 MAINTENANCE SCHEDULE ................................38 MAINTENANCE....................................39 1.-Clutch ....................................39 2.-Clutch discs ..................................39 3.-Thrott le cable ..................................39 4.-Spark plug ..................................39 5.-Air fi lter ...................................40 6.-Carburetor ..................................42 7.-Transmission oil ................................42 8.-Piston and ring ................................43 9.-Cylinder head, cylinder, ex. valve ............................43 10.-Exhaust system ................................43 11.-Muffl...
  • Page 5 Owner’s manual Contents CARBURETION TUNNING ................................62 Thrott le valve opening infl uences ............................62 Idle jet and mixture screw ..............................62 Needle ....................................63 Main jet ....................................63 Reference carbureti on (competi ti on use only) ........................63 correcti on Factors ................................64 Symptoms of improper setti ngs ............................65 CDI MAP ......................................66 SECONDARY TRANSMISSION RATIO..............................66 SUSPENSION TUNNING ...................................67...
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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 confi dence. With the choose of your new GAS GAS EC 2012 you just entered the great GAS GAS team and, as a user of the brand number one on off - road motorcycles, deserves disti nguished treatment that we want to off...

  • 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 ti mes 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 protecti on and gloves, boots and other items for protecti on that are in perfect conditi on.

  • Page 10: Controls Ans Components Location

    Owner’s manual Controls and components location Number Name Number Name Headlamp with positi on, low beam and high beam lamps Front fork Front turn signals CDI switch Fuel tank Electric Starter Fuel valve Gear shift pedal Rear shock Carburetor Air fi lter Secondary transmission chain Side stand Chain guide...
  • Page 11 Owner’s manual Controls and components location 12 13 Number Name Number Name License plate light Muffl er Brake light Rear brake disc Seat Rear brake caliper Rear shock gas reservoir Rear brake master cylinder Kick-starter Suspension linkage Manufacturer’s identi fi cati on plate Rear brake pedal Radiator Sump guard...
  • Page 12 Owner’s manual Controls and Components location Number Name Number Name Clutch lever Front brake master cylinder Choke lever Thrott le Clutch fl uid reservoir Front brake lever Multi functi on gauge Turn signals, lights, horn and engine stop controls Fuel tank cap Steering lock Not available on CrossCountry models.

  • Page 13: Identification

    Owner’s manual Identifi cation Your GAS GAS has a manufacturer’s identi fi cati on plate (1) in which details are: manufacturer, chassis number, homologati on 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 14: Specifications

    Owner’s manual Specifi cations Code GG-E2512-E GG-E3012-E Comercial model EC250E EC300E31 Cycle 2 strokes Cylinder number Monocylinder Refrigerati on 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 Intake type Reed Valves into the cranckcase Lubricati on system...
  • Page 15 Owner’s manual Specifi cations EC250 EC300 Suspension travel Front 298 mm Rear 298 mm Front fork oil level 130 mm (compressed, without spring) Brakes Front Brake disc, with 2 parallel fl oati ng piston caliper Trasero Brake disc, with 1 fl oati ng piston caliper Brake disc Front Ø260 mm...

  • Page 16: Ec Models Electrical Diagram

    Owner’s manual EC models electrical diagram -16-...

  • Page 17: Crosscountry Models Electrical Diagram

    Owner’s manual CrossCountry models electrical diagram -17-...

  • Page 18: 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 19 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 -19-...

  • Page 20: 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 -20-...
  • Page 21 Owner’s manual Torque Values Nº Name Size Torque (Nm) Cylinder head bolt M8x40 Cylinder nut Igniti on 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 Igniti on motor stator bolt Igniti on motor coil nut Selector spring fi...

  • Page 22: Multifunction Gauge

    Owner’s manual Multifunction gauge NOTE: This chapter is not valid on CrossCountry models. The multi functi on device is water resistant, has 3 butt ons, 2 LEDs. And a brigthly lit LCD. Amber warning led Red warning led LCD screen Left butt on Middle butt on or MODE Right butt on...

  • Page 23: Reset And Change Of Battery

    Owner’s manual Quick guide TEMPORAL DATA RESET + 3 sec. Resets temporal data (MS, TT, DST and RT) TRIP ADJUST + 3 sec. Enter/exit the trip adjustment mode Change distance value Reset and change of battery When the device turns on the LO icon, indicates that the batt ery charge is low and should be changed.

  • Page 24: Confi Guration

    Owner’s manual Confi guration ENTER CONFIGURATION MODE To enter the confi gurati on mode press the three front butt ons for three seconds, release them to conti nue. SET SPEED UNITS To switch between Km/h and MPH use the left butt on. To confi...

  • Page 25: Set High Temperature Warning

    Owner’s manual Confi guration 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 butt on. Change to next digit using the butt on To confi...

  • Page 26: Method 2

    Owner’s manual Measure of the wheel circumference METHOD 2 Find a totally fl at surface. Make a mark on the fl ank of the ti re and the ground. Advance with the motorcycle unti l the wheel complete one revoluti on. Make a mark on the ground at this point.

  • Page 27: Sleep Mode

    Owner’s manual Sleep mode If the device is not used for 5 minutes is it will be automati cally into sleep mode to save batt ery. In this mode it will only show the clock on the display. The device will automati cally exit this mode when it receives any sensor data or when you press any butt on.

  • Page 28: Homologation

    Owner’s manual Homologation NOTE: This chapter is not valid on CrossCountry models. The vehicle just acquired is a vehicle approved under the EU directi ves and comply with all the requirements for type-approval. The components of approval required to ride on public roads and to pass technical legislati ve inspecti ons, which are detailed below. The components of type-approval are identi fi...

  • Page 29: Operating Instructions

    Owner’s manual OPERATING INSTRUCTIONS -29-...

  • Page 30: Starting Procedure

    Owner’s manual Starting procedure To start your GAS GAS you can used the kickstarter or by electric start: For start by electric start follow this steps: Open the fuel tap. Turn on the key (1). Give the thrott le two energic strokes. Pull the choke lever (2).

  • Page 31: 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 32 Owner’s manual Daily inspection Is the brake fl uid level correct? Front and rear brake fl uid tanks have a viewfi n- der (1 and 2) to check its level. DANGER The brake fl uid level must be in the center of the viewfi nder, 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 33 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 functi on 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 34 Owner’s manual Daily inspection Does the wheel spokes have a properly ti ghtness? Pressing with the fi ngers, 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 offi...

  • Page 35: Cleaning

    Owner’s manual Daily inspection Is there any leakage? Visually check the possible existence of leaks, assess them in functi on of their locati on, amount, or escaped product (att enti on to the fi re danger). Always go as soon as possible to your GAS GAS offi cial service. DANGER These controls are really very easy to make, it is a matt er of habit, the rider knows the use that has undergone the motorcycle in its last use and knows where...

  • Page 36: Storage

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

  • Page 37: Service And Maintenance

    Owner’s manual SERVICE AND MAINTENANCE -37-...

  • Page 38: 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 39: 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 positi on can’t change when you ride. DANGER •...

  • Page 40: Air Fi Lter

    Owner’s manual Maintenance 5.-AIR FILTER Removing the fi lter To access the air fi lter must remove the seat and the batt ery box. Loosen the screw of the seat (1). Remove the seat by pulling it back. Loosen the 4 fi xing screws of the batt ery box (2). Remove the batt ery box (3).
  • Page 41 Owner’s manual Maintenance Air fi lter cleaning Clean inside the fi lter box with a damp cloth. Remove the cage (2) of the air fi lter (3). Clean the fi lter using a soft brush in a bath of fi lter cleaning liquid. Squeeze it and dry with a clean cloth.

  • Page 42: Carburetor

    Owner’s manual Maintenance 6.-CARBURETOR Idling adjustment It is carried out by adjusti ng the air screw (1) and the idling screw (2). Turn the air screw clockwise unti l you reach the top of its travel and open 1 turn. Warm up the engine.

  • Page 43: Piston And Ring

    Owner’s manual Maintenance Transmission oil change El aceite de transmisión debe cambiarse periódicamente para asegurar la vida del motor. 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 positi on to allow the complete oil drain.

  • Page 44: Muffl Er Fi Ber

    Owner’s manual Maintenance 11.-MUFFLEER FIBER The Muffl er on your GAS GAS is a silencer of absorpti on. The absorbent element is the silencer fi ber. If you noti ce an increase in exhaust noise should proceed to change the Muffl er fi ber. Muffl...

  • Page 45: 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 offi cial service. 13.-KICK-STARTER AND GEAR SHIFT PEDAL Lubricate arti culated and mobile parts with oil or grease. Lubricati on excess can cause slip of your boots on the pedals.

  • Page 46: 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 positi on for use. Remove the radiator cap. Place a pan under drain plug (3) which is located at the bott om of the top of the water pump (2).

  • Page 47: 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 connecti ons losses. Radiator Check if radiator fi ns (1) are blocked (insects or mud). For clearing obstructi ons use a low pressure water jet. WARNING Using a high pressure water jet can damage the radiator fi...

  • Page 48: 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 aff ected 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 49 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 fi ber plate (5) if the new pads does not have them.

  • Page 50: Brake Fl Uid

    Owner’s manual Maintenance 20.-BRAKE FLUID Inspect the brake fl uid and change it periodically. It should also be changed if it becomes contaminated with dirt or water. Recommended fl uid: GRO Brake Fluid DOT-4. DANGER Do not mix diff erent types of brake fl uid. The liquid used to fi ll or renew your cir- cuit must meet the standard specifi...

  • Page 51: 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 offi cial service. 24.-BRAKE HOSES For this check, adjustment, or change, you must go to your GAS GAS offi cial service.

  • Page 52: 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 53: Front Suspension Oil

    Owner’s manual Maintenance 31.-FRONT SUSPENSION OIL Adjust the oil level To adjust the oil level you must fi rst remove the spring, follow the steps descri- bed in “Changing the fork spring” to do so. Once removed the spring compress the fork completely and gently push the hydraulic rod (1) down unti l it stops.

  • Page 54: 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 55: General Lubricati On

    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 lubricati ng each part, clean rusty spots with rust remover and clean any grease, oil or dirt. General lubricati on •...
  • Page 56 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 57 Owner’s manual Maintenance 11. Pass a rope or a strap for the swingarm and subframe (7) to prevent the wheel from falling once the shock is removed. 12. Loosen the link suspension system (8) to have access to and remove the screw connecti on between the connecti ng rod and shock (9).

  • Page 58: 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 positi on: It must be a space of 35 ~ 60 mm between the chain and the swingarm at the rear of the guide.

  • Page 59: Batt Ery Load

    Owner’s manual Maintenance 43.-BATTERY CHARGE The Furukawa FTZ7S 12V and 7Ah batt ery, is without maintence. Change of batt ery The batt ery is within the box of the batt ery, underneath the seat. In order to chan- ge it, it follows the following steps: Loosen the screw of subjecti on the seat (1) and remove it throwing of him backwards.
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  • Page 61: Adjustments

    Owner’s manual ADJUSTMENTS -61-...

  • Page 62: 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 offi cial service. Carburetor setting THROTTLE VALVE OPENING INFLUENCES The elements of the carburetor that alters the compositi on of the mixture ba- sed on the opening of the thrott le valve (load) depends on the openness of it: •...

  • Page 63: Needle

    Owner’s manual Carburetor setting NEEDLE The needle and the main jet together have an eff ect 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 positi on determines the amount of fuel passing. At the top of the needle are fi...

  • Page 64: Correction Factors

    Owner’s manual Carburetor setting CORRECTION FACTORS (For temperature or alti tude changes). Needle positi on / Mixture screw opening Correcti on factor 1,06 o higher 1,06~1,02 1,02~0,98 0,98~0,94 0,94 or lower Needle positi on Lower clip 1 positi on Same Same Same Raise clip 1 position...

  • Page 65: Symptoms Of Improper Settings

    Owner’s manual Carburetor setting SYMPTOMS OF IMPROPER SETTINGS If your bike has one of the following symptoms the changes must be adjusted. Before att empti ng any change make sure everything else is working properly. Check the conditi on of the spark plug, make sure the igniti on ti ming is correct, clean the air fi...

  • Page 66: Cdi Map

    Owner’s manual CDI map Your GAS GAS has an igniti on map switch with two positi ons. In positi on 1 the behavior and engine power delivery is more aggressive, suita- ble for terrains with good grip and / or experienced riders. In positi on 2 the performance and power delivery are more progressive, suita- ble for slippery surfaces and / or inexperienced riders.

  • Page 67: Suspension Tunning

    Owner’s manual Suspension setting AVAILABLE SETTINGS Your motorcycle has adjustable suspension, these regulati ons are: Front fork • Rebound (1) - 22 clicks, located at the top of the fork. • Compression (2) - 18 clicks , located at the bott om of the fork •...

  • Page 68: Standard Settings

    Owner’s manual Suspension setting STANDARD SETTINGS Fork Shock Rebound 11 clicks from fully closed Preload 12 mm Compression 9 clicks from fully closed Rebound 10 clicks from fully closed Low speed compression 10 clicks from fully closed High speed compression 10 clicks from fully closed STATIC SAG To adjust the SAG of the suspension, follow these steps:...
  • Page 69 Owner’s manual Suspension setting in the fork. Rebound • If the motorcycle feels unstable or so , easily losses the path or oscillates widely, although the speed and the obstacles are small. You must ti ghten the adjustment in rebound in both the fork and the shock. The failure to correct may be indicati ve of a too soft or fati gued spring, and low SAE or insuffi...
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  • Page 71: Troubleshooting

    Owner’s manual TROUBLESHOOTING -71-...
  • Page 72 Owner’s manual Troubleshooting Fault Cause Soluti on The engine does not crank. Seized crankshaft . Go to your GAS GAS offi cial service. Seized cylinder, piston, etc. Go to your GAS GAS offi cial service. Seized transmission assembly. Go to your GAS GAS offi cial service. The electric starter motor does The fusible of starter relay is fuse Remove the seat and check the fusible...
  • Page 73 Owner’s manual Troubleshooting The engine operates irregularly Spark plug dirrty or misadjusted. Verify the spark plug conditi on and clean, ti ghten or replace it. Poor contact between spark plug and spark plug Verify the spark plug conditi on. Replace if dete- cap.
  • Page 74 Owner’s manual Troubleshooting Clutch slips. Excessive clutch fl uid level. Verify the clutch fl uid level and adjust. Worn clutch fricti on plate. Go to your GAS GAS offi cial service. Broken or weak clutch springs. Go to your GAS GAS offi cial service. The motorcycle is unstable.
  • Page 75 Owner’s manual Troubleshooting Brakes do not operate correctly Worn brake discs. Replace brake discs. Brake fl uid leakage. Go to your GAS GAS offi cial service. Deteriorated brake fl uid. Go to your GAS GAS offi cial service. Broken pump piston. Go to your GAS GAS offi...
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  • Page 77: Warranty Manual

    Owner’s manual WARRANTY MANUAL -77-...
  • Page 78 Owner’s manual Warranty manual (According to Law decree 23/2003 on the 10th of July, covering Warranti es on Consumer Item Sales) Warranty terms of the manufacturer GAS GAS Motos, S.A. The company GAS GAS Motos, S.A. (hereaft er 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 79 Owner’s manual Warranty manual c.) Inspecti on, adjustments and other maintenance tasks, as well as all kinds of cleaning work. d.) 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.

This manual is also suitable for:

Ec300e31 2012Ec250 2012Ec300 2012

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