GasGas EC 125,200,250,300 2003 Owner's manual
SERVICE MANUAL
SERVICE MANUAL
GAS GAS thank you for your confidence
Foreword
By choosing the new GAS GAS EC 125/ 200/ 250/ 300 you have just entered the great GAS GAS family and,
as a user of the number one of
we wish to offer to you both in our after-sale relationship and in the explanations that we provide in this manual.
Our EC 125/ 200/ 250/ 300 is a bike conceived for the practice of high-competition enduro. It is actually the
fruit of many years of competition and experimentation in this demanding discipline, as well as the many great
successes achieved thanks to great trial riders who have contributed with their expertise to the basic data that
have allowed us to create a high-level motorbike.
Congratulations for making the right choice. With your skills at the commands of this motorbike, an adequate
preparation and the indispensable servicing for this GAS GAS to be highly reliable, you will be able to enjoy
the most comfortable and rewarding enduro practice.
Thanks for your confidence and welcome to GAS GAS Motos.
February 2003
f-road motorbike manufacturer, you deserve the distinguished treatment that
EC 2003 -64-
COMMON NOTICE
Whenever you see the symbols shown below
, heed their instructions!
Always follow safe operating and maintenance practices.
WARNING
This warning symbol identifies special instructions or procedures
which, if not correctly followed, could result in personal injury, or loss
of live.
CAUTION
This caution symbol identifies special instructions or procedures
which, if noto strictly observed, could result in damage to or destruction
of equipment.
NOTE
This note symbol indicates points of particular interest for more
efficient and convenient operation.
However, if improverly conducted, the sport has the potential to
cause environmental problems as well as conflicts with other people.
Responsible use of your off-road motorcycle will ensure that these
problems and conflicts do not occur.
TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE
YOU USE YOUR BIKE LEGALL
Y, SHOW CONCERN FOR THE
ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER
PEOPLE.
Off-road motorcycle riding is a wonderful sport, and we hope you
will enjoy it to the fullest.
EC 2003 -65-
TABLE OF CONTENTS
Foreword.........................................................................................64
Common notice...............................................................................65
able of contents.............................................................................66
T
Specifications..................................................................................67
Location of Components.................................................................69
Side Stand.......................................................................................71
Fuel .................................................................................................71
Serial number..................................................................................73
Starting the engine..........................................................................73
Shifting gears ..................................................................................74
Stopping the motorcycle .................................................................75
Table of maintenance......................................................................76
Ignition timing..................................................................................78
Cooling system................................................................................78
Spark plug.......................................................................................81
Transmission...................................................................................81
Air cleaner.......................................................................................83
Throtlle cable...................................................................................84
Carburetor.......................................................................................84
Clutch..............................................................................................85
Silencer packing change.................................................................85
Drive chain ......................................................................................86
Handlebar........................................................................................88
Brakes.............................................................................................89
Steering...........................................................................................90
Steering blocade .............................................................................91
Front fork.........................................................................................92
Rear suspension .............................................................................95
Wheel..............................................................................................97
Cleaning..........................................................................................98
Bolt and nut tightening ....................................................................99
Lubrication.....................................................................................101
T
unning (Carburetor and suspension) ..........................................102
Preparation check..........................................................................111
Storage..........................................................................................112
Gas Gas speedo instructions ........................................................112
Troubleshooting.............................................................................114
Warranty regulations .....................................................................118
EC 2003 -66-
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.
Engine 250 cc.
Bore and stroke 66.4 x 72 mm.
Displacement in cubic centimeters 249,3 cc.
Engine 300 cc.
Bore and stroke 72 x 72 mm.
Displacement in cubic centimeters 294,7 cc.
Type
Carburetor KEIHIN PWK 38
Lubrication system Fuel premix (ratio) (50:1)(2%)
Starting system Kick start pedal
Ignition system CDI system.
Ignition timing 1 mm APMS.
Spark plug NGK BR8EG
TRANSMISSION
Transmission type 6 speed
Clutch type Multidisc in oil bath, hidraulic actuation
Driving system Chain
Gear Ratio 1ª 2.071(29/14)
2ª 1.625(26/16)
3ª 1.333(24/18)
4ª 1.100(22/20)
5ª 0.913(21/23)
6ª 0.791(19/24)
Primary reduction ratio 2.85 (57/20)
Final reduction ratio 3.692 (48/13)
Overall drive ratio 8.149 (6th gear)
EC 2003 -67-
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 45mm Marzocchi fork.
Rear Progressive system with single shock, multi adjustable, ÖHLINS
Suspension stroke Front 282 mm.
Rear 320 mm.
Front fork oil (each) Marzocchi SAE 7,5
WP SAE 5
ÖHLINS SAE 5 - 7,5
Front fork oil level Marzocchi: 110 mm (compressed with spring removed).
WP: 120 mm (compressed with spring removed).
ÖHLINS: 110 mm (compressed with spring removed).
BRAKES
Type Front, rear Disc brake
Effective disc diameter Front 260 mm.
Rear 220 mm.
DIMENSIONS
Overall length 2135 mm.
Overall width 810 mm.
Overall height 1260 mm.
Wheell base 1475 mm.
Ground clearance 340 mm.
Fuel tank capacity 9,5 Litre (2,5 gallons u.s.)
Height seat 940 mm.
(Specifications are subject to change without notice and are not applicable in some countries).
EC 2003 -68-
Location of components
GAS GAS EC 2003 cc.
1 3 24 5 6
1- Clutch lever
2- Engine Stop Button
3- Fuel T
ank Fill Cap
4- Front Brake Fluid Reservoir
5- Front Brake lever
6- Throttle Twist-Grip
EC 2003 -69-
8
10
9
12 18
197
2011
13 9
14
1615
17
7- Brake Disc, front
8- Front Suspension
9- Brake fluid reservoir
10- Fuel Tank
11- Carburetor
12- Rear shock absorber
13- Brake Caliper, front
14- Radiator
15- Fuel Tap
16- Shift pedal
, rear
EC 2003 -70-
21
22
24 25
17- Air Cleaner
18- Silencer
19- Seat
20- Nitrogen Reservoir
21- Chain Guide
22- Drive chain
23- Rear Suspension Linkage
24- Rear Brake Pedal
25- Kick Start Pedal
26- Exhaust Expansion Chamber
2623
SIDE STAND
FUEL
o operate the side stand:
T
Release the security strap (B), the sidestand is held in the down
position by the weight of the motorcycle. Thes sidestand automatically
retracts when the motorcycle is placed in the upright position.
(B)
(C)
(A)
(B). Sidestand spring
NOTE
Do not start the engine or ride the motorcycle when the side
stand is down. Always engage the security strab (B) before
operation of the motorcycle.
(A). Side Stand
(C). Security strap
The GAS GAS FSE 400 cc has a four stroke engine and requires
95 octane, unleaded gasoline
ank Capacity
Gas T
ENDUCROSS FSE 9,5L
(B)
(A)
(A). Fuel Cap.
(B). Fuel Vent hose.
Position the vent hose clip in a position which prevents spillage on
the steering bearings and the clock.
EC 2003 -71-
RECOMENDED FUEL
Use premium gasoline with an octane rating equal to or higher than
that shown in the table.
Recomended Oil:
OIL 2T SINTETIC
OCT
ANE RATING METHOD MINIUM
RATING
Antiknock Index (RON+MON)/2 90
Research Octane No. (RON) 98
NOTE
If "knocking" or "pinging" occurs, try a different brand of
gasoline or higher octane grade.
WARNING
Gasoline is extremely flammable and can be explosive under certain
conditions. Always stop the engine and do not smoke. Make sure
the area is well ventilated and free from any source of flame or
sparks; this includes any appliance with a pilot light.
Engine Oil Mixing
Oil must be mixed with the gasoline to lubricate the piston, cylinder,
crankshaft, bearings, and connecting rod bearings.
EC 2003 -72-
If recommended oil is not available, use only synthetic oil
NOTE
designed for use in racing 2 cycle engines.
Proporción of gasoline and oil mixture (premix ratio)(50 parts gasoline
to 1 part oil).
CAUTION
Do not mix vegetable and mineral based oils.
T
oo much oil will cause excessive smoking and spark plug fouling.
Too little oil will cause engine damage or premature wear.
To make an gasoline-oil mixture, pour oil and half of the gasoline
into a container first and stir the mixture thoroughly. Then add the
rest of the gasoline and stir the mixture well.
NOTE
At low temperature, oil will not easily mix with gasoline. Take
time to ensure a well-blended mixture.
The lubricative quality of this mixture deteriorates rapidly; use
a fresh mixture for each day of operation.
SERIAL NUMBER
START THE ENGINE
This number allows the motorcycle to be registered. The serial
number (or V
Official approval plate
This motorcycle has an official approval plate. It shows the serial
number.
.I.N.) is located on the steering stem of the frame.
(A)
1.
You have to assure the motorcycle to the neutral position.
2. Turn right the key of fuel tank (A).
ON
Open
OFF
Close
(A)
(B)
RES
Reserve
3. If the engine is
cold, pull up the
choke knob (B).
EC 2003 -73-
- When the engine is already warm or on hot days, open
(F)
the throttle part way instead of using the choke knob.
- If the engine is flooded, kick with the throttle fully open.
- If the clutch lever is pulled, the motorcycle can be
started while in any gear
NOTE
.
SHIFTING GEARS
The transmission is a 6 speed, return shift type with neutral halfaway
between 1st and 2nd gears. A ¨return shift¨means that to go back
to first gear from a higher gear
one by one. The same is true when upshifting: each gear must be
engaged before the next higher gear may be selected.
To engage first gear from neutral, pull in the clutch lever and push
down on the shift pedal, gently release the clutch lever, then release
the shift pedal.
, you must shift back through the gears
4. Start the
motorcycle with
kick start pedal (F).
5. Even after the engine starts, keep the choke knob pulled up. Until
the engine is thoroughly warmed up.
Stopping the engine
1. Change to the neutral position.
(A)
3. Turn the key in the unclock direction (position in "OFF" (C)).
2. After racing the
engine slightly
close the throttle
completely and
push the engine
stop button (A).
,
When changing gears, press firmly on the shift pedal to ensure
CAUTION
complete, positive shifting. Careless, incomplete shifts can cause
the transmission to jump out of gear and lead to engine damage.
(A)
(A). Shift pedal.
EC 2003 -74-
STOPPING THE MOTORCYCLE
For maximum deceleration, close the throttle (A) and apply both
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.
Downshift progressively as speed is reduced to ensure good engine
response when you want to accelerate.
(A)
BREAK-IN
Para obtener un óptimo funcionamiento del motor y la transmisión,
es necesario una suave ejecución, teniendo que llevarse a cabo un
rodaje previo. Para la primera hora o 20 Km. de la operación, rodar
el motor a una baja y moderada velocidad y r/min.
NOTE
The slow riding necessary during the break-in period may cause
carbon to build up on the spark plug and foul it. If inspection
of the spark plug shows this to be the case, replace the standard
spark plug with a hotter spark plug for the duration of the breakin period.
SPARK PLUG
Standard Plug Hotter Plug
NGK BR8EG
1. Start the engine and let it run at idle until the engine is thoroughly
warmed up.
2. Stop and let the engine cool completely.
3. Start the engine and ride for 10 minutes at moderate speed NEVER ACCELERATE HARD.
4. Stop and let the engine cool completely. Be sure to check and
adjust chain slack and spoke tightness and make a general inspection.
5. Start the engine and ride for 20 minutes at moderate speed. NEVER ACCELERATE HARD.
6. Stop and let the engine cool completely. Check and adjust as step
(look maintenance and adjustment table).
7. Install the parts removed.
8. Fill the radiator up to the bottom of the radiator filler, bleed the
air from the cooling system.
9. Start the engine and ride for 30 minutes at moderate speed NEVER ACCELERATE HARD.
10. Stop and let the engine cool completely, check and adjust.
11. After the break-in procedure has been properly carried out, the
motorcycle is ready for regular operation. However, since recklessly
high r/min (rpm) will lead to engine trouble, take care to use the
necessary skill and technique in operating the motorcycle.
CAUTION
However, since recklessly high r/min (rpm) will lead to engine trouble,
take care to use the necessary skill and technique in operating the
motorcycle.
NOTE
After break-in, install a new standard spark plug, and change
the transmission oil.
EC 2003 -75-
Part
MAINTENANCE AND ADJUSTMENT
Check /
inspect
Adjust
Replace /
Change
Clean
Grease /
Lubricate
Clutch
Friction plates
Throttle cable
Spark plug
Air cleaner element
Carburetor
T
ransmission oil
Piston and piston ring
Cylinder head, cyl. & exhaust valves
Muffler
Silencer packing
Small end bearing
Kick pedal and shift pedal
Exhaust pipe o'ring
Engine bearings check
Coolant
Radiator hoses, connections
Brake adjustment
Brake wear
Brake fluid level
Brake fluid
Brake master cyl. cup & dust seat
Each race
3 races
-
-
-
Each race
3 races
3 races
Each race
3 races
-
-
10 races
3 races
Each race
3 races
5 races
3 races
-
-
Each race
3 races*
Each race
-
-
Each race
3 races*
3 races*
1 race*
10 races*
3 races*
-
-
10 races*
3 races*
1 race*
3 races*
5 races*
3 races*
-
-
Each race*
3 races*
-
-
If it's damaged
-
3 races
3 races*
3 races*
1 race*
10 races
10 races
-
3 races
10 races*
3 races*
1 race*
3 races*
5 races*
3 races*
Every 2 years
Every 2 years
-
-
1 race
1 race
-
-
3 races
1 race
-
-
-
-
-
-
-
-
-
-
-
-
Each race
-
-
-
-
-
-
-
-
-
-
3 races
1 race
-
-
-
-
-
-
-
-
-
The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance
Chart to keep the motorcycle in good running condition.
NOT
A: (*) Inspect and do this operations only if it is necessary.
EC 2003 -76-
Part
MAINTENANCE AND ADJUSTMENT
Check /
inspect
Adjust
Replace /
Change
Clean
Grease /
Lubricate
Brake caliper pisto seal & dust seal
Brake hose and pipe
Spoke tightness and rim runout
Lubricate drive chain
Drive chain
Drivechain wear
Chain slider
Front fork
Front fork oil
Nuts, bolt, fasteners
Fuel hose
Fuel system
Steering play
Rear sprocket
General lubrication
Steering bearing
Wheel bearing
Swing arm and uni-trak linkage pivots
Rear chock oil
-
-
1 race
-
1 race
-
5 races
1 race
5 races
7 races
-
1 race
5 races
5 races
-
10 races
5 races
Every 2 years
-
-
1 race*
-
-
5 races
5 races*
If it's damaged
5 depósitos*
7 depósitos*
-
5 depósitos*
-
-
10 depósitos*
5 depósitos*
2 years*
Every 2 years
Every 4 years
1 race*
-
-
5 races
5 races*
If it's damaged
Each year
5 races*
7 races
10 races
-
5 races*
-
-
10 races*
5 races*
2 years*
-
-
-
-
-
-
-
If it's damaged
-
-
-
If it's necessary
-
-
-
-
-
-
-
-
-
-
1 race
-
-
-
-
-
-
-
-
-
-
5 races
10 races
-
5 races
-
The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance
Chart to keep the motorcycle in good running condition.
NOT
A: (*) Inspect and do this operations only if it is necessary.
EC 2003 -77-
IGNITION TIMING
Because a capacitor discharge ignition (CDI) system is used on this
motorcycle, the ignition timing should never require adjustment
unless the magneto stator is incorrectly installed during engine
reassembly
and adjust, if necessary, as follows:
. However, if there is any doubt as to the timing, inspect
- If the marks are not aligned, loosen the magneto stator screws
and turn the magneto stator
- Tighten the screws securely.
- Install the magneto cover.
The ignition timing can be adjusted for different power and to
suit the rider´s preference and ability.
.
NOTE
Ignition Timing Adjustment
- Remove the magneto cover (A).
- Check to see if the center mark of the three marks on the magneto
stator (C) is aligned with the mark on the crankcase (B).
125 cc.
(A)
200/250/300 cc.
(C)
(B)
- Remove the magneto cover.
- Loosen the stator screws.
- Adjust the timing by shifting the stator position within the three
lines.
NOTE
For the best engine performance, it is very important to adjust
the ignition timing within the adjustable range just explained.
- Tighten the stator screws securely.
- Install the magneto cover.
- Test ride the motorcycle and readjust the ignition timing if necessary.
COOLING SYSTEM
Radiator Hoses
Check the radiator hoses for cracks or deterioration, and connections
for looseness in acordance with the Periodic Maintenance Chart.
Radiator
Check the radiator fins for obstruction by insects or mud. Clean off
any obstructions with a stream of lowpressure water.
EC 2003 -78-
CAUTION
Using high-pressure water
, as from a car wash facility, could damage
the radiator fins and impair the radiator´s effectiveness.
Do not obstruct or deflect airflow through the radiator by installing
unauthorized accessories in front of the radiator.
Interference with the radiator airflow can lead to overheating and
consequent engine damage.
Coolant information
To protect the cooling system aluminum parts (engine and radiator)
from rust and corrosion, the use for corrosion and rust inhibitor
chemicals in the coolant is essential. If coolant containing corrosion
and rust inhibitor chemicals is not used, over a period of time, the
cooling system accumulates rust and scale in the water jacket and
radiator. This will clog coolant passages, and reduce the efficiency
of the cooling system.
CAUTION
Use of incorrect coolant solutions will cause severe engine and
cooling system damage.
Use coolant containing corrosion inhibitors made specifically for
aluminum engines and radiators in accordance with the instructions
of the manufacturer.
WARNING
Coolant chemicals are harmful to the human body. Follow coolant
manufacturer warnings and coolant handing instructions.
If the lowest ambient temperature encountered falls below the freezing
point of water
, protect the cooling system against engine and radiator
freeze-up.
Use a permanent type of anti-freeze (soft water and ethylene glycol
plus corrossion and rust inhibitor chemicals for aluminium engines
and radiators) in the cooling system. For the coolant mixture ratio
under extreme conditions, choose the mixture ratio listed on the
container for the lowest ambient temperature.
CAUTION
Permantent types of antifreeze on the market have anticorrosion
and anti-rust properties. When it is diluted excessively, it loses its
antifreeze and anticorrosion properties. Dilute a permanent type of
antifreeze in accordance with the instructions of manufacturer.
Coolant
Coolant absorbs excessive heat from the engine and transfers it to
the air at the radiator. If the coolant level becomes low, the engine
overheats and may suffer severe damage. Check the coolant level
each day before riding the motorcycle. Replenish coolant if the level
is low.
WARNING
Soft or distilled water must be used with the inhibitor chemicals and
CAUTION
the antifreeze (see below for antifreeze) in the cooling system. If
hard water is used in the system, it causes scale accumulation in
the water passages, and considerably reduces the efficiency of the
cooling system.
Para evitar quemaduras, no saque el tapón del radiador o trate de
cambiar el líquido cuando el motor esté todavía caliente. Espere
hasta que se enfríe.
EC 2003 -79-
Coolant level
Recommended coolant
- Situate the motorcycle so that it is perpendicular to the ground.
- Remove the radiator (A) cap in two steps. First turn the cap
counterclockwise to the first stop and wait there for a few seconds.
Then push and turn it further in the same direction and remove the
cap.
(A)
Check the level when the engine is cold.
- Check the coolant level in the radiator
be to the bottom of the radiator filler neck. (see illustration).
- If the coolant level is low, add the correct amount of coolant through
the filler opening.
NOTE
. The coolant level should
(1). Coolant level.
(2). Breather Hose.
Permanent type of antifreeze (soft water and ethylene glycol plus
corrosion and rust inhibitor chemicals for aluminum engines and
radiators.
A permanent type of antifreeze is installed in the cooling system
when shipped. It is colored green, contains a 50% solution of
ethylene glycol, and has a freezing point of -35º C. (-32º F )(USA).
ater and coolant mixture ratio
W
1:1 (Water 50%, coolant 50%).
Tatal amount: 1,1 L.
Coolant Change
The coolant should be changed periodically to ensure long engine
life.
- Wait for the engine to cool completely.
- Situate the motorcycle so that it is perpendicular to the ground.
- Remove the radiator cap.
- Place a container under the coolant drain plug, and drain the coolant
from the radiator and engine by removing the drain plug at the bottom
of the water pump cover. Immediately wipe or wash off any coolant
that spills on the frame, engine, or wheels.
NOTE
125 cc.
200 / 250 / 300 cc.
(A)
(A)
(B)
(B)
EC 2003 -80-
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