GasGas EC 125,200,250,300 2003 Owner's manual

SERVICEI MANUAL

Foreword

GAS GAS thank you for your confidence

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 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.

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

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 LEGALLY, 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
Table of contents.............................................................................	66
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
Tunning (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

4 2

5

6

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 2003 -69-

7

8

9

10

11

12

18

19

20

13 14 15 16 9 17 21 22 23 24 25 26

7-	Brake Disc, front	17Air Cleaner
8-	Front Suspension	18Silencer
9- Brake fluid reservoir, rear		19Seat
10Fuel Tank		20Nitrogen Reservoir
11Carburetor		21Chain Guide
12Rear shock absorber		22Drive chain
13Brake Caliper, front		23Rear Suspension Linkage
14Radiator		24Rear Brake Pedal
15Fuel Tap		25Kick Start Pedal
16Shift pedal		26Exhaust Expansion Chamber

EC 2003 -70-

SIDE STAND

To operate the side stand:

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)

(A). Side Stand

(B). Sidestand spring

(C). Security strap

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.

FUEL

The GAS GAS FSE 400 cc has a four stroke engine and requires 95 octane, unleaded gasoline

Gas Tank Capacity

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.

OCTANE 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.

Recomended Oil:

OIL 2T SINTETIC

NOTE

If recommended oil is not available, use only synthetic oil 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.

Too 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.

EC 2003 -72-

SERIAL NUMBER

This number allows the motorcycle to be registered. The serial number (or V.I.N.) is located on the steering stem of the frame.

Official approval plate

This motorcycle has an official approval plate. It shows the serial number.

(A)

START THE ENGINE

1.You have to assure the motorcycle to the neutral position.

2.Turn right the key of fuel tank (A).

ON

Open

	OFF	RES
		Reserve
	Close

(A)

(B)

3. If the engine is cold, pull up the choke knob (B).

EC 2003 -73-

NOTE

- When the engine is already warm or on hot days, open

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.

(F)

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)

2. After racing the engine slightly, close the throttle completely and push the engine stop button (A).

3. Turn the key in the unclock direction (position in "OFF" (C)).

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, you must shift back through the gears 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.

CAUTION

When changing gears, press firmly on the shift pedal to ensure 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-

MAINTENANCE AND ADJUSTMENT

Part	Check /	Adjust	Replace /	Clean	Grease /
	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	-	-	If it's damaged	1 race	-
Carburetor	Each race	Each race	-	-	-
Transmission oil	-	-	3 races	-	-
Piston and piston ring	3 races	3 races*	3 races*	3 races	-
Cylinder head, cyl. & exhaust valves	3 races	3 races*	3 races*	-	-
Muffler	Each race	1 race*	1 race*	1 race	-
Silencer packing	-	10 races*	10 races	-	-
Small end bearing	3 races	3 races*	10 races	-	3 races
Kick pedal and shift pedal	-	-	-	-	1 race
Exhaust pipe o'ring	-	-	3 races	-	-
Engine bearings check	10 races	10 races*	10 races*	-	-
Coolant	3 races	3 races*	3 races*	-	-
Radiator hoses, connections	Each race	1 race*	1 race*	-	-
Brake adjustment	3 races	3 races*	3 races*	-	-
Brake wear	5 races	5 races*	5 races*	-	-
Brake fluid level	3 races	3 races*	3 races*	-	-
Brake fluid	-	-	Every 2 years	-	-
Brake master cyl. cup & dust seat	-	-	Every 2 years	-	-

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.

NOTA: (*) Inspect and do this operations only if it is necessary.

EC 2003 -76-

MAINTENANCE AND ADJUSTMENT

Part	Check /	Adjust	Replace /	Clean	Grease /
	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
Drive chain	1 race	-	-	-	-
Drivechain wear	-	5 races	5 races	-	-
Chain slider	5 races	5 races*	5 races*	-	-
Front fork	1 race	If it's damaged	If it's damaged	If it's damaged	-
Front fork oil	-	-	Each year	-	-
Nuts, bolt, fasteners	5 races	5 depósitos*	5 races*	-	-
Fuel hose	7 races	7 depósitos*	7 races	-	-
Fuel system	-	-	10 races	If it's necessary	-
Steering play	1 race	-	-	-	-
Rear sprocket	5 races	5 depósitos*	5 races*	-	-
General lubrication	5 races	-	-	-	5 races
Steering bearing	-	-	-	-	10 races
Wheel bearing	10 races	10 depósitos*	10 races*	-	-
Swing arm and uni-trak linkage pivots	5 races	5 depósitos*	5 races*	-	5 races
Rear chock oil	Every 2 years	2 years*	2 years*	-	-

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.

NOTA: (*) 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. However, if there is any doubt as to the timing, inspect and adjust, if necessary, as follows:

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.

(B)(C)

-If the marks are not aligned, loosen the magneto stator screws and turn the magneto stator.

-Tighten the screws securely.

-Install the magneto cover.

NOTE

The ignition timing can be adjusted for different power and to suit the rider´s preference and ability.

-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.

CAUTION

Soft or distilled water must be used with the inhibitor chemicals and 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.

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

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

-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)

NOTE

Check the level when the engine is cold.

-Check the coolant level in the radiator. The coolant level should 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.

(1). Coolant level.

(2). Breather Hose.

Recommended coolant

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators.

NOTE

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).

Water and coolant mixture ratio 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.

125 cc.

200 / 250 / 300 cc.

(A)

(A)

(B)

(B)

EC 2003 -80-