GasGas EC 2004 Owner's manual

MANUAL DEL USUARIO

MANUAL DEL USUARIO

SERVICE MANUAL

SERVICE MANUAL

MANUEL D’ENTRETIEN

MANUEL D’ENTRETIEN

LIBRETTO USO E MANUTENZIONE

LIBRETTO USO E MANUTENZIONE

Compuesta

SERVICE MANUAL

SERVICE MANUAL

ENGLISH

Foreword

GAS GAS thank you for your confidence

By choosing the new GAS GAS EC 2004 you have just entered the great GAS GAS family and, as a user of
the number one off-road motorbike manufacturer, you deserve the distinguished treatment that we wish to offer
to you both in our after-sale relationship and in the explanations that we provide in this manual.

Our EC 2004 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.

July 2003

EC 2004 -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 2004 -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 2004 -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)

EC 2004 -67-

Overall drive ratio 8.149 (6th gear)
Transmission oil Capacity 1800 cc.

Type 5W50 API SF o SG

CHASSIS
Type Chromolly tubular semi double cradle
Tires Front 80/100 x 21

Rear 120/90 x 18

Suspension Front Upside-down telescopic ø 43mm WP fork.

Upside-down telescopic ø 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 2004 -68-

LOCATION OF COMPONENTS

GAS GAS EC 2004 cc.

1 3 24 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 2004 -69-

8

10

9

12 18

197

2011

13 9

14

1615

17

7- Brake Disc, front
8- Front Suspension
9- Brake fluid reservoir, rear
10- Fuel Tank
11- Carburetor
12- Rear shock absorber
13- Brake Caliper, front
14- Radiator
15- Fuel Tap
16- Shift pedal

EC 2004 -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

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.

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 2004 -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 2004 -72-

SERIAL NUMBER

START THE ENGINE

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)

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

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

ON

Open

OFF

Close

RES

Reserve

(A)

(B)

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

EC 2004 -73-

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

(F)

NOTE

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.

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.

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 2004 -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 2004 -75-

Part

MAINTENANCE AND ADJUSTMENT

Check /

inspect

Adjust

Replace /

Change

Clean

Grease /

Lubricate

Clutch
Friction plates
Throttle cable
Spark plug
Air cleaner element
Carburetor
Transmission 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.

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

EC 2004 -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.

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

EC 2004 -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:

- 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.

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 2004 -78-