Gas gas EC 2005, MC 2005 SERVICE MANUAL

MANUAL DEL USUARIO

SERVICE MANUAL

MANUEL D’ENTRETIEN

LIBRETTO USO E MANUTENZIONE

Foreword

GAS GAS thanks you for the trust you have placed in us.

By choosing the new GAS GAS EC / MC / SM 2005 you have become part of the great GAS GAS family and, as a user of the number one manufacturer of off-road motorbikes, 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 / MC / SM 2005 is a motorcycle conceived for the practice of high-competition. 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 motorcycles of the highest level, GAS GAS unique motorcycles which count on important key factors: reliability, high features and a good stability.

Congratulations for making the right choice. With your skills at the command of this motorcycle, its adequate preparation and the corresponding indispensable servicing, this motorcycle will prove to be highly reliable, and you will be able to enjoy the most comfortable and rewarding practice of your favorite sport.

Thank you for your trust in us, and welcome to GAS GAS Motos, S.A.

October 2004

EC / MC / SM 2005 -66-

HOW TO USE THIS MANUAL

Read this Manual carefully. You will find it contains all the necessary information for your safety, and that of other persons, as well as guaranteeing the correct conservation and maintenance of the GAS GAS motorcycle that you have just acquired.

You will find all the necessary instructions for the correct riding and control of this vehicle are set out below. Each message is preceded by a symbol with the following meaning: .

WARNING

This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury or even death.

Motorcycle riding, if improverly conducted, has the potential to cause environmental problems as well as conflicts with other people. Responsible riding use of your motorcycle will ensure that these problems and conflicts do not develop.

TO PROTECT THE FUTURE OF YOUR SPORT MAKE SURE YOU USE YOUR MOTORCYCLE WHITHIN THE LAW, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE.

Motorcycle riding is a wonderful sport, and we hope you will enjoy it to the fullest.

CAUTION

This symbol identifies instructions or procedures which, if not followed strictly, could result in damage to or destruction of equipment.



NOTE

This note symbol indicates points of particular interest for more efficient and convenient operation.

EC / MC / SM 2005 -67-

RECOMMENDS THE USE OF OIL:

TABLE OF CONTENTS

Foreword ........................................................................................66

How to use this manual...................................................................67

Table of contents.............................................................................68

Specifications..................................................................................69

Location of components..................................................................71

Side Stand ......................................................................................75

Fuel.................................................................................................75

Serial Number.................................................................................77

Homologation Plate.........................................................................77

Starting the engine..........................................................................77

Shifting gears..................................................................................78

Stopping the motorcycle .................................................................79

Riding during the Break-In Period...................................................79

Maintenance Schedule ...................................................................80

Electronic Ignition............................................................................82

Cooling System...............................................................................82

Spark Plug ......................................................................................85

Transmission...................................................................................85

Air Cleaner......................................................................................87

Throttle Cable .................................................................................88

Carburetor.......................................................................................88

Clutch..............................................................................................89

Exhaust System..............................................................................89

Drive Chain Guide...........................................................................90

Handlebar .......................................................................................92

Brakes.............................................................................................93

Steering...........................................................................................94

Steering blockage ...........................................................................95

Front Fork .......................................................................................96

Rear suspension.............................................................................99

Wheels..........................................................................................101

Cleaning........................................................................................102

Bolts and nuts tightening...............................................................103

Lubrication ....................................................................................105

Tunning (Carburetor and Suspension)..........................................106

Final recommendatios...................................................................114

Homologation................................................................................115

Preparation for competition...........................................................116

Storage..........................................................................................117

GAS GAS Multifunction Instructions ............................................117

Troubleshooting.............................................................................119

Warranty Manual...........................................................................124

EC / MC / SM 2005 -68-

SPECIFICATIONS

ENGINE  2 cycles, single cylinder, crankcase intake, liquid cooled.

125 cc Engine 

Bore and stroke  54 x 54.5 mm. Displacement  124 c.c.

200 cc Engine (only EC)

Bore and stroke  62.5 x 65 mm. Displacement 199,4 cc.

250 cc Engine

Bore and stroke  66.4 x 72 mm. Displacement  249,3 cc.

300 cc Engine (only EC)

Bore and stroke  72 x 72 mm. Displacement  294,7 cc.

Carburetor type  KEIHIN PWK 38. Lubrication system Mixture.

100% Synthetic Oil 50:1 = 2%

Mineral Oil (Only USA) 32:1 = 3% Starting system Starting lever. Ignition system CDI system. Ignition timing 1 mm BTDC. Spark plug  NGK BR9EG ( 125 c.c. )

NGK BR8EG ( 200 c.c. / 250 c.c. / 300 c.c. )

TRANSMISSION

Transmission type  6 speed in cascade. Clutch type  Hydraulic operated multi-plate in oil bath. Secondary drive  Chain driven. Gear ratio  1st 2.071 (29/14) 

2nd 1.625 (26/16)  3rd 1.333 (24/18)  4th 1.100 (22/20)  5th 0.913 (21/23)  6th 0.791 (19/24)

EC / MC / SM 2005 -69-

Primary reduction  2.85 (57/20) Final reduction 3.615 (47/13) Overall gear ratio  8.149 (6th gear) Transmission oil Capacity  750 cc. ( 125 c.c. )

900 cc. ( 200 c.c. / 250 c.c. / 300 c.c. )

Type  10W30 API SF or SG.

CHASSIS

Type   Tubular, semi-double cradle. Tire size  Front   EC & MC - 90/90 x 21.

SM - 120/60 ZR17.

Rear  EC - 140/80 x 18.

MC - 120/80 x 19. SM - 150/60 ZR17.

Suspension  Front Inverted telescopic fork Marzocchi ø 45 mm (only EC and SM )

Inverted telescopic fork Marzocchi ø 50 mm (only MC )

Inverted telescopic fork ÖHLINS.  Rear Progressive system with single multi-adjustable shock ÖHLINS. Suspension stroke  Front  282 mm.

Rear  320 mm.

Front fork oil   Marzocchi SAE 7,5. 

ÖHLINS SAE 5 - 7,5. Front fork oil level  Marzocchi: 110 mm (compressed, without spring)

ÖHLINS: 110 mm (compressed, without spring)

BRAKES

Type  Front, Rear Disc brake Effective disc diameter Front 260 mm. (only EC and MC )

320 mm. (only SM ) 

Rear 220 mm.

DIMENSIONES

Overall height 1260 mm. Overall length  2135 mm. Overall width  810 mm. Seat height  940 mm. Minimum height  340 mm. Wheelbase  1475 mm. Fuel tank capacity 9 l.

(Specifications are subject to change without notice and probably do not apply to all countries).

EC / MC / SM 2005 -70-

LOCATION OF COMPONENTS

1 32 4 5 6

GAS GAS EC 2005

GAS GAS MC 2005

GAS GAS SM 2005

1 32 4 5 6

1- Clutch lever 2- Steering and lighting controls 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip

1- Clutch lever 2- Engine stop button 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip

1- Clutch lever 2- Steering and lighting controls 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip

EC / MC / SM 2005 -71-

GAS GAS EC 2005

13 9

1615

12 18

7- Brake disc 8- Front suspension 9- Brake fluid reservoir 10- Fuel tank 11- Carburetor 12- Rear shock absorber 13- Brake caliper 14- Radiator 15- Gasoline cock 16- Shift pedal

17- Air cleaner 18- Muffler 19- Seat 20- Gas reservoir 21- Chain guide 22- Chain 23- Suspension linkage and swingarm 24- Rear brake pedal 25- Kick-start pedal 26- Exhaust

197

2011

24 25

2623

EC / MC / SM 2005 -72-

GAS GAS MC 2005

92220

1019 7

7- Brake disc 8- Front suspension 9- Brake fluid reservoir 10- Fuel tank 13- Brake caliper 14- Radiator 18- Muffler 19- Seat

EC / MC / SM 2005 -73-

24 25

2623

20- Gas reservoir & Rear shock absorber 21- Chain guide 22- Chain 23- Suspension linkage and swingarm 24- Rear brake pedal 25- Kick-start pedal 26- Exhaust

GAS GAS SM 2005

1019 7

7- Brake disc 8- Front suspension 9- Brake fluid reservoir 10- Fuel tank 14- Radiator 18- Muffler 19- Seat

EC / MC / SM 2005 -74-

24 25

2623

20- Gas reservoir & Rear shock absorber 21- Chain guide 22- Chain 23- Suspension linkage and swingarm 24- Rear brake pedal 25- Kick-start pedal 26- Exhaust

SIDE STAND (only EC and SM)

FUEL

To set the side stand only turn it until it contacts the stopper, then the side stand will be parallel to the ground and rest securely.

The side stand will return to its original position by means of the double spring. The function of the double spring insures that, when the side stand is down, the rest position is stable and above all secure; moreover, it also returns the side stand to its original position.

EC 2005 and SM 2005

(A)

(A). Side stand.

(B)

MC 2005

(A). Side stand.

NOTE

Do not start the engine or ride the motorcycle when the side stand is down.

(B). Double  spring

(A)

The GAS GAS EC / MC / SM models have 2-cycle engines that require a mixture of gasoline and oil.

Gas Tank Capacity

9 L

(B)

(A)

(A). Fuel tank cap. (B). Vapor outlet tube.

The fuel tank cap is of the quick-release type. To open the fuel tank cap, lift the plated latch and turn cap counterclockwise. To close it, turn the cap clockwise and lower the latch.

NOTE

It is recommended that the rubber seal should be checked thoroughly to insure it is airtight.

EC / MC / SM 2005 -75-

RECOMMENDED FUEL

Use gasoline with an octane rating equal to or higher than that shown in the table.

Recommended oil:

2-CYCLE SYNTHETIC

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.

Mixing oil inside the engine

Oil must be mixed with gasoline to lubricate the piston, cylinder, crankshaft, and connecting rod bearings.

If the recommended oil is not available, use only oil designed

NOTE

for racing with 2-cycle engines.

Gasoline and engine oil mixing proportions:

Synthetic oil 100%: gasoline 50, engine oil 1 = 2%

Semi-synthetic oil: gasoline 50, engine oil 1 = 2%

Mineral oil: gasoline 32, engine oil 1 = 3%

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.

CAUTION

Below 0 ºC do not use 100% synthetic oil.

To prepare the mixture, first pour oil and half of the gasoline used into a container 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 lubrication quality of this mixture deteriorates rapidly; use a fresh mixture for each day of operation.

EC / MC / SM 2005 -76-

SERIAL NUMBER (A)

STARTING THE ENGINE

It is stamped on the steering pipe. It indicates the frame number registered for this motorcycle.

HOMOLOGATION PLATE (B)

This motorcycle carries its corresponding homologation plate where it also shows the serial number, and this data must match the information registered in the motorcycle documents.

(A)

(B)

1. Make sure the motorcycle is in the neutral position.

2. Turn the gasoline cock (A) clockwise to the "ON" position.

Open

OFF

RES

Reserve

(A)

(B)

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

EC / MC / SM 2005 -77-

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

(C)

NOTE

the throttle 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.

Stopping the engine (MC model)

1. Shift the transmission into neutral.

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

(A)

4. Start the

motorcycle with kick-start pedal (C).

5. Even after the engine starts, keep the choke knob pulled up.

Stopping the engine (EC and SM models)

1. Shift the transmission into neutral.

(D)

3. Turn the key in counterclockwise direction to the "OFF" position.

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

EC / MC / SM 2005 -78-

SHIFTING GEARS

The transmission is a 6-speed, of the return shift type. A return shift means that to go from first gear to third gear it must go first through the second gear, that is to say that it upshifts gears one by one. To engage first gear from neutral, pull the clutch lever in and push down on the gearshift pedal, then release the gearshift pedal and gently release the clutch lever.

CAUTION

When shifting gears, press firmly on the gearshift pedal to ensure a positive shifting. Careless, incomplete shifts can cause the transmission to jump out of gear and cause engine damage.

(A)

(A). Gearshift pedal.

STOPPING THE MOTORCYCLE

Perform the break-in period following these steps:

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)

RIDING DURING THE BREAK-IN PERIOD 

A break-in period is necessary to ensure a smooth operation and obtain an optimum engine and the transmission responses. During the first hour or 20 km of operation, run the engine at low and moderate speeds and revolutions per minute (RPM).

NOTE

The slow riding necessary during the break-in period may cause carbon deposits 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 another of a higher heat range.

1. Start the engine and let it run at idle until the engine is warm.

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 cxarry out 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

needed (Refer to the table of adjustments).

7.  Install the parts removed.

8.  Fill the radiator with the recommended coolant. Before starting

the motorcycle, bleed the air from the cooling system.

9.  Start the engine and ride for 30 minutes at moderate speed.

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.

CAUTION

However, avoid accelerating recklessly that can lead to engine failure. Be careful to use the necessary skills and techniques while operating the motorcycle.

NOTE

After the break-in period, install a new set of standard spark plugs.

EC / MC / SM 2005 -79-

Item

MANTENANCE SCHEDULE

Check / Inspect Change / Replace Apply grease /

Adjust

Clean

Lubricate

Clutch Discs Throttle cable Spark plug Air cleaner element Carburetor Transmission oil Piston and piston ring Cylinder head, cyl. & exhaust valves Exhaust Muffler gasket Piston bearing Kick-start pedal and gearshift pedal Exhaust pipe o'ring Engine bearings Coolant Radiator tube and connections Brake adjustment Brake pads wear Brake fluid level Brake fluid Brake pump piston & dust cover

At each fill up

3 fill ups

1 fill up

3 fill ups 3 fill ups

1 fill up

3 fill ups

10 fill ups

3 fill ups

1 fill up 3 fill ups 5 fill ups 3 fill ups

At each fill up

3 fill ups*

1 fill up

3 fill ups* 3 fill ups*

1 fill up*

10 fill ups*

3 fill ups*

10 fill ups*

3 fill ups*

1 fill up* 3 fill ups* 5 fill ups* 3 fill ups*

At each fill up*

3 fill ups*

When damaged

3 fill ups 3 fill ups* 3 fill ups*

1 fill up*

10 fill ups 10 fill ups

3 fill ups

10 fill ups*

3 fill ups*

1 fill up* 3 fill ups* 5 fill ups* 3 fill ups*

Every 2 years Every 2 years

1 fill up 1 fill up

3 fill ups

1 fill up

At each fill up

3 fill ups

1 fill up

The maintenance and adjustments in this table are easy to follow and must be carried out to keep the motorcycle in good running condition.

NOTE: (*) Inspect and carry out these operations only if it is necessary.

EC / MC / SM 2005 -80-

Item

MANTENANCE SCHEDULE

Check / Inspect Change / Replace Apply grease /

Adjust

Clean

Lubricate

Brake caliper piston seal & dust seal Brake hose and pipe Spoke tightness and rim runout Lubricate drive chain Drive chain Drive chain 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 Swingarm and linkages Rear shock absorber oil

1 fill up

5 fill ups

1 fill up

5 fill ups 7 fill ups

1 fill up 5 fill ups 5 fill ups

10 fill ups

5 fill ups

Every 2 years

1 fill up*

5 fill ups

5 fill ups*

When necessary

5 fill ups* 7 fill ups*

5 fill ups*

10 fill ups*

5 fill ups*

2 years*

Every 2 years Every 4 years

1 fill up*

5 fill ups

5 fill ups*

When damaged

Every year

5 fill ups*

7 fill ups

10 fill ups

5 fill ups*

10 fill ups*

5 fill ups*

2 years*

When necessary

1 fill up

5 fill ups

10 fill ups

5 fill ups

The maintenance and adjustments in this table are easy to follow and must be carried out to keep the motorcycle in good running condition.

NOTE: (*) Inspect and carry out these operations only if it is necessary.

EC / MC / SM 2005 -81-

ELECTRONIC IGNITION

This motorcycle uses a capacitor discharge ignition system (CDI). The ignition system should never require adjustment unless the stator of the magnetic flywheel was incorrectly installed during engine reassembly.

If necessary, inspect and adjust as follows:

Adjustment

- Remove the magnetic flywheel cover (A).

- Verify that the mark (C) on the magnetic flywheel is aligned with the mark on the crankcase (B).

- If the marks are not aligned, loosen the magnetic inertia wheel screws and turn it.

- Tighten the screws securely.

- Install the magnetic flywheel cover.

NOTE

Engine tune-up can be adjusted to match the rider´s preferences and skills.

- Remove the magnetic flywheel cover.

- Loosen the stator screws.

- Adjust the engine tune-up by changing the position of the stator within prudent limits

NOTE

For the best engine performance, it is very important to adjust the engine tune-up within the set of limits described.

(A)

(B)

(C)

125 cc.

200/250/300 cc.

EC / MC / SM 2005 -82-

- Tighten the stator screws.

- Install the magnetic flywheel cover.

- Test ride the motorcycle and readjust the engine tune-up, if necessary.

COOLING SYSTEM

Radiator Hoses

Check the radiator hoses for cuts or deterioration, and the connections for looseness and leaks.

Radiator

Check the radiator fins for obstructions (insects or mud). Remove any obstructions with a stream of low water pressure.

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