Gas gas EC 2006, MC 2006, SM 2006 USER MANUAL

MANUAL DEL USUARIO
USER MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
BETRIEBSANLEITUNG

RECOMIENDA EL USO DE ACEITE:

RECOMMENDS THE USE OF OIL:

RECOMMANDE L’USAGE DE L’HUILE:

CONSIGLIA L’USO D’OLIO:

EMPFIEHLT DEN GEBRAUCH VON ÖL:

JUNIO / JUNE / JUIN / GIUGNO / JUNI 2006

C/ UNICEF nº 17 · Poligon Industrial Torremirona · 17190 Salt (Girona) SPAIN · Tel: [phone] Fax: [phone]

E-mail: [e-mail] / [e-mail]

PUO10638002

USER MANUAL

USER MANUAL

ENGLISH

Foreword

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

By choosing the new GAS GAS EC / MC / SM 2006 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 2006 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.

April 2005

-3-

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.

RECOMMENDS THE USE OF OIL:

-4-

TABLE OF CONTENTS

Foreword...........................................................................................3

How to use this manual.....................................................................4

Table of contents...............................................................................5

Specifications....................................................................................6

Location of components....................................................................8

Side Stand ......................................................................................12

Fuel.................................................................................................12

Serial Number.................................................................................14

Homologation Plate.........................................................................14

Starting the engine..........................................................................14

Shifting gears..................................................................................15

Stopping the motorcycle .................................................................16

Riding during the Break-In Period...................................................16

Maintenance Schedule ...................................................................17

Electronic Ignition............................................................................19

Cooling System...............................................................................19

Spark Plug ......................................................................................20

Transmission...................................................................................22

Air Cleaner......................................................................................24

Throttle Cable .................................................................................25

Carburetor.......................................................................................25

Clutch..............................................................................................26

Exhaust System..............................................................................26

Drive Chain Guide...........................................................................27

Handlebar .......................................................................................29

Brakes.............................................................................................30

Steering...........................................................................................31

Steering blockage ...........................................................................32

Front Fork .......................................................................................33

Rear suspension.............................................................................36

Wheels............................................................................................38

Cleaning..........................................................................................39

Bolts and nuts tightening.................................................................40

Lubrication ......................................................................................42

Tunning (Carburetor and Suspension)............................................43

Final recommendatios.....................................................................51

Homologation..................................................................................52

Preparation for competition.............................................................53

Storage ...........................................................................................54

GAS GAS Multifunction Instructions ..............................................55

Troubleshooting ..............................................................................61

Electric Schemas ............................................................................66

Warranty Manual.............................................................................67

-5-

SPECIFICATIONS

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

125 cc Engine

Bore and stroke 54 x 54.5 mm
Displacement 124 cc

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

Starting system Starting lever
Ignition system CDI system
Ignition timing 1 mm BTDC
Spark plug NGK BR9EG (125 cc) NDW27ESR-U

TRANSMISSION

Transmission type 6 speed in cascade
Clutch type Hydraulic operated multi-plate in oil bath
Secondary drive Chain driven
Gear ratio (200 cc, 250 cc, 300 cc) 1st 2.071 (29/14)

100% Synthetic Oil 50:1 = 2%
Mineral Oil (Only USA) 32:1 = 3%

NGK BR8EG (200 cc / 250 cc / 300 cc) NDW24ESR-U

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)

-6-

Primary reduction 2.85 (57/20) (250 cc, 300 cc)
Final reduction 3.692 (48/13) (250 cc, 300 cc)
Overall gear ratio 8.323 (6th gear)
Transmission oil Capacity 750 cc ( 125 cc )

900 cc ( 200 cc / 250 cc / 300 cc )

Type 10W30 API SF or S.

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, SM and MC 125)

Inverted telescopic fork Marzocchi ø 50 mm (only MC 250)

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).

-7-

LOCATION OF COMPONENTS

GAS GAS EC 2006

1 32

4

5 6

7

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

GAS GAS MC 2006

GAS GAS SM 2006

1

1 32 4 5 6

2

3

7

4

5

7

-8-

6

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

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

GAS GAS EC 2006

8

13 9

14

10

9

1615

12 18

17

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

21

197

2011

24 25

22

2623

-9-

GAS GAS MC 2006

18

92220

1019 7

8

21

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

24 25

14

2623

13

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

-10-

GAS GAS SM 2006

18

20

1019 7

8

9

21

22

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

24 25

14

2623

13

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

-11-

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 2006 and
SM 2006

(A)

(A). Side stand.

(B)

MC 2006

(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.

-12-

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.

-13

-

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.

ON

Open

OFF

Close

RES

Reserve

(A)

(B)

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

-14-

- 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).

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.

-15-

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.

-16-

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

-

-

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.

-17-

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

-

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

-

-

-

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.

-18-

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).

- Make sure that the mark on the stator plate is aligned with the
mark on the crankcase.

- 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)

125 cc

200 / 250 / 300 cc

- 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.

-19-

If high water pressure is used the radiator fins could be damaged

CAUTION

and impair the radiator effectiveness.
Do not obstruct or deflect airflow through the radiator by installing
unauthorized accessories. Any interference with the radiator airflow
can lead to engine overheating and damage.

Coolant information

To protect the cooling system aluminum parts (engine and radiator)
from rust and corrosion, the use of corrosion and rust inhibitors
chemicals in the coolant is essential. If rust inhibitors were not used,
over a period of time the radiator will be corroded. This will clog the
tubes of the cooling system.

If the lowest ambient temperature encountered falls below the freezing
point of water, protect the cooling system. Use a permanent type of
antifreeze in the cooling system (distilled water and ethylene glycol
and corrossion inhibitors for aluminium engines and radiators).

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 have anticorrosion and anti-rust
properties. When it is diluted excessively, it loses its antifreeze and
anticorrosion properties. Mix in accordance with the instructions of
manufacturer.

Liquid recommended

Use of incorrect coolant solutions will cause engine and cooling

CAUTION

system damage.
Use coolant containing corrosion inhibitors made specifically for
aluminum engines and radiators in accordance with the instructions

of the manufacturer.

WARNING

Chemical liquids are harmful to the human body. Follow manufacturer
instructions.

CAUTION
Distilled water must be used with corrosion inhibitors and the
antifreeze in the cooling system. If tap water is used in the system,
the cooling tubes can be clogged and reduce the cooling system
efficiency.

Permanent type of antifreeze (distilled water and ethylene glycol)
plus corrossion inhibitors for aluminium engines and radiators.

NOTE

Initially, at the factory a permanent type of antifreeze is installed
in the cooling system. It is colored green, it contains a 50%
solution of ethylene glycol, and has a freezing point of –35 ºC.

Coolant recommended

Coolant absorbs excessive heat from the engine and transfers it to
the air at the radiator. If the coolant level is low, the engine overheats
and may suffer severe damage. Check the coolant level each day
before riding the motorcycle. Add liquid recommended if the level is
low (see next page).

-20-

WARNING

To prevent severe scalding do not remove the radiator cap or try to
change liquid, when the engine is still hot. Wait until it cools.

Coolant level

- Place the motorcycle in riding position.

- Turn the radiator cap (A) counterclockwise and wait a few seconds

until vapors inside are released. Then push and turn it further in
the same direction and remove the cap.

(A)

(1). Coolant level.
(2). Filler opening.

Total quantity

Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze
50%).
Capacity: 1.1 L

Coolant Replacement

Coolant should be changed periodically to ensure long engine life.

- Wait for the engine to cool completely.

- Place the motorcycle in riding position.

- Remove the radiator cap.

- Place a container under the coolant drain screw, and drain the
coolant from the radiator and engine by removing the drain screw
(B) at the bottom of the water pump cover (A). Wash off immediately
any coolant spilled on the chassis, engine, or wheels.

Check the level when the engine is cold.

NOTE

- Check the coolant level. The coolant level should be just at a level
below de cap rubber seal.

- If the coolant level is low, add the correct amount of coolant
through the filler opening.

-21-

(A)

(B)

(A)

(B)

125 cc.200 / 250 / 300 cc.