GasGas EC 250 F 2012 Owner's manual

EC250-F SUOMI

FOREWORD

GAS GAS thanks you for your confidence.

By choosing the new GAS GAS EC 250-F SUOMI 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 250-F is a bike conceived for highly competitive performance. In fact this bike is the fruit of many years of competition and experimentation in these demanding disciplines; many great trial riders have contributed their expertise and achievements to the essential data we have used to create these high-quality, exclusive motorcycles incorporating key features such as reliability, high performance and stability.

Congratulations for making, without a doubt, the right choice. With skill at the controls of this motorbike, an adequate preparation and the corresponding essential servicing this GAS GAS will remain highly reliable and you will be able to enjoy the most comfortable and rewarding motor sport.

Thank you for your confidence and welcome to GAS GAS motos SA.

July 2011

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IMPORTANT NOTICE

Read this manual carefully. This manual covers aspects that will contribute to your security and to that of others, as well as guaranteeing a correct conservation and maintenance of this GAS GAS motorcycle you have just acquired.

All of the instructions to correctly handle and drive this motorcycle are described in detail. Each message will be preceded by a symbol.

WARNING

This title identifies special instructions or procedures that, if not correctly followed, could result in personal injury, or even death.

CAUTION

This title identifies special instructions or procedures that, if not strictly observed, could result in damage to or destruction of equipment.

NOTE

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

Inadequate driving skill could cause problems to the environment and conflict with other people. Responsible use of your 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, WITH CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE.

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

OIL RECOMMENDED:

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TABLE OF CONTENTS
Foreword.........................................................................................	3
Important notice ..............................................................................	4
Table of contents ............................................................................	5
Specifications..................................................................................	6
Component locations ......................................................................	8
Side stand.....................................................................................	10
Petrol ............................................................................................	10
Serial number and the qualification approval plate.......................	11
Starting and stopping the engine ..................................................	12
Cold starting..................................................................................	13
Gear changes ...............................................................................	13
Stopping the motorcycle ...............................................................	14
Break-in ........................................................................................	14
Maintenance chart ........................................................................	15
Battery ..........................................................................................	16
Cooling system .............................................................................	17
Spark plug.....................................................................................	20
Air filter..........................................................................................	23
Accelerator cable ..........................................................................	24
Clutch............................................................................................	25
Exhaust system ............................................................................	25

Chain guide...................................................................................	26
Tension adjustment ......................................................................	27
Handle bars ..................................................................................	29
Brakes...........................................................................................	29
Steering ........................................................................................	31
Steering lock .................................................................................	32
Front forks.....................................................................................	33
Rear suspension...........................................................................	36
Wheels..........................................................................................	38
Cleaning........................................................................................	39
Tighten bolts and nuts ..................................................................	40
Tightening torque table.................................................................	41
Lubrication ....................................................................................	42
Engine oil ......................................................................................	43
Suspension adjustment ................................................................	46
In competition ...............................................................................	50
Storage .........................................................................................	51
Multi-function instructions ............................................................	52
Fault diagnosis..............................................................................	58
Electrical schemas........................................................................	64
Guarantee manual........................................................................	66

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SPECIFICATIONS

ENGINE
Engine		4 stroke, single-cylinder DOHC 5 valves, liquid cooled
Displacement in cubic centimetres		249cc
Bore and stroke		77 x 53,6mm
Fuel supply		Carburator Keihin FCR MX37
TRANSMISSION
Transmission type		5 speed
Clutch type		Multi disc wet clutch with hydraulic command
Secondary transmission		Chain
Gear ratio		1st 2.385 (31/13)
		2nd 1.750 (28/16)
		3rd 1.353 (23/17)
		4th 1.095 (23/21)
		5th 0.895 (17/19)
Primary reduction ratio		3.353 (57/17)
Final reduction ratio		3.846 (50/13)
Overall drive ratio		11 .5 (5th)
Transmission oil	Capacity	1.300	cc
	Type	SAE 5W40 API SG
CHASSIS
Type		DELTABOX, semi double cradle chassis made from “B” profile Cromoly tubes.
		Aluminium rocker
Tyre sizes	Front	EC	- 90/90 x 21
		EC SM - 120/60 ZR17
	Rear	EC	- 140/80 x 18
		EC SM - 150/60 ZR17

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Suspension	Front	ø 48 mm inverted fork
	Rear	ø 45 mm inverted fork
		Progressive system with single multi-adjustment shock absorber
Suspension stroke	Front	295 mm
	Rear	320 mm
Front suspension oil		Between SAE 5 and 7.5 (check manufacturer’s information)
Front fork oil level		110 mm (compressed, without spring)
BRAKES
Type	Front / rear	Disk brakes, pump and double callipers / simple
Effective disk diameter	Front	260 mm
	Rear	220 mm
DIMENSIONS
Overall height		1260 mm
Overall length		2135 mm
Overall width		810 mm
Wheel base		1475 mm
Minimum ground clearance		340 mm
Fuel tank capacity		7 litres
Weight		118 Kg

(Specifications subject to change without notification, also possibly not applicable in some countries).

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LOCATION OF COMPONENTS

GAS GAS EC250 F

3

4

2

5

6

1	7

1- Clutch handle

2- Engine start button

3- Fuel tank cap

4- Front brake fluid tank

5- Front brake handle

6- Throttle control

7- Clutch fluid tank

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13

8

10

12

19

20

21

9	24	16	11	17	18	15	22	23	25
14
				8- Front suspension		17Rear shock absorber
				9- Radiator		18Chain guide
			10Fuel tank			18Chain
			11Air filter			20Silencer
			12Seat			21Rear shock absorber gas tank
			13Front brake disk			22Tie rod and rocker suspension
			14Front brake callipers			23Rear brake pedal
			15Rear brake fluid tank			24Engine oil cap
			16Shift pedal			25Exhaust bend

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SIDE STAND

To unfold the side stand (A) must be opened to vertical position.

The stand returns to its original position with the aid of the spring

(B).

(A)

(B)

(A). Side stand.

(B). Spring.

NOTE

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

PETROL

The GAS GAS EC 250 F has a four stroke engine and requires 98 octane, unleaded petrol.

Fuel Tank Capacity

7 L

(B)

(A)

(A). Fuel cap.

(B). Fuel vent hose.

To open the gas tank cover (A), turn it anti-clockwise.

To close the fuel cap, rotate it in a clockwise direction.

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RECOMMENDED FUEL

Use lead-free petrol with an octane rating equal to or higher than that shown in the table.

OCTANE RATING METHOD		OCTANE
		RATING (MIN)
Antiknock Index	(RON+MON)/2	90
Research Octane No.	(RON)	98

NOTE

If knocking 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.

SERIAL NUMBER

Printed on the steering tube. Indicates the frame number with which the motorcycle is registered.

Qualification approval plate

The motorcycle is fitted with its own corresponding qualification approval plate with the serial number, also printed on the steering tube and whose data also coincides with that in the documents.

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STARTING THE ENGINE

-Ensure that the motorcycle is in neutral.

-Press button (A) to turn on the electrical circuit, so that the motor may be started.

STOPPING THE ENGINE

-Change gear to neutral.

-After accelerating lightly, cut the gas completely and press button

(C). The electrical circuits are closed.

(A)

(C)

NOTE

Start the engine soon after making contact with the ON button

(A) or the battery may lose its change.

(B)

- Without using the throttle, press the electric start button (B).

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COLD STARTING

To do the cold start, pull the starter.

- There is no need to use the throttle, simply start the engine. Note that the engine will start after a certain number of revolutions.

After the warming time, you can pull out the cold starter. With the cold start, the bike warm slowly without damages.

NOTE

- If the engine is drowned, you can pres the hot starter and on the same time, press the kick pedal 10 at 20 times. When the engine is dry, you can start normally.

HOT START

Don’t use the cold start and don’t touch the trotle. Press the hot starter and start the engine with the kick or the electric starter. When the engine is running, pull out the hot start.

SHIFTING GEARS

The transmission is with 5 speeds, return shift type meaning that to go back to first gear from a higher gear, you must shift back through the gears one by one.

To engage first gear from neutral, pull in the clutch lever and push down on the shift pedal then release the pressure on the shift pedal and gently release the clutch lever.

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.

(B)	(B). Shift pedal.

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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

To obtain the proper operating clearances in the engine and transmission that are necessary for smooth engine performance and reliability, an initial break-in must be completed. For the first hour or 100 Km of operation, run the engine at low rpm.

NOTE

The slow speed necessary during the break-in period may cause carbon to build up on the spark plug and soil it. If inspection of the spark plug shows this to be the case, replace the standard spark plug with a higher heat grade spark plug for the duration of the break-in period.

Break-in following these steps:

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 FULLY.

4.Stop and let the engine cool completely. Check and adjust chain slack and spoke tightness and make a general inspection.

5.Start the engine and ride for 20 minutes at

moderate engine speed. NEVER ACCELERATE FULLY.

6.Stop and let the engine cool completely. Check and adjust (4).

7.Fit the inspected parts.

8.Fill the radiator up completely with cooling liquid. Before starting the engine 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 (4).

11.After the break-in procedure has been properly carried out, the motorcycle is ready for regular operation.

CAUTION

In any case, even an imprudent acceleration can cause engine trouble, take special care and use the proper skills and techniques required for correct driving of the motorcycle.

NOTE

Following the break-in, fit a new standard spark plug.

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MAINTENANCE CHART

Article	Period	Period	Period
	First 5 hours	Every 30 hours	Every 60 hours
Air filter	Inspect each time that the motorcycle has run or when necessary
*Exhaust connectors and bolts
	T	T	T
*Valve tolerances	I	-	I
Spark plug	-	I	R
Fuel tub	I	I	I
		*Revise every 4 years
Engine oil and filter oil	R	R	R
*Engine oil pipes	I	I	I
Coolant	-	I	I
		Revise every 2 years
Radiator hoses	I	I	I
Clutch	I	I	I
Chain	Clean, lubricate	and inspect each time the motorcycle has run
*Brakes	I	I	I
Brake lines	I	I	I
		*Revise every 4 years
Brake liquid	I	I	I
		*Revise every 2 years
Tyres	Inspect tyres for damage and check the tyre pressure every time the motorcycle has run
*Steering assembly	I	-	I
*Front forks	I	-	I
*Rear suspension	I	-	I
*Chassis bolts and nuts	T	T	T

NOTE: I = Inspect and clean, adjust, replace or lubricate if necessary; R = Replace, T = Tighten, C = Clean

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BATTERY

This battery is maintenance free and checking the fluid level is not required. It is advisable to check the charge of the battery periodically

To remove the battery, follow these steps:

(A)(B)

(C)

1.Remove the bolt (A) and remove the seat (B).

2.Release the rubber (C).

3. Disconnect the terminals ensuring that they do not enter into contact with metal parts then extract the battery.

WARNING

Hydrogen gas produced by the battery may explode if exposed to open flame or sparks.

Keep the area ventilated and free from naked flames.

The operating instructions for the battery are as follows:

1.Check the battery tension in open circuit status (disconnected).

2.In case the battery's tension is below 12.60 V, or if the storage period has exceeded 6 months, the battery has to be recharged following the instructions in paragraph 3.

If the battery voltage is above 12.60 V, the battery can be installed on the vehicle without having to recharge it.

3.1.Constant voltage charge mode.

-Constant voltage = 14.40 - 14.70V

-Initial charge current = 0.1 – 0.5 Cn

-Charge duration = 6 hours minimum / 24 hours maximum.

3.2.Constant power charge mode.

-Maximum charge current = 0.1 Cn

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-Recommended charging duration = 5 - 8 hours.

-The product (charge current) X (charge duration) must be within the range: 0.5 - 0.8 Cn.

Note

In case that a different mode of charging is used to those established here, never exceed the maximum allowed currents nor the maximum charge duration of 24 hours.

CAUTION

Not using the standard manner of charging may seriously shorten the battery life.

Never exceed the standard charge.

CAUTION

Inverting the polarity of the battery terminals may cause battery charge problems and cause damage to the battery system.

The red terminal is positive (+) and the black terminal is negative (-).

THE COOLING SYSTEM

Radiator hose

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

Radiator

Check the radiator fins for obstruction by insects or mud. Clean off any obstructions with a stream of low-pressure water.

CAUTION

Using a high pressure water source could damage the radiator fins and render it ineffective.

Do not obstruct or deviate the radiator air intake by installing nonapproved accessories. Interfering with the radiator could cause overheating and result in engine damage.

Coolant

This 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

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait for it to cool down.

Anti-freeze liquid information

To protect the cooling system aluminium parts (engine and radiator) from rust and corrosion, the use of 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 radiator will rust. This will block the cooling hoses.

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CAUTION

Use of incorrect coolant solutions will cause severe engine and cooling system damage.

Use coolant containing corrosion inhibitors made specifically for aluminium 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 in the cooling system.

If normal water is used in the system, it the cooling system tubes may become blocked.

If the lowest ambient temperature encountered falls below the freezing point of water, protect the cooling system against freezing.

Use a permanent type of anti-freeze (soft water and ethylene glycol plus corrosion 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.

Coolant Level

-Situate the motorcycle so that it is perpendicular to the ground.

-Remove the radiator cap in two stages. First turn the cap anti-clock wise and wait for a few seconds. Then push and turn it further in the same direction to remove the cap.

(A)

(A). Radiator Cap.

CAUTION

Permanent types of antifreeze on the market have anticorrosion and anti-rust properties. When diluted excessively these lose their antifreeze and anticorrosion properties. These must be diluted in accordance with the instructions of manufacturer.

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NOTE

Check the level when the engine is cold.

(1). Coolant level.

(2). Filler opening.

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

Recommended liquid

Permanent type of antifreeze (distilled water and ethylene glycol) with corrosion and rust inhibitor chemicals for aluminium engines and radiators).

NOTE

Initially a permanent type of antifreeze is installed in the cooling system by the manufacturer. This is green in colour, containing 30 % ethylene glycol with a freezing point of –18°C.

Changing the coolant

-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 bowl under the water pump cover and remove all the liquid in the radiator and engine, uclock the drain screw (B). Immediately wipe or wash off any coolant that spills on the frame, engine, or wheels.

(A)

(B)

(A). Water pump cover.

(B). Screw to drain.

WARNING

If coolant gets on the tyres this will make them slippery and could result in an accident.

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-Examine the used coolant. If white cotton-like patches appear in the liquid then this means that the aluminium elements of the cooling system are corroded. If the liquid is brown then this means that the steal or iron parts of the system are oxidized. In either case clean out the system.

-Check the cooling system for damage, loose joints, or leaks.

-Put the drain screw on the water pump cover and lock it with the indicated torque. Change the copper washer by a new one.

Screw torque:

Drain screw on the water pump cover: 9 Nm.

-Fill the radiator up to the edge and install the radiator cap.

-Check the cooling system for leaks.

-Start the engine, warm up the engine, and then stop it.

-Check the coolant level after the engine cools down. Add coolant up to the bottom of the radiator filler neck.

SPARK PLUG

The standard spark plug is indicated inside the table and the torque to lock it is 13 Nm.

Standard spark plug

Standard spark plug Gap between electrodes: 0.7-0.8 mm.

The spark plug should be taken out periodically to check the electrode gap. If the plug is oily or has carbon build up on it the clean it with a sand blaster. Following abrasive particle cleaning, the spark plug should be cleaned with a wire brush or similar. Measure the distance

between electrodes using a gauge and adjust in case that it is not correct by bending the outer electrode. If the spark plug electrodes are oxidised, damaged or the insulation is broken then replace the plug.

NOTE

Inspect every 30 hours. Replace every 60 hours.

To find the correct heat grade spark plug is being used, take it out and examine the insulation around the electrode. If the ceramic is light brown, the spark plug is correctly matched to engine temperature. If the ceramic is white, the plug should be replaced with the next coldest plug. If the ceramic is black, the plug should be replaced with the next hottest plug.

NOTE

If the engine output decreases, replace the spark plug to regain performance.

Spark plug maintenance

COMMENTS

If the standard spark plug is wet then replace it.

If the standard spark plug looks glassy or has a white colour, replace it

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WARNING

An incorrectly fitted spark plug, or an incorrect temperature can lead to severe damage to the engine, and this damage is not covered by the warranty.

Always use the manufacturer's recommended brand of spark plug. Check with your dealer or a qualified mechanic to determine the correct spark plug for your motorbike.

Removing the spark plug

To remove the spark plug, follow these steps:

(A)

(B)

1. Remove the bolt (A) and remove the seat (B).

	(C)		2. Remove the bolts
			(C) (left and right).

(C)

3. Remove the	(D)
rubber attachment
on the tank (D).

(E)	4. Remove the tank
	securing bolt (E).

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