GasGas EC Racing 2011 Owner's manual

EC 2 STROKES RACING 2011

ENGLISH

Foreword

GAS GAS thanks you for the trust you have placed in us. By choosing the new GAS GAS EC 2011 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 2011 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.

February 2011

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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:

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TABLE OF CONTENTS

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

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

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

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

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

Side Stand ......................................................................................10

Fuel.................................................................................................10

Serial Number.................................................................................12

Homologation Plate.........................................................................12

Starting the engine..........................................................................12

Shifting gears..................................................................................13

Stopping the motorcycle .................................................................14

Riding during the Break-In Period...................................................14

Maintenance Schedule ...................................................................15

Electronic Ignition............................................................................17

Cooling System...............................................................................17

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

Transmission...................................................................................20

Air Cleaner......................................................................................22

Throttle Cable .................................................................................23

Carburetor.......................................................................................23

Clutch..............................................................................................24

Exhaust System..............................................................................24

Drive Chain Guide...........................................................................25

Handlebar .......................................................................................27

Brakes.............................................................................................28

Steering...........................................................................................29

Steering blockage...........................................................................30

Front Fork .......................................................................................31

Rear suspension.............................................................................34

Wheels............................................................................................36

Cleaning..........................................................................................37

Bolts and nuts tightening.................................................................38

Lubrication ......................................................................................40

Tunning (Carburetor and Suspension)............................................41

Final recommendatios.....................................................................49

Homologation..................................................................................50

Preparation for competition.............................................................51

Storage ...........................................................................................52

GAS GAS Multifunction Instructions ..............................................53

Troubleshooting..............................................................................60

Electric Schemas............................................................................65

Warranty Manual.............................................................................66

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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

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

Bore and stroke 72 x 72 mm Displacement 294.7 cc

Carburettor, diameter of diffusor 38 (125 cc : 36) Lubrication system Mixture

Starting system Starting lever Ignition system CDI system Ignition timing 1 mm BTDC

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%

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)

(125cc)

1st. 2,308 (30/13) 2nd. 1,867 (28/15) 3rd. 1,529 (26/17) 4th. 1,286 (27/21) 5th. 1,130 (26/23) 6th. 1,000 (24/24)

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Primary reduction 2.85 (57/20) (250 cc, 300 cc); 3,32 (63/19) (125cc) Final reduction 3.692 (48/13) (125 cc, 250 cc, 300 cc); 3,667 (44/12) (200cc) Transmission oil Capacity 750 cc (125 cc)

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

Type 10W30 API SF or SG

CHASSIS

Type Tubular, semi-double cradle Tire size Front EC - 90/90 x 21

Rear EC - 140/80 x 18

Suspension Front Inverted telescopic fork ø 45 mm (EC 125, 200 )

Inverted telescopic fork ø 48 mm (EC 250, 300 ) Rear Progressive system with single multi-adjustable shock Suspension stroke Front ø45: 290mm / ø48: 305mm

Rear 320 mm

Front fork oil SAE 5 - 7.5 Quantity of oil in front fork ø45: 595cc / ø48: 320cc

Level of oil in front fork ø45: 100mm ( without spring, without preload tube and compressed )

ø48: not possible to measure

BRAKES

Type Front, Rear Disc brake Effective disc diameter Front 260 mm

Rear 220 mm

DIMENSIONS

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 9.5 l

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

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LOCATION OF COMPONENTS

GAS GAS EC 2010

1- Clutch lever 2- Steering, lights, horn and headlamp controls 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip 7- Clutch fluid reservoir 8- Choke Trigger

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GAS GAS EC

25- Kick-start pedal 26- Exhaust 27- CDI switch 28- Front axe puller

17- Shift pedal 18- Muffler 19- Seat 20- Gas reservoir 21- Chain guide 22- Chain 23- Suspension linkage and swingarm

9- Brake disc 10- Front suspension 11- Fuel tank 12- Carburetor 13- Rear shock absorber 14- Brake caliper 15- Radiator 16- Gasoline cock

24- Rear brake pedal

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SIDE STAND

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.

(A). Side stand. (B). Double spring.

(A). Side stand.

(A)

NOTE

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

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

Gas Tank Capacity

9,5 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.

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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.

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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 trigger (B).

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

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.

4. Start the motorcycle with

kick-start pedal (C).

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

Stopping the engine

1. Shift the transmission into neutral.

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.

(D)

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

(A). Gearshift 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.

inspection of the spark plug shows this to be the case, replace the standard spark plug with another of a higher heat range.

Perform the break-in period following these steps:

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

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

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.

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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.

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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

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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.

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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 30% solution of ethylene glycol, and has a freezing point of –18 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).

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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.

Total quantity

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

Coolant Replacement

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.

NOTE

Check the level when the engine is cold.

- 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.

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.

200/250/300

(A)

(B)

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125 cc.200 / 250 / 300 cc.

(A)

(B)

WARNING

If coolant gets on the tires will make them very slippery and can cause an accident.

- Visually inspect the old coolant. If whitish spots are observed in the liquid is a clear indication that the aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts of the system are rusting. In both cases, flush the cooling system.

- Check the cooling system for damage, leaks or missing gaskets in the cooling system.

- Install the water pump cover drain screw with the specified torque values shown in the table. Always replace the gasket with a new one.

Standard Spark Plug 125 cc Denso W27ESR-U 0.7-0.8 mm OR NGK BR9EG

200 / 250 / 300 cc Denso W24ESR-U 0.7-0.8 mm OR NGK BR8EG

The spark plug should be removed periodically to check its gap. If the plug is oily or has carbon deposits, clean it with a sandblaster. After removing the abrasive particles, the spark plug must be cleaned using a wire brush or a similar tool. Measure the gap with a feeler gauge, if incorrect adjust the gap by bending the side electrode. If the spark plug electrodes are corroded or damaged, or if insulator is cracked, replace the plug.

NOTE

Inspect every 30 hours and change every 60 hours.

Drain plug tightening torque (refer to torque table)

Water pump screw: 9 Nm

- Fill the radiator up to the edge of the cap with coolant, and install the radiator cap.

- Inspoect the cooling system for leaks.

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

- Check the coolant level after the engine cools down. Add coolant up to the cap.

SPARK PLUG

The standard spark plug is a shown in the table and should be tightened to 27 Nm.

To find out whether the right heat range plug is being used, remove it and inspect the ceramic insulator around the center electrode. If the ceramic is light brown, the spark plug is correctly matched to engine temperature. If the ceramic is whie, the spark plug should be replaced with the next colder plug. If the ceramic is black, the spark plug should be replaced with the next hotter plug.

NOTE

If the engine performance drops, replace the spark plug first to recover its output.

TRANSMISSION

For the transmission and clutch to function properly, maintain the transmission oil level at the optimum level and change it periodically. A motorcycle with insufficient transmission oil, deteriorated or contaminated can accelerate wear and tear and cause transmission

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Oil level inspection

Oil change

- Wait a few minutes if the motorcycle has been operating.

(A)

(B)

- If the level is low, add the necessary quantity of oil by opening the

plug (C). Use the same type and oil manufacturer used currently with the engine.

Transmission Oil Viscosity: SAE 10W30

Capacity: 750 cc (EC 125)

900 cc (EC 200-250-300)

- Check the oil level through the inspection window in the lower right hand side of the engine (A).

- Oil level must be kept between the maximum and minimum marks.

- If the lever is too

high, you have to remove the excess oil through the drain

plug (B).

125 cc.

NOTE

200 / 250 / 300 cc

The engine must be completely cool and then warm up the engine again for a few minutes to normal operating temperature, to register the correct engine oil temperature and to obtain an accurate oil level measurement.

- The transmission oil should be changed periodically to ensure long engine life.

- Warm up the engine for 5 minutes so any oil sediment will float.

- Stop the engine, and place an oil pan under the engine.

- Remove the drain screw (see previous photo) and place the motorcycle in riding position to allow the oil to drain out.

- Clean the drain screw magnet of any iron particles.

- Tighten the oil drain screw with its O-ring to 20-Nm.

- Remove the oil filler opening plug (C) and pour 900 cc of new transmission oil for the models 200 / 250 / 300, and 750 cc for model 125.

- Check the oil level, after kicking the kick-start pedal 3 or 4 times.

- Install the oil filler opening plug.

(C)

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+ 46 hidden pages

GasGas EC Racing 2011 Owner's manual

Specifications and Main Features

Frequently Asked Questions

User Manual