GasGas EC Rookie 2005 Owner's manual

MANUAL DEL USUARIO

SERVICE MANUAL

MANUEL D’ENTRETIEN

LIBRETTO D’USO

SERVICE MANUAL

ENGLISH

PRESENTATION

GAS GAS appreciates your trust.

We are happy to see that you have decided on a GAS GAS EC ROOKIE moped and welcome you into the great family of GAS GAS users. Learn everything about your new machine. It contains a large amount of experience accumulated from many competitions where we have won important prizes. You are now the owner of a moped that, besides making you feel comfortable, offers a great many opportunities for you to show your skills while providing top safety levels.

This manual provides a wealth of basic information on the moped features and how best to use it. It also includes important safety instructions , together with basic maintenance and inspection routines.

Thank you for trusting us and welcome to GAS GAS Motorcycles.

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IMPORTANT NOTICE

prevent the appearance of such damage or conflicts.

Read this manual thoroughly. It contains every single aspect that should help to provide safety for yourself and others, and to ensure the appropriate preservation and maintenance of the GAS GAS moped you have just purchased.

READ THE WHOLE CONTENTS OF THIS MANUAL BEFORE USING THE VEHICLE.

Important information about this manual

Specially important information is highlighted in this manual as follows:

WARNINIG

Ignoring the WARNING notice may result in serious or fatal injuries to the moped user, as well as to bystanders or the technicians inspecting or repairing it.

ATTENTION This symbol identifies instructions or procedures that, unless strictly followed, may damage or destroy the equipment. 

NOTE

This symbol shows items of special interest for a better performance and a more convenient operation.

Inadequate riding may cause environmental damage and conflicts with other people. Riding your moped in a responsible manner will

PROTECTING THE FUTURE OF YOUR SPORT ENSURES THE LEGAL USE OF YOUR MOPED WHEN PROPER RESPECT FOR THE ENVIRONMENT AND OTHER PEOPLE’S RIGHTS IS SHOWN.

This manual includes the data and specifications available at the time of compilation. Any difference you may find with your vehicle data and specifications is a consequence of manufacturing and quality improvements. GAS GAS Motos S.A. constantly improves its vehicles so that you may enjoy them at their best.

INSTRUCTIONS FOR USE

A deep knowledge of your vehicle and how it works is extremely important.

- Remember that you are not to leave the engine running within a closed area, as the toxic exhaustion fumes might have fatal consequences.

- Tyre pressure has a direct influence on the vehicle stability.

- Sudden braking may result in skidding.

Engine performance and life depend to a great extent on how it is run in. We recommend strict adherence to the instructions supplied, at the very least during the initial 500 Kms.

- Do not keep the engine running at a high-revolution level.

- Do not change down as soon as the engine starts striving.

- Do not keep the engine running at top speed for a long time.

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TABLE OF CONTENTS

- Presentation........................................................................3

- Important notice.....................................................................4

Instructions for use......................................................4

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

- Specifications.......................................................................6

- Important information...........................................................8

Identification numbers.............................................8

- Component location..............................................................10

- Moped components..........................................................12

Main-beam pilot light................................................12

Indicator pilot light...................................................12

Multifunction.................................................................12

Ignition key...........................................................12

Neutral pilot light................................................12

Oil-reserve pilot light.............................................12

Headlight indicator......................................................... 12

Clutch..............................................................12

Lights.....................................................................12 

Start button.....................................................13

Front brake.........................................................13

Accelerator grip.........................................................13

Fuel tank...............................................................13

Oil.....................................................................14

Oil reservoir........................................................14

Fuel tap.............................................................14

Saddle.........................................................................15

Starting pedal........................................................15

Rear brake pedal..................................................15

Gear pedal.............................................................15

- Starting the cycle.............................................................16

Starting the engine...................................................16

Stopping the engine..................................................16

Choke......................................................................16

Gear box..................................................................17

Stopping the moped......................................................17

Adjustment........................................................17

- Maintenance...........................................................................18

Maintenance schedule.....................................................18

Before starting the moped for the first time...................19

Engine............................................................................19

Gearbox and clutch.........................................................19

Carburettor........................................................................19

Air filter...........................................................................20

Sparking-plug check.........................................................20

Radiator...........................................................................21

Strip box.........................................................................21

Clutch adjustment.............................................................22

Chain lubrication...............................................................22

Chain tightening..............................................................22

Front suspension............................................................23

Rear suspension...........................................................23

Cables............................................................................24

Front brake.....................................................................24

Rear brake........................................................................24

Pump and brake pads...................................................25

Steering..............................................................................25

Tyre pressure.................................................................25

Checking operations at specialised garages..................26

Storage...........................................................................27

- Final advice..................................................................................27

Preventive advice...........................................................27

Safe use of this moped....................................................27

- Events on the road.......................................................................28

Carburettor problems......................................................28

Ignition problems...........................................................28

- Multifunction...................................................................................29

- Guarantee manual..........................................................................31

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SPECIFICATIONS

ENGINE

Cubic Capacity: Type: Number of Cylinders: Fuel Supply: Cooling System: Diameter per Stroke: Carburettor:

Ignition: Clutch:

Gearbox: Transmission: Engine Lubrication: Cooling:

49,38 cc Two-stroke single-cylinder engine with straight-into-crankcase strip admission. One. Fuel supply by means of petrol with separate oil-lubrication pump. Liquid. 40 x 39.3 mm Dell'Ortho* SMA 1412N. 14 mm-diameter diffuser with air intake through an easy-to-clean filter placed within a large filter housing. Electronic with adjustable early timing. Specially designed hydraulic clutch, featuring multiple steel- and friction disks fitted with springs, submerged in a highly effective oil bath. 6 gears. Primary, gear-operated; secondary, chain-operated. Oil mixture. Engine cooling is achieved through a large radiator that keeps the fluid at a constant temperature, never above 80° C.

CHASSIS: Engine:

Chassis: Front Suspension:

Rear Suspension:

Front Brake: Rear Brake:

The radiator, secured onto a double-wedge chassis that unfolds at cylinder level, has been welded with chromolibdene and features reinforcing brackets for a highly resistant, robust assembly. Deltabox, made from Cromoly rectangular tubes, aluminium rocker. High-performance 32 mm-diameter inverted hydraulic fork. Showa* inverted fork, 160 mm stroke.

- Right-hand rod:  175 cc SAE 5.

- Left-hand rod: 150 cc SAE 5. Aluminium rocker. Progressive system fitted with BOGE* single shock absorber providing an extremely long wheel stroke. 250 mm stroke. 240 mm disk fitted with 2-piston clip. 220 mm disk fitted with 4-piston clip. Wrought aluminium.

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Front Tyres:

Rear Tyres:

Starting Pedal: Brake Pedal:

DIMENSIONS

Wheelbase: Saddle Height: Minimum Distance to Ground: Deadweight: Tank Capacity: Oil Reservoir Capacity: Oil Reservoir Reserve: Gearbox Oil: Engine Output Pinion: Driving Chuck: Early Timing: Chain: Sparking Plug: Air Filter:

EC - 80 x 90 x 21" 48P T63 SM - 100 x 80 x 17" EC - 110 x 80 x 18" 58P T63 SM - 130 x 70 x 17"

Wrought aluminium Wrought aluminium with retractable tip.

1.330 mm 920 mm 370 mm 93 Kg 8 litres. 98 NO unleaded petrol. 1,5 litres. 200 cc SAE 15 - 30 Z/ 12 Z/ 52 1,5 mm before PMS. 1/2" reinforced. NGK BR8 ES. 0.6 – 0.7 mm electrode gap. Humid-type foam rubber.

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IMPORTANT INFORMATION

IDENTIFICATION NUMBERS

Enter the vehicle identification number (serial number), the particulars shown on the model label, and the ignition-key identification number in the spaces provided, in order to simplify your future orders for spare parts or as a useful reference in the event of your vehicle being stolen.

Serial Number (A)

This has been printed on the steering arm. It shows the frame number used for registering this moped.

(A)

(B)

SERIAL NUM.

Certification Plate (B)

The moped carries a certification plate showing a serial number (B) that has also been printed on the front, and this information must coincide with that contained in the vehicle documents. We recommend that this information be entered in the box below.

CERTIFICATION PL.

Ignition Key Identification Number (C)

The moped carries one two-key set (C). The identification number appears right on the key joints, as illustrated. This number may be quoted when ordering a spare to replace a lost key.

(C)

KEY NUM.

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No-tampering transfer

The moped carries an information label with a diagram illustrating some vehicle parts and their part numbers. Because these parts were included with the moped during the certification process, replacing some of them might be punished with a fine if traffic police checks the vehicle.

(E)

(F)

(E). Part Numbers. (F). Numbered Diagram.

NOTE

We recommend that a specialised garage be contacted if one of these parts requires replacement. The garage will provide advice on certified spare parts.

As above, again for your own information and safety, we also recommend that all of these part numbers be entered in the spaces provided.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

REFERENCE

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COMPONENT LOCATION

GAS GAS EC / SM ROOKIE 2005

9 10 11 12 13 141 42 3 5 7 86 15

1- Clutch handle 2- Light Switches 3- Clutch fluid reservoir 4- Petrol tank 5- Brake fluid reservoir 6- Start button 7- Accelerator grip 8- Front brake handle

9- Main beam pilot light 10- Indicator pilot light 11- Multifunction 12- Ignition key 13- Neutral pilot light 14- Oil reserve pilot light 15- Headlight indicator

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