GasGas Enduro 2T 125-200-250-300cc 2014 Owner's manual

2013 GAS GAS Motos, S.A. All rights reserved.

The reproduction, distribution, public communication and transformation, totally or partially, is prohibited without the express authorization of the copyright owner.

The Company has the right, without prior notice, to change the technical content of the products. The models of the images may appear with special equipment that does not carry the standard model.

Manual made by: Automotive Technical Projects, S.L.

Owner´s manual

Contents

GENERAL INFORMATION..................................................................................................................................................................		7
INTRODUCTION...............................................................................................................................................................................		8
LEGAL NOTICES................................................................................................................................................................................	Contents	8
NOTICES AND WARNINGS...............................................................................................................................................................		8
PRELIMINARY WARNINGS...............................................................................................................................................................		9
CONTROLS ANS COMPONENTS LOCATION...................................................................................................................................		10
EC 2T 125/200/250/300cc STANDARD / RACING.................................................................................................................		10
EC 2T 250/300cc STANDARD / RACING E-START...................................................................................................................		12
XC 2T 125/200/250/300cc STANDARD / RACING (USA)........................................................................................................		14
IDENTIFICATION.............................................................................................................................................................................		17
STEERING LOCK..............................................................................................................................................................................		17
SPECIFICATIONS.............................................................................................................................................................................		18
ELECTRICAL DIAGRAM...................................................................................................................................................................		20
EC 2T 200/250/300cc...........................................................................................................................................................		20
EC 2T 250/300cc E-START....................................................................................................................................................		21
EC 2T 125cc General............................................................................................................................................................		22
EC 2T 125cc Turn Signals......................................................................................................................................................		23
TORQUE VALUES............................................................................................................................................................................		24
General................................................................................................................................................................................		24
Chassis.................................................................................................................................................................................		24
Engine..................................................................................................................................................................................		26
Engine “E-START”.................................................................................................................................................................		28
MULTIFUNCTION GAUGE..............................................................................................................................................................		30
Quick guide..........................................................................................................................................................................		30
Screens in normal mode......................................................................................................................................................		31
Installing the sensor and magnet.........................................................................................................................................		32
Measure of the wheel circumference..................................................................................................................................		32
HOMOLOGATION...........................................................................................................................................................................		33
OPERATING INSTRUCTIONS............................................................................................................................................................		35
STARTING PROCEDURE..................................................................................................................................................................		36
BREAK-IN PROCEDURE..................................................................................................................................................................		36
DAILY INSPECTION.........................................................................................................................................................................		37
CLEANING.......................................................................................................................................................................................		41
STORAGE........................................................................................................................................................................................		42
SERVICE AND MAINTENANCE.........................................................................................................................................................		43
MAINTENANCE SCHEDULE............................................................................................................................................................		44
MAINTENANCE...............................................................................................................................................................................		44
1.-Clutch..............................................................................................................................................................................		45
2.-Clutch discs......................................................................................................................................................................		45
3.-Throttle cable..................................................................................................................................................................		45
4.--Spark plug......................................................................................................................................................................		45
5.-Air filter...........................................................................................................................................................................		46
5.1-Air filter.............................................................................................................................................................		46
5.2-Air filter E-START................................................................................................................................................		47
6.-Carburetor.......................................................................................................................................................................		49
7.-Transmission oil...............................................................................................................................................................		49
8.-Piston and ring.................................................................................................................................................................		50
9.-Cylinder head, cylinder, ex. valve.....................................................................................................................................		50
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Owner´s manual

Contents
10.-Exhaust system..............................................................................................................................................................	50
11.-Muffler fiber..................................................................................................................................................................	51
12.-Connecting rod and bearings.........................................................................................................................................	52
13.-Kick-starter and gear shift pedal....................................................................................................................................	52
14.-Rubber joint exhaust/silencer........................................................................................................................................	52
15.-Motor bearings..............................................................................................................................................................	52
16.-Coolant..........................................................................................................................................................................	52
17.-Radiator hose and connections......................................................................................................................................	54
18.-Brakes adjustment.........................................................................................................................................................	54
19.-Brake wear.....................................................................................................................................................................	55
20.-Brake fluid.....................................................................................................................................................................	57
21.-Brake fluid level.............................................................................................................................................................	57
22.-Pump piston and dust cover (front and rear).................................................................................................................	58
23.-Caliper piston and dust cover (all calipers)....................................................................................................................	58
24.-Brake hoses...................................................................................................................................................................	58
25 Y 26.-Wheels and spokes................................................................................................................................................	58
27.-chain guide....................................................................................................................................................................	58
28.-Chain guide wear...........................................................................................................................................................	58
29.-Chain guide shoe...........................................................................................................................................................	58
30.-Front suspension...........................................................................................................................................................	59
31.-Front suspension oil.......................................................................................................................................................	60
32.-Bolts, nuts and fasteners...............................................................................................................................................	60
33.-Gas tube........................................................................................................................................................................	60
34.-Fuel system....................................................................................................................................................................	61
35.-Steering head adjustment.............................................................................................................................................	61
36.-General lubrication........................................................................................................................................................	62
37.-Steering bearings...........................................................................................................................................................	62
38.-Wheel bearing...............................................................................................................................................................	62
39.-Swingarm and linkage....................................................................................................................................................	62
40.-Rear suspension.............................................................................................................................................................	62
41.-Chain.............................................................................................................................................................................	65
42.-Tires...............................................................................................................................................................................	65
43.-Battery charge...............................................................................................................................................................	66
ADJUSTMENTS................................................................................................................................................................................	67
INTRODUCTION.............................................................................................................................................................................	68
CARBURETION TUNNING..............................................................................................................................................................	68
Throttle valve opening influences........................................................................................................................................	68
Idle jet and mixture screw...................................................................................................................................................	68
Needle.................................................................................................................................................................................	69
Main Jet...............................................................................................................................................................................	69
Reference carburetion (competition use only).....................................................................................................................	69
Correction Factors...............................................................................................................................................................	70
Symptoms of improper settings...........................................................................................................................................	71
CDI MAP.........................................................................................................................................................................................	72
SECONDARY TRANSMISSION RATIO.............................................................................................................................................	72
SUSPENSION TUNNING.................................................................................................................................................................	72
Available settings.................................................................................................................................................................	72
Standard settings.................................................................................................................................................................	74
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Owner´s manual

Contents
Static SAG............................................................................................................................................................................	76
Correction acording to terrains............................................................................................................................................	76
Adjusting your bike..............................................................................................................................................................	76
REGULATION FOOTRESTS..............................................................................................................................................................	78
TROUBLESHOOTING........................................................................................................................................................................	79
WARRANTY MANUAL......................................................................................................................................................................	85

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Owner´s manual

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Owner´s manual

GENERAL INFORMATION

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Owner´s manual

Introduction

GAS GAS Motos, S.A. thanks you for your confidence.

With the choose of your new GAS GAS EC 2014 or XC 2014 you just entered the great GAS GAS team and, as a user of the brand number one on off-road motorcycles, deserves distinguished treatment that we want to offer both our relationship after the acquisition of your GAS GAS and in the explanations that you are in this manual.

Your GAS GAS EC 2014 or XC 2014 s a bike designed for the practice of the high competition, it is the result of many years of racing and experience in such demanding disciplines. The many successes achieved by great riders with our GAS GAS bikes, have provided basic data in order to create these high level motorcycle. A few exclusive motorcycles GAS GAS with three key factors: reliability, high performance and good stability.

Congratulations because your election has been, without doubt, the right one. With your prowess to the handlebars of your GAS GAS and with adequate preparation and corresponding revisions are essential to ensure that your GAS GAS is highly reliable, you can enjoy more comfortable and grateful practice the sport motorcycle.

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

Legal notices

In the interest of technical development GAS GAS Motos, S.A. reserves the right to modify the construction, staffing, and accessories of the motorcycle without prior notice. Data measures, weights, and powers are understood with the respective tolerances.

Depending on the volume of equipment and accessories for your GAS GAS, as well as the versions certified to respect the various laws of each State, there may be variations on the descriptions and illustrations. So the pictures exposed in this manual may therefore not correspond to the purchased model. That’s why not may arise claim some exception error, error of printing or omission.

Notices and warnings

Please read carefully this manual with special attention to the following notices:

DANGER

Notice about a danger that leads to serious injury and even death.

WARNING

Notice about a danger which may cause personal injury and/or damage to the vehicle.

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Owner´s manual

Preliminary warnings

DANGER

Three of each four fatal accidents are due to head injuries. The risk of brain injury is three times higher if you don’t use a helmet. Always take a helmet approved, the probability of leaving unharmed in an accident increases by 20%. It also recommends the use of eye protection and gloves, boots and other items for protection that are in perfect condition.

Never carry passenger. Your GAS GAS is not approved for this purpose, does not have an appropriate saddle, handles or footrests for passenger. In addition weight and imbalance can affect handling.

Avoid modifications in your GAS GAS with non-original accessories and don’t remove off the original elements, these changes can affect stability and handling, making it a dangerous and illegal vehicle. GAS GAS requires the use of original spare parts and accessories, or parts and accessories homologated by GAS GAS Motorcycles, S.A. It is an essential condition for maintaining the warranty.

Your GAS GAS has been designed for off-road use, not designed for long travel on highways. Such use could lead to engine damages becauseitmaintainedhighrevolutions.Alsotyresarenotsuitableforuseonpavedsurfaces.Ithasnotbeendesignedforurbanuse.Longtops at traffic lights in town could overheat the engine.

Maintain your GAS GAS in good condition. To avoid any problem, inspect your motorcycle before each use and then all maintenance recommended in this manual. After a fall, inspect that the main elements have not been damaged. Driving a motorcycle in a bad state can be cause of an accident with serious injuries and even death.

DANGER

Theexhaustpipeandotherpartsreachedhightemperaturesduringuseandtaketocooldownoncetheengineshutdown.Avoidhandling or touching anything during this period. The use of shorts is not recommended, may cause burns on the legs.

DANGER

Avoid wearing loose clothing that could engage with parts of the vehicle or the environment. Although total security is impossible, the use of suitable equipment reduces the possibility and/or the severity of injuries.

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Owner´s manual

Controls and components location EC 2T 125/200/250/300cc STANDARD-RACING

1

2

3

4

5

6

7

8

9

10

11

12

13

* Image taken from the EC 2T 300cc RACING.

14

15

16

17

18

19

Number	Name	Number	Name
1	Headlampwithposition,lowbeamandhighbeamlamps	11	Front brake caliper
2	Front turn signals	12	Front fork
3	Fuel tank	13	CDI switch
4	Fuel valve	14	Gear shift pedal
5	Rear shock	15	Carburetor
6	Air filter	16	Secondary transmission chain
7	Side stand	17	Chain guide
8	Chain guard	18	License plate holder
9	Rear turn signals	19	Rear reflector
10	Front brake disc

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Owner´s manual

Controls and components location			EC 2T 125/200/250/300cc STANDARD-RACING
1	2	3	4	5	6	7	8

9

10

11

12

13

14

15

16

* Image taken from the EC 2T 300cc RACING.

Number	Name	Number	Name
1	License plate light	9	Muffler
2	Brake light	10	Rear brake disc
3	Seat	11	Rear brake caliper
4	Rear shock gas reservoir	12	Rear brake master cylinder
5	Kick-starter	13	Suspension linkage
6	Manufacturer’s identification plate	14	Rear brake pedal
7	Radiator	15	Sump guard
8	Exhaust	16	Front axle handle

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Owner´s manual

Controls and components location EC 2T 250/300cc STANDARD - RACING E-START

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

* Image taken from the EC 2T 300cc RACING E-START

16

17

18

19

20

Number	Name	Number	Name
1	Headlampwithposition,lowbeamandhighbeamlamps	11	Front brake caliper
2	Front turn signals	12	Front fork
3	Fuel tank	13	CDI switch
4	Fuel valve	14	Starter
5	Rear shock	15	Gear shift pedal
6	Air filter	16	Carburetor
7	Side stand	17	Secondary transmission chain
8	Chain guard	18	Chain guide
9	Rear turn signals	19	License plate holder
10	Front brake disc	20	Rear reflector

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Owner´s manual

Controls and components location EC 2T 250/300cc STANDARD - RACING E-START

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

* Image taken from the EC 2T 300cc RACING E-START

Number	Name	Number	Name
1	License plate light	9	Muffler
2	Brake light	10	Rear brake disc
3	Seat	11	Rear brake caliper
4	Rear shock gas reservoir	12	Rear brake master cylinder
5	Kick-starter	13	Suspension linkage
6	Manufacturer’s identification plate	14	Rear brake pedal
7	Radiator	15	Sump guard
8	Exhaust	16	Front axle handle

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Owner´s manual

Controls and components location XC 2T 125/200/250/300cc STANDARD - RACING

1

2

3

4

5

6

7

8

9

10

* Image taken from the XC 2T 300cc RACING

11

12

13

14

Number	Name	Number	Name
1	Headlampwithposition,lowbeamandhighbeamlamps	8	Front brake caliper
2	Fuel tank	9	Front fork
3	Fuel valve	10	CDI switch
4	Rear shock	11	Gear shift pedal
5	Air filter	12	Carburetor
6	Side stand	13	Secondary transmission chain
7	Front brake disc	14	Chain guide

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Owner´s manual

Controls and components location XC 2T 125/200/250/300cc STANDARD - RACING

1

2

3

4

5

6

7

8

9

10

11

* Image taken from the XC 2T 300cc RACING

12

13

14

15

Number	Name	Number	Name
1	License plate light	9	Rear brake disc
2	Brake light	10	Rear brake caliper
3	Seat	11	Rear brake master cylinder
4	Kick-starter	12	Suspension linkage
5	Manufacturer’s identification plate	13	Rear brake pedal
6	Radiator	14	Sump guard
7	Exhaust	15	Front axle handle
8	Muffler

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Owner´s manual

Controls and components location EC STANDARD-RACING / EC STANDARD-RACING E-START

1

2

3

4

5

6

7

8

9

10

11

Number	Name	Number	Name
1	Clutch lever	7	Front brake master cylinder
2	Choke lever	8	Throttle
3	Clutch fluid reservoir	9	Front brake lever
4	Multifunction gauge1	10	Turn signals, lights, horn and engine stop controls
5	Fuel tank cap	11	Steering lock
6	Ignition key 2

1Except XC models.

2Only EC Standard/Racing E-START models.

1

2

3

4

4

5

Number	Name	Number	Name
1	Horn	4	Position, low beam and high beam lights
2	Starter Switch 1	5	Turn signals.
3	Engine stop

1 Only EC Standard/Racing E-START models.

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Owner´s manual

Identification

Your GAS GAS has a manufacturer’s identification plate (1) in which details are: manufacturer, chassis number, homologation number and noise level.

The chassis number is also stamped in the right side of the steering column.

1

Steering lock

Your GAS GAS has a steering lock. It’s found on the right side of the steering column. To lock the steering:

1.Turn the handlebar fully to the right.

2.Insert the key into the lock and rotate it ⅛ of turn counter-clockwise.

3.Press the key inside.

4.Turn the key clockwise to its original position and remove.

The lock should be sunk for the steering lock to be effective.

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Owner´s manual

Specifications

ENGINE

Cycle

Cylinder number

Refrigeration

Capacity

Bore

Stroke

Carburetor

Intake type

Lubrication system

Starting mechanism

Ignition type

Pre-ignition set-up

Spark plug

Electrode gap

2 strokes

Monocylinder

Liquid cooled

124,8 cc 1		199,4 cc		249,3 cc		294,7 cc
54 mm		62,5 mm		66,4 mm		72,0 mm
54,5 mm		65,0 mm		72,0 mm		72,0 mm
		Keihin PWKS 38
		Reed Valves into the cranckcase
		Mixture in gasoline
Kick-starter				Kick-starter / Electric starter E-START models
			CDI
		0 mm from TDC
NGK BR9ECMIX			DENSO W24ESR-U y NGK BR8EG
			0,7~0,8 mm

TRANSMISSION

Primary ratio				3,31 (63/19)
Gearbox					6 gears
		1ª	2,692 (13/35)		2,07 (14/29)
		2ª	2 (16/32)		1,63 (16/26)
Gear ratio		3ª	1,578 (19/30)		1,33 (18/24)
		4ª	1,318 (22/29)		1,10 (20/22)
		5ª	1,13 (23/26)		0,91 (23/21)
		6ª	0,96 (25/24)		0,79 (24/19)
Secondary transmission					By chain
Secondary ratio			3,85 (13/50)	3,67 (12/44)		3,69 (13/48)
Drive chain			5/8” x 1/4” with O-	5/8” x 1/4” with O-Rings (112 links)
			Rings (114 links)
Clutch type				Multi-disc wet clutch, hydraulically operated
Clutch trigger					Hydraulic
Lubrication		Type			Oil
		Capacity			900cc
Available rear sprockets				39, 40, 42, 44, 46, 47, 48, 49, 50, 51, 52
Available front sprockets					12, 13

	Type
	Tires
CHASSIS	Tire pressure
	Suspension

Suspension travel

1125cc capacity only RACING

2For STANDARD models

	Perimeter CrMo alloy frame, multitubular aluminium alloy subframe
Front		1.6 x 21 - 90/90 - 21 Metzeler Six Days Extreme
Rear		2.15 x 18 - 140/80 - 18 Metzeler Six Days Extreme
Front			1,0 bar
Rear			1,0 bar
Front	Inverted telescopic fork		Inverted telescopic fork, with spring pre-load, rebound and compression dam-
	ø 45 mm		ping settings. ø45mm (STANDARD models) y ø48 mm (RACING models)
Rear	Progressive shock absorber with spring pre-load, rebound, high speed and low speed com-
			pression damping settings
Front	290mm (Marzocchi 45)		290mm (Marzocchi 45)2 / 305mm (Marzocchi 48)3 / 296mm (Öhlins RXF)4
Rear	298 mm (Reiger)		298 mm (Sachs)2 / 298 mm (Reiger)3 / 298 mm (Öhlins TTX44)4

3For RACING models

4For SWEDISH Edition models

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Owner´s manual

Specifications

DIMENSIONS CHASSIS

			125		200		250		300
	Front fork oil level	MARZOCCHI	100 mm. (level)		90 mm. (level) (ø45) / 320 ml. (quantity) (ø48)
		ÖHLINS	-				300 ml. (quantity)
	Brakes	Front		Brake disc, with Nissin floating 2 piston caliper
		Rear		Brake disc, with Nissin floating 1 piston caliper
	Brake disc	Front			Galfer “wave” disc Ø260 mm
		Rear			Galfer “wave” disc Ø220 mm
	Total height					1260 mm
	Total length					2200 mm
	Seat height					950 mm
	Minimum height					375 mm
	Total width					830 mm
	Wheelbase					1480 mm
	Dry weight		96 kg		106 kg		106 kg / 109 kg.1		106 kg / 109 kg.1
	Fuel tank capacity					9,5 l

LIQUIDS

		RECOMMENDED
	Fuel			Unleaded (RON 98 minimum)
	Mixture fuel/oil			100% synthetic oil ratio 2% (50:1)
		GRO Off Road 1		Semisynthetic oil ratio 2% (50:1)
	(JASO FC)
				Mineral oil ratio 3% (32:1)
	Coolant2	GRO GCC 30% Long		Coolant mixture at 30%
		Time
	Brake fluid	GRO Brake Fluid		DOT-4
		DOT-4
	Clutch fluid	GRO Global Ultra-5		Mineral oil
	Transmission oil	GRO Gear Trans		10W30 API SF o SG
		10W30
	Fork oil	MARZOCCHI		EBH16 7,5WT
		ÖHLINS	-	Öhlins 01312

CARBURETION	3	Carburetor type
	HomologationCompetition4	Main jet	100
		Idle jet	35
		Needle
		Needle position
		Throttle valve	6,5
		Mixture screw
		Carburetor type
		Main jet	180
		Idle jet	45
		Needle	NOZE
		Needle position	4th from top
		Throttle valve	7
		Mixture screw

1For E-START models

2Cold countries must adjust the coolant to their temperature.

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Keihin PWKS 38

115		115	115
35		35	35
	CHN
	5th from top
7		7	7
1 turn from fully closed
	Keihin PWKS 38
175
		175	175
42		42	42
		N1EF
		3rd. from top
6		7	7

1 turn from fully closed

3Does not apply to XC USA models.

4Closed-circuit use only.

Owner´s manual

Electrical diagram 200/250/300cc

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Owner´s manual

Electrical diagram 250/300cc “E-START” models

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Owner´s manual

Electrical diagram 125cc General

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Owner´s manual

Electrical diagram 125cc Turn Signals

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Owner´s manual

Torque Values

GENERAL

1

4

5

6

GENERAL

Size	Torque (Nm)
M4 nuts and bolts	3
M5 nuts and bolts	6
M6 nuts and bolts	10
M8 nuts and bolts	25
M10 nuts and bolts	45

CHASSIS

2

3

7

8

CHASSIS

Nº	Name	Size	Torque(Nm)
1	Steering nut	M24	40
2	Rear shock bolt	M10x50	45
3	Swingarm bolt	M14	80
4	Brake disc bolt	M6x14	12
5	Front axle bolt	M20	50
6	Brake caliper bolt	M8x30	30
7	Engine mount bolt	M10x118	40
8	Rear sprocket bolt	M8x30	30

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Owner´s manual

Torque Values

1

2

3

4

5

6

7

CHASSIS

Nº	Name	Size	Torque(Nm)
1	Subframe bolt	M8x50	25
2	Brake banjo bolt	-	6
3	Upper clamp bolt	M7x30	15
4	Spokes	-	1,5
5	Rear axle nut	M20	100
6	Linkage bolt	M14x110	100
7	Rear brake pedal bolt	M8x45	25

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Owner´s manual

Torque Values

ENGINE

ENGINE

1

2

3	4	5
		200/250/300cc	125cc

Nº	Name	Size	Torque (Nm)	Size	Torque (Nm)
1	Valve cover bolt	M5x15	8	M5x12	8
2	Gearshift pedal bolt	M6x25	12	M6x20	12
3	Kick-starter bolt	M6x12	12	M6x12	12
4	Kick-starter bolt	M6x20	12	M6x12	12
5	Crankcase bolt	M6x75	12	-	12
		-26-

Owner´s manual

Torque Values

1

2

5

ENGINE

3

4

6

7

8

				200/250/300cc				125cc
	Nº		Name	Size		Torque (Nm)	Size		Torque (Nm)
	1		Cylinder head bolt	M8x35		25	M8x35		25
	2		Cylinder nut	M10		40	M8		30
	3		Ignition cover bolt	M6x40		8	M6x40		8
	4		Reed block bolt	M6x25		12	M6x20		12
	5		Spark plug	-		25	-		25
	6		Engine drain plug	-		15	-		15
	7		Clutch cover bolt	M6x75		12	M6		12
	8		Water pump drain bolt	M6x8		8	-		8
	-		Starter pedal plate bolt	M6x15		8	M5x12		8
	-		Ignition motor stator bolt	M5x25		8	M5x20		8
	-		Ignition motor coil nut	-		40	-		40
	-		Selector spring fixing bolt	-		15	-		15
	-		Primary nut	-		40	-		40
	-		Clutch spring bolt	-		10	-		10
	-		Valve control support bolt	-		10	-		10
	-		Valve control nut	-		8	-		8
	-		Thermostat cover bolt	-		12	x		x
				-27-