GAS GAS EC 2008, MC 2008, SM 2008, 2011 EC-250, 2011 EC-300-E User Manual
MANUAL DEL USUARIO
USER MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
BETRIEBSANLEITUNG
enducross EC´08
enducross EC´08
enducross EC´08
ENGLISH
USER MANUAL
USER MANUAL
enducross EC´08
enducross EC´08
enducross EC´08
-3-
Foreword
GAS GAS thanks you for the trust you have placed in us.
By choosing the new GAS GAS EC / MC / SM 2008 you have become part of the great GAS GAS family and,
as a user of the number one manufacturer of off-road motorbikes, you deserve the distinguished treatment
that we wish to offer to you both in our after-sale relationship and in the explanations that we provide in this
manual.
Our EC / MC / SM 2008 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.
Julyl 2007
-4-
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.
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.
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.
RECOMMENDS THE USE OF OIL:
-5-
TABLE OF CONTENTS
Foreword...........................................................................................3
How to use this manual.....................................................................4
Table of contents...............................................................................5
Specifications....................................................................................6
Location of components....................................................................8
Side Stand ......................................................................................12
Fuel.................................................................................................12
Serial Number.................................................................................14
Homologation Plate.........................................................................14
Starting the engine..........................................................................14
Shifting gears..................................................................................15
Stopping the motorcycle .................................................................16
Riding during the Break-In Period...................................................16
Maintenance Schedule ...................................................................17
Electronic Ignition............................................................................19
Cooling System...............................................................................19
Spark Plug ......................................................................................20
Transmission...................................................................................22
Air Cleaner......................................................................................24
Throttle Cable .................................................................................25
Carburetor.......................................................................................25
Clutch..............................................................................................26
Exhaust System..............................................................................26
Drive Chain Guide...........................................................................27
Handlebar .......................................................................................29
Brakes.............................................................................................30
Steering...........................................................................................31
Steering blockage ...........................................................................32
Front Fork .......................................................................................33
Rear suspension.............................................................................36
Wheels............................................................................................38
Cleaning..........................................................................................39
Bolts and nuts tightening.................................................................40
Lubrication ......................................................................................42
Tunning (Carburetor and Suspension)............................................43
Final recommendatios.....................................................................51
Homologation..................................................................................52
Preparation for competition.............................................................53
Storage ...........................................................................................54
GAS GAS Multifunction Instructions ..............................................55
Troubleshooting ..............................................................................63
Electric Schemas ............................................................................68
Warranty Manual.............................................................................69
-6-
SPECIFICATIONS
ENGINE 2 cycles, single cylinder, crankcase intake, liquid cooled
125 cc Engine
Bore and stroke 54 x 54.5 mm
Displacement 124 cc
200 cc Engine (only EC)
Bore and stroke 62.5 x 65 mm
Displacement 199.4 cc
250 cc Engine
Bore and stroke 66.4 x 72 mm
Displacement 249.3 cc
300 cc Engine (only EC)
Bore and stroke 72 x 72 mm
Displacement 294.7 cc
Carburettor, diameter of diffusor 38
Lubrication system Mixture
100% Synthetic Oil 50:1 = 2%
Mineral Oil (Only USA) 32:1 = 3%
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)
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)
-7-
Primary reduction 2.85 (57/20) (250 cc, 300 cc)
Final reduction 3.692 (48/13) (250 cc, 300 cc)
Overall gear ratio 8.323 (6th gear)
Transmission oil Capacity 750 cc (125 cc)
900 cc (200 cc / 250 cc / 300 cc)
Type 10W30 API SF or SG
CHASSIS
Type Tubular, semi-double cradle
Tire size Front EC & MC - 90/90 x 21
SM - 120/60 ZR17
Rear EC - 140/80 x 18
MC - 120/80 x 19
SM - 150/60 ZR17
Suspension Front Inverted telescopic fork ø 45 mm (only EC, SM and MC 125)
Inverted telescopic fork ø 50 mm (only MC 250)
Rear Progressive system with single multi-adjustable shock
Suspension stroke Front 282 mm
Rear 320 mm
Front fork oil SAE 5 - 7.5
Front fork oil level 110 mm (compressed, without spring)
BRAKES
Type Front, Rear Disc brake
Effective disc diameter Front 260 mm (only EC and MC)
320 mm (only SM)
Rear 220 mm
DIMENSIONES
Overall height 1260 mm
Overall length 2135 mm
Overall width 810 mm
Seat height 940 mm
Minimum height 340 mm
Wheelbase 1475 mm
Fuel tank capacity 9 l
(Specifications are subject to change without notice and probably do not apply to all countries).
-8-
LOCATION OF COMPONENTS
GAS GAS EC 2008
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- CDI Switch
GAS GAS MC 2008
1- Clutch lever
2- Engine stop button
3- Fuel tank cap
4- Brake fluid reservoir
5- Front brake lever
6- Throttle grip
7- CDI Switch
GAS GAS SM 2008
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- CDI Switch
1
3
2
4
5
6
1 32 4 5 6
7
7
-9-
7- Brake disc
8- Front suspension
9- Brake fluid reservoir
10- Fuel tank
11- Carburetor
12- Rear shock absorber
13- Brake caliper
14- Radiator
15- Gasoline cock
16- Shift pedal
17- Air cleaner
18- Muffler
19- Seat
20- Gas reservoir
21- Chain guide
22- Chain
23- Suspension linkage and swingarm
24- Rear brake pedal
25- Kick-start pedal
26- Exhaust
GAS GAS EC 2008
-10-
7- Brake disc
8- Front suspension
9- Brake fluid reservoir
10- Fuel tank
13- Brake caliper
14- Radiator
18- Muffler
19- Seat
20- Gas reservoir & Rear shock absorber
21- Chain guide
22- Chain
23- Suspension linkage and swingarm
24- Rear brake pedal
25- Kick-start pedal
26- Exhaust
GAS GAS MC 2008
8
14
1019
7
13
21
18
24 25
92220
2623
-11-
7- Brake disc
8- Front suspension
9- Brake fluid reservoir
10- Fuel tank
14- Radiator
18- Muffler
19- Seat
20- Gas reservoir & Rear shock absorber
21- Chain guide
22- Chain
23- Suspension linkage and swingarm
24- Rear brake pedal
25- Kick-start pedal
26- Exhaust
GAS GAS SM 2008
8
14
1019 7
13
21
18
24 25
9
22
20
2623
FUEL
The GAS GAS EC / MC / SM models have 2-cycle engines that
require a mixture of gasoline and oil.
Gas Tank Capacity
9 L
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.
SIDE STAND (only EC and SM)
To set the side stand only turn it until it contacts the stopper, then
the side stand will be parallel to the ground and rest securely.
The side stand will return to its original position by means of the
double spring. The function of the double spring insures that, when
the side stand is down, the rest position is stable and above all
secure; moreover, it also returns the side stand to its original position.
EC 2008 and
SM 2008
(A). Side stand.
(B). Double
spring.
MC 2008
(A). Side stand.
NOTE
Do not start the engine or ride the motorcycle when the side
stand is down.
-12-
(A). Fuel tank cap.
(B). Vapor outlet tube.
(A)
-13
-
RECOMMENDED FUEL
Use gasoline with an octane rating equal to or higher than that shown
in the table.
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.
Recommended oil:
2-CYCLE SYNTHETIC
NOTE
If the recommended oil is not available, use only oil designed
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.
-14-
STARTING THE ENGINE
1. Make sure the motorcycle is in the neutral position.
2. Turn the gasoline cock (A) clockwise to the "ON" position.
3. If the engine is
cold, pull up the
choke knob (B).
SERIAL NUMBER (A)
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.
ON
Open
OFF
Close
RES
Reserve
(A)
(B)
(A)
(B)
Stopping the engine (MC model)
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.
(A). Gearshift pedal.
-15-
NOTE
- When the engine is already warm or on hot days, open
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.
5. Even after the engine starts, keep the choke knob pulled up.
Stopping the engine (EC and SM models)
1. Shift the transmission into neutral.
4.
Start the
motorcycle with
kick-start pedal
(C).
2. After racing the
engine slightly,
close the throttle
completely and
depress the engine
stop button (D).
2. After racing the engine
slightly, close the throttle
completely and depress
the engine stop button
(A).
(A)
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.
RIDING DURING THE BREAK-IN PERIOD
A break-in period is necessary to ensure a smooth operation and
obtain an optimum engine and the transmission responses. During
the first hour or 20 km of operation, run the engine at low and
moderate speeds and revolutions per minute (RPM).
NOTE
The slow riding necessary during the break-in period may cause
carbon deposits to build up on the spark plug and foul it. If
inspection of the spark plug shows this to be the case, replace
the standard spark plug with another of a higher heat range.
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
However, avoid accelerating recklessly that can lead to engine failure.
Be careful to use the necessary skills and techniques while operating
the motorcycle.
NOTE
After the break-in period, install a new set of standard spark
plugs.
-16-
-17-
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.
Item
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
MANTENANCE SCHEDULE
Check / Inspect Change / Replace Apply grease /
Lubricate
Adjust
At each fill up
3 fill ups
-
-
-
1 fill up
3 fill ups
3 fill ups
1 fill up
3 fill ups
-
-
10 fill ups
3 fill ups
1 fill up
3 fill ups
5 fill ups
3 fill ups
-
-
At each fill up
3 fill ups*
1 fill up
-
-
1 fill up
3 fill ups*
3 fill ups*
1 fill up*
10 fill ups*
3 fill ups*
-
-
10 fill ups*
3 fill ups*
1 fill up*
3 fill ups*
5 fill ups*
3 fill ups*
-
-
At each fill up
-
-
-
-
-
-
-
-
-
-
3 fill ups
1 fill up
-
-
-
-
-
-
-
-
-
Clean
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
-
-
-
-
-
-
-
-
-
-
-
-
-18-
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.
Item
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
MANTENANCE SCHEDULE
Check / Inspect Change / Replace Apply grease /
Lubricate
Adjust
-
-
1 fill up
-
1 fill up
-
5 fill ups
1 fill up
5 fill ups
7 fill ups
-
1 fill up
5 fill ups
5 fill ups
-
10 fill ups
5 fill ups
Every 2 years
-
-
1 fill up*
-
-
5 fill ups
5 fill ups*
When necessary
5 fill ups*
7 fill ups*
-
5 fill ups*
-
-
10 fill ups*
5 fill ups*
2 years*
-
-
-
1 fill up
-
-
-
-
-
-
-
-
-
-
5 fill ups
10 fill ups
-
5 fill ups
-
Clean
Every 2 years
Every 4 years
1 fill up*
-
-
5 fill ups
5 fill ups*
When damaged
Every year
5 fill ups*
7 fill ups
10 fill ups
-
5 fill ups*
-
-
10 fill ups*
5 fill ups*
2 years*
-
-
-
-
-
-
-
When necessary
-
-
-
When necessary
-
-
-
-
-
-
-
-19-
- 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.
- 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.
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.
125 cc
200 / 250 / 300 cc
(A)
-20-
CAUTION
If high water pressure is used the radiator fins could be damaged
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.
CAUTION
Use of incorrect coolant solutions will cause engine and cooling
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.
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
Permanent type of antifreeze (distilled water and ethylene glycol)
plus corrossion inhibitors for aluminium engines and radiators.
NOTE
Initially, at the factory a permanent type of antifreeze is installed
in the cooling system. It is colored green, it contains a 50%
solution of ethylene glycol, and has a freezing point of –35 ºC.
Coolant recommended
Coolant absorbs excessive heat from the engine and transfers it to
the air at the radiator. If the coolant level is low, the engine overheats
and may suffer severe damage. Check the coolant level each day
before riding the motorcycle. Add liquid recommended if the level is
low (see next page).
-21-
Total quantity
Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze
50%).
Capacity: 1.1 L
Coolant Replacement
Coolant should be changed periodically to ensure long engine life.
- Wait for the engine to cool completely.
- Place the motorcycle in riding position.
- Remove the radiator cap.
- Place a container under the coolant drain screw, and drain the
coolant from the radiator and engine by removing the drain screw
(B) at the bottom of the water pump cover (A). Wash off immediately
any coolant spilled on the chassis, engine, or wheels.
WARNING
To prevent severe scalding do not remove the radiator cap or try to
change liquid, when the engine is still hot. Wait until it cools.
Coolant level
- Place the motorcycle in riding position.
- Turn the radiator cap (A) counterclockwise and wait a few seconds
until vapors inside are released. Then push and turn it further in
the same direction and remove the cap.
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.
(1). Coolant level.
(2). Filler opening.
125 cc.200 / 250 / 300 cc.
(B)
(A)
(A)
(B)
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