GAS GAS MC Boy 50, EC Boy 50 User Manual

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MANUAL DEL USUARIO USER MANUAL MANUEL D’ENTRETIEN LIBRETTO D’USO BETRIEBSANLEITUNG

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ENGLISH

USER MANUAL

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ACKNOWLEDGEMENTS TO THE PURCHASER

GAS GAS thanks you for the trust you have placed in us. We are delighted that you have selected the MC Boy 50 / EC Boy 50 motorcycle and we would

like to welcome you to the GAS GAS family. Get to know your new machine well. This bike incorporates our accumulated competition experience

and that which we have gained from the achievement of many important titles. You now possess a motorcycle with which, as well as feeling comfortable, you are offered the infinite possibilities of driving at the highest level of your skill while maintaining a maximum of security.

This manual provides you with a good basic knowledge of the features and machine handling. It also contains many important instructions regarding safety and provides information about the basic maintenance and inspection procedures.

Thank you for your trust in us, and welcome to GAS GAS motorbikes.

GAS GAS MOTOS, S.A.

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Important warning

Read this Manual carefully. It contains all the necessary information for your safety, and that of others, as well as guaranteeing the correct conservation and maintenance of the GAS GAS motorcycle you have just acquired.

All of the necessary instructions for the correct driving and handling of this vehicle are set out below. Each message is preceded by a symbol whose meaning is as follows:

Caution! This symbol indicates all of the rules and precautionary measures that must be taken in order to avoid any physical injury, serious or slight, including death of the user; to ignore these represents a serious danger.

Warning! This symbol introduces special warnings to avoid damage to your motorcycle. Should these warnings be ignored, the guarantee may be automatically invalidated.

Miscellaneous notes. These are instructions necessary for optimum use of control and adjustment operations, as well as conservation and maintenance work on the motorcycle, so that you may benefit from a maximum of driving satisfaction.

The aim of this Manual is to help the user minimise or avoid possible damage to people, property, the environment, and naturally to your new motorbike. Therefore, all the information presented here is based on data obtained from the latest models put on the market just before publication. However, GAS GAS Motos, S.A. reserves the right to make modifications without any prior warning to consumers and without incurring any additional obligations in so doing. Your local dealer will also provide you with any information as might be deemed necessary.

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Index

Acknowledgements to the purchaser 3 Important warning 4 Index 5 Quick Guide to Maintenance 6 Fuel - Petrol/oil mixture 7 Fuel tank 7 Fuel tap 8 Before starting the engine 8 Starting the engine 9 Stopping the engine 9 Riding the motorcycle 10 Stopping the motorcycle 10 Running-in period 11 Transmission oil - Checking the level 11

-Filling 12

-Changing 12 MC Boy 50 cooling system - Checking/filling 13 EC Boy 50 cooling system - Checking 13

Carburettor - Adjusting throttle cable 14

- Adjusting idle speed 14 Spark plugs - Inspecting 15 Air Filter - Cleaning 15 Front brake fluid - Checking 16 Rear brake fluid - Checking 16 Front brake lever - Adjusting 16 Rear wheel - Centre alignment 17 Chain slack - Checking 17 Master link - Checking 17 Tyre pressures - Checking 18 Brake pads - Checking 18 Brake circuit - Bleeding 19 Front fork - Oil level 19 Lubrication 20 Identification 21 Guarantee manual 22

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Specifications

EC Boy-50 MC Boy-50

49.38 / 5 49.38 / 12

1 (one)

39 x 41.8 mm

Air Liquid

Electronic with variable advance

Automatic

Single gear

Primary by gears,

Secondary by chain

250 cc of SAE 20 oil

CHASSIS

Deltabox, elliptic profile tubes in CRMo, aluminium rear swingarm Marzocchi hydraulic fork - 140 mm Single-shock absorber Sachs - 155 mm stroke Disk, 160 mm diameter, AJP calliper Disk, 150 mm diameter, AJP calliper Duralumin wheels

2.5 - 14" 2.5 - 10"

2.75 / 3.00 - 12 2.75 - 10"

Forged aluminium with retractable toecap

Dell'Orto 19 mm diameter carburettor with polyurethane sponge filter diffuser

Dell'Orto 14 mm diameter carburettor with polyurethane sponge filter diffuser

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Description

Displacement / power cc/CV Type Number of cylinders Bore and stroke Cooling system Engine lubrication system Engine supply system

Ignition system Clutch Gear changes Transmission

Transmission lubrication system

Type Front suspension Rear suspension Front brake Rear brake Wheels Tyres

- Front

- Rear Kick-start pedal Shift pedal and rear brake

ENGINE

Two-stroke single cylinder, layer admission directly to crankcase

2% mixture ratio

Forged aluminium

Quick guide to maintenance

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Fuel – Petrol/oil mixture

The motorcycle is fitted with a two-stroke internal combustion engine. This type of engine requires a

mixture of petrol and oil. To ensure the correct working of the engine, the following are recommended:

- Use high quality petrol, with an octane rating equal to or above 90 (RON + MON)/2 or 98 (RON).

- Use 2T synthetic oil.

Warning:

- If the recommended oil is not available, use semi-synthetic oil.

- Do not mix different oil-types. Mixture ratio: oil, 2% of petrol volume (50 parts petrol to every 1 part oil). Note: we recommend first preparing the mixture in a suitable container and then filling the fuel tank.

Fuel tank

This has a rapid access cap (A) and a vent hose (B) to allow gases produced in the tank to escape.

- To open the cap, lift the clip in the direction shown by the arrow and turn to the left. Warning: Regularly check the cap seal and vent hose to ensure they are leak proof. Risk of spillage.

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Before starting the engine

- Open the fuel tap.

Note:

- If the engine is cold then pull the

choke upwards (A) and, then, rotate it 1/4 of a turn to the left or the right to secure it in place. Once the engine is turning over regularly at idle speed, return the choke (A) to the rest position.

- Do not use the choke on hot days or when the engine is hot. In this case, hold the throttle lever partially open until the engine starts.

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Reserve

Open

Closed

Fuel tap

This has three positions: open, closed and reserve. The diagrams below show the

position of tap (A) for each case.

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Stopping the engine

-With the throttle grip in rest position

(engine idle), press stop button (A) until

the engine stops.

Starting the engine

Kick the start-pedal (A) in the direction shown by the arrow until the

engine starts. Warning: once the engine is running, fold the kick starter into the engine.

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Riding the motorcycle

- To ride the motorcycle simply accelerate, this will activate the automatic clutch system.

Stopping the motorcycle

- Release the throttle lever.

- Use the front (A) and rear (B) brakes.

Warning: Depending on circumstances and ground surface, it may be better to use the front or rear brakes independently.

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Running-in period

Care of the engine during the first hours

of use is vital for obtaining the best from your motorcycle. Therefore, we recommend:

- Strictly observe the oil and petrol ratios shown, and use the recommended 2T oil – see section “Fuel

- petrol/oil mixture”, page 7.

- In the first hour of use, keep the engine at a moderate turnover speed (never go to maximum turnover).

- Constantly change the speed, by opening and closing the throttle alternately.

Transmission oil – Checking the level

If the motorcycle has been used recently, wait a few minutes before checking the level. Note: the motorcycle should be perpendicular to the ground. Warning: Place a suitable recipient under the engine to collect possible oil spillage.

- Remove the oil level screw (A). The level is correct if it reaches the lower edge of the oil level hole (A). If the level is lower then more oil must be added.

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Transmission oil – Topping up

If necessary, top up with oil:

- Remove the oil filler cap (A).

Warning: Use the recommended oil – See Quick guide to maintenance, page 6.

- Add oil until it begins to pour out of the hole (B). Warning: Do not overfill the engine! Risk of damage to engine.

- Fit and tighten the oil level screw (B).

- Replace filler cap and tighten (A).

Transmission oil – Changing

- Start the engine and keep it running until it warms up, then stop the engine. To drain

out the used oil, remove the oil release plug (A) located underneath the engine.

- Replace the drain plug using a new seal washer. Tighten to 20 Nm.

- Remove the filler cap (B) and fill with oil (250 cc). Warning: Use the recommended oil – See Quick guide to maintenance, page 6.

- Tighten the filler cap.

Warning: Do not pour used oil down the drain.

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MC Boy - 50 cooling system – Checking/filling

The MC Boy-50 is fitted with a liquid cooling system.

Warning: If the motorcycle has just been used, wait a few minutes before opening the radiator cap. Risk of burns!

- Rotate the cap (A) anti-clockwise and remove it.

- The level of coolant should be at the lower edge of the filler neck of the radiator, below the position of the cap seal. If this is not the case, top up with coolant. Warning: only use coolant suited to light-alloy engines, with antifreeze protection of up to -30 ºC.

EC Boy-50 cooling system – Checking

EC Boy-50 is fitted with an air cooling system.

The maintenance of this system consists of keeping the cylinder blades and cylinder head (A) clean of mud and accumulations that may obstruct the air flow.

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Carburettor – Adjusting throttle cable

The throttle lever cable should have a free play of between 2 to 3 mm.

If necessary, adjust as described below:

- Raise the dust guard (A) on the throttle lever cable.

- Turning the threaded terminal (B) to the right increases the play of the cable, and turning it to the left reduces the play.

Carburettor – Adjusting the idle speed

The carburettor has an idle

adjusting screw (A), which acts on the opening of the carburettor throttle curtain, and an air adjusting screw for the low system (B), which controls the air/fuel mixture.

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Spark plugs – Inspecting

The electrode separation is from

0.6 to 0.7 mm.

Air Filter – Cleaning

A clean air filter not only improves engine

performance but also prolongs its useful life. It should therefore be cleaned regularly. To reach the air filter, proceed as follows:

- Remove the bolt indicated by the arrow, remove the seat by pulling it backwards to dislodge it from its forward attachment.

- Using a screwdriver or similar, remove the elastic band (A) from the bolt holding it.

- Remove cover (B) from the filter box.

- Remove filter.

- Wash the filter in warm water and soap and, once dry, grease with special filter oil.

- Refit the elements in reverse order, noting that the seat must be pressed downwards and forwards to insert it into its forward attachment, in the front part of the padding.

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0.6 ~ 0.7 mm

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Front brake fluid – Checking

The level is correct if it falls within the upper half of the transparent

window (A). If not, top up with a recommended brake fluid.

Rear brake fluid – Checking

The level is correct

if it falls within the upper half of the transparent window (A). If not, top up with a recommended brake fluid.

Front brake lever – Adjusting

The front brake lever should have a maximum play of 3 mm. To adjust, proceed as follows:

- Adjust the maximum turn of the lever using bolt (A), to suit the driver.

- Adjust the play of the lever using bolt (B).

3 mm max.

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Rear wheel – Centre alignment

The rear axle has easily

graduated eccentrics for this operation. To ensure perfect wheel alignment, make sure that the marks of both eccentrics are in the same position on both sides.

Chain slack – Checking

Adjust chain tension with the eccentrics so that the slack in the

tensed zone is 1.5 cm.

Master link – Checking

The master link of the chain has an elastic

locking clip. As shown in the photo, place the closed part of the clip in the direction of the chain rotation.

1.5 cm

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Tyre pressures – Checking

Check tyre pressures regularly in order to obtain the best road

holding possible.

INFLATION PRESSURES: EC BOY-50 Front wheel: 0.8 BAR / 11.5 PSI Rear wheel: 0.8 BAR / 11.5 PSI

MC BOY-50 Front wheel: 0.9 BAR / 13 PSI Rear wheel: 0.8 BAR / 11.5 PSI

Brake pads – Checking

The brake pads, both front and rear,

should be checked for wear periodically, in order to enable you to brake effectively in any situation. Replace if the thickness of the friction material of the pads reaches 1 mm.

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Brake circuit – Bleeding

If the system has been dismantled for repair, or if faults are detected in the brake system, the air in the hydraulic circuit

can be removed using the bleeders (A). Once the air has been removed from the system, replace the rubber cap on the bleeder to prevent dirt from entering the system.

Front fork – Oil level

Each of the suspension rods is filled with 310 cm

of SAE 5 oil.

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Lubrication

Clean and lubricate frequently with

oil:

-The joint and spring of the foot pegs.

Lubrication

Clean and lubricate frequently with oil:

- The joint of the kick-start pedal.

Lubrication

Clean and lubricate frequently with oil:

-The joints of the clutch and front brake levers.

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Lubrication

Clean and lubricate frequently with oil:

- The secondary chain.

Lubrication

Clean and lubricate frequently with oil:

- The throttle lever, especially after washing the motorcycle with high-pressure hoses.

Identification

The serial number of the motorcycle

is engraved on the steering tube. This number should match that which appears in the accompanying documents.

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WARRANTY TERMS AND CONDITIONS

(According to Law decree 23/2003 on the 10th of July, covering Warranties on Consumer Item Sales)

Warranty terms of the manufacturer GASGAS Motos, S.A.

The company GAS GAS MOTOS, S.A. (hereafter referred to as “GG”), with this present document guarantees the consumer, the purchaser of a vehicle manufactured by GG, that both the materials and the manufacturing are free of defects in accordance with the highest standards of quality. Consequently, GG with this document guarantees the consumer (hereafter referred to as the “purchaser”), in accordance with the conditions set out below, the repair, free of charge, of any defect in materials or that might result from faulty manufacture that is detected in a new motorcycle within the period covered by this Warranty and with no limit on the number of kilometres covered or hours of use.

Warranty Period

The period covered by this Warranty will begin on the day of delivery of the vehicle to the purchaser by a GG authorised dealer, or in the case of demonstration models, on the date in which the vehicle is used for the first time. The seller will be responsible for any unwarranted faults that become apparent within the period established in the Law decree 23/2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance with the Directive 1999/44/EC for other members of the European Community. For countries outside the European Community, the Warranty Period will be determined by the existing regulations in those countries. Nevertheless, should the fault appear during the first six months after the delivery of the motorcycle, it will be presumed that the said fault existed at the time of delivery; from the end of the sixth month onwards, the purchaser must demonstrate that the unwarranted fault existed at the moment of delivery. During the first six months subsequent to the delivery of the repaired vehicle, the seller will be responsible for any unwarranted faults arising out of the repair. Any defects detected in the product must be brought to the attention of a GG authorised dealer within the Warranty Period. If the last day of this period is a Sunday or an official holiday, the Warranty period will be extended such that the last day of the period covered will be the first working day after the Sunday or official holiday.

Those claims under Warranty for defects not brought to the attention of a GG authorised dealer before the end of the Warranty Period will be excluded.

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Obligation of the purchaser

GG will have the right to reject any claims under Warranty in the event that:

a) the purchaser has failed to submit the vehicle to any of the inspections and/or maintenance work required in the Users’ Manual, or has exceeded the date set for such inspections or maintenance work. Also excluded from guarantee are those faults that appeared prior to the dates established for an inspection or maintenance work where the latter was not carried out, or was carried out later than the date established. b) an inspection, maintenance or repair has been performed on the vehicle by third parties not recognised or authorised by GG. c) any maintenance or repair has been carried out on the vehicle that violates the technical requirements, specifications and/or instructions indicated by the manufacturer. d) spare parts whose use has not been authorised by GG have been used during the course of maintenance work or repairs to the vehicle, or in the event that the vehicle has been used with fuels, lubricants or other liquids (including, amongst others, cleaning products) that have not been expressly mentioned in the specifications set out in the User’s Manual. e) the vehicle has been altered or modified in any way or fitted with components other than those expressly authorised by GG as accepted components of the vehicle. f) the vehicle has been stored or transported in a way that is not in accordance to the corresponding technical requirements. g) the vehicle has been used for special purposes other than ordinary use, such as competition, races or record breaking attempts. h) the vehicle has been directly or indirectly damaged as a result of a fall or an accident.

Warranty exclusions

The following items are not covered by this Warranty:

a) worn parts, including, without any limitation, spark plugs, batteries, petrol filters, oil filter elements, (secondary) chains, engine output pinions, rear sprockets, air filters, brake discs, brake pads, clutch plates and discs, bulbs, fuses, carbon brushes, footrest rubbers, tyres, inner tubes, cables and other rubber components b) lubricants (for example, oil, grease, etc.) and working fluids (for example, battery liquid, coolant, etc.) c) inspection, adjustments and other maintenance tasks, as well as all kinds of cleaning work d) damage to the paint-work and consequent corrosion due to external causes, such as stones, salt, industrial fumes and

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other environmental impact, or inadequate cleaning with inappropriate products e) any damages caused as a result of the defects, as well as any expenses incurred either directly or indirectly as a consequence of the defects (for example, communication costs, accommodation expenses, car hire costs, public transport costs, breakdown truck fees,, courier costs, etc.), as well as other financial losses (for example, those caused by the loss of the use of the vehicle, loss of income, time lost, etc.) f) any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle (for example, small or hidden imperfections, noise or vibrations that are normal in use, etc.) g) phenomena that are the result of the ageing of the vehicle (for example, discolouring of painted or metallic coated surfaces).

Various

1.- GG shall have the prerogative to decide, at its own discretion, whether to repair or replace defective parts. Where parts are replaced, ownership of the parts removed shall pass to GG without any other consideration. The GG authorised dealer, to whom the making good of the defects has been entrusted, is not authorised to make any declarations that are binding on GG.

2.- In case of doubt regarding the existence of a defect, or a visual or material inspection is required, GG reserves the right to demand the return of the parts which are the object of a claim under Warranty, or to arrange an inspection of the defect by an expert from GG. Any additional obligations arising out of guarantees on parts replaced free of charge, or any other service rendered free of charge, are excluded from the effects of this present warranty. The Warranty on parts replaced within the Warranty Period will end at the expiry date for the Warranty Period of the product concerned.

3.- Should it prove to be the case that a defect can not be repaired, the purchaser guaranteed shall have the right to the cancellation of the contract (payment of compensation) or a partial refund of the purchase price (discount), instead of repairing the motorcycle.

4.- Any claims against Warranty by the purchaser under the terms of the sale contract with the corresponding authorised dealer shall not be affected by the terms of this present Warranty. Neither will this present Warranty affect those additional contractual rights acquired by the purchaser under the general commercial terms and conditions of the authorised dealer. However, such additional rights may only be exercised through claims against the authorised dealer.

5.- Should the purchaser resell the product within the Warranty Period, the duration and conditions of the present Warranty will remain unaltered, in such a way as that the rights to make claims under the present Warranty in accordance with the terms and conditions set out in this present document shall be transferred to the new owner of the motorcycle.

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