SERVICE MANUAL SERVICE MANUAL Foreword GAS GAS thank you for your confidence By choosing the new GAS GAS EC 125/ 200/ 250/ 300 you have just entered the great GAS GAS family and, as a user of the number one off-road motorbike manufacturer, 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 125/ 200/ 250/ 300 is a bike conceived for the practice of high-competition enduro. 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 a high-level motorbike. Congratulations for making the right choice. With your skills at the commands of this motorbike, an adequate preparation and the indispensable servicing for this GAS GAS to be highly reliable, you will be able to enjoy the most comfortable and rewarding enduro practice. Thanks for your confidence and welcome to GAS GAS Motos. February 2003 EC 2003 -64- COMMON NOTICE Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE YOU USE YOUR BIKE LEGALLY, SHOW CONCERN FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER PEOPLE. Off-road motorcycle riding is a wonderful sport, and we hope you will enjoy it to the fullest. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of live. CAUTION This caution symbol identifies special instructions or procedures which, if noto strictly observed, could result in damage to or destruction of equipment. NOTE This note symbol indicates points of particular interest for more efficient and convenient operation. However, if improverly conducted, the sport has the potential to cause environmental problems as well as conflicts with other people. Responsible use of your off-road motorcycle will ensure that these problems and conflicts do not occur. EC 2003 -65- TABLE OF CONTENTS Foreword .........................................................................................64 Common notice ...............................................................................65 Table of contents .............................................................................66 Specifications ..................................................................................67 Location of Components .................................................................69 Side Stand.......................................................................................71 Fuel .................................................................................................71 Serial number..................................................................................73 Starting the engine ..........................................................................73 Shifting gears ..................................................................................74 Stopping the motorcycle .................................................................75 Table of maintenance ......................................................................76 Ignition timing ..................................................................................78 Cooling system................................................................................78 Spark plug .......................................................................................81 Transmission ...................................................................................81 Air cleaner .......................................................................................83 Throtlle cable...................................................................................84 Carburetor .......................................................................................84 Clutch ..............................................................................................85 Silencer packing change .................................................................85 Drive chain ......................................................................................86 Handlebar........................................................................................88 Brakes .............................................................................................89 Steering...........................................................................................90 Steering blocade .............................................................................91 Front fork.........................................................................................92 Rear suspension .............................................................................95 Wheel ..............................................................................................97 Cleaning ..........................................................................................98 Bolt and nut tightening ....................................................................99 Lubrication.....................................................................................101 Tunning (Carburetor and suspension) ..........................................102 Preparation check..........................................................................111 Storage..........................................................................................112 Gas Gas speedo instructions ........................................................112 Troubleshooting.............................................................................114 Warranty regulations .....................................................................118 EC 2003 -66- SPECIFICATIONS ENGINE Engine 125 cc. Bore and stroke Displacement in cubic centimeters Engine 200 cc. Bore and stroke Displacement in cubic centimeters Engine 250 cc. Bore and stroke Displacement in cubic centimeters Engine 300 cc. Bore and stroke Displacement in cubic centimeters Type Carburetor Lubrication system Starting system Ignition system Ignition timing Spark plug TRANSMISSION Transmission type Clutch type Driving system Gear Ratio 2 cycle, single cylinder, crank case induction, liquid cooled 54 x 54.5 mm. 124 cc. 62.5 x 65 mm. 199,4 cc. 66.4 x 72 mm. 249,3 cc. 72 x 72 mm. 294,7 cc. KEIHIN PWK 38 Fuel premix (ratio) (50:1)(2%) Kick start pedal CDI system. 1 mm APMS. NGK BR8EG 6 speed Multidisc in oil bath, hidraulic actuation Chain 1ª 2.071(29/14) 2ª 1.625(26/16) 3ª 1.333(24/18) 4ª 1.100(22/20) 5ª 0.913(21/23) 6ª 0.791(19/24) 2.85 (57/20) 3.692 (48/13) 8.149 (6th gear) EC 2003 -67- Primary reduction ratio Final reduction ratio Overall drive ratio Transmission oil CHASSIS Type Tires Suspension Suspension stroke Front fork oil (each) Front fork oil level Capacity Type 1800 cc. 5W50 API SF o SG Chromolly tubular semi double cradle 80/100 x 21 120/90 x 18 Upside-down telescopic ø 43mm WP fork. Upside-down telescopic ø 45mm Marzocchi fork. Progressive system with single shock, multi adjustable, ÖHLINS 282 mm. 320 mm. Marzocchi SAE 7,5 WP SAE 5 ÖHLINS SAE 5 - 7,5 Marzocchi: 110 mm (compressed with spring removed). WP: 120 mm (compressed with spring removed). ÖHLINS: 110 mm (compressed with spring removed). Disc brake 260 mm. 220 mm. 2135 mm. 810 mm. 1260 mm. 1475 mm. 340 mm. 9,5 Litre (2,5 gallons u.s.) 940 mm. Front Rear Front Rear Front Rear BRAKES Type Effective disc diameter DIMENSIONS Overall length Overall width Overall height Wheell base Ground clearance Fuel tank capacity Height seat Front, rear Front Rear (Specifications are subject to change without notice and are not applicable in some countries). EC 2003 -68- Location of components GAS GAS EC 2003 cc. 1 3 42 56 123456- Clutch lever Engine Stop Button Fuel Tank Fill Cap Front Brake Fluid Reservoir Front Brake lever Throttle Twist-Grip EC 2003 -69- 7 8 9 10 11 12 18 19 20 13 14 15 16 9 17 21 22 23 24 25 26 7- Brake Disc, front 8- Front Suspension 9- Brake fluid reservoir, rear 10- Fuel Tank 11- Carburetor 12- Rear shock absorber 13- Brake Caliper, front 14- Radiator 15- Fuel Tap 16- Shift pedal 17- Air Cleaner 18- Silencer 19- Seat 20- Nitrogen Reservoir 21- Chain Guide 22- Drive chain 23- Rear Suspension Linkage 24- Rear Brake Pedal 25- Kick Start Pedal 26- Exhaust Expansion Chamber EC 2003 -70- SIDE STAND To operate the side stand: Release the security strap (B), the sidestand is held in the down position by the weight of the motorcycle. Thes sidestand automatically retracts when the motorcycle is placed in the upright position. FUEL The GAS GAS FSE 400 cc has a four stroke engine and requires 95 octane, unleaded gasoline Gas Tank Capacity ENDUCROSS FSE 9,5L (B) (B) (C) (A) (A) (A). Side Stand (B). Sidestand spring (C). Security strap NOTE Do not start the engine or ride the motorcycle when the side stand is down. Always engage the security strab (B) before operation of the motorcycle. (A). Fuel Cap. (B). Fuel Vent hose. Position the vent hose clip in a position which prevents spillage on the steering bearings and the clock. EC 2003 -71- RECOMENDED FUEL Use premium gasoline with an octane rating equal to or higher than that shown in the table. OCTANE RATING METHOD Antiknock Index Research Octane No. (RON+MON)/2 (RON) MINIUM RATING 90 98 Proporción of gasoline and oil mixture (premix ratio)(50 parts gasoline to 1 part oil). 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. To make an gasoline-oil mixture, pour oil and half of the gasoline into a container first 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 lubricative quality of this mixture deteriorates rapidly; use a fresh mixture for each day of operation. Recomended Oil: OIL 2T SINTETIC NOTE If recommended oil is not available, use only synthetic oil designed for use in racing 2 cycle engines. 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. Engine Oil Mixing Oil must be mixed with the gasoline to lubricate the piston, cylinder, crankshaft, bearings, and connecting rod bearings. EC 2003 -72- SERIAL NUMBER This number allows the motorcycle to be registered. The serial number (or V.I.N.) is located on the steering stem of the frame. Official approval plate This motorcycle has an official approval plate. It shows the serial number. START THE ENGINE 1. You have to assure the motorcycle to the neutral position. 2. Turn right the key of fuel tank (A). Open ON OFF Close Reserve RES (A) (A) (B) 3. If the engine is cold, pull up the choke knob (B). EC 2003 -73- NOTE - When the engine is already warm or on hot days, open the throttle part way 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. SHIFTING GEARS The transmission is a 6 speed, return shift type with neutral halfaway between 1st and 2nd gears. A ¨return shift¨means that to go back to first gear from a higher gear, you must shift back through the gears one by one. The same is true when upshifting: each gear must be engaged before the next higher gear may be selected. To engage first gear from neutral, pull in the clutch lever and push down on the shift pedal, gently release the clutch lever, then release the shift pedal. CAUTION When changing gears, press firmly on the shift pedal to ensure complete, positive shifting. Careless, incomplete shifts can cause the transmission to jump out of gear and lead to engine damage. (F) 4. Start the motorcycle with kick start pedal (F). 5. Even after the engine starts, keep the choke knob pulled up. Until the engine is thoroughly warmed up. Stopping the engine 1. Change to the neutral position. (A) (A) 2. After racing the engine slightly, close the throttle completely and push the engine stop button (A). 3. Turn the key in the unclock direction (position in "OFF" (C)). EC 2003 -74- (A). Shift pedal. 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 ...