User manual GAS GAS EC ROOKIE - 2005

MANUAL DEL USUARIO MANUAL DEL USUARIO SERVICE MANUAL SERVICE MANUAL MANUEL D'ENTRETIEN MANUEL D'ENTRETIEN LIBRETTO D'USO LIBRETTO D'USO SERVICE MANUAL SERVICE MANUAL ENGLISH PRESENTATION GAS GAS appreciates your trust. We are happy to see that you have decided on a GAS GAS EC ROOKIE moped and welcome you into the great family of GAS GAS users. Learn everything about your new machine. It contains a large amount of experience accumulated from many competitions where we have won important prizes. You are now the owner of a moped that, besides making you feel comfortable, offers a great many opportunities for you to show your skills while providing top safety levels. This manual provides a wealth of basic information on the moped features and how best to use it. It also includes important safety instructions , together with basic maintenance and inspection routines. Thank you for trusting us and welcome to GAS GAS Motorcycles. -3- IMPORTANT NOTICE Read this manual thoroughly. It contains every single aspect that should help to provide safety for yourself and others, and to ensure the appropriate preservation and maintenance of the GAS GAS moped you have just purchased. READ THE WHOLE CONTENTS OF THIS MANUAL BEFORE USING THE VEHICLE. Important information about this manual Specially important information is highlighted in this manual as follows: WARNINIG Ignoring the WARNING notice may result in serious or fatal injuries to the moped user, as well as to bystanders or the technicians inspecting or repairing it. prevent the appearance of such damage or conflicts. PROTECTING THE FUTURE OF YOUR SPORT ENSURES THE LEGAL USE OF YOUR MOPED WHEN PROPER RESPECT FOR THE ENVIRONMENT AND OTHER PEOPLE'S RIGHTS IS SHOWN. This manual includes the data and specifications available at the time of compilation. Any difference you may find with your vehicle data and specifications is a consequence of manufacturing and quality improvements. GAS GAS Motos S.A. constantly improves its vehicles so that you may enjoy them at their best. INSTRUCTIONS FOR USE A deep knowledge of your vehicle and how it works is extremely important. - Remember that you are not to leave the engine running within a closed area, as the toxic exhaustion fumes might have fatal consequences. - Tyre pressure has a direct influence on the vehicle stability. - Sudden braking may result in skidding. Engine performance and life depend to a great extent on how it is run in. We recommend strict adherence to the instructions supplied, at the very least during the initial 500 Kms. - Do not keep the engine running at a high-revolution level. - Do not change down as soon as the engine starts striving. - Do not keep the engine running at top speed for a long time. ATTENTION This symbol identifies instructions or procedures that, unless strictly followed, may damage or destroy the equipment. NOTE This symbol shows items of special interest for a better performance and a more convenient operation. Inadequate riding may cause environmental damage and conflicts with other people. Riding your moped in a responsible manner will -4- TABLE OF CONTENTS - Presentation........................................................................3 - Important notice.....................................................................4 Instructions for use......................................................4 - Table of contents.......................................................................5 - Specifications.......................................................................6 - Important information...........................................................8 Identification numbers.............................................8 - Component location..............................................................10 - Moped components..........................................................12 Main-beam pilot light................................................12 Indicator pilot light...................................................12 Multifunction.................................................................12 Ignition key...........................................................12 Neutral pilot light................................................12 Oil-reserve pilot light.............................................12 Headlight indicator......................................................... 12 Clutch..............................................................12 Lights.....................................................................12 Start button.....................................................13 Front brake.........................................................13 Accelerator grip.........................................................13 Fuel tank...............................................................13 Oil.....................................................................14 Oil reservoir........................................................14 Fuel tap.............................................................14 Saddle.........................................................................15 Starting pedal........................................................15 Rear brake pedal..................................................15 Gear pedal.............................................................15 - Starting the cycle.............................................................16 Starting the engine...................................................16 Stopping the engine..................................................16 Choke......................................................................16 Gear box..................................................................17 -5- Stopping the moped......................................................17 Adjustment........................................................17 - Maintenance...........................................................................18 Maintenance schedule.....................................................18 Before starting the moped for the first time...................19 Engine............................................................................19 Gearbox and clutch.........................................................19 Carburettor........................................................................19 Air filter...........................................................................20 Sparking-plug check.........................................................20 Radiator...........................................................................21 Strip box.........................................................................21 Clutch adjustment.............................................................22 Chain lubrication...............................................................22 Chain tightening..............................................................22 Front suspension............................................................23 Rear suspension...........................................................23 Cables............................................................................24 Front brake.....................................................................24 Rear brake........................................................................24 Pump and brake pads...................................................25 Steering..............................................................................25 Tyre pressure.................................................................25 Checking operations at specialised garages..................26 Storage...........................................................................27 - Final advice..................................................................................27 Preventive advice...........................................................27 Safe use of this moped....................................................27 - Events on the road.......................................................................28 Carburettor problems......................................................28 Ignition problems...........................................................28 - Multifunction...................................................................................29 - Guarantee manual..........................................................................31 SPECIFICATIONS ENGINE Cubic Capacity: Type: Number of Cylinders: Fuel Supply: Cooling System: Diameter per Stroke: Carburettor: Ignition: Clutch: Gearbox: Transmission: Engine Lubrication: Cooling: 49,38 cc Two-stroke single-cylinder engine with straight-into-crankcase strip admission. One. Fuel supply by means of petrol with separate oil-lubrication pump. Liquid. 40 x 39.3 mm Dell'Ortho* SMA 1412N. 14 mm-diameter diffuser with air intake through an easy-to-clean filter placed within a large filter housing. Electronic with adjustable early timing. Specially designed hydraulic clutch, featuring multiple steel- and friction disks fitted with springs, submerged in a highly effective oil bath. 6 gears. Primary, gear-operated; secondary, chain-operated. Oil mixture. Engine cooling is achieved through a large radiator that keeps the fluid at a constant temperature, never above 80° C. The radiator, secured onto a double-wedge chassis that unfolds at cylinder level, has been welded with chromolibdene and features reinforcing brackets for a highly resistant, robust assembly. Deltabox, made from Cromoly rectangular tubes, aluminium rocker. High-performance 32 mm-diameter inverted hydraulic fork. Showa* inverted fork, 160 mm stroke. - Right-hand rod: 175 cc SAE 5. - Left-hand rod: 150 cc SAE 5. Aluminium rocker. Progressive system fitted with BOGE* single shock absorber providing an extremely long wheel stroke. 250 mm stroke. 240 mm disk fitted with 2-piston clip. 220 mm disk fitted with 4-piston clip. Wrought aluminium. CHASSIS: Engine: Chassis: Front Suspension: Rear Suspension: Front Brake: Rear Brake: -6- Front Tyres: Rear Tyres: Starting Pedal: Brake Pedal: EC - 80 x 90 x 21" 48P T63 SM - 100 x 80 x 17" EC - 110 x 80 x 18" 58P T63 SM - 130 x 70 x 17" Wrought aluminium Wrought aluminium with retractable tip. DIMENSIONS Wheelbase: Saddle Height: Minimum Distance to Ground: Deadweight: Tank Capacity: Oil Reservoir Capacity: Oil Reservoir Reserve: Gearbox Oil: Engine Output Pinion: Driving Chuck: Early Timing: Chain: Sparking Plug: Air Filter: 1.330 mm 920 mm 370 mm 93 Kg 8 litres. 98 NO unleaded petrol. 1,5 litres. 200 cc SAE 15 - 30 Z/ 12 Z/ 52 1,5 mm before PMS. 1/2" reinforced. NGK BR8 ES. 0.6 ­ 0.7 mm electrode gap. Humid-type foam rubber. -7- IMPORTANT INFORMATION IDENTIFICATION NUMBERS Enter the vehicle identification number (serial number), the particulars shown on the model label, and the ignition-key identification number in the spaces provided, in order to simplify your future orders for spare parts or as a useful reference in the event of your vehicle being stolen. Serial Number (A) This has been printed on the steering arm. It shows the frame number used for registering this moped. SERIAL NUM. Certification Plate (B) The moped carries a certification plate showing a serial number (B) that has also been printed on the front, and this information must coincide with that contained in the vehicle documents. We recommend that this information be entered in the box below. CERTIFICATION PL. Ignition Key Identification Number (C) (A) (B) The moped carries one two-key set (C). The identification number appears right on the key joints, as illustrated. This number may be quoted when ordering a spare to replace a lost key. (C) KEY NUM. -8- No-tampering transfer The moped carries an information label with a diagram illustrating some vehicle parts and their part numbers. Because these parts were included with the moped during the certification process, replacing some of them might be punished with a fine if traffic police checks the vehicle. As above, again for your own information and safety, we also recommend that all of these part numbers be entered in the spaces provided. (E) (F) (E). Part Numbers. (F). Numbered Diagram. NOTE We recommend that a specialised garage be contacted if one of these parts requires replacement. The garage will provide advice on certified spare parts. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. REFERENCE -9- COMPONENT LOCATION GAS GAS EC / SM ROOKIE 2005 1 2 3 4 56 7 8 9 10 15 11 12 13 14 12345678- Clutch handle Light Switches Clutch fluid reservoir Petrol tank Brake fluid reservoir Start button Accelerator grip Front brake handle -10- 9- Main beam pilot light 10- Indicator pilot light 11- Multifunction 12- Ignition key 13- Neutral pilot light 14- Oil reserve pilot light 15- Headlight indicator 15 16 17 18 26 19 20 21 22 23 24 25 27 28 29 30 31 151617181920212223- Front shock absorber Oil reservoir Petrol tanck Saddle Front brake disk Front brake clip Sparking plug Gearbox pedal Air filter -11- 24- Rack 25- Chain guide 26- Rear shock absorber 27- Exhaust pipe 28- Rocker 29- Rear brake 30- Starting pedal 31- Exhaust MOPED COMPONENTS NEUTRAL PILOT LIGHT (E) This lights up when the selector lever is in the neutral position. OIL-RESERVE PILOT LIGHT (F) This lights up when the oil level is too low, i.e. when the reserve level is reached. At this point, approximately 1/4 of a litre of oil are left in the reservoir. HEADLIGHT INDICATOR (K) All light controls. When lit, it indicates that the headlight is on CLUTCH (G) The clutch handle has been located on the left-hand side of the handlebars. Clutch engagement and disengagement is achieved by operating this handle. For the clutch to operate smoothly, the lever should be pressed quickly and released slowly. LIGHTS (H) (A) (B) (K) (C) (D) (E) (F) MAIN-BEAM PILOT LIGHT (A) This only lights up when the main beam is on. INDICATOR PILOT LIGHT (B) When lit, it confirms that either the left-hand or the right-hand indicator is on. MULTIFUNCTION (C) This provides information on speed, mileage, etc. (further details may be found at the end of this manual, under "Multifunction Instructions"). IGNITION KEY (D) The key has been located on the front of the handlebars. To start the engine, turn the key clockwise to the "ON" position. To stop the engine, turn the key anticlockwise to the "OFF" position. -12- (G) (H)(I) (G). Clutch. (H). Light button. (I). Stopped button. (J). Horn button. (J) All light controls have been located on the left-hand grip; the various positions available are reached by sliding the main switch, which is on the left end of the grip. FRONT BRAKE (M) Short beam Low beam Whithout lights Front-wheel braking is achieved through a 240mm-diameter disk brake operated by a clip and a hydraulic pump. For optimum results, the braking surface must be oil-free and clean. If, for any reason, the brake fluid must be drained and replaced, read the "Maintenance" section beforehand. Light button diagram. ACCELERATOR GRIP (N) Make sure that this works properly by turning the grip to see if it has the right free play. The grip must spring back to its original position when the accelerator is released. The indicator control has been located on the underside of the lefthand grip. This is an orange-colour button. To start the right-hand indicator, move this switch to the right; and likewise, to start the lefthand indicator, move this switch to the left. START BUTTON (L) The start button is red in colour and has been located on the inside of the right-hand grip. This is used for starting the engine. The engine is stopped by pressing the grey-coloured button (J) on the left-hand grip of the handlebars (previous illustration). WARNING Improper operation of the accelerator may impair your efforts to increase or reduce speed when required. This may result in an accident. Check the accelerator before starting the engine. If the accelerator does not work smoothly, find out the reason. Solve the problem before using the moped, or contact a specialised garage. PETROL TANK This holds 8 litres. To access the tank, unscrew the filler cap. Once open, fill up the tank and replace the cap correctly by turning it anticlockwise. Recommended Petrol (M). Front brake. (N). Accelerator grip. (L). Strart button. -13- (M) (N) (L) Use unleaded petrol with an octane rating equal to or higher than the one shown in the chart. WARNING Petrol is extremely flammable and may become explosive under certain conditions. Never keep the engine running or smoke when refuelling. Make sure that the area is properly ventilated and free from flammable materials or sparks; this includes the operation of any light sources. OCTANE RATING METHOD Antiknock Index (RON + MON)/2 Research Octane No. (RON) MINIMUM RATING 90 98 OIL RESERVOIR This holds 1.65 litres. It has been placed in the left of the moped, behind of the left radiator. To access the reservoir, unscrew the filler cap and fill with oil. Never allow it to exhaust the oil contents, as this would require draining the oil pump to eliminate air accumulations. (A) OIL This engine is designed to burn a mixture of combustible fuels, leadfree petrol and oil. The mixing is performed automatically by a mechanical pump. The only precaution it is necessary to take is that of maintaining an optimum level of fuel in the oil tank. Recomended oil: 2T SINTETIC ATENTION Never mix vegetal and mineral oils together. Too much oil may cause an excessive amount of fumes and spark-plug dirt. Too little oil may cause engine damage or early wear. RECOMIENDA EL USO DE ACEITE: (A). Oil tank. FUEL TAP This tap supplies fuel to the carburettor and has been located on the left-hand side, under the saddle. The tap has three positions. OFF: No fuel flows through the system when the lever is in this position. Always turn the lever to this position when the engine is not running. -14- Open ON Closed OFF Reserve RES ON: Fuel flows into the carburettor when the lever is in this position. Normal operation of the moped is achieved with the lever in this position. REAR BRAKE PEDAL (D) The rear brake pedal is located on the right side of the lower chassis. Activate it to apply the brake to the rear wheels. (C) (D) (E) RES: This refers to the fuel reserve. If you should run out of fuel on the road, turn the lever to this position. ATTENTION If you must use the reserve, remember to fill the tank as soon as possible! After refuelling, turn the fuel-tap lever (C) back to the "ON" position. SADDLE This has been joined to the chassis by means of a screw secured to the tank and its housing in the saddle tongue. The rear section is also secured with screws that must be tightened through the top of the number plates. STARTING PEDAL (E) The pedal has been placed on the right-hand side of the moped and is in the off-position; pull to place it in the on-position. The moped features two starting options: A button and a pedal. Use the pedal only if absolutely necessary. -15- (D). Rear brake pedal. (E). Starting pedal. GEAR PEDAL The vehicle features a 6-speed gearbox. The change pedal is located on the left side of the engine and is used in combination with the clutch when changing gears. (F) (F). Gear pedal. STARTING THE CYCLE STARTING THE ENGINE - Make sure that the moped is in neutral (this is shown on the control panel). - Check to see that there is fuel in the tank. - Turn the fuel tap to the "ON" position. - Turn the ignition key clockwise (to the "ON" position), in order to open the electric circuits required for the engine to start. - If the engine is cold, operate the choke by lifting the lever on the right-hand side of the carburettor (as illustrated on this page). This should provide a richer fuel mixture. - Without operating the accelerator grip, press the electric starting button. - If the engine still fails to start properly, you may also operate the starting lever. STOPPING THE ENGINE - Change down to neutral (the relevant control-panel pilot light will come on). - Accelerate slightly, and then turn off the supply of fuel and press the stop button. - Turn the key anticlockwise. The key will lodge to the left, a position where all the electric circuits remain closed. The engine will not start. - You will be able to remove the ignition key. - Finally, turn the fuel tap to the "OFF" position. CHOKE The choke is a device that increases the supply of fuel to a given extent, without the need to operate the accelerator grip, in order to help the operation of a cold engine. The engine will quickly reach its optimum working temperature with no danger to its component parts. (A) (B) To use the choke, lift the lever on the left-hand side of the carburettor (A). This will allow the engine to start on reaching a given amount of revolutions. NOTE Unless the engine is started when the ignition key is on the "ON" position, the battery may lose some power. -16- Turn off the choke (B) after a few seconds, as the engine will have then reached the right temperature. To turn off the choke, just turn the accelerator grip as far as it will go. NOTE If the engine should flood, start the moped with the accelerator fully on. The moped may be started with one gear in, if you press the clutch. GEAR BOX This being a six-gear transmission with a return gear, shifting from first to third gear requires going through second gear, i.e. shifting gears upwards in a sequence. To go into first gear from neutral it is imperative to press the clutch, then step on the gearbox pedal, release the gearbox pedal and finally release the clutch slowly. Change down sequentially while decelerating, to ensure the right response from the engine when you wish to accelerate. ADJUSTMENT The smooth operation required to maximize engine and transmission performance must be achieved through a previous running-in process. During the first hour or 20 Km, have the engine running at low speed and a moderate rpm level. NOTE Low speed during the running-in process may result in a dirty sparking plug. Check the condition of the standard sparking plug supplied and replace it, if necessary, with one of a higher thermal grade. ATTENTION When shifting gears, press firmly on the gearbox pedal in order to ensure a positive shift. Incomplete gear shifting may cause the transmission to go into the wrong gear, thus damaging the engine. STOPPING THE MOPED For maximum deceleration, release the accelerator grip and operate both the front and rear brakes. Release the clutch and the moped will gradually stop. A separate use of either the front or the rear brake may be advantageous under certain conditions. During the initial 10-hour period, it is advisable not to go beyond medium speed for a long time and to avoid any type of situation that might cause the engine to reach too high a temperature. However, short-time (3 to 4 seconds) accelerations cannot damage the engine; on the contrary, they are beneficial. Every acceleration sequence must be followed by a rest period, to allow the engine to remove all of the heat accumulated. During this initial 10-hour period, it is advisable not to keep a constant speed, but to change it instead every now and then. During the next 10-hour period (10-20), it is advisable not to go beyond 3/4 of the speed available for a long time. ATTENTION In any event, reckless accelerations may suffice to cause engine trouble. Be sure to always apply the skills and techniques required for a proper use of this moped. -17- MAINTENANCE MAINTENANCE SCHEDULE After the initial 500 Km: - Gearbox-oil replacement after the running-in period. - Screw tightening and control adjustments. - Cooling-circuit inspection. - Brake-circuit level checking. - Electrode-gap inspection and sparking plug cleaning. - Chain adjustment, tightening and lubrication. - Brake-circuit level checking. - Cooling-circuit level checking. - Air-filter cleaning. - Spark-plug replacement. - Brake-pad wear inspection. - Engine-oil replacement. - Piston-, cylinder-head-, and exhaust-port decalcification. - Check to see that there are no obstructions in the exhaust pipe and silencer. - Check the early timing. If dirt or particles get into the engine, this can cause wear of the pistons and rings. After using the moped, check the crank and replace it if the wear shown is excessive. 1. Lubricate the rocker arm and the suspension system. 2. Check the chain and the wear on the crown wheel and pinion. 3. Clean the pinion and crown wheel and grease them together with the chain. 4. Check the cylinder piston and the crank bearings. 5. Lubricate the accelerator grip and the cable. 6. Clean the foam filter and the interior of the filter chamber. -18- Every 1.000 km: Every 2.000 km: Every 8.000 km: Maintenance after riding over dusty ground: Maintenance after riding over muddy ground or in the rain: BEFORE STARTING THE MOPED FOR THE FIRST TIME It is advisable to make sure that transportation from our warehouse to its final destination has not altered the original condition of the moped. - Check the condition of the sparking plug by removing the cap and unscrewing the plug. GEARBOX AND CLUTCH Gearbox and clutch lubrication is achieved through the spluttering of the oil inside the crankcase. Both the gearbox and the clutch are lubricated by the same oil contained in the 500cc crankcase. This draining operation may be carried out by removing the clutch cap or by operating the oil-drain screw. - Draining the oil by operating the screw is easier. This should be done while the engine is still hot, in order to achieve a cleaner crankcase and to benefit from a more fluid condition of the oil that will speed up the draining operation. Remove the screw and wait for the crankcase to empty. Next, replace the screw, fill the crankcase, and use the dipstick to check that the right level has been reached. It is advisable to change the oil after the initial 500 Kms, with an oillevel check every 2500 Kms and a new change every 5000 Kms. CARBURETTOR Spark plug condition Correct Poor Rich Dry and clear insulation White insulation Damp and black insulation Change carburation one step higher. Change carburation one step lower. - Check to see that there is oil in the oil reservoir. Before starting the engine, make sure that the oil supply reaches the right level. Upon removal of the screw, a slight tilting of the moped should suffice for the oil to issue through the oil-level hole. - Check the clutch-fluid level and the front- and rear-brake fluid level. This is one of the most crucial items for a proper engine performance, as it is within the carburettor that the petrol-air mixture is produced: a deficient carburetion process translates into a poor performance and may damage the thermal area of the engine. Consequently, it is advisable to have the carburettor adjustment checked, ideally by an Authorized GAS GAS Dealer. Efforts must be made to ensure that the carburettor internal components are clean and in good condition. For this purpose, periodically clean the carburettor and especially its jet by using an air jet or simply by blowing through it. Never use a wire to clean the carburettor, as this might alter the bore and affect the engine negatively. Yet another cause of carburettor malfunctioning may be a blocked fuel-intake filter. Remove the screw securing the intake adapter, clean the filter if it is dirty, and replace it carefully to avoid damaging its filtering cloth. -19- ENGINE Engine lubrication is carried out by means of the fuel, with the oil being supplied from a separate reservoir through a pump driven by the moped engine. AIR FILTER The adequate performance and durability of the various engine components (connecting rod, piston, piston rings, crank bearings, even the cylinder) depend to a great extent on the air filter being clean and properly lubricated. To access the filter, remove the cap on the filter-housing, which has been placed on the left-hand side of the moped. (B) (B). Air box situation. (A) Upon removal of the cap, check the condition of the filter housing, wash the filter if it is dirty, and then lubricate it. To lubricate the filter, apply a few drops of oil to soak the foam and press it with one hand without twisting it, then make sure to replace it correctly in its housing; otherwise, unfiltered air might reach the carburettor and cause serious damage to the moped. (A). Air filter box. SPARKING-PLUG CHECK WARNING Always clean the filter in an area that is properly ventilated and free from sparks or flames in the vicinity (this includes any powerful light sources). Do not use petrol to clean the filter, as this might cause an explosion. (C) (C). Spark plug removed from the valve cover. -20- The proper working of the engine depends on the good condition of the sparking plug; therefore, this is an extremely important component that can be easily inspected. Disassemble and check the sparking plug periodically. For instance, if the central-electrode porcelain insulation appears to be too white, this might be due to a leak in the carburettor air-intake tube, or to carburettor damage or malfunction. The high temperatures the electrode is subjected to, together with carbon deposits, result in excessive wear and eventually render it useless. When this stage is reached, replace the sparking plug with a new one of the same type and recommended thermal grade (NGK BR 8 ES), or any other brand of a similar thermal grade. Carburettors must always be checked by an authorized GAS GAS dealer. (D) The only precaution to bear in mind is that of ensuring that it is completely full of liquid, since, in this way, the water is guaranteed to complete the whole circuit. The use of closed circuit antifreeze liquid is strongly recommended. In this way the you avoid the freezing of the water with the attendant risks engine seizures or breakages of the pump blades. STRIP BOX ~ 0,6 _ 0,7 mm In order to enhance its performance, this engine has been fitted with strip admission. These strips are extremely fragile. Because of their fragility, the strips must not be tampered with, either by opening or by folding them, as this would result in engine malfunction and in the invalidation of the dealer's guarantee. Remove the dirt on the thread and clean the gasket seating, in order to prevent any foreign matter from entering the combustion chamber. Sparking-plug replacement requires checking to see that the electrode gap remains between 0.6 and 0.7 mm. RADIATOR (D) The radiator, which reduces the temperature of the engine-cooling water, has been secured with silent blocks under the petrol tank. -21- Strip box. CLUTCH ADJUSTMENT Clutch adjustment may be carried out by means of the tightening device supplied with the handle. This is achieved by tightening or loosening the tightening screw, as required. The handle should have a 4-5 mm clearance. Due to its hydraulic action, the clutch assembly requires no handle-clearance adjustments. Chain lubrication. CHAIN TIGHTENING Tightening and aligning the chain is easily achieved by loosening the nuts on the wheel axle (A) and by turning the nuts on the chain tighteners (B) as required, until the right chain tension or sag is achieved, together with a proper wheel centering and alignment. (A) CHAIN LUBRICATION (A). Clutch. WARNING Always try to achieve a proper chain-and-wheel alignment, as otherwise the chain might come off and hit and damage the crankcase. The chain should be cleaned and checked periodically. To achieve this, remove the chain while keeping the hook at one of its ends, which will both confirm its previous position and avoid the risk of losing it. Clean the chain thoroughly with a metal brush, by submerging it in a petrol bath and shaking it until all of its links are clean and free from obstructions. Submerge it again in clean petrol or gas oil, rinse and allow it to dry for a few minutes. Lubricate and reassemble it, always making sure that the hook is placed in the opposite direction to the chain movement. It is most advisable to lubricate the chain every 100 or 200 Kms with special chain-lubrication oil. (A) (B) (A). Wheel axle nut. (B). Chain adjuster locknuts. -22- FRONT SUSPENSION The front suspension, featuring state-of-the-art technology and design, includes an inverted hydraulic fork with 32mm-diameter rods. Each rod has its own purpose and effect, as, whilst one of them acts mechanically through compression springs, the other one only operates hydraulically. Oil supply per rod - Right-hand fork...175 cc. - Left-hand fork.....150 cc. Hydraulic oil SAE 5 - Press the suspension spring and insert the key (5) into the locknut (2) locking the cap (3). - Fit the suspension cap onto the fork rod and tighten to 29 N-m. - Fit the other fork. - Fit the disassembled components. (1). Spring. (2). Locknut. (3). Suspension cap. (4). Cap wrench. (5). Locknut wrench. (D) REAR SUSPENSION The rear suspension, which is of the swivelling type and features a hydraulic shock absorber, requires no more attention than checking its wear and the play on the swivelling arm. Should the silent blocks securing the shock absorber loose their shape, for any reason whatsoever, replace the shock absorber to prevent damaging the chassis geometry. - Pull the hydraulic-system rod (D) slowly. - The fork oil will now issue through the hole in the hydraulic-system rod; keep it raised until it stops. - Insert the suspension spring (1) into the fork tube. -23- CABLE The accelerator cable should always be in perfect condition; therefore, whenever the slightest crack is detected, it must be replaced immediately. However, in order to extend its life and enhance its operation, it should be lubricated approximately every 1000 Kms. Do this by inserting a few drops of SAE-20 between the cable and its guide. Use an aerosol cable lubricant with a pressure luber: (B) (C) (D) (B). Bleeder screw. (C). Disk brake. (D). Brake caliper. (A) Apply grease to the following point throttle inner cable upper ends (A). Remove the pump cap and pour brake fluid to just under the top level. Next, loosen the bleeder screw and insert a tube in it. The tube end should be inserted in a container to avoid fluid spilling. After filling the pump and loosening the bleeder, operate the brake handle until the fluid drops, making sure that no bubbles come out through the inserted tube. Then, turn off the bleeder and pour brake fluid into the reservoir to reach the mid-level mark. Replace the cap and operate until the braking is perfect. REAR BRAKE (E) (G) FRONT BRAKE Front-wheel braking is achieved through a 240mm-diameter disk brake operated by a clip and a hydraulic pump. For optimum results, the braking surface must be oil-free and clean. If, for any reason, the brake fluid must be drained and replaced, proceed as follows: -24- (F) (E). Bleeder screw. (F). Disk brake. (G). Brake caliper. Rear-wheel braking is achieved through a foot-operated lever and a 220mm-diameter disk brake. It is very important that the fluidpump piston push rod has some play with the piston, as otherwise an excessively hot fluid would cause it to expand and might block the wheel, with serious consequences for the user. (I) (J) PUMP AND BRAKE PADS Make sure that both brakes have the right amount of brake fluid, and refill if required. Replace any worn brake pads on the hydraulic clips. STEERING Minimum pad thickness: 2mm The steering of a properly tuned up moped must turn easily; therefore, if the steering feels hard or works erratically, this may be due to either excessive tightening or defective condition of the ball race or of the ball-bearing balls. Should the latter be the cause of the problem, disassemble and replace the ball races and the steel balls. Remember that the steering should always turn smoothly and must never have any play. (I). Brake caliper. (J). Pad. Below this level, they still work correctly. However, besides the risk of defective braking, when this is required, the braking surface of the disk might also be seriously damaged. Remember that these operations should always be carried out by a specialised garage. TYRE PRESSURE (A) (A). Break pump. (B). Rear brake pedal adjustment rod. -25- The EC Rookie features two wheels of different sizes and pressures: Front wheel: 80 x 90 x 21" With 1 passenger: 1 Bar With 2 passengers: 1,5 Bar 110 x 80 x 18" With 1 passenger: 1,2 Bar With 2 passengers: 1,7 Bar (B) Rear wheel: CHECKING OPERATIONS AT SPECIALISED GARAGES MAINTENANCE OPERATIONS Checking brake systems Checking transmission oil level Checking chain tightening and wear Checking suspension systems Checking, adjusting & lubr. controls and cables Tightening spokes Checking filter and carburettor (cleaning) Check and adjust the spark plug electrode. Checking chassis screws and nuts (plastics) Checking brake- and clutch-fluid levels Checking braking-pad wear Checking electric system Checking piston-ring wear Checking radiator water levels -26- STORAGE Proceed as follows, before storing the moped for some time: - Clean the moped thoroughly. - Start the engine and keep it running for approximately 5 minutes to heat the transmission oil, then drain it (see the Transmission section). - Refill with new oil. - Drain the petrol tank (if left in the tank for a long time, petrol loses quality). - Disconnect the battery. - Lubricate the chain and all the cables. - Apply oil on all non-sprayed metal surfaces to prevent rust, but not on the brakes or rubber parts. - Wrap the outside of the exhaust pipe in a plastic bag to prevent rust. - Place the moped in such a way as to avoid contact of the wheels with the ground (if this is not possible, place some cardboard under the wheels). - Cover the moped to avoid dust and dirt. Starting the moped after a period in storage: - Remove the plastic bag from the exhaust pipe. - Tighten the sparking plug. - Fill the petrol tank. - Check the steps set forth in the section entitled "Inspection prior to using the moped". - General lubrication. - Connect the battery. - Check tyre pressure. FINAL THINKS PREVENTIVE ADVICE Periodic maintenance and thorough checking of every function before starting the moped. Periodic checking operations of this moped must only be carried out by GAS GAS After-Sales specialists. SAFE USE OF THIS MOPED Safe use of a moped does not only depend on the vehicle. Here, the rider's common sense and intelligence play a crucial role. Therefore, we recommend that you wear the required gear (helmet, boots, etc.) to practise your favourite sport. In the interest of technical development, we reserve the right to modify the construction, standard equipment and accessories of this moped. Data concerning measurements, weights and power includes the relevant tolerances. Depending on the equipment and accessories included with this moped, as well as on the various versions designed for world markets, there may be differences between this vehicle and the descriptions and illustrations supplied. Because of this, errors and omissions excepted, no claims will be accepted in this connection. GAS GAS MOTOS, S.A. reserves the right to introduce changes and / or modifications without prior warning. -27- EVENTS ON THE ROAD If the engine works normally, it should start with no difficulties. Should the engine fail to start after repeated attempts, check to see whether the problem is with the carburettor or with the ignition. CARBURETTOR PROBLEMS - The engine is cold. - There is no petrol in the tank. - The petrol tap is off. - The petrol-cap hole (breather) is obstructed. - There is an obstruction between the petrol tank and the carburettor tap. - Partial breakage of one or more of the reeds in the reed valve assembly or their opening. IGNITION PROBLEMS - Check to see that the sparking plug is clean and the electrode gap is correct. - Make sure that the sparking plug is producing sparks; to do this, bring the sparking plug (connected to the tube) closer to the fins or outside area of the cylinder, then kick the starting pedal. - Make sure that the sparking-plug tube is properly connected. - If the sparking plug fails to produce sparks, replace it with a new one and check again. Should the moped still fail to start after the above checking operations, there may be a mechanical problem. Have it checked by an authorised GAS GAS Dealer. GAS GAS MOTOS, S.A. recommends the use of the following products for its EC ROOKIE 50 cc model. UTILISATION Gear oil Engine pump oil TYPE SAE 15 - 30 2T sintetic REMARK: -28- MULTIFUNCTION Functions - Work mode. This can be activated (ON) and deactivated (OFF). - Clock. Indicates hour and minutes. - Chronometer. Indicates the time passed since the last activation of the work mode. - Partial distance. Indicates the distance covered since the last activation of the work mode. - Maximum speed obtained since the last activation of the work mode. - Average speed during the last activation of the work mode. - Total distance covered since the equipment was turned on. - Instantaneous speed. ET TD MAX AVE TOD KmH NOTE In order to select any of the functions, the motor must remain stopped for ten seconds. A minute after selecting a function, the screen will turn off automatically. It is activated again by pressing the MODE key or putting on the motor. Work mode This option is selected by means of the MODE key. By pressing START it goes from the deactivated state (OFF) to the activated stated (ON) and viceversa. When it is in the activated mode, the symbol is visualised permanently on the screen. The gathering of data then begins and the calculations are carried out to obtain the information which is visualised in the function Chronometer, partial Distance, maximum Speed and average Speed. When OFF is pressed, the adquisition of data and the calculations are detained, but the calculated values are not lost, and can be visualised by selecting the corresponding function. By activating once more the work mode (ON), the values previously stored are wiped out. -29- Chronometer The chronometer visualises the time passed since the last activation of the work mode. Initially, minutes and seconds are visualised. After an hour has passed, hours and minutes are visualised. Maximum speed This shows the maximum speed reached during the activated work mode. Average speed This shows the average speed reached during the activated work mode. Total distance This visualises the total distance covered since the moment when the equipment was turned on for the first time. The value accumulated is maintained permanently, even without batteries, and is independent of the condition of the work mode. Fig.2 Installation of batteries - To replace the batteries, remove the cover of the battery space by unscrewing the two screws at the back of the multi-function. - Substitute the old batteries with the new ones, maintaining the same polarity which is indicated on the diagram. - Finally, screw on the cover again. (Fig. 2) - If the previous process has been carried out correctly, all the segments and legends of the screen will appear momentarily. (Fig. 3). After a few seconds, the clock symbol will appear with a reading of zeros (Fig. 4), disappearing after 10 seconds. Fig.3 Fig.4 Instantaneous speed On turning on the motor, the reading of Km/h. will appear automatically. While the motor is in operation, the instantaneous speed reading will remain on the screen (Fig. 5). On detaining the motor, the screen will remain lit up for about ten seconds with the indication of zero Km/h. After this time, if the motor is not turned on again, the last function previously selected will appear on the screen. The screen will turn off completely after one minute, if during this time the power has not been turned on again or if a function has been selected. While this function is visualised, it is not possible to select any other one. Fig.5 Setting the time Press the MODE key until the clock symbol appears. By pressing the START key, the minute digits and the clock symbol will flash, indicating that it is in time set mode (Fig. 6). By pressing lightly on the START key, the minutes indicator will be advanced. On keeping the same key pressed, the advance will be automatic, being detained on letting go of the key. On pressing the MODE key, the hour digits will flash, proceeding in the same way as above. Once the correct values have been selected, press the MODE key to give said values. The digits will stop flashing. -30- Fig.6 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 -31- 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. 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 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). -32- 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. 6.- In the case of used motorcycles sold by Gas Gas the Warranty Period will be one year from date of delivery of the goods. And in no case shall the consumer request replacement of the goods. Notes Notes RECOMIENDA EL USO DE ACEITE: RECOMMENDS THE USE OF: RECOMMANDE L'USAGE DE L'HUILE: CONSIGLIA L'USO D'OLIO: FEBRERO / FEBRUARY / FEBRER 2005 C/ UNICEF nº 17 · Poligon Industrial Torremirona · 17190 Salt (Girona) SPAIN · Tel: +34 902 47 62 54 Fax: +34 902 47 61 60 E-mail: officegg@gasgasmotos.es / partsgg@gasgasmotos.es PU010538006