User manual GAS GAS MC - 2005

MANUAL DEL USUARIO SERVICE MANUAL MANUEL D'ENTRETIEN LIBRETTO USO E MANUTENZIONE Foreword GAS GAS thanks you for the trust you have placed in us. By choosing the new GAS GAS EC / MC / SM 2005 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 2005 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. October 2004 EC / MC / SM 2005 -66- 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: . 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. 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. RECOMMENDS THE USE OF OIL: EC / MC / SM 2005 -67- TABLE OF CONTENTS Foreword ........................................................................................6 6 How to use this manual...................................................................67 Table of contents.............................................................................68 Specifications..................................................................................69 Location of components..................................................................71 Side Stand ......................................................................................75 Fuel .................................................................................................75 Serial Number .................................................................................77 Homologation Plate.........................................................................77 Starting the engine..........................................................................77 Shifting gears ..................................................................................78 Stopping the motorcycle .................................................................79 Riding during the Break-In Period...................................................79 Maintenance Schedule ...................................................................80 Electronic Ignition............................................................................82 Cooling System...............................................................................82 Spark Plug ......................................................................................85 Transmission...................................................................................85 Air Cleaner ......................................................................................87 Throttle Cable .................................................................................88 Carburetor.......................................................................................88 Clutch..............................................................................................89 Exhaust System ..............................................................................89 Drive Chain Guide...........................................................................90 Handlebar .......................................................................................92 Brakes.............................................................................................93 Steering...........................................................................................94 Steering blockage ...........................................................................95 Front Fork .......................................................................................96 Rear suspension .............................................................................99 Wheels ..........................................................................................101 Cleaning........................................................................................102 Bolts and nuts tightening...............................................................103 Lubrication ....................................................................................105 Tunning (Carburetor and Suspension)..........................................106 Final recommendatios...................................................................114 Homologation ................................................................................115 Preparation for competition ...........................................................116 Storage..........................................................................................117 GAS GAS Multifunction Instructions ............................................117 Troubleshooting.............................................................................119 Warranty Manual...........................................................................124 EC / MC / SM 2005 -68- SPECIFICATIONS ENGINE 125 cc Engine Bore and stroke Displacement 200 cc Engine (only EC) Bore and stroke Displacement 250 cc Engine Bore and stroke Displacement 300 cc Engine (only EC) Bore and stroke Displacement Carburetor type Lubrication system Starting system Ignition system Ignition timing Spark plug 2 cycles, single cylinder, crankcase intake, liquid cooled. 54 x 54.5 mm. 124 c.c. 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. Mixture. 50:1 = 2% 32:1 = 3% Starting lever. CDI system. 1 mm BTDC. NGK BR9EG ( 125 c.c. ) NGK BR8EG ( 200 c.c. / 250 c.c. / 300 c.c. ) 100% Synthetic Oil Mineral Oil (Only USA) TRANSMISSION Transmission type Clutch type Secondary drive Gear ratio 6 speed in cascade. Hydraulic operated multi-plate in oil bath. Chain driven. 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) EC / MC / SM 2005 -69- Primary reduction Final reduction Overall gear ratio Transmission oil Capacity Type 2.85 (57/20) 3.615 (47/13) 8.149 (6th gear) 750 cc. ( 125 c.c. ) 900 cc. ( 200 c.c. / 250 c.c. / 300 c.c. ) 10W30 API SF or SG. Tubular, semi-double cradle. EC & MC - 90/90 x 21. SM - 120/60 ZR17. EC - 140/80 x 18. MC - 120/80 x 19. SM - 150/60 ZR17. Inverted telescopic fork Marzocchi ø 45 mm (only EC and SM ) Inverted telescopic fork Marzocchi ø 50 mm (only MC ) Inverted telescopic fork ÖHLINS. Progressive system with single multi-adjustable shock ÖHLINS. 282 mm. 320 mm. Marzocchi SAE 7,5. ÖHLINS SAE 5 - 7,5. Marzocchi: 110 mm (compressed, without spring) ÖHLINS: 110 mm (compressed, without spring) CHASSIS Type Tire size Front Rear Suspension Front Rear Front Rear Suspension stroke Front fork oil Front fork oil level BRAKES Type Effective disc diameter Front, Rear Front Rear Disc brake 260 mm. (only EC and MC ) 320 mm. (only SM ) 220 mm. 1260 mm. 2135 mm. 810 mm. 940 mm. 340 mm. 1475 mm. 9 l. DIMENSIONES Overall height Overall length Overall width Seat height Minimum height Wheelbase Fuel tank capacity (Specifications are subject to change without notice and probably do not apply to all countries). EC / MC / SM 2005 -70- LOCATION OF COMPONENTS 1 2 3 4 5 6 GAS GAS EC 2005 1- Clutch lever 2- Steering and lighting controls 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip 1 2 3 4 56 GAS GAS MC 2005 1- Clutch lever 2- Engine stop button 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip 1 2 3 4 5 6 GAS GAS SM 2005 1- Clutch lever 2- Steering and lighting controls 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip EC / MC / SM 2005 -71- GAS GAS EC 2005 7 8 9 10 11 12 18 19 20 13 14 15 16 9 17 21 22 23 24 25 26 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 EC / MC / SM 2005 -72- GAS GAS MC 2005 18 19 9 20 10 8 7 21 22 23 24 25 26 14 13 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 EC / MC / SM 2005 -73- GAS GAS SM 2005 18 19 20 10 9 8 7 21 22 23 24 25 26 14 13 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 EC / MC / SM 2005 -74- 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 2005 and SM 2005 FUEL The GAS GAS EC / MC / SM models have 2-cycle engines that require a mixture of gasoline and oil. Gas Tank Capacity 9L (A) (A). Side stand. (B). Double spring (B) (B) (A) MC 2005 (A). Side stand. (A) (A). Fuel tank cap. (B). Vapor outlet tube. 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. NOTE Do not start the engine or ride the motorcycle when the side stand is down. EC / MC / SM 2005 -75- RECOMMENDED FUEL Use 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 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. 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. NOTE If knocking or pinging occurs, try a different brand of gasoline or higher octane grade. WARNING 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. Mixing oil inside the engine Oil must be mixed with gasoline to lubricate the piston, cylinder, crankshaft, and connecting rod bearings. EC / MC / SM 2005 -76- 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. STARTING THE ENGINE 1. Make sure the motorcycle is in the neutral position. 2. Turn the gasoline cock (A) clockwise to the "ON" position. Open ON OFF Close Reserve RES (A) (B) (A) (B) 3. If the engine is cold, pull up the choke knob (B). EC / MC / SM 2005 -77- 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. Stopping the engine (MC model) 1. Shift the transmission into neutral. 2. After racing the engine slightly, close the throttle completely and depress the engine stop button (A). (A) (C) 4. Start the motorcycle with kick-start pedal (C). 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. 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. 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. 2. After racing the engine slightly, close the throttle completely and depress the engine stop button (D). (A). Gearshift pedal. (D) (A) 3. Turn the key in counterclockwise direction to the "OFF" position. EC / MC / SM 2005 -78- 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. Perform the break-in period following these steps: Start the engine and let it run at idle until the engine is warm. Stop and let the engine cool completely. 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 1. 2. 3. (A) 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. 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. EC / MC / SM 2005 -79- MANTENANCE SCHEDULE 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 Check / Inspect Adjust Change / Replace Clean Apply grease / Lubricate 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* 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 - At each fill up 3 fill ups 1 fill up - 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. EC / MC / SM 2005 -80- MANTENANCE SCHEDULE 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 Check / Inspect Adjust Change / Replace Clean Apply grease / Lubricate 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* 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 - 1 fill up 5 fill ups 10 fill ups 5 fill ups - 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. EC / MC / SM 2005 -81- 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). - Verify that the mark (C) on the magnetic flywheel is aligned with the mark on the crankcase (B). - 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. 125 cc. (A) 200/250/300 cc. (B) (C) EC / MC / SM 2005 -82- 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). EC / MC / SM 2005 -83- 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. (1). Coolant level. (2). Filler opening. 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. 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. (A) 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. 200 / 250 / 300 cc. EC / MC / SM 2005 -84- (A) (A) (B) 125 cc. (B) Standard Spark Plug WARNING If coolant gets on the tires will make them very slippery and can cause an accident. - Visually inspect the old coolant. If whitish spots are observed in the liquid is a clear indication that the aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts of the system are rusting. In both cases, flush the cooling system. - Check the cooling system for damage, leaks or missing gaskets in the cooling system. - Install the water pump cover drain screw with the specified torque values shown in the table. Always replace the gasket with a new one. Drain plug tightening torque (refer to torque table) Water pump screw: 9 Nm. - Fill the radiator up to the edge of the cap with coolant, and install the radiator cap. - Inspoect the cooling system for leaks. - Start and warm up the engine, then stop the engine. - Check the coolant level after the engine cools down. Add coolant up to the cap. 125 cc. NGK BR9 EG 200 / 250 / 300 cc. NGK BR8 EG 0.7-0.8 mm. 0.7-0.8 mm. The spark plug should be removed periodically to check its gap. If the plug is oily or has carbon deposits, clean it with a sandblaster. After removing the abrasive particles, the spark plug must be cleaned using a wire brush or a similar tool. Measure the gap with a feeler gauge, if incorrect adjust the gap by bending the side electrode. If the spark plug electrodes are corroded or damaged, or if insulator is cracked, replace the plug. NOTE Inspect every 30 hours and change every 60 hours. To find out whether the right heat range plug is being used, remove it and inspect the ceramic insulator around the center electrode. If the ceramic is light brown, the spark plug is correctly matched to engine temperature. If the ceramic is whie, the spark plug should be replaced with the next colder plug. If the ceramic is black, the spark plug should be replaced with the next hotter plug. NOTE If the engine performance drops, replace the spark plug first to recover its output. TRANSMISSION SPARK PLUG The standard spark plug is a shown in the table and should be tightened to 27 Nm. For the transmission and clutch to function properly, maintain the transmission oil level at the optimum level and change it periodically. A motorcycle with insufficient transmission oil, deteriorated or contaminated can accelerate wear and tear and cause transmission damages. EC / MC / SM 2005 -85- Oil level inspection - Wait a few minutes if the motorcycle has been operating. Oil change NOTE The engine must be completely cool and then warm up the engine again for a few minutes to normal operating temperature, to register the correct engine oil temperature and to obtain an accurate oil level measurement. - The transmission oil should be changed periodically to ensure long engine life. - Warm up the engine for 5 minutes so any oil sediment will float. - Stop the engine, and place an oil pan under the engine. - Remove the drain screw (see previous photo) and place the motorcycle in riding position to allow the oil to drain out. - Clean the drain screw magnet of any iron particles. - Tighten the oil drain screw with its O-ring to 20-Nm. - Remove the oil filler opening plug (C) and pour 900 cc of new transmission oil for the models 200/ 250/ 300, and 650 cc for model 125. - Check the oil level, after kicking the kick-start pedal 3 or 4 times. - Install the oil filler opening plug. (A) - Check the oil level through the inspection window in the lower right hand side of the engine (A). - Oil level must be kept between the maximum and minimum marks. (B) - If the lever is too high, you have to remove the excess oil through the drain plug (B). - If the level is low, add the necessary quantity of oil by opening the plug (C). Use the same type and oil manufacturer used currently with the engine. Transmission Oil Viscosity: SAE 10W30. Capacity: 1000 cc. EC / MC / SM 2005 -86- 125 cc. 200/250/300 cc. (C) (C) AIR CLEANER A clogged air cleaner restricts the engine air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. WARNING - Place a lint-free towel in the intake port of the carburetor so no dirt is allowed to enter the carburetor. CAUTION Do not turn the filter since it can be easily damaged or torn. - Wipe out inside the air cleaner hoousing with a clean damp towel. A clogged air cleaner may allow dirt and dust to enter the carburetor and stick the throttle open. This could cause an accident. CAUTION A clogged air cleaner may allow dirt and dust to enter the engine causing excessive wear and tear and other damages. Do not omit checking the element, before and after each race or practice session. Clean it if necessary. Element Cleaning WARNING Clean the element in a well-ventilated area, and make sure that there are no sparks or flame anywhere near the working area (this includes any appliance with a pilot light). Do not use gasoline to clean the element because could cause an explosion. - Clean the filter using a soft bristle brush in a bath of filter cleaning fluid. - Pull the cage (B) out of the air cleaner (A) - Remove the cover (A) - Remove the screw (B) and remove the filter (C) (B) (A) (C) EC / MC / SM 2005 -87- - Squeeze it dry with a clean towel. Do not wring the element or blow it dry since it can be damaged. - Inspect the filter for damage such as tears, hardening, or shrinkage. If damaged, replace it or it will allow dirt into the carburetor. - Apply grease to all connections and screws in the air cleaner and intake ports. - If the free play cannot be set by adjusting the cable, remove the cable protector in the throttle body. Make the necessary free play adjustments with the tensor at the end of the cable, tighten the locknut, and reinstall the protector. CARBURETOR - Install the filter in the cage and pack the filter lip with grease (A), to ensure good sealing and prevent dirt entrance. - Install the seat. THROTLE CABLE - Check that the throttle grip turns smoothly. - Check that the throttle grip has 2-3 mm of free play. - If the free play is incorrect, loosen the locknut on the upper end of the throttle cable, and turn the adjuster to obtain the correct amount of free play. - Tighten the locknut again. Idle speed adjustment Is carried out using the air screw (A) and idle screw (B). - First turn in the air screw until it is loose, then tighten it 1 1/2 turns. - After thoroughly warming up the engine, turn the idle adjusting screw to obtain the desired idle speed. If there are no idle preferences, turn the screw until the engine stops. - Tighten lightly the idle screw.. (B) (A) (A). Air screw. (B). Idle screw. - Open and close the throttle a few times to make sure the idle speed does not change. Readjust if necessary. - With the engine idling, turn the handlebar to each side. If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or routed incorrectly, or it may be damaged. Be sure to correct any of these conditions before riding. (C) (B) (A) (A). Adjuster. (B). Locknut. (C). Throttle grip. EC / MC / SM 2005 -88- WARNING Riding with a damaged throttle cable could be dangerous. CLUTCH The clutch lever free play should be 2-3 mm. The free play increases as the clutch plate wears out, then a new adjustment will be required. If there is too much free play, first try to adjust the clutch lever free play. Tighten the adjusting screw to obtain the optimum free play specified. (D) (B) EXHAUST SYSTEM The exhaust and the muffler reduce the noise and send gases away from the rider. If the exhaust is badly damaged, dented, cracked or rusted, replace it with a new one. Replace the muffler fibre if the exhaust noise becomes too loud or if the engine performance drops. Muffler replacement - Remove the right side number-posting cover. EC 2005 / SM 2005 - Remove the retaining screws (A) of the right side numberposting cover (B). (B) (A) (C) (A) (D) (B) MC 2005 - Remove the retaining screws (C) of the muffler (D) and remove the muffler towards the rear. (C) (C) (A) (A). Clutch lever. (B). Clutch pump piston plunger. (C). Adjusting screw. (D). Hydraulic fluid reservoir. If the clutch lever adjustment reaches its limit, further adjustments should be made adjusting the clutch pump pistón plunger. (D) - Replace the muffler and reinstall the assembly. EC / MC / SM 2005 -89- Muffler fibre replacement - Remove all cover rivets with a drill. - Remove the inside core of the muffler. - Replace the muffler fibre by wraping it around the inner tube. - Reinstall the assembly. EC Model MC and SM Models (A). Rivets. (B). Cover. (A) (B) Drive Chain Slack Inspection The space between the chain and the swingarm at the same height of the chain slider should be 30-50 mm.Rotate the rear wheel to find the place where the chain is tighter. Adjust the drive chain if it has too much or too little slack. 125 / 200 cc. 250 250 // 300 cc. DRIVE CHAIN GUIDE The drive chain must be checked, adjusted, and lubricated in accordance with the Maintenance Schedule. If the chain is worn or adjusted incorrectly (either too loose or too tight) the chain could become loose or break. Replace the chain, if necessary. WARNING A chain that breaks or becomes loose could snag on the engine or on the rear wheel, severely damaging the motorcycle and causing it to go out of control In addition to checking the slack, rotate the rear wheel to inspect for damaged rollers, loose pin and links, unevenly or excessively worn teet, and damaged teeth. 30-50 mm. EC / MC / SM 2005 -90- Drive Chain Slack Adjustment - Loosen the rear axle nut (A). - Turn the nuts on the chain adjusting tensors (B) until the drive chain has a gap of 30-50 mm between the chain and the swing arm. To keep the chain and wheel aligned, the left chain tensor should aligned with the right chain tensor. - Tighten the chain tensor nuts (B). - Tighten rear axle nut to 98 Nm. - Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary. WARNING If the axle nut is not securely tightened an unsafe riding condition may result. Drive chain, chain guide, chain slider, and rear sprocket teeth. (A) When the chain is worn so much that it is more than 2% longer than when new, it is no longer safe for use and should be replaced. Whenever the chain is replaced, inspect both the engine output pinion and rear sprocket teeth, and replace them if necessary. Worn sprocket teeth will cause a new chain to wear quickly. NOTE When a part ir worn, replace it with a genuine part for maximum resistance and safety. (B) To minimize any chance of the master link coming apart, the master link clip must be installed with the closed end of the «U» facing in the direction of the chain rotation. (A). Clip. (B). Direction of rotation WARNING Misalignment of the wheel will result in abnormal wear and may cause an unsafe riding condition. NOTE Wheel alignment can also be checked using the string metod. EC / MC / SM 2005 -91- Chain Guide Slider Visually inspect the upper and lower chain slider at the location of the swingarm. If damaged or worn, replace it with a new part. Apply oil to the sides of the chain rollers for better oil penetration. Wipe off any excess oil. (A) (B) HANDLEBAR (A). Apply oil. To suit various riding positions, the handlebar position can be adjusted front to rear. Handlebar position adjustment (A). Chain Guide Slider. (B). Swingarm. Pinion Teeth, Pinion Sprocket and Sprocket Wear Visually inspect the pinion teeth. If they are worn or damaged, replace the the pinion or the sprocket. Lubrication Lubrication is necessary after riding through rain or in the mud, or any time that the chain appears dry. A heavy oil is preferred to a lighter ol because it will stay on the chain longer and provide better lubrication. EC / MC / SM 2005 -92- Loosen the handlebar holder (A) screws (B), turn the handlebar and place it in the desired position. (B) (A) Tighten the bolts, front first and then the rear, to 25 Nm of torque. Rear brake pedal position When the brake pedal is in rest position, there should be a free play of 10 mm. If not, adjust the pedal position. Check the brake for good braking power and no brake drag. To adjust the pedal free play, loosen the locknut and turn the screw. After adjustment, tighten the locknut securely. (A) BRAKES If the handlebar is installed correctly, there will be an even gap at the front and rear after tightening (A). (A) (B) Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action. So there are no parts that require adjustment on the brakes except brake lever free play and brake pedal position Front brake lever free play Adjust the front brake lever (A) to match your requirements. To adjust, loosen the nut (B). After adjustment, tighten it securely. Then check that the brake response is correct. (D) (C) (A). Brake pedal. (B). 10 mm free play. (C). Adjusting screw. (D). Locknut. WARNING (A) (B) If the brake pedal feels spongy when it is applied, there might be air trapped in the brake pump or the brake may be defective. Since it is dangerous to operate the motorcycle under such conditions, have the brake checked inmediately. EC / MC / SM 2005 -93- Brake fluid Inspect the brake fluid level and change it periodically. The brake fluid should also be changed if it becomes contaminated with dirt or water. Liquid recommended Use D.O.T. 3 or D.O.T. 4. Brake fluid level inspection The front (A) and rear (B) reservoirs must be kept more than half full with brake fluid. If the brake fluid is insufficient, add brake fluid. Brake wear inspection EC and MC Models If the thickness of either pad, front and rear, is less than 1 mm, replace both pads as a set. Pad replacement should be carried out only by an authorized GAS GAS dealer. STEERING The steering should always be kept adjusted so that the handlebar will turn freely but without free play. WARNING Do not mix different types of fluid. Change the brake fluid in the reservoirs completely if the same type of brake fluid is not available. CAUTION Do not spill brake fluid onto any painted surface. Do not use fluid from a container that has been left open or that has been unsealed for a long time. Check for fluid leakage around the fittings. Check for brake hose damage. SM Model (A) (A) (B) ALL Models EC / MC / SM 2005 -94- To check the steering adjustment use a stand under the chassis, and lift the motorcycle off the ground. Move the handlebar lightly to either side; if the handlebar continues moving under its own momentum, the steering is not too tight. Squatting in front of the motorcycle, grasp the lower end of the front fork (at the axle), and push and pull the fork (as shown on the previous photo); if free play is felt, the steering is too loose. If the steering needs adjustment - Use a stand or a special support to stabilize the motorcycle. - Raise the front wheel off the ground. - Remove the handlebar (A) by loosening the handlebar holder screws and removing the upper holders. - Install the suspension top bridge (D). - Tighten the steering stem nut, and front fork washers and screws. Steering nut: 44 Nm (4,5 Kgm). Suspension top bridge: 22 Nm (2,25 Kgm). - Check the steering again, and readjust if necessary. - Install the removed parts. STEERING BLOCKAGE As indicated by its name, this mechanism allows us to lock the handlebar. Is located in the steering pipe. You have to turn the handlebar completely to the right, next insert the key, turn left, press, turn right and remove the key. (A) (C) (D) (B) (A) - Loosen the steering stem nut (B). - Loosen the screws of the suspension top bridge (C) and remove it. - Turn the steering adjustment nut with the special wrench to obtain the proper adjustment. EC / MC / SM 2005 -95- (A). Steering lock. CAUTION Never leave the key in the latch. If the steering is turned to the left with the key inerted in the latch it will be severely damaged. FRONT FORK The front fork should always be adjusted for the rider´s weight and road conditions. The adjustments must be performed in 4 steps: - Air pressure: Air pressure affects the fork travel. The air pressure increases as the fork heats up, in other words it varies as a function of time of operation. We do not recommend using air pressure, because the suspension has been designed to work without air pressure. - Rebound and compression dampening adjustment: This adjustment affects how quickly it rebounds. The fork rebound dampening adjuster has 18 positions. The tightest position is full hard. The position 12 from close is the standard setting, and position 18 from close is full soft. - Oil level adjustment: The effects of higher or lower fork oil level are only felt during the final 100 mm of fork travel. A higher oil level will make the fork rebound faster. The lower the oil level is the fork rebound will be slower. - Fork spring: Optional springs are available that are softer and stiffer than standard. Air Pressure The standard air pressure in the fork is atmospheric air pressure. The air pressure increases as the fork heats up, because of this the fork action becomes harder. - Using a stand under the frame, and stabilize the motorcycle. - Place a support under the engine so that the front wheel is raised off the ground. - Remove the purge screw at the top of the front fork to bleed the air out. (A) (A). Air purge screw. Rebound Dampening Adjustment - To adjust the rebound, turn and hand tighten the adjuster knob (A) located at the top of the front fork. - Adjust the rebound to suit the rider's preference under determined conditions. (A) (A). Adjuster knob. EC / MC / SM 2005 -96- Use the standard settings to adjust the rebound (turn it 6 positions counterclockwise). CAUTION The left and right fork tubes must be at the same level and aligned with the top bridge. Compression dampening adjustment - To adjust the compression, turn with your finger the adjusting knob located at the top of the front fork. - Adjust the compression to suit the rider's preference under determined conditions. - Use the standard measures to adjust the compression (turn it 6 positions counterclockwise). Oil level adjustment - Place a stand under the motorcycle engine (to keep it in a straight and stable position). - Remove the handlebar screws and remove the handlebar. - Remove the suspension caps from the tubes. - Compress the front fork slowly all the way. - Lift the fork springs. - Hold the suspension tube cap with a spanner, the loosen the cap locknut. - Remove the suspension tube caps. - Remove the suspension srping guide. - Use a wrench to remove the fork springs. - Put the oil level gauge on the upper portion of the fork tube, and measure the distance from the top of the fork tube to the oil level. Standard oil level Marzocchi: 110 mm. Öhlins: 110 mm. (A). Drain oil. (B). Add oil. Adjust the oil level as required within the adjustable range using the following oil: Recommended oil MARZOCCHI SAE 7´5 ÖHLINS 5 - 7'5 EC / MC / SM 2005 -97- (1). Spring. (2). Locknut. (3). Suspension cap. (4). Cap wrench. (5). Locknut wrench. Suspension tube spring Different springs are available in accordance with the rider´s weight or the road conditions. - Harder springs make the fork stiffer, and rebound action quicker. - Softer springs make the fork softer, and rebound action slower. Suspension top bridge position adjustment Make sure the front tire does not rub against the fender when the fork tubes are compressed fully. Make this adjustment to a minimum of 5 mm. CAUTION The suspension tubes, both right and left, must be adjusted evenly. (A). Hydraulic rod. - Pull the hydraulic rod (A) out slowly. - At this time, the fork oil pours out of the hydraulic rod hole, keep it raised to let it drain until it stops. - Install the fork spring (1) inside the fork tube. - Tighten the suspension spring and insert the wrench (5) in the locknut (2) to lock the cap (3). - Install the suspension cap (3) in the fork tube and tighten it to 29 Nm. - Mount the other fork. - Install the parts removed. EC / MC / SM 2005 -98- Shock absorber extension adjustment To adjust, turn by hand the extension adjuster in the lower part of the shock absorber until a "click" is heard. Total number of adjustments possible is: 40 "CLICKS". Rebound adjustment standard measures: Between 18 and 25 "CLICKS" (Counterclockwise from fully closed position). (1) (1). Suspension top bridge position. REAR SUSPENSION (A). Extension adjuster. Low compression adjustment The rear suspension is composed of the shock absorber, swingarm, linkages and torque rod. Generally speaking, the operating characteristics are similar to the front fork. But its unique characteristic is that it has, besides the shock absorber, an articulated quadrilateral composed of the linkages and torque rod. To match various riding condition types, the shock absorber spring can be adjusted or replaced with an optional one. Also the dampening force can be easily adjusted, this feature makes it unnecessary to change oil viscosity. To adjust, turn the fuel tank control with a screwdriver until you hear a "click". The total number of possible positions is: 30 "CLICKS" Rebound adjustment standard measures: 15 "CLICKS" (Counterclockwise from fully closed position). High compression adjustment To adjust, use a number 17 hex wrench. The control has 4 complete turns. As the control is closed the compression will be harder, on the other EC / MC / SM 2005 -99- hand as it is opened it will be softer. The normal standard measure is two turns. (A). Low and high compression adjuster. Suspension spring The standard spring is 4,0. The spring length preloaded with the shock absorber at rest is 258 mm. (A) (A) (C) Spring adjustment - Remove the seat and side covers. - Loosen the air cleaner duct clamp screw. - Remove the muffler. - Remove the subframe with the air cleaner box. (B) (A). Nut. (B). Spring. (C). Locknut. - Tighten the locknut securely. - After adjustment, move the spring up and down to make sure that the spring is fully seated. - Install the parts removed. Rear shock absorber spring replacement Harder and softer springs are available. If the standard spring is not adequate for your purpose, select a proper one according to the rider´s weight and the road conditions. - Using the harder spring:The rebound is quicker. - Using the softer spring:The rebound is slower. NOTE Refer to the suspension adjustments on page 110. (B) (A) (A). Subframe. (B). Air cleaner box. EC / MC / SM 2005 -100- WARNING Improper installation of the rear shock absorber spring may cause the spring and any of its related parts to be ejected at high velocity. Always wear eye and face protection. The installation of these parts should be performed by an authorized dealer. WHEELS Tires - Tire pressure affects traction, and tire life. - Adjust the tire pressure to match road conditions and rider's preference, but do not stray too far from the recommended pressure. NOTE Tire pressure should be checked when the tires are cold before riding. Road conditions - When the road is wet, muddy, sandy or slippery, reduce the tire pressure. - On gravel roads or hard terrain, increase the tire pressure. Spokes and wheel rims The spokes on both wheels must be tightened evenly and should not be allowed to have free play. Unevenly tightened or loose spokes will cause wheel rim runout, the other spokes will be stressed and might break. Wheel rim runout Place a dial indicator at the rim side, and spin the wheel by hand to measure the axial runout. Place the dial indicator at the inner circumference of the wheel and spin the wheel, the difference between the highest and lowest quantities is the runout. If the runout is not excesive it can be corrected tightening or loosening some spokes with the spoke adjusting wrench (B). If the wheel rim is curved or bent it must be replaced. NOTE A welded area on the rim may indicate excessive runout. Disregard this when measuring rim runout. (A). Spoke adjusting wrench. EC / MC / SM 2005 -101- CLEANING 1- Preparation for washing Before washing the motorcycle, precautions must be taken to prevent water from entering the following parts of the motorcycle. Exhaust: Cover it with a plastic bag tightened with rubber bands. Clutch and brake levers, hand grips, and engine stop button: Cover these parts with plastic bags. Air cleaner intake: Cover the opening with tape or with a rag. CAUTION To avoid excessive ageing of the plastic parts and other washable pieces of the motorcycle, it is suggested that these items must be washed carefully. If the washer applies water at high pressure and/or temperature, take the precaution of maintaining the washer outlet gun at a distance of 30 centimeters minimum, this will ensure the correct gloss of the plastics and maintain adherence of the selfadhesive labels that decorate the motorcycle. 3- After washing: - Remove the plastic bags, and clean the air cleaner intake. - Lubricate the points listed in the lubrication section (see pag. 41). - Start the engine and let it run for 5 minutes. - Check the brakes before operating the motorcycle. WARNING Never wax or lubricate the brake disc. Loss of braking and an accident could result. Clean the disc with trichloroethylene or acetone. 2- Where to be careful Avoid spraying water with any great force near the following areas: - Brake calipers and brake pump piston. - Ignition coil or into the spark plug cap. - Front and rear wheel hubs. - Steering bearings. - Rear suspension system. - Swingarm bearings. EC / MC / SM 2005 -102- BOLTS AND NUTS TIGHTENING Every day before riding, check the tighteness of the bolts and nuts described here. Also check that all other fasteners are in place and in good condition. 1 2 3,4 5,6,7 8 9 1 19 20 21 22 23,24,25 10 11 12 13 14 15 16 17 18 26 27 28,29 30,31,32 33 123456789- Front and rear wheel. Front fork. Handlebar. Clutch lever holder screw. Cylinder head bolt. Spark plug. Cylinder nuts. Air cleaner box holder bolts. Trailing plate bolts. 10- Spokes. 11- Front axle bolt. 12- Brake hose screw. 13- Radiator bracket bolts. 14- Engine holder bolts and nuts. 15- Gearshift pedal bolt. 16- Subframe bracket bolt. 17- Chain guide bolts. 18- Chain adjuster nut. 19- Seat mounting bolts. 20- Subframe bolts. 21- Rear shock absorber bolts. 22- Exhaust mounting bolts. 23- Suspension top bridge bolts. 24- Steering stem nut. 25- Brake lever bracket screw. 26- Rear axle nut. 27- Linkage mounting bolt. 28- Rear brake pedal bolt. 29- Torque rod mounting bolt. 30- Swingarm shaft nut. 31- Kick-start pedal bolt. 32- Kick-start pedal nut. 33- Front brake hose fastening screw. EC / MC / SM 2005 -103- Torque Values Table Tighten all bolts and nuts to the proper torque using an adequate wrench. A bolt or nut loose might damage the motorcycle or even cause an accident. PART NAME N-m PART NAME N-m F R A M E Brake caliper mounting bolt Disc mounting screw Engine mounting bolt Front axle bolt Front brake hose mounting bolt Suspension clamp bolt Steering nut Rear axle nut Rear brake pedal bolt Subframe bracket bolt Rear shock absorber bolt Rear drive plate nut Spokes Steering stem nut Torque rod bolt Rear linkage bolt 25 10 36 51 6 29 98 98 9 26 39 29 1.5 4 81 81 E N G I N E Cylinder head screws Cylinder nut Engine drain plug Kick-start pedal bolt Kick-start pedal nut Gearshift pedal bolt Spark plug Water pump cover drain plug Crankcase screws Starter pedal plate screw Ignition motor stator screws Ignition motor coil nut Selector spring fixing screw Primary nut Clutch spring screws Valve control support screws Valve control nuts Reed valve screws Thermostat housing screws Clutch housing screws Valve housing screws Ignition housing screws 25 25 20 20 25 15 27 9 10 8 8 40 15 40 10 10 8 10 10 10 8 10 EC / MC / SM 2005 -104- LUBRICATION Lubricate the points shown here, apply either engine oil or grease, periodically or whenever the vehicle has been operated under wet or rainy conditions, and especially after using high water pressure. Before lubricating each part, remove any rusty spots with rust remover and wipe off any grease, oil, or dirt. General lubrication - Clutch lever (A). - Front brake lever (B). - Rear brake pedal (C). - Rear brake bearing (D). - Gearshift pedal (E). (E) Use an aerosol with a tube for pressure lubrication: (A) (B) (D) (C) Apply grease inside the gas cable (A). EC / MC / SM 2005 -105- Drive Chain Lubrication Lubricate the drive chain after driving on wet terrein or when the chain looks dry. A high viscosity oil is preferred rather than a lower viscosity because it will stick to the chain longer and lubricate the chain better. Apply oil to the sides of the chain rollers (A) for better oil penetration. Wipe off any excess oil. NOTE The main jet should be increased or decreased 1 to 5 sizes and tested until the engine gives maximum power. Main jet It has a great overall effect. The number stamped on lower part of the main jet indicates the size of the hole metering fuel. A greater number corresponds to a bigger hole which supplies more fuel. (A) (A) (A). Apply grease. TUNE-UP 1. CARBURETOR TUNE-UP Mixture First step is to establish a basic knowledge on the identification and operation of carburetor components. Change settings in accordance with the temperature: Condition Cold air Warm air Dry air Low altitude High altitude mixture lean rich lean standard rich change setting rich lean rich standard lean 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). (A). Main jet. EC / MC / SM 2005 -106- Slow Jet Controls the mixture from the closed position to an opening of 1/8 of throttle range, but has little effect on full throttle. To adjust the mixture in this range, the air screw can be turned to change the air flow through the circuit, or the slow jet can be changed to provide more or less fuel. Start by turning the air screw. Screwing it in richens the mixture. The air screw must be turned from a lightly seated position. Make changes in 1/2 turn increments. If turning the screw between 1 and 2,5 turns does not give the desired results, change the slow jet (A) one step and tune up with the air screw (B). Carburetor jet needle The jet needle and jet needle hole together have their greatest effect in the one-half throttle range. The needle moves in and out of the jet needle hole; since the needle is tapered, its position in the jet determines the amount of fuel allowed to flow. There are five grooves in the upper section of the needle where a circlip fits. This clip locates the needle in the throttle valve and determines its relative position in the jet needle hole, and provides a rich mixture. Moving the clip to the top will provide a lean mixture. Change the clip position one step at a time. The straight area of the needle affects throttle valve response in the small openings range. Clip position Jet needle number Right section Test runs with the motorcycle - Warm up the engine with the carburetor at the standard setting, and inspect the operating conditions of the spark plug. - Test-ride the motorcycle with the throttle opened. Symptoms of improper settings (B) If your motorcycle exhibits one of the following symptoms the changes must be adjusted. Before attempting any changes, make sure that everything else is in good operating condition. EC / MC / SM 2005 -107- Check the condition of the spark plug, make sure the ingnition timing is correct, service the air cleaner element, decarbonize the exhaust tube If you machine has run properly up to this point, it is possible that the problem is elsewhere; changing the carburetor settings in such a case would probably be a waste of time. Spark plug condition Correct Too lean Too rich Insulator is dry & light tan color Correction factors: (For altitude or temperature changes). 1. Find the correction factor to adjust the carburetor. Example: 1000 meters altitude with an air temperature of 35 °C. The correction factor is 0,94. 2. Using the correction factor, select the correct slow jet and main jet. Example: For a correction factor of 0,94 multiply the jet size by that number. Idle jet: # 50 x 0,94 = #47. Main jet: # 162 x 0,94 = # 158. 3. Find the correction factor on the Jet Needle / Air Screw chart and change the jet needle clip position and air screw opening as indicated. - Jet needle clip setting: from the 3rd groove to the 2nd groove. - Air screw opening: 1 1/2 + 1 turn = 2 1/2 turns out. NOTE For the following recommendations to be accurate, you must use the standard settings as a base-line. Also do not change any of the settings until you have determined what changes are necessary. All specifications are based on the use of the fuel and oil specified. Replace the main jet to one step larger Insulator is wet & black color Replace the main jet to one step smaller White color insulator - Set the carburetor so that the engine delivers satisfactory power with the throttle valve opened. - If the air-fuel mixture is too lean, the engine tends to overheat and may be seized. On the other hand, if it is too rich, the spark plug easily gets wet and causes misfires. The proper mixture varies depending on atmospheric conditions. Taking these conditions into consideration, adjust the carburetor settings properly. NOTE Keep in mind that the carburetor components that regulate fuel flow and the screw that control the flow of air must be tight. Standard Settings FUEL Throttle valve Idle jet Needle Main Jet UNLEADED 7 38 N1EC 185 LEADED 7 35 N1ED 160 EC / MC / SM 2005 -108- (ºC) U R (ºF)E T ET M PE EM RP AE T UR RA AT 30 40 (104) 30 (86) 20 (68) 10 (50) 0 (32) -10 (14) 00 20 m (9 60 0 00 ft) 10 m (6 40 00 Se m (3 20 0 ALTITUD a Le ve l ALTITUDE 0 ft) ft) °C (°F) T