enducross EC'07 MANUAL DEL USUARIO USER MANUAL MANUEL D'ENTRETIEN LIBRETTO D´USO BETRIEBSANLEITUNG enducross EC´07 USER MANUAL ENGLISH Foreword GAS GAS thanks you for the trust you have placed in us. By choosing the new GAS GAS EC / MC / SM 2007 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 2007 is a motorcycle conceived for the practice of high-competition. It is actually the fruit of many years of competition and experimentation in this demanding discipline, as well as the many great successes achieved thanks to great trial riders who have contributed with their expertise to the basic data that have allowed us to create motorcycles of the highest level, GAS GAS unique motorcycles which count on important key factors: reliability, high features and a good stability. Congratulations for making the right choice. With your skills at the command of this motorcycle, its adequate preparation and the corresponding indispensable servicing, this motorcycle will prove to be highly reliable, and you will be able to enjoy the most comfortable and rewarding practice of your favorite sport. Thank you for your trust in us, and welcome to GAS GAS Motos, S.A. Julyl 2006 -3- 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: -4- TABLE OF CONTENTS Foreword...........................................................................................3 How to use this manual.....................................................................4 Table of contents...............................................................................5 Specifications....................................................................................6 Location of components....................................................................8 Side Stand ......................................................................................12 Fuel .................................................................................................12 Serial Number .................................................................................14 Homologation Plate.........................................................................14 Starting the engine..........................................................................14 Shifting gears ..................................................................................15 Stopping the motorcycle .................................................................16 Riding during the Break-In Period...................................................16 Maintenance Schedule ...................................................................17 Electronic Ignition............................................................................19 Cooling System...............................................................................19 Spark Plug ......................................................................................20 Transmission...................................................................................22 Air Cleaner ......................................................................................24 Throttle Cable .................................................................................25 Carburetor.......................................................................................25 Clutch..............................................................................................26 Exhaust System ..............................................................................26 Drive Chain Guide...........................................................................27 Handlebar .......................................................................................29 Brakes.............................................................................................30 Steering...........................................................................................31 Steering blockage ...........................................................................32 Front Fork .......................................................................................33 Rear suspension .............................................................................36 Wheels ............................................................................................38 Cleaning..........................................................................................39 Bolts and nuts tightening.................................................................40 Lubrication ......................................................................................42 Tunning (Carburetor and Suspension)............................................43 Final recommendatios.....................................................................51 Homologation..................................................................................52 Preparation for competition.............................................................53 Storage ...........................................................................................54 GAS GAS Multifunction Instructions ..............................................55 Troubleshooting ..............................................................................61 Electric Schemas ............................................................................66 Warranty Manual............................................................................ .67 -5- 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 Carburettor, diameter of diffusor Lubrication system 100% Synthetic Oil Mineral Oil (Only USA) Starting system Ignition system Ignition timing 2 cycles, single cylinder, crankcase intake, liquid cooled 54 x 54.5 mm 124 cc 62.5 x 65 mm 199.4 cc 66.4 x 72 mm 249.3 cc 72 x 72 mm 294.7 cc 38 Mixture 50:1 = 2% 32:1 = 3% Starting lever CDI system 1 mm BTDC TRANSMISSION Transmission type Clutch type Secondary drive Gear ratio (200 cc, 250 cc, 300 cc) 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) -6- Primary reduction Final reduction Overall gear ratio Transmission oil Capacity Type 2.85 (57/20) (250 cc, 300 cc) 3.692 (48/13) (250 cc, 300 cc) 8.323 (6th gear) 750 cc (125 cc) 900 cc (200 cc / 250 cc / 300 cc) 10W30 API SF or SG CHASSIS Type Tire size Front Rear Suspension Suspension stroke Front fork oil Front fork oil level Front Rear Front Rear 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 ø 45 mm (only EC, SM and MC 125) Inverted telescopic fork ø 50 mm (only MC 250) Progressive system with single multi-adjustable shock 282 mm 320 mm SAE 5 - 7.5 110 mm (compressed, without spring) BRAKES Type Effective disc diameter Front, Rear Front Rear Disc brake 260 mm (only EC and MC) 320 mm (only SM) 220 mm DIMENSIONES Overall height Overall length Overall width Seat height Minimum height Wheelbase Fuel tank capacity 1260 mm 2135 mm 810 mm 940 mm 340 mm 1475 mm 9l (Specifications are subject to change without notice and probably do not apply to all countries). -7- LOCATION OF COMPONENTS 1 2 3 4 7 5 6 GAS GAS EC 2007 1- Clutch lever 2- Steering and lighting controls 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip 7- CDI Switch 1 2 3 4 7 56 GAS GAS MC 2007 1- Clutch lever 2- Engine stop button 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip 7- CDI Switch 1 2 3 47 56 GAS GAS SM 2007 1- Clutch lever 2- Steering and lighting controls 3- Fuel tank cap 4- Brake fluid reservoir 5- Front brake lever 6- Throttle grip 7- CDI Switch -8- GAS GAS EC 2007 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 -9- 17- Air cleaner 18- Muffler 19- Seat 20- Gas reservoir 21- Chain guide 22- Chain 23- Suspension linkage and swingarm 24- Rear brake pedal 25- Kick-start pedal 26- Exhaust GAS GAS MC 2007 18 19 9 20 10 8 7 21 22 23 24 25 2614 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 -10- GAS GAS SM 2007 18 19 19 20 20 10 10 9 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 -11- 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 2007 and SM 2007 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 2007 (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. -12- 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. NOTE If knocking or pinging occurs, try a different brand of gasoline or higher octane grade. WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. 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 th ...