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enducross EC`07

1. Pull the cage B out of the air cleaner A Clean the filter using a soft bristle brush in a bath of filter cleaning fluid 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 ni 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 C B A me A Adjuster L B Locknut C Throttle grip COP IIOP KT Ifthe 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 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 thorou
2. Gr Grey Br Brown E W White tA ai es R Red SEED G Green T tr IT Ignition coil P Pink j O Orange ty wie Y Yellow V Violet Front right pHa A GL Bright green indicator ici Lie F Ri IEE Magnetic flywheel Front brake MF sh Rear brake Wa i pru sensor i Rear right sa MED indicator F so si Rear Ea T hola sidelight Pepi brake light Front sidelight j os Rear left rae indicator Dipped Full beam Headlights Indicator relay CL Front left I Magnetic indicator flywheel Horn Power i controller FEE Cras dt risco a Di LE N dea aa miin en E F CP KC KT 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
3. damaged rollers loose pin and links unevenly or excessively worn teet and damaged teeth P_NVIPRANVI Drive Chain Slack Adjustment Tighten the chain tensor nuts B Tighten rear axle nut to 98 Nm Loosen the rear axle nut A Rotate the wheel measure the chain slack again at the tightest Turn the nuts on the chain adjusting tensors B until the drive position and readjust if necessary 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 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 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 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 WARNING B Poirettion of ation Misalignment of the wheel will result in abnormal wear and may i cause an unsafe riding condit
4. of the defects for example communication costs accommodation expenses car hire costs public transport costs breakdown truck fees courier costs etc aS well as other financial losses for example those caused by the loss of the use of the vehicle loss of income time lost etc f Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle for example small or hidden imperfections noise or vibrations that are normal in use etc g Phenomena that are the result of the ageing of the vehicle for example discolouring of painted or metallic coated surfaces Various 1 GG shall have the prerogative to decide at its own discretion whether to repair or replace defective parts Where parts are replaced ownership of the parts removed shall pass to GG without any other consideration The GG authorised dealer to whom the making good of the defects has been entrusted is not authorised to make any declarations that are binding on GG 2 In case of doubt regarding the existence of a defect or a visual or material inspection is required GG reserves the right to demand the return of the parts which are the object of a claim under Warranty or to arrange an inspection of the defect by an expert from GG Any additional obligations arising out of guarantees on parts replaced free of charge or any other service rendered free of charge are excluded from the effects of this present warranty Th
5. 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 Tubular semi double cradle EC amp 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 45 mm only EC SM and MC 125 Inverted telescopic fork 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 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 Specifications are subject to change without notice and probably do not apply to all countries 7 CP KC KT LOCATION OF COMPONENTS 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 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 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 GAS GAS EC 2007 1415 16 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
6. KP KT 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 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 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 CP ENCE RECOMMENDS THE USE OF OIL Global Racing Oil TABLE OF CONTENTS
7. and with no limit on the number of kilometres covered or hours of use Warranty Period The period covered by this Warranty will begin on the day of delivery of the vehicle to the purchaser by a GG authorised dealer or in the case of demonstration models on the date in which the vehicle is used for the first time The seller will be responsible for any unwarranted faults that become apparent within the period established in the Law decree 23 2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance with the Directive 1999 44 EC for other members of the European Community For countries outside the European Community the Warranty Period will be determined by the existing regulations in those countries Nevertheless should the fault appear during the first six months after the delivery of the motorcycle it will be presumed that the said fault existed at the time of delivery from the end of the sixth month onwards the purchaser must demonstrate that the unwarranted fault existed at the moment of delivery During the first six months subsequent to the delivery of the repaired vehicle the seller will be responsible for any unwarranted faults arising out of the repair Any defects detected in the product must be brought to the attention of a GG authorised dealer within the Warranty Period If the last day of this period is a Sunday or an official holiday the Warranty period will be extended such that t
8. 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 Insulator is dry amp light tan color BY Correct Too lean White color insulator Replace the main jet to one step larger Too rich Insulator is wet amp black color Replace the main jet to one step smaller 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 The standard competition measurements EC 250 are an example UNLEADED Throttle valve Idle jet Needle Main Jet CP KP KT 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
9. 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 SPARK PLUG The standard spark plug is a shown in the table and should be tightened to 27 Nm Standard Spark Plug 125 cc 200 250 300 cc 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 For the transmission and clutch to function properly maintain the transmission
10. is low add the correct amount of coolant through the filler opening COP KP KT 1 Coolant level 2 Filler opening 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 COP KP KT 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
11. mm This increases agility Fast course with many jumps Raise the fornt end slightly Lower the fork tubes 5 mm Deep potholes or sandy ground Raise the front end slightly to gain stability After making such preliminary adjustments begin the actual on track testing and evaluation CAUTION 1 Make changes one step at a time 2 Make sure the rider is consistent in this evaluation 3 A change in the front suspension requires a change in the rear and vice versa CP KOCK Front and rear compatibility Use this procedure to determine if the suspension is balanced Place the motorcycle upright While standing next to the right side of the motorcycle hold the front brake and press the rear brake pedal firmly If the motorcycle maintains its level attitude as the suspension is compressed the spring rates are well balanced Sit astride the motorcycle and take a riding posture Next check to see that the motorcycle is in a horizontal position If one end drops noticeably more than the other the front and rear are not compatible and must be readjusted to achieve a better balance This is one of the most effective adjustment procedures but suspension settings will vary depending on the conditions at the terrain and the rider s preferences Does the motorcycle skids when driving down hill or when accelerating out of a curve Front fork is too soft 1 Increase the compression or rebound damping 2 Increase the
12. 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 Oil level inspection Wait a few minutes if the motorcycle has been operating Check the oil level through the inspection window in the lower right hand side of the engine A fae Oil level must be kept between the maximum and minimum marks a 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 750 cc EC 125 900 cc EC 200 250 300 COP KP KT 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 th
13. pads wear Brake fluid level Brake fluid S Evey2 years _ Brake pump piston amp dust cover __ Every years Radiator tube and connections 1 fill up 1 fill up 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 17 MANTENANCE SCHEDULE Brake caliper piston seal amp dustseal Every2yeas oOo Brake hose and pipe i Every4years _ _ Spoke tightness and rim runout 1fillup ffilu ffilu to Lubricate drive chain a ee 0 Drive chain dfl of o es Drive chain wear Sfilus Sfilups_ cei Chain slider I Front fork When necessary Front fork oil Po Everyyea_ E Nuts bolt fasteners oe Fuel hose LS e When necessary o i a Fuel system Steering play flu Te Rear sprocket 5 fill ups 5 fill ups General lubrication 5 fill ups Steering bearing 5 fill ups 5 fill ups ee ee lt lt ee o Swingarm and linkages Rear shock absorber oi 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 18 ELECTRONIC IGNITION This motorcycle uses a capacitor discharge ignition system CDI The
14. to the OFF position A Gearshift pedal 15 COP KC KT 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 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 16 Perform the break in period following these steps 1 Start the engine and let it run at idle until the engine is warm 2 Stop and let the engine cool completely 3 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 HA
15. 1 Electric Schemas 225 csssaccccacaenctonccancadesccoantenia aaa 66 Warranty Manual scecsissinianisisssisinrirsarinniniaininn ai 67 CP KC KT 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 TRANSMISSION Transmission type Clutch type Secondary drive Gear ratio 200 cc 250 cc 300 cc 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 x72 mm 294 7 cc 38 Mixture 50 1 2 32 1 3 Starting lever CDI system 1mm BTDC 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 Primary reduction Final reduction Overall gear ratio Transmission oil Capacity Type CHASSIS Type Tire size Suspension Suspension stroke Front fork oil Front fork oil level BRAKES Type Front Rear Effective disc diameter Front Rear DIMENSIONES Overall height Overall length Overall width Seat height Minimum height Wheelbase Fuel tank capacity 2 85 57 20
16. 2007 and SM 2007 A Side stand B Double MC 2007 A Side stand NOTE Do not start the engine or ride the motorcycle when the side stand is down 12 FUEL The GAS GAS EC MC SM models have 2 cycle engines that require a mixture of gasoline and oil Gas Tank Capacit 9 L 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 counter clockwise 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 RECOMMENDED FUEL Use gasoline with an octane rating equal to or higher than that shown MINIUM RATING in the table OCTANE RATING METHOD Antiknock Index 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 Research Octane No 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 Mixing oil inside the engine Oil must be mixed with gasoline to lubricate the piston cylinder crankshaft and connecting rod bearings 13 CP KC KT Recommended oil 2 CYCLE SYNTHETIC NOTE If the recommended oil is not availa
17. 6 17 18 26 27 28 29 30 31 32 33 1 Front and rear wheel 10 Spokes 19 Seat mounting bolts 28 Rear brake pedal bolt 2 Front fork 11 Front axle bolt 20 Subframe bolts 29 Torque rod mounting bolt 3 Handlebar 12 Brake hose screw 21 Rear shock absorber bolts 30 Swingarm shaft nut 4 Clutch lever holder screw 13 Radiator bracket bolts 22 Exhaust mounting bolts 31 Kick start pedal bolt 5 Cylinder head bolt 14 Engine holder bolts and nuts 23 Suspension top bridge bolts 32 Kick start pedal nut 6 Spark plug 15 Gearshift pedal bolt 24 Steering stem nut 33 Front brake hose fastening screw 7 Cylinder nuts 16 Subframe bracket bolt 25 Brake lever bracket screw 8 Air cleaner box holder bolts 17 Chain guide bolts 26 Rear axle nut 9 Trailing plate bolts 18 Chain adjuster nut 27 Linkage mounting bolt 40 CP KC KT 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 Brake caliper mounting bolt PE Disc mounting screw sis Engine mounting bolt ti accident Pr PI Cylindernut S nut sea Kick startpedalbolt 20 Front axle bolt S5 Front brake hose mounting bolt 6 Suspensionclampbolt 29 Steeringnut 98 Rearaxlenut 98 Rearbrakepedalbolt 9 Subframe bracketbolt 26 Rear shock absorberbolt 39 Reardriveplatenut 29 Spokes 15 Steering
18. 94 multiply the jet size by that number Idle jet 40 x 0 94 38 Main jet 180 x 0 94 170 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 CP KC KT ALTITUDE gt T to w A 7 E 40 D K M beso La Ga C P Oo NG 30 i 86 A 20 T 68 U R 10 E 50 0 C F 32 10 14 0 90 092 094 0 96 CORRECTION FACTOR NEEDLE POSITION AIR SCREW OPENING CORRECTION FACTOR 1 06 or HIGHER 1 06 1 02 1 02 0 98 0 98 0 94 0 94 or LOWER NEEDLE LOWER CLIP 1 SAME SAME SAME RAISE CLIP POSITION POSITION 1 POSITION AIR SCREW TIGHTEN 1 TURN TIGHTEN 1 2 SAME LOOSEN LOOSEN OPENING TURN 1 2 TURN 1 TURN 2 SUSPENSION TUNE UP This adjustment is very critical because if an improperly tuned suspension will keep even the best rider from attaining the full benefit of his machine s ability Check the suspension in accordance to the rider and the terrain conditions If the motorcycle is new break in the suspension with at least
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20. 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 CP KC KT 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 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 Adjuster knob CP KC KT Standard oil level 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 A Drai
21. PO OU asena E EE EEE EEEE 3 How to use Mis Manbdal c ria 4 Table of COmMeniS cits cce tagssecteysnectscedaoecaciarsassaceertaqnadacsesarsodaaedacecssies 5 SC NVC AON Screen 6 Location of COMPONEnNiSs rsscr ae 8 de AN eo RE 12 PU EPSE E EA EE ii 12 Serial MINN SF eee lai 14 Homologation Faleria 14 Staring eee rare aiar 14 Wet RAR EA 15 Stopping th IMOLON CY Cle CR RR OA AA 16 Riding during the Break In Period ccccccssceccssseeeesssseeenseseeeees 16 Maintenance Schedule i 17 EISCHONIGIGRINO siii iraniana irpini 19 Congo sele 19 PIER 20 TRANS ANS SIO Gaia 22 AIr NAN Me nale 24 Throttle Gable ile diodo centeehabahbesddedededs 25 CAMDUICIO oa io on 25 UR E IATA 26 CP KC KT Exhaust Syster arabe eda dite 26 Drive Chain GUd6 s criirsriiorrranigsesianaszianicanina rina 27 DEE EE ETENEE rea 29 BrO e EAE AA ica 30 OERD ea TA 31 Steering Dlbekagb rca 32 FODE FOI ooer aren i E EEE 33 Rear SUSPENSION s acioni ra 36 WY TSS e IE 38 E EE 39 Bolts and nuts TGNTCMING basa nteswsscixaidiernccnteovsehiunivadeatintaidbinnedtbieraaatons 40 01 CRCR RR RE RAZIA 42 Tunning Carburetor and SUSpenSIion i 43 Final rEGOMIendaloS ssagis iaia orta 51 PION a E1 E EPEAT ATETA E AAT 52 Preparation for COMPEtIHON iii ica dt 53 S19 e lt oa E een eee IA 54 GAS GAS Multifunction Instructions 55 TroubleshooliNhg sirisser ridan ir a E REE 6
22. RD 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 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 MANTENANCE SCHEDULE Clutch At each fill up At each fill up At each fill up Le At each fill up Discs 3 fill ups 3 fill ups afilupst o dm a wrote ca I tg I E Air cleaner element po Whendamaged _ 1filup Carburetor o tfillup ft flu gt Transmission al CI E E Piston and piston ring 3 fill ups Cylinder head cyl amp exhaust valves Exhaust 1 fill up Muffler gasket Po 10 fillups tofilups Throttle cable Piston bearing 3 fill ups 3 fill ups 10 fill ups 3 fill ups Kick start pedal and gearshift pedal 1 fill up Exhaust pipe o ring po fill ups Engine bearings 10 fill ups 10 fill ups 10 fill ups Coolant 3 fill ups 3 fill ups 3 fill ups Brake adjustment Brake
23. UTION 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 C 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 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 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 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
24. Wipe off any excess oil 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 fixture Change setting ten Rich Cold air Lean Warm air Dry air Standard Standard Low altitude High altitude CP KC KT 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 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 CP KC KT Idling nozzle and mixture adjustment screw 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
25. ble 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 C do not use 100 synthetic oil 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 CP KC KT 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 l lo lt 3 If the engine is cold pull up the choke kn
26. ch 5 in the of 5 mm 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 The suspension tubes both right and left must be adjusted evenly Install the parts removed CAUTION 1 Suspension top bridge position REAR SUSPENSION 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 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 25 CLICKS Counterclockwise from fully closed position High compression adjustment Use a screwdriver for adjustments The control has 4 complete turns As the control is closed the compression will be harder on the other hand as it is opened it will be softer Normally the standard measurement would be 1 5 turns from the
27. chometer with bar graph The bar graph of the tachometer displays up to 11 000 rpm RPM Digital Tachometer The rpm is shown in the second row The digital tachometer displays up to 19 900 rom The tachometer signal can be read from the CDI Capacitator Discharge Ignition or the ignition coil Gear change indicator according to rpm This function permits setting an indicator for changing gear at a specific rom level The tachometer bar flashes when the rom reaches the specific level and stops flashing when the gear is changed MAX RPM Maximum tachometer value It appears in the 2 row It shows the highest level reached by the tachometer since the last resetting of the data SPD Speedometer The speedometer information appears in the first line of the screen It shows up to 300 km h or 187 5 mph MAX Maximum speed gauge The MAX value appears in the 1st line It shows the highest speed reached since the last resetting of the data AVG Average driving speed The AVG value appears in the st line It calculates the average speed since the last RESET operation TRIP Journey counter This appears in the second line of the screen The TRIP function contains the vehicle s accumulated mileage since the last RESET operation 57 CP KC KT ODO Mileometer It shows the total mileage accumulated by the vehicle The data is stored in the memory even when the device is not running RT Time of use controller It calculates the
28. cock 16 Shift pedal 21 22 23 2425 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 26 CP KC KT CP KC KET GAS GAS MC 2007 18 19 9 20 10 8 7 21 22 23 24 25 2614 13 7 Brake disc 20 Gas reservoir amp Rear shock absorber 8 Front suspension 21 Chain guide 9 Brake fluid reservoir 22 Chain 10 Fuel tank 23 Suspension linkage and swingarm 13 Brake caliper 24 Rear brake pedal 14 Radiator 25 Kick start pedal 18 Muffler 26 Exhaust 19 Seat 10 GAS GAS SM 2007 18 19 20 21 22 23 24 25 7 Brake disc 8 Front suspension 9 Brake fluid reservoir 10 Fuel tank 14 Radiator 18 Muffler 19 Seat 11 26 14 13 20 Gas reservoir amp Rear shock absorber 21 Chain guide 22 Chain 23 Suspension linkage and swingarm 24 Rear brake pedal 25 Kick start pedal 26 Exhaust CP KC KT CP KC KT 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
29. completely closed position A Ajustador de ta com rest ni 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 CP KC KT Suspension spring The standard spring is 5 2 250 cc 300 cc 5 0 125 cc 200 cc 5 6 MC The spring length preloaded with the shock absorber at rest is 258 mm A Nut B Spring a 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 47 CP KTP KT 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 th
30. d 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 A Brake pedal check that the brake response is correct B 10 mm free play WARNING 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 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 EC and MC Models SM Model ma ALL Models CP KTP KT 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 WARNING Do not mix different types of fluid Change the brake flu
31. e 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 69 CAF KI FF RECOMIENDA EL USO DE ACEITE RECOMMENDS THE USE OF OIL RECOMMANDE L USAGE DE L HUILE CONSIGLIA L USO D OLIO EMPFIEHLT DEN GEBRAUCH VON OL Global Racing Oil PU010738010 JULIO JULY JUILLET LUGLIO JU
32. e 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 750 cc for model 125 Checkthe oil level after kicking the kick start pedal 3 or 4 times Install the oil filler opening plug CP KK KT AIR CLEANER A clogged air cleaner restricts the engine air intake increasing fuel consumption reducing engine power and causing spark plug fouling WARNING 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 Remove the cover Remove the screw A and remove the filter B 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
33. e 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 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
34. en 7 Motor oil Red Optional Right indicator Green D Full headlights Blue Neutral Green Optional CP KTP KF Technical characteristics FUNCTIONS Symbol TECHNICAL CHARACTERISTICS INCREMENTS PRECISION Bar Tachometer 500 11 000 rom 500 rpm Digital Tachometer 100 19 900 rom 100 rom Gear change indicator 100 19 900 rom 100 rpm Maximum Tachometer Value 100 19 900 rom 100 rpm AX RPM MAX me i o TO Speedometer 2 3 300 km h 187 5 m h 0 1 km h o m h AH Speedometer 2 3 300 km h 187 5 m h 0 1 km h o m h I oS DS o 3w 34 Solo a I O 1 km h m 0 1 0 1 Average Speed AVG 2 3 300 km h 187 5 m h 0 1 km h o m h Distance counter 1 amp 2 TRIP 1 amp 2 0 999 9 km or 0 624 9 miles 0 1 km or miles Mileometer 0 999 999 km or 0 624 999 miles 0 1 km or miles Time in use 0 00 00 99 59 59 1 second 50 ppm 50 ppm Total time 0 00 9999 59 1 minute Clock 0 00 00 23 59 59 1 second 1 minute 50 ppm Initial voltage 12v CC Speed sensor Non contact magnetic sensor Tachometer entry CDI capacitor discharge ignition or ignition coil signal Wheel circumference adjustment 1 mm 3 999 mm 1 mm increments Working temperature 10 C 80 C engine casing interior Fuel sensor resistance 100 Q only in models with fuel level indicator 56 Functions RPM Bar Ta
35. enducrosssEG 0IN MANUAL DEL USUARIO CASCAS USER MANUAL MANUEL D ENTRETIEN LIBRETTO D USO BETRIEBSANLEITUNG enaduiciossseCGx0nN USER MANUAL CP KC KT 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 July 2006 CP
36. epending on the terrain conditions on the day of the race and therefore be sure to run through the racing circuit prior to a race and set the machine suitable for the entire course If the straight portion of a course on which the machine can be run at maximum speed is long the motorcycle should be set so that the maximum machine speed can be developed towards the end of the straight course but care should be taken not to over rev the engine It is very difficult to adjust the motorcycle to be best setting for all portions of the circuit Therefore determine which circuit portions will have the greatest effect on lap time and set the motorcycle for these portions In this manner the motorcycle will deliver best performance for the entire circuit Special care according to the terrain conditions 1 In dry dusty conditions special care must be given to keep the air cleaner element clean since it accumulates dirt and the engine operates too rich 2 When riding on wet heavy clay the mud adheres to the tires and other parts of the vehicle The mud can add significantly to the weight of the vehicle and therefore reduce performance Take care so that the engine is not overheated The same applies when driving in deep sand 3 In muddy or sandy conditions loosen the drive chain slack to release its tension 4 Check chain and sprocket pinion wear frequently when riding in mud or sand since wear is increased under these condit
37. ghly 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 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 WARNING Riding with a damaged throttle cable could be dangerous CLUTCH The clutch lever should have a maximum play of 3 mm This margin increases with the wear on the clutch plate To adjust proceed as follows Use bolt A to adjust the lever s range of movement to the rider s convenience Adjust the play of the lever using bolt B WARNING Maintain the clutch lever with the play shown otherwise the performance and useful life of the clutch may be adversely affected The EC 2006 model uses mineral oil GRO ULTRA 5 for the clutch hydraulic circuit Tank C must not be filled with liquid from the models of previous years OR 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 Re
38. he gear change indicator according to the rpm 3 The tachometer with bar graph and a LED will flash to indicate the need to change gear 4 Use the steps 1 and 2 to readjust the gear change according to RPM 58 CP KC KT Multifunction and wheel circumference adjustment The configuration operations include the 12 24 hour clock the gear change according to rpm indicator the number of engine revolutions by signal the wheel circumference and the units of measurement The configuration must be carried out step by step The computer will return automatically to the main screen if no button is pressed in any adjustment screen for 75 seconds 1 Press the MODE and RESET buttons to switch to the adjustment screen In the adjustment screen press the RESET button to increase the value of the flashing digits or to convert units press the MODE button to confirm the configuration and move on to the next digit or the next adjustment screen to be configured Press the MODE button for 2 seconds in any adjustment screen to conclude the configuration and return to the main screen 2 The screen shows 12 or 24 h and the symbols XX XX XX and AM PM if the 12h option has been selected 3 When the RESET button is pressed the 12 24h system changes and when MODE is pressed the configuration concludes and the configuration of the clock digits opens 4 Press the RESET button to increase the value of the flashing digit one by one press the MODE button
39. he 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 67 CP KC KT 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
40. hows the most common problems MALFUNCTION POSSIBLE CAUSE REMEDY Engine does not crank Seized crankshaft Go to a specialized workshop Seized cylinder piston jornal bearing Go to a specialized workshop Seized transmission assembly Go to a specialized workshop Motorcycle inactive too long Drain old fuel out of the tank With the fuel tank filled with new fuel the engine will start immediately Wet or fouled spark plug Clean and dry or replace the spark plug Flooded engine In order to relieve the engine accelerate to max speed press the starter pedal 5 or 10 times Then start the engine as described above If the engine fails to start remove the spark plug and dry it Incorrect air fuel mixture Clean the fuel tank air vent Adjust the air cleaner duct Exhaust valve stuck open Verify the exhaust valve and repair as necessary Engine cranks but then stops Incorrect air supply Close the starter Clean fuel tank air vent Adjust the air cleaner duct No fuel Fill up the fuel tank Engine overheating Insufficient cooling liquid in the circuit Fill up cooling liquid verify the refrigeration system watertightness Radiator is dirty or partially restricted Clean radiator fins or replace it The engine operates irregularly Spark plug dirty or misadjusted Verify the spark plug condition and clean it accordingly Poor contact with the spark plug cap or tighten or rep
41. id in the reservoirs completely if the same type of brake fluid is not available Brake wear inspection 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 CP KC KT 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 D B 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 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 Chec
42. 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 Make sure that the mark on the stator plate is aligned with the mark on the crankcase COP KICKS 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 COP KICKS CAUTION If high water pressure is used the radiator fins could be damaged and impair the radiator effectiveness Do not obstruct or deflect airflow thro
43. 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 B one step and tune up with the air screw A 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 Il Right section il 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 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 Check the condition of the spark plug make sure the ingnition timing is correct service the air cleaner element decarbonize the
44. ion NOTE Wheel alignment can also be checked using the string metod 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 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 CP KC KT Apply oil to the sides of the chain rollers for better oil penetration Wipe off any excess oil A Apply oil HANDLEBAR To suit various riding positions the handlebar position can be adjusted front to rear Handlebar position adjustment Loosen the handlebar holder A screws B turn the handlebar and place it in the desired position AE SC A SE Tighten the bolts front first and then the rear to 25 Nm of torque Rear brake pedal position i i J When the brake pedal is in rest position there should be a free play FF i of 10 mm Check the brake for good braking power and no brake drag If the handlebar is installed correctly there will be an even gap at the front and rear after tightening A BRAKES Disc and disc pa
45. ions SPARE PARTS AVAILABLE Refer to the sparts parts catalogue CP KC KT FINAL RECOMMENDATIONS PREVENTIVE ADVICE Before you ride the motorcycle take all the time you may require to check your motorcycle carry out the periodical upkeep and check all functions In different sections of this manual you will find data and work specifications that must be done at an autorized GAS GAS dealer because of this and to extend the useful life of the motorcycle all periodical inspections must be carried out by specially trained professionals at a GAS GAS Post Sale Service Shop Poor maintenance work of the motorcycle or not taking proper care of any problem even if its is a small concern can cause severe personal injury and may lead to death SAFE RIDING OF YOUR MOTORCYCLE Safe riding of a motorcycle does not only depend on the vehicle The driver s intelligence and common sense are key factors to be taken into consideration It is recommended that you practice your favorite sport wearing all the necessary safety equipment helmet protection gear boots etc LEGAL ADVICE In the interest of technical development we reserve the right to modify the construction the equipment and accesories of the motorcycle It is understood that all measurements weights and power data must include their respective tolerances The photographs included in this manual may not match the model you have purchased The descriptions and the illustratio
46. is problem PREPARATION FOR COMPETITION 1 Check Front axle and bridges nuts tightness Front fork clamp bolts tightness Handlebar clamp bolts tightness Throttle grip screws tightness Throttle grip operation and apply grease Front and rear brake hose inspection Front and rear brake fluid level Front and rear brake disc and caliper inspection Front and rear brake operation test 10 Fuel tank inspection 11 Verify the installation of all cables 12 Engine mounting bolts tightness 13 Verify output pinion 14 Gearshift pedal bolts tightness 15 Transmission oil level 16 Battery charge 17 Throttle body 18 Linkage tie rod mounting bolts tightness 19 Linkages mounting bolts tightness 20 Rear shock absorber bolts tightness 21 Swingarm shaft nut tightness 22 Rear axle nut tightness 23 Rear sprocket bolts and nuts tightness 24 Rear brake pedal operation 25 Seat inspection 26 Wheel spokes tightness 27 Front and rear tire air pressure 28 Drive chain slack 29 Coolant level OP NDE NE CP KC KT 2 After 1 day of racing competition Clean the air cleaner element Adjust drive chain slack Tighten rear sprocket nuts Tighten all spokes Check the tires air pressure Tighten front and rear axle nuts Tighten swingarm shaft nut Tighten muffler and exhaust bolts and nuts Tighten front and rear fender mounting bolts and nuts 10 Tighten fuel tank and seat mo
47. k 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 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
48. lace it cable loose in cap Verify the spark plug cap condition Replace if deteriorated MALFU MALFUNCTION POSSIBLECAUSE CAUSE REMEDY The engine operates irregularly Ignition rotor damaged Replace the rotor Water in fuel Drain the fuel tank and fill up with new fuel Engine lacks power or poor Fuel supply defective Clean the fuel system and verify its operation acceleration Dirty air cleaner Clean or replace the air cleaner Verify its operation Leaking or deteriorated exhaust system Verify if the exhaust system is damaged Replace the muffler fiberglass packing if necessary Dirty carburetor jets Disassembly the carburetor and clean all jets Worn or damaged crankshaft bearings Replace the crankshaft bearings Clutch slips Verify the clutch operation Go to a specialized workshop Abnormal engine noise Ignition problem Go to a specialized workshop Overheating Refer to section 5 Detonations from the exhaust Carbon build up in combustion chamber Clean the combustion chamber pipe Incorrect octane or poor quality gasoline Drain all gasoline and fill up with a higher octane fuel Damaged spark plug or incorrect Replace the spark plug with a new one of the correct type specifications Deteriorated exhaust system gaskets Verify if the exhaust system is damaged All gaskets must be in perfect conditions otherwise replace them with new ones if neces
49. le to protect it from dust and dirt When starting off after an extended storage Remove the plastic bag from the exhaust pipe Tighten the spark plug Fill the fuel tank Check all points marked in the section Daily Inspection Before Riding General lubrication Connect the battery GAS GAS MULTIFUNCTION INSTRUCTIONS The multifunction apparatus which is waterproof has 4 8 LED indicators on both sides of a central indicator screen This central indicator screen made of liquid crystal and with illumination gives information about the rom speed journey kilometres travelled time average speed maximum speed length of time with motor running and total time and fuel level The data relative to the distance travelled and total time of use is stored in the memory even when the apparatus is switched off When the multifunction apparatus is not activated it displays a clock The wheel circumference value is adaptable as is the measuring system metric or imperial The number and distribution of the LED indicators and the amount of information on screen may vary according to model Panel 55 CP KCK Panel description RESET button 2nd row of indicators 1st row of indicators Tachometer with bar graph Tachometer scale Fuel indicator bars optional LED indicator symbols MODE button ONOORWN Description of symbols Left indicator Green Dipped headlights Gre
50. mnes hard at the end of travel 1 The oil level is too high The fork operates but slides hard 1 Oil too dense 2 Degraded fork oil Too soft The fork shakes excessively when slowing down or applying brakes 1 Fork oil level is low 2 Springs are too soft 3 Oil too light 4 Degraded fork oil 5 Incorrect rebound or compression Symptoms of the rear shock absorber Too hard 1 The suspension is too stiff Compression damping is too high e Spring is too hard 2 ls hard to ride e Unbalanced condition between the spring and rebound too low 3 The spring is hard or preloaded too much Too soft On landing after a big jump the suspension makes jounce stops 1 Soft spring or compression damping is too soft 2 Degraded shock absorber oil Determining the proper settings Standard Settings From the factory the machine is set up for an average weight rider with average riding abilities Hence if the actual rider s weight or if his riding experience and abilities are considerably superior or below the average ii is necessary to make adjustments to the suspension Readjustment of the suspension Ground surface Smooth Soft spring Rough Hard spring Riding experience Beginner Soft spring with rebound Experienced Harder spring Rider s weight Heavy Hard spring Light Soft spring Type of racing circuit Many corners Lower the front end slightly Raise the fork tubes 5
51. n oil Remove the handlebar screws and remove the handlebar B Add oil Remove the suspension caps from the tubes Compress the front fork slowly all the way Adjust the oil level as required within the adjustable range using the Lift the fork springs following oil Hold the suspension tube cap with a spanner the loosen the ca locknut i P i i Oil recommended by the manufacturer 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 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 A Hydraulic rod Harder springs make the fork stiffer and rebound action quicker Softer springs make the fork softer and rebound action slower Pull the hydraulic rod A out slowly Suspension top bridge position adjustment At this time the fork oil pours out of the hydraulic rod hole keep it raised to let it drain until it stops Make sure the front tire does not rub against the fender when the Install the fork spring 1 inside the fork tube fork tubes are compressed fully Make this adjustment to a minimum Tighten the suspension spring and insert the wren
52. n shift drum groove Replace Go to a specialized workshop Worn shift fork shaft Replace shaft Go to a specialized workshop Broken selector drum position spring Replace the spring Go to a specialized workshop Broken gears Go to a specialized workshop Clutch slips No clutch lever free play Go to a specialized workshop Worn clutch friction plate Replace the clutch friction plate Go to a specialized workshop Worn clutch center hub Replace the clutch center hub Broken or weak clutch spring Adjust or replace the clutch spring Unevenly worn clutch discs Replace the clutch discs Go to a specialized workshop The motorcycle is unstable Cable interferes with the handlebar turns Move or loosen the cable just a little Steering stem locknut too tight Loosen the steering stem locknut Damaged or worn steering bearings Replace the steering bearings Bent steering stem Replace the steering stem Go to a specialized workshop MALFUNCTION POSSIBLE CAUSE REMEDY Shock absorber set too hard Excessive front fork oil Pour excess oil until reaching the correct oil level Front fork oil viscosity too high Drain fork oil and fill with correct fork oil viscosity Bent front fork Replace the front fork Go to a specialized workshop Tire air pressure set too high Check tire air pressure Incorrect rear shock absorber adjustment Adjust rear shock absorber Shock abso
53. ns may vary depending on the volume of equipment and accesories of your motorcycle and also of the versions exported Because of this there can be no liability except in case of errors misprint or omission GAS GAS MOTOS S A reserves the right to make changes and or modifications at any time without notice CP KC KT HOMOLOGATION SM y EC The vehicle you have just acquired has been homologated under the directives of the EU and complies with all the homologation requirements demanded Compulsory homologation elements required among others when travelling on a public road and to meet periodical vehicle inspection approval at state controlled plants are listed below Among other requirements all homologation components are identified with a determined and registered mark List of elements required Quantity motorcycle Manufacture identification plate Catalyzed exhaust Muffler Carburettor jets Front and rear turn signals License plate holder Speedometer Electrical installation homologated lights Horn Rearview mirror Antitheft system Antimanipulation plate 125 cc version Secondary air valve Air filter restiction Throttle limiter EC 200 250 300 AA da a AO Ai BR mA mA om or Each one of the homologation components must form part of the vehicle and in case of loss breakage or malfunction it is recommended that the owner contact his official dealer to correct th
54. ob B CP KC KT NOTE Stopping the engine MC model When the engine is already warm or on hot days open the throttle instead of using the choke knob 1 Shift the transmission into neutral If the engine is flooded kick with the throttle fully open If the clutch lever is pulled the motorcycle can be 2 After racing the started while in any gear engine slightly close the throttle completely and depress the engine stop button A I 4 Start the SHIFTING GEARS motorcycle with oo kick start pedal C The transmission is a 6 speed of the return shift type A return shift bd sali means that to go from first gear to third gear it must go first through RE 4 a a the second gear that is to say that it upshifts gears one by one To 7 engage first gear from neutral pull the clutch lever in and push down 5 Even after the engine starts keep the choke knob pulled up on the gearshift pedal then release the gearshift pedal and gently release the clutch lever 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 i CEIR y J engine slightly o a close the throttle ha i completely and depress the engine stop button D 3 Turn the key in counterclockwise direction
55. oil level 10 mm 3 Use a harder spring or increase spring preload Does the front end tends to turn inward Front fork is too soft 1 Increase the compression or rebound damping 2 Increase the oil level 10 mm Does the front end slips when entering in a curve 1 Decrease the compression or rebound damping 2 Bleed air trapped in the fork 3 Decrease the oil level 10 20 mm 4 Use a softer spring CP KC KT Does the front fork fails to respond to small potholes while managing wide turns Front Fork is hard 1 Decrease the compression or rebound damping 2 Decrease the oil level 10 mm 3 Use softer duty spring Does the rear end jumps when braking over potholes The shock absorber probably has too little rebound damping Increase the rebound damping Does the rear tire lacks traction when coming out of corners The shock absorber is too hard 1 Decrease the rear shock absorber spring 2 Decrease the compression damping 3 Use a softer spring Does it land on the front wheel in high speed jumps there may be a problem with the driver s posture Rebound damping too soft or hard spring 1 Increase the rebound damping 2 Decrease the shock absorber spring preload 3 Decrease the compression damping Does the suspension jounce stops at front and rear of the motorcycle in high speed jumps If this occurs 1 or 2 times in the same lap of the race Front and rear suspension system are too sof
56. one hour of riding before making any setting evaluations or changes The three factors which must be considered are rider s weight rider s ability and terrain conditions additional influences include the rider s style and position on the motorcycle If you have a problem test by changing your riding posture or position so it can be deduced Adjust the suspension to match the rider s strong points If he is fast through the corners adjust the suspension to allow fast cornering Make setting changes in small increments a little bit goes a long way and it is very easy to overadjust a setting The front and rear suspension should be balanced when one is changed the other might need to be changed similarly When evaluating suspension performance the rider must make every effort to ride consistently and recognizing the effects of his input such things as changes in rider position and increasing fatigue may lead to incorrect judgments about necessary setting adjustments When the proper settings have been determined for a particular terrain the settings should be written down for later reference when returning to the same type of terrain Before making any changes and also every 5 fill ups lubricate the swingarm bearings torque rod linkages and O rings this precaution will prevent excesive friction that can affect the suspension performance Front fork The oil level is adjustable A change in the oil level will n
57. opening with tape or with a rag 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 CP KTP KT 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 self adhesive 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 40 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 CP KC KT 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 1314 15 1
58. ot affect the lower part of travel but it will have an affect on the upper part of travel CP KP II When the oil level is raised The spring effects become more progressive and the front fork action feels harder at the end of travel If the front suspension is making jounce stops raise the oil level 10 mm This increase will provoke a change in upper part of travel of the spring When the oil level is lowered The spring effects are less progressive and the front fork action does not become hard at the end of travel Change the oil level correctly and the fork will work more at the end of fork travel Oil level adjustment Adjust the front fork oil level refer to the maintenance chart High level Standard oil level Low level End of travel Suspension travel CP KC KT Troubleshooting Improper Settings Listed below are some symptoms of improper suspension settings and the most likely means of correcting them The proper settings can be achieved by applying the information in this chapter in a scientific manner Take time to think about the changes you believe necessary check them against the symptoms and cures described here and make the changes in small increments and take notes on the changes and their effects Symptoms of the front fork The front fork is too stiff 1 Incorrect rebound adjustment 2 The springs are too hard 3 Too much oil 4 Oil too dense The fork beco
59. place the muffler fibre if the exhaust noise becomes too loud or if the engine performance drops Muffler replacement Remove the retaining screws of the right side number posting cover Remove the retaining screws A of the muffler B and remove the muffler towards the rear Separate the silencer from the joint arrow Replace the muffler and reinstall the assembly 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 A Rivets B Cover A B 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 CP KC KT 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 ue A j et DO i In addition to checking the slack rotate the rear wheel to inspect for
60. rber set too soft Insufficient front fork oil Fill with fork oil until reaching the correct oil level Front fork oil viscosity too low Drain fork oil and fill with correct fork oil viscosity Bent front fork Replace the front fork Go to a specialized workshop Tire air pressure too low Check tire air pressure Incorrect rear shock absorber adjustment Adjust the rear shock absorber Abnormal motorcycle noises Incorrect drive chain adjustment Adjust the drive chain Worn drive chain Replace the drive chain rear sprocket and the secondary transmission pinion Worn rear sprocket teeth Replace the rear sprocket Insufficient drive chain lubrication Lubricate with appropriate chain oil Incorrect rear wheel alignment Align the rear wheel Go to a specialized workshop Insufficient front fork oil Add front fork oil until reaching the correct level Weak or broken front fork spring Replace the front fork spring Worn disc brake Change the disc brake Pad installed incorrectly or surface glazed Reinstall or replace pad Damaged cylinder Replace the damaged cylinder Improperly tightened brackets nuts bolts Verify and adjust to the correct torque values Handlebar vibration Worn tire and worn swingarm or its Replace worn parts with new ones needle bearings Wheel rim off centre Centre rim Incorrect wheel alignment Verify wheel spokes tension Readjus
61. sary White smoke coming out of the Deteriorated cylinder head gasket water Replace the cylinder head gasket Go to a exhaust pipe leakage into the cylinder specialized workshop Incorrect throttle valve cable adjustment Readjust the throttle valve cable Brown smoke coming out of the Restricted air cleaner Clean or replace the air cleaner Go to a specialized exhaust pipe workshop Main jet set too high Verify main jet operation Go to a specialized workshop MALFUNCTION POSSIBLE CAUSE REMEDY Gears do not engage correctly Clutch does not disengage Go to a specialized workshop Bent or seized shift fork Replace the shift fork Gear seized at the transmission Go to a specialized workshop Damaged gearshift lever Replace the gearshift lever Broken or loose selector position spring Adjust or replace the selector position spring Broken spring in the reverse selector Replace the spring in the reverse selector mechanism mechanism Broken spring in the reverse selector Replace the spring in the reverse selector mechanism mechanism Broken gear drum Replace the gear drum Broken spring in the gear selector ratchet Replace the spring in the gear selector ratchet Jumps out of gear Shift fork worn at the gears Replace the shift fork Worn gear grooves Replace Go to a specialized workshop Worn gear dogs Replace Go to a specialized workshop Wor
62. stem nut 4 Torquerodbolt Sa Rearlinkagebolt 81 Kick startpedalnut 25 Gearshiftpedalboltt 15 Water pump cover drain plug 9 Crankcase screws 10 Starter pedal platescrew 8 Ignition motor stator screws 8 Ignition motor coil nut 4 Selector spring fixing screw 15 Primary nuti Oo Clutch spring screws 10 Valve control support screws 10 Valve control nuts Reed valve screws 10 Thermostat housing screws 10 Clutch housing screws 10 Valve housing screws B Ignition housing screws 10 CP KC KT 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 A B Apply grease inside the gas cable A 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
63. t 1 Front Increase the oil lever and or use a harder spring 2 Rear Increase compression damping or use a harder spring NOTE After any adjustment check front and rear compatibility Adjustments that depend on the conditions of the jounce stops rear shock absorber Suspension jounce stops at low speed increase the spring preload to the maximum setting Jounce stops after 3 or 4 successive jumps decrease the rebound damping NOTE The rear shock absorber due to its setting possibilities may mislead some riders a The rear shock absorber does not jounce stop when the spring is correct for the total weight of the machine and rider b A jounce stop sensation of the shock absorber may be caused by the rider s inexperience in riding a machine with a harder spring Observe the rear end while it jumps if it does not approach the stopper try lowering the sping preload Gearshift Select the ratio development Preconditions Race conditions vary the transmission replacing the rear pinion Fast race use pinions with less teeths Winding road or soft or sandy uphill surface use pinions with more teeths Ifthe straight portion of the course is long the ratio development can be extended and due to this the speed increases When the course has many corners or uphills or is wet the ratio development will be reduced so that gear shifting is possible at low speed Actually the speed can be changed d
64. t if necessary MALFUNCTION POSSIBLE CAUSE REMEDY Handlebar vibration Loose handlebar bracket and loose handlebar stem locknut Bent chassis Incorrect steering adjustment Bent steering stem Bent front fork Incorrect wheel alignment Motorcycle pull to one side Deteriorated brake fluid Broken pump piston Incorrect brake adjustment Blown light bulbs Voltage regulator faulty Brakes do not operate correctly Worn discs Leaking brake fluid Excessive steering axles tolerances Tighten steering bracket and steering stem locknut to the correct torque values Tighten steering bracket and steering stem locknut to the correct torque values Replace the chassis Go to a specialized workshop Adjust the steering Go to a specialized workshop Replace the steering stem Go to a specialized workshop Replace the front fork Align the wheels Replace the discs Verify the brake circuits Replace the damaged or broken parts Drain the brake fluid and fill with the new fluid recommended by the manufacturer Replace the pump piston Adjust brakes Remove the seat and the fuel tank and check all connections check the voltage regulator and the fuses in the fuse box Lighting system does not Blown lighting relay fuse Remove the seat the fuse box cover and replace the operate fuse P_NVIPRANVI BI Black ELECTRIC SCHEMAS Bu Blue
65. to confirm the configuration and pass on to the following digit 5 Press the MODE button to switch to the adjustment screen of the gear change according to rpm once the clock has been configured 6 The screen will show RPM rXXX00 Press the RESET button to increase the value of the digit one by one press the MODE button to confirm the configuration and pass on to the following digit 7 Press the MODE button to switch to the adjustment screen for the engine revolution by signal once the gear change according to rpm configuration is completed 8 The screen will show SPC X X RPM with 1 0 as the default value There are 4 options 1 0 2 0 3 0 and 0 5 They correspond to the number of revolutions for each signal For example a value of 2 0 means that the motor turns over twice to produce a signal 9 Press the RESET button to move between the four values Press the MODE button to confirm the configuration and to move on to the wheel circumference adjustment screen 10 When cXXXX appears on screen the c stands for circumference and is followed by four digits by default the flashing digit is the one to be changed 59 CP KTP KT 11 Press the RESET button to increase the value of the flashing digit one by one press the MODE button for 2 seconds to confirm the digit change and pass on to the following digit 60 CP KTP KT TROUBLESHOOTING NOTE This is not an exhaustive list of malfunctions it only s
66. total time in use since the last RESET operation It starts counting from the moment that movement begins TT Total time of use controller It calculates the vehicle s total time in use It starts counting from the moment that movement begins The data is stored in the memory even when the device is not running 12 24 hour clock It shows the time in either 12 or 24 hour formats n Fuel level indicator only vehicles with this function It has 7 bars showing the amount of fuel remaining in the fuel tank The last bar flashes to indicate that the fuel level is too low CP KC KT Operation of the buttons MODE BUTTON 1 Press the MODE button to switch from one function screen to another when the speed sensor detects no signal MODE MODE MODE 2 Press the MODE button to switch from one partial screen to another when the speed lal detects a signal MODE ODE MODE RESET BUTTON 1 Press the MODE button to reach the appropriate screen and then press RESET for 2 seconds to return the data stored in TRIP 2 MAX and MAX RPM to zero cri separately REGET 2 Return the data in TRIP 1 AVG and RT at the same time The data of the ODO 2 nec CLOCK and TT cannot be returned to zero OPERATION OF THE GEAR CHANGE ACCORDING TO RPM 1 Press the MODE button to switch to the RPM screen accelerate to the rom which is desired for the gear change indicator to be activated 2 Press the RESET button to confirm and establish t
67. ugh 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 CA
68. unting bolts and nuts 11 Check brakes 12 Check steering free play 13 Fill fuel tank 14 Check coolant level oe ee ay 3 Maintenance after riding on dusty course If dirt or dust gets into the engine the crankshaft will wear out excessively After riding inspect the crankshaft If the crankshaft is worn beyond the service limit change it 4 Maintenance after riding in rain or muddy course 1 Apply grease to swingarm pivot and the suspension system 2 Inspect the drive chain and rear sprocket and pinion wear 3 Clean the sprocket and pinion 4 Check the cylinder piston and crankshaft bearings 5 Grease the throttle grip and cable CP KC KT STORAGE For extended storage of the motorcycle you must do the following Clean the motorcycle thoroughly Start the engine for about 5 minutes to warm up the transmission oil and then drain it refer to the transmission section Fill with new transmission oil Empty the fuel tank gasoline will deteriorate if left too long Disconnect the battery Lubricate the drive chain and all cables Cover all unpainted metal surfaces with a coat of oil to prevent rust do not apply oil to the brakes and rubber parts Cover the exhaust pipe with a plastic bag to prevent corrosion Place the motorcycle in such a position so that the wheels do not touch the ground if this is not possible place cardboards under the wheels Cover the motorcyc
69. 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 68 CP KC KT e Any damages caused as a result of the defects as well as any expenses incurred either directly or indirectly as a consequence

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