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SERVICE MANUAL SERVICE MANUAL

1. CP IEICE Foreword GAS GAS thank you for your confidence By choosing the new GAS GAS EC 125 200 250 300 you have just entered the great GAS GAS family and as a user of the number one off road motorbike manufacturer you deserve the distinguished treatment that we wish to offer to you both in our after sale relationship and in the explanations that we provide in this manual Our EC 125 200 250 300 is a bike conceived for the practice of high competition enduro It is actually the fruit of many years of competition and experimentation in this demanding discipline as well as the many great successes achieved thanks to great trial riders who have contributed with their expertise to the basic data that have allowed us to create a high level motorbike Congratulations for making the right choice With your skills at the commands of this motorbike an adequate preparation and the indispensable servicing for this GAS GAS to be highly reliable you will be able to enjoy the most comfortable and rewarding enduro practice Thanks for your confidence and welcome to GAS GAS Motos February 2003 EC 2003 64 CP CCP KT COMMON NOTICE Whenever you see the symbols shown below heed their instructions Always follow safe operating and maintenance practices WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in personal injury or loss of live CAUTION This c
2. Wheel misaligned Front rear axle runout excessive Frame bent Steering maladjusted Steering stem bent Front fork bent Wheel misalignment Motorcycle pull to one side Brakes don t hold Pad or disc worn Brake fluid leak Brake fluid deteriorated Piston pump damaged Brake maladjustment EC FSE 2003 11 7 Change it Lubricate with apropiate chain oil Align rear wheel Add oil until correct level Change spring Change disc brake Replace pad or change Change cylinder damaged Go to specialized garage Change it for new pieces Centre rim Check wheel rim pressure Adjust if it is necessary Check rear front axle steering Adjust if it s necessary Go to specialized garage Adjust steering Go to specialized garage Change steering stem and go to specialized garage Change front fork Align wheel Change disc Check and replace Empty brake fluid and replace with new recomended one Replace pump piston Adjust brake Las lamparas se funden El regulador de la tension estan Dismount seat and fuel tank and chec connections have defectuosos voltage regulator checked and fuse of box fuses El sistema de iluminacion no El El fusible del rel de iluminaci n est del rel de iluminaci n est funciona El fusible del rel de iluminaci n est Dismount seat and fuse box cover and Dismount seat and fu
3. Remove the spark plug and put several drops of SAE 30 oil into the cylinder Kick the engine over slowly a few times to coat the cylinder wall with oil and install the plug Lubricate the drive chain and all the cables Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes Tie a plastic bag over the exhaust pipe to prevent moisture from entering Set the motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards under the front and rear wheels to keep dampness away from the tire rubber Put a cover over the motorcycle to keep dust and dirt from collecting on it To put the motorcycle back into use after storage Remove plastic bag from exhaust Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Pre ride Inspection Section Perform the General lubrication procedure CP KC KT GAS GAS SPEEDO INSTRUCTIONS The top button is the reset button The bottom button is the mode button The initial display is the clock time if you press mode btm button the display goes 1 Speedometer 2 Speed Km or miles 3 Total distance in kmh or miles this has a memory even if battery disconnected 4 Trip distance Speedometer EC 2003 112 CP KCK RE 0000 D E O O Total distance E C Trip dista
4. COOLING SYSTEM Radiator Hoses Check the radiator hoses for cracks or deterioration and connections for looseness in acordance with the Periodic Maintenance Chart Radiator Check the radiator fins for obstruction by insects or mud Clean off any obstructions with a stream of lowpressure water EC 2003 78 CAUTION Using high pressure water as from a car wash facility could damage the radiator fins and impair the radiator s effectiveness Do not obstruct or deflect airflow through the radiator by installing unauthorized accessories in front of the radiator Interference with the radiator airflow can lead to overheating and consequent engine damage Coolant information To protect the cooling system aluminum parts engine and radiator from rust and corrosion the use for corrosion and rust inhibitor chemicals in the coolant is essential If coolant containing corrosion and rust inhibitor chemicals is not used over a period of time the cooling system accumulates rust and scale in the water jacket and radiator This will clog coolant passages and reduce the efficiency of the cooling system CAUTION Use of incorrect coolant solutions will cause severe 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 Coolant chemicals are harmful to the human body Follow coolant man
5. gt f ps W 7 f l aay i tale 7 17 S ft 7 Reserve 3 If the engine is cold pull up the choke knob B N a a 4 EC 2003 73 NOTE When the engine is already warm or on hot days open the throttle part way instead of using the choke knob If the engine is flooded kick with the throttle fully open If the clutch lever is pulled the motorcycle can be started while in any gear aT 4 Start the motorcycle with A kick start pedal F aN 5 Even after the engine starts keep the choke knob pulled up Until the engine is thoroughly warmed up Stopping the engine 1 Change to the neutral position Sees 2 After racing the engine slightly close the throttle completely and push the engine stop button A ONT gt EO F 96 ann o J 3 Turn the key in the unclock direction position in OFF C CP KCK SHIFTING GEARS The transmission is a 6 speed return shift type with neutral halfaway between ist and 2nd gears A return shift means that to go back to first gear from a higher gear you must shift back through the gears one by one The same is true when upshifting each gear must be engaged before the next higher gear may be selected To engage first gear from neutral pull in the clutch lever and push down on the shift pedal gently release the clutch lever then release the shift pedal CAUTION When changing
6. oil to settle Viscosity SAE 10W30 mw Capacity 1000 cc gt Oil Change The transmission oil should be changed periodically to assure long engine life Warm the engine over 5 minutes to suspend the sediment liquify the impurities and faciclitate removal Observe the oil level Stop the engine and place an oil pan beneath the engine at the window A on Remove the drain plug and position the vehicle so that it is the lower right side of perpendicular to the ground to allow all the oil to drain out the engine case Install the drain plug with its gasket tightening it to20 Nm Remove the oil filler opening plug of fresh transmission oil C EC 200 250 300 remove with 900 cc and EC 125 with 650 cc Check the oil level after kicking the kick pedal 3 or 4 times Install the oil filler opening plug If the lever is higher you have to empty the leftover oil by the oil drain plug B D P lt kuud mEn S M h N F j gt e ij By another way if the oil level is smaller fill up opening the fill plug C Use the same oil type than you had EC 2003 82 CP KC KT AIR CLEANER Stuff a clean lint free towel into the carburetor so no dirt is allowed to enter the carburetor A clogged air cleaner restricts the engine s air intake increasing fuel consumption reducing engine power and causing spark plug fouling Do not spin the filter on its cage It is p
7. 2 After first race maintenance Air cleaner element Drive chain slack Rear sprocket nuts Sprockets Front and rear tire air pressure Front and rear axle shaft nuts Pivot shaft nut Muffler silencer bolts or nuts Front rear fender mounting bolts or nuts 10 Fuel tank seat mounting bolts or nuts 11 Front and rear brakes 12 Steering play 13 Fuel tank fill 14 Coolant level check Seah YS 3 Maintenance notice for after riding on dusty course If dirt or dust gets through into the engine the crankshaft big end will wear excessively After riding inspect the crankshaft big end If the crankshaft big end is worn past the service limit replace the crankshaft big end with a new one 4 Maintenance notice for after riding in rain on muddy course 1 Apply grease to swing arm pivot and rear suspension system 2 Inspect the drive chain and rear sprocket wear 3 Clean the air cleaner element 4 Check the cylinder and crankshaft big end bearing 5 Grease the throttle grip and cable EC 2003 111 STORAGE When the motorcycle is to be stored for any lenght of time it should be prepared for storage as follows Clean the entire vehicle thoroughly Run the engine for about five minutes to warm the oil shut it off and drain the transmission oil Put in fresh trransmission oil Empty the fuel from the fuel tank and empty the carburetor float bowl If left in for a long time the fuel will deteriorate
8. 21 Chain Guide 22 Drive chain 23 Rear Suspension Linkage 24 Rear Brake Pedal 25 Kick Start Pedal 26 Exhaust Expansion Chamber EC 2003 70 CP KC KT SIDE STAND To operate the side stand FUEL The GAS GAS FSE 400 cc has a four stroke engine and requires 95 octane unleaded gasoline Release the security strap B the sidestand is held in the down position by the weight of the motorcycle Thes sidestand automatically Gas Tank Capacit retracts when the motorcycle is placed in the upright position ENDUCROSS FSE 9 5L A Side Stand B Sidestand spring C Security strap NOTE Do not start the engine or ride the motorcycle when the side stand is down Always engage the security strab B before operation of the motorcycle A Fuel Cap B Fuel Vent hose Position the vent hose clip in a position which prevents spillage on the steering bearings and the clock EC 2003 71 RECOMENDED FUEL Use premium gasoline with an octane rating equal to or higher than that shown in the table OCTANE RATING METHOD MINIUM RATING Antiknock Index RON MON 2 w Research Octane No RON PB NOTE If knocking or pinging occurs try a different brand of gasoline or higher octane grade WARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or s
9. 221 Cylinder base nuts 34 25 3 5 300 Engine drain plug 20 15 2 0 177 Caliper mounting bolts 25 18 2 5 221 Disc plate mounting screws 10 7 1 0 88 EC 2003 100 CP KC KT LUBRICATION Lubricate the points shown here with either motor oil or regular grease in accordance with the Periodic Maintenance Chart or whenever the vehicle has been operated under wet or rainy conditions and especially after using a high pressure spray washer Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime General lubrication Clutch lever A Front brake lever B Rear brake pedal C Rear brake rod joints D Shift pedal E Apply grease to the following point throttle inner cable upper ends EC 2003 101 Chain lubrication Lubricate the chain after drive over wet places or when the chain looks dry It s better a high viscosity oil than a small viscosity oil because it will stay a long time in chain TUNING 1 CARBURETOR TUNING Tuning a carburetor is not the mysterious science many racers belive it to be One needs only to establish a basic knowledge of the identification and function of carb components as well as how the work together to do the job well Change due to temperature Condition setting change Cold air Warm air rich lean Dry air lean rich Low altitude CP KP KT NOTE The main jet should be incr
10. counterclockwise 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 more slowly Fork springs Optional springs are available that are softer and stiffer than standard Air Pressure The standard air pressure in the front fork legs is atmospheric pressure The air pressure in the fork legs increases as operation progresses CP KC KT Using the stand under the frame stabilize the motorcycle Place a stand or block under the engine so that the front wheel is raised off the ground Remove the screws at the top of the front fork top bolts to let the air pressure equalize Then replace them A Screw air purge Ajustar extension Rebound Dampening Adjustment To adjust turn the knob located at the top of the fork Adjust to rider preferance ae A Adjuster knobs EC 2003 92 CP CCP KT Stand oil level CAUTION The left and right fork tubes must bealigned level at the top clamps see the illustration Marzocchi 110 mm WP 120 mm Ohlins 110 mm Compression Dampening Adjustment To adjust turn the knob located at the top of the fork Adjust to rider preferance Oil level Adjustment Using the stand under the frame stabilize the motorcycle Place a stand or block under the engine so that the front wheel is raised off the grou
11. engine delivers satisfactory power at any throttle opening If the air fuel mixture is too lean the engine tends to overheat and may seize up on the other hand if it is too rich the spark plug easily gets wet thus causing richness the spark plug easily gets wet thus causing misfires The proper strength of the mixture varies depending on atmospheric conditions pressure humidity and temperature Taking these conditions into consideration adjust the carburetor settings properly Standard Settings UNLEADED LEADED Throttle valve cutaway 7 7 Slow jet 38 35 Jet needle N1EC N1ED Main Jet 185 160 CP KCK Correction factors For changes in altitude and temperature 1 Find your correction factor to adjust the carburetor EXAMPLE 1000 meters 3200 ft altitude with an air temperature of 35 C 95 F The correction factor is 0 94 see dotted line for the example 2 Using your correction factor select the correct slow jet and main jet Example For a correction factor of 0 94 multiply the jet size by that number Slow jet 50 x 0 94 47 Chicl principal 162 x 0 94 1 3 Find your correction factor on the Jet Needle Air Screw chart and change the jet needle clip position and air screw opening as indicated Example For correction factor of 0 94 raise the needle clip one position and turn out the air screw one extra turn Jet needle clip setting 3rd groove from top minus 1 2nd groove A
12. garage Clutch not disengaging properly No clutch lever play maladjusted Go to specialized garage Friction plate worn or warped Change friction plate Steel plate worn or warped Go to specialized garage Gear lever damaged Change gear lever Clutch spring broken or weak Check or change clutch spring Clutch release mechanism trouble Check clutch release mechanism EC FSE 2003 115 TROUBLE CAUSE REMEDY a Clutch not disengaging properly Clutch hub or housing unevenly worn Change clutch hub Jumps out of gear Shift fork worn gear worn Change it and go to specialized garage Gear dogs and or dog holes worn Change it and go to specialized garage Shift drum groove worn Change it and go to specialized garage Gear positioning Change it and go to specialized garage Lever spring weak or broken Change it and go to specialized garage Clutch slipping No clutch lever play maladjusted Go to specialized garage Friction plate worn or warped Change friction plate and go to specialized garage Steel plate worn or warped Change steel plate Clutch spring broken or weak Check or change clutch spring Clutch disc unevenly worn Change clutch disc Go to specialized garage Wiring routing incorrect Unscrew wiring routing Steering stem locknut too tight Change steering stem locknut Steering stem bent Change and go to specialized garage Shock absorpti
13. gears press firmly on the shift pedal to ensure complete positive shifting Careless incomplete shifts can cause the transmission to jump out of gear and lead to engine damage A Shift pedal EC 2003 74 COP KTP 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 BREAK IN Para obtener un ptimo funcionamiento del motor y la transmisi n es necesario una suave ejecucion teniendo que llevarse a cabo un rodaje previo Para la primera hora o 20 Km de la operaci n rodar el motor a una baja y moderada velocidad y r min NOTE The slow riding necessary during the break in period may cause carbon 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 a hotter spark plug for the duration of the break in period SPARK PLUG Standard Plug Hotter Plug NGKBR8EG 1 Start the engine and let it run at idle until the engine is thoroughly warmed up 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
14. Be sure to check and adjust chain slack and spoke tightness and make a general inspection 5 Start the engine and ride for 20 minutes at moderate speed NEVER ACCELERATE HARD 6 Stop and let the engine cool completely Check and adjust as step look maintenance and adjustment table 7 Install the parts removed 8 Fill the radiator up to the bottom of the radiator filler bleed the air from the cooling system 9 Start the engine and ride for 30 minutes at moderate speed NEVER ACCELERATE HARD 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 However since recklessly high r min rpm will lead to engine trouble take care to use the necessary skill and technique in operating the motorcycle CAUTION However since recklessly high r min rpm will lead to engine trouble take care to use the necessary skill and technique in operating the motorcycle NOTE After break in install a new standard spark plug and change the transmission oil EC 2003 5 MAINTENANCE AND ADJUSTMENT Clutch Eachrae Eachrace Eachrace Eachrace Friction plates SS races _ 3races _ Sraces Throttle cable Oooo o Eaha o Spark plug Do e d a o a l e a Air cleaner element aooo o s O O OOOO eee If it s damaged 1 race Carburetor Transmission oil a a ee 3 races Piston and piston ring 3 races Cylin
15. If not adjust the pedal position Check the brake for good braking power and no brake drag To adjust the pedal play loosen the locknut and turn the adjuster After adjustment tighten the locknut securely pe WES A Rear brake pedal B 10 mm of play C Adjusting bolt D Locknut WARNING If the brake lever or pedal feels mushy when it is applied there might be air in the brake lines or the brake may be defective Since it is dangerous to operate the motorcycle under such conditions have the brake checked inmediately EC 2003 89 Disc brake fluid In accordance with the Periodic Maintenance Chart inspect the brake fluid level in the reservoir and change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Disc brake fluid Use D O T 3 o D O T 4 Fluid level inspection The front A and rear B reservoirs must be kept more than half full with brake fluid If the amount of brake fluid is insufficient add brake fluid S S H4 V Hi l ah Se 4 fe K COP KP 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 two brands of fluid Change the brake fluid in the brake line completely if the brake flu
16. OE aeee ee centeaavedsceteencetcansestadeianaetees 112 Gas Gas speedo instructions wicicccscccesiccccielacscssesscaelocienseeseineacesecet 112 MVOUIDIGSHOOUNG PERAE EEE E EE E E E 114 Waranty TEQUIATIONS irctintasacsaatamioiivientatumnencanimbbituniantdnasianieiieiediaatan 118 EC 2003 66 CP CCP KT SPECIFICATIONS ENGINE Engine 125 cc Bore and stroke Displacement in cubic centimeters Engine 200 cc Bore and stroke Displacement in cubic centimeters Engine 250 cc Bore and stroke Displacement in cubic centimeters Engine 300 cc Bore and stroke Displacement in cubic centimeters Type Carburetor Lubrication system Starting system Ignition system Ignition timing Spark plug TRANSMISSION Transmission type Clutch type Driving system Gear Ratio Primary reduction ratio Final reduction ratio Overall drive ratio 2 cycle single cylinder crank case induction liquid cooled 54 x 54 5 mm 124 cc 62 5 x 65 mm 199 4 cc 66 4 x 72 mm 249 3 cc 72 x 72 mm 294 7 cc KEIHIN PWK 38 Fuel premix ratio 50 1 2 Kick start pedal CDI system 1mm APMS NGK BR8EG 6 speed Multidisc in oil bath hidraulic actuation Chain 1 2 071 29 14 2 1 625 26 16 3 1 333 24 18 4 1 100 22 20 5a 0 913 21 23 67 0 791 19 24 2 85 57 20 3 692 48 13 8 149 6th gear EC 2003 67 CP KC KT Transmission oil Capacity 1800 cc Type 5W50 API SF o SG CHASSIS Type Chromolly tubular semi
17. Y 5 Engine flooded Wiring shorted or open Change wiring Water in fuel Empty fuel tank and fill up with new one Engine does not rev high will Fuel supply partically interrupted or Clean and check fuel system as well as carburettor not reach full power carburettor dirty Dirty air filter Clean and change the air filter Hose of engine ventilation is bent Replace non buckling ventilation hose Main jet clogged Dismount carburetor and clean main jet Crankshaft bearing worn or damaged Change crankshaft bearing Clutch slipping Check clutch Go to specialized garage 7 Abnormal engine noise Starter problem Go to specialized garage Overheating Look number 5 Spark knock Carbon in combustion chamber Clean combustion chamber Incorrect or poor gasoline Empty and fill up with good gasoline Incorrect spark plug Cambiar bujia por otra nueva o adecuada Connecting rod exhaust system damage Check if the exhaust system is damaged Connecting rods have to be perfect if they aren t change them Exhaust pipe get out white Cylinder head gasket leaking Change cylinder head gasket leaking Go to specialized smoke garage Gas valve passage maladjusted Adjust gas valve passage Go to specialized garage Exhaust pipe get out brown Air filter is bloked Clean or change the air filter Go to specialized garage smoke Main jet higher Check main jet Go to specialized
18. and out of the jet needle hole since the needle is tapered its position in the jet determines the amount of fuel allowed through There are five grooves in the top of the needle in which a circlip fits This clip locates the needle in the throttle valve and therefore determines its position relative to the jet needle hole Clip position Needle size number Working area Test runs Warm up the engine with the carburetor at the standard settings and run two or three laps of the course while examining the operating condition of the spark plug Test ride the bike by varying the throttle opening Symptoms of improper settings If your machine exhibits one or more of the symptoms listed below it may need carb tuning changes Before attempting any changes however make sure that everything else is in good shape and tuned properly EC 2003 103 Check the condition of the spark plug make sure the ingnition timing is correct service the air cleaner element decarbonize the muffler If you machine has run properly at a certain track in the past and then starts running poorly with the same carb settings the problem is almost certain to be elsewhere changing the carb settings in such a case would probably be a waste of time Condition of spark plug Insulator dry andiight tan color O step larger Too rich Insulator is wet black and Replace the main jet wit one sooty step smaller Set the carburetor so that the
19. apter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition NOTA Inspect and do this operations only if it is necessary EC 2003 COP KTP KT IGNITION TIMING Because a capacitor discharge ignition CDI system is used on this motorcycle the ignition timing should never require adjustment unless the magneto stator is incorrectly installed during engine reassembly However if there is any doubt as to the timing inspect and adjust if necessary as follows Ignition Timing Adjustment Remove the magneto cover A Check to see if the center mark of the three marks on the magneto stator C is aligned with the mark on the crankcase B 125 cc 200 250 300 cc If the marks are not aligned loosen the magneto stator screws and turn the magneto stator Tighten the screws securely Install the magneto cover NOTE The ignition timing can be adjusted for different power and to suit the rider s preference and ability Remove the magneto cover Loosen the stator screws Adjust the timing by shifting the stator position within the three lines NOTE For the best engine performance it is very important to adjust the ignition timing within the adjustable range just explained Tighten the stator screws securely Install the magneto cover Test ride the motorcycle and readjust the ignition timing if necessary
20. aution symbol identifies special instructions or procedures which if noto strictly observed could result in damage to or destruction of equipment NOTE This note symbol indicates points of particular interest for more efficient and convenient operation However if improverly conducted the sport has the potential to cause environmental problems as well as conflicts with other people Responsible use of your off road motorcycle will ensure that these problems and conflicts do not occur TO PROTECT THE FUTURE OF YOUR SPORT MAKE SURE YOU USE YOUR BIKE LEGALLY SHOW CONCERN FOR THE ENVIRONMENT AND RESPECT THE RIGHTS OF OTHER PEOPLE Off road motorcycle riding is a wonderful sport and we hope you will enjoy it to the fullest EC 2003 65 TABLE OF CONTENTS PORE WOK as ceatceiasacoisatansnrchaciauesmeiansaincesdehseniisutniaudabs mianaeinatriaeiantietanl 64 COMMON NOCO erriren rn nA LANE TENEAN EiS 65 Table of COntentS ecexezacicneccccseccsacrctectececcextesescesotiacecsescaiattedcenictentacads 66 EOC ANON acris riana aei 67 Location of Components osc sccciesenstcnnciattccnatdnierannecteticiapeieiactorechecneiee 69 lde AN esae E E E S 71 PIC Ee E EE EE EEEE E E TT E E EEEE inadaenbe T1 Sena PUD SE cise cs nee cetera co ads en ees eee oadeds Sulatee uted atte 73 Starting the engine siccnuss cetentonrsancubranssbemxceeniuotancekacteaxtacamendaneskedtencuass l3 SUUE ES e E SETE EAEN ATTE T AA 74 Stopping the motorcycle cac
21. bstitute for the defective product 4 The warranty claims of the purchaser under the contract of purchase and sale concluded with the respective licensed dealer shall not be affected by the present warranty Neither shall the present warranty affect any additional contractual rights of the purchaser under de General Business Conditions of the licensed dealer However such additional rights can only be claimed against the licensed dealer 5 If the purchaser resells the product within the warranty period the terms and conditions of the present warranty shall continue to exist in their present scope the right to put forward claims under the present warranty according to the terms and conditions hereof will be passed on to the new owner of the motorcycle February 2003 EC FSE 2003 119 FEBRERO FEBRUARY 2003 C UNICEF n 17 Poligon Industrial Torremirona 17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 E mail officegg gasgasmotos es partsgg gasgasmotos es Web www gasgasmotos es PU010338018
22. der head cyl amp exhaust valves 3 races Muffler 1 race Silencer packing Pe 1 races O 10 races Small end bearing 10 races Kick pedal and shift pedal Pete Se ee oe Exhaust pipe o ring Pos le 3 races Engine bearings check 10 races Coolant 3 racos Radiator hoses connections 1 race Brake adjustment 3 races Brake wear 5 races Brake fluid level 3 races Brake fluid Ls O ee Every 2 years E Brake master cyl cup amp dust seat Every 2 years The maintenance and adjustments outlined in this chapter are easily carried out and must be done in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition NOTA Inspect and do this operations only if it is necessary EC 2003 76 MAINTENANCE AND ADJUSTMENT Brake caliper pisto seal amp dustseal Every2 years Brake hose and pipe po Every years S o Lubricate drive chain E Drive chain po trace o o o S o Drivechain wear pS races S races Chain slider Sraces_ 5race Sraces Spoke tightness and rim runout Front fork Front fork O a Nuts bot fastener Braces S depestog 5 races Fuel hose Traces 7depositos 7races aaa T e a a Steering play Oo Irae J CT Rear sprockel General lubrication braces Steering bearing Lt Swing arm and uni trak linkage pivots 5races 5 depdsitos dSraces Rear chock oil 2 years The maintenance and adjustments outlined in this ch
23. difficulties TROUBLE CAUSE REMEDY Engine doesn t crank Crankshaft seizure Cylinder piston connecting rod big end seizure Transmission set seizure Engine cranks but doesn t start The motorcycle has been out of operation for a longer period of time Therefore old fuel has accumulated in the float chamber Scooty or wet spark plug Flooded engine Fuel air mixture incorrect Engine start but stops few Incorrect air supply seconds ago There isn t fuel 4 Engine gets to hot Insufficient cooling liquid Radiators very dirty 5 Engine flooded Spark plug dirty or maladjusted Spark plug cap or high tension wiring trouble EC FSE 2003 114 Go to specialized garage Go to specialized garage Go to specialized garage ls recomended to drain the old fuel from the float chamber Clean and dry the spark plug or exchange it respectively In order to pump the engine free pull de starter pedal 5 or 10 times Then start the engine as described above If the engine fails to start unscrew the spark pulug and dry it Clean tank cap air vent Check by pass throttle body Check the air filter Close the starter Clean fuel tank air vent Check the air filter Fill up fuel tank Full up cooling liquid check system refrigeration Clean radiators Check spark plug clean adjust or replace Check spark plug cap if it s damaged change it TROUBLE CAUSE REMED
24. double cradle Tires Front 80 100 x 21 Rear 120 90 x 18 Suspension Front Upside down telescopic 43mm WP fork Upside down telescopic 45mm Marzocchi fork Rear Progressive system with single shock multi adjustable OHLINS Suspension stroke Front 282 mm Rear 320 mm Front fork oil each Marzocchi SAE 7 5 WP SAE 5 OHLINS SAE 5 7 5 Front fork oil level Marzocchi 110 mm compressed with spring removed WP 120 mm compressed with spring removed OHLINS 110 mm compressed with spring removed BRAKES Type Front rear Disc brake Effective disc diameter Front 260 mm Rear 220 mm DIMENSIONS Overall length 2135 mm Overall width 810 mm Overall height 1260 mm Wheell base 1475 mm Ground clearance 340 mm Fuel tank capacity 9 5 Litre 2 5 gallons u s Height seat 940 mm Specifications are subject to change without notice and are not applicable in some countries EC 2003 68 CP KP KT Location of components GAS GAS EC 2003 cc 1 Clutch lever 2 Engine Stop Button 3 Fuel Tank Fill Cap 4 Front Brake Fluid Reservoir 5 Front Brake lever 6 Throttle Twist Grip EC 2003 69 13 14 1516 9 17 7 8 9 10 11 12 13 14 15 16 Brake Disc front Front Suspension Brake fluid reservoir rear Fuel Tank Carburetor Rear shock absorber Brake Caliper front Radiator Fuel Tap Shift pedal 21 22 23 2425 26 17 Air Cleaner 18 Silencer 19 Seat 20 Nitrogen Reservoir
25. e chain slack 5 Check chain and sprocket wear frequently when riding in mud or sand since wear is increased in these conditions 6 In dusty conditions as the air cleaner collects dust the engine runs richer Therefore it may be advisable to run slightly leaner jetting main jet in very dusty conditions SPARE PARTS Look at part list EC 2003 110 CP KC KT PREPARATION FOR COMPETITION 1 Check Front axle shaft and nut or axle clamp nut tightness Front fork clamp bolt tightness Handlebar clamp bolt tightness Throttle grip screw tightness Throttle grip operation Front and rear brake hose installation Front and rear brake fluid level Front and rear brake disc and caliper installation Front and rear brake function 10 Fuel tank installation 11 Shift pedal bolt tightness 12 Engine mounting bolt tightness 13 Engine sprocket installation 14 Brake pedal bolt tightness 15 Transmission oil level 16 Carburetor clamp screw tightness 17 Carburetor top cap tightness 18 Linkage tie rod mounting bolt tightness 19 Linkage rocker arm mounting bolt tightness 20 Rear shock absorber bolt tightness 21 Swing arm pivot shaft nut tightness 22 Rear axle shaft nut tightness 23 Rear sprocket bolts or nuts tightness 24 Rear brake pedal operation 25 Seat installation 26 Front and rear wheel sproke tightness 27 Front and rear tire air pressure 28 Drive chain slack 29 Coolant level cl de a a
26. eased or decreased one to five sizes and tested until the engine gives maximum power Main jet The number of the main jet stamped on the bottom or side of the jet indicates the relative size of the hole in the jet which meaters fuel _ lt gt A ae f a 49 A E Ea 4 gee Sg pi d amp Me A Main jet WARNING Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine and do not smoke Make suure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light EC 2003 102 CP CCP KT Slow Jet piltot jet and air screw The slow jet and air srew controls the mixture in the closed to 1 8 throttle range but has little effect on up to 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 to provide more or less fuel Screwing it in richens the mixture Air screw A specs indicate the turns out from a lightly seated position Make changes in 1 2 turn increments If turning the srew between one and two and a half turns doesn t provide the desired results change the slow jet B Jet needle The jet needle and jet needle hole together have their greatest effect in the 1 4 to 3 4 throttle range The needle moves in
27. hat does not meet the corresponding technical requirements g The vehicle has been used for competitions races or attempts at any record whatsoever Exclusion from warranty The following items shall be excluded from warranty a wear and tear parts including without limitation sparks plugs batteries fuel filters oil filter elements driving chains engine sprockets rear sprockets air filters brake discs brake pads clutch discs lamps fuses carbon brushes footrest rubbers tires tubes cables and other rubber components EC FSE 2003 118 CP KC KT b Lubricants e g oil grease etc and operating fluids e g battery fluid cooling liquid etc c Inspection adjusting and other periodical maintenance work as well as all kinds of cleaning work d Damage to paint work and corrosion thereof due to external influences such as stones salt industrial exhaust gases and other environmental impacts or inadequate cleaning with inadequate products e Any consequential harms caused by defects as well as incidental expenses directly or indirectly related to defects e g telecommunication charges cost of board and lodging cost of rental cars public transport charges cost of salvage and towing overnight expenses etc as well as other financial disadvantages e g caused by loss of use of a motor vehicle loss of earnings loss of time etc f Any aesthetic or acoustic phenomena that does not significantly affect
28. hese conditions before riding EC 2003 84 CP CCP KET WARNING Operation with a damaged cable could result in an unsafe riding condition CLUTCH Proper clutch lever play between the clutch lever and the clutch lever holder is 2 3 mm When there is too much lever play first try adjusting the clutch lever Loosen the knurled locknut turn the adjuster to obtain the proper amount of lever play and tighten the locknut B A Clutch lever B Knurled Locknut C Adjuster D Hydraulic fluid tank EXHAUST SYSTEM The muffler and silencer reduce exhaust noise and conduct the exhaust gases back away from the rider If the muffler is badly damaged dented cracked or rusted replace it with a new one Replace the silencer packing If the exhaust noise becomes too loud or the engine performance drops Silencer Packing Cange Remove the right side cover Remove the silencer B mounting bolts A and pull the silencer off toward the rear Install the inner pipe Remove the inner pipe mounting rivots and pull out the inner pipe Pull off the old silencer packing and install the new silencer packing Install the inner pipe into the silencer Install the silencer and right side cover EC 2003 85 A Rivots B Inner Pipe DRIVE CHAIN The drive chain must be checked adjusted and lubricated in accordance with the Periodic Maintenance table If the chain becomes badly w
29. hould be taken out periodically to check its gap and ceramic insulator If the plug is oily or has carbon build up on it clean it preferably with a sandblaster and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool Measure the gap with a wire type thickness gauge and adjust the gap if incorrect by bending the outer electrode If the spark plug electrodes are corroded or damaged or if insulator is cracked replace the plug NOTE Inspect every 30 hours and replace every 60 hours To find out whether the right temperature plug is being used pull it out and examine 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 burned whit the plug should be replaced with the next colder plug If the ceramic is black the plug should be replaced with the next hotter plug NOTE If the engine performance drops replace the spark plug first to regain performance TRANSMISSION For the transmission and clutch to function properly maintain the oil level at the proper level Change the oil periodically Oil at an insufficient level deteriorates and contaminates rapidly This accelerates wear and promotes premature failures EC 2003 81 CP KP KT Oil level Transmission oil type Stand the motorcycle upright and level allow a few minutes for the
30. id must be refilled with a type other than the brake fluid already in the reservoirs Brake wear inspection In accordance with the Periodic Maintenance Chart inspect the brakes for wear For each front and rear disc brake caliper If the thickness of either pad is less than 1 mm replace both pads in the caliper as a set Pad replacement should be done by an authorized GAS GAS dealer Steering The steering should always be kept adjusted so that the handlebar will turn freely but have no excessive play EC 2003 90 CP KP KT To check the steering adjustment using a stand under the frame raise the wheel off the ground Push the handlebar lightly to either side if it continues moving under its own momentum the steering is not too light Squatting in front of the motorcycle grasp the lower ends of the front fork at the axle and push and pull the bottom end of the front fork back and forth if play is felt the steering is too loose If the steering needs adjustment Using the stand under the frame stabilize the motorcycle Place a stand or block under the engine to raise the front wheel off the ground Remove the handlebar A Loosen the front fork upper clamp bolts and remove the steering head nut and washer and take off the steering stem head B Turn the steering stem locknut with the stem nut wrench to obtain the proper adjustment C Install the stem head D Tighten the steer
31. ing stem head nut B and front fork upper or lower clamp bolts to the specified torque Stem head nut 44 N m 4 5 Kg m Fork clamp bolts 22 N m 2 25 Kg m Check the steering again and readjust if necessary Install the removed parts STEERING BLOCADE This mecanism A allows us to blokade the steering Is placed on pipe steering You have to turn right the handlebar pull in the key turn left the key push turn right and pull out the key A Steering blocade EC 2003 91 CAUTION Never forget the key in the lock If you turn left the steering with the key in it will be damaged FRONT FORK The front fork should always be adjusted for the rider s weight and track conditions by using one or more of the following methods Air pressure Air pressure acts as a progressive spring and affects the entire range of fork travel The air pressure in the fork increases as the fork heats up so the fork action on your GAS GAS will get stiffer as the race progresses Because of this we don t recommend using air pressure for additional springing Your GAS GAS forks are designed to work without adding any air Rebound and compression dampening adjustment This adjustment affects how quickly the rebound The fork rebound dampening adjuster has 16 clicks The seated position fully clockwise until the adjuster stops is full hard From the point 6 8 clicks counterclockwise is the standar setting and 16 clicks
32. ir 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 don t change any of the settings until you ve determined what changes are necessary All specifications are based on the use of the specified fuel and oil EC 2003 104 CP KC KT L ALTITUDE y 4 40 ba X Ge Sb E 104 Zo NG Y E 104 2 2 2G R D I 4 A 30 l i 86 i R 20 F 68 C 10 eF 50 0 32 10 14 0 86 0 88 0 90 0 92 0 94 0 96 0 98 1 00 1 02 1 04 1 06 CORRECTION FACTOR JET NEEDLE AIR SCREW CHART CORRECTION FACTORS 1 06 or ABOVE 1 06 1 02 1 02 0 98 0 98 0 94 0 94 or BELOW JET NEEDLE LOWER CLIP SAME SAME SAME RAISE CLIP ONE SETTING ONE POSITION POSITION AIR SCREW ONE TURN IN 1 2 TURN IN SAME 1 2 TURN OUT ONE TURN OUT OPENING POSITION EC 2003 105 2 SUSPENSION TUNING No area of machine adjustment is more critical than proper suspension tuning An improperly tuned suspension will keep even the best rider from attaining the full benefit of his machine s ability Match the suspension to the rider and the course conditions If the machine is new break in the suspension with at least one hour of riding before making any setting evaluations or changes The three major factors which must be considered in suspension tuning are Rider weight rider hability and track conditions Additional influences includE the ride
33. l will result in abnormal wear and may result in an unsafe riding condition Tighten the axle nut to 98 N m 7Oft Ibs Tighten both chain adjuster locknuts Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary WARNING If the axle nut is not securely tightened an unsafe riding condition may result Drive chain chain guide chain slidder and sprockets wear inspection When the chain has 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 and rear sprockets and replace them if necessary Worn sprockets will cause a new chain to wear quickly NOTE For maximum strech resistance and safety a genuine part must be used for replacement To minimize any chance of the master link coming apart the master link clip must be installed with the closed end of the U points in the direction of chain rotation A Clip B Direction of Chain Rotation Chain Guide Wear Visually inspect the drive chain guide If the guide is worn excessively or damaged replace it A Chain Guide EC 2003 87 CP KC KT Cain Slider Wear Apply oil to the side of the rollers so that it will penetrate to the rollers and bushings Wipe off any excess oil Visually inspect the upper and lower chain sliders A Apply oil HANDLEBAR To suit va
34. ncdcsssaccrcardisatmustienddeesaaaddandurgbendendanedeawennnbas 75 Table of maintenance sccsciccieicestaeciiccsecccesccsctieseisdedeccoresassabastadeiaceanndes 76 enea an ae E E S E AET 78 Cooling Syte Messinia ai AnA PE E EENAA R 78 Eo elde 010 PE EE E E een eee ee E 81 Transmission sacitceranniademaianiasdaccmntatiiiacinmaiadabinbiatdaiamenaaiuntiniadaddmrentan 81 Air cleaner eee on ne ne a ee ee ee ee nanna 83 Throtlle CADIS vs iis wsiceiscivsniesucvinnniniobconsbidunaetsnbdbvosebuiewiudexeoinbinebainaveneds 84 MS A NON ape aw ete tes eee ona eee eter 84 CP KC KT ONE e a PETETA E sec PAIS T IAE EA ATE EA T N 85 Silencer packing change cccsseccceceeesseeeeeseeeeseeeeessenesseeeesseeeess 85 DEE E E ENEE E E A OT TA NENE A A E TT 86 Pandile Dai serina aE a aA AE nEaN 88 BAEO ser Ea in 89 See P E E E EEE A TE 90 Steering blocade acccitessiveanvicnitancnisencinssortannndalsdancatcebthucmesetvausaidaieraverts 91 FO FO ee E E estan despenseeseeo ete sere 92 Rear SUSDENISION eszipacsacesaacccentecsesessacnateractarseiesaceiniannacuneepaceureideens 95 1 212 Ene meen ee ene per eee ee ee eee ea oe a ee er ee 97 AU WEN ees cantata AE T EE E PEE E A E oo eee A 98 Boltang NUl UgNTEnINg arsson eni rea Ee SEE 99 PTAC AON suier EnA EA EEATT AERAR ERISEERIA 101 Tunning Carburetor and SUSPENSION sseeeeeeeeeeseeeeeeeeeeaaees 102 Preparation CHECK cisescnecenaccnanccsuscndancendennehescancesensandenewbassadedncnnendeie 11
35. nce To change the time Press mode until time display is shown Press mode again keeping the button pressed the hour will display only add the hours by pressing the reset top button Press mode again to adjust the minutes in the same way Press mode again and the time is now set when you have set the time the seconds automatically start from zero Trip distance From time display press mode 3 times l 0 to zero the trip keep the reset button pressed until it zeros To change to kilometers per hour or miles per hour Disconnect the battery the total distance will be saved Re connect the battery whilst holding down either button and it will read either met for km h mil for mp h The white plastic block connector on the speedo is for the display backlight The red wire is positve The black wire is negative Warning your speedo is set for the diameter of your front wheel enduro 21 supermoto 17 If you get the display to read a 00 then you are in the rolling radius changing mode you can trim the speed to run fast or slow It ranges from a 25 to a 25 NOTE Standard setting is a 00 we recommend you keep it at that EC 2003 113 CP KC KT TROUBLESHOOTING NOTE This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common
36. nd Remove the front fender and front disc cover Unbolt the brake hose holder mounting bolts Remove the front fork protectors Remove the handlebar clamp bolts and remove the handlebar Remove the top clamps of the forklegs Let the forks completely compress Raise the fork springs from the fork Grasp the top casps and loosen the clck nuts on the caps Remove the caps from the fork legs Remove the fork springs Put the oil level gauge on the top of the fork tube and measure the distance from the top of the fork tube to the oil level A Draining Oil B Filling oil Adjust the oil level as required within the adjustable range using the following oil Recomended oil MARZOCCHI SAE 7 5 WP SAE 5 OHLINS 5 7 5 EC 2003 93 A Push Rod Pull up the push rod A slowly At this time the fork oil comes out of the push rod hole let it overflow until it stops Put the fork spring 1 into the fork tube Pull down the fork spring and insert the spring holder 5 special tool under the push rod nut or piston holder Install the top cap bolt 3 on the top of the fork tube and tighten it to 29 N m 21 ft lbs Repeat on other fork Install removed parts 1 Spring 2 Locknut 3 Suspension cap 4 Cap Wrench 5 Lock nut wrench Fork Springs Different fork springs are available to achieve suitable front fork action in accordance with the ride
37. ng The spring rate is higher Using the softer spring The spring rate is lower NOTE Look at page 106 EC 2003 96 WARINING Improper removal of the spring from the rear shock absorber body may cause the spring and associated parts to be ejected at high velocity Always wear eye and face protection Removal and installation of spring should be performed by an person or company WHEELS Tires Tire pressure affects traction handling and tire life Adjust the tire pressure to suit track conditions and rider preference but do not stray too far from the recommended pressure NOTE Tire pressure should be checked when the tires are cold before you ride Track condition When the track is wet muddy sandy or slippery reduce the tire pressure When the track is pebbly or hard increase the tire pressure Spokes and Rim The spokes on both wheels must all be tightened securely and evenly and not be allowed to loosen Unevenly tightened or loose spokes will cause the rim to warp hasten nipple and overall spoke fatigue and may result in spoke breakage A Spoke Wrench k Tire bead lock clamp There is a lock clamp on the front and rear wheels The bead lock clamp prevents the tire and tube from slipping on the rim and damaging the valve stem Valve stem damage may cause the tube to leak necessitating tube replacement In order that the tire and tube remain fixed in position on the rim in
38. ock absorber Bottoms at low speed Increase spring preload until maximum preload is achieved Bottom after successive 3 or 4 successive jumps Decrease rebound damping NOTE The rear shock on this machine may mislead some riders a The rear shock bottoms when the spring and damping are overcome by the total weight of the machine and rider due to full stroke b A bottoming sensation even through the machine is not bottoming may actually be the inability of rider and machine weight to overcome an overly stiff spring or excessive damping Observe the rear end off jumps if it doesn t approach bottoming try lowering the sping preload and damping Gearing Preconditions Course condition Rear sprocket Fast course Small Many courves or hills Large Sandy or soft groud Si la parte recta de la crono es larga el desarrollo puede alargarse por lo tanto la velocidad aumenta EC 2003 109 If the straight portion of a course is longer the secondary reduction ratio should be reduced so that the machine speed can be increased When the course has many corners or uphills or is wet the secondary reduction rario should be increased so that gear shifting is possible with smooth acceleration Actually the speed must be changed depending on the ground condition on the day of race and therefore be sure to run through the racing circuit prior to a race and set the machine suitable for the entire cou
39. on too hard Front fork oil excessive Empty and review level oil Front fork oil viscosity too hight Empty oil from fork and go to specialized garage Front fork leg bent Change it Go to a specialized garage Tire air pressure too high Check tire air pressure Rear shock absorber maladjusted Check rear shock absorber Shock absorption too soft Front fork oil insufficient and or leaking Fill up until correct level Front fork oil viscosity too low Empty oil from fork and fill up with suitable viscosity oil Front fork leg bent Change front fork Go to specialized garage Tire air pressure too small Check tire air pressure Rear shock absorber maladjusted Check rear shock absorber 17 Abnormal train noise Drive chain adjusted improperly Adjust chain Chain worn Change chain and rear engine sprocket EC FSE 2003 116 r Stability Unsatisfactory Control cable routing incorrect Move control cable or unscrew TROUBLE CAUSE REMEDY Abnormal train noise Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Oil front fork insufficient or too thin Spring weak or broken Disc brake worn Pad installed incorrectly or surface glazed Cylinder damaged Bracket nut bolt etc not properly mounted or tightened Handlebar shakes or excessivery vibrates Tire swing arm sleeve or needle bearin damaged Rim warped
40. oo heavy 2 Worn out fork oil Too soft The fron fork dive excessively during braking and deceleration 1 Fork oil level is low 2 Springs are too soft 3 Oil too light 4 Fork oil is worn out 5 Rebound or compression damping adjusting incorrect Symptoms of the rear shok Too hard The suspension is too stiff 1 Compression damping is too high 2 Spring is too hard Too soft On landing after a big jump bottoming occurs normally O K 1 Spring preload is too soft or compression damping is too soft 2 Spring is too soft 3 Shock oil is worn Determining the Proper Settings Standard Settings From the factory the machine is set up for an intermediate weight rider possessing intermediate riding ability Hence if the actual rider weight is considerably more or less than this or if his riding experience and ability are much greater or lesser than the intermediate made to put the suspension in the ballpark Readjustment of the suspension Softer spring EC 2003 107 Riding experience Beginner Softer spring with more rebound damping Experienced Harder spring Rider s weight Heavy Harder spring Light Softer spring Type of course Many corners Lower the front end slightly increase the fork tube height 5mm This quickes steering and turning ability Fast course with many jumps Raise the fornt end slightly decrease the front tube height 5 mm Deep wh
41. oops or sandy ground Raise the front end slightly to gain stability fter making such preliminary adjustments begin the actual on track testing and evaluation CAUTION 1 Always make changes in small increments 2 Make sure the rider is consistent in this evaluation of improper suspension performance 3 A change in the front suspension might require a change in the rear and vise versa CP KP KT Front and rear compability Use this procedure to determine if the suspension is balanced reasonably well Hold the bike upright retract the side stand While standing next to the machine lightly pull on the front brake place one foot on the footpeg closest to you and push down hard If the bike maintains its level attitude as the suspension is compressed the spring rates are well balanced Sit astride the bike and take a riding posture Next check to see that the bike is in a horitzontal 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 track and the rider s preferences Front end seaching during down hill or during acceleration out of corner Front fork is too soft 1 Increase the compression damping or rebound damping 2 Increase the oil level 10 mm 3 Use alternate harder sping or increase sp
42. orn or maladjusted either too loose or too tight the chain could jump off the sprockets or break WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Slack Inspection The space between the chain and the swing arm at the rear of the chain slider should be 30 50 mm Rotate the rear wheel to find the place where the chain is tightest because it wears unevenly Adjust the drive chain if it has too much or too little slack lt I a een i f v S CEN 30 50 mms mar H y In addition to checking the slack rotate the rear wheel to inspect the drive chain and sprockets for damaged rollers loose pin and links unevenly or excessively worn teet and damaged teeth Slack Adjustment Loosen the rear axle A nut B and both chain adjuster locknuts Turn the nuts on the chain adjusting bolts evenly until the drive chain has 30 50 mm of space between the chain and the swing arm To keep the chain and wheel aligned the notch on the left chain adjuster should align with the same swing arm mark that the on the right chain adjuster aligns with il 7 s a EAS 2 SORE cS lt Saat Kis Mab Gio N a d es D y AD EC 2003 86 CP KP KET NOTE Wheel alignment can also be checked using the straightedge or string metod WARNING Misalignment of the whee
43. ossible to tear or damage the filter WARNING Wipe out the inside of the air cleaner hoousing with a clean damp A clogged air cleaner may allow dirt and dust to enter the carburetor towel and stick the throttle open This could cause an accident CAUTION A clogged air cleaner may allow dirt and dust to enter the engine A Causing excessive wear and possible engine damage Inspect the element without fail before and after each racing or practice session Clean it if necessary Take the element B off the frame A Element Cleaning WARNING Clean the element ina bath of a filter cleaning Clean the element in a well ventilated area and take care that there fluid using a soft bristle are no sparks or flame anywhere near the working area this includes brush any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the element A fire or explosion coluld result Squeeze it dry ina clean towel Do not wring the element or blow it dry the element can be damaged EC 2003 83 Inspect the element 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 srew hole in the air cleaner housing and intake tract A Install the element in the machine A and make sure the sealing surface of the element is seated properly Install the sea
44. parks this includes any appliance with a pilot light Engine Oil Mixing Oil must be mixed with the gasoline to lubricate the piston cylinder crankshaft bearings and connecting rod bearings CPi KTP KT Recomended Oil OIL 2T SINTETIC NOTE If recommended oil is not available use only synthetic oil designed for use in racing 2 cycle engines Proporcion of gasoline and oil mixture premix ratio 50 parts gasoline to 1 part oil CAUTION Do not mix vegetable and mineral based oils Too much oil will cause excessive smoking and spark plug fouling Too little oil will cause engine damage or premature wear To make an gasoline oil mixture pour oil and half of the gasoline into a container first and stir the mixture thoroughly Then add the rest of the gasoline and stir the mixture well NOTE At low temperature oil will not easily mix with gasoline Take time to ensure a well blended mixture The lubricative quality of this mixture deteriorates rapidly use a fresh mixture for each day of operation EC 2003 72 CP KC KT SERIAL NUMBER START THE ENGINE This number allows the motorcycle to be registered The serial number or V I N is located on the steering stem of the frame 1 You have to assure the motorcycle to the neutral position 2 Turn right the key of fuel tank A Official approval plate This motorcycle has an official approval plate It shows the serial number 5 7 Pe a a 4
45. r s style and positioning on the machine If you have a problem test by changing your riding posture or position so that the cause of the problem can be deduced It is a wise practice to adjust suspension settings to suit the rider s strong points If you are 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 recognize the effects of his input such things as changes in rider position and increasing fatigue may lead to incorrect judgments about neceessary setting adjustments When the proper settings have been determined for a particular track they should be written down for reference when returning to that track CP KC KT Front fork The fork oil level in the fork tube is adjustable A change in the fork oil level will not affect the spring force much at the top of fork travel but it will have a great effect at the bottom When the oil level is raised The air spring effect becomes more progressive and the front fork action feels harder in the later stage of travel near the bottom When the oil level is lowered The aire spring is less progressive and
46. r s weight and track conditions Harder springs make the fork stiffer and rebound action quicker Softer sprigs make the fork softer and rebound action slower Fork Clamp Position Adjustment Steering qualities are greatly affected by the fork clamp position the amount of the outer tube projecting above the steering stem head When the fork tube height is smaller the front end becomes lighter due to change in weight bias Also it tends to understeer in turns at whash out When the height is greater the results are opposite Be sure the front tire doesn t rub the fender when the fork tubes compress fully Make this adjustment in 5mm increments CAUTION pC AUTION i O The outer tubes both right and left should be adjusted evenly EC 2003 94 1 Fork tube height REAR SUSPENSION The rear suspension system of this motorcycle is single shock It consist of a rear shock absorber swing arm tie rods and rocker arm In general the operating characteristics of the single shock are similar to the front fork But in achieving progressive spring characteristics a linkage system is used To suit various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the dampening force can be adjusted easily so changing oil viscosity is unnecessary Shock Rebound Dampening Adjustment Rear shock Absorber o adjust shock rebound dampening turn
47. ring preload Front end knifes or oversteers in turns front end tends to turn inward Front fork is too soft 1 Increase the compression damping or rebound damping 2 Increase the oil level 10 mm Front end pushes or washes out in turns 1 Decrease the compression damping or rebound damping 2 Release the air at the fork tubes 3 Decrease oil level 10 20 mm 4 Use softer spring EC 2003 108 CP KTP KF Front fork doesn t respond to small bumps in sweeping turns Front Fork is too hard 1 Decrease the compression damping or rebound damping 2 Decrease oil level 10 mm 3 Use softer duty spring Rear end kicks when braking over bumps The shock probably has too little rebound damping Increase the rebound damping Rear tire won t hook up out of corners A lack of traction coming out of turns The shock may be too stiff 1 Decrease the rear shock spring preload 2 Decrease the compression damping 3 Use softer spring In case of a lightweight rider Front and rear of the bike bottom off high speed jumps If harsh bottoming occurs once or twice per lap of the race Front and rear suspension system are too soft 1 Delantera Increase oil lever and or use harder spring 2 Rear Increase spring preload and or increase compression damping or use harder spring NOTE After any adjustment check front and rear compatibility Adjustment depending on bottoming condition rear sh
48. rious riding positions the handlebar position can be adjusted front to rear Handlebar position adjustment A Chain Slider B Seing Arm Loosen the handlebar holder A nuts B turn about the handlebar holder and tighten the nuts securely Sprocket Wear Visually inspect the sprocket teeth If they are worn or damaged replace the sprockets Lubrication Lubrication is necessary after riding through rain or in the mud or any time that the chain appears dry A heavy oil is preferred to a lighter ol because it will stay on the chain longer and provide better lubrication EC 2003 88 CP KC KT Tighten the clamp bolts front first and then the rear to 25 Nm of torque 18 ft lbs If the handlebar clamp is correctly installed there will be an even gap at the front and rear after tightening A BRAKES Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action So there are no parts that require adjustment on the brakes except brake lever play and brake pedal position Front brake lever play Adjust the front brake lever A to suit you To adjust the brake lever play loosen the locknut B and turn the adjuster to either side After adjustment tighten the locknut securely Then check the brake for good braking power and no brake drag Rear brake pedal position When the brake pedal is in rest position there should be a play of 10 mm
49. rse If the straight portion of a course on which the machine can be run at maximum speed is longer the machine should be set so that the maximum machine speed can be developed toward the end of the straight course but care should be taken not to over rev the engine It is difficult to set the machine to be best suited for all portions of the circuit Therefore determine which circuit portions will have the greatest effect on lap time Set the machine for these portions Confirm your settings by recording lap times after each change In this way the machine will deliver best performance for the entire circuit Special Care According to Track Conditions 1 In dry dusty conditions such as volcanic ash or fine powdery dust special care must be given to keep the air cleaner element clean 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 to remove built up mud from the tires and chassis after each ride before drying occurs CP KC KT 3 The engine works hardest in muddy conditions and the radiator can become clogged with mud Take care not to overheat the engine in these conditions The engine also works very hard when ridden in deep sand 4 In muddy or sandy conditions adjust the chain looser than in other conditions as the chain and sprockets will pack with mud sand and reduc
50. sc with an oil less solvent such as trichloroethylene or acetone EC 2003 98 CP CCP KT BOLT AND NUT TIGHTENING Every day before riding check without fail the tighteness of the bolts and nuts described here Also check to see whether or not each cotter pin is in place and in good condition 19 20 21 22 23 24 25 10 11 12 13 14 15 16 17 18 26 27 28 29 30 31 32 33 1 Bead lock nut 10 Spokes 19 Seat mounting bolt 28 Rear brake pedal bolt 2 Front fork clamp bolts 11 Front axle clamps nuts 20 Subframe bolts 29 Rocker arm mounting bolt 3 Handlebar mounting bolt 12 Brake hose clamp nuts 21 Rear chock absorber bolts 30 Swingarm shaft nut 4 Clutch lever support bolt 13 Radiator mounting bolts 22 Exhaust mounting bolts and nut 31 Kick pedal bolt 5 Cylinder head bolts 14 Engine mounting nuts 23 Fork clampbots 32 Kick pedal nut 6 Spark plug 15 Shift pedal bolt 24 Steering shaft nut 33 Brake hose mounting bolts 7 Cylinder head bolts 16 Rear subframe mounting bolts 25 Rear brake mounting bolt 8 Air cleaner box bolts 17 Chain guide bolts 26 Rear axle nut 9 Disc plate screws 18 Chain adjuster locknuts 27 Connecting rod mounting bolt EC 2003 99 CP KTP KT Torque Table Tighten all bolts and nuts to the proper torque using an accurate torque wrench A bolt or nut if insufficiently tightened may become damaged or fall out possibly resulting in damage to the motorcycle and injury to the rider H Cylinder head bolts 25 18 2 5
51. se box cover and replace fuse fuse WARRANTY REGULATIONS Manufacturer s warranty The Company GAS GAS Motos S A hereby warrants to the final purchaser of a vehicle manufactured by GG that both materials and workmanship are free from defects according to the corresponding state of the art Accordingly GG hereby warrants to the final purchaser hereinafter referred to as the purchaser subject to the conditions stated below to remove any defects in material or production detected in a new motorcycle free of charge within the agreed period of warranty without any limitation whatsoever in terms of the number of kilometres travelled or the number of operating hours Period of warranty The period of warranty shall commence on the day of delivery of the vehicle by a licensed GG dealer to the purchaser or in the case of demonstration models on the date on which the vehicle is put into operation for the first time The length of the warranty period depends on the type of vehicle and is stated in the document of delivery Any defects detected in the product shall be brought to the attention of a licensed GG dealer within the warranty period If the last day of the warranty period is a Sunday or public holiday the warranty period shall be extended in such a way that the last day of the warranty period is the next working day following the respective Sunday or public holiday Warranty claims shall be excluded for any defects not brought
52. spect the bead lock clamp before riding and tighten it if necessary Tighten the valve stem nut finger tight only NOTE The weld joint area of the rim may show excessive runout Disregard this when measuring runout EC 2003 97 CLEANING 1 Preparation for washing Before washing precautions must be taken to keep water off the following places Rear opening of The silencer cover with a plastic bag secured with rubber bands Clutch and brake levers hand grips engine stop button Cover with plastic bags Air cleaner intake Close up the opening with tape or stuff in rags 2 Where to be careful Avoid spraying water with any great force near the following places Disc brake master cylinders and calipers Under the fuel tank If water gets into the ignition coil or into the spark plug cap the spark will jump through the water and be grounded out When this happens the motorcycle will not start and the affected parts must be wiped dry Front and rear hubs Steering pivots Steering stem head pipe Suspension linkage system pivots Swing arm pivot CP KCK 3 After washing Remove the plastic bags and clean the air cleaner intake Lubricate the points listed in the lubrication section Start the engine and run for 5 minutes Dry the brakes before operating the motorcycle WARNING Never wax or lubricate the brake disc Loss of braking and an accident could result Clean the di
53. t THROTLLE CABLE Inspect the throttle grip for smooth operation in all steering positions In accordance with the Periodic Maintenance Chart check and adjust the throttle cable Check that the throttle grip has 2 3 mm of play and turns smoothly If the play is incorrect loosen the locknut on the upper end of the throttle cable and turn the adjuster to obtain the correct amount of play Tighten the locknut C B A A Adjuster B Locknut C Throttle grip COP IICT I If the free play cannot beset by adjusting the upper cable adjuster pull the rubber boot off of the carburetor top Make the necessary free play adjustment at the lower cable adjuster tighten the locknut and reinstall the rubber boot CARBURETOR Idling Adjustment Iding adjustment is carried out using the air screw A and idle ajusting screw B First turn in the air screw until it seats lightly and back it out 1 1 2 turns After thoroughly warming up the engine turn the idle adjusting screw to obtain the desired idle speed If no idle is preferred turn out the screw until the engine stops 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 incorrectly routed or it may be damaged Be sure to correct any of t
54. the coolant drain plug and drain the coolant from the radiator and engine by removing the drain plug at the bottom of the water pump cover Immediately wipe or wash off any coolant that spills on the frame engine or wheels EC 2003 80 CP KTP KT WARNING Coolant on tires will make them slippery and can cause an accident and injury Visually inspect the old coolant If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system Check the cooling system for damage loose joints or leaks Install the water pump cover drain plug and cylinder drain plug with the specified torques shown in the table Always replace the gasket with a new one if it damaged Drain plug tightening torque look maintenance table Water Pump Cover Plug 9 Nm Fill the radiator up to the bottom of the radiator filler neck with coolant and install the radiator cap Check the cooling system for leaks Start the engine warm up the engine throughly then stop the engine Check the coolant level after the engine cools down Add coolant up to the bottom of the radiator filler neck SPARK PLUG The standard spark plug is a shown in the table Spark plug should have a specified gap and be tightened to 27 N m 20FT LBS Standard Spark Plug NGK CR8 E o DENSO U24ESR N 0 7 0 8 mm The spark plug s
55. the front fork does not become as hard in the later stage of travel Changing the fork oil level works effectively at the end of fork travel If fork bottoming is experienced raise fork fork oil level in 10 mm increments This will change the secondary spring rate Oil level adjustment Adjust the front fork oil level see the Oil Level Adjustment of the Front Fork section in the Maintenance and adjustment chapter Increase level Standard oil level Decrease level Later stage Fork stroke of travel EC 2003 106 CP KP 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 methodical manner this does not mean however that you must be a scientist or trained technician to succeed Simply take time a think about the changes you believe necessary check them against the symptoms and cures described here make the changes in small increments and take notes on the changes and their effects Simptoms of the Front Forks Too hard The front forks are too stiff 1 Rebound or compression damping adjustment incorrect 2 The springs are too strong 3 Too much oil 4 Too heavy oil The front forks stiffens up the end of stroke 1 The fork oil level is too high The front forks operate but ride is too hard 1 Oil t
56. the rebound dampening adjuster on the rear shock absorber lower end until you feel a click The total number of adjustments is 60 CLICKS The standard setting is 25 CLICKS Counterclockwise from fully closed A Rebound dampening adjuster Shock compression dampening adjustment To adjust schock compression dampening turn the adjuster screw on the gas reservoir until you feel a click The total number of adjustments is 60 CLICKS The standard setting is 30 CLICKS Counterclockwise from fully closed EC 2003 95 i A Compression dampening adjuster Adjusting the spring Remove the seat right and left side number plates Loosen the air cleaner duct clamp screw Remove the silencer Remove the rear subframe with the air cleaner box A Rear subframe B Air cleaner box CP KC KT Suspension spring The standard spring is a 4 0 The standard spring preload length is 258 mm A Adjusting B Spring C Lock nut ring Tighten the locknut ring securely After adjustment move the spring up and down to make sure that the spring is seated Install the parts removed Rear Shock Absorber Spring Replacement In addigtion to the standard spring harder and softer springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions Using the harder spri
57. the serviceable condition of the motorcycle e g hidden or minor blemishes normal operating noise or vibrations g Phenomena due to the aging of the vehicle e g fading of painted or metal coated surfaces Miscellaneous 1 GG shall be entitled to decide in its sole discretion whether to repair or to replace defective parts The ownership of parts replaced if any shall pass to GG free of any consideration whatsoever The licensed GG dealer entrusted wit the removal of defects shall not be authorized to issue binding declarations on behalf of 2 In cases of doubt regarding the existence of a defect or if a visual inspection or material testing is required GG shall be entitled to demand submission of the parts for which warranty claims are put forward or to order an examination of the defect by a GG expert Any additional warranty obligations for parts replaced free of charge or for any service performed free of charge under the present warranty shall be excluded The warranty components replaced within the warranty period shall end at the date of expiry of the warranty period agreed for the respective product 3 If it turns out that any defect cannot be removed the warranty shall be entitled to demand termination of the contract payment of a compensation or partial reimbursement for the purchasing price discount instead of repair of the motorcycle The warranty shall in no case be entitled to receive a new motorcycle as a su
58. to the attention of a licensed GG dealer by the end of the warranty period Obligation of the purchaser GG shall be entitled to refuse to accept warranty claims if and to the extent that CP KTP KT a The purchaser has failed to subject the vehicle to any of the inspections and or maintenance work prescribed in the operating manual or has exceeded the date stated for such inspections or maintenance work also excluding from the warranty defects that appeared before the prescribed date of such inspection or maintenance work performed not at all or performed only after the prescribed date b Inspection maintenance work and repair work on the vehicle has been performed by a party neither recognized nor licensed by GG c Any maintenance or repair work has been performed on the vehicle in violation of the technical requirements specifications and instructions indicated by the manufacturer d Spare parts not released for use by GG have been used to perform maintenance or repair work on the vehicle or if and to the extent that the vehicle has been operated using other fuels lubricants or operating fluids including but not limited to cleaning agents than those expressly stated in the specifications in the operating manual e The vehicle has been altered or modified in any way or equipped with other components than those expressly released by GG as admissible vehicle components f The vehicle has been stored or transported in a way t
59. trate de cambiar el l quido cuando el motor est todavia caliente Espere hasta que se enfr e EC 2003 79 Coolant level Situate the motorcycle so that it is perpendicular to the ground Remove the radiator A cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds 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 in the radiator The coolant level should be to the bottom of the radiator filler neck see illustration If the coolant level is low add the correct amount of coolant through the filler opening 1 Coolant level 2 Breather Hose CP KCK Recommended coolant Permanent type of antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators NOTE A permanent type of antifreeze is installed in the cooling system when shipped It is colored green contains a 50 solution of ethylene glycol and has a freezing point of 35 C 32 F USA Water and coolant mixture ratio 1 1 Water 50 coolant 50 Tatal amount 1 1 L Coolant Change The coolant should be changed periodically to ensure long engine life Wait for the engine to cool completely Situate the motorcycle so that it is perpendicular to the ground Remove the radiator cap Place a container under
60. ufacturer warnings and coolant handing instructions CAUTION Soft or distilled water must be used with the inhibitor chemicals and the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system If the lowest ambient temperature encountered falls below the freezing point of water protect the cooling system against engine and radiator freeze up Use a permanent type of anti freeze soft water and ethylene glycol plus corrossion and rust inhibitor chemicals for aluminium engines and radiators in the cooling system For the coolant mixture ratio under extreme conditions choose the mixture ratio listed on the container for the lowest ambient temperature CAUTION Permantent types of antifreeze on the market have anticorrosion and anti rust properties When it is diluted excessively it loses its antifreeze and anticorrosion properties Dilute a permanent type of antifreeze in accordance with the instructions of manufacturer Coolant Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level becomes low the engine overheats and may suffer severe damage Check the coolant level each day before riding the motorcycle Replenish coolant if the level is low WARNING Para evitar quemaduras no saque el tapon del radiador o

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