MANUAL DEL USUARIO USER MANUAL MANUEL D
Contents
1. Bleeding If the system has been dismantled for repair or if faults are detected in the brake system the air in the hydraulic circuit can be removed using the bleeders A Once the air has been removed from the system replace the rubber cap on the bleeder to prevent dirt from entering the system Front fork Oil level Each of the suspension rods is filled with 310 cm of SAE 5 oll gt gt Lubrication Clean and lubricate frequently with oil Lubrication Clean and lubricate frequently with oil The joints of the clutch and front brake levers Lubrication Clean and lubricate frequently with oil ine joint of the kick start pedal 44 20 CP kc KT Lubrication Lubrication Clean and lubricate frequently with Clean and lubricate frequently with oil oil The throttle lever especially after washing the motorcycle with high pressure hoses Y y Identification The serial number of the motorcycle is engraved on the steering tube um number should match that which appears in the accompanying documents CP KP 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 t2. Each message is preceded by a symbol whose meaning is as follows Caution This symbol indicates all of the rules and precautionary measures that must be N taken in order to avoid any physical injury serious or slight including death of the user 3 to ignore these represents a serious danger N Warning This symbol introduces special warnings to avoid damage to your motorcycle D Should these warnings be ignored the guarantee may be automatically invalidated y Miscellaneous notes These are instructions necessary for optimum use of control and adjustment operations as well as conservation and maintenance work on the motorcycle so that you may benefit from a maximum of driving satisfaction The aim of this Manual is to help the user minimise or avoid possible damage to people property the environment and naturally to your new motorbike Therefore all the information presented here is based on data obtained from the latest models put on the market just before publication However GAS GAS Motos S A reserves the right to make modifications without any prior warning to consumers and without incurring any additional obligations in so doing Your local dealer will also provide you with any information as might be deemed necessary 4 Index Acknowledgements to the purchaser Important warning Index Quick Guide to Maintenance Fuel Petrol oil mixture Fuel tank Fuel tap Before starting the engine Starting the engine
3. 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 24 HET AT Notes Notes CP kc KT CASCAS 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 L Global Racing Oil PUO10638042 JUNIO JUNE JUIN GIUGNO JUNI 2006 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
4. I A CHLL ALAN AALS MANUAL DEL USUARIO FI HI V USER MANUAL MANUEL D ENTRETIEN LIBRETTO D USO BETRIEBSANLEITUNG FAENA LIRA ES USER MANUAL HET AT ACKNOWLEDGEMENTS TO THE PURCHASER GAS GAS thanks you for the trust you have placed in us We are delighted that you have selected the MC Boy 50 EC Boy 50 motorcycle and we would like to welcome you to the GAS GAS family Get to know your new machine well This bike incorporates our accumulated competition experience and that which we have gained from the achievement of many important titles You now possess a motorcycle with which as well as feeling comfortable you are offered the infinite possibilities of driving at the highest level of your skill while maintaining a maximum of security This manual provides you with a good basic knowledge of the features and machine handling It also contains many important instructions regarding safety and provides information about the basic maintenance and inspection procedures Thank you for your trust in us and welcome to GAS GAS motorbikes GAS GAS MOTOS S A CP KC KT Important warning Read this Manual carefully It contains all the necessary information for your safety and that of others as well as guaranteeing the correct conservation and maintenance of the GAS GAS motorcycle you have just acquired All of the necessary instructions for the correct driving and handling of this vehicle are set out below
5. Stopping the engine Riding the motorcycle Stopping the motorcycle Running in period Transmission oil Checking the level Filling Changing MC Boy 50 cooling system Checking filling EC Boy 50 cooling system Checking OO OONN OD OF W CP KC KT Carburettor Adjusting throttle cable Adjusting idle speed Spark plugs Inspecting Air Filter Cleaning Front brake fluid Checking Rear brake fluid Checking Front brake lever Adjusting Rear wheel Centre alignment Chain slack Checking Master link Checking Tyre pressures Checking Brake pads Checking Brake circuit Bleeding Front fork Oil level Lubrication Identification Guarantee manual CP CCP KET Quick guide to maintenance Description MC Boy 50 49 38 5 49 38 12 Two stroke single cylinder layer admission directly to crankcase 1 one 39 x 41 8 mm Displacement power cc CV Number of cylinders Bore and stroke Cooling system Air Liquid Engine lubrication system 7 mixture ratio Engine supply system Dell Orto 19 mm diameter carburettor with polyurethane sponge filter diffuser polyurethane sponge filter diffuser Ignition system Electronic with variable advance Automatic Single gear Primary by gears Secondary by chain Transmission lubrication system 250 cc of SAE 20 oil CHASSIS Deltabox elliptic profile tubes in CRMo aluminium rear swingarm Marzocchi hydraulic fork 140 mm Single shock absorber Sachs 155 mm stroke Di
6. arranted 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 the last day of the period covered will be the first working day after the Sunday or official holiday Those claims under Warranty for defects not brought to the attention of a GG authorised dealer before the end of the Warranty Period will be excluded 22 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 tec
7. d Strictly observe the oil and petrol ratios shown and use the recommended 2T oil see section Fuel petrol oil mixture page 7 In the first hour of use keep the engine at a moderate turnover speed never go to maximum turnover Constantly change the speed by opening and closing the throttle alternately CP kc KT FAN Transmission oil Checking the e level A If the motorcycle has been used recently wait a few minutes before checking the level Note the motorcycle should be perpendicular to the ground Warning Place a suitable recipient under the engine to collect possible oil spillage Remove the oil level screw A The level is correct if it reaches the lower edge of the oil level hole A If the level is lower then more oil must be added su Transmission oil Topping up e If necessary top up with oil uec Remove the oil filler cap A Warning Use the recommended oil See Quick guide to maintenance page 6 Add oil until it begins to pour out of the hole B Warning Do not overfill the engine Risk of damage to engine Fit and tighten the oil level screw B Replace filler cap and tighten A Start the engine and keep it running until e it warms up then stop the engine To drain out the used oil remove the oil release plug A located underneath the engine Replace the drain plug using a new seal washer Tighten to 20 Nm Remove the filler cap B an
8. d fill with oil 250 cc Warning Use the recommended oil See Quick guide to maintenance page 6 Tighten the filler cap Warning Do not pour used oil down the drain Transmission oil Changing pa MC Boy 50 cooling system Checking filling e The MC Boy 50 is fitted with a liquid cooling system O e Warning If the motorcycle has just been used wait a few minutes before opening the radiator cap Risk of burns Rotate the cap A anti clockwise and remove it The level of coolant should be at the lower edge of the filler neck of the radiator below the position of the cap seal If this is not the case top up with coolant Warning only use coolant suited to light alloy engines with antifreeze protection of up to 30 C amp EC Boy 50 cooling system Checking EC Boy 50 is fitted with an air cooling system The maintenance of this system consists of keeping the cylinder blades and cylinder head A clean of mud and accumulations that may obstruct the air flow CP KC KT The throttle lever cable should have a J free play of between 2 to 3 mm If necessary adjust as described below Raise the dust guard A on the throttle lever cable Turning the threaded terminal B to the right increases the play of the cable and turning it to the left reduces the play e Carburettor Adjusting throttle cable b d a D Ki j A Udi 7 i idle speed The carburetto
9. e of doubt regarding the existence of a defect or a visual or material inspection is required GG reserves the right to demand the return of the parts which are the object of a claim under Warranty or to arrange an inspection of the defect by an expert from GG Any additional obligations arising out of guarantees on parts replaced free of charge or any other service rendered free of charge are excluded from the effects of this present warranty The Warranty on parts replaced within the Warranty Period will end at the expiry date for the Warranty Period of the product concerned 3 Should it prove to be the case that a defect can not be repaired the purchaser guaranteed shall have the right to the cancellation of the contract payment of compensation or a partial refund of the purchase price discount instead of repairing the motorcycle 4 Any claims against Warranty by the purchaser under the terms of the sale contract with the corresponding authorised dealer shall not be affected by the terms of this present Warranty Neither will this present Warranty affect those additional contractual rights acquired by the purchaser under the general commercial terms and conditions of the authorised dealer However such additional rights may only be exercised through claims against the authorised dealer 5 Should the purchaser resell the product within the Warranty Period the duration and conditions of the present Warranty will remain unaltered in such a way
10. 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 53 HET AT other environmental impact or inadequate cleaning with inappropriate products e any damages caused as a result of the defects as well as any expenses incurred either directly or indirectly as a consequence of the defects for example communication costs accommodation expenses car hire costs public transport costs breakdown truck fees courier costs etc as well as other financial losses for example those caused by the loss of the use of the vehicle loss of income time lost etc f any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle for example small or hidden imperfections noise or vibrations that are normal in use etc g phenomena that are the result of the ageing of the vehicle for example discolouring of painted or metallic coated surfaces 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 cas
11. hat both the materials and the manufacturing are free of defects in accordance with the highest standards of quality Consequently GG with this document guarantees the consumer hereafter referred to as the purchaser in accordance with the conditions set out below the repair free of charge of any defect in materials or that might result from faulty manufacture that is detected in a new motorcycle within the period covered by this Warranty and with no limit on the number of kilometres covered or hours of use Warranty Period The period covered by this Warranty will begin on the day of delivery of the vehicle to the purchaser by a GG authorised dealer or in the case of demonstration models on the date in which the vehicle is used for the first time The seller will be responsible for any unwarranted faults that become apparent within the period established in the Law decree 23 2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance with the Directive 1999 44 EC for other members of the European Community For countries outside the European Community the Warranty Period will be determined by the existing regulations in those countries Nevertheless should the fault appear during the first six months after the delivery of the motorcycle it will be presumed that the said fault existed at the time of delivery from the end of the sixth month onwards the purchaser must demonstrate that the unw
12. hnical requirements specifications and or instructions indicated by the manufacturer d spare parts whose use has not been authorised by GG have been used during the course of maintenance work or repairs to the vehicle or in the event that the vehicle has been used with fuels lubricants or other liquids including amongst others cleaning products that have not been expressly mentioned in the specifications set out in the User s Manual e the vehicle has been altered or modified in any way or fitted with components other than those expressly authorised by GG as accepted components of the vehicle f the vehicle has been stored or transported in a way that is not in accordance to the corresponding technical requirements g the vehicle has been used for special purposes other than ordinary use such as competition races or record breaking attempts h the vehicle has been directly or indirectly damaged as a result of a fall or an accident Warranty exclusions The following items are not covered by this Warranty a worn parts including without any limitation spark plugs batteries petrol filters oil filter elements secondary chains engine output pinions rear sprockets air filters brake discs brake pads clutch plates and discs bulbs fuses carbon brushes footrest rubbers tyres inner tubes cables and other rubber components b lubricants for example oil grease etc and working fluids for example battery liquid coolant
13. just the maximum turn of the lever The level is correct using bolt A to suit the driver if it falls within the upper half rosa o he of the transparent window A E e play of the lever using bolt If not top up with a recommended brake fluid Rear brake fluid Checking Rear wheel Centre alignment The rear axle has easily graduated eccentrics for this operation To ensure perfect wheel alignment make sure that the marks of both eccentrics are in the same position on both sides CP KC KT Chain slack Checking Adjust chain tension with the eccentrics so that the slack in the tensed zone is 1 5 cm Master link Checking The master link of the chain has an elastic locking clip As shown in the photo place the closed part of the clip in the direction of the chain rotation 17 CP KTP KT n Tyre pressures Checking Check tyre pressures regularly in Sf order to obtain the best road holding possible INFLATION PRESSURES EC BOY 50 Front wheel 0 8 BAR 11 5 PSI Rear wheel 0 8 BAR 11 5 PSI MC BOY 50 Front wheel 0 9 BAR 13 PSI Rear wheel 0 8 BAR 11 5 PSI TE Brake pads Checking The brake pads both front and rear ai should be checked for wear periodically in order to enable you to brake effectively in any situation Replace if the thickness of the friction material of the pads reaches 1 mm CP KC KT Brake circuit
14. r has an idle adjusting screw A which acts on the opening of the carburettor throttle curtain and an air adjusting screw for the low system B which controls the air fuel mixture e Carburettor Adjusting the HET AT 4 PER Spark plugs Inspecting 0 6 0 7 mm The electrode separation is from Fa Y Air Filter Cleaning y A clean air filter not only improves engine performance but also prolongs its useful life It should therefore be cleaned regularly To reach the air filter proceed as follows Remove the bolt indicated by the arrow remove the seat by pulling it backwards to dislodge it from its forward attachment Using a screwdriver or similar remove the elastic band A from the bolt holding it Remove cover B from the filter box Remove filter Wash the filter in warm water and soap and once dry grease with special filter oil Refit the elements in reverse order noting that the seat must be pressed downwards and forwards to insert it into its forward attachment in the front part of the padding 0 6 to 0 7 mm CP KC KT Front brake fluid Checking The level is correct if it falls within the upper half of the transparent window A If not top up with a recommended brake fluid b d b 4 PF SES 3 mm max Front brake lever Adjusting The front brake lever should have a maximum play of 3 mm To adjust proceed as follows Ad
15. sk 160 mm diameter AJP calliper Disk 150 mm diameter AJP calliper Duralumin wheels Gear changes Transmission Clutch ront Suspension Rear suspension ront brake Wheels T Tl e z e D o CU 3 O 2 5 14 2 5 10 2 75 13 00 12 2 75 10 Kick start pedal Forged aluminium Shift pedal and rear brake Forged aluminium with retractable toecap Fuel Petrol oil mixture w The motorcycle is fitted with a two stroke internal combustion engine This type of engine requires a mixture of petrol and oil To ensure the correct working of the engine the following are recommended Use high quality petrol with an octane rating equal to or above 90 RON MON 2 or 98 RON Use 2T synthetic oil Warning f the recommended oil is not available use semi synthetic oil Do not mix different oil types Mixture ratio oil 2 of petrol volume 50 parts petrol to every 1 part oil Note we recommend first preparing the mixture in a suitable container and then filling the fuel tank Fuel tank This has a rapid access cap A and a vent hose B to allow gases produced in the tank to escape To open the cap lift the clip in the direction shown by the arrow and turn to the left Warning Regularly check the cap seal and vent hose to ensure they are leak proof Risk of spillage COP KC KT CP KC KT VA Before starting the engine e Open the fuel tap my Note f the engine is cold then p
16. ull the choke upwards A and then rotate it 1 4 of a tum to the left or the right to secure it in place Once the engine is turning over regularly at idle speed return the choke A to the rest position Do not use the choke on hot days or when the engine is hot In this case hold the throttle lever partially open until the engine starts p Fuel tap e This has three positions open ad closed and reserve The diagrams below show the position of tap A for each case Tred f Reserve Open Closed E l Gi Starting the engine e Kick the start pedal A n in the direction shown by the arrow until the engine starts Warning once the engine is running fold the kick starter into the engine CP KC KT ke gt a Stopping the engine A 4 y With the throttle grip in rest position engine idle press stop button A until the engine stops CP KC KS x FAN Riding the motorcycle e To ride the motorcycle simply accelerate this will activate INN f the automatic clutch system N Stopping the motorcycle Release the throttle lever Use the front A and rear B brakes Warning Depending on circumstances and ground surface it may be better to use the front or rear brakes independently Running in period Y Care of the engine during the first hours of use is vital for obtaining the best from your motorcycle Therefore we recommen
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