GAS GAS 2009 EC 200 2T Owner'S Manual Download

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Owner’s manual

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Components location EC 2T 250cc/300cc RACING E-START

12 13

Number

Name

Number

Name

License plate light

Muffler

Brake light

Rear brake disc

Seat

Rear brake caliper

Rear shock gas reservoir

Rear brake master cylinder

Kick-starter

Suspension linkage

Manufacturer’s identification plate

Rear brake pedal

Radiator

Sump guard

Exhaust

Front axle handle

Summary of Contents for 2009 EC 200 2T

Page 1: ......

Page 2: ... The reproduction distribution public communication and transformation totally or partially is prohibited without the express authorization of the copyright owner The company has the right whithout notice to change technical content of products ...

Page 3: ...0cc 300cc RACING Cross Country E START 28 XC 2T 200cc 250cc 300cc RACING USA 30 XC 2T 250cc 300cc RACING E START USA 32 ELECTRICAL DIAGRAMS 34 EC Racing EC Replica Factory 34 EC Racing CrossCountry XC Racing USA 35 EC Racing E START 36 EC Racing CrossCountry E START XC Racing E START USA 37 TORQUE VALUES 38 General 38 Chassis 38 Engine 40 E START Engine 42 MULTIFUNCTION GAUGE 44 Quick guide 44 Nor...

Page 4: ...ilter 62 5 2 EC Racing E START Air filter 63 5 3 XC Racing USA Air filter 64 5 4 XC Racing E START USA Air filter 65 6 Carburetor 67 7 Transmission oil 67 8 Piston and ring 68 9 Cylinder head cylinder ex valve 68 10 Exhaust system 68 11 Muffler fiber 69 12 Connecting rod and bearings 70 13 Kick starter and gear shift pedal 70 14 Rubber joint exhaust silencer 70 15 Motor bearings 70 16 Coolant 70 1...

Page 5: ...1 Chain 83 42 Tires 83 43 Battery Load 84 SETTINGS 85 INTRODUCTION 86 CARBURETION SETTINGS 86 Throttle valve opening influences 86 Idle jet and mixture screw 86 Needle 87 Main jet 87 Reference carburetion competition use only 87 Correction factors 88 Symptoms of improper settings 89 CDI MAP 90 SECONDARY TRANSMISSION RATIO 90 SUSPENSION SETTINGS 91 Available settings 91 Standard settings 92 Static ...

Page 6: ... 6 Owner s manual This page is intentionally left blank ...

Page 7: ...Owner s manual 7 GENERALINFORMATION ...

Page 8: ...d with adequate preparation and corresponding revisions are essential to ensure that your GAS GAS is highly reliable you can enjoy more comfortable and grateful practice the sport motorcycle Thank you for your trust and welcome to GAS GAS Motos S A Legal notices In the interest of technical development GAS GAS Motos S A reserves the right to modify the construction staffing and accessories of the ...

Page 9: ...tion for maintaining the warranty Your GAS GAS has been designed for off road use not designed for long travel on highways Such use could lead to engine damages be cause it maintained high revolutions Also tyres are not suitable for use on paved surfaces It has not been designed for urban use Long tops at traffic lights in town could overheat the engine Maintain your GAS GAS in good condition To a...

Page 10: ...Name 1 Headlamp with position low beam and high beam lamps 11 Front brake caliper 2 Front turn signals 12 Front fork 3 Fuel tank 13 CDI switch 4 Fuel valve 14 Gear shift pedal 5 Rear shock 15 Carburetor 6 Air filter 16 Secondary transmission chain 7 Side stand 17 Chain guide 8 Chain guard 18 License plate holder 9 Rear turn signals 19 Rear reflector 10 Front brake disc ...

Page 11: ...14 15 16 Number Name Number Name 1 License plate light 9 Muffler 2 Brake light 10 Rear brake disc 3 Seat 11 Rear brake caliper 4 Rear shock gas reservoir 12 Rear brake master cylinder 5 Kick starter 13 Suspension linkage 6 Manufacturer s identification plate 14 Rear brake pedal 7 Radiator 15 Sump guard 8 Exhaust 16 Front axle handle ...

Page 12: ...ition low beam and high beam lamps 11 Front brake caliper 2 Front turn signals 12 Front fork 3 Fuel tank 13 CDI switch 4 Fuel valve 14 Electric Starter 5 Rear shock 15 Gear shift pedal 6 Air filter 16 Carburetor 7 Side stand 17 Secondary transmission chain 8 Chain guard 18 Chain guide 9 Rear turn signals 19 License plate holder 10 Front brake disc 20 Rear reflector ...

Page 13: ...Name Number Name 1 License plate light 9 Muffler 2 Brake light 10 Rear brake disc 3 Seat 11 Rear brake caliper 4 Rear shock gas reservoir 12 Rear brake master cylinder 5 Kick starter 13 Suspension linkage 6 Manufacturer s identification plate 14 Rear brake pedal 7 Radiator 15 Sump guard 8 Exhaust 16 Front axle handle ...

Page 14: ...with position low beam and high beam lamps 9 Front fork 2 Fuel tank 10 CDI switch 3 Fuel valve 11 Gear shift pedal 4 Rear shock 12 Carburetor 5 Air filter 13 Secondary transmission chain 6 Side stand 14 Chain guide 7 Front brake disc 15 License plate holder available in certain countries 8 Front brake caliper 16 Rear reflector available in certain countries ...

Page 15: ...r Name 1 License plate light available in certain countries 9 Muffler 2 Brake light 10 Rear brake disc 3 Seat 11 Rear brake caliper 4 Rear shock gas reservoir 12 Rear brake master cylinder 5 Kick starter 13 Suspension linkage 6 Manufacturer s identification plate 14 Rear brake pedal 7 Radiator 15 Sump guard 8 Exhaust 16 Front axle handle ...

Page 16: ...sition low beam and high beam lamps 10 CDI switch 2 Fuel tank 11 Electric Starter 3 Fuel valve 12 Gear shift pedal 4 Rear shock 13 Carburetor 5 Air filter 14 Secondary transmission chain 6 Side stand 15 Chain guide 7 Front brake disc 16 License plate holder available in certain countries 8 Front brake caliper 17 Rear reflector available in certain countries 9 Front fork ...

Page 17: ...ber Name 1 License plate light available in certain countries 9 Muffler 2 Brake light 10 Rear brake disc 3 Seat 11 Rear brake caliper 4 Rear shock gas reservoir 12 Rear brake master cylinder 5 Kick starter 13 Suspension linkage 6 Manufacturer s identification plate 14 Rear brake pedal 7 Radiator 15 Sump guard 8 Exhaust 16 Front axle handle ...

Page 18: ...12 13 14 Number Name Number Name 1 Headlamp with position low beam and high beam lamps 8 Front brake caliper 2 Fuel tank 9 Front fork 3 Fuel valve 10 CDI switch 4 Rear shock 11 Gear shift pedal 5 Air filter 12 Carburetor 6 Side stand 13 Secondary transmission chain 7 Front brake disc 14 Chain guide ...

Page 19: ...ber Name Number Name 1 Brake light 9 Rear brake disc 2 Seat 10 Rear brake caliper 3 Rear shock gas reservoir 11 Rear brake master cylinder 4 Kick starter 12 Suspension linkage 5 Manufacturer s identification plate 13 Rear brake pedal 6 Radiator 14 Sump guard 7 Exhaust 15 Front axle handle 8 Muffler 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 20: ... Number Name Number Name 1 Headlamp with position low beam and high beam lamps 9 Front fork 2 Fuel tank 10 CDI switch 3 Fuel valve 11 Electric Starter 4 Rear shock 12 Gear shift pedal 5 Air filter 13 Carburetor 6 Side stand 14 Secondary transmission chain 7 Front brake disc 15 Chain guide 8 Front brake caliper ...

Page 21: ...6 5 Number Name Number Name 1 Brake light 9 Rear brake disc 2 Seat 10 Rear brake caliper 3 Rear shock gas reservoir 11 Rear brake master cylinder 4 Kick starter 12 Suspension linkage 5 Manufacturer s identification plate 13 Rear brake pedal 6 Radiator 14 Sump guard 7 Exhaust 15 Front axle handle 8 Muffler 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 22: ...3 Clutch fluid reservoir 9 Front brake lever 4 Multifunction gauge 10 Turn signals lights horn and engine start stop controls 5 Fuel tank cap 11 Steering lock 6 Ignition key 1 1 Only models EC Racing E START 1 1 2 3 4 5 5 Number Name Number Name 1 Horn 4 Position low beam and high beam lights 2 Starter Switch 1 5 Turn signals 3 Engine stop 1 Only models EC Racing E START ...

Page 23: ... lever 8 Front brake lever 3 Clutch fluid reservoir 9 Lights switch ON OFF 4 Fuel tank cap 10 Engine stop 5 Ignition key 1 11 Steering lock 6 Front brake master cylinder 12 Starter Switch 1 1 Only models EC Racing E START CrossCountry 1 2 3 Number Name 1 Lights switch ON OFF 2 Engine stop 3 Starter Switch 1 1 Only models EC Racing E START CrossCountry ...

Page 24: ... 2 Choke lever 8 Front brake lever 3 Clutch fluid reservoir 9 Lights switch ON OFF 4 Fuel tank cap 10 Engine stop 5 Ignition key 1 11 Steering lock 6 Front brake master cylinder 12 Starter Switch 1 1 Only models XC Racing E START 1 2 3 Number Name 1 Lights switch ON OFF 2 Engine stop 3 Starter Switch 1 1 Only models XC Racing E START ...

Page 25: ...right side of the steering column 2 1 Steering lock Your GAS GAS has a steering lock It s found on the right side of the steering column 3 To lock the steering 1 Turn the handlebar fully to the right 2 Insert the key into the lock and rotate it of turn counter clockwise 3 Press the key inside 4 Turn the key clockwise to its original position and remove The lock should be sunk for the steering lock...

Page 26: ... 85 57 20 Gearbox 6 gears Gear ratio 1ª 2 07 29 14 2ª 1 63 26 16 3ª 1 33 24 18 4ª 1 10 22 20 5ª 0 91 21 23 6ª 0 79 19 24 Secondary transmission By chain Secondary ratio 3 67 44 12 3 69 48 13 Drive chain 5 8 x 1 4 with O Rings 112 links Clutch type Multi disc wet clutch Clutch trigger Hydraulic Lubrication Medium Oil Capacity 900cc Available rear sprockets 39 40 42 44 46 47 48 49 50 51 52 Available...

Page 27: ...height 375 mm Total width 830 mm Wheelbase 1475 mm Dry weight 102 kg Fuel tank capacity 9 5 l RECOMMENDED Fuel Unleaded RON 95 minimum Mixture fuel oil JASO FC GRO Off Road 1 100 synthetic oil ratio 2 50 1 Semisynthetic oil ratio 2 50 1 Mineral oil ratio 3 32 1 Coolant1 GRO GCC 30 Long Time Brake fluid GRO Brake Fluid DOT 4 Coolant mixture at 30 DOT 4 Clutch fluid GRO Global Ultra 5 Mineral oil Tr...

Page 28: ...earbox 6 gears Gear ratio 1ª 2 07 29 14 2ª 1 63 26 16 3ª 1 33 24 18 4ª 1 10 22 20 5ª 0 91 21 23 6ª 0 79 19 24 Secondary transmission By chain Secondary ratio 3 69 48 13 Drive chain 5 8 x 1 4 with O Rings 112 links Clutch type Multi disc wet clutch Clutch trigger Hydraulic Lubrication Medium Oil Capacity 900cc Available rear sprockets 39 40 42 44 46 47 48 49 50 51 52 Available front sprockets 12 13...

Page 29: ...5 mm Total width 830 mm Wheelbase 1475 mm Dry weight 105 kg Fuel tank capacity 9 5 l RECOMMENDED Fuel Unleaded RON 95 minimum Mixture fuel oil JASO FC GRO Off Road 1 100 synthetic oil ratio 2 50 1 Semisynthetic oil ratio 2 50 1 Mineral oil ratio 3 32 1 Coolant1 GRO GCC 30 Long Time Brake fluid GRO Brake Fluid DOT 4 Coolant mixture at 30 DOT 4 Clutch fluid GRO Global Ultra 5 Mineral oil Transmissio...

Page 30: ... Gearbox 6 gears Gear ratio 1ª 2 07 29 14 2ª 1 63 26 16 3ª 1 33 24 18 4ª 1 10 22 20 5ª 0 91 21 23 6ª 0 79 19 24 Secondary transmission By chain Secondary ratio 4 17 50 12 3 85 50 13 Drive chain 5 8 x 1 4 with O Rings 112 links Clutch type Multi disc wet clutch Clutch trigger Hydraulic Lubrication Medium Oil Capacity 900cc Available rear sprockets 39 40 42 44 46 47 48 49 50 51 52 Available front sp...

Page 31: ...mm Dry weight 102 kg Fuel tank capacity 9 5 l RECOMMENDED Fuel Unleaded RON 95 minimum Mixture fuel oil JASO FC GRO Off Road 1 100 synthetic oil ratio 2 50 1 Semisynthetic oil ratio 2 50 1 Mineral oil ratio 3 32 1 Coolant1 GRO GCC 30 Long Time Brake fluid GRO Brake Fluid DOT 4 Coolant mixture at 30 DOT 4 Clutch fluid GRO Global Ultra 5 Mineral oil Transmission oil GRO Gear Trans 10W30 10W30 API SF...

Page 32: ...ars Gear ratio 1ª 2 07 29 14 2ª 1 63 26 16 3ª 1 33 24 18 4ª 1 10 22 20 5ª 0 91 21 23 6ª 0 79 19 24 Secondary transmission By chain Secondary ratio 3 85 50 13 Drive chain 5 8 x 1 4 with O Rings 112 links Clutch type Multi disc wet clutch Clutch trigger Hydraulic Lubrication Medium Oil Capacity 900cc Available rear sprockets 39 40 42 44 46 47 48 49 50 51 52 Available front sprockets 12 13 Type Perim...

Page 33: ...ight 105 kg Fuel tank capacity 9 5 l RECOMMENDED Fuel Unleaded RON 95 minimum Mixture fuel oil JASO FC GRO Off Road 1 100 synthetic oil ratio 2 50 1 Semisynthetic oil ratio 2 50 1 Mineral oil ratio 3 32 1 Coolant1 GRO GCC 30 Long Time Brake fluid GRO Brake Fluid DOT 4 Coolant mixture at 30 DOT 4 Clutch fluid GRO Global Ultra 5 Mineral oil Transmission oil GRO Gear Trans 10W30 10W30 API SF o SG For...

Page 34: ...Owner s manual 34 EC Racing EC Replica Factory electrical diagram ...

Page 35: ...Owner s manual 35 EC Racing CrossCountry XC Racing USA electrical diagram ...

Page 36: ...Owner s manual 36 EC Racing E START electrical diagram ...

Page 37: ...Owner s manual 37 EC Racing CrossCountry E START XC Racing E START USA electrical diagram ...

Page 38: ...s 10 M8 nuts and bolts 25 M10 nuts and bolts 45 CHASSIS 1 2 3 4 5 6 7 8 CHASSIS Nº Name Size Torque Nm 1 Steering nut M24 20 2 Rear shock bolt M10x50 45 3 Swingarm bolt M14 70 4 Brake disc bolt M6x15 12 5 Front axle bolt M20x15 50 6 Brake caliper bolt M8x30 30 7 Engine mount bolt M10x120 50 8 Rear sprocket bolt M8x25 30 ...

Page 39: ...ue Values 1 2 3 4 5 6 7 CHASSIS Nº Name Size Torque Nm 1 Subframe bolt M8x25 25 2 Brake banjo bolt 6 3 Upper clamp bolt M8x35 15 4 Spokes 1 5 5 Rear axle nut M20 80 6 Linkage bolt M14x115 80 7 Rear brake pedal bolt M8x45 20 ...

Page 40: ...nual 40 Torque Values ENGINE 1 2 3 4 5 ENGINE Nº Name Size Torque Nm 1 Valve cover bolt M6x15 8 2 Gearshift pedal bolt M6x20 15 3 Kick starter bolt M6x10 12 4 Kick starter bolt M6x20 10 5 Crankcase bolt M6x65 10 ...

Page 41: ...0 12 4 Reed block bolt M6x30 12 5 Spark plug 25 6 Engine drain plug 20 7 Clutch cover bolt M6x75 10 8 Water pump drain bolt M6x10 9 Starter pedal plate bolt 8 Ignition motor stator bolt 8 Ignition motor coil nut 40 Selector spring fixing bolt 15 Primary nut 40 Clutch spring bolt 10 Valve control support bolt 10 Valve control nut 8 Thermostat cover bolt 10 ...

Page 42: ... 42 E START Torque Values ENGINE 1 2 3 4 5 ENGINE Nº Name Size Torque Nm 1 Valve cover bolt M6x15 8 2 Gearshift pedal bolt M6x20 15 3 Kick starter bolt M6x10 12 4 Kick starter bolt M6x20 10 5 Crankcase bolt M6x65 10 ...

Page 43: ...M6x40 12 4 Reed block bolt M6x30 12 5 Spark plug 25 6 Engine drain plug 20 7 Clutch cover bolt M6x75 10 8 Water pump drain bolt M6x10 9 Starter pedal plate bolt 8 Ignition motor stator bolt 8 Ignition motor coil nut 40 Selector spring fixing bolt 15 Primary nut 40 Clutch spring bolt 10 Valve control support bolt 10 Valve control nut 8 Thermostat cover bolt 10 ...

Page 44: ...or is optional and is not available in GAS GAS WARNING The multifunction device is water resistant but not waterproof Do not wash with pressure washer Do not leave the device in direct sunlight when the motorcycle is stopped Avoid contact with gasoline degreasers or other cleaning chemical products that could be cause damages in the device Always remember to pay attention to the road when you re d...

Page 45: ...verage speed AS 4 299 9 km h or MPH km h or MPH 0 1 km h or MPH 0 1 Maximum speed MS 4 299 9 km h or MPH km h or MPH 0 1 km h or MPH 0 1 Distance DST 0 00 299999 KM or M km or M 0 1 km or M 0 1 Odometer ODO 0 00 299999 KM or M km or M 1 km or M 0 1 Stopwatch TT 0 9999 hours 59 minutes Hours Minutes 1 Minute 0 1 Ride time RT 0 9999 hours 59 minutes Hours Minutes 1 Minute 0 1 Accumulated ride time A...

Page 46: ...he distance and speed makes this measure as precise as possi ble See the Measure of the wheel circumference section for more information Change the blinking digit with the left button Change to next digit using the button To confirm press the button SET CLOCKFORMAT To switch between 12h and 24h format use the left button To confirm press the button SET TIME Change the blinking digit with the left ...

Page 47: ...on To confirm press the button SET MAINTENANCEREMINDER When programmed kilometers or miles are reacher the maintenance reminder icon will turn on Change the blinking digit with the left button Change to next digit using the button To confirm and go back to normal mode press the button NOTE the oil and maintenance reminders must be manually reset by entering them again in the configuration mode Mea...

Page 48: ... speed MS Odometer ODO Maximum engine temperature Accumulated ride time ART Clock Maximum voltage MAX V and minimum voltage MIN V Alternately displays min max voltage and avg max speed every 2 seconds NOTE Engine temperature and voltage sensor is optional and is not available in GAS GAS Sleep mode If the device is not used for 5 minutes is it will be automatically into sleep mode to save battery I...

Page 49: ...f type approval are identified with a determined and registered stamp Component list Amount moto Manufacturer identification plate 1 Catalyzed exhaust 1 Silencer 1 Carburetor jets 1 Front and rear turning lights 4 Plate holder 1 Speedometer 1 Electrical equipment homologated lights 1 Horn 1 Rear view mirror 2 Anti theft lock 1 Secondary air valve 1 Air filter restriction 1 Throttle opening limiter...

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Page 51: ...Owner s manual 51 OPERATINGINSTRUCTIONS ...

Page 52: ...re it will not be necessary to 2 pull the choke lever Break in procedure It is important to respect the break in procedure with this you will ensure the duration and correct function of your GAS GAS in the long term Intervals to res pect are as follows 1 From 0 to 200 Km Ride between 50 and 75 of load throttle opening alternatively without continued use of the 75 load 2 From 200 a 300 Km Ride equa...

Page 53: ...rive to the carburetor the motorcycle engine does not run this position is used only when the engine is stopped If you know that there is litt le fuel in the tank you must start the use with the tap in the RES position and go immediately to refuel If all is correct always be used the valve in the ON position NOTE Always close the fuel valve position OFF when you stop the engine 1 Is the engine oil...

Page 54: ... its lateral stand and the handlebar at the right side in this position take off the top tank cover with its rubber attention to the dirt is necessary to have a clean space where you leave the disassembled parts slowly turn the handlebar to the left to get the level of the fluid to be parallel to the upper edge of the tank The correct level is 6 8 mm from upper edge of the tank If you have any dou...

Page 55: ... motorcycle any change that you appreciate will make you immediately go to your GAS GAS official service Your GAS GAS official service will be happy to assist you and ensure your safety Does the side stand have a correct touch and function This is a part of motor cycles that often cause problems including safety problems Because it is a part of your motorcycle with have a severe work If you percei...

Page 56: ... official GAS GAS service this affects your safety Is the seat properly fixed This is a point of vital importance for your safety if you have some doubt about this fixation you must go to your GAS GAS official service Is there some element with risk to fly off when the motorcycle is running Fenders side covers fuel tank coveralls etc You can fix provisionally the parts or disassemble these parts i...

Page 57: ...e for your GAS GAS Cleaning To clean your GAS GAS follow these steps 1 Put a plug in the exhaust system to prevent water entry 2 Cover with a piece of duct tape the lock anti theft steering lock 3 Remove mud and dirt with a jet of water at low pressure 4 Clean especially soiled areas with a special cleaner for motorcycles 5 Rinse with a jet of water at low pressure 6 Allow the bike to drain natura...

Page 58: ...hain and all cables Spray oil on all unpainted metal surfaces to prevent oxidation avoid oil on the brakes and rubber parts Tie a plastic bag the exhaust pipe to prevent corrosion Place the motorcycle so that the wheels do not touch the ground if you can not put cardboard under the wheels Cover the motorcycle to keep dust and dirt To put into use after storage Remove the plastic bag from the exhau...

Page 59: ... 59 Owner s manual SERVICEAND MAINTENANCE ...

Page 60: ...tions 10 hours 40 hours 18 Brakes adjustment 20 hours When necessary 19 Brake wear 30 hours When necessary 20 Brake fluid Every 2 years 21 Brake fluid level 10 hours 20 hours When necessary 22 Pump piston and dust cover Every 2 years 23 Caliper piston and dust cover Every 2 years 24 Brake hoses Every 4 years 25 Front wheel and spokes 10 hours When necessary 26 Rear wheel and spokes 10 hours When n...

Page 61: ...le remove the end cable protector in the carburetor adjust with a tensor tighten lock nut 1 and reinstall protector 4 SPARKPLUG The standard spark plug Denso W24ESR U o NGK BR8EG must be tightened to 25 Nm The spark plug must be removed periodically to check electrodes gap 0 7 0 8 mm If the spark plug contains oil or cinder clean with a wire brush or similar Measure the electrodes gap with a gauge...

Page 62: ...REPLICA FACTORY AIR FILTER Removing the filter To access the air filter must remove the seat and the battery box 1 Loosen the screw of the seat 1 1 2 2 Remove the seat by pulling it back 2 3 Remove the filter fixing 3 3 4 4 Remove the air filter 4 ...

Page 63: ... Removing the filter To access the air filter must remove the seat and the battery box 1 Loosen the screw of the seat 1 1 2 2 Remove the seat by pulling it back 2 3 3 Leave it hanging from the left side 3 4 Remove the filter fixing 4 4 5 5 Remove the air filter 5 ...

Page 64: ...CING USA AIR FILTER Removing the filter To access the air filter must remove the seat and the battery box 1 Loosen the screw of the seat 1 1 2 2 Remove the seat by pulling it back 2 3 Remove the filter fixing 3 3 4 Remove the air filter 4 4 ...

Page 65: ...ER Removing the filter To access the air filter must remove the seat and the battery box 1 Loosen the screw of the seat 1 1 2 2 Remove the seat by pulling it back 2 3 Leave it hanging from the left side 3 3 4 Remove the filter fixing 4 4 5 5 Remove the air filter 5 ...

Page 66: ...re the sealing and prevent the entry of dirt DANGER A clogged air filter allows the entry of dirt into the engine causing excessive wear and damage Inspect by all means before and after each race or practice session Clean if 1 necessary Clean the filter in a ventilated area and make sure that no sparks or flames near the workplace includes a powerful light source Do not use gasoline to clean the f...

Page 67: ...is in poor condition Be sure to correct this before riding 7 TRANSMISSIONOIL PFor properly function of transmission and clutch maintain the optimum trans mission oil and change it periodically A bike with insufficient transmission oil damaged or polluted oil can accelerate wear and damages in transmission Checking the oil level 1 If the bike has been used wait a few minutes 2 Check the oil level t...

Page 68: ...ing the kick starter for 3 or 4 times 9 Screw the oil filling plug 8 PISTONAND RING For this check adjustment or change you must go to your GAS GAS official service 9 CYLINDERHEAD CYLINDER EX VALVE For this check adjustment or change you must go to your GAS GAS official service 3 1 2 10 EXHAUSTSYSTEM Exhaust and muffler reduces noise and lead gases away from the rider If the exhaust is damaged oxi...

Page 69: ...ce an increase in exhaust noise should proceed to change the Muffler fiber Muffler fiber change Once dismantled the silencer see Muffler change Remove the 4 bolts 1 1 Get out the muffler front end 1 2 Change the muffler fiber 2 by wrapping it in the inner tube 3 Insert the fiber around the exhaust pipe 3 in the rear of the silencer 4 Reassembly all parts 2 3 ...

Page 70: ...itors are used in the coolant essence If an anticorrosive coolants ir not used after some time the radiator will rust This will block the cooling tubes NOTE Initially from the factory a permanent type antifreeze is used It s green containing 30 of ethylene glycol and has a freezing point of 18 C DANGER The liquid chemicals are harmful to the human body Follow the manufacturer s instructions WARNIN...

Page 71: ... is cool Add if necessary DANGER To avoid burns do not remove the radiator cap or try to change the coolant when the engine is hot Wait until it cools DANGER Coolant on tires will make them slippery and can cause an accident Immedia tely clean up any coolant that might fall into the chassis engine or wheels Inspect the old coolant If you see white spots in the liquid means that the aluminum parts ...

Page 72: ... and damage your engine 2 1 18 BRAKESADJUSTMENT Front brake lever Adjust the brake lever 1 until you feel comfortable To adjust loosen the nut 2 After adjust tight it correctly Check the brake response is correct Rear brake pedal When the brake pedal 3 is in resting position you must have 10 mm of clea rance Check if the brake responds correctly and there is no friction DANGER If the brake lever o...

Page 73: ...n your brake discs Changing the front brake pads To change the front pads follow these steps 1 Loosen the pin 1 and remove it 2 Remove the pads 2 3 Put a paper around the brake fluid reservoir to prevent falls Open the co ver by loosening the screws 3 NOTE For better access is recommended 2 to loosen the screw 4 and turn the throttle assembly 4 Remove the cover 5 trying not to get brake fluid out ...

Page 74: ...eep the metal plate 4 and the fiber plate 5 if the new pads does not have them 5 Loosen the screws 6 and remove the lid of the brake fluid 6 Put a paper around the brake fluid reservoir to prevent falls 7 Retract the caliper piston taking care not to damage it 8 Place the pin and protector 9 Place the tank cover 10 Operate the brake pedal several times to get the right feeling 2 3 5 4 6 ...

Page 75: ...ect the DOT 4 specification it is important that the brake fluid is of the same brand but it must be of the same specification Do not use fluid from a container that is not sealed unopened of origin Never at all use brake fluid container or unsealed obviously already used brake fluid 1 21 BRAKEFLUID LEVEL The front 1 and rear 2 fluid reservoirs must be filled to at least half If neces sary refill ...

Page 76: ...entering If you are slightly offset can be corrected by tightening or loosening some spokes with the spoke wrench 3 If the rim is bent or curved must be replaced 2 NOTE A welded area on the rim may show an excessive offset Ignore when measuring the centering WARNING The wheels and spokes interventions require action by a specialist so we re commend that you to consult your GAS GAS official service...

Page 77: ... the bike on a stand or support The front fork must be fully extended 2 Remove the axle and the front wheel 3 Remove the handlebar by loosening the handlebar clamps 2 and remo ving the upper flanges 4 Release the hooks 3 of the front mask 5 Protect the multifunction gauge with a paper 6 Loosen the cap of the fork 4 7 Separate hydraulic rod from the cap 5 8 Remove the spring 6 Replace the spring an...

Page 78: ...d the correct operation thereof Reassemble the whole fork Recommended oil MARZOCCHI 48 MARZOCCHI EBH16 7 5WT Oil volume 320 ml 2 Recommended oil ÖHLINS RXF ÖHLINS 01312 Oil volume 300 ml 32 BOLTS NUTSAND FASTENERS Every day before riding the bike you should check that all bolts and nuts are tightened Also check that the other fasteners are in place and in good condition 33 GAS TUBE Given the obser...

Page 79: ...hat the steering is not too tight Squatting in front of the bike grasp the bottom of the front fork on axis push and pull the fork 1 If there is play the steering is too loose If you have to adjust the steering 1 Stabilize the bike with a stand or a support 1 2 Keep the front wheel off the ground 3 Remove the handlebar by loosening the handlebar clamps 2 and remo ving the upper flanges 4 Loosen th...

Page 80: ...ain lubrication It is necessary after driving on wet ground when the chain looks dry The chain is an o ring chain therefore a specific lubricant should be used for this type of chains Your GAS GAS official service will be pleasured to provide it 37 STEERINGBEARINGS For this check adjustment or change you must go to your GAS GAS official service 38 WHEEL BEARING For this check adjustment or change ...

Page 81: ... ground 3 Loosen the seat clamping screw 1 and remove it by pulling it back 4 Remove the silencer see Silencer change in point 10 2 3 5 Disengage the side covers of their hooves on the radiator 2 6 Disengage the side covers of their hooves on the fuel tank 3 7 Loosen the carburettor flange in filter air side 4 4 8 Loosen and put out two lower screws that fastening subframe in both sides 5 5 ...

Page 82: ...on between the connecting rod and shock 8 11 Loosen and remove the shock top mounting screw 9 7 12 Turn up the subframe rotating on his top anchor 13 To remove the shock from the frame move it toward the bottom in it s housing to then be able to rotate it and extract it through the frame rear 8 side 10 To reinstall the shock on the motorcycle follow the same steps in reverse order 9 10 ...

Page 83: ...ts too Usually when a chain is too used stretched more than 2 should be replaced 2 1 Usually it is the right time to change guide front and rear sprockets It is for practical reasons economic and security A chain in the limit of its life has partially worn teeth rear sprocket guide etc If you mount a new chain and other compo nents are not changed its life will be shortened by 40 and already deter...

Page 84: ...g it back slightly 2 Loosen the fixing screws of battery cover 2 and remove it 1 3 Loosen the battery terminals 3 and remove it Replace the battery by a new one and follow the steps in sequence inverse to 2 mount it DANGER Doesn t manipulate not tries to open the battery the electrolyte and the gases are toxic and can cause serious injuries Keep sparks flames and cigarettes away Provide adequate v...

Page 85: ... 85 Owner s manual SETTINGS ...

Page 86: ...B from to load Influenced primarily by the height of the slide B bezel A Zone C to load Responsible is the jet needle Zone D full load Responsible is the main jet IDLE JET AND MIXTURESCREW Controls the mixture from the closed position to of charge but has little effect on total openness To adjust the mixture the mixture screw can be rotated to change the air flow or change the idle jet so it lets ...

Page 87: ... of the clip is set counting from the top position MAIN JET Has a greater effect from 75 to 100 load The number stamped on the bottom of the jet 1 indicates the flow of fuel passing through the hole A higher number corresponds to a larger hole more fuel passes NOTE Never use jet gauge sets that are in the market Its use is incorrect Always use new jets without manipulating sealed in their bags DAN...

Page 88: ... Example 1000 m altitude and 35 C temperature the correction factor is 0 94 2 Using the correction factor select the main jet Example Factor 0 94 multiply the main jet size by this number Main jet 175 x 0 94 165 3 Find the correction factor for the needle and air screw on the table and change the clip position and air screw opening Example Raise clip 1 position and loosen 1 turn the mixture screw ...

Page 89: ... that the problem is elsewhere and therefore changing the carburetion would be a waste of time Set the carburetor until the engine responds satisfactorily with the throttle opening If mixture is too lean the engine tends to overheat On the other hand if too rich the spark plug easily gets wet causing failure The proper mixture varies according to atmospheric conditions pressure and temperature Thi...

Page 90: ...ienced riders 1 2 Secondary transmissionratio The secondary transmission ratio can be modified by changing the front and or rear sprockets Available GAS GAS sprockets are as follows Rear 39 40 42 44 46 47 48 49 50 51 52 teeth Front 12 13 teeth If you shorten the ratio your GAS GAS will lose top speed but will gain in acce leration and low speeds will be more manageable in difficult terrain NOTE At...

Page 91: ...t the top of the fork Air purge 7 left screw located at the top of the fork Spring Preload not externally adjustable Oil Volume 300 ml Öhlins 01312 7 6 8 5 WARNING The screw on the right side 8 of the compression adjustment should not be unscrewed It isn t an adjustment The oil level can be adjusted A change in oil level does not affect the first part of fork travel but it will affect at the final...

Page 92: ...e bottom of the shock Low speed compression 5 total 24 clicks located at the top right of the 6 5 shock High speed compression 6 3 positions located at the top left of the shock Standard spring preload 7 260 mm adjustable between 255 mm and 265 mm between planes of support K spring 52N m ideal pilot weight 75 85 kg To adjust the preload measure the distance between support surfaces mounted on the ...

Page 93: ...the compression damping or replace the spring for one more stiffer on the fork Stiffen the compression and especially the rebound of the rear shock it can also help to reduce the spring preload Muddy terrain Stiffen the compression damping or replace the spring for one more stiffer on the fork Stiffen the compression and rebound in the rear shock it can also help to increase the spring preload SET...

Page 94: ...performance on the motorcycle Check the suspension according to the driver and terrain conditions When tuning the suspension do not forget If the bike is new get used to the suspension for at least an hour of riding before making any changes Factors to consider are the rider s weight ability of the rider and terrain conditions If you have problems try changing your position on the bike to reduce i...

Page 95: ... top 5 Retighten the screws to the frame using threadlocker 3 6 While holding the footpeg 7 Place the spring 6 within the window and align with the hole to insert the bolt 2 requires some pressure in the footpeg 7 Place the washer 5 and insert the cotter pin 4 then open the ends 4 5 6 7 Position 2 Height 12mm 1 2 3 1 Release the cotter pin 4 and remove the washer 5 in order to remove the bolt 2 2 ...

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Page 97: ... 97 Owner s manual TROUBLESHOOTING ...

Page 98: ...spark plug then put a gear and push the bike several feet with the throttle fully open Visually you will know when the pre compression pan is empty Mount the spark plug and start the bike You may have to remove the spark plug again if the operation was not enough the spark plug will get wet and must be cleaned Repeat the pushing mount the spark plug and the engine will start DANGER For your safety...

Page 99: ...eplace the spark plug with a new one of the co rrect type Deteriorated exhaust gaskets Verify the the exhaust gaskets All gaskets must be in perfect condition otherwise replace them with new ones White smoke coming out from the exhaust Deteriorated cylinder head gasket water leaka ge into cylinder Go to your GAS GAS official service Black smoke coming out from the exhaust Restricted air filter Rep...

Page 100: ...in tension Worn chain Replace chain front and rear sprockets Worn rear sprocket teeth Replace rear sprocket Insufficient chain lubrication Lubricate with appropiate chain oil Incorrect rear wheel alignment Verify wheel spokes tension Adjust if necessary Weak or broken front fork spring Replace front fork spring Worn brake disc Replace brake disc Incorrectly installed brake pads o surface glazed Re...

Page 101: ...fficial service Deteriorated brake fluid Go to your GAS GAS official service Broken pump piston Go to your GAS GAS official service Worn brake pads Verify and replace brake pads Blown light bulbs Faulty voltage regulator Go to your GAS GAS official service Lighting system does not operate Lighting relay is blown Remove mask and check the relay ...

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Page 103: ... 103 Owner s manual WARRANTYMANUAL ...

Page 104: ...ended 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 Obligation of the purchaser GG will have the right to reject any claims under Warranty in the event that a The purchaser has failed ...

Page 105: ...garding 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 char ge are excluded from the...

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GAS GAS 2009 EC 200 2T, Owner'S Manual

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