GAS GAS EC 2T 20012501300cc RACING Page 65 Owner'S Manual Download

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Owner’s manual

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Maintenance

5.4- “XC RACING E-START (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).

2. Remove the seat by pulling it back (2).

3. Leave it hanging from the left side (3).

4. Remove the filter fixing (4).

5. Remove the air filter (5).

Summary of Contents for EC 2T 20012501300cc RACING

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 not...

Page 3: ...cc 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...

Page 4: ...lter 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...

Page 5: ...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 carburet...

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

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

Page 8: ...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...

Page 9: ...ion 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...

Page 10: ...ame 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 Carbureto...

Page 11: ...4 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...

Page 12: ...tion 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...

Page 13: ...ame 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 link...

Page 14: ...ith 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 1...

Page 15: ...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 start...

Page 16: ...ition 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 1...

Page 17: ...er 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 sta...

Page 18: ...2 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 f...

Page 19: ...er 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 identifi...

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 C...

Page 21: ...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 i...

Page 22: ...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...

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 mode...

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 O...

Page 25: ...ight 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...

Page 26: ...io 2 85 57 20 Gearbox 6 gears Gear ratio 1 2 07 29 14 2 1 63 26 16 3 1 33 24 18 4 1 10 22 20 5 0 91 21 23 6 0 79 19 24 Secondary transmission By chain Secondary ratio 3 67 44 12 3 69 48 13 Drive chain...

Page 27: ...eight 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...

Page 28: ...20 Gearbox 6 gears Gear ratio 1 2 07 29 14 2 1 63 26 16 3 1 33 24 18 4 1 10 22 20 5 0 91 21 23 6 0 79 19 24 Secondary transmission By chain Secondary ratio 3 69 48 13 Drive chain 5 8 x 1 4 with O Ring...

Page 29: ...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 Semi...

Page 30: ...7 20 Gearbox 6 gears Gear ratio 1 2 07 29 14 2 1 63 26 16 3 1 33 24 18 4 1 10 22 20 5 0 91 21 23 6 0 79 19 24 Secondary transmission By chain Secondary ratio 4 17 50 12 3 85 50 13 Drive chain 5 8 x 1...

Page 31: ...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 r...

Page 32: ...6 gears Gear ratio 1 2 07 29 14 2 1 63 26 16 3 1 33 24 18 4 1 10 22 20 5 0 91 21 23 6 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...

Page 33: ...ht 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...

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: ...10 M8 nuts and bolts 25 M10 nuts and bolts 45 CHASSIS 1 2 3 4 5 6 7 8 CHASSIS N 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...

Page 39: ...ue Values 1 2 3 4 5 6 7 CHASSIS N 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 bra...

Page 40: ...nual 40 Torque Values ENGINE 1 2 3 4 5 ENGINE N 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 bol...

Page 41: ...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...

Page 42: ...42 E START Torque Values ENGINE 1 2 3 4 5 ENGINE N 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...

Page 43: ...x40 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 m...

Page 44: ...r 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 th...

Page 45: ...erage 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 Odomete...

Page 46: ...e 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 di...

Page 47: ...n 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 t...

Page 48: ...peed 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 N...

Page 49: ...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 turn...

Page 50: ...Owner s manual 50 This page is intentionally left blank...

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

Page 52: ...e 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...

Page 53: ...ive 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...

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 disassem...

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 s...

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...

Page 57: ...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 Remo...

Page 58: ...ain 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...

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

Page 60: ...ions 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 pis...

Page 61: ...e 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 2...

Page 62: ...EPLICA 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...

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 sid...

Page 64: ...ING 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...

Page 65: ...R 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 sid...

Page 66: ...e 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 pr...

Page 67: ...s 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 w...

Page 68: ...ng 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...

Page 69: ...e 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...

Page 70: ...tors 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...

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 an...

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...

Page 73: ...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 preve...

Page 74: ...ep 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 fall...

Page 75: ...ct 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 Ne...

Page 76: ...ntering 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 sho...

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...

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 HLINS RXF HLINS 01312 Oil volume 300 ml 32 BOLTS NUTSAN...

Page 79: ...at 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...

Page 80: ...in 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 offi...

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 Dis...

Page 82: ...n 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 t...

Page 83: ...s 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 secur...

Page 84: ...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...

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

Page 86: ...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...

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...

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...

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 le...

Page 90: ...enced 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...

Page 91: ...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 hlins 01312 7 6 8 5 WARNING The screw on the right side 8 of the c...

Page 92: ...ottom 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...

Page 93: ...he 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 t...

Page 94: ...erformance 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...

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 t...

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

Page 98: ...park 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...

Page 99: ...place 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...

Page 100: ...n 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 align...

Page 101: ...ficial 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 Fault...

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

Page 104: ...nded 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 author...

Page 105: ...arding 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...

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