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GAS GAS EC250 2012, Owner'S Manual

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Owner’s manual

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Contents

CARBURETION TUNNING ................................................................................................................................................................62

Thro

tt

 le valve opening in

fl

 uences .......................................................................................................................................62

Idle jet and mixture screw ..................................................................................................................................................62

Needle ................................................................................................................................................................................63

Main jet ..............................................................................................................................................................................63

Reference carbure

ti

 on (compe

ti

 

ti

 on use only) ....................................................................................................................63

correc

ti

 on Factors ...............................................................................................................................................................64

Symptoms of improper se

tti

  ngs ..........................................................................................................................................65

CDI MAP ..........................................................................................................................................................................................66

SECONDARY TRANSMISSION RATIO.................................................................................................................................................66

SUSPENSION TUNNING ...................................................................................................................................................................67

available Se

tti

  ngs ................................................................................................................................................................67

Standard se

tti

  ngs ................................................................................................................................................................68

Sta

ti

 c sag .............................................................................................................................................................................68

Correc

ti

 on acording to terrains ...........................................................................................................................................68

Adjus

ti

 ng your bike .............................................................................................................................................................68

TROUBLESHOOTING ....................................................................................................................................................................... 71

WARRANTY MANUAL ..................................................................................................................................................................... 77

Summary of Contents for EC250 2012

Page 1: ......

Page 2: ...rights reserved The reproduction distribution public communication and transformation totally or partially is prohibited without the express authorization of the copyright owner Manual made by Automot...

Page 3: ...eset and change of battery 23 Specifications 23 Temporal data reset 23 Trip adjust 23 Configuration 24 Enter configuration mode 24 Set Speed units 24 set wheel size 24 Set clock format 24 set time 24...

Page 4: ...r hose and connections 47 18 Brakes adjustment 47 19 Brake wear 48 20 Brake fluid 50 21 Brake fluid level 50 22 Pump piston and dust cover front and rear 50 23 Caliper piston and dust cover all calipe...

Page 5: ...in jet 63 Reference carburetion competition use only 63 correction Factors 64 Symptoms of improper settings 65 CDI MAP 66 SECONDARY TRANSMISSION RATIO 66 SUSPENSION TUNNING 67 available Settings 67 St...

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

Page 7: ...Owner s manual 7 GENERAL INFORMATION...

Page 8: ...te 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 tru...

Page 9: ...ion for maintaining the warranty Your GAS GAS has been designed for o road use not designed for long travel on highways Such use could lead to engine damages be cause it maintained high revolutions Al...

Page 10: ...ont turn signals 12 CDI switch 3 Fuel tank 13 Electric Starter 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 Re...

Page 11: ...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...

Page 12: ...ignals lights horn and engine stop controls2 5 Fuel tank cap 10 Steering lock 1 Not available on CrossCountry models 2 The CrossCountry models have an independent lights on o and engine stop switches...

Page 13: ...stamped in the right side of the steering column 2 1 2 Your GAS GAS has a steering lock It s found on the left side of the steering column To lock the steering 1 Turn the handlebar fully to the right...

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

Page 15: ...oil ratio 2 50 1 Semisynthetic oil ratio 2 50 1 Mineral oil ratio 3 32 1 Coolant1 GRO GCC 30 Long Time Coolant mixture at 30 Brake fluid GRO Brake Fluid DOT 4 DOT 4 Clutch fluid GRO Global Ultra 5 Mi...

Page 16: ...Owner s manual 16 EC models electrical diagram...

Page 17: ...Owner s manual 17 CrossCountry models electrical diagram...

Page 18: ...rm 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 GENERAL Size Torque Nm M4 nuts and bolt...

Page 19: ...ue Values 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 brake pedal bolt...

Page 20: ...nual 20 Torque Values 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 bolt M6x65 10 ENGINE...

Page 21: ...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 Sel...

Page 22: ...waterproof 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 devic...

Page 23: ...verage speed AS 4 399 9 km h or MPH km h or MPH 0 1 km h or MPH 0 1 Maximum speed MS 4 399 9 km h or MPH km h or MPH 0 1 km h or MPH 0 1 Distance DST 0 00 9999 99 KM or M km or M 0 1 km or M 0 1 Odome...

Page 24: ...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 dig...

Page 25: ...L REMINDER When programmed kilometers or miles are reacher the oil change reminder icon will turn on Change the blinking digit with the left button Change to next digit using the button To confirm pre...

Page 26: ...main at the motorcycle during this process Screens in normal mode SCREEN 1 The following information is displayed Actual speed SPD Distance DST Engine temperature Ride time RT Clock SCREEN 2 The follo...

Page 27: ...not used for 5 minutes is it will be automatically into sleep mode to save battery In this mode it will only show the clock on the display The device will automatically exit this mode when it receives...

Page 28: ...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 Pl...

Page 29: ...Owner s manual 29 OPERATING INSTRUCTIONS...

Page 30: ...00 Km increase demand with progressivity for about 60 80 Km to reach its full performance DANGER An imprudent acceleration can cause engine problems Be careful to use the skills and techniques necessa...

Page 31: ...fuel can t arrive 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...

Page 32: ...s lateral stand and the handlebar at the right side in this position take o the top tank cover with its rubber attention to the dirt is necessary to have a clean space where you leave the disassembled...

Page 33: ...ur motorcycle any change that you appreciate will make you immediately go to your GAS GAS o cial service Your GAS GAS o cial service will be happy to assist you and ensure your safety Does the side st...

Page 34: ...tor you must go to your o cial GAS GAS service this a ects 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 mus...

Page 35: ...Daily inspection 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 Remov...

Page 36: ...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 tou...

Page 37: ...Owner s manual 37 SERVICE AND MAINTENANCE...

Page 38: ...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 s...

Page 39: ...ove the end cable protector in the carburetor adjust with a tensor tighten lock nut and reinstall protector 2 1 1 3 2 4 SPARK PLUG The standard spark plug Denso W24ESR U o NGK BR8EG must be tightened...

Page 40: ...by pulling it back 3 Loosen the 4 fixing screws of the battery box 2 4 Remove the battery box 3 DANGER Do not remove the battery box from the motorcycle under any circumstances It is a structural par...

Page 41: ...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 42: ...Be sure to correct this before riding 1 2 7 TRANSMISSION OIL PFor properly function of transmission and clutch maintain the optimum trans mission oil and change it periodically A bike with insu cient...

Page 43: ...g the kick starter for 3 or 4 times 9 Screw the oil filling plug Maintenance 8 PISTON AND RING For this check adjustment or change you must go to your GAS GAS o cial service 9 CYLINDER HEAD CYLINDER E...

Page 44: ...rease in exhaust noise should proceed to change the Mu er fiber Mu er fiber change Once dismantled the silencer see Mu er change Remove the 4 bolts 1 1 Get out the mu er front end 2 Change the mu er f...

Page 45: ...ors 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 a...

Page 46: ...ecessary 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 a...

Page 47: ...d damage your engine 18 BRAKES ADJUSTMENT 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 c...

Page 48: ...cs 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 t...

Page 49: ...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...

Page 50: ...not mix di erent types of brake fluid The liquid used to fill or renew your cir cuit must meet the standard specified in the fluid reservoir each circuit Therefore in the rear brake must use DOT 4 No...

Page 51: ...ore 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 o cial service 27 CHAIN GUIDE Lubricate th...

Page 52: ...e on a stand or support The front fork must be fully extended 5 Remove the axle and the front wheel 6 Remove the handlebar by loosening the handlebar clamps 2 and remo ving the upper flanges 7 Release...

Page 53: ...d oil FUCHS TITAN 1091 SAF Capacity 612 cc 1 32 BOLTS NUTS AND FASTENERS Every day before riding the bike you should check that all bolts and nuts are tightened Also check that the other fasteners are...

Page 54: ...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 th...

Page 55: ...rication 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 o cial ser...

Page 56: ...oint 10 5 Disengage the side covers of their hooves on the radiator 2 6 Loosen the screw of the fuel tank 3 and the side fairings screws 4 DANGER Check that the fuel tap is closed and the gas tube is...

Page 57: ...ss to and remove the screw connection between the connecting rod and shock 9 13 Loosen and remove the shock top mounting screw 10 14 To remove the shock from the frame move it toward the bottom in it...

Page 58: ...y when a chain is too used stretched more than 2 should be replaced Usually it is the right time to change guide front and rear sprockets It is for practical reasons economic and security A chain in t...

Page 59: ...throwing of him backwards 2 Loosen the srews of subjection of the cover of battery 2 and remove it 3 Loosen the screws of the battery and remove it Replace the battery by a new one and follow the step...

Page 60: ...Owner s manual 60 This page is intentionally left blank...

Page 61: ...Owner s manual 61 ADJUSTMENTS...

Page 62: ...ure screw must rotate from a position of fully closed Make changes by half turn increments If turning the screw 1 to 2 5 turns do not get the desired result change a step in the idle jet 1 and tune th...

Page 63: ...ing NEEDLE The needle and the main jet together have an e ect ranging from 25 to 75 load The needle moves into the main jet when the needle narrows changes from cylindrical 1 to conical 2 its position...

Page 64: ...pening Example Raise clip 1 position and loosen 1 turn the mixture screw WARNING To make corrections always take as reference the competition carburetion Do not make changes if you are not sure that t...

Page 65: ...hat 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 lea...

Page 66: ...enced riders 1 2 Secondary transmission ratio 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 4...

Page 67: ...is harder at the end of the fork travel When you decrease the oil level the suspension is less progressive and fork action is softer at the end of the fork travel If the fork is bottoming increasing...

Page 68: ...round not supported on the side stand 4 Re measure the vertical distance between the rear axle nut and bolt clam ping the mu er If the di erence between the measures is di erent from 35 mm vary the sp...

Page 69: ...ll 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...

Page 70: ...Owner s manual 70 This page is intentionally left blank...

Page 71: ...Owner s manual 71 TROUBLESHOOTING...

Page 72: ...ve the 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 m...

Page 73: ...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...

Page 74: ...chain Replace chain front and rear sprockets Worn rear sprocket teeth Replace rear sprocket Insu cient chain lubrication Lubricate with appropiate chain oil Incorrect rear wheel alignment Verify wheel...

Page 75: ...Deteriorated brake fluid Go to your GAS GAS o cial service Broken pump piston Go to your GAS GAS o cial service Worn brake pads Verify and replace brake pads Blown light bulbs Faulty voltage regulato...

Page 76: ...Owner s manual 76 This page is intentionally left blank...

Page 77: ...Owner s manual 77 WARRANTY MANUAL...

Page 78: ...ded such that the last day of the period covered will be the first working day after the Sunday or o cial holiday Those claims under Warranty for defects not brought to the attention of a GG authorise...

Page 79: ...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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