GAS GAS EC250-4T 2010 User Manual Download Page 63

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- Chassis twisted.

- Steering incorrectly adjusted.

- Steering shaft bent.

- Front forks twisted.

- Rear wheel misaligned.

- Disk worn.

- Loss of brake fluid.

- Brake fluid deteriorated.

- Piston cylinder broken.

- Brakes incorrectly adjusted.

- Voltage regulator faulty.

- The light cable connector is destroyed

or disconnected

FAULT

CAUSE

SOLUTION

Motorcycle pulls to one side

The brakes do not function

correctly

The lights blow

The lighting system does not

work

- Change the chassis. Go to a specialist workshop.

- Adjust the steering. Go to a specialist workshop.

- Change steering shaft. Go to a specialist workshop.

- Change front fork.

- Align the wheels.

- Change disk.

- Check the brake circuits. Change those that are damaged

or broken.

- Drain the brake fluid and put a new product, recommended

by the maker.

- Replace the piston cylinder.

- Adjust the brakes.

- -Remove the seat and the fuel tank and check the

connectors and the regulator.

- Remove the back light cover.

Summary of Contents for EC250-4T 2010

Page 1: ...EC250 4T 10 EC250 4T 10 EC250 4T 10...

Page 2: ......

Page 3: ...any years of competition and experimentation in these demanding disciplines many great trial riders have contributed their expertise and achievements to the essential data we have used to create these...

Page 4: ...ult in personal injury or even death CAUTION This title identifies special instructions or procedures that if not strictly observed could result in damage to or destruction of equipment NOTE This titl...

Page 5: ...Maintenance chart 15 Battery 16 Cooling system 17 Spark plug 20 Air filter 23 Accelerator cable 24 Clutch 25 Exhaust system 25 Chain guide 26 Tension adjustment 27 Handle bars 29 Brakes 29 Steering 31...

Page 6: ...ulic command Secondary transmission Chain Gear ratio 1st 2 385 31 13 2nd 1 750 28 16 3rd 1 333 28 21 4th 1 042 25 24 5th 0 815 22 27 Primary reduction ratio 3 353 57 17 Final reduction ratio 3 846 50...

Page 7: ...level 100 mm compressed without spring 120 mm compressed without spring BRAKES Type Front rear Disk brakes pump and simple double callipers Effective disk diameter Front 260 mm Rear 220 mm DIMENSIONS...

Page 8: ...8 1 Clutch handle 2 Engine start button 3 Fuel tank cap 4 Front brake fluid tank 5 Front brake handle 6 Throttle control LOCATION OF COMPONENTS GAS GAS EC250 4T 1 3 4 2 6 5...

Page 9: ...Front brake callipers 14 Rear brake fluid tank 15 Shift pedal 16 Rear shock absorber 17 Chain guide 18 Chain 19 Silencer 20 Rear shock absorber gas tank 21 Tie rod and rocker suspension 22 Rear brake...

Page 10: ...el cap rotate it in a clockwise direction SIDE STAND To unfold the side stand A the securing strap must be released B then the stand is opened to vertical position The stand returns to its original po...

Page 11: ...RECOMMENDED FUEL Use lead free petrol with an octane rating equal to or higher than that shown in the table OCTANE RATING METHOD OCTANE RATING MIN Antiknock Index RON MON 2 90 Research Octane No RON 9...

Page 12: ...its are closed NOTE Start the engine soon after making contact with the ON button A or the battery may lose its change 12 STARTING THE ENGINE Ensure that the motorcycle is in neutral Press button A to...

Page 13: ...t of gear and lead to engine damage B Shift pedal 13 COLD STARTING To do the cold start pull the starter There is no need to use the throttle simply start the engine Note that the engine will start af...

Page 14: ...hese steps 1 Start the engine and let it run at idle until the engine is thoroughly warmed up 2 Stop and let the engine cool completely 3 Start the engine and ride for 10 minutes at moderate speed NEV...

Page 15: ...I I I T Inspect each time that the motorcycle has run or when necessary Revise every 4 years Revise every 2 years Clean lubricate and inspect each time the motorcycle has run Revise every 4 years Revi...

Page 16: ...p the area ventilated and free from naked flames The operating instructions for the battery are as follows 1 Check the battery tension in open circuit status disconnected 2 In case the battery s tensi...

Page 17: ...ater CAUTION Using a high pressure water source could damage the radiator fins and render it ineffective Do not obstruct or deviate the radiator air intake by installing non approved accessories Inter...

Page 18: ...rotect the cooling system against freezing Use a permanent type of anti freeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminium engines and radiators in the coo...

Page 19: ...the tyres this will make them slippery and could result in an accident 19 NOTE Check the level when the engine is cold 1 Coolant level 2 Filler opening If the coolant level is low add the correct amou...

Page 20: ...0 8 mm The spark plug should be taken out periodically to check the electrode gap If the plug is oily or has carbon build up on it the clean it with a sand blaster Following abrasive particle cleanin...

Page 21: ...correctly fitted spark plug or an incorrect temperature can lead to severe damage to the engine and this damage is not covered by the warranty Always use the manufacturer s recommended brand of spark...

Page 22: ...8 mm 0 028 0 031 in Before removing the carbon deposits check its colour this colour tells us whether the standard plug is the best for our use WARNING Becareful to the fuel loss when you remove the...

Page 23: ...fter each race or session Clean if necessary Cleaning the air filter WARNING Clean the filter in a well ventilated zone and ensure that there are no sources of naked flame or sparks near the work area...

Page 24: ...hrottle grip D Brake fluid reservoir NOTES Before the cable adjustment you must adjust the idle WARNING After the adjustment start the engine and turn the handlebar left and right at the maximum to ch...

Page 25: ...e exhaust flange A Silencer B Silencer attachment bolts 25 CLUTCH Proper clutch lever play is 2 3 mm Play increases with the clutch wear and thus requires adjustment When there is too much play first...

Page 26: ...ak WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Checking tension...

Page 27: ...ed using the straightedge or string method WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Tighten the chain adjustment nuts Tighten the axl...

Page 28: ...n excessively or damaged replace it Chain guide slide Visually inspect the upper and lower part of the chain slider on the swing arm If this is worn then replace it A Chain guide slide B Rocker arm Pi...

Page 29: ...bars to desired position A Apply oil A A Tighten the bolts securely first the forward bolts then the rear to a torque of 25 Nm If the handlebar is correctly installed there will be a minimal gap at t...

Page 30: ...d also be changed if it is contaminated by water or dirt 30 Front brake lever Adjust brake lever to a comfortable position To adjust loosen the nut under the rubber protection B Tighten after adjustme...

Page 31: ...time Check for fluid leakage around the fittings Check for brake line damage WARNING Do not mix brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled...

Page 32: ...protector Remove the handlebar by loosening the handlebar clamp bolts A Loosen the steering stem bolt B Loosen the bolts for the upper suspension plate and remove it C Rotate the steering adjustment b...

Page 33: ...ions The adjustments are done in 5 stages Adjust the compression and the rebond The range of both is 22 clicks If you close 0clicks the hyfraulic become very hard The standart adjustmenst is 16 clicks...

Page 34: ...motorcycle upright Take out the handlebar bolts and take out the handlebars Remove the suspension caps from the rods Slowly compress the front forks all the way Lift the fork springs Holding the suspe...

Page 35: ...t all removed parts 1 Spring 2 Counter nut 3 Suspension cap 4 Cap spanner 5 Counter nut spanner Suspension rod spring Different springs can be used depending on the weight of the driver and the track...

Page 36: ...h an optional one Also the dampening force can be adjusted easily so changing oil viscosity is unnecessary Extension adjustment To adjust this rotate the screw on the rear of the shock until noting a...

Page 37: ...tandard rear spring is k 5 2 Tighten the counter nut correctly Following the adjustment move the spring up and down to ensure that this is correctly in place Refit all removed parts Rear shock absorbe...

Page 38: ...ber body may cause the spring and associated parts to be ejected at high velocity Always wear eye and face protection Removal and installation of spring should be performed by an official distributor...

Page 39: ...cylinders and callipers under the fuel tank If water gets into the ignition coil or into the spark plug cap the spark will jump through the water and be grounded out the affected parts must be dried F...

Page 40: ...lts 8 Spokes 9 Disk plate screws 18 Rear axle bolt 19 Silencer support bolts 20 Sub chassis bolts 21 Rear shock bolts 22 Exhaust flange bolt 23 Upper suspension plate bolts 24 Steering head nut 25 Bra...

Page 41: ...p cover drain plug Calliper mounting bolts Disc plate mounting screws Engine mounting bolts Front axle bolt Front brake lever support bolt Fork flange bolt Steering nut Rear axle nut Rear brake pedal...

Page 42: ...a high pressure spray washer Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime General lubrication Clutch lever A Front brake lever B...

Page 43: ...eep the engine in perfect shape After 5 hours of running of a new bike remove and change the oil and the oil filter After that you must change the oil every 10 hours or 500 kms NOTE The engine oil exp...

Page 44: ...is given that this could provoke irritations and in the worst cases skin cancer Keep new or used oil away from the reach of children and animals Clean clothes sleeves and pants Wash yourself with soap...

Page 45: ...his pression control screw After 1 min if the oil is not coming stop the engine Check if the oil tub or the oil pump are not block and check the etancheity After the solving problem check again the oi...

Page 46: ...ing before making any setting evaluations or changes The major factors which must be considered in suspension tuning are rider weight rider skill and the track conditions as well as the rider s style...

Page 47: ...o hard Oil too dense Fork oil degraded Too soft The front forks dive excessively during braking and deceleration 1 Front fork oil level low 2 The springs are too soft 3 Oil too light 4 Fork oil degrad...

Page 48: ...and place one foot on the brake firmly If the bike maintains its level attitude as the suspension is compressed the suspensions are well balanced Sit astride the bike and take up a riding posture the...

Page 49: ...of the suspension rear shock Bottoms at low speed Increase spring preload to maximum Bottom after successive 3 or 4 successive jumps NOTE The rear shock on this machine due to its adjustment possibili...

Page 50: ...n in other conditions as the chain and sprockets will pack with mud sand and reduce chain slack 4 Check chain and pinion sprocket wear frequently when riding in mud or sand since wear is increase d in...

Page 51: ...th fuel Check all the points listed in the Daily Pre ride Inspection Section General lubrication Connect the battery 2 Following a day of competition 1 Clean the air filter and change the oil filter a...

Page 52: ...maximum speed length of time with motor running and total time The odometer and the control for the total time with motor running save the data to the memory even when the device is switched off When...

Page 53: ...CURRENT SPEED SPD 4 399 9 kmph or mph 0 1 kmph or mph 0 1 MAXIMUM SPEED MS 4 399 9 kmph or mph 0 1 kmph or mph 0 1 DISTANCE TRAVELLED DST 0 0 19999 km or mi 0 1 kmph or mph 0 1 TIME RUNNING TT 0 9999...

Page 54: ...last RESET operation ODO Odometer It shows the total mileage accumulated by the vehicle The data is stored in the memory even when the device is not running ART Time of use controller Calculates the...

Page 55: ...nds and then release Selecting the values for the wheel circumference Enter the value for the wheel circumference by pressing button 1 in succession To go on to the next digit press button 3 Confirm b...

Page 56: ...pm Confirm the reset by pressing buttons 1 and 2 simultaneously Total reset of the display Press the RESET button using a suitable object The display will start from zero except for the data for total...

Page 57: ...for 3 seconds when the button is pressed If the lighting is connected to the 12V system on the vehicle it will be brighter and stay on for up to 20 minutes after the vehicle has come to a full halt S...

Page 58: ...the fuel tub remove the fuel tap to clean it and reassemble it correctly remove the old fuel and change it the engine would start imediately Dry the spark plug or change it If the engine is drowned yo...

Page 59: ...Valve set too small Decompression maladjusted Piston cylinder ring diameter tolerance excessive 3 4 5 6 7 8 Clean the connectors and use a electric contact spray Clean the venting tub from the fuel t...

Page 60: ...be in perfect condition if not then they must be changed for new ones Change the cylinder head gasket Go to a specialist workshop Clean or change the air filter Go to a specialist workshop Go to a sp...

Page 61: ...hock absorption too hard Replace the down selector mechanism spring Replace the gear drum Replace the ratchet spring of the selector Change gear fork Change Go to a specialist workshop Change Go to a...

Page 62: ...cket loose steering shaft bolt loose Adjust the rear shock Add oil to the forks as required Empty the fork oil and fill with oil of the recommended viscosity Change front fork Go to a specialist works...

Page 63: ...e brakes do not function correctly The lights blow The lighting system does not work Change the chassis Go to a specialist workshop Adjust the steering Go to a specialist workshop Change steering shaf...

Page 64: ...s 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 Direc...

Page 65: ...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 t...

Page 66: ...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 rend...

Page 67: ......

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GAS GAS EC250-4T 2010, User Manual

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