GAS GAS SM 2008 User Manual Download | Manualshive

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Torque Values Table

Tighten all bolts and nuts to the proper torque using an adequate wrench. A bolt or nut loose might damage the motorcycle or even cause an
accident.

F

R
A
M
E

PART NAME

Brake caliper mounting bolt
Disc mounting screw
Engine mounting bolt
Front axle bolt
Front brake hose mounting bolt
Suspension clamp bolt
Steering nut
Rear axle nut
Rear brake pedal bolt
Subframe bracket bolt
Rear shock absorber bolt
Rear drive plate nut
Spokes
Steering stem nut
Torque rod bolt
Rear linkage bolt

Nm

25
10
36
51

6

29
98
98

9

26
39
29

1.5

4

81
81

E
N

G

I

N
E

PART NAME

Cylinder head screws
Cylinder nut
Engine drain plug
Kick-start pedal bolt
Kick-start pedal nut
Gearshift pedal bolt
Spark plug
Water pump cover drain plug
Crankcase screws
Starter pedal plate screw
Ignition motor stator screws
Ignition motor coil nut
Selector spring fixing screw
Primary nut
Clutch spring screws
Valve control support screws
Valve control nuts
Reed valve screws
Thermostat housing screws
Clutch housing screws
Valve housing screws
Ignition housing screws

Nm

25
25
20
20
25
15
27

9

10

8
8

40
15
40
10
10

8

10
10
10

8

10

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Summary of Contents for SM 2008

Page 1: ...MANUAL DEL USUARIO USER MANUAL MANUEL D ENTRETIEN LIBRETTO D USO BETRIEBSANLEITUNG enducross EC 08 enducross EC 08 enducross EC 08 ...

Page 2: ......

Page 3: ...ENGLISH USER MANUAL USER MANUAL enducross EC 08 enducross EC 08 enducross EC 08 ...

Page 4: ......

Page 5: ...entation in this demanding discipline as well as the many great successes achieved thanks to great trial riders who have contributed with their expertise to the basic data that have allowed us to create motorcycles of the highest level GAS GAS unique motorcycles which count on important key factors reliability high features and a good stability Congratulations for making the right choice With your...

Page 6: ...onal injury or even death CAUTION This symbol identifies instructions or procedures which if not followed strictly could result in damage to or destruction of equipment NOTE This note symbol indicates points of particular interest for more efficient and convenient operation Motorcycle riding if improverly conducted has the potential to cause environmental problems as well as conflicts with other p...

Page 7: ...nition 19 Cooling System 19 Spark Plug 20 Transmission 22 Air Cleaner 24 Throttle Cable 25 Carburetor 25 Clutch 26 Exhaust System 26 Drive Chain Guide 27 Handlebar 29 Brakes 30 Steering 31 Steering blockage 32 Front Fork 33 Rear suspension 36 Wheels 38 Cleaning 39 Bolts and nuts tightening 40 Lubrication 42 Tunning Carburetor and Suspension 43 Final recommendatios 51 Homologation 52 Preparation fo...

Page 8: ...re and stroke 72 x 72 mm Displacement 294 7 cc Carburettor diameter of diffusor 38 Lubrication system Mixture 100 Synthetic Oil 50 1 2 Mineral Oil Only USA 32 1 3 Starting system Starting lever Ignition system CDI system Ignition timing 1 mm BTDC TRANSMISSION Transmission type 6 speed in cascade Clutch type Hydraulic operated multi plate in oil bath Secondary drive Chain driven Gear ratio 200 cc 2...

Page 9: ...C SM and MC 125 Inverted telescopic fork ø 50 mm only MC 250 Rear Progressive system with single multi adjustable shock Suspension stroke Front 282 mm Rear 320 mm Front fork oil SAE 5 7 5 Front fork oil level 110 mm compressed without spring BRAKES Type Front Rear Disc brake Effective disc diameter Front 260 mm only EC and MC 320 mm only SM Rear 220 mm DIMENSIONES Overall height 1260 mm Overall le...

Page 10: ... 6 Throttle grip 7 CDI Switch GAS GAS MC 2008 1 Clutch lever 2 Engine stop button 3 Fuel tank cap 4 Brake fluid reservoir 5 Front brake lever 6 Throttle grip 7 CDI Switch GAS GAS SM 2008 1 Clutch lever 2 Steering lights horn and headlamp controls 3 Fuel tank cap 4 Brake fluid reservoir 5 Front brake lever 6 Throttle grip 7 CDI Switch 1 3 2 4 5 6 1 3 2 4 5 6 7 7 ...

Page 11: ...11 Carburetor 12 Rear shock absorber 13 Brake caliper 14 Radiator 15 Gasoline cock 16 Shift pedal 17 Air cleaner 18 Muffler 19 Seat 20 Gas reservoir 21 Chain guide 22 Chain 23 Suspension linkage and swingarm 24 Rear brake pedal 25 Kick start pedal 26 Exhaust GAS GAS EC 2008 ...

Page 12: ... Fuel tank 13 Brake caliper 14 Radiator 18 Muffler 19 Seat 20 Gas reservoir Rear shock absorber 21 Chain guide 22 Chain 23 Suspension linkage and swingarm 24 Rear brake pedal 25 Kick start pedal 26 Exhaust GAS GAS MC 2008 8 14 10 19 7 13 21 18 24 25 9 22 20 26 23 ...

Page 13: ...ervoir 10 Fuel tank 14 Radiator 18 Muffler 19 Seat 20 Gas reservoir Rear shock absorber 21 Chain guide 22 Chain 23 Suspension linkage and swingarm 24 Rear brake pedal 25 Kick start pedal 26 Exhaust GAS GAS SM 2008 8 14 10 19 7 13 21 18 24 25 9 22 20 26 23 ...

Page 14: ...only EC and SM To set the side stand only turn it until it contacts the stopper then the side stand will be parallel to the ground and rest securely The side stand will return to its original position by means of the double spring The function of the double spring insures that when the side stand is down the rest position is stable and above all secure moreover it also returns the side stand to it...

Page 15: ...LE SYNTHETIC NOTE If the recommended oil is not available use only oil designed for racing with 2 cycle engines Gasoline and engine oil mixing proportions Synthetic oil 100 gasoline 50 engine oil 1 2 Semi synthetic oil gasoline 50 engine oil 1 2 Mineral oil gasoline 32 engine oil 1 3 CAUTION Do not mix vegetable and mineral based oils Too much oil will cause excessive smoking and spark plug foulin...

Page 16: ... the choke knob B SERIAL NUMBER A It is stamped on the steering pipe It indicates the frame number registered for this motorcycle HOMOLOGATION PLATE B This motorcycle carries its corresponding homologation plate where it also shows the serial number and this data must match the information registered in the motorcycle documents ON Open OFF Close RES Reserve A B A B ...

Page 17: ...g Careless incomplete shifts can cause the transmission to jump out of gear and cause engine damage A Gearshift pedal 15 NOTE When the engine is already warm or on hot days open the throttle instead of using the choke knob If the engine is flooded kick with the throttle fully open If the clutch lever is pulled the motorcycle can be started while in any gear 5 Even after the engine starts keep the ...

Page 18: ... Start the engine and let it run at idle until the engine is warm 2 Stop and let the engine cool completely 3 Start the engine and ride for 10 minutes at moderate speed NEVER ACCELERATE HARD 4 Stop and let the engine cool completely Be sure to check and adjust chain slack and spoke tightness and cxarry out a general inspection 5 Start the engine and ride for 20 minutes at moderate speed NEVER ACCE...

Page 19: ...ke fluid level Brake fluid Brake pump piston dust cover MANTENANCE SCHEDULE Check Inspect Change Replace Apply grease Lubricate Adjust At each fill up 3 fill ups 1 fill up 3 fill ups 3 fill ups 1 fill up 3 fill ups 10 fill ups 3 fill ups 1 fill up 3 fill ups 5 fill ups 3 fill ups At each fill up 3 fill ups 1 fill up 1 fill up 3 fill ups 3 fill ups 1 fill up 10 fill ups 3 fill ups 10 fill ups 3 fil...

Page 20: ...et General lubrication Steering bearing Wheel bearing Swingarm and linkages Rear shock absorber oil MANTENANCE SCHEDULE Check Inspect Change Replace Apply grease Lubricate Adjust 1 fill up 1 fill up 5 fill ups 1 fill up 5 fill ups 7 fill ups 1 fill up 5 fill ups 5 fill ups 10 fill ups 5 fill ups Every 2 years 1 fill up 5 fill ups 5 fill ups When necessary 5 fill ups 7 fill ups 5 fill ups 10 fill u...

Page 21: ... cover Test ride the motorcycle and readjust the engine tune up if necessary COOLING SYSTEM Radiator Hoses Check the radiator hoses for cuts or deterioration and the connections for looseness and leaks Radiator Check the radiator fins for obstructions insects or mud Remove any obstructions with a stream of low water pressure ELECTRONIC IGNITION This motorcycle uses a capacitor discharge ignition s...

Page 22: ...nd reduce the cooling system efficiency If the lowest ambient temperature encountered falls below the freezing point of water protect the cooling system Use a permanent type of antifreeze in the cooling system distilled water and ethylene glycol and corrossion inhibitors for aluminium engines and radiators For the coolant mixture ratio under extreme conditions choose the mixture ratio listed on th...

Page 23: ...ant spilled on the chassis engine or wheels WARNING To prevent severe scalding do not remove the radiator cap or try to change liquid when the engine is still hot Wait until it cools Coolant level Place the motorcycle in riding position Turn the radiator cap A counterclockwise and wait a few seconds until vapors inside are released Then push and turn it further in the same direction and remove the...

Page 24: ...ssion and clutch to function properly maintain the transmission oil level at the optimum level and change it periodically A motorcycle with insufficient transmission oil deteriorated or contaminated can accelerate wear and tear and cause transmission damages WARNING If coolant gets on the tires will make them very slippery and can cause an accident Visually inspect the old coolant If whitish spots...

Page 25: ...ts O ring to 20 Nm Remove the oil filler opening plug C and pour 900 cc of new transmission oil for the models 200 250 300 and 750 cc for model 125 Check the oil level after kicking the kick start pedal 3 or 4 times Install the oil filler opening plug 23 Oil level inspection Wait a few minutes if the motorcycle has been operating If the level is low add the necessary quantity of oil by opening the...

Page 26: ... that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline to clean the element because could cause an explosion To access the air filter remove the seat by removing the bolt that secures it Place a lint free towel in the intake port of the carburetor so no dirt is allowed to enter the carburetor CAUTION Do not turn the filt...

Page 27: ...h side If handlebar movement changes the idle speed the throttle cable may be improperly adjusted or routed incorrectly or it may be damaged Be sure to correct any of these conditions before riding Inspect the filter for damage such as tears hardening or shrinkage If damaged replace it or it will allow dirt into the carburetor Apply grease to all connections and screws in the air cleaner and intak...

Page 28: ... Riding with a damaged throttle cable could be dangerous CLUTCH The clutch lever should have a maximum play of 3 mm This margin increases with the wear on the clutch plate To adjust proceed as follows Use bolt A to adjust the lever s range of movement to the rider s convenience Adjust the play of the lever using bolt B WARNING Maintain the clutch lever with the play shown otherwise the performance...

Page 29: ...ace the chain if necessary WARNING A chain that breaks or becomes loose could snag on the engine or on the rear wheel severely damaging the motorcycle and causing it to go out of control 30 50 mm 27 EC Model MC and SM Models Drive Chain Slack Inspection The space between the chain and the swingarm at the same height of the chain slider should be 30 50 mm Rotate the rear wheel to find the place whe...

Page 30: ...st position and readjust if necessary WARNING If the axle nut is not securely tightened an unsafe riding condition may result Drive chain chain guide chain slider and rear sprocket teeth When the chain is worn so much that it is more than 2 longer than when new it is no longer safe for use and should be replaced Whenever the chain is replaced inspect both the engine output pinion and rear sprocket...

Page 31: ...cation is necessary after riding through rain or in the mud or any time that the chain appears dry A heavy oil is preferred to a lighter ol because it will stay on the chain longer and provide better lubrication Apply oil to the sides of the chain rollers for better oil penetration Wipe off any excess oil HANDLEBAR To suit various riding positions the handlebar position can be adjusted front to re...

Page 32: ... front first and then the rear to 25 Nm of torque BRAKES Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action So there are no parts that require adjustment on the brakes except brake lever free play and brake pedal position Front brake lever free play Adjust the front brake lever A to match your requirements To adjust loosen the nut B After a...

Page 33: ...from a container that has been left open or that has been unsealed for a long time Check for fluid leakage around the fittings Check for brake hose damage WARNING Do not mix different types of fluid Change the brake fluid in the reservoirs completely if the same type of brake fluid is not available Brake wear inspection If the thickness of either pad front and rear is less than 1 mm replace both p...

Page 34: ... handlebar A by loosening the handlebar holder screws and removing the upper holders Loosen the steering stem nut B Loosen the screws of the suspension top bridge C and remove it Turn the steering adjustment nut with the special wrench to obtain the proper adjustment Install the suspension top bridge D Tighten the steering stem nut and front fork washers and screws Steering nut 44 Nm 4 5 Kgm Suspe...

Page 35: ...nd position 18 from close is full soft Oil level adjustment The effects of higher or lower fork oil level are only felt during the final 100 mm of fork travel A higher oil level will make the fork rebound faster The lower the oil level is the fork rebound will be slower Fork spring Optional springs are available that are softer and stiffer than standard Air Pressure The standard air pressure in th...

Page 36: ...lace a stand under the motorcycle engine to keep it in a straight and stable position Remove the handlebar screws and remove the handlebar Remove the suspension caps from the tubes Compress the front fork slowly all the way Lift the fork springs Hold the suspension tube cap with a spanner the loosen the cap locknut Remove the suspension tube caps Remove the suspension srping guide Use a wrench to ...

Page 37: ... the parts removed 1 Spring 2 Locknut 3 Suspension cap 4 Cap wrench 5 Locknut wrench Suspension tube spring Different springs are available in accordance with the rider s weight or the road conditions Harder springs make the fork stiffer and rebound action quicker Softer springs make the fork softer and rebound action slower Suspension top bridge position adjustment Make sure the front tire does n...

Page 38: ...e easily adjusted this feature makes it unnecessary to change oil viscosity 36 A Extension adjuster Shock absorber extension adjustment To adjust turn by hand the extension adjuster in the lower part of the shock absorber until a CLICK is heard Total number of adjustments possible is 40 CLICKS Rebound adjustment standard measures 25 CLICKS Counterclockwise from fully closed position High compressi...

Page 39: ...rder and softer springs are available If the standard spring is not adequate for your purpose select a proper one according to the rider s weight and the road conditions Using the harder spring The rebound is quicker Using the softer spring The rebound is slower NOTE Refer to the suspension adjustments on page 47 37 A Nut B Spring C Locknut Spring adjustment Remove the seat and side covers Loosen ...

Page 40: ... terrain increase the tire pressure Spokes and wheel rims The spokes on both wheels must be tightened evenly and should not be allowed to have free play Unevenly tightened or loose spokes will cause wheel rim runout the other spokes will be stressed and might break Wheel rim runout Place a dial indicator at the rim side and spin the wheel by hand to measure the axial runout Place the dial indicato...

Page 41: ...arings CAUTION To avoid excessive ageing of the plastic parts and other washable pieces of the motorcycle it is suggested that these items must be washed carefully If the washer applies water at high pressure and or temperature take the precaution of maintaining the washer outlet gun at a distance of 30 centimeters minimum this will ensure the correct gloss of the plastics and maintain adherence o...

Page 42: ...ck absorber bolts 22 Exhaust mounting bolts 23 Suspension top bridge bolts 24 Steering stem nut 25 Brake lever bracket screw 26 Rear axle nut 27 Linkage mounting bolt 10 Spokes 11 Front axle bolt 12 Brake hose screw 13 Radiator bracket bolts 14 Engine holder bolts and nuts 15 Gearshift pedal bolt 16 Subframe bracket bolt 17 Chain guide bolts 18 Chain adjuster nut 28 Rear brake pedal bolt 29 Torque...

Page 43: ...eering stem nut Torque rod bolt Rear linkage bolt Nm 25 10 36 51 6 29 98 98 9 26 39 29 1 5 4 81 81 E N G I N E PART NAME Cylinder head screws Cylinder nut Engine drain plug Kick start pedal bolt Kick start pedal nut Gearshift pedal bolt Spark plug Water pump cover drain plug Crankcase screws Starter pedal plate screw Ignition motor stator screws Ignition motor coil nut Selector spring fixing screw...

Page 44: ...onditions and especially after using high water pressure Before lubricating each part remove any rusty spots with rust remover and wipe off any grease oil or dirt General lubrication Clutch lever A Front brake lever B Rear brake pedal C Rear brake bearing D Gearshift pedal E Use an aerosol with a tube for pressure lubrication Apply grease inside the gas cable A ...

Page 45: ...mperature 43 NOTE The main jet should be increased or decreased 1 to 5 sizes and tested until the engine gives maximum power Main jet It has a great overall effect The number stamped on lower part of the main jet indicates the size of the hole metering fuel A greater number corresponds to a bigger hole which supplies more fuel WARNING Gasoline is extremely flammable and can be explosive under cert...

Page 46: ... out of the jet needle hole since the needle is tapered its position in the jet determines the amount of fuel allowed to flow There are five grooves in the upper section of the needle where a circlip fits This clip locates the needle in the throttle valve and determines its relative position in the jet needle hole and provides a rich mixture Moving the clip to the top will provide a lean mixture C...

Page 47: ...or altitude or temperature changes 1 Find the correction factor to adjust the carburetor Example 1000 meters altitude with an air temperature of 35 C The correction factor is 0 94 2 Using the correction factor select the correct slow jet and main jet Example For a correction factor of 0 94 multiply the jet size by that number Main jet 180 x 0 94 170 3 Find the correction factor on the Jet Needle A...

Page 48: ...U R A ºC ºF FACTOR DE CORRECCIÓN ALTITUD NEEDLE POSITION AIR SCREW OPENING CORRECTION FACTOR NEEDLE POSITION AIR SCREW OPENING 1 06 or HIGHER LOWER CLIP 1 POSITION TIGHTEN 1 TURN 1 06 1 02 SAME TIGHTEN 1 2 TURN 1 02 0 98 SAME SAME 0 98 0 94 SAME LOOSEN 1 2 TURN 0 94 or LOWER RAISE CLIP 1 POSITION LOOSEN 1 TURN ALTITUDE CORRECTION FACTOR T E M P E R A T U R E C F T T ...

Page 49: ... to ride consistently and recognizing the effects of his input such things as changes in rider position and increasing fatigue may lead to incorrect judgments about necessary setting adjustments When the proper settings have been determined for a particular terrain the settings should be written down for later reference when returning to the same type of terrain Before making any changes and also ...

Page 50: ...cessively when slowing down or applying brakes 1 Fork oil level is low 2 Springs are too soft 3 Oil too light 4 Degraded fork oil 5 Incorrect rebound or compression Symptoms of the rear shock absorber Too hard 1 The suspension is too stiff Compression damping is too high Spring is too hard 2 Is hard to ride Unbalanced condition between the spring and rebound too low 3 The spring is hard or preload...

Page 51: ...edal firmly If the motorcycle maintains its level attitude as the suspension is compressed the spring rates are well balanced Sit astride the motorcycle and take a riding posture Next check to see that the motorcycle is in a horizontal position If one end drops noticeably more than the other the front and rear are not compatible and must be readjusted to achieve a better balance This is one of the...

Page 52: ...n damping or use a harder spring NOTE After any adjustment check front and rear compatibility Adjustments that depend on the conditions of the jounce stops rear shock absorber Suspension jounce stops at low speed increase the spring preload to the maximum setting Jounce stops after 3 or 4 successive jumps decrease the rebound damping NOTE The rear shock absorber due to its setting possibilities ma...

Page 53: ... Refer to the sparts parts catalogue FINAL RECOMMENDATIONS PREVENTIVE ADVICE Before you ride the motorcycle take all the time you may require to check your motorcycle carry out the periodical upkeep and check all functions In different sections of this manual you will find data and work specifications that must be done at an autorized GAS GAS dealer because of this and to extend the useful life of...

Page 54: ...etermined and registered mark Each one of the homologation components must form part of the vehicle and in case of loss breakage or malfunction it is recommended that the owner contact his official dealer to correct this problem List of elements required Quantity motorcycle Manufacture identification plate 1 Catalyzed exhaust 1 Muffler 1 Carburettor jets 1 Front and rear turn signals 4 License pla...

Page 55: ... spokes tightness 27 Front and rear tire air pressure 28 Drive chain slack 29 Coolant level 2 After 1 day of racing competition 1 Clean the air cleaner element 2 Adjust drive chain slack 3 Tighten rear sprocket nuts 4 Tighten all spokes 5 Check the tires air pressure 6 Tighten front and rear axle nuts 7 Tighten swingarm shaft nut 8 Tighten muffler and exhaust bolts and nuts 9 Tighten front and rea...

Page 56: ...ed metal surfaces with a coat of oil to prevent rust do not apply oil to the brakes and rubber parts Cover the exhaust pipe with a plastic bag to prevent corrosion Place the motorcycle in such a position so that the wheels do not touch the ground if this is not possible place cardboards under the wheels Cover the motorcycle to protect it from dust and dirt When starting off after an extended stora...

Page 57: ... motor running save the data to the memory even when the device is switched off When the multifunction apparatus is not activated it displays a clock The value of the wheel circumference can be altered as well as the system of measurement metric or British The ambient temperature is displayed on the upper left hand part of the screen The screen can display the engine temperature from an optional t...

Page 58: ...RECISION CHARACTERISTICS CURRENT SPEED SPD 4 399 9 kmph or mph 0 1 kmph or mph 0 1 TACHOMETER RPM 0 19999 rpm 10 rpm 0 1 TACHOMETER BAR 0 12000 rpm Variable 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 hours 59 minutes 1 second 0 1 ODOMETER ODO 0 0 999999 1 0 1 OPERATION TIME RT 0 999 hours 59 minu...

Page 59: ...eter 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 total time in operation It starts counting from the moment the motor is turned on RT Total time of use controller It calculates the vehicle s operation time since the last RESET operation It starts counting from the moment that mo...

Page 60: ...onds 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 by pressing button 2 Note If you do not know the value of the wheel circumference see the section on Measuring the wheel circumference Selecting the speed unit To change between kmph and mph press but...

Page 61: ...ss button 3 Confirm by pressing button 2 Setting the pulse per revolution PPR The gauge receives one electrical pulse for each revolution on the engine PPR Default value for 2 and 4 stroke engines 1 PPR Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Setting the pulse per revolution PPR Note This step is only to be taken if ...

Page 62: ...nfirm by pressing button 2 Selecting the warning temperature Note This step can only be taken on vehicles fitted with the optional temperature sensor When the engine temperature exceeds the set value the warning LED on the left lights up Default value 90 C 190ºF Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Selecting the r...

Page 63: ...aximum speed Distance Chronometer Maximum temperature Maximum rpm 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 accumulated distance and time Internal battery The display is powered by an internal 3 V battery type CR2032 When the voltage in the int...

Page 64: ...y 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 Sleep Mode If the multifunction display does not receive any information for 20 minutes signal from wheels turning or a button pressed the screen goes off showing only the time When the vehicle starts...

Page 65: ...ialized workshop Go to a specialized workshop Go to a specialized workshop Drain old fuel out of the tank With the fuel tank filled with new fuel the engine will start immediately Clean and dry or replace the spark plug In order to relieve the engine accelerate to max speed press the starter pedal 5 or 10 times Then start the engine as described above If the engine fails to start remove the spark ...

Page 66: ... Main jet set too high Replace the rotor Drain the fuel tank and fill up with new fuel Clean the fuel system and verify its operation Clean or replace the air cleaner Verify its operation Verify if the exhaust system is damaged Replace the muffler fiberglass packing if necessary Disassembly the carburetor and clean all jets Replace the crankshaft bearings Verify the clutch operation Go to a specia...

Page 67: ...orn steering bearings Bent steering stem Go to a specialized workshop Replace the shift fork Go to a specialized workshop Replace the gearshift lever Adjust or replace the selector position spring Replace the spring in the reverse selector mechanism Replace the spring in the reverse selector mechanism Replace the gear drum Replace the spring in the gear selector ratchet Replace the shift fork Repl...

Page 68: ...ft Abnormal motorcycle noises Handlebar vibration Pour excess oil until reaching the correct oil level Drain fork oil and fill with correct fork oil viscosity Replace the front fork Go to a specialized workshop Check tire air pressure Adjust rear shock absorber Fill with fork oil until reaching the correct oil level Drain fork oil and fill with correct fork oil viscosity Replace the front fork Go ...

Page 69: ...eering bracket and steering stem locknut to the correct torque values Tighten steering bracket and steering stem locknut to the correct torque values Replace the chassis Go to a specialized workshop Adjust the steering Go to a specialized workshop Replace the steering stem Go to a specialized workshop Replace the front fork Align the wheels Replace the discs Verify the brake circuits Replace the d...

Page 70: ... Speed sensor Ignition coil Magnetic flywheel Indicator relay Horn Power controller Magnetic flywheel Rear brake sensor Rear right indicator Rear sidelight brake light Rear left indicator ELECTRIC SCHEMAS Bl Black Bu Blue Gr Grey Br Brown W White R Red G Green P Pink O Orange Y Yellow V Violet GL Bright green ...

Page 71: ...ts 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 Neverthe...

Page 72: ...e 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...

Page 73: ...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 con...

Page 74: ...E L HUILE CONSIGLIA L USO D OLIO EMPFIEHLT DEN GEBRAUCH VON ÖL C UNICEF nº 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 AGOSTO AUGUST AOÛT AGOSTO AUGUST 2007 PU010838019 ...

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