GAS GAS EC 125 - 2003 SERVICE Service Manual Download

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SERVICE MANUAL

Summary of Contents for EC 125 - 2003 SERVICE

Page 1: ...SERVICE MANUAL SERVICE MANUAL...

Page 2: ...ompetition enduro It is actually the fruit of many years of competition and experimentation in this demanding discipline as well as the many great successes achieved thanks to great trial riders who h...

Page 3: ...in damage to or destruction of equipment NOTE This note symbol indicates points of particular interest for more efficient and convenient operation However if improverly conducted the sport has the pot...

Page 4: ...on timing 78 Cooling system 78 Spark plug 81 Transmission 81 Air cleaner 83 Throtlle cable 84 Carburetor 84 Clutch 85 Silencer packing change 85 Drive chain 86 Handlebar 88 Brakes 89 Steering 90 Steer...

Page 5: ...ore and stroke 72 x 72 mm Displacement in cubic centimeters 294 7 cc Type Carburetor KEIHIN PWK 38 Lubrication system Fuel premix ratio 50 1 2 Starting system Kick start pedal Ignition system CDI syst...

Page 6: ...rk oil each Marzocchi SAE 7 5 WP SAE 5 HLINS SAE 5 7 5 Front fork oil level Marzocchi 110 mm compressed with spring removed WP 120 mm compressed with spring removed HLINS 110 mm compressed with spring...

Page 7: ...EC 2003 69 Location of components GAS GAS EC 2003 cc 1 Clutch lever 2 Engine Stop Button 3 Fuel Tank Fill Cap 4 Front Brake Fluid Reservoir 5 Front Brake lever 6 Throttle Twist Grip 1 3 2 4 5 6...

Page 8: ...ck absorber 13 Brake Caliper front 14 Radiator 15 Fuel Tap 16 Shift pedal 17 Air Cleaner 18 Silencer 19 Seat 20 Nitrogen Reservoir 21 Chain Guide 22 Drive chain 23 Rear Suspension Linkage 24 Rear Brak...

Page 9: ...clock SIDE STAND To operate the side stand Release the security strap B the sidestand is held in the down position by the weight of the motorcycle Thes sidestand automatically retracts when the motorc...

Page 10: ...h gasoline Take time to ensure a well blended mixture The lubricative quality of this mixture deteriorates rapidly use a fresh mixture for each day of operation RECOMENDED FUEL Use premium gasoline wi...

Page 11: ...A 3 If the engine is cold pull up the choke knob B SERIAL NUMBER This number allows the motorcycle to be registered The serial number or V I N is located on the steering stem of the frame Official app...

Page 12: ...k to first gear from a higher gear you must shift back through the gears one by one The same is true when upshifting each gear must be engaged before the next higher gear may be selected To engage fir...

Page 13: ...up 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 ch...

Page 14: ...pipe o ring Engine bearings check Coolant Radiator hoses connections Brake adjustment Brake wear Brake fluid level Brake fluid Brake master cyl cup dust seat MAINTENANCE AND ADJUSTMENT Check inspect R...

Page 15: ...e 5 races 1 race 5 races 7 races 1 race 5 races 5 races 10 races 5 races Every 2 years 1 race 5 races 5 races If it s damaged 5 dep sitos 7 dep sitos 5 dep sitos 10 dep sitos 5 dep sitos 2 years 1 rac...

Page 16: ...on timing if necessary COOLING SYSTEM Radiator Hoses Check the radiator hoses for cracks or deterioration and connections for looseness in acordance with the Periodic Maintenance Chart Radiator Check...

Page 17: ...d with the inhibitor chemicals and the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably...

Page 18: ...Place a container under the coolant drain plug and drain the coolant from the radiator and engine by removing the drain plug at the bottom of the water pump cover Immediately wipe or wash off any cool...

Page 19: ...SSION For the transmission and clutch to function properly maintain the oil level at the proper level Change the oil periodically Oil at an insufficient level deteriorates and contaminates rapidly Thi...

Page 20: ...to20 Nm Remove the oil filler opening plug of fresh transmission oil C EC 200 250 300 remove with 900 cc and EC 125 with 650 cc Check the oil level after kicking the kick pedal 3 or 4 times Install th...

Page 21: ...area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the element...

Page 22: ...movement changes the idle speed the throttle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding Inspect the element f...

Page 23: ...he inner pipe mounting rivots and pull out the inner pipe Pull off the old silencer packing and install the new silencer packing Install the inner pipe into the silencer Install the silencer and right...

Page 24: ...e the rear wheel to find the place where the chain is tightest because it wears unevenly Adjust the drive chain if it has too much or too little slack 30 50 mm A Rivots B Inner Pipe B A In addition to...

Page 25: ...n When the chain has 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 and rear sprock...

Page 26: ...n 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 side of the rollers so that it will penetrate to the rol...

Page 27: ...ten the clamp bolts front first and then the rear to 25 Nm of torque 18 ft lbs BRAKES Disc and disc pad wear is automatically compensated for and has no effect on the brake lever or pedal action So th...

Page 28: ...s 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 two brands of fluid Change the brake fluid in the...

Page 29: ...front wheel off the ground Remove the handlebar A Loosen the front fork upper clamp bolts and remove the steering head nut and washer and take off the steering stem head B Turn the steering stem lock...

Page 30: ...he fork increases as the fork heats up so the fork action on your GAS GAS will get stiffer as the race progresses Because of this we don t recommend using air pressure for additional springing Your GA...

Page 31: ...ng the stand under the frame stabilize the motorcycle Place a stand or block under the engine so that the front wheel is raised off the ground Remove the front fender and front disc cover Unbolt the b...

Page 32: ...e front fork action in accordance with the rider s weight and track conditions Harder springs make the fork stiffer and rebound action quicker Softer sprigs make the fork softer and rebound action slo...

Page 33: ...the dampening force can be adjusted easily so changing oil viscosity is unnecessary EC 2003 95 Shock Rebound Dampening Adjustment Rear shock Absorber o adjust shock rebound dampening turn the rebound...

Page 34: ...f the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions Using the harder spring The spring rate is higher Using the softer spring Th...

Page 35: ...y or hard increase the tire pressure Spokes and Rim The spokes on both wheels must all be tightened securely and evenly and not be allowed to loosen Unevenly tightened or loose spokes will cause the r...

Page 36: ...If water gets into the ignition coil or into the spark plug cap the spark will jump through the water and be grounded out When this happens the motorcycle will not start and the affected parts must be...

Page 37: ...frame bolts 21 Rear chock absorber bolts 22 Exhaust mounting bolts and nut 23 Fork clampbots 24 Steering shaft nut 25 Rear brake mounting bolt 26 Rear axle nut 27 Connecting rod mounting bolt 10 Spoke...

Page 38: ...ounting bolts Disc plate mounting screws Engine mounting bolts Front axle Trottle clamp bolts Tripple clamp bolts Steering shaft nut Rear axle nut Brake pedal nut Front fork top bolts Handlebar clamp...

Page 39: ...itions and especially after using 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 Cl...

Page 40: ...EC 2003 102 NOTE The main jet should be increased or decreased one to five sizes and tested until the engine gives maximum power Main jet The number of the main jet stamped on the bottom or side of th...

Page 41: ...her have their greatest effect in the 1 4 to 3 4 throttle range The needle moves in and out of the jet needle hole since the needle is tapered its position in the jet determines the amount of fuel all...

Page 42: ...t altitude with an air temperature of 35 C 95 F The correction factor is 0 94 see dotted line for the example 2 Using your correction factor select the correct slow jet and main jet Example For a corr...

Page 43: ...ft 3000 m 9600 ft T E M P E R A T U R E C F CORRECTION FACTOR ALTITUDE JET NEEDLE AIR SCREW CHART CORRECTION FACTORS JET NEEDLE SETTING AIR SCREW OPENING 1 06 or ABOVE LOWER CLIP ONE POSITION ONE TUR...

Page 44: ...of his machine s ability Match the suspension to the rider and the course conditions If the machine is new break in the suspension with at least one hour of riding before making any setting evaluatio...

Page 45: ...ings Listed below are some symptoms of improper suspension settings and the most likely means of correcting them The proper settings can be achieved by applying the information in this chapter in a sc...

Page 46: ...ront brake place one foot on the footpeg closest to you and push down hard If the bike maintains its level attitude as the suspension is compressed the spring rates are well balanced Sit astride the b...

Page 47: ...ompression damping or use harder spring NOTE After any adjustment check front and rear compatibility Adjustment depending on bottoming condition rear shock absorber Bottoms at low speed Increase sprin...

Page 48: ...es after each change In this way the machine will deliver best performance for the entire circuit Special Care According to Track Conditions 1 In dry dusty conditions such as volcanic ash or fine powd...

Page 49: ...he cylinder and crankshaft big end bearing 5 Grease the throttle grip and cable PREPARATION FOR COMPETITION 1 Check 1 Front axle shaft and nut or axle clamp nut tightness 2 Front fork clamp bolt tight...

Page 50: ...lastic bag over the exhaust pipe to prevent moisture from entering Set the motorcycle on a box or stand so that both wheels are raised off the ground If this cannot be done put boards under the front...

Page 51: ...e to kilometers per hour or miles per hour Disconnect the battery the total distance will be saved Re connect the battery whilst holding down either button and it will read either met for km h mil for...

Page 52: ...ect Incorrect air supply There isn t fuel Insufficient cooling liquid Radiators very dirty Spark plug dirty or maladjusted Spark plug cap or high tension wiring trouble Go to specialized garage Go to...

Page 53: ...Gear lever damaged Clutch spring broken or weak Clutch release mechanism trouble Change wiring Empty fuel tank and fill up with new one Clean and check fuel system as well as carburettor Clean and cha...

Page 54: ...t fork leg bent Tire air pressure too small Rear shock absorber maladjusted Drive chain adjusted improperly Chain worn Change clutch hub Change it and go to specialized garage Change it and go to spec...

Page 55: ...Abnormal train noise Handlebar shakes or excessivery vibrates Motorcycle pull to one side Brakes don t hold Las l mparas se funden El sistema de iluminaci n no funciona Change it Lubricate with apropi...

Page 56: ...and to the extent that a The purchaser has failed to subject the vehicle to any of the inspections and or maintenance work prescribed in the operating manual or has exceeded the date stated for such...

Page 57: ...he existence of a defect or if a visual inspection or material testing is required GG shall be entitled to demand submission of the parts for which warranty claims are put forward or to order an exami...

Page 58: ...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 Web www gasgasmotos es PU010338018 FEBRERO FEBR...

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