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EC 2004 -

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(2). After first race maintenance:

1. Air cleaner element
2. Drive chain slack
3. Rear sprocket nuts
4. Sprockets
5. Front and rear tire air pressure
6. Front and rear axle shaft nuts
7. Pivot shaft nut
8. Muffler, silencer bolts or nuts
9. Front, rear fender mounting bolts or nuts
10. Fuel tank, seat mounting bolts or nuts
11. Front and rear brakes
12. Steering play
13. Fuel tank fill
14. Coolant level check

(3) Maintenance notice for after riding on dusty course:

If dirt or dust gets through into the engine, the crankshaft big end
will wear excessively. After riding, inspect the crankshaft big end. If
the crankshaft big end is worn past the service limit, replace the
crankshaft big end with a new one.

(4) Maintenance notice for after riding in rain on muddy course:

1. Apply grease to swing arm pivot and rear suspension system
2. Inspect the drive chain and rear sprocket wear
3. Clean the air cleaner element
4. Check the 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 tightness
3. Handlebar clamp bolt tightness
4. Throttle grip screw tightness
5. Throttle grip operation
6. Front and rear brake hose installation
7. Front and rear brake fluid level
8. Front and rear brake disc and caliper installation
9. Front and rear brake function
10. Fuel tank installation
11. Shift pedal bolt tightness
12. Engine mounting bolt tightness
13. Engine sprocket installation
14. Brake pedal bolt tightness
15. Transmission oil level
16. Carburetor clamp screw tightness
17. Carburetor top cap tightness
18. Linkage tie rod mounting bolt tightness
19. Linkage rocker arm mounting bolt tightness
20. Rear shock absorber bolt tightness
21. Swing arm pivot shaft nut tightness
22. Rear axle shaft nut tightness
23. Rear sprocket bolts or nuts tightness
24. Rear brake pedal operation
25. Seat installation
26. Front and rear wheel sproke tightness
27. Front and rear tire air pressure
28. Drive chain slack
29. Coolant level

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Содержание EC - 2004

Страница 1: ...Compuesta MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO USO E MANUTENZIONE MANUAL DEL USUARIO SERVICE MANUAL MANUEL D ENTRETIEN LIBRETTO USO E MANUTENZIONE...

Страница 2: ......

Страница 3: ...SERVICE MANUAL SERVICE MANUAL ENGLISH...

Страница 4: ......

Страница 5: ...n 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 have contr...

Страница 6: ...es special instructions or procedures which if not correctly followed could result in personal injury or loss of live CAUTION This caution symbol identifies special instructions or procedures which if...

Страница 7: ...tion check 111 Storage 112 Gas Gas speedo instructions 112 Troubleshooting 114 Warranty regulations 118 TABLE OF CONTENTS Foreword 64 Common notice 65 Table of contents 66 Specifications 67 Location o...

Страница 8: ...cc Engine 300 cc Bore 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 Igniti...

Страница 9: ...r 320 mm Front fork 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 compr...

Страница 10: ...EC 2004 69 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 LOCATION OF COMPONENTS GAS GAS EC 2004 cc...

Страница 11: ...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...

Страница 12: ...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...

Страница 13: ...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...

Страница 14: ...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...

Страница 15: ...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...

Страница 16: ...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...

Страница 17: ...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...

Страница 18: ...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...

Страница 19: ...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...

Страница 20: ...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...

Страница 21: ...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...

Страница 22: ...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...

Страница 23: ...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...

Страница 24: ...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...

Страница 25: ...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...

Страница 26: ...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...

Страница 27: ...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...

Страница 28: ...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...

Страница 29: ...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...

Страница 30: ...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...

Страница 31: ...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...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ...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...

Страница 35: ...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...

Страница 36: ...the dampening force can be adjusted easily so changing oil viscosity is unnecessary EC 2004 95 Shock Rebound Dampening Adjustment Rear shock Absorber o adjust shock rebound dampening turn the rebound...

Страница 37: ...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...

Страница 38: ...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...

Страница 39: ...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...

Страница 40: ...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...

Страница 41: ...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...

Страница 42: ...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...

Страница 43: ...EC 2004 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...

Страница 44: ...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...

Страница 45: ...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...

Страница 46: ...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...

Страница 47: ...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...

Страница 48: ...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...

Страница 49: ...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...

Страница 50: ...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...

Страница 51: ...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...

Страница 52: ...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...

Страница 53: ...uel will deteriorate Remove the spark plug and put several drops of SAE 30 oil into the cylinder Kick the engine over slowly a few times to coat the cylinder wall with oil and install the plug Lubrica...

Страница 54: ...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...

Страница 55: ...t fuel Insufficient cooling liquid Radiators very dirty Spark plug dirty or maladjusted Spark plug cap or high tension wiring trouble Wiring shorted or open Go to specialized garage Go to specialized...

Страница 56: ...ever damaged Clutch spring broken or weak Clutch release mechanism trouble Empty fuel tank and fill up with new one Clean and check fuel system as well as carburettor Clean and change the air filter R...

Страница 57: ...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 specia...

Страница 58: ...normal 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 apropiat...

Страница 59: ...nd 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 in...

Страница 60: ...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...

Страница 61: ...ICEF n 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 JULIO JULY 2003 RE...

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