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EC / MC / SM 2005 -

115

HOMOLOGATION (SM y EC):

The vehicle you have just acquired has been homologated under the directives of the EU and complies with all the homologation requirements

demanded.

Compulsory homologation elements required, among others, when travelling on a public road and to meet periodical vehicle inspection

approval at state controlled plants are listed below.

Among other requirements, all homologation components are identified with a determined 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

- Catalyzed exhaust

- Muffler

- Carburettor jets

- Front and rear turn signals

- License plate holder

- Speedometer

- Electrical installation, homologated lights

- Engine output pinnion and sprocket for a correct transmission gear ratio

- Horn

- Rearview mirror

- Antitheft system

- Antimanipulation plate (125 cc version)

Содержание EC - 2005

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

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Страница 4: ...perimentation 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...

Страница 5: ...n personal 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 ind...

Страница 6: ...Electronic Ignition 82 Cooling System 82 Spark Plug 85 Transmission 85 Air Cleaner 87 Throttle Cable 88 Carburetor 88 Clutch 89 Exhaust System 89 Drive Chain Guide 90 Handlebar 92 Brakes 93 Steering 9...

Страница 7: ...e 72 x 72 mm Displacement 294 7 cc Carburetor type KEIHIN PWK 38 Lubrication system Mixture 100 Synthetic Oil 50 1 2 Mineral Oil Only USA 32 1 3 Starting system Starting lever Ignition system CDI syst...

Страница 8: ...C Inverted telescopic fork HLINS Rear Progressive system with single multi adjustable shock HLINS Suspension stroke Front 282 mm Rear 320 mm Front fork oil Marzocchi SAE 7 5 HLINS SAE 5 7 5 Front fork...

Страница 9: ...r 5 Front brake lever 6 Throttle grip GAS GAS MC 2005 1 Clutch lever 2 Engine stop button 3 Fuel tank cap 4 Brake fluid reservoir 5 Front brake lever 6 Throttle grip GAS GAS SM 2005 1 Clutch lever 2 S...

Страница 10: ...ock 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 pe...

Страница 11: ...oir 10 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...

Страница 12: ...d reservoir 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 Exhau...

Страница 13: ...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 mean...

Страница 14: ...2 CYCLE 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 oi...

Страница 15: ...ll up 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 ho...

Страница 16: ...e transmission to jump out of gear and cause engine damage A Gearshift pedal EC MC SM 2005 78 NOTE When the engine is already warm or on hot days open the throttle instead of using the choke knob If t...

Страница 17: ...steps 1 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...

Страница 18: ...ar Brake 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...

Страница 19: ...procket 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...

Страница 20: ...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 leak...

Страница 21: ...gged and 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...

Страница 22: ...coolant 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 leve...

Страница 23: ...smission 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 contaminate...

Страница 24: ...with its 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 650 cc for model 125 Check the oil level after kicking the kick sta...

Страница 25: ...lement in a well ventilated area and make sure 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...

Страница 26: ...idling turn the handlebar to each 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 t...

Страница 27: ...he rear Replace the muffler and reinstall the assembly WARNING Riding with a damaged throttle cable could be dangerous CLUTCH The clutch lever free play should be 2 3 mm The free play increases as the...

Страница 28: ...over rivets with a drill Remove the inside core of the muffler Replace the muffler fibre by wraping it around the inner tube Reinstall the assembly DRIVE CHAIN GUIDE The drive chain must be checked ad...

Страница 29: ...ightest 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...

Страница 30: ...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 lubricatio...

Страница 31: ...e brake checked inmediately EC MC SM 2005 93 Tighten the bolts 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...

Страница 32: ...uid 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 flu...

Страница 33: ...he 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 a...

Страница 34: ...ng and 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...

Страница 35: ...er 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...

Страница 36: ...er fork Install 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...

Страница 37: ...viscosity EC MC SM 2005 99 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...

Страница 38: ...r 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 sus...

Страница 39: ...r hard 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 c...

Страница 40: ...arm bearings 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...

Страница 41: ...ar shock 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 bol...

Страница 42: ...es Steering stem nut Torque rod bolt Rear linkage bolt N m 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...

Страница 43: ...y conditions 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...

Страница 44: ...EC MC SM 2005 106 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 pa...

Страница 45: ...e 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...

Страница 46: ...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 je...

Страница 47: ...R A T U R A C F FACTOR DE CORRECCI N 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 T...

Страница 48: ...uences include the rider s style and position on the motorcycle If you have a problem test by changing your riding posture or position so it can be deduced Adjust the suspension to match the rider s s...

Страница 49: ...kes excessively 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 ab...

Страница 50: ...rake pedal 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 s...

Страница 51: ...ression 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...

Страница 52: ...ILABLE 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 up...

Страница 53: ...with a determined 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 off...

Страница 54: ...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 sprock...

Страница 55: ...s is not possible place cardboards under the wheels Cover the motorcycle to protect it from dust and dirt When starting off after an extended storage Remove the plastic bag from the exhaust pipe Tight...

Страница 56: ...he Reset button is maintained pressed Trip Kilometers To change the trip distance from km to miles and vice versa When the battery is first connected the program will indicate its current setting METr...

Страница 57: ...orkshop 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...

Страница 58: ...leaner 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...

Страница 59: ...d or worn 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 spri...

Страница 60: ...too soft 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 spec...

Страница 61: ...hten steering 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 wor...

Страница 62: ...s been stored or transported in a way that is WARRANTY TERMS AND CONDITIONS Warranty terms of the manufacturer GASGAS Motos S A The company GAS GAS MOTOS S A hereafter referred to as GG with this pres...

Страница 63: ...Where parts are replaced ownership of the parts removed shall pass to GG without any other consideration The GG authorised dealer to whom the making good of the defects has been entrusted is not auth...

Страница 64: ......

Страница 65: ...17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 E mail officegg gasgasmotos es partsgg gasgasmotos es OCTUBRE OCTOBER OCTOBRE 0TTOBRE 2004 RECOMIENDA EL USO DE ACEITE RECOMMENDS THE US...

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