GAS GAS ENDUCROSS EC - 2007, User Manual

Page 1: ...MANUAL DEL USUARIO USER MANUAL MANUEL D ENTRETIEN LIBRETTO D USO BETRIEBSANLEITUNG enducross EC 07 enducross EC 07...

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Page 3: ...ENGLISH USER MANUAL USER MANUAL enducross EC 07 enducross EC 07...

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Page 5: ...ntation 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 creat...

Page 6: ...nal 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...

Page 7: ...ition 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 blo...

Page 8: ...e 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 Ignitio...

Page 9: ...SM and MC 125 Inverted telescopic fork 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...

Page 10: ...tle grip 7 CDI Switch GAS GAS MC 2007 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 2007 1 Clutch lever 2 Stee...

Page 11: ...orber 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...

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 Exh...

Page 13: ...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 2007 7 8 10 1...

Page 14: ...nly 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...

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...

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 homologa...

Page 17: ...ause 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 engi...

Page 18: ...ps 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 Sto...

Page 19: ...e 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...

Page 20: ...t 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...

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...

Page 22: ...d 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 coolin...

Page 23: ...t 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...

Page 24: ...sion 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 ca...

Page 25: ...s 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 peda...

Page 26: ...nt 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 beca...

Page 27: ...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 these co...

Page 28: ...ing 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...

Page 29: ...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 250 300 cc 30 50 mm 27 EC M...

Page 30: ...t 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...

Page 31: ...ion 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 lub...

Page 32: ...ront 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 a...

Page 33: ...m 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 Chan...

Page 34: ...lebar 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 adjustme...

Page 35: ...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 rebou...

Page 36: ...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 s...

Page 37: ...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 road co...

Page 38: ...force can be 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...

Page 39: ...ings 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 Us...

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 wh...

Page 41: ...rings 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 p...

Page 42: ...k 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 Br...

Page 43: ...ering 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 s...

Page 44: ...tions 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...

Page 45: ...perature 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 t...

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 f...

Page 47: ...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 se...

Page 48: ...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 TIGHTEN...

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 t...

Page 50: ...essively 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...

Page 51: ...dal 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...

Page 52: ...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 a...

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 an...

Page 54: ...termined 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 dea...

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...

Page 56: ...d 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 positi...

Page 57: ...urney kilometres travelled time average speed maximum speed length of time with motor running and total time and fuel level The data relative to the distance travelled and total time of use is stored...

Page 58: ...er 1 2 TRIP 1 2 0 999 9 km or 0 624 9 miles 0 1 km or miles Mileometer ODO 0 999 999 km or 0 624 999 miles 0 1 km or miles Time in use RT 0 00 00 99 59 59 1 second Total time TT 0 00 9999 59 1 minute...

Page 59: ...he second row The digital tachometer displays up to 19 900 rpm The tachometer signal can be read from the CDI Capacitator Discharge Ignition or the ignition coil Gear change indicator according to rpm...

Page 60: ...IP 2 MAX and MAX RPM to zero separately 2 Return the data in TRIP 1 AVG and RT at the same time The data of the ODO CLOCK and TT cannot be returned to zero OPERATION OF THE GEAR CHANGE ACCORDING TO RP...

Page 61: ...nd the configuration of the clock digits opens Press the RESET button to increase the value of the flashing digit one by one press the MODE button to confirm the configuration and pass on to the follo...

Page 62: ...60 11 Press the RESET button to increase the value of the flashing digit one by one press the MODE button for 2 seconds to confirm the digit change and pass on to the following digit...

Page 63: ...alized 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 repl...

Page 64: ...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...

Page 65: ...rn 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 Repl...

Page 66: ...t 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...

Page 67: ...ering 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 Ad...

Page 68: ...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 SCHE...

Page 69: ...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 70: ...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 v...

Page 71: ...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...

Page 72: ...DE L HUILE CONSIGLIA L USO D OLIO EMPFIEHLT DEN GEBRAUCH VON L C UNICEF 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...