GAS GAS EC - 2005 User Manual

MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE
MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE

GAS GAS EC - 2005 Specifications

General

Year	2005
Category	Enduro / offroad
Engine Type	Single cylinder, two-stroke
Ignition	Electronic
Cooling System	Liquid
Transmission	6-speed
Front Brake	Single disc
Rear Brake	Single disc
Fuel System	Carburetor
Front Suspension	Marzocchi upside-down fork

Summary

Foreword

How to Use This Manual

Specifications

Engine Specifications

Technical specifications for the motorcycle engines.

Transmission Specifications

Technical specifications for the transmission system.

Chassis Specifications

Specifications related to the motorcycle chassis, suspension, and dimensions.

Brake Specifications

Specifications for the braking system components.

Motorcycle Dimensions

Key physical dimensions of the motorcycle.

Component Location Overview

Handlebar Controls (EC, MC, SM)

Identifies handlebar controls for EC, MC, and SM motorcycle models.

EC 2005 Component Identification

MC 2005 Component Identification

SM 2005 Component Identification

Motorcycle Operation Basics

Side Stand Usage (EC & SM Models)

Instructions for operating the side stand on EC and SM models.

Fuel Requirements

Details on fuel mixture for 2-cycle engines.

Recommended Fuel and Oil

Vehicle Identification and Starting

Serial Number and Homologation Plate

Location and importance of serial number and homologation plate.

Engine Starting Procedure

Step-by-step guide to start the motorcycle engine.

Motorcycle Operation: Shifting and Stopping

Gear Shifting Procedure

How to use the 6-speed transmission and shift gears correctly.

Engine Stopping Procedure

Steps to safely stop the motorcycle engine.

Motorcycle Handling and Break-In

Motorcycle Stopping Procedure

How to properly stop the motorcycle using brakes and clutch.

Break-In Riding Guidelines

Recommendations for the initial riding period to ensure proper engine and transmission response.

Maintenance Schedule - Part 1

Maintenance Schedule - Part 2

Electronic Ignition System

Adjustment Procedures

How to inspect and adjust the electronic ignition timing and components.

Cooling System Maintenance

Radiator and Hoses Inspection

Checks for radiator hoses and fins for damage, obstructions, and leaks.

Cooling System Precautions

Coolant Properties and Protection

Information on coolant, corrosion inhibitors, and protection for aluminum parts.

Recommended Coolant and Level Checks

Coolant Level and Replacement

Checking and Adding Coolant

Step-by-step guide to check and replenish the coolant level.

Coolant Replacement Procedure

Instructions for draining and replacing the motorcycle's coolant.

Spark Plug Maintenance

Spark Plug Specifications and Inspection

Details on spark plug types, gap setting, and inspection for correct heat range.

Transmission Oil Management

Transmission Oil Management

Checking Oil Level

Procedure to inspect the transmission oil level using the inspection window.

Changing Transmission Oil

Step-by-step guide for draining and refilling transmission oil.

Air Cleaner System

Air Cleaner Importance and Warnings

Explains the function of the air cleaner and potential issues from a clogged filter.

Air Filter Cleaning Procedure

Detailed steps for cleaning the air filter element safely and effectively.

Throttle Cable Adjustment

Carburetor Idle Speed Tuning

Clutch Lever Adjustment

Exhaust System Maintenance

Muffler Replacement Procedure

Steps for replacing the exhaust muffler and associated parts.

Muffler Fiber Replacement

Drive Chain Maintenance

Drive Chain Slack Inspection

How to check and inspect the drive chain slack for proper tension.

Drive Chain Slack Adjustment

Chain and Sprocket Wear

Chain Guide and Sprocket Inspection

Chain Guide Slider Inspection

How to inspect the chain guide slider for wear or damage.

Handlebar Adjustment

Handlebar Position Adjustment

How to adjust the handlebar position for rider comfort and control.

Brake System Adjustments

Front Brake Lever Free Play

How to adjust the front brake lever for optimal feel and response.

Rear Brake Pedal Position

Procedure for adjusting the rear brake pedal position and free play.

Brake Fluid Management

Brake Fluid Level and Inspection

How to inspect and maintain the brake fluid level in reservoirs.

Brake Pad Wear Inspection

Steering Adjustment

Steering System Adjustment

Checking and Adjusting Steering

Procedure to check for steering looseness and perform adjustments.

Steering Lock Operation

Front Fork Adjustments

Rebound Dampening Adjustment

How to adjust the front fork's rebound damping for desired response.

Air Pressure Considerations

Front Fork Compression Adjustment

Front Fork Oil Level Adjustment

Suspension Spring Installation

Suspension Top Bridge Adjustment

Rear Suspension Overview

Shock Absorber Extension Adjustment

How to adjust the rear shock absorber's extension damping.

Rear Suspension Compression Adjustment

Low Compression Adjustment

How to adjust the low compression damping on the rear shock absorber.

High Compression Adjustment

How to adjust the high compression damping on the rear shock absorber.

Suspension Spring Adjustment

Rear Shock Absorber Spring Replacement

Wheel and Tire Considerations

Tire Pressure and Road Conditions

Adjusting tire pressure based on road conditions and rider preference.

Wheel Rim Runout

Motorcycle Cleaning Procedures

Bolt and Nut Tightening Checks

Torque Specifications Table

Lubrication Procedures

General Lubrication Points

Identifies key points for applying grease or oil for general lubrication.

Drive Chain Lubrication

How to properly lubricate the drive chain for optimal performance and longevity.

Carburetor Tune-Up: Mixture

Mixture Settings by Condition

How to adjust fuel mixture based on air temperature and altitude.

Main Jet Function

Carburetor Jet Adjustment

Slow Jet and Air Screw Adjustment

How to adjust the slow jet and air screw for low-speed mixture control.

Carburetor Jet Needle Tuning

Troubleshooting Carburetor Settings

Symptoms of Improper Settings

Identifying common engine issues caused by incorrect carburetor settings.

Spark Plug Diagnosis

Carburetor Correction Factors

Carburetor Tuning Charts

Suspension Tuning Overview

Suspension Tuning Factors

Key factors influencing suspension tuning: rider weight, ability, and terrain.

Front Fork Oil Level Adjustment

Suspension Troubleshooting and Settings

Front Fork Issues and Solutions

Common front fork issues and their likely corrections.

Rear Shock Absorber Issues

Common rear shock absorber issues and their likely corrections.

Determining Proper Settings

Guidelines for setting up suspension based on rider and conditions.

Suspension Tuning Based on Rider and Performance

Rider Experience and Weight Considerations

How rider factors influence suspension setup choices.

Suspension Balance and Performance Checks

Procedure to check if front and rear suspension are balanced.

Front Fork Performance Issues

Diagnosing and correcting issues like skidding, turning inward, or slipping.

Suspension Troubleshooting: Specific Scenarios

Front Fork Response and Rear End Issues

Diagnosing and correcting issues with front fork response and rear end jumping.

Gearshift Ratio Development

Final Recommendations and Advice

Preventive Advice and Safe Riding

General recommendations for maintenance, safety, and responsible riding.

Terrain-Specific Care

Homologation Requirements

Competition Preparation and Maintenance

Motorcycle Storage Procedures

Multifunction Display Operation

Multifunction Display Settings

Clock Accuracy and Trip Meter

How to adjust clock accuracy and reset trip distance.

Wheel Travel Adjustment

Troubleshooting Engine Issues

Troubleshooting Engine and Exhaust Issues

Troubleshooting Transmission and Stability Issues

Troubleshooting Suspension and Vibration Issues

Troubleshooting Handling, Brakes, and Electrical Issues

Warranty Terms and Conditions

Warranty Exclusions and Various Clauses