GAS GAS EC 125 Racing 2013 User manual

-3-
Foreword
GAS GAS thanks you for the trust you have placed in us.
By choosing the new GAS GAS EC 2013 you have become part of the great GAS GAS family and, as a user
of the number one manufacturer of off-road motorbikes, you deserve the distinguished treatment that we wish
to offer to you both in our after-sale relationship and in the explanations that we provide in this manual.
Our EC 2013 is a motorcycle conceived for the practice of high-competition. 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 contributed with their expertise to the basic data that have
allowed us to create motorcycles of the highest level, GAS GAS unique motorcycles which count on important
key factors: reliability, high features and a good stability.
Congratulations for making the right choice. With your skills at the command of this motorcycle, its adequate
preparation and the corresponding indispensable servicing, this motorcycle will prove to be highly reliable, and
you will be able to enjoy the most comfortable and rewarding practice of your favorite sport.
Thank you for your trust in us, and welcome to GAS GAS Motos, S.A.
August 2012

-4-
HOW TO USE THIS MANUAL
Read this Manual carefully. You will find it contains all the necessary
information for your safety, and that of other persons, as well as
guaranteeing the correct conservation and maintenance of the GAS
GAS motorcycle that you have just acquired.
You will find all the necessary instructions for the correct riding and
control of this vehicle are set out below. Each message is preceded
by a symbol with the following meaning: .
WARNING
This warning symbol identifies special instructions or procedures
which, if not correctly followed, could result in 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 indicates points of particular interest for more
efficient and convenient operation.
Motorcycle riding, if improverly conducted, has the potential to cause
environmental problems as well as conflicts with other people.
Responsible riding use of your motorcycle will ensure that these
problems and conflicts do not develop.
TO PROTECT THE FUTURE OF YOUR SPORT MAKE SURE YOU
USE YOUR MOTORCYCLE WHITHIN THE LAW, SHOW CONCERN
FOR THE ENVIRONMENT, AND RESPECT THE RIGHTS OF
OTHER PEOPLE.
Motorcycle riding is a wonderful sport, and we hope you will enjoy
it to the fullest.
RECOMMENDS THE USE OF OIL:

-5-
TABLE OF CONTENTS
Foreword...........................................................................................3
How to use this manual.....................................................................4
Table of contents...............................................................................5
Specifications....................................................................................6
Location of components....................................................................8
Side Stand ......................................................................................10
Fuel.................................................................................................10
Serial Number.................................................................................12
Homologation Plate.........................................................................12
Starting the engine..........................................................................12
Shifting gears..................................................................................13
Stopping the motorcycle .................................................................14
Riding during the Break-In Period...................................................14
Maintenance Schedule ...................................................................15
Electronic Ignition............................................................................17
Cooling System...............................................................................17
Spark Plug ......................................................................................20
Transmission...................................................................................20
Air Cleaner......................................................................................22
Throttle Cable .................................................................................23
Carburetor.......................................................................................23
Clutch..............................................................................................24
Exhaust System..............................................................................24
Drive Chain Guide...........................................................................25
Handlebar .......................................................................................27
Brakes.............................................................................................28
Steering...........................................................................................29
Steering blockage...........................................................................30
Front Fork .......................................................................................31
Rear suspension.............................................................................34
Wheels............................................................................................36
Cleaning..........................................................................................37
Bolts and nuts tightening.................................................................38
Lubrication ......................................................................................40
Tunning (Carburetor and Suspension)............................................41
Final recommendatios.....................................................................49
Homologation..................................................................................50
Preparation for competition.............................................................51
Storage ...........................................................................................52
GAS GAS Multifunction Instructions ..............................................53
Troubleshooting ..............................................................................60
Electric Schemas............................................................................65
Warranty Manual.............................................................................66

-6-
SPECIFICATIONS
ENGINE 2 cycles, single cylinder, crankcase intake, liquid cooled
125 cc Engine
Bore and stroke 54 x 54.5 mm
Displacement 124 cc
Carburettor, diameter of diffusor 36
Lubrication system Mixture
100% Synthetic Oil 50:1 = 2%
Mineral Oil (Only USA) 32:1 = 3%
Starting system Starting lever
Ignition system CDI system
Ignition timing 1 mm BTDC
TRANSMISSION
Transmission type 6 speed
Clutch type Hydraulic operated multi-plate in oil bath
Secondary drive Chain driven
Gear ratio (125 cc) 1st. 2,308 (30/13)
2nd. 1,867 (28/15)
3rd. 1,529 (26/17)
4th. 1,286 (27/21)
5th. 1,130 (26/23)
6th. 1,000 (24/24)

-7-
Primary reduction 3,32 (63/19)
Final reduction 4,17 (50/12)
Transmission oil Capacity 750 cc
Type 10W30 API SF or SG
CHASSIS
Type Tubular, semi-double cradle
Tire size Front EC - 90/90 x 21
Rear EC - 140/80 x 18
Suspension Front Inverted telescopic fork ø 45 mm
Rear Progressive system with single multi-adjustable shock
Suspension stroke Front 298 mm
Rear 298 mm
Front fork oil SAE 5 - 7.5
Front fork oil level 110 mm (compressed, without spring)
BRAKES
Type Front, Rear Disc brake
Effective disc diameter Front 260 mm
Rear 220 mm
DIMENSIONS
Overall height 1260 mm
Overall length 2200 mm
Overall width 830 mm
Seat height 950 mm
Minimum height 340 mm
Wheelbase 1540 mm
Fuel tank capacity 9.5 l
(Specifications are subject to change without notice and probably do not apply to all countries).

-8-
LOCATION OF COMPONENTS
6 Front Brake fluid reservoir
7 Throttle grip
8 Front brake lever
9 Steering, lights, horn and headlamp controls
10 Burglar by locking direction
1 Clutch lever
2 Starter lever
3 Clutch fluid reservoir
4 Multifunction scoreboard
5 Fuel tank cap
GAS GAS EC

-9-
9- Brake disc
10- Front suspension
11- Fuel tank
12- Carburetor
13- Rear shock absorber
14- Brake caliper
15- Radiator
16- Gasoline cock
17- Shift pedal
18- Muffler
19- Seat
20- Gas reservoir
21- Chain guide
22- Chain
23- Suspension linkage
and swingarm
24- Rear brake pedal
25- Kick-start pedal
26- Exhaust
27- CDI switch
28- Front axe puller
29- Skid plate
30- Rear brake pump intercooler
10
11
12
18
13
914
15
16
17
19
22 23
24 25
27
14
20
21 26
27
28
GAS GAS EC

-10-
(A). Fuel tank cap.
(B). Vapor outlet tube.
SIDE STAND
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 means of the
double spring. The function of the double spring insures that, when
the side stand is down, the rest position is stable and above all
secure; moreover, it also returns the side stand to its original position.
EC
(
A). Side stand.
(B). Double spring.
NOTE
Do not start the engine or ride the motorcycle when the side
stand is down.
FUEL
The GAS GAS EC models have 2-cycle engines that require a
mixture of gasoline and oil.
Gas Tank Capacity
9,5 L
The fuel tank cap is of the quick-release type.
To open the fuel tank cap, lift the plated latch and turn cap counter-
clockwise.
To close it, turn the cap clockwise and lower the latch.
NOTE
It is recommended that the rubber seal should be checked
thoroughly to insure it is airtight.
(A)
(A)
(B)
(A)
(B)

-11-
RECOMMENDED FUEL
Use gasoline with an octane rating equal to or higher than that shown
in the table.
OCTANE RATING METHOD MINIUM
RATING
Antiknock Index (RON+MON)/2 90
Research Octane No. (RON) 98
NOTE
If knocking or pinging occurs, try a different brand of gasoline
or higher octane grade.
WARNING
Gasoline is extremely flammable and can be explosive under certain
conditions. Always stop the engine and do not smoke. Make sure
the area is well ventilated and free from any source of flame or
sparks; this includes any appliance with a pilot light.
Mixing oil inside the engine
Oil must be mixed with gasoline to lubricate the piston, cylinder,
crankshaft, and connecting rod bearings.
Recommended oil:
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 oil 1 = 2%
Semi-synthetic oil: gasoline 50, engine oil 1 = 2%
Mineral oil: gasoline 32, engine oil 1 = 3%
CAUTION
Do not mix vegetable and mineral based oils.
Too much oil will cause excessive smoking and spark plug fouling.
Too little oil will cause engine damage or premature wear.
CAUTION
Below 0 ºC do not use 100% synthetic oil.
To prepare the mixture, first pour oil and half of the gasoline used
into a container and stir the mixture thoroughly. Then add the rest
of the gasoline and stir the mixture well.
NOTE
At low temperature, oil will not easily mix with gasoline. Take
time to ensure a well-blended mixture.
The lubrication quality of this mixture deteriorates rapidly; use
a fresh mixture for each day of operation.

-12-
3. If the engine is cold, pull up the choke trigger (B).
ON
Open
OFF
Close RES
Reserve
(A)
(B) (B)
STARTING THE ENGINE
1. Make sure the motorcycle is in the neutral position.
2. Turn the gasoline cock (A) clockwise to the "ON" position.
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 homologation plate where
it also shows the serial number, and this data must match the
information registered in the motorcycle documents.

(D)
(C)
SHIFTING GEARS
The transmission is a 6-speed, of the return shift type. A return shift
means that to go from first gear to third gear it must go first through
the second gear, that is to say that it upshifts gears one by one. To
engage first gear from neutral, pull the clutch lever in and push down
on the gearshift pedal, then release the gearshift pedal and gently
release the clutch lever.
CAUTION
When shifting gears, press firmly on the gearshift pedal to ensure
a positive shifting. Careless, incomplete shifts can cause the
transmission to jump out of gear and cause engine damage.
(A). Gearshift pedal.
-13-
NOTE
- When the engine is already warm or on hot days, open
the throttle instead of using the choke knob.
- If the engine is flooded, kick with the throttle fully open.
- If the clutch lever is pulled, the motorcycle can be
started while in any gear.
5. Even after the engine starts, keep the choke knob pulled up.
Stopping the engine
1. Shift the transmission into neutral.
4. Start the
motorcycle with
kick-start pedal (C).
2. After racing the
engine slightly,
close the throttle
completely and
depress the engine
stop button (D). (A)

inspection of the spark plug shows this to be the case, replace
the standard spark plug with another of a higher heat range.
Perform the break-in period following these 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. Stop and let the engine cool completely. Be sure to check and
adjust chain slack and spoke tightness and cxarry out a general
inspection.
5. Start the engine and ride for 20 minutes at moderate speed. -
NEVER ACCELERATE HARD.
6. Stop and let the engine cool completely. Check and adjust as
needed (Refer to the table of adjustments).
7. Install the parts removed.
8. Fill the radiator with the recommended coolant. Before starting
the motorcycle, bleed the air from the cooling system.
9. Start the engine and ride for 30 minutes at moderate speed.
10. Stop and let the engine cool completely. Check and adjust.
11. After the break-in procedure has been properly carried out, the
motorcycle is ready for regular operation.
CAUTION
However, avoid accelerating recklessly that can lead to engine failure.
Be careful to use the necessary skills and techniques while operating
the motorcycle.
NOTE
After the break-in period, install a new set of standard spark
plugs.
-14-
STOPPING THE MOTORCYCLE
For maximum deceleration, close the throttle (A) and apply both
front and rear brakes. Disengage the clutch as the motorcycle comes
to a stop. Independent use of the front or rear brake may be
advantageous under certain conditions.
Downshift progressively as speed is reduced to ensure good engine
response when you want to accelerate.
RIDING DURING THE BREAK-IN PERIOD
A break-in period is necessary to ensure a smooth operation and
obtain an optimum engine and the transmission responses. During
the first hour or 20 km of operation, run the engine at low and
moderate speeds and revolutions per minute (RPM).
NOTE
The slow riding necessary during the break-in period may cause
carbon deposits to build up on the spark plug and foul it. If
(A)

-15-
The maintenance and adjustments in this table are easy to follow and must be carried out to keep the motorcycle in good running condition.
NOTE: (*) Inspect and carry out these operations only if it is necessary.
Item
Clutch
Discs
Throttle cable
Spark plug
Air cleaner element
Carburetor
Transmission oil
Piston and piston ring
Cylinder head, cyl. & exhaust valves
Exhaust
Muffler gasket
Piston bearing
Kick-start pedal and gearshift pedal
Exhaust pipe o'ring
Engine bearings
Coolant
Radiator tube and connections
Brake adjustment
Brake pads wear
Brake fluid level
Brake fluid
Brake pump piston & dust cover
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 up
-
3 fill ups
-
-
10 fill ups
3 fill ups
1 fill up
3 fill ups
5 fill ups
3 fill ups
-
-
At each fill up
3 fill ups*
1 fill up
-
-
1 fill up
-
3 fill ups*
3 fill ups*
1 fill up*
10 fill ups*
3 fill ups*
-
-
10 fill ups*
3 fill ups*
1 fill up*
3 fill ups*
5 fill ups*
3 fill ups*
-
-
At each fill up
-
-
-
-
-
-
-
-
-
-
3 fill ups
1 fill up
-
-
-
-
-
-
-
-
-
Clean
At each fill up*
3 fill ups*
-
-
When damaged
-
3 fill ups
3 fill ups*
3 fill ups*
1 fill up*
10 fill ups
10 fill ups
-
3 fill ups
10 fill ups*
3 fill ups*
1 fill up*
3 fill ups*
5 fill ups*
3 fill ups*
Every 2 years
Every 2 years
-
-
-
1 fill up
1 fill up
-
-
3 fill ups
-
1 fill up
-
-
-
-
-
-
-
-
-
-
-
-
MANTENANCE SCHEDULE

-16-
The maintenance and adjustments in this table are easy to follow and must be carried out to keep the motorcycle in good running condition.
NOTE: (*) Inspect and carry out these operations only if it is necessary.
Item
Brake caliper piston seal & dust seal
Brake hose and pipe
Spoke tightness and rim runout
Lubricate drive chain
Drive chain
Drive chain wear
Chain slider
Front fork
Front fork oil
Nuts, bolt, fasteners
Fuel hose
Fuel system
Steering play
Rear sprocket
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 fill ups
1 fill up
-
5 fill ups
7 fill ups
-
1 fill up
5 fill ups
5 fill ups
-
10 fill ups
5 fill ups
Every 2 years
-
-
1 fill up*
-
-
5 fill ups
5 fill ups*
When necessary
-
5 fill ups*
7 fill ups*
-
-
5 fill ups*
-
-
10 fill ups*
5 fill ups*
2 years*
-
-
-
1 fill up
-
-
-
-
-
-
-
-
-
-
5 fill ups
10 fill ups
-
5 fill ups
-
Clean
Every 2 years
Every 4 years
1 fill up*
-
-
5 fill ups
5 fill ups*
When damaged
Every year
5 fill ups*
7 fill ups
10 fill ups
-
5 fill ups*
-
-
10 fill ups*
5 fill ups*
2 years*
-
-
-
-
-
-
-
When necessary
-
-
-
When necessary
-
-
-
-
-
-
-

-17-
- If the marks are not aligned, loosen the magnetic inertia wheel
screws and turn it.
- Tighten the screws securely.
- Install the magnetic flywheel cover.
NOTE
Engine tune-up can be adjusted to match the rider´s preferences
and skills.
- Remove the magnetic flywheel cover.
- Loosen the stator screws.
- Adjust the engine tune-up by changing the position of the stator
within prudent limits
NOTE
For the best engine performance, it is very important to adjust
the engine tune-up within the set of limits described.
- Tighten the stator screws.
- Install the magnetic flywheel 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.
Radiator
Check the radiator fins for obstructions (insects or mud). Remove
any obstructions with a stream of low water pressure.
ELECTRONIC IGNITION
This motorcycle uses a capacitor discharge ignition system (CDI).
The ignition system should never require adjustment unless the
stator of the magnetic flywheel was incorrectly installed during engine
reassembly.
If necessary, inspect and adjust as follows:
Adjustment
- Remove the magnetic flywheel cover (A).
- Make sure that the mark on the stator plate is aligned with the
mark on the crankcase.
(A)

-18-
CAUTION
If high water pressure is used the radiator fins could be damaged
and impair the radiator effectiveness.
Do not obstruct or deflect airflow through the radiator by installing
unauthorized accessories. Any interference with the radiator airflow
can lead to engine overheating and damage.
Coolant information
To protect the cooling system aluminum parts (engine and radiator)
from rust and corrosion, the use of corrosion and rust inhibitors
chemicals in the coolant is essential. If rust inhibitors were not used,
over a period of time the radiator will be corroded. This will clog the
tubes of the cooling system.
CAUTION
Use of incorrect coolant solutions will cause engine and cooling
system damage.
Use coolant containing corrosion inhibitors made specifically for
aluminum engines and radiators in accordance with the instructions
of the manufacturer.
WARNING
Chemical liquids are harmful to the human body. Follow manufacturer
instructions.
CAUTION
Distilled water must be used with corrosion inhibitors and the
antifreeze in the cooling system. If tap water is used in the system,
the cooling tubes can be clogged 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 cooling system (distilled water and ethylene glycol
and corrossion inhibitors for aluminium engines and radiators).
For the coolant mixture ratio under extreme conditions, choose the
mixture ratio listed on the container for the lowest ambient temperature.
CAUTION
Permantent types of antifreeze have anticorrosion and anti-rust
properties. When it is diluted excessively, it loses its antifreeze and
anticorrosion properties. Mix in accordance with the instructions of
manufacturer.
Liquid recommended
Permanent type of antifreeze (distilled water and ethylene glycol)
plus corrossion inhibitors for aluminium engines and radiators.
NOTE
Initially, at the factory a permanent type of antifreeze is installed
in the cooling system. It is colored green, it contains a 50%
solution of ethylene glycol, and has a freezing point of –35 ºC.
Coolant recommended
Coolant absorbs excessive heat from the engine and transfers it to
the air at the radiator. If the coolant level is low, the engine overheats
and may suffer severe damage. Check the coolant level each day
before riding the motorcycle. Add liquid recommended if the level is
low (see next page).

-19-
Total quantity
Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze
50%).
Capacity: 1.1 L
Coolant Replacement
Coolant should be changed periodically to ensure long engine life.
- Wait for the engine to cool completely.
- Place the motorcycle in riding position.
- Remove the radiator cap.
- Place a container under the coolant drain screw, and drain the
coolant from the radiator and engine by removing the drain screw
(B) at the bottom of the water pump cover (A). Wash off immediately
any 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 level
- Place the motorcycle in riding position.
- Turn the radiator cap (A) counterclockwise and wait a few seconds
until vapors inside are released. Then push and turn it further in
the same direction and remove the cap.
NOTE: Check the level when the engine is cold.
- Check the coolant level. The coolant level should be just at a level
below de cap rubber seal.
- If the coolant level is low, add the correct amount of coolant
through the filler opening.
(B) (A)
(A)

-20-
WARNING
If coolant gets on the tires will make them very slippery and can
cause an accident.
- Visually inspect the old coolant. If whitish spots are observed in
the liquid is a clear indication that the aluminum parts in the cooling
system are corroded. If the coolant is brown, iron or steel parts
of the system are rusting. In both cases, flush the cooling system.
- Check the cooling system for damage, leaks or missing gaskets
in the cooling system.
- Install the water pump cover drain screw with the specified torque
values shown in the table. Always replace the gasket with a new
one.
Drain plug tightening torque (refer to torque table)
Water pump screw: 9 Nm
- Fill the radiator up to the edge of the cap with coolant, and install
the radiator cap.
- Inspoect the cooling system for leaks.
- Start and warm up the engine, then stop the engine.
- Check the coolant level after the engine cools down. Add coolant
up to the cap.
SPARK PLUG
The standard spark plug is a shown in the table and should be
tightened to 27 Nm.
Standard Spark Plug
125 cc Denso W27ESR-U 0.7-0.8 mm OR NGK BR9EG
The spark plug should be removed periodically to check its gap. If
the plug is oily or has carbon deposits, clean it with a sandblaster.
After removing the abrasive particles, the spark plug must be cleaned
using a wire brush or a similar tool. Measure the gap with a feeler
gauge, if incorrect adjust the gap by bending the side electrode. If
the spark plug electrodes are corroded or damaged, or if insulator
is cracked, replace the plug.
NOTE
Inspect every 30 hours and change every 60 hours.
To find out whether the right heat range plug is being used, remove
it and inspect the ceramic insulator around the center electrode. If
the ceramic is light brown, the spark plug is correctly matched to
engine temperature. If the ceramic is whie, the spark plug should
be replaced with the next colder plug. If the ceramic is black, the
spark plug should be replaced with the next hotter plug.
NOTE
If the engine performance drops, replace the spark plug first to
recover its output.
TRANSMISSION
For the transmission 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 can accelerate wear and tear and cause transmission
damages.