GAS GAS EC - 2005 User manual

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

SERVICE MANUAL
SERVICE MANUAL
ENGLISH

PRESENTATION
GAS GAS appreciates your trust.
We are happy to see that you have decided on a GAS GAS EC ROOKIE moped and welcome you into the
great family of GAS GAS users. Learn everything about your new machine. It contains a large amount of
experience accumulated from many competitions where we have won important prizes. You are now the owner
of a moped that, besides making you feel comfortable, offers a great many opportunities for you to show your
skills while providing top safety levels.
This manual provides a wealth of basic information on the moped features and how best to use it. It also
includes important safety instructions , together with basic maintenance and inspection routines.
Thank you for trusting us and welcome to GAS GAS Motorcycles.
-3-

IMPORTANT NOTICE
Read this manual thoroughly. It contains every single aspect that
should help to provide safety for yourself and others, and to ensure
the appropriate preservation and maintenance of the GAS GAS
moped you have just purchased.
READ THE WHOLE CONTENTS OF THIS MANUAL BEFORE
USING THE VEHICLE.
Important information about this manual
Specially important information is highlighted in this manual as
follows:
WARNINIG
Ignoring the WARNING notice may result in serious or fatal injuries
to the moped user, as well as to bystanders or the technicians
inspecting or repairing it.
ATTENTION
This symbol identifies instructions or procedures that, unless strictly
followed, may damage or destroy the equipment. 
NOTE
This symbol shows items of special interest for a better
performance and a more convenient operation.
Inadequate riding may cause environmental damage and conflicts
with other people. Riding your moped in a responsible manner will
prevent the appearance of such damage or conflicts.
PROTECTING THE FUTURE OF YOUR SPORT ENSURES THE
LEGAL USE OF YOUR MOPED WHEN PROPER RESPECT FOR
THE ENVIRONMENT AND OTHER PEOPLE’S RIGHTS IS SHOWN.
This manual includes the data and specifications available at the
time of compilation. Any difference you may find with your vehicle
data and specifications is a consequence of manufacturing and
quality improvements. GAS GAS Motos S.A. constantly improves
its vehicles so that you may enjoy them at their best.
INSTRUCTIONS FOR USE
A deep knowledge of your vehicle and how it works is extremely
important.
- Remember that you are not to leave the engine running within a
closed area, as the toxic exhaustion fumes might have fatal
consequences.
- Tyre pressure has a direct influence on the vehicle stability.
- Sudden braking may result in skidding.
Engine performance and life depend to a great extent on how it is
run in. We recommend strict adherence to the instructions supplied,
at the very least during the initial 500 Kms.
- Do not keep the engine running at a high-revolution level.
- Do not change down as soon as the engine starts striving.
- Do not keep the engine running at top speed for a long time.
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TABLE OF CONTENTS
- Presentation........................................................................3
- Important notice.....................................................................4
Instructions for use......................................................4
- Table of contents.......................................................................5
- Specifications.......................................................................6
- Important information...........................................................8
Identification numbers.............................................8
- Component location..............................................................10
- Moped components..........................................................12
Main-beam pilot light................................................12
Indicator pilot light...................................................12
Multifunction.................................................................12
Ignition key...........................................................12
Neutral pilot light................................................12
Oil-reserve pilot light.............................................12
Headlight indicator......................................................... 12
Clutch..............................................................12
Lights.....................................................................12 
Start button.....................................................13
Front brake.........................................................13
Accelerator grip.........................................................13
Fuel tank...............................................................13
Oil.....................................................................14
Oil reservoir........................................................14
Fuel tap.............................................................14
Saddle.........................................................................15
Starting pedal........................................................15
Rear brake pedal..................................................15
Gear pedal.............................................................15
- Starting the cycle.............................................................16
Starting the engine...................................................16
Stopping the engine..................................................16
Choke......................................................................16
Gear box..................................................................17
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Stopping the moped......................................................17
Adjustment........................................................17
- Maintenance...........................................................................18
Maintenance schedule.....................................................18
Before starting the moped for the first time...................19
Engine............................................................................19
Gearbox and clutch.........................................................19
Carburettor........................................................................19
Air filter...........................................................................20
Sparking-plug check.........................................................20
Radiator...........................................................................21
Strip box.........................................................................21
Clutch adjustment.............................................................22
Chain lubrication...............................................................22
Chain tightening..............................................................22
Front suspension............................................................23
Rear suspension...........................................................23
Cables............................................................................24
Front brake.....................................................................24
Rear brake........................................................................24
Pump and brake pads...................................................25
Steering..............................................................................25
Tyre pressure.................................................................25
Checking operations at specialised garages..................26
Storage...........................................................................27
- Final advice..................................................................................27
Preventive advice...........................................................27
Safe use of this moped....................................................27
- Events on the road.......................................................................28
Carburettor problems......................................................28
Ignition problems...........................................................28
- Multifunction...................................................................................29
- Guarantee manual..........................................................................31

-6-
SPECIFICATIONS
ENGINE
Cubic Capacity:
Type:
Number of Cylinders:
Fuel Supply:
Cooling System:
Diameter per Stroke:
Carburettor:
Ignition:
Clutch:
Gearbox:
Transmission:
Engine Lubrication:
Cooling:
CHASSIS:
Engine:
Chassis:
Front Suspension:
Rear Suspension:
Front Brake:
Rear Brake:
49,38 cc
Two-stroke single-cylinder engine with straight-into-crankcase strip admission.
One.
Fuel supply by means of petrol with separate oil-lubrication pump.
Liquid.
40 x 39.3 mm
Dell'Ortho* SMA 1412N. 14 mm-diameter diffuser with air intake through an
easy-to-clean filter placed within a large filter housing.
Electronic with adjustable early timing.
Specially designed hydraulic clutch, featuring multiple steel- and friction disks
fitted with springs, submerged in a highly effective oil bath.
6 gears.
Primary, gear-operated; secondary, chain-operated.
Oil mixture.
Engine cooling is achieved through a large radiator that keeps the fluid at a
constant temperature, never above 80° C.
The radiator, secured onto a double-wedge chassis that unfolds at cylinder level,
has been welded with chromolibdene and features reinforcing brackets for a
highly resistant, robust assembly.
Deltabox, made from Cromoly rectangular tubes, aluminium rocker.
High-performance 32 mm-diameter inverted hydraulic fork.
Showa* inverted fork, 160 mm stroke.
- Right-hand rod:  175 cc SAE 5.
- Left-hand rod: 150 cc SAE 5.
Aluminium rocker. Progressive system fitted with BOGE* single shock absorber
providing an extremely long wheel stroke. 250 mm stroke.
240 mm disk fitted with 2-piston clip.
220 mm disk fitted with 4-piston clip. Wrought aluminium.

-7-
DIMENSIONS
Wheelbase:
Saddle Height:
Minimum Distance to Ground:
Deadweight:
Tank Capacity:
Oil Reservoir Capacity:
Oil Reservoir Reserve:
Gearbox Oil:
Engine Output Pinion:
Driving Chuck:
Early Timing:
Chain:
Sparking Plug:
Air Filter:
1.330 mm
920 mm
370 mm
93 Kg
8 litres. 98 NO unleaded petrol.
1,5 litres.
200 cc
SAE 15 - 30
Z/ 12
Z/ 52
1,5 mm before PMS.
1/2" reinforced.
NGK BR8 ES. 0.6 – 0.7 mm electrode gap.
Humid-type foam rubber.
EC - 80 x 90 x 21" 48P T63
SM - 100 x 80 x 17"
EC - 110 x 80 x 18" 58P T63
SM - 130 x 70 x 17"
Wrought aluminium
Wrought aluminium with retractable tip.
Front Tyres:
Rear Tyres:
Starting Pedal:
Brake Pedal:

KEY NUM.
IMPORTANT INFORMATION
IDENTIFICATION NUMBERS
Enter the vehicle identification number (serial number), the particulars
shown on the model label, and the ignition-key identification number
in the spaces provided, in order to simplify your future orders for
spare parts or as a useful reference in the event of your vehicle
being stolen.
Serial Number (A)
This has been printed on the steering arm. It shows the frame number
used for registering this moped.
Certification Plate (B)
The moped carries a certification plate showing a serial number (B)
that has also been printed on the front, and this information must
coincide with that contained in the vehicle documents. We recommend
that this information be entered in the box below.
Ignition Key Identification Number (C)
The moped carries one two-key set (C). The identification number
appears right on the key joints, as illustrated. This number may be
quoted when ordering a spare to replace a lost key.
-8-
CERTIFICATION PL.
SERIAL NUM.
(C)
(A) (B)

As above, again for your own information and safety, we also
recommend that all of these part numbers be entered in the spaces
provided.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
-9-
No-tampering transfer
The moped carries an information label with a diagram illustrating
some vehicle parts and their part numbers. Because these parts
were included with the moped during the certification process,
replacing some of them might be punished with a fine if traffic police
checks the vehicle.
NOTE
We recommend that a specialised garage be contacted if one
of these parts requires replacement. The garage will provide
advice on certified spare parts.
(E)
(F)
(E). Part Numbers.
(F). Numbered
Diagram.
REFERENCE

-10-
COMPONENT LOCATION
GAS GAS EC / SM ROOKIE 2005
1- Clutch handle
2- Light Switches
3- Clutch fluid reservoir
4- Petrol tank
5- Brake fluid reservoir
6- Start button
7- Accelerator grip
8- Front brake handle
9- Main beam pilot light
10- Indicator pilot light
11- Multifunction
12- Ignition key
13- Neutral pilot light
14- Oil reserve pilot light
15- Headlight indicator
9 10 11 12 13 141 42 3 5 7 86 15

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15- Front shock absorber
16- Oil reservoir
17- Petrol tanck
18- Saddle
19- Front brake disk
20- Front brake clip
21- Sparking plug
22- Gearbox pedal
23- Air filter
24- Rack
25- Chain guide
26- Rear shock absorber
27- Exhaust pipe
28- Rocker
29- Rear brake
30- Starting pedal
31- Exhaust
1816
2921 25243022 31
1715
2019 2827
26
23

-12-
MOPED COMPONENTS
MAIN-BEAM PILOT LIGHT (A)
This only lights up when the main beam is on.
INDICATOR PILOT LIGHT (B)
When lit, it confirms that either the left-hand or the right-hand indicator
is on.
MULTIFUNCTION (C)
This provides information on speed, mileage, etc. (further details
may be found at the end of this manual, under “Multifunction
Instructions”).
IGNITION KEY (D)
The key has been located on the front of the handlebars. To start
the engine, turn the key clockwise to the “ON” position.
To stop the engine, turn the key anticlockwise to the “OFF” position.
NEUTRAL PILOT LIGHT (E)
This lights up when the selector lever is in the neutral position.
OIL-RESERVE PILOT LIGHT (F)
This lights up when the oil level is too low, i.e. when the reserve
level is reached. At this point, approximately 1/4 of a litre of oil are
left in the reservoir.
HEADLIGHT INDICATOR (K)
When lit, it indicates that the headlight is on
CLUTCH (G)
The clutch handle has been located on the left-hand side of the
handlebars. Clutch engagement and disengagement is achieved by
operating this handle.
For the clutch to operate smoothly, the lever should be pressed
quickly and released slowly.
LIGHTS (H)
All light controls have been located on the left-hand grip; the various
positions available are reached by sliding the main switch, which is
on the left end of the grip.
(J)
(I)(H)(G)
Clutch.
Light button.
Stopped button.
Horn button.
(G).
(H).
(I).
(J).
All light
controls.
(A) (B) (C) (D) (E) (F)(K)

-13-
The indicator control has been located on the underside of the left-
hand grip. This is an orange-colour button. To start the right-hand
indicator, move this switch to the right; and likewise, to start the left-
hand indicator, move this switch to the left.
START BUTTON (L)
The start button is red in colour and has been located on the inside
of the right-hand grip. This is used for starting the engine. The engine
is stopped by pressing the grey-coloured button (J) on the left-hand
grip of the handlebars (previous illustration).
Short beam
Low beam
Whithout lights
FRONT BRAKE (M)
Front-wheel braking is achieved through a 240mm-diameter disk
brake operated by a clip and a hydraulic pump. For optimum results,
the braking surface must be oil-free and clean. If, for any reason,
the brake fluid must be drained and replaced, read the “Maintenance”
section beforehand.
ACCELERATOR GRIP (N)
Make sure that this works properly by turning the grip to see if it has
the right free play. The grip must spring back to its original position
when the accelerator is released.
WARNING
Improper operation of the accelerator may impair your efforts to
increase or reduce speed when required. This may result in an
accident. Check the accelerator before starting the engine. If the
accelerator does not work smoothly, find out the reason. Solve the
problem before using the moped, or contact a specialised garage.
PETROL TANK
This holds 8 litres. To access the tank, unscrew the filler cap. Once
open, fill up the tank and replace the cap correctly by turning it
anticlockwise.
Recommended Petrol
Use unleaded petrol with an octane rating equal to or higher than
the one shown in the chart.
(M) (N)
(L)
Front brake.
Accelerator grip.
Strart button.
(M).
(N).
(L).
Light button diagram.

OIL
This engine is designed to burn a mixture of combustible fuels, lead-
free petrol and oil.
The mixing is performed automatically by a mechanical pump.
The only precaution it is necessary to take is that of maintaining an
optimum level of fuel in the oil tank.
Recomended oil:
2T SINTETIC
ATENTION
Never mix vegetal and mineral oils together. Too much oil may cause
an excessive amount of fumes and spark-plug dirt. Too little oil may
cause engine damage or early wear.
OIL RESERVOIR
This holds 1.65 litres. It has been placed in the left of the moped,
behind of the left radiator. To access the reservoir, unscrew the filler
cap and fill with oil. Never allow it to exhaust the oil contents, as this
would require draining the oil pump to eliminate air accumulations.
FUEL TAP
This tap supplies fuel to the carburettor and has been located on the
left-hand side, under the saddle.
The tap has three positions.
OFF: No fuel flows through the system when the lever is in this
position. Always turn the lever to this position when the engine is
not running.
-14-
OCTANE RATING METHOD
Antiknock Index (RON + MON)/2
Research Octane No. (RON)
MINIMUM RATING
90
98
WARNING
Petrol is extremely flammable and may become explosive under
certain conditions. Never keep the engine running or smoke when
refuelling. Make sure that the area is properly ventilated and free
from flammable materials or sparks; this includes the operation of
any light sources.
(A)
(A). Oil tank.
RECOMIENDA EL USO DE ACEITE:

-15-
REAR BRAKE PEDAL (D)
The rear brake pedal is located on the right side of the lower chassis.
Activate it to apply the brake to the rear wheels.
GEAR PEDAL
The vehicle features a 6-speed gearbox.
The change pedal is located on the left side of the engine and is
used in combination with the clutch when changing gears.
RES: This refers to the fuel reserve. If you should run out of fuel on
the road, turn the lever to this position.
ATTENTION
If you must use the reserve, remember to fill the tank as soon as
possible!
After refuelling, turn the fuel-tap lever (C) back to the “ON” position.
SADDLE
This has been joined to the chassis by means of a screw secured
to the tank and its housing in the saddle tongue. The rear section
is also secured with screws that must be tightened through the top
of the number plates.
STARTING PEDAL (E)
The pedal has been placed on the right-hand side of the moped and
is in the off-position; pull to place it in the on-position. The moped
features two starting options: A button and a pedal. Use the pedal
only if absolutely necessary.
(D). Rear brake pedal.
(E). Starting pedal.
(F)
(F). Gear
pedal.
ON: Fuel flows
into the
carburettor when
the lever is in this
position. Normal
operation of the
moped is
achieved with the
lever in this
position.
ON
Open
OFF
Closed
RES
Reserve
(C)
(E)
(D)

CHOKE
The choke is a device that increases the supply of fuel to a given
extent, without the need to operate the accelerator grip, in order to
help the operation of a cold engine. The engine will quickly reach
its optimum working temperature with no danger to its component
parts.
To use the choke, lift the lever on the left-hand side of the carburettor
(A). This will allow the engine to start on reaching a given amount
of revolutions.
-16-
STARTING THE CYCLE
STARTING THE ENGINE
- Make sure that the moped is in neutral (this is shown on the control
panel).
- Check to see that there is fuel in the tank.
- Turn the fuel tap to the "ON" position.
- Turn the ignition key clockwise (to the "ON" position), in order to
open the electric circuits required for the engine to start.
- If the engine is cold, operate the choke by lifting the lever on the
right-hand side of the carburettor (as illustrated on this page). This
should provide a richer fuel mixture.
- Without operating the accelerator grip, press the electric starting
button.
- If the engine still fails to start properly, you may also operate the
starting lever.
STOPPING THE ENGINE
- Change down to neutral (the relevant control-panel pilot light will
come on).
- Accelerate slightly, and then turn off the supply of fuel and press
the stop button.
- Turn the key anticlockwise. The key will lodge to the left, a position
where all the electric circuits remain closed. The engine will not start.
- You will be able to remove the ignition key.
- Finally, turn the fuel tap to the "OFF" position.
NOTE
Unless the engine is started when the ignition key is on the
“ON” position, the battery may lose some power.
(A) (B)

Turn off the choke (B) after a few seconds, as the engine will have
then reached the right temperature. To turn off the choke, just turn
the accelerator grip as far as it will go.
NOTE
If the engine should flood, start the moped with the accelerator
fully on. The moped may be started with one gear in, if you
press the clutch.
GEAR BOX
This being a six-gear transmission with a return gear, shifting from
first to third gear requires going through second gear, i.e. shifting
gears upwards in a sequence.
To go into first gear from neutral it is imperative to press the clutch,
then step on the gearbox pedal, release the gearbox pedal and
finally release the clutch slowly.
ATTENTION
When shifting gears, press firmly on the gearbox pedal in order to
ensure a positive shift. Incomplete gear shifting may cause the
transmission to go into the wrong gear, thus damaging the engine.
STOPPING THE MOPED
For maximum deceleration, release the accelerator grip and operate
both the front and rear brakes. Release the clutch and the moped
will gradually stop. A separate use of either the front or the rear
brake may be advantageous under certain conditions.
-17-
Change down sequentially while decelerating, to ensure the right
response from the engine when you wish to accelerate.
ADJUSTMENT
The smooth operation required to maximize engine and transmission
performance must be achieved through a previous running-in process.
During the first hour or 20 Km, have the engine running at low speed
and a moderate rpm level.
NOTE
Low speed during the running-in process may result in a dirty
sparking plug. Check the condition of the standard sparking
plug supplied and replace it, if necessary, with one of a higher
thermal grade.
During the initial 10-hour period, it is advisable not to go beyond
medium speed for a long time and to avoid any type of situation that
might cause the engine to reach too high a temperature. However,
short-time (3 to 4 seconds) accelerations cannot damage the engine;
on the contrary, they are beneficial. Every acceleration sequence
must be followed by a rest period, to allow the engine to remove all
of the heat accumulated.
During this initial 10-hour period, it is advisable not to keep a constant
speed, but to change it instead every now and then.
During the next 10-hour period (10-20), it is advisable not to go
beyond 3/4 of the speed available for a long time.
ATTENTION
In any event, reckless accelerations may suffice to cause engine
trouble. Be sure to always apply the skills and techniques required
for a proper use of this moped.

-18-
MAINTENANCE
MAINTENANCE SCHEDULE
After the initial 500 Km:
Every 1.000 km:
Every 2.000 km:
Every 8.000 km:
Maintenance after riding over dusty
ground:
Maintenance after riding over muddy
ground or in the rain:
- Gearbox-oil replacement after the running-in period.
- Screw tightening and control adjustments.
- Cooling-circuit inspection.
- Brake-circuit level checking.
- Electrode-gap inspection and sparking plug cleaning.
- Chain adjustment, tightening and lubrication.
- Brake-circuit level checking.
- Cooling-circuit level checking.
- Air-filter cleaning.
- Spark-plug replacement.
- Brake-pad wear inspection.
- Engine-oil replacement.
- Piston-, cylinder-head-, and exhaust-port decalcification.
- Check to see that there are no obstructions in the exhaust pipe and
silencer.
- Check the early timing.
If dirt or particles get into the engine, this can cause wear of the pistons
and rings. After using the moped, check the crank and replace it if the
wear shown is excessive.
1. Lubricate the rocker arm and the suspension system.
2. Check the chain and the wear on the crown wheel and pinion.
3. Clean the pinion and crown wheel and grease them together with the
chain.
4. Check the cylinder piston and the crank bearings.
5. Lubricate the accelerator grip and the cable.
6. Clean the foam filter and the interior of the filter chamber.