GAS GAS EC 2T 20012501300cc RACING User manual

2012 GAS GAS Motos, S.A.
All rights reserved.
The reproduction, distribution, public communication and transformation, totally or
partially, is prohibited without the express authorization of the copyright owner.
The company has the right, whithout notice, to change technical content of products.

Owner’s manual
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Contents
GENERAL INFORMATION ................................................................................................................................................................. 7
INTRODUCTION ............................................................................................................................................................................... 8
LEGAL NOTICES ............................................................................................................................................................................... 8
NOTICES AND WARNINGS...............................................................................................................................................................8
PRELIMINARY WARNINGS ..............................................................................................................................................................9
CONTROLS ANS COMPONENTS LOCATION..................................................................................................................................10
EC 2T 200cc/250cc/300cc RACING //250cc/300cc Replica Factory.......................................................................................10
EC 2T 250cc/300cc RACING E-START ...................................................................................................................................12
EC 2T 200cc/250cc/300cc RACING “Cross Country”............................................................................................................14
EC 2T 250cc/300cc RACING E-START “Cross Country”.........................................................................................................16
XC 2T 200cc/250cc/300cc RACING (USA) ............................................................................................................................18
XC 2T 250cc/300cc RACING E-START (USA) .........................................................................................................................20
IDENTIFICATION ............................................................................................................................................................................ 25
STEERING LOCK .............................................................................................................................................................................25
SPECIFICATIONS ............................................................................................................................. ............................................... 26
EC 2T 200cc/250cc/300cc RACING & “Cross Country”// 250cc/300cc Replica Factory ...........................................................26
EC 2T 250cc/300cc RACING & “Cross Country”E-START .....................................................................................................28
XC 2T 200cc/250cc/300cc RACING (USA) ............................................................................................................................30
XC 2T 250cc/300cc RACING E-START (USA) .........................................................................................................................32
ELECTRICAL DIAGRAMS ................................................................................................................................................................34
EC Racing // EC Replica Factory............................................................................................................................................. 34
EC Racing “CrossCountry”& XC Racing (USA) .....................................................................................................................35
EC Racing “E-START”...........................................................................................................................................................36
EC Racing CrossCountry “E-START”& XC Racing “E-START”(USA) .......................................................................................37
TORQUE VALUES ........................................................................................................................................................................... 38
General ............................................................................................................................................................................... 38
Chassis ................................................................................................................................................................................ 38
Engine.................................................................................................................................................................................40
“E-START”Engine .................................................................................................... ............................................................ 42
MULTIFUNCTION GAUGE..............................................................................................................................................................44
Quick g uid e ......................................................................................................................................................................... 44
Normal mode..........................................................................................................................................................44
Configuration mode ................................................................................................................................................44
Temporal data reset................................................................................................................................................45
Trip adjust ...............................................................................................................................................................45
Reset and change of battery ..............................................................................................................................................45
Specifications ........................................................................................................................................................................ 45
Configuration ...................................................................................................................................................................... 46
Enter configuration mode .......................................................................................................................................46
Set Speed units ....................................................................................................................................................... 46
Set wheel size .........................................................................................................................................................46
Set clock format ......................................................................................................................................................46
Set time .................................................................................................................................................................. 46
Set temperature units.............................................................................................................................................46
Set high temperature warning ................................................................................................................................47
Set danger temperature warning ............................................................................................................................47
Set oil reminder ...................................................................................................................................................... 47
Set maintenance reminder......................................................................................................................................47

Owner’s manual
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Contents
Measure of the wheel circumference .................................................................................................................................47
Method 1 ................................................................................................................................................................47
Method 2 ................................................................................................................................................................47
Screens in normal mode .....................................................................................................................................................48
Screen 1..................................................................................................................................................................48
Screen 2..................................................................................................................................................................48
Screen 3..................................................................................................................................................................48
Sleep mode .............................................................................................................................................................. ........... 48
HOMOLOGATION .......................................................................................................................................................................... 49
OPERATING INSTRUCTIONS ............................................................................................................................. ............................... 51
STARTING PROCEDURE ............................................................................................................................. .................................... 52
BREAK-IN PROCEDURE................................................................................................................................................................. . 52
DAILY INSPECTION ............................................................................................................................. ........................................... 53
CLEANING ......................................................................................................................................................................................57
STORAGE........................................................................................................................................................................................ 58
SERVICE AND MAINTENANCE ......................................................................................................................................................... 59
MAINTENANCE SCHEDULE ........................................................................................................................................................... 60
MAINTENANCE ............................................................................................................................. ................................................. 61
1 .-Clu tc h..............................................................................................................................................................................61
2.-Clutch discs ........................................................................................... .......................................................................... 61
3.-Throttle cable.................................................................................................................................................................. 61
4.-Spark plug ....................................................................................................................................................................... 61
5.-Air fi lter.......................................................................................................................................................................... . 62
5.1-“EC Racing”// EC Replica Factory Air fi lter...................................................................................................... 62
5.2-“EC Racing E-START”Air filter ...........................................................................................................................63
5.3-“XC Racing (USA)”Air filter ...............................................................................................................................64
5.4-“XC Racing E-START (USA)”Air fi lter..................................................................................................................65
6.-Carburetor ......................................................................................................................................................................67
7.-Transmission oil ..............................................................................................................................................................67
8.-Piston and ring................................................................................................................................................................68
9.-Cylinder head, cylinder, ex. valve ....................................................................................................................................68
10.-Exhaust system .............................................................................................................................................................68
11.-Muffler fi ber.................................................................................................................................................................. 69
12.-Connecting rod and bearings ........................................................................................................................................70
13.-Kick-starter and gear shift pedal ...................................................................................................................................70
14.-Rubber joint exhaust/silencer .......................................................................................................................................70
15.-Motor bearings .............................................................................................................................................................70
16.-Coolant ......................................................................................................................................................................... 70
17.-Radiator hose and connections ...................................................................................................................................... 72
18.-Brakes adjustment ........................................................................................................................................................72
19.-Brake wear....................................................................................................................................................................73
20.-Brake fl uid.....................................................................................................................................................................75
21.-Brake fluid level............................................................................................................................................................. 75
22.-Pump piston and dust cover (front and rear) ................................................................................................................75
23.-Caliper piston and dust cover (all calipers)....................................................................................................................76
24.-Brake hoses ..................................................................................................................... .............................................. 76
25 and 26.-Wheels and spokes............................................................................................................................................76
27.-chain guide ...................................................................................................................................................................76

5
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Contents
28.-Chain guide wear .......................................................................................................................................................... 76
29.-Chain guide shoe...........................................................................................................................................................76
30.-Front suspension...........................................................................................................................................................77
31.-Front suspension oil......................................................................................................................................................78
32.-Bolts, nuts and fasteners...............................................................................................................................................78
33.-Gas tube......................................................................................................................... ............................................... 78
34.-Fuel system ........................................................................................................................................................ ........... 79
35.-Steering head adjustment.............................................................................................................................................79
36.-General lubrication .......................................................................................................................................................80
37.-Steering bearings .......................................................................................................................................................... 80
38.-Wheel bearing ..............................................................................................................................................................80
39.-Swingarm and linkage ...................................................................................................................................................80
40.-Rear suspension............................................................................................................................................................ 80
41.-Chain............................................................................................................................................................................ . 83
42.-Tires ................................................................................................................................................................................ 83
43.-Battery Load....................................................................................................................................................................84
SE TT IN G S ........................................................................................................................................................................................ 85
INTRODUCTION ............................................................................................................................................................................. 86
CARBURETION SETTINGS..............................................................................................................................................................86
Throttle valve opening influences .......................................................................................................................................86
Idle jet and mixture screw ..................................................................................................................................................86
Needle ................................................................................................................................................................................ 87
Main jet .............................................................................................................................................................................. 87
Reference carburetion (competition use only) ................................................................................................................... .87
Correction factors ...............................................................................................................................................................88
Symptoms of improper settings ............................................................................................................................. ............. 89
CDI MAP......................................................................................................................................................................................... 90
SECONDARY TRANSMISSION RATIO.............................................................................................................................................90
SUSPENSION SETTINGS .......................................................................................................................... ...................................... 91
Available settings ................................................................................................................................................................91
Standard settings ................................................................................................................................................................92
Static sag............................................................................................................................................................................. 93
Correction acording to terrains ........................................................................................................................................... 93
Set up your motorbike ........................................................................................................................................................ 93
FOOTPEGS SETTINGS .................................................................................................................................................................... 95
TROUBLESHOOTING ....................................................................................................................................................................... 97
WARRANTY MANUAL ......................................................................................................................................................................103

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Owner’s manual
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Owner’s manual
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GENERAL INFORMATION

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Owner’s manual
Introduction
GAS GAS Motos, S.A. thanks you for your confidence.
With the choose of your new GAS GAS EC 2013 or XC 2013 you just entered the great GAS GAS team and, as a user of the brand number
one on off-road motorcycles, deserves distinguished treatment that we want to offer both our relationship after the acquisition of your GAS
GAS and in the explanations that you are in this manual.
Your GAS GAS EC 2013 or XC 2013 is a bike designed for the practice of the high competition, it is the result of many years of racing and
experience in such demanding disciplines. The many successes achieved by great riders with our GAS GAS bikes, have provided basic data
in order to create these high level motorcycle. A few exclusive motorcycles GAS GAS with three key factors: reliability, high performance
and good stability.
Congratulations because your election has been, without doubt, the right one. With your prowess to the handlebars of your GAS GAS and
with adequate preparation and corresponding revisions are essential to ensure that your GAS GAS is highly reliable, you can enjoy more
comfortable and grateful practice the sport motorcycle.
Thank you for your trust and welcome to GAS GAS Motos, S.A.
Legal notices
In the interest of technical development GAS GAS Motos, S.A. reserves the right to modify the construction, staffing, and accessories of
the motorcycle without prior notice. Data measures, weights, and powers are understood with the respective tolerances.
Depending on the volume of equipment and accessories for your GAS GAS, as well as the versions certified to respect the various laws of
each State, there may be variations on the descriptions and illustrations. So the pictures exposed in this manual may therefore not corres-
pond to the purchased model. That’s why not may arise claim some exception error, error of printing or omission.
Notices and warnings
Please read carefully this manual with special attention to the following notices:
DANGER
Notice about a danger that leads to serious injury and even death.
WARNING
Notice about a danger which may cause personal injury and/or damage to the vehicle.

Owner’s manual
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Preliminary warnings
DANGER
Three of each four fatal accidents are due to head injuries. The risk of brain injury is three times higher if you don’t use a helmet. Always
take a helmet approved, the probability of leaving unharmed in an accident increases by 20%. It also recommends the use of eye protection
and gloves, boots and other items for protection that are in perfect condition.
Never carry passenger. Your GAS GAS is not approved for this purpose, does not have an appropriate saddle, handles or footrests for
passenger. In addition weight and imbalance can affect handling.
Avoid modifications in your GAS GAS with non-original accessories and don’t remove off the original elements, these changes can affect
stability and handling, making it a dangerous and illegal vehicle. GAS GAS requires the use of original spare parts and accessories, or parts
and accessories homologated by GAS GAS Motorcycles, S.A. It is an essential condition for maintaining the warranty.
Your GAS GAS has been designed for off-road use, not designed for long travel on highways. Such use could lead to engine damages be-
cause it maintained high revolutions. Also tyres are not suitable for use on paved surfaces. It has not been designed for urban use. Long tops
at traffic lights in town could overheat the engine.
Maintain your GAS GAS in good condition. To avoid any problem, inspect your motorcycle before each use and then all maintenance re-
commended in this manual. After a fall, inspect that the main elements have not been damaged. Driving a motorcycle in a bad state can be
cause of an accident with serious injuries and even death.
DANGER
The exhaust pipe and other parts reached high temperatures during use and take to cool down once the engine shutdown. Avoid handling
or touching anything during this period. The use of shorts is not recommended, may cause burns on the legs.
DANGER
Avoid wearing loose clothing that could engage with parts of the vehicle or the environment. Although total security is impossible, the
use of suitable equipment reduces the possibility and/or the severity of injuries.

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Owner’s manual
Components location EC 2T 200cc/250cc/300cc RACING// EC 2T 250cc/300cc/ REPLICA FACTORY
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
Number
Na me
Number
Na me
1
Headlamp with position,low beam and high beam lamps
11
Front brake caliper
2
Front turn signals
12
Front fork
3
Fuel tank
13
CDI switch
4
Fuel valve
14
Gear shift pedal
5
Rear shock
15
Carburetor
6
Air filter
16
Secondary transmission chain
7
Side stand
17
Chain guide
8
Chain guard
18
License plate holder
9
Rear turn signals
19
Rear reflector
10
Front brake disc

Owner’s manual
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Components location EC 2T 200cc/250cc/300cc RACING// EC 2T 250cc/300cc/ REPLICA FACTORY
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Number
Na me
Number
Na me
1
License plate light
9
Muffler
2
Brake light
10
Rear brake disc
3
Seat
11
Rear brake caliper
4
Rear shock gas reservoir
12
Rear brake master cylinder
5
Kick-starter
13
Suspension linkage
6
Manufacturer’s identification plate
14
Rear brake pedal
7
Radiator
15
Sump guard
8
Exhaust
16
Front axle handle

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Owner’s manual
Components location EC 2T 250cc/300cc RACING E-START
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
Number
Na me
Number
Na me
1
Headlamp with position,low beam and high beam lamps
11
Front brake caliper
2
Front turn signals
12
Front fork
3
Fuel tank
13
CDI switch
4
Fuel valve
14
Electric Starter
5
Rear shock
15
Gear shift pedal
6
Air filter
16
Carburetor
7
Side stand
17
Secondary transmission chain
8
Chain guard
18
Chain guide
9
Rear turn signals
19
License plate holder
10
Front brake disc
20
Rear reflector

Owner’s manual
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Components location EC 2T 250cc/300cc RACING E-START
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Number
Na me
Number
Na me
1
License plate light
9
Muffler
2
Brake light
10
Rear brake disc
3
Seat
11
Rear brake caliper
4
Rear shock gas reservoir
12
Rear brake master cylinder
5
Kick-starter
13
Suspension linkage
6
Manufacturer’s identification plate
14
Rear brake pedal
7
Radiator
15
Sump guard
8
Exhaust
16
Front axle handle

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Owner’s manual
Components location EC 2T 200cc/250cc/300cc RACING “Cross Country”
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16
Number
Name
Number
Name
1
Headlamp with position,low beam and high beam lamps
9
Front fork
2
Fuel tank
10
CDI switch
3
Fuel valve
11
Gear shift pedal
4
Rear shock
12
Carburetor
5
Air filter
13
Secondary transmission chain
6
Side stand
14
Chain guide
7
Front brake disc
15
License plate holder (available in certain countries)
8
Front brake caliper
16
Rear reflector (available in certain countries)

Owner’s manual
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Components location EC 2T 200cc/250cc/300cc RACING “Cross Country”
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Number
Na me
Number
Na me
1
License plate light (available in certain countries)
9
Muffler
2
Brake light
10
Rear brake disc
3
Seat
11
Rear brake caliper
4
Rear shock gas reservoir
12
Rear brake master cylinder
5
Kick-starter
13
Suspension linkage
6
Manufacturer’s identification plate
14
Rear brake pedal
7
Radiator
15
Sump guard
8
Exhaust
16
Front axle handle

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Owner’s manual
Components location EC 2T 250cc/300cc RACING E-START “Cross Country”
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15 16 17
Number
Name
Number
Name
1
Headlamp with position,low beam and high beam lamps
10
CDI switch
2
Fuel tank
11
Electric Starter
3
Fuel valve
12
Gear shift pedal
4
Rear shock
13
Carburetor
5
Air filter
14
Secondary transmission chain
6
Side stand
15
Chain guide
7
Front brake disc
16
License plate holder (available in certain countries)
8
Front brake caliper
17
Rear reflector (available in certain countries)
9
Front fork

Owner’s manual
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Components location EC 2T 250cc/300cc RACING E-START “Cross Country”
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Number
Na me
Number
Na me
1
License plate light (available in certain countries)
9
Muffler
2
Brake light
10
Rear brake disc
3
Seat
11
Rear brake caliper
4
Rear shock gas reservoir
12
Rear brake master cylinder
5
Kick-starter
13
Suspension linkage
6
Manufacturer’s identification plate
14
Rear brake pedal
7
Radiator
15
Sump guard
8
Exhaust
16
Front axle handle

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Owner’s manual
Components location XC 2T 200cc/250cc/300cc RACING (USA)
1 2 3 4 5 6
7 8 9 10 11 12 13 14
Number
Na me
Number
Na me
1
Headlamp with position,low beam and high beam lamps
8
Front brake caliper
2
Fuel tank
9
Front fork
3
Fuel valve
10
CDI switch
4
Rear shock
11
Gear shift pedal
5
Air filter
12
Carburetor
6
Side stand
13
Secondary transmission chain
7
Front brake disc
14
Chain guide

Owner’s manual
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Components location XC 2T 200cc/250cc/300cc RACING (USA)
23 43 54 6
98 190 110 121 132 143 1154 1165
Number
Na me
Number
Na me
1
Brake light
9
Rear brake disc
2
Seat
10
Rear brake caliper
3
Rear shock gas reservoir
11
Rear brake master cylinder
4
Kick-starter
12
Suspension linkage
5
Manufacturer’s identification plate
13
Rear brake pedal
6
Radiator
14
Sump guard
7
Exhaust
15
Front axle handle
8
Muffler
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15

Owner’s manual
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Components location XC 2T 250cc/300cc RACING E-START (USA)
1 2 3 4 5 6
7 8 9 10 11 12 13 14 15
Number
Na me
Number
Na me
1
Headlamp with position,low beam and high beam lamps
9
Front fork
2
Fuel tank
10
CDI switch
3
Fuel valve
11
Electric Starter
4
Rear shock
12
Gear shift pedal
5
Air filter
13
Carburetor
6
Side stand
14
Secondary transmission chain
7
Front brake disc
15
Chain guide
8
Front brake caliper