GAS GAS EC250-4T 2010 User manual

EC250-4T´10
EC250-4T´10
EC250-4T´10

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Foreword
GAS GAS thanks you for your confidence.
By choosing the new GAS GAS EC 250 T you have just entered the great GAS GAS family and, as a user
of the number one off-road motorbike manufacturer, 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 250- T is a bike conceived for highly competitive performance. In fact this bike is the fruit of many
years of competition and experimentation in these demanding disciplines; many great trial riders have contributed
their expertise and achievements to the essential data we have used to create these high-quality, exclusive
motorcycles incorporating key features such as reliability, high performance and stability.
Congratulations for making, without a doubt, the right choice. With skill at the controls of this motorbike, an
adequate preparation and the corresponding essential servicing this GAS GAS will remain highly reliable and
you will be able to enjoy the most comfortable and rewarding motor sport.
Thank you for your confidence and welcome to GAS GAS motos SA.

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OIL RECOMMENDED:
IMPORTANT NOTICE
Read this manual carefully. This manual covers aspects that will
contribute to your security and to that of others, as well as guaranteeing
a correct conservation and maintenance of this GAS GAS motorcycle
you have just acquired.
All of the instructions to correctly handle and drive this motorcycle
are described in detail. Each message will be preceded by a symbol.
WARNING
This title identifies special instructions or procedures that, if not
correctly followed, could result in personal injury, or even death.
CAUTION
This title identifies special instructions or procedures that, if not
strictly observed, could result in damage to or destruction of equipment.
NOTE
This title indicates points of particular interest for more efficient
and convenient operation.
Inadequate driving skill could cause problems to the environment
and conflict with other people. Responsible use of your motorcycle
will ensure that these problems and conflicts do not occur.
TO PROTECT THE FUTURE OF YOUR SPORT, MAKE SURE
YOU USE YOUR IKE LEGALLY, WITH CONCERN FOR THE
ENVIRONMENT, AND RESPECT THE RIGHTS OF OTHER
PEOPLE.
Motorcycle riding is a fantastic sport, and we hope you will enjoy it
to the fullest.

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TA LE OF CONTENTS
Foreword.........................................................................................3
Important notice ..............................................................................
Table of contents ............................................................................5
General information ........................................................................6
Component locations ......................................................................8
Side stand.....................................................................................10
Petrol.............................................................................................10
Serial number and the qualification approval plate.......................11
Starting and stopping the engine ..................................................12
Cold starting..................................................................................13
Gear changes ...............................................................................13
Stopping the motorcycle ...............................................................1
Break-in.........................................................................................1
Maintenance chart ........................................................................15
Battery...........................................................................................16
Cooling system .............................................................................17
Spark plug.....................................................................................20
Air filter..........................................................................................23
Accelerator cable ..........................................................................2
Clutch............................................................................................25
Exhaust system.............................................................................25
Chain guide...................................................................................26
Tension adjustment ......................................................................27
Handle bars ..................................................................................29
Brakes...........................................................................................29
Steering.........................................................................................31
Steering lock .................................................................................32
Front forks.....................................................................................33
Rear suspension...........................................................................36
Wheels..........................................................................................38
Cleaning........................................................................................39
Tighten bolts and nuts .................................................................. 0
Tightening torque table ................................................................. 1
Lubrication .................................................................................... 2
Engine oil ...................................................................................... 3
Suspension adjustment ................................................................ 6
In competition................................................................................50
Storage .........................................................................................51
Multi-function instructions ............................................................52
Fault diagnosis..............................................................................58
Electrical schemas........................................................................6
Guarantee manual ........................................................................66

GENERAL INFORMATION
ENGINE
Engine stroke, single-cylinder DOHC 5 valves, liquid cooled
Displacement in cubic centimetres 2 9cc
Bore and stroke 77 x 53,6mm
Fuel supply Carburator Keihin FCR MX37
TRANSMISSION
Transmission type 5 speed
Clutch type Multi disc wet clutch with hydraulic command
Secondary transmission Chain
Gear ratio 1st 2.385(31/13)
2nd 1.750(28/16)
3rd 1.333(28/21)
th 1.0 2(25/2 )
5th 0.815(22/27)
Primary reduction ratio 3.353(57/17)
Final reduction ratio 3.8 6(50/13)
Overall drive ratio 10.5(5th)
Transmission oil Capacity 1000 cc
Type SAE 5W 0 API SG
C ASSIS
Type DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes.
Aluminium rocker
Tyre sizes Front EC - 90/90 x 21
EC SM - 120/60 ZR17
Rear EC - 1 0/80 x 18
EC SM - 150/60 ZR17
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Suspension Front ø 8 mm inverted fork
ø 5 mm inverted fork
Rear Progressive system with single multi-adjustment shock absorber
Suspension stroke Front 295 mm
Rear 320 mm
Front suspension oil Between SAE 5 and 7.5 (check manufacturers information)
Front fork oil level 100 mm (compressed, without spring)
120 mm (compressed, without spring)
BRAKES
Type Front / rear Disk brakes, pump and simple / double callipers
Effective disk diameter Front 260 mm
Rear 220 mm
DIMENSIONS
Overall height 1260 mm
Overall length 2135 mm
Overall width 810 mm
Wheel base 1 75 mm
Minimum ground clearance 3 0 mm
Fuel tank capacity 7 litres
Weight 118 Kg
(Specifications subject to change without notification, also possibly not applicable in some countries).

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1- Clutch handle
2- Engine start button
3- Fuel tank cap
- Front brake fluid tank
5- Front brake handle
6- Throttle control
LOCATION OF COMPONENTS
GAS GAS EC250 4T
13426
5

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7- Front suspension
8- Radiator
9- Fuel tank
10- Air filter
11- Seat
12- Front brake disk
13- Front brake callipers
1 - Rear brake fluid tank
15- Shift pedal
16- Rear shock absorber
17- Chain guide
18- Chain
19- Silencer
20- Rear shock absorber gas tank
21- Tie rod and rocker suspension
22- Rear brake pedal
23- Engine oil cap
2 - Exhaust bend
79
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1112
13 16 15 17
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2019
14 21 2422

PETROL
The GAS GAS EC 250 T has a four stroke engine and requires 98
octane, unleaded petrol.
Fuel Tank Capacity
7 L
(A). Fuel cap.
( ). Fuel vent hose.
To open the gas tank cover (A), turn it anti-clockwise.
To close the fuel cap, rotate it in a clockwise direction.
SIDE STAND
To unfold the side stand (A) the securing strap must be released
( ) then the stand is opened to vertical position.
The stand returns to its original position with the aid of the spring
( ).
(A). Side stand.
( ). Spring.
NOTE
Do not start the engine or ride the motorcycle when the side
stand is down. Always engage the security strap before driving
the motorcycle.
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( )
(A)
( )
(A)

SERIAL NUM ER
Printed on the steering tube. Indicates the frame number with which
the motorcycle is registered.
Qualification approval plate
The motorcycle is fitted with its own corresponding qualification
approval plate with the serial number, also printed on the steering
tube and whose data also coincides with that in the documents.
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RECOMMENDED FUEL
Use lead-free petrol with an octane rating equal to or higher than
that shown in the table.
OCTANE RATING METHOD OCTANE
RATING (MIN)
Antiknock Index (RON+MON)/2 90
Research Octane No. (RON) 98
NOTE
If knocking 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.

Stopping the engine
- Change gear to neutral.
- After accelerating lightly, cut the gas completely and press button
(C). The electrical circuits are closed.
NOTE
Start the engine soon after making contact with the ON button
(A) or the battery may lose its change.
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STARTING THE ENGINE
- Ensure that the motorcycle is in neutral.
- Press button (A) to turn on the electrical circuit, so that the motor
may be started.
- Without using the throttle, press the electric start button ( ).
(A)
( )
(C)

SHIFTING GEARS
The transmission is with 5 speeds, return shift type meaning that to
go back to first gear from a higher gear, you must shift back through
the gears one by one.
To engage first gear from neutral, pull in the clutch lever and push
down on the shift pedal then release the pressure on the shift pedal
and gently release the clutch lever.
CAUTION
When changing gears, press firmly on the shift pedal to ensure
complete, positive shifting. Careless, incomplete shifts can cause
the transmission to jump out of gear and lead to engine damage.
( ). Shift pedal.
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COLD STARTING
To do the cold start, pull the starter.
- There is no need to use the throttle, simply start the engine. Note
that the engine will start after a certain number of revolutions.
After the warming time, you can pull out the cold starter. With the
cold start, the bike warm slowly without damages.
NOTE
- If the engine is drowned, you can pres the hot starter and on
the same time, press the kick pedal 10 at 20 times. When the
engine is dry, you can start normally.
OT START
Dont use the cold start and dont touch the trotle. Press the hot
starter and start the engine with the kick or the electric starter. When
the engine is running, pull out the hot start.
( )

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.
REAK-IN
To obtain the proper operating clearances in the engine and
transmission that are necessary for smooth engine performance
and reliability, an initial break-in must be completed. For the first
hour or 100 Km of operation, run the engine at low rpm.
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NOTE
The slow speed necessary during the break-in period may cause
carbon to build up on the spark plug and soil it. If inspection
of the spark plug shows this to be the case, replace the standard
spark plug with a higher heat grade spark plug for the duration
of the break-in period.
Break-in following these steps:
1. Start the engine and let it run at idle until the engine is thoroughly
warmed up.
2. Stop and let the engine cool completely
3. Start the engine and ride for 10 minutes at
moderate speed. NEVER ACCELERATE FULLY.
. Stop and let the engine cool completely. Check and adjust chain
slack and spoke tightness and make a general inspection.
5. Start the engine and ride for 20 minutes at
moderate engine speed. NEVER ACCELERATE FULLY.
6. Stop and let the engine cool completely. Check and adjust ( ).
7. Fit the inspected parts.
8. Fill the radiator up completely with cooling liquid. Before
starting the engine 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
In any case, even an imprudent acceleration can cause engine
trouble, take special care and use the proper skills and techniques
required for correct driving of the motorcycle.
NOTE
Following the break-in, fit a new standard spark plug.
(A)

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Article
Air filter
*Exhaust connectors and bolts
*Valve tolerances
Spark plug
Fuel tub
Engine oil and filter oil
*Engine oil pipes
Coolant
Radiator hoses
Clutch
Chain
*Brakes
Brake lines
Brake liquid
Tyres
*Steering assembly
*Front forks
*Rear suspension
*Chassis bolts and nuts
Period
First 5 hours
T
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I
I
I
I
I
I
I
T
Inspect each time that the motorcycle has run or when necessary
*Revise every years
Revise every 2 years
Clean, lubricate and inspect each time the motorcycle has run
*Revise every years
*Revise every 2 years
Inspect tyres for damage and check the tyre pressure every time the motorcycle has run
Period
Every 30 hours
T
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R
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Period
Every 60 hours
T
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R
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MAINTENANCE CHART
NOTE: I = Inspect and clean, adjust, replace or lubricate if necessary; R = Replace, T = Tighten, C = Clean

ATTERY
This battery is maintenance free and checking the fluid level is not
required. It is advisable to check the charge of the battery periodically
To remove the battery, follow these steps:
1. Remove the bolt (A) and remove the seat ( ).
2. Release the rubber (C).
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3. Disconnect the terminals ensuring that they do not
enter into contact with metal parts then extract the
battery.
WARNING
Hydrogen gas produced by the battery may explode if exposed to
open flame or sparks.
Keep the area ventilated and free from naked flames.
The operating instructions for the battery are as follows:
1. Check the battery tension in open circuit status (disconnected).
2. In case the battery's tension is below 12.60 V, or if the storage
period has exceeded 6 months, the battery has to be recharged
following the instructions in paragraph 3.
If the battery voltage is above 12.60 V, the battery can be
installed on the vehicle without having to recharge it.
3.1. Constant voltage charge mode.
- Constant voltage = 1 . 0 - 1 .70V
- Initial charge current = 0.1  0.5 Cn
- Charge duration = 6 hours minimum / 2 hours maximum.
3.2. Constant power charge mode.
- Maximum charge current = 0.1 Cn
(A)
(C)
( )

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- Recommended charging duration = 5 - 8 hours.
- The product (charge current) X (charge duration) must be within
the range: 0.5 - 0.8 Cn.
Note
In case that a different mode of charging is used to those
established here, never exceed the maximum allowed currents
nor the maximum charge duration of 24 hours.
CAUTION
Not using the standard manner of charging may seriously shorten
the battery life.
Never exceed the standard charge.
CAUTION
Inverting the polarity of the battery terminals may cause battery
charge problems and cause damage to the battery system.
The red terminal is positive (+) and the black terminal is negative
(-).
THE COOLING SYSTEM
Radiator hose
Check the radiator hoses for cracks or deterioration, and connections
for leaks.
Radiator
Check the radiator fins for obstruction by insects or mud. Clean off
any obstructions with a stream of low-pressure water.
CAUTION
Using a high pressure water source could damage the radiator fins
and render it ineffective.
Do not obstruct or deviate the radiator air intake by installing non-
approved accessories. Interfering with the radiator could cause
overheating and result in engine damage.
Coolant
This absorbs excessive heat from the engine and transfers it to the
air at the radiator. If the coolant level becomes low, the engine
overheats and may suffer severe damage. Check the coolant level
each day before riding the motorcycle. Replenish coolant if the level
is low.
WARNING
To avoid burns, do not remove the radiator cap or try to change the
coolant when the engine is still hot. Wait for it to cool down.
Anti-freeze liquid information
To protect the cooling system aluminium parts (engine and radiator)
from rust and corrosion, the use of corrosion and rust inhibitor
chemicals in the coolant is essential. If coolant containing corrosion
and rust inhibitor chemicals is not used, over a period of time, the
radiator will rust. This will block the cooling hoses.

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(A)
CAUTION
Use of incorrect coolant solutions will cause severe engine and
cooling system damage.
Use coolant containing corrosion in ibitors made specifically for
aluminium engines and radiators in accordance wit t e instructions
of t e manufacturer.
WARNING
Coolant c emicals are armful to t e uman body. Follow coolant
manufacturer warnings and coolant anding instructions.
CAUTION
Soft or distilled water must be used wit t e in ibitor c emicals and
t e antifreeze in t e cooling system.
If normal water is used in t e system, it t e cooling system tubes
may become blocked.
If t e lowest ambient temperature encountered falls below t e freezing
point of water, protect t e cooling system against freezing.
Use a permanent type of anti-freeze (soft water and et ylene glycol
plus corrosion and rust in ibitor c emicals for aluminium engines
and radiators) in t e cooling system.
For t e coolant mixture ratio under extreme conditions, c oose t e
mixture ratio listed on t e container for t e lowest ambient temperature.
Coolant Level
- Situate t e motorcycle so t at it is perpendicular to t e ground.
- Remove t e radiator cap in two stages. First turn t e cap anti-clock
wise and wait for a few seconds. T en pus and turn it furt er in t e
same direction to remove t e cap.
(A). Radiator Cap.
CAUTION
Permanent types of antifreeze on t e market ave anticorrosion and
anti-rust properties. W en diluted excessively t ese lose t eir
antifreeze and anticorrosion properties. T ese must be diluted in
accordance wit t e instructions of manufacturer.

Changing the coolant
- T e coolant s ould be c anged periodically to ensure long engine life.
- Wait for t e engine to cool completely.
- Situate t e motorcycle so t at it is perpendicular to t e ground.
- Remove t e radiator cap.
- Place a bowl under t e water pump cover and remove all t e liquid
in t e radiator and engine, uclock t e drain screw (B). Immediately
wipe or was off any coolant t at spills on t e frame, engine, or
w eels.
(A). Water pump cover.
(B). Screw to drain.
WARNING
If coolant gets on t e tyres t is will make t em slippery and could
result in an accident.
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NO E
Check the level when the engine is cold.
(1). Coolant level.
(2). Filler opening.
If t e coolant level is low, add t e correct amount of coolant t roug
t e filler opening.
Recommended liquid
Permanent type of antifreeze (distilled water and et ylene glycol)
wit corrosion and rust in ibitor c emicals for aluminium engines
and radiators).
NO E
Initially a permanent type of antifreeze is installed in the cooling
system by the manufacturer. This is green in colour, containing
5 % ethylene glycol with a freezing point of 35°C.
otal quantity
Mix antifreeze and distilled water 1:1 (distilled water 50%, antifreeze
50%).
(A)
(A)
(B)

- Examine t e used coolant. If w ite cotton-like patc es appear in
t e liquid t en t is means t at t e aluminium elements of t e cooling
system are corroded. If t e liquid is brown t en t is means t at t e
steal or iron parts of t e system are oxidized. In eit er case clean
out t e system.
- C eck t e cooling system for damage, loose joints, or leaks.
- Put t e drain screw on t e water pump cover and lock it wit t e
indicated torque. C ange t e copper was er by a new one.
Screw torque:
Drain screw on the water pump cover: 9 Nm.
- Fill t e radiator up to t e edge and install t e radiator cap.
- C eck t e cooling system for leaks.
- Start t e engine, warm up t e engine, and t en stop it.
- C eck t e coolant level after t e engine cools down. Add
coolant up to t e bottom of t e radiator filler neck.
SPARK PLUG
T e standard spark plug is indicated inside t e table and t e torque
to lock it is 13 Nm.
Standard spark plug
Standard spark plug Gap between electrodes: 0.7-0.8 mm.
T e spark plug s ould be taken out periodically to c eck t e electrode
gap. If t e plug is oily or as carbon build up on it t e clean it wit
a sand blaster. Following abrasive particle cleaning, t e spark plug
s ould be cleaned wit a wire brus or similar. Measure t e distance
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between electrodes using a gauge and adjust in case t at it is not
correct by bending t e outer electrode. If t e spark plug electrodes
are oxidised, damaged or t e insulation is broken t en replace t e
plug.
NO E
Inspect every 3 hours. Replace every 6 hours.
To find t e correct eat grade spark plug is being used, take it out
and examine t e insulation around t e electrode. If t e ceramic is
lig t brown, t e spark plug is correctly matc ed to engine temperature.
If t e ceramic is w ite, t e plug s ould be replaced wit t e next
coldest plug. If t e ceramic is black, t e plug s ould be replaced
wit t e next ottest plug.
NO E
If the engine output decreases, replace the spark plug to regain
performance.
Spark plug maintenance
COMMEN S
If t e standard spark plug is wet t en replace it.
If t e standard spark plug looks glassy or as a w ite
colour, replace it(