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MANUAL DEL USUARIO USER MANUAL MANUEL DENTRETIEN LIBRETTO DUSO BETRIEBSANLEITUNG
USER MANUAL USER 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.
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.
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 PEOPLES 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.
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
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
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. 35
SPECIFICATIONS ENGINE Cubic Capacity: Type: Number of Cylinders: Fuel Supply: Cooling System: Diameter per Stroke: Carburettor: Ignition: Clutch: Gearbox: Transmission: Engine Lubrication: Cooling: 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 Hydraulic forks 40 mm. – 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.
CHASSIS: Engine: Chassis: Front Suspension: Rear Suspension: Front Brake: Rear Brake:
Front Tyres: Rear Tyres: Starting Pedal: Brake Pedal:
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.
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.
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.
SERIAL NUM.
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.
CERTIFICATION PL.
(E). Part Numbers. (F). Numbered Diagram. 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.
COMPONENT LOCATION GAS GAS EC / SM ROOKIE 2005
(C) (D) (E)
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. 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.
(F). Gear pedal.
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.
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.
NOTE Unless the engine is started when the ignition key is on the ON position, the battery may lose some power.
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.
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.
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.
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.
MAINTENANCE MAINTENANCE SCHEDULE After the initial 500 Km: – 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.
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:
BEFORE STARTING THE MOPED FOR THE FIRST TIME It is advisable to make sure that transportation from our warehouse to its final destination has not altered the original condition of the moped. – Check the condition of the sparking plug by removing the cap and unscrewing the plug.
GEARBOX AND CLUTCH Gearbox and clutch lubrication is achieved through the spluttering of the oil inside the crankcase. Both the gearbox and the clutch are lubricated by the same oil contained in the 500cc crankcase. This draining operation may be carried out by removing the clutch cap or by operating the oil-drain screw. – Draining the oil by operating the screw is easier.
This should be done while the engine is still hot, in order to achieve a cleaner crankcase and to benefit from a more fluid condition of the oil that will speed up the draining operation. Remove the screw and wait for the crankcase to empty. Next, replace the screw, fill the crankcase, and use the dipstick to check that the right level has been reached.
It is advisable to change the oil after the initial 500 Kms, with an oillevel check every 2500 Kms and a new change every 5000 Kms. CARBURETTOR
Spark plug condition
Correct Poor Rich Dry and clear insulation White insulation Damp and black insulation Change carburation one step higher. Change carburation one step lower.
– Check to see that there is oil in the oil reservoir. Before starting the engine, make sure that the oil supply reaches the right level. Upon removal of the screw, a slight tilting of the moped should suffice for the oil to issue through the oil-level hole. – Check the clutch-fluid level and the front- and rear-brake fluid level.
This is one of the most crucial items for a proper engine performance, as it is within the carburettor that the petrol-air mixture is produced: a deficient carburetion process translates into a poor performance and may damage the thermal area of the engine. Consequently, it is advisable to have the carburettor adjustment checked, ideally by an Authorized GAS GAS Dealer. Efforts must be made to ensure that the carburettor internal components are clean and in good condition.
For this purpose, periodically clean the carburettor and especially its jet by using an air jet or simply by blowing through it. Never use a wire to clean the carburettor, as this might alter the bore and affect the engine negatively. Yet another cause of carburettor malfunctioning may be a blocked fuel-intake filter.
Remove the screw securing the intake adapter, clean the filter if it is dirty, and replace it carefully to avoid damaging its filtering cloth.
ENGINE Engine lubrication is carried out by means of the fuel, with the oil being supplied from a separate reservoir through a pump driven by the moped engine.
AIR FILTER The adequate performance and durability of the various engine components (connecting rod, piston, piston rings, crank bearings, even the cylinder) depend to a great extent on the air filter being clean and properly lubricated.
To access the filter, remove the cap on the filter-housing, which has been placed on the left-hand side of the moped.
(B). Air box situation.
Upon removal of the cap, check the condition of the filter housing, wash the filter if it is dirty, and then lubricate it. To lubricate the filter, apply a few drops of oil to soak the foam and press it with one hand without twisting it, then make sure to replace it correctly in its housing; otherwise, unfiltered air might reach the carburettor and cause serious damage to the moped.
(A). Air filter box. SPARKING-PLUG CHECK WARNING Always clean the filter in an area that is properly ventilated and free from sparks or flames in the vicinity (this includes any powerful light sources).
Do not use petrol to clean the filter, as this might cause an explosion.
(C). Spark plug removed from the valve cover.
The proper working of the engine depends on the good condition of the sparking plug; therefore, this is an extremely important component that can be easily inspected. Disassemble and check the sparking plug periodically. For instance, if the central-electrode porcelain insulation appears to be too white, this might be due to a leak in the carburettor air-intake tube, or to carburettor damage or malfunction.
The high temperatures the electrode is subjected to, together with carbon deposits, result in excessive wear and eventually render it useless. When this stage is reached, replace the sparking plug with a new one of the same type and recommended thermal grade (NGK BR 8 ES), or any other brand of a similar thermal grade. Carburettors must always be checked by an authorized GAS GAS dealer.
The only precaution to bear in mind is that of ensuring that it is completely full of liquid, since, in this way, the water is guaranteed to complete the whole circuit. The use of closed circuit antifreeze liquid is strongly recommended. In this way the you avoid the freezing of the water with the attendant risks engine seizures or breakages of the pump blades.
STRIP BOX
0,6 _ 0,7 mm
In order to enhance its performance, this engine has been fitted with strip admission. These strips are extremely fragile. Because of their fragility, the strips must not be tampered with, either by opening or by folding them, as this would result in engine malfunction and in the invalidation of the dealers guarantee.
Remove the dirt on the thread and clean the gasket seating, in order to prevent any foreign matter from entering the combustion chamber. Sparking-plug replacement requires checking to see that the electrode gap remains between 0.6 and 0.7 mm. RADIATOR (D) The radiator, which reduces the temperature of the engine-cooling water, has been secured with silent blocks under the petrol tank.
CLUTCH ADJUSTMENT Clutch adjustment may be carried out by means of the tightening device supplied with the handle. This is achieved by tightening or loosening the tightening screw, as required. The handle should have a 4-5 mm clearance.
Due to its hydraulic action, the clutch assembly requires no handle-clearance adjustments. Chain lubrication. CHAIN TIGHTENING Tightening and aligning the chain is easily achieved by loosening the nuts on the wheel axle (A) and by turning the nuts on the chain tighteners (B) as required, until the right chain tension or sag is achieved, together with a proper wheel centering and alignment.
CHAIN LUBRICATION
(A). Clutch. WARNING Always try to achieve a proper chain-and-wheel alignment, as otherwise the chain might come off and hit and damage the crankcase.
The chain should be cleaned and checked periodically. To achieve this, remove the chain while keeping the hook at one of its ends, which will both confirm its previous position and avoid the risk of losing it. Clean the chain thoroughly with a metal brush, by submerging it in a petrol bath and shaking it until all of its links are clean and free from obstructions.
Submerge it again in clean petrol or gas oil, rinse and allow it to dry for a few minutes. Lubricate and reassemble it, always making sure that the hook is placed in the opposite direction to the chain movement. It is most advisable to lubricate the chain every 100 or 200 Kms with special chain-lubrication oil.
(A). Wheel axle nut. (B). Chain adjuster locknuts.
FRONT SUSPENSION The front suspension, featuring state-of-the-art technology and design, includes an inverted hydraulic fork with 40 mm-diameter rods. Each rod has its own purpose and effect, as, whilst one of them acts mechanically through compression springs, the other one only operates hydraulically. Oil supply per rod – Right-hand fork.175 cc. – Left-hand fork..150 cc. Hydraulic oil SAE 5
– Press the suspension spring and insert the key (5) into the locknut (2) locking the cap (3). – Fit the suspension cap onto the fork rod and tighten to 29 N-m. – Fit the other fork. – Fit the disassembled components.
(1). Spring. (2). Locknut. (3). Suspension cap. (4). Cap wrench. (5). Locknut wrench.
REAR SUSPENSION The rear suspension, which is of the swivelling type and features a hydraulic shock absorber, requires no more attention than checking its wear and the play on the swivelling arm. Should the silent blocks securing the shock absorber loose their shape, for any reason whatsoever, replace the shock absorber to prevent damaging the chassis geometry.
– Pull the hydraulic-system rod (D) slowly. – The fork oil will now issue through the hole in the hydraulic-system rod; keep it raised until it stops. – Insert the suspension spring (1) into the fork tube.
CABLE The accelerator cable should always be in perfect condition; therefore, whenever the slightest crack is detected, it must be replaced immediately. However, in order to extend its life and enhance its operation, it should be lubricated approximately every 1000 Kms. Do this by inserting a few drops of SAE-20 between the cable and its guide.
Use an aerosol cable lubricant with a pressure luber: lube.
(B). Bleeder screw. (C). Disk brake. (D). Brake caliper.
Apply grease to the following point throttle inner cable upper ends (A).
FRONT BRAKE 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, proceed as follows:
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