GASGAS EC 250 2021 (01) PDF Document

The symbols used in the manual for your GASGAS EC 250 2021 have specific meanings:

✓: Indicates an expected reaction (e.g., of a work step or a function).

✗: Indicates an unexpected reaction (e.g., of a work step or a function).

🔧: Indicates work that requires expert knowledge and technical understanding. For your safety, this work should be performed by an authorized GASGAS Motorcycles workshop.

📖: Indicates a page reference for more information.

ℹ️: Indicates information with more details or tips.

»: Indicates the result of a testing step.

V: Indicates a voltage measurement.

A: Indicates a current measurement.

▶: Indicates the end of an activity, including potential reworking.

The manual for your GASGAS EC 250 2021 uses the following degrees of risk:

Danger: Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning: Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution: Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note: Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Note (Environmental): Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

When working on your GASGAS EC 250 2021, follow these rules:

• Unless specified otherwise, the ignition must be turned off or the engine must be at a standstill.

• Special tools may be necessary for certain tasks and can be ordered.

• Assume normal ambient conditions unless otherwise noted:

• Ambient temperature: 20 °C (68 °F)

• Ambient air pressure: 1,013 mbar (14.69 psi)

• Relative air humidity: 60 ± 5 %

• During assembly, use new parts to replace those which cannot be reused (e.g., self-locking screws, seals, O-rings).

• If a screw adhesive like Loctite® is required, observe the manufacturer’s instructions.

• Do not apply additional thread locker if a new part already has it applied (e.g., Precote®).

• After disassembly, clean reusable parts and check them for damage and wear. Replace any damaged or worn parts.

• After completing any repair or service work, always check the operating safety of the vehicle.

The serial numbers for your GASGAS EC 250 2021 are located in the following places:

• Vehicle Identification Number (VIN): Stamped on the right side of the steering head.

• Type Label: Fixed to the front of the steering head.

• Key Number (All EU models): Stamped onto the key connector for the steering lock.

• Engine Number: Located on the left side of the engine over the engine sprocket.

• Fork Part Number: Stamped on the inside of the axle clamp.

• Shock Absorber Article Number: Stamped on the top of the shock absorber above the adjusting ring, towards the engine side.

Here is a guide to the handlebar controls on your GASGAS EC 250 2021:

• Clutch Lever: Fitted on the left handlebar. It is activated hydraulically and adjusts itself automatically.

• Hand Brake Lever: Fitted on the right handlebar to engage the front brake.

• Throttle Grip: Fitted on the right side of the handlebar.

• Stop Button (All EU models and EC 300 US): Fitted on the left handlebar. In its basic position, the ignition circuit is closed and the engine can start. When pressed, the ignition circuit is interrupted, stopping a running engine and preventing a non-running engine from starting.

• Horn Button (All EU models): Fitted on the left handlebar. Press to operate the horn.

• Light Switch (All EU models): Located on the left handlebar. The central position switches on the low beam and tail light. Turned to the left, it switches on the high beam and tail light.

• Light Switch (EC 300 US): Located to the left of the combination instrument. Pressed in, the light is off. Pulled out, the low beam and tail light are on.

• Turn Signal Switch (All EU models): On the left handlebar. Central position is off. Turn left for left signal, right for right signal.

• Emergency OFF Switch (All EU models): On the right handlebar. In the “ignition off” position, the circuit is interrupted. In the “ignition on” position, the circuit is closed and the engine can start.

• Start Button: On the right handlebar. Press to actuate the starter motor.

For All EU Models:

• High Beam Indicator Lamp (Blue): The high beam is switched on.

• Malfunction Indicator Lamp (Yellow, lights up/flashes): The On-Board Diagnostics (OBD) has detected an error. Stop safely and contact an authorized workshop.

• Fuel Level Warning Lamp (Yellow): The fuel level has reached the reserve mark.

• Turn Signal Indicator Lamp (Green, flashes): The turn signal is switched on.

• Oil Level Warning Lamp (Red): Oil level has reached the MIN marking. Refuel with 2-stroke oil at the next opportunity before the fuel in the tank is depleted.

For EC 300 US Model:

• High Beam Indicator Lamp: Inoperative.

• Malfunction Indicator Lamp (Yellow, lights up/flashes): The OBD has detected an error. Stop safely and contact an authorized workshop.

• Fuel Level Warning Lamp (Yellow): The fuel level has reached the reserve mark.

• Oil Level Warning Lamp (Red): Oil level has reached the MIN marking. Refuel with 2-stroke oil at the next opportunity before the fuel in the tank is depleted.

Opening the Fuel Tank Filler Cap:

1. Press the release button.

2. Turn the fuel tank filler cap counterclockwise and lift it off.

Closing the Fuel Tank Filler Cap:

1. Mount the fuel tank filler cap and turn it clockwise until the release button engages.

2. Ensure the fuel tank breather hose is routed without kinks.

Opening 2-Stroke Oil Tank Cap:

1. Fold the loop upward.

2. Turn the 2-stroke oil tank cap counterclockwise and pull it up.

Closing 2-Stroke Oil Tank Cap:

1. Put the 2-stroke oil tank cap on and turn it clockwise.

2. Fold the loop down. The cap will engage.

Cold Start Button:

The cold start button is on the side of the throttle valve body. It supplies additional oxygen to help burn the increased fuel quantity during a cold start.

• To activate: Pull the cold start button out all the way and turn it by a ¼ turn.

• To deactivate: Turn the button a further ¼ turn to return it to the basic position. The button must be deactivated when the engine is warm.

Idle Speed Adjusting Screw:

The idle speed is adjusted using the idle speed adjusting screw, which influences starting behavior and throttle response.

• If the idle speed is high (engine is slow to run, low engine brake, aggressive response), turn the adjusting screw clockwise.

• If the idle speed is low (engine running fast, high engine brake, unclean response), turn the adjusting screw counterclockwise.

• Shift Lever: Mounted on the left side of the engine. The gear positions are 1st, Neutral, 2nd, 3rd, 4th, 5th, 6th. Neutral is between first and second gears.

• Foot Brake Lever: Located in front of the right footrest. It is used to activate the rear brake.

• Side Stand: Located on the left of the vehicle for parking. When riding, the side stand must be folded up and secured with the rubber strap.

Locking the Steering:

1. Park the vehicle on a firm and level surface.

2. Turn the handlebar as far as possible to the right.

3. Insert the key for the steering lock into the lock, turn it to the left, press it in, and turn it to the right.

4. Pull out the key. The steering is now locked. Never leave the key in the steering lock.

Unlocking the Steering:

1. Insert the key for the steering lock into the lock, turn it to the left, pull it out, and turn it to the right.

2. Pull out the key. The handlebar can now be moved again. Never leave the key in the steering lock.

To access the setup menu on your GASGAS EC 250 2021, the motorcycle must be stationary.

1. Press both buttons for 3–5 seconds to enter the Setup menu. The UNIT display will flash.

2. Set Units (KM/H or M/H):

• Press one of the buttons to select between KM/H and M/H.

3. Set Clock Display (24h or 12h):

• Wait for 5 seconds. The clock symbol will flash.

• Press one of the buttons to select a 24h or 12h display.

4. Set the Time:

• Wait for 5 seconds. The time symbol will flash.

• Press the left button to decrease the value (Resetting the time).

• Press the right button to increase the value (Advancing the time).

5. Set the Service Interval:

• Wait for 5 seconds. The service symbol will flash.

• Press the left button to shorten the service interval.

• Press the right button to extend the service interval.

6. Switch Off Service Interval Display:

• In the service interval menu, press and hold the left button. “off” will appear in the display.

You can cycle through different display modes on the combination instrument of your GASGAS EC 250 2021. Press one of the buttons briefly to switch between modes.

Mode 1: Speed, time, and DST (distance 1)

• Shows current speed, time, and distance since the last reset (e.g., between refueling stops).

• To reset DST to 0.0: Press the right button for 3-5 seconds.

• To preset DST: Press the left button for 3-5 seconds.

Mode 2: Speed, time, and DST2 (distance 2)

• Shows current speed, time, and a second distance since the last reset.

• To reset DST2 to 0.0: Press the right button for 3-5 seconds.

• To preset DST2: Press the left button for 3-5 seconds.

Mode 3: AVG (average speed), ART (operating hours), and ODO (total distance)

• Shows average speed since last reset, total operating hours, and total distance covered.

• To reset AVG to 0.0: Press the right button for 3-5 seconds.

• To view remaining service hours: Press the left button for 3-5 seconds. The wrench symbol and remaining hours until the next service will be displayed.

Before your first ride on the GASGAS EC 250 2021, follow these steps:

• Ensure the pre-sales inspection was done by an authorized workshop.

• Read the entire Owner’s Manual carefully.

• Familiarize yourself with all the controls.

• Adjust the basic position of the clutch lever.

• For All EU models: Adjust the free travel of the handbrake lever.

• For EC 300 US models: Adjust the basic position of the hand brake lever, foot brake lever, and shift lever.

• Practice handling the motorcycle on a suitable surface before taking on challenging trips.

• Ride slowly and in a standing position to get a feel for the motorcycle.

• Hold the handlebar firmly with both hands and keep your feet on the footrests.

• Do not exceed the maximum permissible overall weight and axle loads.

• Check the spoke tension after half an hour of operation.

• Run in the engine according to the manual’s instructions.

During the running-in phase for your GASGAS EC 250 2021, it is important to not exceed the specified engine performance to ensure a long service life.

Maximum engine performance:

• Avoid fully opening the throttle during this period.

• Check the idle speed regularly, as it may change during the run-in time. The specified idle speed is 1,400 – 1,500 rpm. If it changes, adjust it accordingly.

Preparing your GASGAS EC 250 2021 for difficult conditions can prevent premature wear.

General Preparation for All Difficult Conditions:

• Seal the air filter box.

• Clean the air filter and air filter box. Check the air filter approximately every 30 minutes.

• Check electrical connectors for humidity and corrosion.

For Rides on Dry or Wet Sand:

• Check that the radiator cap value is 1.8 bar (26 psi). If not, change it.

• For dry sand: Mount the air filter dust cover (79006920000).

• For dry sand: Mount the air filter sand cover (79006922000).

• For wet sand: Mount the air filter rain cover (79006921000).

• Clean the chain and grease it.

• Mount a steel sprocket.

• Clean and straighten any bent radiator fins.

• For regular use in sand, change the piston every 10 operating hours.

For Rides on Wet and Muddy Circuits:

• Mount the air filter rain cover (79006921000).

• Mount the steel sprocket.

• Clean the motorcycle thoroughly after the ride.

• Straighten any bent radiator fins.

For High Temperatures or Slow Riding:

• Check that the radiator cap value is 1.8 bar (26 psi). If not, change it.

• Adjust the secondary drive to the road conditions to avoid overheating the transmission oil.

• Clean the chain and radiator fins.

For Low Temperatures or Snow:

• Mount the air filter rain cover (79006921000).

• Straighten bent radiator fins.

• Check the coolant level.

Before every trip, check the condition of your GASGAS EC 250 2021 to ensure it is safe to operate. The vehicle must be in perfect technical condition.

• Check the gear oil level.

• Check the electrical system.

• Check the front and rear brake fluid levels.

• Check the front and rear brake linings.

• Check that the brake system is functioning properly.

• Check the coolant level.

• Check the chain for dirt.

• Check the chain, rear sprocket, engine sprocket, and chain guide for wear.

• Check the chain tension.

• Check the tire condition and tire pressure.

• Check the spoke tension (incorrect tension can impair riding safety).

• Clean the dust boots of the fork legs.

• Bleed the fork legs.

• Check the air filter.

• Check that all controls operate smoothly.

• Check all screws, nuts, and hose clamps for tightness.

• Check the fuel level.

• Check the 2-stroke oil level.

Starting the Vehicle:

1. Take the motorcycle off the side stand and secure the stand with the rubber strap.

2. Shift the transmission to the neutral position.

3. If the ambient temperature is below 10°C (50°F), pull the cold start button fully out and turn it by ¼ turn.

4. Press the start button for a maximum of 5 seconds without opening the throttle. Wait 30 seconds before another attempt. At temperatures below 15°C (60°F), several attempts may be necessary to warm up the lithium-ion battery.

Starting Off:

1. Switch on the light.

2. Pull the clutch lever, shift into first gear.

3. Release the clutch lever slowly while carefully opening the throttle.

Shifting and Riding:

• To shift up, release the throttle, pull the clutch lever, shift into the next gear, release the clutch lever, and open the throttle.

• Deactivate the cold start button after the engine has warmed up.

• After reaching maximum speed, turn the throttle back to ¾ open to reduce fuel consumption.

• To shift down, apply the brakes, close the throttle, pull the clutch lever, shift to a lower gear, and slowly release the clutch lever.

• Switch off the engine if it will be stationary for 2 minutes or more.

• Avoid prolonged clutch slipping to prevent overheating.

• If the oil level warning light comes on, add 2-stroke oil at the next opportunity before refueling.

Refueling:

1. Switch off the engine. Do not refuel near open flames or lit cigarettes.

2. Open the fuel tank filler cap.

3. Fill the fuel tank with Super unleaded (ROZ 95) fuel up to the level marked ‘A’ (35 mm / 1.38 in below the filler neck). Do not overfill. Do not use pre-mixed fuel.

• Total fuel tank capacity: approx. 8.5 l (2.25 US gal)

4. Close the fuel tank filler cap securely.

Adding 2-Stroke Oil:

1. Open the 2-stroke oil tank cap.

2. Fill the 2-stroke oil tank up to the lower edge of the filler neck. Only use 2-stroke oil appropriate for separate lubrication.

• 2-stroke oil tank content: approx. 0.6 l (0.6 qt.)

3. Close the 2-stroke oil tank cap securely.

The service schedule for your GASGAS EC 250 2021 consists of required work and recommended work at specified intervals. A (●) indicates a periodic interval and a (○) indicates a one-time interval.

Required Work

Recommended Work

To tune the chassis of your GASGAS EC 250 2021, first adjust the shock absorber, then the fork. The basic settings must match the rider’s weight for optimal performance. The standard delivered setting is for a rider weight of 75 – 85 kg (165 – 187 lb.).

Shock Absorber Adjustments:

• Low-Speed Compression Damping: Turn the adjusting screw clockwise to the last click, then turn counterclockwise by the number of clicks for your preference (Comfort: 17, Standard: 15, Sport: 13).

• High-Speed Compression Damping: Turn the adjusting screw clockwise all the way, then turn counterclockwise by the number of turns for your preference (Comfort: 2.5, Standard: 2, Sport: 1.5).

• Rebound Damping: Turn the adjusting screw clockwise to the last click, then turn counterclockwise by the number of clicks for your preference (Comfort: 17, Standard: 15, Sport: 13).

• Spring Preload / Riding Sag: Check static sag (target: 37 mm) and riding sag (target: 110 mm). Adjust the spring preload or change the spring if necessary to achieve the correct riding sag. The standard spring rate (42 N/mm) is for riders 75-85 kg. Use a 39 N/mm spring for 65-75 kg, or a 45 N/mm spring for 85-95 kg.

Fork Adjustments:

• Compression Damping (White adjuster, left fork leg): Turn the white adjuster clockwise all the way, then turn counterclockwise by the number of clicks for your preference (Comfort: 18, Standard: 15, Sport: 12).

• Rebound Damping (Red adjuster, right fork leg): Turn the red adjuster clockwise all the way, then turn counterclockwise by the number of clicks for your preference (Comfort: 18, Standard: 15, Sport: 12).

Turn adjusters clockwise for more damping and counterclockwise for less damping.

The handlebar on your GASGAS EC 250 2021 can be mounted in four different positions for rider comfort. If the handlebar is bent or damaged, it must be replaced.

1. Remove the screws and the handlebar clamps. Lay the handlebar to one side, covering components to prevent damage.

2. Remove the screws and the handlebar supports.

3. Place the handlebar supports in your desired position. Mount and tighten the screws.

4. Position the handlebar, ensuring cables and wiring are positioned correctly.

5. Position the handlebar clamps and tighten the screws evenly.

Ensure the gap widths between the clamps are even.

Regularly checking and adjusting the chain tension is crucial for safety and component longevity on your GASGAS EC 250 2021.

Checking Chain Tension:

1. Raise the motorcycle with a lift stand so the rear wheel is off the ground.

2. Pull the chain upward at the end of the chain sliding piece. The lower chain section must be taut.

3. Measure the distance between the chain and the swingarm. The correct chain tension is 55 – 58 mm (2.17 – 2.28 in).

4. Repeat this measurement at different chain positions as wear may be uneven.

Adjusting Chain Tension:

1. Loosen the rear wheel spindle nut.

2. Loosen the nuts on the chain adjuster screws.

3. Turn the adjusting screws on the left and right to set the correct chain tension. Ensure the markings on both chain adjusters are in the same position relative to the reference marks for proper wheel alignment.

4. Tighten the nuts on the chain adjuster screws.

5. Make sure the chain adjusters are fitted correctly on the adjusting screws.

6. Tighten the rear wheel spindle nut to 80 Nm (59 lbf ft).

The blink codes are displayed by the derestricted version of the vehicle and indicate specific errors detected by the On-Board Diagnostics system. The codes are represented by a series of long and short flashes.

Here are some of the important engine tightening torques for your GASGAS EC 250 2021. Always use a torque wrench for accuracy.

Chassis Specifications:

Tire Specifications: