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GAS GAS EC ENDUCROSS 200 250 300 Motor Service Repair Manual 2006

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The EC Enducross, available in 200, 250, and 300cc variants for the 2006 model year, represents a robust line of off-road enduro motorcycles engineered for competition and demanding terrain. Known...
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Type: Motorcycle
Vendor:
Gas Gas
Sku: 137862
Tags: 2006 EC ENDUCROSS 200 EC ENDUCROSS 250 EC ENDUCROSS 300 EC Models Gas Gas Motorcycle Motorcycles
GAS GAS EC ENDUCROSS 200 250 300 Motor Service Repair Manual 2006
The EC Enducross, available in 200, 250, and 300cc variants for the 2006 model year, represents a robust line of off-road enduro motorcycles engineered for competition and demanding terrain. Known for their Spanish heritage and success in trials and enduro racing, these models are characterized by their powerful two-stroke engines, liquid-cooling, and kickstart starting systems. The EC series has consistently evolved, with the 2006 models showcasing refined chassis and engine performance, making them a favored choice for enthusiasts and competitors alike seeking reliable and capable off-road machines. This comprehensive A-Z service repair workshop manual provides detailed, professional-level guidance for the EC Enducross 200, 250, and 300 models from 2006. It covers all aspects of maintenance, repair, and diagnostics, including engine overhaul, clutch and transmission servicing, cooling and fuel systems, electrical components, brakes, suspension, and frame. With abundant high-quality illustrations and step-by-step instructions, this manual is an essential resource for owners, DIY mechanics, and professional technicians aiming to maintain, troubleshoot, and repair these off-road motorcycles effectively.
🏷️ Basic Information
Identification
Make:
Gas Gas
Model:
EC Enducross
Model Variants:
200, 250, 300
Year:
2006
Codes
Platform Code:
EC Series (Specific chassis codes may vary by engine displacement)
👋 Introduction
Market Position
Target Audience:
Enthusiasts, DIY mechanics, professional workshops working on Gas Gas Enducross motorcycles
Vehicle Segment:
Off-road Enduro / Cross-Country Competition Motorcycles
Competitive Analysis
Manual Value Proposition:
Provides comprehensive, professional-grade repair and maintenance information, enabling users to perform their own servicing and repairs, saving time and money compared to dealership service.
Key Features
Availability:
Instant Download, No Waiting
Comprehensiveness:
All Repairs Covered A-Z, All Models Covered
Usability:
Easy to Read PDF Format, High Quality Pictures & Diagrams
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive A-Z Service Repair Workshop
Applicable Models:
Gas Gas EC Enducross 200, 250, 300 (2006 Model Year)
Page Count
Estimated Page Count:
Likely 400-800 pages (typical for comprehensive service manuals of this era)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English (Implied by typical market availability, no explicit mention of other languages)
Format
Delivery Format:
PDF (Portable Document Format)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, top-end, bottom-end, piston, rings, cylinder, crankshaft, connecting rod, valve train (if applicable to model variant), timing (if applicable)
Clutch:
Clutch operation, adjustment, component inspection (plates, springs, basket), hydraulic system (if applicable)
Transmission:
Gearbox disassembly and assembly, shift mechanism, lubrication, component inspection
Cooling Systems:
Radiator, hoses, water pump, thermostat, coolant specifications and bleeding procedures
Fuel System:
Carburetor (likely Keihin or Mikuni for this era), jetting, float adjustment, fuel pump (if equipped), fuel lines, fuel filter
Exhaust System:
Exhaust pipe, muffler, sealing, inspection for leaks or damage
Ignition System:
Spark plug specifications, ignition timing (if adjustable), CDI unit, stator, rotor, wiring
Electrical System:
Battery, charging system, lighting (headlight, taillight, indicators), wiring harness inspection, component testing
Brakes:
Brake system operation, hydraulic components (master cylinder, caliper, slave cylinder), brake fluid specifications, bleeding, pad and rotor replacement, drum brakes (if applicable)
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, rim types, spoke tension (if applicable)
Steering Suspension:
Handlebar setup, steering head bearing adjustment and replacement, front fork service (oil change, seal replacement), rear shock absorber service, linkage maintenance (if applicable)
Frame Bodywork:
Frame inspection for cracks or damage, body panel removal and installation, seat, fuel tank, fenders
Wiring Diagrams:
Detailed wiring schematics for all electrical systems, troubleshooting guides based on wiring
Fault Finding Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides
Procedures Included
Maintenance:
Routine servicing, pre-ride checks, lubrication schedules, filter replacements, fluid changes
Repair:
Step-by-step instructions for all repair tasks from minor adjustments to major component overhauls
Disassembly Assembly:
Detailed instructions for taking apart and reassembling all major vehicle systems and components
Diagnostics:
Tools and techniques for identifying and resolving mechanical and electrical problems
Troubleshooting Guides:
Specific guides for diagnosing and fixing common performance issues or failures
Special Tool Requirements:
Identification of any specialized tools required for specific procedures
Technical Depth
Depth:
Professional Level, covering complete rebuilds and advanced diagnostics
Detail Level:
High, with detailed instructions and explanations
Illustrations:
Abundant high-quality pictures and diagrams
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
All Operating Systems (Windows 95, 98, 2000, Me, XP, Vista, 7, 8, etc., Mac Compatible)
Searchability:
Likely text-searchable PDF for efficient information retrieval
Print Quality
Quality:
Professional Quality Information
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-Stroke, Single Cylinder (typical for Gas Gas EC models of this era)
Engine Displacement 200:
Approximately 193.4 cc
Engine Displacement 250:
Approximately 249 cc
Engine Displacement 300:
Approximately 294 cc
Bore Stroke 200 Approx:
66.0 mm x 57.5 mm
Bore Stroke 250 Approx:
67.0 mm x 70.5 mm
Bore Stroke 300 Approx:
72.0 mm x 72.0 mm
Cooling Method:
Liquid-Cooled
Induction:
Carburetor (likely Keihin PWK or Mikuni TMX)
Starting System:
Kickstart
Performance
Horsepower 200 Est:
Approx. 30-35 HP (varies by tuning)
Horsepower 250 Est:
Approx. 40-45 HP (varies by tuning)
Horsepower 300 Est:
Approx. 45-50 HP (varies by tuning)
Fuel System
Fuel Type:
Unleaded Gasoline (mixed with 2-stroke oil, specific ratio in manual)
Carburetor Size 200:
Likely 28-30mm
Carburetor Size 250 300:
Likely 36-38mm
🔧 Transmission
Standard
Type:
6-Speed Constant Mesh Sequential
Clutch Type:
Wet Multi-Plate (Hydraulic actuation typical)
Features
Lubrication:
Manual specifies gearbox oil type and capacity
📐 Dimensions
Exterior
Wheelbase Approx:
1460-1490 mm (varies by model and suspension setting)
Seat Height Approx:
950-970 mm (varies by model and suspension setting)
Weights
Dry Weight 200 Approx:
99-102 kg
Dry Weight 250 Approx:
102-105 kg
Dry Weight 300 Approx:
104-107 kg
🛡️ Safety Features
Ratings
Crash Test Rating:
N/A (Motorcycles are not subject to standardized crash testing like cars)
Active Features
Braking System:
Hydraulic Disc Brakes (Front and Rear, typically Brembo or similar)
Tire Grip:
Off-road specific tire compounds and tread patterns
Passive Features
Frame Construction:
Robust Chromoly steel frame designed for off-road stresses
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic off-road motorcycle, no advanced infotainment features)
Driver Assistance
Traction Control:
N/A
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Gearbox:
Refer to manual for specific intervals, typically every 15-25 hours of riding or annually.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours).
Spark Plug Replacement:
Refer to manual, typically every 20-50 hours depending on usage and plug type.
Top End Rebuild:
Highly dependent on usage and riding style, typically 50-150 hours for piston and rings, potentially more for cylinder.
Fluid Specifications
Gearbox Oil:
Specific gearbox oil viscosity and type (e.g., Motul 75W/90 or equivalent) will be detailed in the manual.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Specifics in manual.
Brake Fluid:
DOT 4 (or DOT 3 if specified for older systems) hydraulic brake fluid.
Fork Oil:
Specific suspension oil viscosity (e.g., Kayaba Fork Oil 01, Showa SS-01, or equivalent) and level will be detailed.
Known Issues
Common Wear Items:
Clutch plates, brake pads, swingarm bearings, steering head bearings, wheel bearings, exhaust packing, reeds.
Carburetion Tuning:
Carburetor jetting often requires adjustment based on altitude, temperature, and rider preference.
Cooling System Maintenance:
Regular flushing and checking of coolant levels is crucial to prevent overheating.
📚 Vehicle History
Brand Heritage
Brand Origin:
Gas Gas is a Spanish manufacturer known for its success in trials and enduro motorcycles.
Model Evolution
Ec Series Evolution:
The EC (Enducross) line has been Gas Gas's flagship enduro model, evolving with chassis and engine improvements over the years. The 2006 models represent a refinement of previous generations.
Production
Manufacturing Location:
Spain (Typical for Gas Gas)
🏆 Awards & Recognition
Recognitions
Model Awards:
Gas Gas EC models have historically been recognized in enduro racing and various off-road competitions, though specific awards for the 2006 model are not readily available without deeper historical research.
Ratings
Professional Reviews 2006:
Likely received positive reviews in motorcycle publications of the time for their performance and handling characteristics in the enduro segment.
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