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

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The ENDUCROSS EC, produced in 2006, represents a line of off-road motorcycles renowned for their robust performance in challenging terrains. Available in EC 200, EC 250, and EC 300 engine...

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Type: Motorcycle

Vendor:

Sku: 101820

Tags: 2006 CAT EC 200 EC 250 EC 300 EC Models Featured Forklifts Gas Gas Material Handling Motorcycle

Product variants

Description

The ENDUCROSS EC, produced in 2006, represents a line of off-road motorcycles renowned for their robust performance in challenging terrains. Available in EC 200, EC 250, and EC 300 engine variants, these liquid-cooled, 2-stroke machines are engineered for extreme off-road riding, competition, and trail exploration. They are celebrated for their agile handling, strong mid-range and top-end power delivery, and the reliability characteristic of the Spanish manufacturer, which has a heritage dating back to 1985. These motorcycles are designed to tackle technical trails and enduro racing, offering a competitive edge against other prominent off-road models of their era. This comprehensive Service Repair Workshop Manual provides factory-level detail for all EC 200, EC 250, and EC 300 models from 2006. It covers every aspect of the motorcycle, from routine scheduled maintenance and lubrication to complete engine and transmission rebuilds, as well as advanced diagnostics. The manual includes detailed procedures for the engine, transmission, chassis, brakes, electrical system, fuel system, cooling system, exhaust, and wheels and tires, along with critical torque specifications. Written in English with high-quality diagrams and images, this manual is an indispensable resource for owners, mechanics, and technicians aiming to maintain, troubleshoot, and repair these capable off-road motorcycles effectively.

🏷️ Basic Information

Identification

Make:

GAS GAS

Model:

ENDUCROSS EC

Year:

Engine Variant:

EC 200, EC 250, EC 300

👋 Introduction

Market Position

Market Segment:

Off-road/Enduro motorcycles, known for their robust performance in challenging terrains.

Competitive Analysis

Competitors 2006:

KTM EXC series, Husqvarna WR series, Beta RR series, Yamaha WR series, Honda CRF-X series.

Key Features Vehicle

Off Road Focus:

Designed for extreme off-road riding, competition, and trail exploration.

Handling:

Known for agile handling characteristics, making them suitable for technical trails and enduro racing.

Key Features Manual

User Friendliness:

Written for both DIY enthusiasts and experienced mechanics, featuring step-by-step instructions.

Visual Aids:

Contains top-quality diagrams, exploded views, and detailed pictures.

📋 Manual Details

Coverage Areas

Coverage:

Complete factory service and repair for all EC 200, EC 250, EC 300 models.

Page Count

Page Count:

Not specified, but described as 'complete'.

Manual Type

Manual Type:

Service Repair Workshop Manual

Detail Level:

Factory-level detail, intended for professional technicians and serious enthusiasts.

Language

Language:

English

Format

Format:

Software Recommendation:

Adobe PDF Reader recommended for optimal viewing of images and graphics.

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive coverage of engine disassembly, assembly, troubleshooting, and tuning for all specified engine variants.

Transmission:

Detailed procedures for transmission maintenance, repair, and overhaul.

Chassis:

Covers suspension, steering, frame, and related components.

Brakes:

Maintenance and repair procedures for both front and rear braking systems.

Electrical System:

Wiring diagrams, troubleshooting, and repair of electrical components.

Fuel System:

Carburetor servicing, fuel tank, and lines for all engine variants.

Cooling System:

Inspection of radiator, hoses, water pump, and thermostat (if applicable).

Exhaust System:

Details on exhaust pipes, mufflers, and their maintenance.

Wheels And Tires:

Information on wheel bearing service, tire mounting, and balancing.

Frame And Suspension:

Detailed disassembly, inspection, and service for the frame, front forks (e.g., Marzocchi or Paioli), and rear shock absorber (e.g., Olle or Sachs).

Clutch System:

Detailed procedures for clutch master cylinder, slave cylinder, and clutch pack service.

Procedures Included

Maintenance:

Scheduled maintenance, lubrication, and routine checks.

Troubleshooting:

Diagnostic procedures for common and complex issues.

Repair:

Step-by-step repair instructions for all major motorcycle components.

Rebuild:

Complete engine and transmission rebuild procedures.

Disassembly Assembly:

Detailed instructions for complete disassembly and reassembly.

Torque Specifications:

Includes critical torque values for fasteners across all systems to ensure correct assembly.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine rebuilds and advanced diagnostics.

Diagnostic Capabilities:

Includes troubleshooting guides and symptom-based diagnostics for engine, electrical, and mechanical issues.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High quality diagrams and images.

Printable

Printable:

Printable without restriction.

Accessibility

Delivery:

Instant PDF download after purchase.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, single-cylinder, liquid-cooled.

Engine Description:

Liquid-cooled, 2-stroke engines with reed valve induction and a power valve system for improved low-to-mid-range torque.

Engine Displacement

Ec 200 Displacement:

Approximately 193cc

Ec 250 Displacement:

Approximately 249cc

Ec 300 Displacement:

Approximately 294cc

Performance

Bore Stroke Typical:

Varies by model, typically around 64x58mm (EC250), 72x72mm (EC300).

Horsepower Range Estimated:

EC200: ~35-40 HP, EC250: ~40-45 HP, EC300: ~45-50 HP (approximate and can vary with tuning).

Power Delivery:

Characteristic strong mid-range and top-end power typical of 2-stroke enduro bikes.

Fuel System

Carburetor Type:

Typically Dell'Orto VHSH/VHSB or Keihin carburetors, size varies by model (e.g., 34mm-38mm).

Fuel Type:

Unleaded gasoline with appropriate 2-stroke oil mixture.

Ignition

Ignition System:

Digital CDI ignition.

Lubrication

Premix Ratio:

Manual specifies recommended 2-stroke oil mix ratio (typically 50:1 or 60:1).

🔧 Transmission

Standard

Transmission Type:

6-speed sequential constant mesh.

Features

Clutch:

Hydraulic clutch actuation.

📐 Dimensions

Weights

Dry Weight Estimated:

Around 100-110 kg (220-240 lbs) depending on model and configuration.

Fuel Tank Capacity:

Typically 8-12 liters (approx. 2.1-3.2 gallons).

🛡️ Safety Features

Active Features

Braking System Front:

Hydraulic disc brakes, typically with Nissin or similar calipers.

Braking System Rear:

Hydraulic disc brakes, typically with Nissin or similar calipers.

Passive Features

Lighting:

Headlight, taillight, brake light (DOT/ECE compliant versions may vary).

💡 Technology Features

Infotainment

Infotainment System:

N/A (Focus is on off-road performance, not typically equipped with advanced infotainment).

Driver Assistance

N/A (ABS was not a standard feature on most enduro bikes of this era).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Spark Plug Replacement Interval:

Check/clean every 20-30 hours, replace as needed (refer to manual for specific type).

Air Filter Cleaning Interval:

Recommended after every few rides, or more frequently in dusty conditions.

Oil Change Transmission:

Typically every 15-25 hours of riding, depending on usage.

Chain And Sprocket Inspection:

Inspect and lubricate chain regularly (every 500-1000 km or more frequently if off-roading).

Fluid Specifications

Transmission Oil Type:

Manual specifies recommended gearbox oil (e.g., SAE 75W/80W or 10W/40 motorcycle specific).

Coolant Type:

Ethylene glycol-based antifreeze and distilled water mixture (typically 50/50).

Brake Fluid Type:

DOT 4 recommended for hydraulic brake systems.

Fork Oil Type:

Manual specifies appropriate fork oil viscosity (e.g., SAE 5W or 10W).

Known Issues

Common Wear Items:

Clutch plates, piston rings, spark plugs, chain, sprockets, wheel bearings, and suspension seals due to demanding off-road use.

Carburetor Tuning:

Sensitivity to altitude and temperature changes, often requiring jetting adjustments.

Suspension Maintenance:

Regular fork oil changes and seal inspections are crucial for optimal performance.

📚 Vehicle History

Brand Heritage

Brand Origin:

GAS GAS is a Spanish manufacturer founded in 1985, renowned for its off-road motorcycles.

Model Evolution

Enducross Lineage:

The EC Enducross line represents GAS GAS's core off-road competition and trail riding platform, continually updated for performance and reliability.

Production

Manufacturing Location:

Spain

🏆 Awards & Recognition

Recognitions

Brand Reputation:

GAS GAS is well-regarded in the enduro and extreme enduro communities for its capable and durable machines.

Ratings

Off Road Performance Ratings:

Consistently reviewed positively for handling, engine power delivery, and suspension performance in challenging terrains.