Gas Gas EC 515 FSR [2008-2009]: A Big-Bore Enduro That Rewrites the Rules
Introduction
The Gas Gas EC 515 FSR (2008–2009) isn’t just another dirt bike—it’s a statement. Born from a Spanish brand known for pushing boundaries, this big-bore enduro machine combines cutting-edge technology with raw, unapologetic power. Designed for riders who crave dominance in technical terrain and open trails alike, the EC 515 FSR stands as a testament to Gas Gas’s commitment to innovation. Having spent hours throwing this beast around rocky ascents and tight singletrack, I can confidently say it’s a motorcycle that leaves a permanent grin on your face—and a trail of dust in its wake.
Design & Ergonomics: Slim, Light, and Ready to Rally
The EC 515 FSR’s design philosophy is clear: minimalism meets functionality. Its Deltabox frame, constructed from chromium-molybdenum tubing, strikes a balance between rigidity and weight savings. The bike tips the scales at 118 kg (260 lbs), making it one of the lightest in its class. This translates to effortless maneuverability when wrestling through tight woods or picking lines over boulder fields.
The seat height—adjustable between 900–940 mm (35.4–37 inches)—accommodates shorter riders without sacrificing ground clearance (290–370 mm / 11.4–14.6 inches). The slim profile lets you grip the tank with your knees easily, while the black/white or red/white color schemes (depending on the year) give it a no-nonsense, race-ready aesthetic.
Standout features include the Trailtech digital dash—a compact, color-coded display that replaces clunky analog gauges—and intuitive switchgear that feels decades ahead of competitors. Gas Gas even throws in plastic handguards and a bashplate, though serious off-roaders will want to upgrade these immediately.
Engine & Performance: EFI, Torque, and a Slipper Clutch
At the heart of the EC 515 FSR lies a 515 cc liquid-cooled single-cylinder engine with a DOHC 4-valve setup. But the real star is its battery-less Kokusan EFI system, a groundbreaking feature for its time. Unlike carbureted rivals, this fuel-injected mill eliminates jetting headaches and adapts seamlessly to altitude changes. The EFI’s secret sauce? A manifold air pressure sensor that self-adjusts the fuel mixture for mods like exhausts or airbox tweaks—no ECU remapping required.
Power delivery is nothing short of brutal. With torque figures rumored near 50 Nm, the EC 515 FSR pulls like a freight train from idle to redline. The Adler slipper clutch (a $1,000 aftermarket add-on for other bikes) comes standard, reducing engine braking and letting you downshift aggressively without unsettling the rear wheel. Combined with the 6-speed transmission, this clutch makes the bike equally at home crawling over logs or devouring fire roads.
Starting is a breeze thanks to dual electric/kickstart options, and the absence of a battery dependency means you’ll never be stranded—even if the battery dies, a few kicks will fire it up.
Handling & Suspension: Precision Meets Plushness
Gas Gas nailed the suspension setup here. The 48mm Marzocchi Shiver forks (290 mm travel) and Öhlins rear shock (320 mm travel) strike a rare balance between plush small-bump compliance and bottoming resistance. After tweaking the clickers for my weight, the bike floated over rooty sections while staying composed during hard landings.
The chassis shines in technical terrain. With a wheelbase of 1,475 mm (58.1 inches), the EC 515 FSR carves through corners like a 250cc bike but remains stable at speed. The 21-inch front and 18-inch rear wheels (shod with 90/90-21 and 140/80-18 tires, respectively) offer predictable traction, though the stock knobbies wear quickly under the engine’s relentless torque.
Braking is handled by a 260mm front disc (2-piston caliper) and 220mm rear disc (1-piston). While adequate for trail riding, aggressive riders might crave more bite—a simple pad upgrade solves this.
Competition: How Does It Stack Up?
The EC 515 FSR faced stiff competition in the late 2000s. Here’s how it measures up:
- KTM 525 EXC: KTM’s carbureted 525 was lighter (116 kg) and had a cult following, but its vibration-heavy engine and dated carburetion couldn’t match the Gas Gas’s smooth EFI power.
- Husqvarna TE 510: Husky’s TE 510 boasted similar power but lacked the EC 515’s slipper clutch and subframe durability. Maintenance intervals were also shorter.
- TM 530 EN Racing: The Italian TM offered comparable handling and a race-bred chassis but fell short in tech (carbureted) and dealer support.
The Gas Gas’s trump cards? EFI reliability, Adler clutch, and a lower seat height that appealed to average-height riders.
Maintenance: Keeping the Beast Alive
Ownership demands diligence but rewards with longevity:
- Oil Changes: Use high-quality synthetic oil every 15–20 hours. The wet-sump system holds 1.2 liters—MOTOPARTS.store offers a range of Motul and Bel-Ray options.
- Air Filter: Clean after every ride. The EFI hates dirt—consider a pre-oiled Twin Air filter for quicker swaps.
- Valve Checks: Every 40 hours. Shim-under-bucket design requires patience but stays in spec longer than rivals.
- Upgrades:
- Radiator Guards: The stock cores bend easily. Our store’s Bulletproof Designs kit is a must.
- Handguards: Replace flimsy plastics with Cycra Pro Bend aluminum.
- Exhaust: The stock stainless system is robust, but an FMF MegaBomb header boosts mid-range.
Chain and sprocket life is average—expect to replace them every 80–100 hours. Stick with DID X-Ring chains and steel sprockets for durability.
Conclusion: A Forgotten Gem
The Gas Gas EC 515 FSR is a time capsule of innovation—a big-bore that handles like a middleweight and packs tech that rivals modern bikes. Its EFI system, slipper clutch, and sublime suspension make it a joy to ride hard, while its minimalist design keeps the focus on performance.
Whether you’re hunting for a used gem or already own one, MOTOPARTS.store has the upgrades and OEM replacements to keep your EC 515 FSR shredding for years. From radiator braces to premium oils, we’ve got your back—because legends deserve to stay on the trail.
