2 - Gas Gas Motorcycles
Contents
1. EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 19 Clutch 1 Screw 6x20 24 Allen key 6x20 v Tightening torque 6 Nm v Tightening torque 6 Nm 2 Clutch pump O ring 25 Clutch spring bushing 3 Hydraulic clutch calliper 26 Clutch spring 4 Line washer 5 Bleeder 6 Bleeder cap 7 Clutch rod 8 Clutch hub 9 Washer 10 Clutch housing bushing 11 Clutch housing rivets 12 Clutch housing bearing 13 Clutch housing crown 14 Rubber silentblock 15 Washer clutch crown 16 Clutch housing washer 22 1x42x2 8 17 Covered clutch disc 18 Iron clutch disc 19 Clutch rod 20 Needle bearing 21 Needle plate 22 Clutch press 23 Circlip 15 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 20 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Clutch spring 26 Check the condition of the springs and their length Length of the springs Min 45 7 mm Limit 44 mm Note The clutch springs are replaced as a set Clutch press 22 Check the condition and the contact surface with the clutch discs for scratches and excessive wear Bearing 20 and rod 19 Check the clutch bearing and the rod for seizure signs of rolling and play Covered clutch discs 17 Check the thickness of the covered clutch discs Thickness of the STD 2 75 to 2 85 mm covered clutch disc Limit 2 68 mm Iron clutch discs 18 Check the condition of the clutch disc for s2. Testing Centrifugal shaft 17 Check that the centrifugal shaft does not show signs of seizure or rust The housing 24 should slide along the shaft easily Centrifugal pinion 18 Check that the pinion does not show signs of wear in the contact area of the teeth Exhaust valve needle cage 21 Check that the needle cage does not show signs of seizure or stiffness on turning and that the plates 23 do not show signs of rolling Centrifugal balls 25 Check the condition of the centrifugal balls They should be spherical and should not show signs of wear or contact Diameter of the centrifugal balls 8mm Needle 35 Check that it is firmly fastened to the centrifugal output lever 33 Centrifugal output lever 33 Check that it is firmly fitted on the shaft of the centrifugal lever 31 If itis necessary to remove it mark its position with respect to the shaft of the centrifugal lever 31 e g with a permanent marker 200 250 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 07 Valve control shaft support 32 Check that the shaft of the centrifugal lever 31 moves freely within the support Exhaust valve bearings 2 and 11 Check that the exhaust valve bearings do not show signs of seizure or stiffness on turning Note The exhaust valve bearings must be replaced together Left exhaust valve 4 central 13
3. REMOVING THE ENGINE FROM THE CHASSIS 01 03 Undo the screws arrows remove the chain pinion and the hydraulic clutch calliper with the gasket Loosen the chain Extract the clutch rod arrow entirely Note The position of the chain pinion before removing It should be replaced in the same position to ensure the same direction of wear Remove the circlip 1 of the chain pinion using circlip pliers Remove the chain pinion 2 from the secondary shaft Remove the gear lever Release the magnetic flywheel wiring from its fastening on the chassis disconnect the connector on the control unit CDI and the remaining wiring connectors Remove the carburettor 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL REMOVING THE ENGINE FROM THE CHASSIS Ed 07 05 Remove the screws arrows fastening the engine to the chassis Loosen the screw fastening the cylinder head support to the chassis Remove the screw arrow fastening the engine to the lower chassis Remove the nut 1 remove swing arm and move backwards Position the engine ready for removal and then take off Engine _________200 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 FITTING THE ENGINE ON THE CHASSIS 02 01 Fit the engine on the chassis and correctly position on the supports Line up swing arm with the engine and chassis grease swing arm and fit Place engine fastening
4. if this is not the case try to release the turn by tapping them with a plastic hammer Fit the chain pinion hub on the shaft Put the nut fastening the engine to the bench back again Check that there are no traces of the half crankcase sealant on the cylinder support surface Fitting the reed valve Remove the remains of the crankcase gasket on the support surface of the reed box Place the reed box in its housing with the new gaskets Tighten the screws arrows Tightening torque 10 Nm Fit the dual mass flywheel of the crankshaft Note The 200 cc engine is not fitted with a flywheel The crankshaft pinion ts fastened with a hexagonal screw Fit the crankshaft pin the flywheel the crankshaft pinion the bevelled washer and the nut on the crankshaft Note The locking nut of the crankshaft is tightened to the left 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 05 04 ASSEMBLING THE ENGINE Ed 07 05 Lock the rotation of the crankshaft pinion and tighten the nut arrow Tightening torque 40 Nm Assembling the gear selector unit Place the gear locking unit with the spring arrow slack and tighten the arrow 1 Use thread lock Tightening torque 6 Nm Position the spring arrow using pliers Fit the centring screw of the selector shaft 2 Use thread lock Tightening torque 15 Nm Insert the selector shaft bushing and fit the complete selector shaft
5. v Tightening torque 6 Nm 3 Flat washer 6x16x1 5 4 Gear locking spring 5 Gear lock plate bushing 6 Gear lock 7 8 9 NO Desmodromic Fork V VI Short fork shaft 10 Desmodromic bearing HK3512 11 Long fork shaft 12 Forks I II III IV 13 Centring pin selector shaft 14 Selector shaft bushing 15 Selector shaft 16 Scorpion spring 17 Scorpion 18 Scorpion guide bushing 19 Selector spring Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 23 Selector shaft 15 Check that the selector shaft shows no signs of excessive wear or contact marks Check that the selector rod bushing 14 is in good condition and without excess play Scorpion guide bushing 18 Check that the guide bushing does not show signs of excess wear in the contact area with the scorpion 17 Selector shaft assembly Insert the selector shaft bushing 14 at the end The assembly position should be with the conical side arrow facing the side opposite the scorpion 17 Insert the scorpion guide bushing 18 in the end of the selector shaft 15 Insert the scorpion 17 in the selector shaft guide Place the selector spring 19 on the shaft support and support the lower foot straight foot on the end Using pliers pass the upper foot curved foot over the end until it is supported on the opposite side to the lower foot Insert the ends of
6. Check that the spark plug shows no signs of knocks or cracks Check that the spark plug is free of carbon deposits and particles Check that the electrode is not over worn or burnt Check the electrode distance with a feeler gauge Electrode distance 0 7 to 0 8 mm Engine _________200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 ASSEMBLING THE ENGINE Notes All the engine parts must be perfectly clean and in optimum conditions for commencing assembly Before assembly apply engine oil to all the moving and sliding parts Place the right half crankcase on the workbench Assembling the crankshaft Lubricate the crankshaft bearing in the crankcase Insert the crankshaft in the crankcase bearing On the opposite side of the crankcase fit the O ring and then the crankshaft seal bushing with the recessed side facing outwards Assembling the selector rod and gears from the gearbox Lubricate the bearings of the gear cams and of the desmodromic in the crankcase Place the pinions of and V gear arrows the needle bearing and the adjustment washers in the crankcase Note The 1st gear pinion should be positioned with the four notches arrows facing the crankcase 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 05 02 ASSEMBLING THE ENGINE Ed 07 05 Carefully place together the gear cams of the primary 1 and secondary 2 shafts Place the pinio
7. Check the existence and condition of the centring bushings 6 Replace non existent centring bushings where necessary Note If there are no centring bushings a correct seal is not guaranteed when the crankcases are fitted Left half crankcase inner side Before making any repairs to the left half crankcase check the deformation to the same in the entire perimeter on the inside using a feeler gauge Maximum deformation of half crankcase Note To remove the bearings of the left half crankcase it should be heated to approximately 150 C using a heating plate oven or similar When it is hot only a standard extractor tool is required a soft metal or wooden rod to completely remove the bearings In exceptional cases it may be necessary to use a press to dislodge the bearings Take out the left crankcase seals using a seal extractor or by carefully levering with a screwdriver Note All gaskets seals and O rings should be replaced whenever the engine is dismounted partially or completely Place the left half crankcase on a heating plate and heat to approximately 150 C 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 14 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Danger When handling the crankcase after heating it heat resistant gloves should be used to protect hands Remove the left crankcase bearings Crankshaft bearing 1 Remove the ball be
8. Fill the coolant system through the left radiator cap Mixture of coolant and distilled water 1 1 antifreeze 50 distilled water 50 Capacity 1 1 litres Note Ensure that the transmission oil drain plug is tightened and has a new gasket Tightening torque 20 Nm Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 FITTING THE ENGINE ON THE CHASSIS 02 03 Remove the oil filler cap arrow and fill with new transmission oil Viscosity 10W30 Capacity 900 cc Fit the oil filler cap with a new gasket and tighten Pump the starter pedal 3 or 4 times and check the oil level through the indicator arrow Apply Nural 29 to the exhaust system unions Fit the complete exhaust system and tighten screws slightly Check the condition of the O rings of the exhaust if they are deteriorated replace them Correctly fit the springs holding the exhaust pipe to the cylinder pipe Tighten the exhaust system screws Tightening torque 6 Nm 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 02 04 FITTING THE ENGINE ON THE CHASSIS Ed 07 05 Fit the kick start pedal lever apply Loctite 243 to the screw arrow and then tighten Tightening torque 20 Nm Fit the fuel tank and the vent hose Check the condition of the air filter If itis damaged replace with a new one If it is undamaged clean and refit see user manual Replace the plast
9. The seal lip should face the outside of the crankcase Press down on the seal with a rod until it fits completely flat in the left crankcase housing Warning When fitting the seal take care not to damage the seal lip Selector shaft seal 3 Fit the new selector shaft seal in the crankcase housing The seal lip should face the outside of the crankcase Press down on the seal with a rod until it fits completely in the left crankcase housing Warning When fitting the seal take care not to damage the seal lip Clutch cover Before any repairs to the clutch cover check the deformation on the inside using a feeler gauge Maximum deformation of clutch cover Note To remove the bearings of the clutch cover it should be heated to approximately 150 C using a heating plate oven or similar When it is hot only a standard extractor tool is required a soft metal or wooden rod to completely remove the bearings In exceptional cases it may be necessary to use a press to dislodge the bearings Take out the clutch cover seals using a seal extractor or by carefully levering with a screwdriver Engine 200 ce 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 17 Note All gaskets seals and O rings should be replaced whenever the engine is dismounted partially or completely Place the clutch cover on a heating plate and heat to
10. and right 10 Check the valves for cracks signs of seizure or damage from overheating Clean the valves of carbon deposits using a wire brush that does not damage the surface of the valves Short exhaust valve shaft 14 and long shaft 12 Check the shafts for cracks signs of seizure or damage from overheating Clean the shafts of carbon deposits using a wire brush that does not damage the surface of the valves Central exhaust valve assembly position 13 Fit the central exhaust valve with the curved surface facing the inside of the exhaust port 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 08 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Crankcase 1 Allen key 6x70 v Tightening torque 6 Nm Left crankcase outer side Cylinder studs Crankcase centring bushing Water intake sump plug Fibre washer 14x20x2 Oil filler cap Copper washer Left crankcase inner side 10 Central crankcase gasket 11 Copper washer 8x12x1 12 Allen key 8x14 v Tightening torque 15 Nm 13 Oil cap O ring 12x2 14 Oil drain cap with magnet v Tightening torque 9 Nm 15 Right crankcase 16 Clutch cover gasket 17 Clutch cover 18 Allen key 6x25 v Tightening torque 6 Nm COND OB C5 Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 09 Right half crankcase inner side Remove the centring
11. approximately 150 C Danger When handling the crankcase after heating it heat resistant gloves should be used to protect hands Remove the clutch cover bearings Centrifugal shaft bearing 1 Remove the ball bearing from the centrifugal shaft using a bearing extractor Gi max 8 mm from the inside of the clutch cover Fit the new ball bearing in the clutch cover housing The closed face of the bearing should face the inside of the opening of the casing Press down on the bearing until it fits completely in the clutch cover housing Pinion shaft bearing of water pump 2 Remove the ball bearing from the pinion shaft of the water pump using a bearing extractor max 10 mm from the inside of the clutch cover Fit the new ball bearing in the clutch cover housing The closed face of the bearing should face the inside of the opening of the casing Press down on the bearing until it fits completely in the clutch cover housing 200 cc 250 300 cc ENDUCROSS WORKSHOP MANUAL 04 18 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Starter shaft seal 1 Fit the new starter shaft seal in the clutch cover housing The seal lip should face the outside of the clutch cover Press down on the seal with a rod until it fits completely in the clutch cover housing Warning When fitting the seal take care not to damage the seal lip Engine 200 ce 250 cc 300
12. arrow Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 ASSEMBLING THE ENGINE 05 05 Assembling the starter pinion unit Lubricate the housing of the starter shaft in the crankcase Insert the starter unit ensuring that the ratchet is located between the plate and the casing Place the spring 1 in the opening in the crankcase using pliers Check that the centring bushing of the starter spring is positioned correctly Lubricate the bearing of the inner pinion of the starter Fit the inner pinion of the starter the spacing washer and the circlip 2 Assembling the centrifugal operating system of the exhaust valve Lubricate the centrifugal shaft bearing in the crankcase Fit the centrifugal mechanism 2 in the crankcase Fit the support 1 ensuring that the output lever is correctly located in the groove of the mechanism Tighten the screws arrows Use thread lock Tightening torque 10 Nm Fit the water pump shaft and pinion Assembling the clutch Check that the primary shaft is clean and particle free Fit the washer 3 the bushing 2 and the clutch housing bearings 1 Lubricate the clutch housing bearings Fit the clutch housing and then the washer arrow Note When fitting the clutch hub note the assembly position with respect to the mark made when dismounting 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 05 0
13. on the bearing housings If too much pressure is applied the half crankcase could get damaged Desmodromic bearing 4 Remove the needle bearing from the desmodromic using a bearing extractor max 25 mm from the inside of the crankcase inwards Fit the new needle bearing in the crankcase housing The stamped face of the bearing should face the inside of the opening of the casing Press down on the bearing until it fits completely in the left crankcase housing Warning When removing and fitting the needle bearing take care not to apply excessive pressure on the casing area of the bearings If too much pressure is applied the crankcase may be damaged Check the opening for lubricating the crankshaft bearing arrow It should be free of obstruction and clean Left crankcase outer side Note All gaskets seals and O rings should be replaced whenever the engine is dismounted partially or completely Crankshaft seal 1 Fit the new crankshaft seal in the crankcase housing The seal lip should face the outside of the crankcase Press down on the seal with a rod until it fits completely in the left crankcase housing Warning When fitting the seal take care not to damage the seal lip 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 16 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Output shaft seal 2 Fit the new crankshaft seal in the crankcase housing
14. screws in supports Note The self locking fastening nuts of the engine must be replaced with new nuts Tighten all the nuts slightly and then to the specified torque Nuts Tightening torque 38 to 48 Nm B 24to29 Nm 38 to 48 Nm Dj Nm 66 Nm Assemble the carburettor Place the magnetic flywheel on the chassis and fasten correctly Connect the control unit connector and the remaining wiring connectors Assemble the gear lever Tightening torque 15 Nm Note The chain pinion must be fitted in the same position as when it was removed to ensure the same direction of wear 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 02 02 FITTING THE ENGINE ON THE CHASSIS Ed 07 05 Place the chain pinion 2 on the secondary shaft and fit the circlip 1 Fit the clutch rod arrow Fit the hydraulic clutch calliper with a new gasket fit the chain pinion guard and tighten screws arrows Tightening torque 6 Nm Tension the chain Assemble the back brake pedal and the back brake pump guard Tightening torque 29 Nm Note Check that the coolant pipes are not cut or worn Connect the spark plug connector arrow and connect the coolant pipes on both sides of the engine Note Ensure that the coolant drain plug in the water pump is screwed in tightly and has a new seal Tightening torque 9 Nm Disconnect the coolant recirculation pipe
15. 3 Needle bearing plate 5 Screw 24 Centrifugal hood v Tightening torque 6 Nm 25 Centrifugal balls 6 Exhaust valve lever 26 O ring 7 Exhaust valve bearing separator 27 Centrifugal star 8 Bearings 28 Pin 9 Exhaust valve bearing spacer 29 Bolts 10 Right exhaust valve v Tightening torque 6 Nm 11 Screw 30 Rod and lever unit v Tightening torque 6 Nm 31 Centrifugal lever shaft 12 Short exhaust valve shaft 32 Control shaft support 13 Central exhaust valve 33 Centrifugal output lever 14 Long exhaust valve shaft 34 Screw 15 Circlip v Tightening torque 6 Nm 16 Pin 35 Needle 17 Centrifugal shaft 18 Centrifugal pinion 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 06 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Dismantling Undo screws 1 and 11 Take out the bearings 2 using an extractor tool together with the washer 3 and the left side exhaust valve 4 Remove the long exhaust valve shaft 12 Release the right exhaust valve through the casing of the left exhaust valve 10 the spacer 9 and the bearing 8 tapping gently with a tappet Remove the short exhaust valve shaft 14 tapping the inside of the screw hole gently with a tappet either 1 or 11 Remove the central exhaust valve through the cylinder exhaust port Note To dismantle the centrifugal mechanism first compress the spring 19 until the pin is released 16 and then remove the mechanism
16. 6 ASSEMBLING THE ENGINE Ed 07 05 Fit the clutch hub the new lock washer and the fastening nut Hold the clutch hub down and tighten the fastening nut Use thread lock Tightening torque 40 Nm Close the catch of the lock washer 1 Check that the clutch discs are perfectly clean and lubricate all the discs Insert the iron discs and the covered discs alternately in the clutch hub beginning and ending with a covered disc Lubricate the rod bearing and fit the clutch press 2 Place the screws 1 with their bushings and springs and tighten them in stages in diagonal pairs Use thread lock Tightening torque 10 Nm Assembling the cylinder and cylinder head Check that the piston and pin are clean Lubricate the connecting rod small end bearing Position the piston with the arrow marked on the head facing the exhaust port Note Before fitting the pin circlip cover the crankcase opening with a clean cloth Engine _________200 ce 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 ASSEMBLING THE ENGINE 05 07 Insert the pin through the piston and the bearing of the connecting rod small end and then fit the new circlip arrow Fit the piston rings with the manufacturer s inscription facing upwards Fit the gaskets at the foot of the cylinder Carefully fit the cylinder making sure that the rings are centred with the locking pins of the piston grooves Fit t
17. ASSIS 01 01 Note The cylinder head the cylinder the clutch and the ignition can be removed without dismounting the engine from the chassis Thoroughly clean the motorcycle before starting to dismantle the engine Place the motorcycle on a support suitable for work Remove the seat Dismantle the plastic covers on both sides Remove the fuel tank Remove the lever from the kick start pedal arrow Release the springs holding the exhaust pipe to the cylinder pipe 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 01 02 REMOVING THE ENGINE FROM THE CHASSIS 07 05 Remove the whole exhaust system Note The oil must never be poured down the drain or into the environment Remove the drain plug arrow and drain the transmission oil Danger Make sure that the coolant fluid is not hot before opening the coolant circuit Note Place the coolant in a clean container it may be reused later Remove the radiator cap Unscrew the coolant drain plug in the water pump and allow the fluid to drain into the containert Clean any fluid which falls on the engine chassis or wheels Disconnect the spark plug connector 1 and disconnect the coolant pipes on both sides of the engine Remove the back brake pedal and the back brake pump guard setting them to one side Engine 200 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05
18. ERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 03 Connecting rod Note The bearing of the connecting rod big end is replaced together with the crankshaft journal the connecting rod and the spacer washers Check the connecting rod small end bearing and housing for seizure signs of rolling and play Measure the play of the connecting rod big end by pushing it to one side and inserting a feeler gauge on the opposite side Connecting rod big end play STD 0 80 mm Limit 1 00 mm Piston Check the piston for scratches signs of seizure and damage from overheating Check the grooves of the rings cleanliness absence of carbon deposits breakage etc If necessary clean with a wire brush that will not damage the piston surface Check that the locking pins of the rings are in their housing and are firmly seated Check that there is no excess play between the rings and the piston grooves Piston assembly play Note The play at assembly of the piston is determined by subtracting the smallest cylinder diameter from the largest piston diameter Play of the piston at 200 STD 0 05 mm assembly Limit 0 10 mm 250 cc STD 0 055 mm Limit 0 10 mm 300 cc STD 0 06 mm Limit 0 10 mm 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 04 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Piston opening at the end of the ring Insert a piston ring in the cylinder a
19. OF THE ENGINE COMPONENTS ASSEMBLING THE ENGINE ELECTRICAL SCHEMAS GENERAL INFORMATION Certain safety and maintenance norms should be remembered when carrying out repairs to the vehicles Some of the more important norms are listed below Safety Do not smoke or cause sparks or naked flames in the work area Petrol is highly inflammable and may be explosive in certain conditions Use cleaning products appropriate to each task ensuring that they have been approved Always wear protective eye equipment when using electric tools such as drills sanders or grinders Apply a protective hand cream before commencing dismantling work This protects the skin from infection and makes subsequent cleaning easier Ensure that hands are not slippery Remember that prolonged contact of the skin with engine oil can be damaging to health Keep loose clothing away from moving parts Do not wear rings wristwatches etc while working on the engine especially the electrical system Keep the work area tidy it is easy to trip over elements left on the floor Avoid leaving oils grease or other fluids on the floor of the work area to avoid slipping on them Use suitable tools for compressing or decompressing springs to prevent these from escaping suddenly Take special care not to inhale dust from parts containing asbestos for example clutch discs this product is extremely dangerous for your health Avoid inhaling fumes from petrol o
20. WORKSHOP MANUAL WERKSTATTHANDBUCH MOTOR EC Enducross 2007 2590 300 INTRODUCTION This manual was created by GAS GAS Motos S A for the use of official GAS GAS services It is principally directed at operators with a basic knowledge of the principles of mechanics and repair techniques It contains precise instructions for making all the repairs in addition to the necessary technical data to carry out the maintenance of the motorbikes There is also considerable information about the special GAS GAS tools and equipment that will be of great help in optimising repair processes In successive editions we will keep you informed of all the updates and evolution of the motorbikes in this family Particularly important information in the manual is preceded by one of the following symbols Note indicates points of particular interest for more efficient and convenient operation Warning indicates special instructions or procedures which should be followed to the letter to avoid damaging the equipment Danger indicates special instructions or procedures which must be followed to the letter to avoid physical injury to the operators GAS GAS Motos S A CONTENTS Sect 01 02 03 04 05 06 Vi 01 01 01 01 01 01 GENERAL INFORMATION TABLE OF TECHNICAL DATA REMOVING THE ENGINE FROM THE CHASSIS FITTING THE ENGINE ON THE CHASSIS DISMOUNTING ENGINE SERVICE AND REPAIR
21. acing plate Reed valve Qo X CD BI s So n 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 30 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Reeds 2 and 3 Check the reeds for cracks or splitting and for signs of ageing Check that the reeds sit firmly one on top of another and are dry Reed spacer plate 7 Check that the spacer 7 does not have any deformed surfaces Reed valve 8 Check that the supporting surfaces of the reeds are in perfect condition Engine _________200 250 cc 300 ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 31 Ignition 1 Ignition rubber top 2 Allen screw 5x20 v Tightening torque 6 Nm 3 Flat washer 5x12x1 5 4 Magnetic flywheel Kokusan FP 8009 Multispark 5 Ignition Centring 6 Spark plug 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 32 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Ignition rubber top 1 Check that the ignition rubber top is in good condition Magnetic flywheel Kokusan 4 Carry out the following tests using a multi tester Impulse coil 100 O 20 Black Red Red White 12 7 O 20 Charge coil Yellow Earth 0 67 O 20 White Yellow 0 16 QO 20 Note All measurements must be taken at a temperature of 20 C Otherwise significant errors may occur in the measurement values Spark plug 6
22. aring from the crankshaft using a bearing extractor max 38 mm from the inside of the crankcase inwards Fit the new ball bearing in the crankcase housing The stamped face of the bearing should face the inside of the crankcase Press on the new ball bearing until it fits level with the inner surface of the crankcase Primary cam bearing 2 Remove the ball bearing from the primary cam by pressing from the outside of the crankcase inwards Fit the new ball bearing in the crankcase housing The stamped face of the bearing should face the outside of the crankcase Press down on the bearing until it fits completely in the left crankcase housing Warning When removing and fitting the ball bearing take care not to apply excessive pressure on the casing area of the bearings If too much pressure is applied the crankcase may be damaged Secondary cam bearing 3 Remove the ball bearing from the secondary cam by pressing from the outside of the crankcase inwards Fit the new ball bearing in the crankcase housing The stamped face of the bearing should face the inside of the crankcase Press down on the bearing until it fits completely in the right crankcase housing Engine _________200 ce 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 15 Warning Be careful when removing and fitting the needle bearings so as not to put too much pressure
23. ase Press down on the bearing until it fits completely in the right Engine 200 ce 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 11 crankcase housing Warning Be careful when removing and fitting the needle bearings so as not to put too much pressure on the bearing housings If too much pressure is applied the crankcase could be damaged Check the opening for lubricating the crankshaft bearing arrow It should be free of obstruction and clean Right half crankcase outer side Note To remove the bearings of the right half crankcase it should be heated to approximately 150 C using a heating plate oven or similar When it is hot only a standard extractor tool is required a soft metal or wooden rod to completely remove the bearings In exceptional cases it may be necessary to use a press to dislodge the bearings Take out the right crankcase seals using a seal extractor or by carefully levering with a screwdriver Note All gaskets seals and O rings should be replaced whenever the engine is dismounted partially or completely Place the right half crankcase on a heating plate and heat to approximately 150 C 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 12 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Danger When handling the crankcase after heating it heat resistant gloves should b
24. bushings 1 and the centring pin of the selector spring 2 Before making any repairs to the right half crankcase check the deformation to the same in the entire perimeter using a feeler gauge both on the inside and the outside Maximum deformation of half crankcase Note To remove the bearings of the right half crankcase it should be heated to approximately 150 C using a heating plate oven or similar When it is hot only a standard extractor tool is required a soft metal or wooden rod to completely remove the bearings In exceptional cases it may be necessary to use a press to dislodge the bearings Take out the right crankcase seals using a seal extractor or by carefully levering with a screwdriver Note All gaskets seals and O rings should be replaced whenever the engine is dismounted partially or completely Place the right half crankcase on a heating plate and heat to approximately 150 C Danger When handling the crankcase after heating it heat resistant gloves should be used to protect hands 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 10 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Remove the right crankcase bearings Crankshaft bearing 1 Remove the ball bearing from the crankshaft by pressing from the outside of the crankcase inwards Fit the new ball bearing in the crankcase housing The stamped face of the bearing should face t
25. cratches and warping or deformation Maximum deformation of 0 05 mm the iron clutch plate Engine _________200 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 21 Check the thickness of the iron clutch disc Thickness of the clutch disc Limit 1 45 to 1 55 mm Limit 1 40 mm Clutch rod 7 Check the clutch rod deformation Maximum deformation of the 0 05 mm clutch rod Clutch hub 8 Check that the clutch disc housings arrow are not out of line due to excessive wear Check the condition and the contact surface 1 with the clutch discs for scratches and excessive wear Check that the oil circulation openings 2 are free from dirt and metal particles Clutch housing crown 13 Check the contact surface of the bearing 1 for seizure signs of rolling and play Check on both sides that the lubrication grooves 2 are free from dirt and metal particles Check there is no play between the housing 3 and the crown 4 Check that the clutch disc housings arrow are not out of line due to excessive wear Clutch housing bearings 12 Check the clutch housing bearings and the bushing for seizure signs of rolling and play 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 22 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Gearshift mechanism 1 Desmodromic bearing Allen key 6x25x8 8
26. d then remove Remove the adjustment washer 4 and the gear of Il speed 5 Remove the gear cams 6 by carefully pulling them upwards Note The pinions of V and speed do not come out together with the gear cams 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL DISMOUNTING ENGINE Ed 07 05 Remove the pinions of V and gear arrows the needle bearing and the adjustment washers Removing the crankshaft Remove the crankshaft unit arrow by pulling upwards Note If the crankshaft does not come off easily alternately tap the two shafts gently with a plastic hammer On the side opposite the dismounted half crankcase first remove the bushing arrow from the crankshaft seal and then the O ring Note All gaskets seals and O rings should be replaced whenever the engine is dismounted partially or completely Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 01 Crankshaft Piston Cylinder Nylon counterweight Nylon counterweight screws Washer Connecting rod piston pin Connecting rod small end bearing 18x22x22 Connecting rod Crankshaft unit Cylinder Hexagonal bolt with 6x14 washer 10 Viton exhaust duct O ring 44x3 11 Exhaust duct 12 Exhaust gasket 13 Vent 14 Piston pin circlip 15 Piston 16 Set of rings 17 Piston pin 18 Cylinder head O ring ga
27. e used to protect hands Remove the right crankcase bearings Centrifugal shaft bearing 1 Remove the ball bearing from the centrifugal pinion using a bearing extractor max 8mm from outside the half crankcase Fitthe new ball bearing in the crankcase housing The closed face of the bearing should face the inside of the opening of the casing Press down on the bearing until it fits completely in the right crankcase housing Pinion shaft bearing of water pump 2 Remove the ball bearing from the water pump pinion shaft using a bearing extractor max 8mm from outside the half crankcase Fit the new ball bearing in the crankcase housing The closed face of the bearing should face the inside of the opening of the casing Press down on the bearing until it fits completely in the right crankcase housing Crankshaft seal 3 Fit the new crankshaft seal in the crankcase housing The seal lip should face the outside of the crankcase Press down on the seal with a rod until it fits completely in the right crankcase housing Warning When fitting the seal take care not to damage the seal lip Starter ratchet plate 4 Remove the starter ratchet plate by undoing the screws 5 Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 13 Fit the plate by applying thread lock on the screws 5 Centring bushings 6
28. en screws 5x15 v Tightening torque 6 Nm Starter ratchet spring Starter ratchet Circlip D20 Stop washer 27x20 2x1 10 Starter pinion 11 Starter shaft 12 Washer 20x40x1 13 Starter spring 14 Starter shaft centring bushing prr 04 28 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Starter shaft 11 Check that the starter shaft teeth show no signs of excessive wear or contact marks Check the play of the shaft in the casing housing Check that the interior lubrication openings are clean and free of particles Ratchet 7 Check that the ratchet teeth do not show signs of excessive wear Starter pinion 10 Check that the pinion does not show signs of excessive wear or play Check that the starter pinion teeth show no signs of excessive wear or contact marks Interior pinion 3 Check that the pinion does not show signs of excessive wear or play Check that the lubrication channels are clean and free of particles Check that the interior bushing of the pinion shows no signs of scratching or excessive wear Engine _________200 250 cc 300 ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 29 Reed valve Allen screws 6x16 v Tightening torque 6 Nm Lower reed Upper reed Screws Reed support Reed valve gaskets Reed sp
29. g torque 27 Nm Engine 200 ce 250 cc 300 ENDUCROSS WORKSHOP MANUAL Ed 07 05 ELECTRICAL SCHEMAS 06 01 por mf m fei es A T amp 5 EE Jo EH le EE ZEE Re lr RE Unicef 17 Pol gon Industrial 1719 Salt Girona SPAIN TEL 34 902 47 62 54 FAX 34 902 47 61 60 www gasgasmotos es PU010638016
30. he four cylinder nuts and adjust slightly Adjust the four nuts at the foot of the cylinder in diagonal pairs Tightening torque 25 Nm Place the exhaust valve operating rod 1 Replace the nuts 2 with new ones and tighten them Tightening torque 8 Nm Test the working of the entire exhaust valve system Note If it is necessary to make adjustments loosen the screw of the centrifugal mechanism lever 3 and place the lever rod unit in the desired position Fit the new O rings on the upper part of the cylinder Check that the support surface of the cylinder head is perfectly clean Place the cylinder head and tighten the screws 2 in diagonal pairs Use thread lock Tightening torque 25 Nm Check that the support surface of the thermostat cover is perfectly clean Fit the thermostat cover with a new gasket and tighten the screws 1 Use thread lock Tightening torque 10 Nm 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 05 08 ASSEMBLING THE ENGINE Ed 07 05 Fit the right cover of the exhaust valve with a new gasket and tighten the screws arrows Tightening torque 8 Nm Fit the left cover of the exhaust valve and tighten the screws arrows Tightening torque 8 Nm Fitting the clutch cover Fit the new gasket of the clutch cover Fit the clutch cover and tighten the screws in diagonal pairs Screws 1 30 mm Screws 2 35 mm Screws 3 55 mm Tighte
31. he inside of the crankcase Press on the new ball bearing until it fits level with the inner surface of the crankcase Primary cam bearing 2 Remove the ball bearing from the primary cam by pressing from the outside of the crankcase inwards Fit the new ball bearing in the crankcase housing The closed face of the bearing should face the outside of the crankcase Press down on the bearing until it fits completely in the right crankcase housing Warning When removing and fitting the ball bearing take care not to apply excessive pressure on the casing area of the bearings If too much pressure is applied the crankcase may be damaged Secondary cam bearing 3 Remove the ball bearing from the secondary cam by pressing from the outside of the crankcase inwards Fit the new ball bearing in the crankcase housing The stamped face of the bearing should face the inside of the crankcase Press down on the bearing until it fits completely in the right crankcase housing Warning When removing and fitting the ball bearing take care not to apply excessive pressure on the casing area of the bearings If too much pressure is applied the crankcase may be damaged Desmodromic bearing 4 Remove the needle bearing from the desmodromic by pressing from the outside of the crankcase inwards Fit the new needle bearing in the crankcase housing The stamped face of the bearing should face the inside of the crankc
32. he magnetic flywheel Remove the magnetic flywheel by holding the extractor with a wrench while threading the screw Remove the pin from the crankshaft Undo the screws arrows from the ignition stator and remove it with the wiring Dismantling the water pump Undo the screws arrows of the water pump cover Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 DISMOUNTING ENGINE 03 03 Block the turbine 1 of the water pump Undo the fastening screw 2 and remove the turbine from the water pump Remove the complete seal arrow from the water pump Removing cylinder head and cylinder Undo bolts 1 on the clutch disc cover and remove cover Undo bolts 2 on the clutch cover and remove cover Remove the clutch cover gasket Undo the screws arrows of the exhaust valve right hand cover 200 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 03 04 DISMOUNTING ENGINE Ed 07 05 Remove the fastening nut 1 from the operating lever and the nut 2 from the exhaust valve rod Loosen screws 1 and remove thermostat cover Loosen cylinder head screws 2 in diagonal pairs and remove cover from cylinder Note If the cylinder head does not come off easily hit lightly with a plastic hammer Remove inner and outer O rings of the cylinder head Undo the screws arrows of the exhaust valve left hand cover Remove the fastening nut
33. ic covers on both sides of the motorcycle Fit the seat Note After the first stage of running in check the oil and coolant levels the chain tension and generally inspect the engine Check no coolant is leaking from the radiator hoses Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 DISMOUNTING ENGINE Prior instructions Note When dismounting the engine keep all the paired parts together This includes gears cylinders pistons and other parts subject to natural wear in pairs Paired components must always be replaced together During the disassembly clean all the parts and place them on trays in the order they are removed This will accelerate assembly and ensure the correct installation of all the parts Parts should be kept away from any source of fire All gaskets seals and O rings should be replaced whenever the engine is dismounted partially or completely Thoroughly clean engine before placing on work bench Place the motor on the bench Remove spark plug from cylinder head Dismantling the ignition Undo the screws arrows of the ignition cover 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 03 02 DISMOUNTING ENGINE Ed 07 05 Block the magnetic flywheel Remove the nut 1 Warning The magnetic flywheel nut is loosened by turning to the left Insert the extractor ref ME25634045 on the internal thread of t
34. ight Block the crankshaft pinion and loosen the nut arrow the 200 cc engine is fitted with a hexagonal screw Note The 200 cc engine is not fitted with flywheel Remove the nut the bevelled washer the crankshaft pinion the flywheel and the crankshaft pin Dismounting the reed valve Undo the screws arrows and remove the reed valve Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 DISMOUNTING ENGINE 03 09 Removing the half crankcases Undo the screws arrows fastening the half crankcases Turn the bench so that the left hand half of the crankcase is facing upwards and remove the nut fastening the engine to the bench Install the extractor ref ME25950000 threading the feet into the openings of the ignition stator as shown in the image Note The height of the extractor feet is adjustable they should be parallel to the surface of the half crankcase Activate the extractor until the left hand half of the crankcase is completely separated from the right hand half During the extraction remove the spacer hub from the engine pinion arrow which is located on the shaft Warning Do not use screwdrivers or levers to separate the crankcase halves Removing the selector rod and gears from the gearbox Remove the fork pivots 1 and remove forks 2 Mark the position of the desmodromic valve 3 with respect to the half crankcase an
35. inion VI Serrated washer 31 5x1 Primary gear Il 10 Shift washer 18x31 5x0 7 11 Circlip D25 12 Secondary pinion Il 13 Secondary shaft 14 Needle cage bearings KD22x25x9 8 15 Secondary pinion VI 16 Secondary pinion III 17 Secondary pinion IV 18 Secondary pinion V 19 Washer 20 8x29x1 20 Secondary pinion 21 Needle bearings K20 24 10 1 2 3 4 5 6 T 8 9 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 26 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Check the contact surface of the bearings for seizure signs of rolling and play Check the pinion teeth for wear or breakage Check the pinions and tracks are free of dirt Check that the lubrication grooves which include some pinions are free of dirt and metal particles After dismounting the parts of the cams clean thoroughly and replace all the circlips Primary cam 1 Thoroughly lubricate all the bearings when assembling Note The assembly order of the pinions is V III IV VI speeds Secondary cam 16 Thoroughly lubricate all the bearings when assembling Note The assembly order of the pinions is IV speeds EC ENDUCROSS WORKSHOP MANUAL Engine _________200 250 cc 300 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 27 Starter mechanism Circlip D15 Washer 24x15 15x0 8 Interior starter pinion Starter ratchet plate All
36. n of 27 gear 1 and the adjustment washer 2 on the primary gear cam Fit the desmodromic in the crankcase lining it up with the marks arrows made when dismounting Position the forks 1 in the grooves of the gears and at the same time in the desmodromic grooves Next slide the shafts 2 short and 3 long across the forks to their housing in the crankcase Note Check the transmission works correctly by turning the desmodromic by hand Place the transmission gears in neutral position Joining the crankcases Turn the bench so that the left hand half of the crankcase is facing upwards and remove the nut fastening the engine to the bench Check that the contact surfaces of the left and right crankcases are perfectly clean Fit the centring bushings in the left crankcase Position the new gasket Fit the right crankcase and gently tap with a plastic hammer until the two surfaces are joined together Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 ASSEMBLING THE ENGINE Note Remember to place the small gasket in the upper part of the crankcase arrow Place the screws in the position shown in the diagram Screws 1 70 mm Screws 2 60 mm Screws 3 65 mm Adjust all the screws slightly and then tighten in diagonal pairs starting at the centre Tightening torque 10 Nm Check that the crankshaft and the transmission shaft turn smoothly
37. ned by turning to the left Remove the lock washer and take out the clutch hub Note The clutch hub has an assembly position with respect to the primary shaft Mark the position using a permanent marker on the grease ring Remove the clutch housing washer Remove the clutch housing Remove the clutch housing bearings 1 the bushing 2 and the washer 3 Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 DISMOUNTING ENGINE 03 07 Dismount the centrifugal operating system of the exhaust valve Take the shaft and pinion off the water pump Undo the screws arrows and remove the support 1 from the exhaust valve control shaft Remove the centrifugal mechanism from the exhaust valve 2 Dismantling the starter pinion unit Dismount the spring 1 using pliers and remove the starter pinion unit Remove the circlip 2 remove the spacer washer and take off the inner starter pinion Dismantling the gear selector unit Remove the complete selector rod arrow by pulling outwards Remove the selector rod bushing arrow 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 03 08 DISMOUNTING ENGINE Ed 07 05 Loosen the spring arrow of the gear lock using pliers Remove the screw 1 and take out the gear locking unit 2 Dismantling crankshaft flywheel Warning The locking nut of the crankshaft is loosened to the r
38. ning torque 10 Nm Fit the clutch disc cover with a new gasket and tighten the screws in diagonal pairs Screws 4 25 mm Screws 5 75 mm Tightening torque 10 Nm Assembling the water pump Fit the new seal of the water pump arrow on the clutch cover Engine _________200 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 ASSEMBLING THE ENGINE 05 09 Position the turbine 1 of the water pump and fit the fastening screw 2 Block the rotation of the turbine and tighten the screw 2 Use thread lock Tightening torque 6 Nm Fit the cover of the water pump and tighten the screws arrows Tightening torque 6 Nm Assembling the ignition Fit the pin from the crankshaft Position the ignition stator and the screws arrows noting the location of the ignition centring washer 1 Tighten the screws arrows Use thread lock Tightening torque 8 Nm Ensure that the rubber tops 2 are correctly fitted Fit the magnetic flywheel and tighten the nut 1 Use thread lock Tightening torque 40 Nm 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 05 10 ASSEMBLING THE ENGINE Ed 07 05 Fit the ignition cover with a new gasket and tighten the SCrews arrows Fit the spark plug in the cylinder head Warning The spark plug should always be hand threaded to the limit and then adjusted with a spark plug wrench without over tightening Tightenin
39. pproximately 20 mm from the upper end Measure the distance between the ends of the ring A with a feeler gauge Opening at the end of 200 cc STD 0 3 mm the ring Limit 0 6 mm 250 STD 0 4 mm Limit 0 7 mm 300 STD 0 5 Limit 0 8 mm Piston pin Check the piston pin for seizure signs of rolling and overheating Measure the diameter of the piston with a micrometer at three different points Cylinder Cylinder interior measurement Check the cylinder for scratches signs of seizure notches or breakage in the intake or exhaust port Measure the diameter of the cylinder approximately 20 mm from the upper end and in different places in order to obtain an exact idea of the possible ovality of the cylinder Cylinder diameter 200 cc STD 62 50 mm Limit 62 60 mm 250 CC STD 66 38 mm Limit 66 50 mm 300 STD 71 99 mm Limit 72 70 mm Cylinder Head Check the cylinder support surface of the cylinder head is not damaged Thoroughly clean the interior of the cylinder head which should be free of carbon deposits Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 05 Operation of the exhaust valve 1 Screw 19 Centrifugal spring v Tightening torque 6 Nm 20 Bearing plate 2 Bearings 21 Exhaust valve needle cage 3 Washer 22 Centrifugal separator bearing 4 Left exhaust valve 2
40. r cleaning fluids these can be highly toxic Ensure that the work area is well ventilated Maintenance Always use original GAS GAS spare parts and lubricants recommended by the manufacturer Other spare parts may damage the engine Only use the tools specified for this vehicle Always replace all the gaskets seals and O rings during service and assembly After dismounting clean components with non inflammable dissolvent Lubricate all work surfaces before assembly except the conical couplings Oil all the paired parts and bearings when assembling When removing servicing and assembling parts only use metric sized tools Metric screws nuts and bolts are not interchangeable with parts with Imperial measurements All the surfaces receiving gaskets seals and O rings must be carefully cleaned Carefully examine all the circlips before assembly and replace any which are damaged Always replace the piston pin circlip after each use After assembly check all the components are correctly fitted and the mechanisms are working perfectly General tightening torques The following table specifies tightening torques for nuts or bolts with ISO threads Tightening torques for components or special units are given in the relevant repair process described in this manual To avoid damage tighten units with various nuts or bolts progressively and in diagonal or alternate pairs until obtaining the specified torque To apply the
41. s arrows from the cylinder to the crankcase on both sides of the engine Remove the cylinder by lifting upwards Note If the cylinder does not come off easily hit lightly with a plastic hammer Remove the cylinder gasket Engine 200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 DISMOUNTING ENGINE Note There may be more than one gasket Mark the orientation of the piston towards the exhaust port using a permanent marker Place a clean cloth at the base of the cylinder to prevent the circlip from falling in the crankcase Remove a circlip from the pin and take out the pin by pushing from the opposite end Note If necessary gently tap the pin using a suitable tappet Dismantling the clutch Note If the clutch is being removed in order to for example replace the discs it is not necessary to remove the complete clutch cover To access the clutch discs it is only necessary to remove the clutch disc cover Remove the screws 1 undoing in diagonal pairs Remove the clutch springs and the rod bushings Remove the clutch press 2 Remove the set of clutch discs from the housing 200 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 03 06 DISMOUNTING ENGINE Ed 07 05 Open the safety catch 1 of the fastening nut of the clutch hub 2 Loosen the nut by holding the clutch hub Warning The clutch hub nut is loose
42. skets 1 2 3 4 5 6 T 8 9 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 02 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Crankshaft Note The crankshaft bearings must be completely replaced for example when replacing the outer piston the inner ring should also be replaced Remove the inner ring of the crankshaft bearing arrow using an extractor tool Place the extractor claws below the lower lip of the inner ring Warning Do not fix the crankshaft in a bench vice by the counterweights Thoroughly clean the surface where the new inner ring of the bearing will be fitted Heat the inner ring of the new bearing on a heating plate oven or similar to approx 150 C Danger When fitting the inner ring of the crankshaft bearing heat resistant gloves must be worn Immediately fit the inner ring of the bearing on the crankshaft ensuring that the lower lip of the inner ring faces downwards Press on the inner ring until it is completely fitted onto the crankshaft Crankshaft outer dimension Measure the distance between the crankshaft counterweights at opposite points Maximum difference between faces Crankshaft eccentricity Measure the eccentricity of the crankshaft by placing it on the bench to check the crankshaft run out ref MFS450450025 Maximum eccentricity Engine 200 ce 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 S
43. the scorpion spring 16 on the supports of the selector shaft 15 and of the scorpion 17 Gear lock 6 Check that the bearing at the end of the lock is in good condition turns easily and does not show signs of excess play Desmodromic 7 Check the rolling tracks of the desmodromic bearings 1 for seizure signs of rolling and play Check the inside of the desmodromic channels for dirt and particles and make sure the channels are not excessively worn Short 9 and long 11 fork shaft Check the fork shafts for deformation Check the shafts for signs of wear or grooving The forks should slide easily across the shafts Maximum deformation of 0 05 mm the fork shafts Forks 8 and 12 Check that the fork is neither damaged nor bent Check that the interior of the fork ride opening shows no signs of wear or grooving 200 cc 250 300 cc EC ENDUCROSS WORKSHOP MANUAL 04 24 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed 07 05 Check the play between the fork and its housing in the pinion Play between the fork and STD 0 15 mm its housing in the pinion Limit 0 25 mm Engine _________200 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 25 Gears Primary shaft Needle bearing K25 29 10 Primary pinion V Washer 25 2x31 5x1 Circlip D25 recessed Primary pinion Ill and IV Primary p
44. tightening torques described below clean dry threads are necessary Components should be at room temperature GENERAL TIGHTENING TORQUES A NUT B BOLT A Distance between the nut faces B External diameter of screw thread Engine serial number The engine serial number is stamped on the lower part of the left crankcase Remember to quote the engine serial number each time you place an order for an original GAS GAS spare part for said engine TABLE OF TECHNICAL DATA Definition Mono cylindrical 2 stroke engine liquid cooled intake to crankcase Displacement in cubic centimetres 200 Engine 199 4cc 250 Engine 249 3cc 300 Engine 294 7cc Fuel RON SUPER LEAD FREE 95 98 octane Mixed with SYNTHETIC 2T oil Mixture ratio 100 synthetic oil petrol 50 oil 1 2 Petrol oil semi synthetic oil petrol 40 oil 1 2 5 Bore and stroke 200 Engine 62 5 x 65 mm 250 Engine 66 4 x 72 mm 300 Engine 72 x 72 mm _ System Liquid cooled with impulse pump Mix ratio Distilled water 50 Antifreeze 50 96 o System Carburetion Carburettor KEIHIN PWK 38 Fuel tank 9 litres Fuel supply Gravity Air filter Dry air filter Ignition system CDI system Voltage Power 12V 110 W Fo 1st gear 2 071 29 14 3rd gear 1 333 24 18 Final reduction ratio 3 615 47 13 Oil capacity 900 cc VI Engine _________200 cc 250 cc 300 EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 REMOVING THE ENGINE FROM THE CH
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