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WORKSHOP MANUAL / WERKSTATTHANDBUCH MOTOR EC Enducross 200 / 250 / 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. i 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 I CONTENTS Sect. P. IV VI 01 02 03 04 05 06 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 OF THE ENGINE COMPONENTS ASSEMBLING THE ENGINE ELECTRICAL SCHEMAS III 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 or 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. IV 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 tightening torques described below, clean, dry threads are necessary. Components should be at room temperature. GENERAL TIGHTENING TORQUES Nm 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 26 mm 6 15 30 55 85 130 Kgf.m 0,6 1,5 3,0 5,5 8,5 13,0 Ft.lb 4,3 11 22 40 61 94 *(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. V TABLE OF TECHNICAL DATA Engine 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 Spark plug NGK BR8EG Electrode separation 0.7 - 0.8 mm Ignition timing 1 mm BTDC Piston rings: quantity 2 rings Starter system Kick-start pedal System Circuit capacity Mix ratio Liquid-cooled, with impulse pump 1.1 litres Distilled water: 50% Antifreeze: 50 % Carburetion KEIHIN PWK 38 9 litres Gravity Dry air filter CDI system 12 V / 110 W 6-speed cascade Oil bath, multi-disk hydraulic action By chain 2.071 (29/14) 1.625 (26/16) 1.333 (24/18) 1.100 (22/20) 0.913 (21/23) 0.791 (19/24) 200 cc: 3.22 (58/18); 250 - 300 cc: 2.85 (57/20) 3.615 (47/13) 200 cc: 9.21; 250 - 300 cc: 8.149 10W30 API SF or SG 900 cc System Carburettor Fuel tank Fuel supply Air filter Ignition system Voltage / Power Transmission Clutch Secondary transmission Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Primary reduction ratio Final reduction ratio Overall drive ratio (6th gear) Oil type Oil capacity VI Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 REMOVING THE ENGINE FROM THE CHASSIS 01-01 i 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. Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 01-02 REMOVING THE ENGINE FROM THE CHASSIS - Remove the whole exhaust system. Note: The oil must never be poured down the drain or into the environment. Ed: 07/05 i - 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. ! i 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 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 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. 1 i 2 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. Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 01-04 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. 1 - 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 cc / 250 cc / 300 cc 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 screws in supports. Note: The self-locking fastening nuts of the engine must be replaced with new nuts. i - Tighten all the nuts slightly and then to the specified torque: Nuts A B C D Tightening torque 38 to 48 Nm 24 to 29 Nm 38 to 48 Nm 66 Nm B A C D - 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. i Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 02-02 FITTING THE ENGINE ON THE CHASSIS Ed: 07/05 1 - Place the chain pinion -2- on the secondary shaft and fit the circlip -1-. - Fit the clutch rod -arrow-. 2 - 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. i - 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. i Tightening torque: 9 Nm - Disconnect the coolant recirculation pipe. - 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. i Tightening torque: 20 Nm Engine 200 cc / 250 cc / 300 cc 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 Engine 200 cc / 250 cc / 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 it is damaged, replace with a new one. If it is undamaged, clean and refit (see user manual). - Replace the plastic 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. i - Check no coolant is leaking from the radiator hoses. Engine 200 cc / 250 cc / 300 cc 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. 03-01 i - 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. Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 03-02 DISMOUNTING ENGINE - Block the magnetic flywheel. - Remove the nut -1-. Warning: The magnetic flywheel nut is loosened by turning to the left! Ed: 07/05 ! 1 - Insert the extractor ref. ME25634045 on the internal thread of the 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 cc 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. 2 1 - Remove the complete seal -arrow- from the water pump. 2 1 2 1 2 1 1 2 1 2 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. 2 - Undo the screws -arrows- of the exhaust valve right-hand cover. Engine 200 cc / 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. 2 1 2 1 2 2 1 2 2 2 - 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. i - Remove inner and outer O-rings of the cylinder head. - Undo the screws -arrows- of the exhaust valve left-hand cover. - Remove the fastening nuts -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. i - Remove the cylinder gasket. Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 DISMOUNTING ENGINE 03-05 i 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. i 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. i 1 1 1 1 1 1 - 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. 2 Engine 200 cc / 250 cc / 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 loosened by turning to the left! 1 ! 2 - Remove the lock washer and take out the clutch hub. i 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. 2 3 - Remove the clutch housing bearings -1-, the bushing -2and the washer -3-. 1 Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 DISMOUNTING ENGINE 03-07 2 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-. 1 1 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. 2 Dismantling the gear selector unit - Remove the complete selector rod -arrow- by pulling outwards. - Remove the selector rod bushing -arrow-. Engine 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-. 2 1