GAS GAS EC 200, Workshop Manual

Page 1: ...WORKSHOP MANUAL WERKSTATTHANDBUCH 200 250 300 200 250 300 MOTOR EC Enducross MOTOR EC Enducross WORKSHOP MANUAL WERKSTATTHANDBUCH...

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Page 3: ...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 impo...

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Page 5: ...ENGINE 04 01 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 05 01 ASSEMBLING THE ENGINE CONTENTS Sect P IV GENERAL INFORMATION VI TABLE OF TECHNICAL DATA 01 01 REMOVING THE ENGINE FROM THE CHASSIS 02 01...

Page 6: ...r 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 da...

Page 7: ...ightening torques described below clean dry threads are necessary Components should be at room temperature A Distance between the nut faces B External diameter of screw thread Engine serial number The...

Page 8: ...ngs Starter system Kick start pedal System Liquid cooled with impulse pump Circuit capacity 1 1 litres Mix ratio Distilled water 50 Antifreeze 50 System Carburetion Carburettor KEIHIN PWK 38 Fuel tank...

Page 9: ...ne 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 spri...

Page 10: ...he 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...

Page 11: ...ely 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 th...

Page 12: ...assis 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...

Page 13: ...then to the specified torque Nuts Tightening torque A 38 to 48 Nm B 24 to 29 Nm C 38 to 48 Nm D 66 Nm Assemble the carburettor Place the magnetic flywheel on the chassis and fasten correctly Connect t...

Page 14: ...arrow and connect the coolant pipes on both sides of the engine Tightening torque 9 Nm Disconnect the coolant recirculation pipe Fill the coolant system through the left radiator cap Mixture of coola...

Page 15: ...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...

Page 16: ...f 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 Check no coolant is...

Page 17: ...he 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 disass...

Page 18: ...wheel 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...

Page 19: ...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...

Page 20: ...he 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 lift...

Page 21: ...m the opposite end Dismantling the clutch 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...

Page 22: ...ve 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 cc EC ENDUCROSS WORKSHOP MANUAL 2 1 Warning The clut...

Page 23: ...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...

Page 24: ...the nut arrow the 200 cc engine is fitted with a hexagonal screw Remove the nut the bevelled washer the crankshaft pinion the flywheel and the crankshaft pin Dismounting the reed valve Undo the screws...

Page 25: ...which is located on the shaft 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 cra...

Page 26: ...Remove the crankshaft unit arrow by pulling upwards On the side opposite the dismounted half crankcase first remove the bushing arrow from the crankshaft seal and then the O ring Note If the crankshaf...

Page 27: ...crews 3 Washer 4 Connecting rod piston pin 5 Connecting rod small end bearing 18x22x22 6 Connecting rod 7 Crankshaft unit 8 Cylinder 9 Hexagonal bolt with 6x14 washer 10 Viton exhaust duct O ring 44x3...

Page 28: ...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 0 05 mm Cra...

Page 29: ...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 f...

Page 30: ...Diameter of the piston pin STD 17 994 mm Limit 17 98 mm Cylinder Cylinder interior measurement Check the cylinder for scratches signs of seizure notches or breakage in the intake or exhaust port Measu...

Page 31: ...t exhaust valve shaft 13 Central exhaust valve 14 Long exhaust valve shaft 15 Circlip 16 Pin 17 Centrifugal shaft 18 Centrifugal pinion 19 Centrifugal spring 20 Bearing plate 21 Exhaust valve needle c...

Page 32: ...on 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...

Page 33: ...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 sha...

Page 34: ...ushing 5 Water intake sump plug 6 Fibre washer 14x20x2 7 Oil filler cap 8 Copper washer 9 Left crankcase inner side 10 Central crankcase gasket 11 Copper washer 8x12x1 12 Allen key 8x14 aTightening to...

Page 35: ...r or by carefully levering with a screwdriver Place the right half crankcase on a heating plate and heat to approximately 150 C 1 2 1 1 Note To remove the bearings of the right half crankcase it shoul...

Page 36: ...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 sh...

Page 37: ...y 150 C 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 Note...

Page 38: ...er 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 op...

Page 39: ...left crankcase seals using a seal extractor or by carefully levering with a screwdriver Place the left half crankcase on a heating plate and heat to approximately 150 C Note If there are no centring b...

Page 40: ...he 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 S...

Page 41: ...ter side 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...

Page 42: ...crankcase housing Clutch cover Before any repairs to the clutch cover check the deformation on the inside using a feeler gauge Maximum deformation of clutch cover 0 05 mm Take out the clutch cover sea...

Page 43: ...e 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 bea...

Page 44: ...SHOP MANUAL 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 com...

Page 45: ...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 C...

Page 46: ...h 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...

Page 47: ...on 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 c...

Page 48: ...Nm 3 Flat washer 6x16x1 5 4 Gear locking spring 5 Gear lock plate bushing 6 Gear lock 7 Desmodromic 8 Fork V VI 9 Short fork shaft 10 Desmodromic bearing HK3512 11 Long fork shaft 12 Forks I II III IV...

Page 49: ...ort 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 the scorpion sprin...

Page 50: ...OF THE ENGINE COMPONENTS 04 24 Engine 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL Check the play between the fork and its housing in the pinion Play between the fork and STD 0 15 mm its housing...

Page 51: ...pinion III and IV 7 Primary pinion VI 8 Serrated washer 31 5x1 9 Primary gear II 10 Shift washer 18x31 5x0 7 11 Circlip D25 12 Secondary pinion II 13 Secondary shaft 14 Needle cage bearings KD22x25x9...

Page 52: ...irt 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...

Page 53: ...ip D15 2 Washer 24x15 15x0 8 3 Interior starter pinion 4 Starter ratchet plate 5 Allen screws 5x15 aTightening torque 6 Nm 6 Starter ratchet spring 7 Starter ratchet 8 Circlip D20 9 Stop washer 27x20...

Page 54: ...ean 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 th...

Page 55: ...MANUAL Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 29 Reed valve 1 Allen screws 6x16 aTightening torque 6 Nm 2 Lower reed 3 Upper reed 4 Screws 5 Reed support 6 Reed valve gaskets 7 Reed s...

Page 56: ...AL 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...

Page 57: ...L Ed 07 05 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04 31 Ignition 1 Ignition rubber top 2 Allen screw 5x20 aTightening torque 6 Nm 3 Flat washer 5x12x1 5 4 Magnetic flywheel Kokusan FP 8009 Multis...

Page 58: ...se coil Red Green 100 20 Exciter Black Red Red White 12 7 20 Charge coil Yellow Earth 0 67 20 White Yellow 0 16 20 Spark plug 6 Check that the spark plug shows no signs of knocks or cracks Check that...

Page 59: ...ing 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 I...

Page 60: ...their housing in the crankcase 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...

Page 61: ...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...

Page 62: ...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...

Page 63: ...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...

Page 64: ...g 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 Ti...

Page 65: ...rque 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 Fit the new O rings on t...

Page 66: ...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 Tightening torque 10 Nm Fit the clutch disc cover with...

Page 67: ...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...

Page 68: ...tighten the screws arrows Fit the spark plug in the cylinder head Engine 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL Warning The spark plug should always be hand threaded to the limit and then...

Page 69: ...Engine 200 cc 250 cc 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed 07 05 ELECTRICAL SCHEMAS 06 01...

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Page 71: ...C Unicef 17 Pol gon Industrial Torremirona 1719 Salt Girona SPAIN TEL 34 902 47 62 54 FAX 34 902 47 61 60 w w w g a s g a s m o t o s e s PU010638016...