User manual GAS GAS EC 250

[. . . ] WORKSHOP MANUAL / WERKSTATTHANDBUCH MOTOR EC Enducross 200 / 250 / 300 INTRODUCTION This manual was created by GAS GAS Motos, S. A. 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. [. . . ] 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. 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. 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 Engine 200 cc / 250 cc / 300 cc 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-. Right half crankcase, outer side i Note: To remove the bearings of the right half crankcase it should be heated to approximately 150 ºC 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. i 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 ºC. Engine 200 cc / 250 cc / 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 be used to protect hands. - Remove the right crankcase bearings. 5 4 5 1 6 6 3 2 Centrifugal shaft bearing -1- Remove the ball bearing from the centrifugal pinion using a bearing extractor ( max. 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. 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. - 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 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 5 4 5 1 6 3 2 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-13 6 - Fit the plate by applying thread-lock on the screws -5Centring bushings -6- Check the existence and condition of the centring bushings -6-. Note: If there are no centring bushings, a correct seal is not guaranteed when the crankcases are fitted. i 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 0. 05 mm i Note: To remove the bearings of the left half crankcase it should be heated to approximately 150 ºC 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. [. . . ] - 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. 2 1 1 1 1 1 1 - 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. Tightening torque: 10 Nm Assembling the cylinder and cylinder head - Check that the piston and pin are clean. [. . . ]