1998-2006 Gas Gas EC 200/250/300 2-Stroke Engine OEM Service & Repair Manual

WORKSHOP MANUAL / WERKSTATTHANDBUCH 200 / 250 / 300 200 / 250 / 300 MOTOR EC Enducross MOTOR EC Enducross WORKSHOP MANUAL / WERKSTATTHANDBUCH

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 I i ! !

CONTENTS Sect. P. IV GENERAL INFORMATION VI TABLE OF TECHNICAL DATA 01 01 REMOVING THE ENGINE FROM THE CHASSIS 02 01 FITTING THE ENGINE ON THE CHASSIS 03 01 DISMOUNTING 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 FITTING THE ENGINE ON THE CHASSIS 03 01 DISMOUNTING ENGINE 04 01 SERVICE AND REPAIR OF THE ENGINE COMPONENTS 05 01 ASSEMBLING THE ENGINE 06 01 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. *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. *(A) NUT *(B) BOLT GENERAL TIGHTENING TORQUES Nm 6 15 30 55 85 130 Ft.lb 4,3 11 22 40 61 94 Kgf.m 0,6 1,5 3,0 5,5 8,5 13,0 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 26 mm 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 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 9 litres Fuel supply Gravity Air filter Dry air filter Ignition system CDI system Voltage / Power 12 V / 110 W Transmission 6-speed cascade Clutch Oil bath, multi-disk hydraulic action Secondary transmission By chain Gear ratio 1st gear 2.071 (29/14) 2nd gear 1.625 (26/16) 3rd gear 1.333 (24/18) 4th gear 1.100 (22/20) 5th gear 0.913 (21/23) 6th gear 0.791 (19/24) Primary reduction ratio 200 cc: 3.22 (58/18); 250 - 300 cc: 2.85 (57/20) Final reduction ratio 3.615 (47/13) Overall drive ratio (6 th gear) 200 cc: 9.21; 250 - 300 cc: 8.149 Oil type 10W30 API SF or SG Oil capacity 900 cc VI

Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 REMOVING THE ENGINE FROM THE CHASSIS 01-01 - 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. Note: The cylinder head, the cylinder, the clutch and the ignition, can be removed without dismounting the engine from the chassis. i

Ed: 07/05 REMOVING THE ENGINE FROM THE CHASSIS 01-02 - Remove the whole exhaust system. - Remove the drain plug -arrow- and drain the transmission oil. - 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 Note: The oil must never be poured down the drain or into the environment. i 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. i !

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1998-2006 Gas Gas EC 200/250/300 2-Stroke Engine OEM Service & Repair Manual

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1998-2006 Gas Gas EC 200/250/300 2-Stroke Engine OEM Service & Repair Manual

Engines Covered:

What’s Inside This Gas Gas Engine Service & Repair Manual

Engine Removal & Installation

Complete Engine Overhaul

Technical Data & Specifications

Electrical Schemas

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