GAS GAS Enduro Series Workshop Manual
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GAS GAS Enduro Series Workshop Manual

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  • Page 2 2017 GAS GAS All rights reserved Reprinting and reproduction of any kind, either in whole or in part, is prohibited without the written permission of the copyright holder. The company has the right, without prior notice, to change the technical content of the products.
  • Page 3 INTRODUCTION This manual was created by TORROT ELECTRIC EUROPA S.L. to be used by official services of the GAS GAS brand (GG). It is mainly aimed at workers with a basic knowledge of the principles of mechanics and repair techniques. It contains precise instructions for carrying out all repairs, as well as the necessary technical data to perform maintenance on the motorcycles.
  • Page 4 Workshop manual Contents GENERAL INFORMATION ...............................6 TECHNICAL DATA TABLE ..............................10 REMOVING THE ENGINEFROM THE FRAME ........................11 FITTING THE ENGINE TO THE FRAME ..........................15 DISMANTLING THE ENGINE ..............................19 SERVICING AND REPAIRING THE ENGINE’S COMPONENTS ....................30 ASSEMBLING THE ENGINE ..............................59 WIRING DIAGRAM ................................
  • Page 5 Workshop manual This page has been left blank intentionally. GeNeRal INfORmaTION...
  • Page 6 Workshop manual GeNeRal INfORmaTION It is necessary to follow certain safety and maintenance rules when doing repair work on vehicles. Here are some of the most important: SAFETY - Do not smoke or cause sparks or flames in the work area. Petrol is extremely flammable and can be explosive under certain conditions. - Use appropriate cleaning products for each task, making sure that they are approved.
  • Page 7 Workshop manual GeNeRal INfORmaTION GENERAL TIGHTENING TORQUES *(A) NUT *(B) SCREW Kgf.m Ft.lb 10 mm 6 mm 12 mm 8 mm 14 mm 10 mm 17 mm 12 mm 19 mm 14 mm 22 mm 26 mm 13.0 *A: Distance between the planes of the nut. *B: External diameter of the screw thread.
  • Page 8 Workshop manual GeNeRal INfORmaTION - This tool will be needed to tighten or loosen the fork bars. Ref: BE21105GG-CLJ-1 - These tools are used to fit the fork seal and dust cover. Ref: BE20225GG-CLJ-1 - This tool is used to remove the fork cartridge. Ref: BE21106GG-CLJ-1 - This tool will be needed to fit the fork seal and dust cover.
  • Page 9 Workshop manual GeNeRal INfORmaTION - This tool is used to hold the clutch hub. Ref: ME250450014 - This tool will be needed to remove the stator. Ref: ME25634045 - This tool is used to fit the crankshaft into the crankcase. Ref: ME25950000 - This tool is used to separate the crankcases and open the engine.
  • Page 10 Workshop manual TeCHNICal DaTa TaBle Cycle 2-stroke Number of cylinders Mono-cylindrical Cooling Liquid cooled Capacity 199.4 cc 249.3 cc 299.3 cc Bore 62.5 mm 66.4 mm 72.0 mm Stroke 65.0 mm 72.0 mm 72.0 mm Carburettor Dell’Orto PHBG 21 (Keihin PWKS 38 competition model) Intake type V-Force 4 reed valve system Lubrication system...
  • Page 11 Workshop manual RemOVING THe eNGINe fROm THe fRame Note: The cylinder head, cylinder, clutch and ignition can be detached without needing to remove the engine from the frame. - Thoroughly clean the motorcycle before beginning the removal. - Place the motorcycle on a suitable support to enable work to be carried out on it. - Remove the fuel tank together with the two side covers, seat and frame side guards.
  • Page 12 Workshop manual RemOVING THe eNGINe fROm THe fRame - Remove the tailpipe (it is not necessary to detach the side covers for this). Note: Oil should never be poured down the drain or discharged into the environment. - Extract the drain plug (arrow) and remove the transmission fluid. Danger: Make sure that the coolant is not at a high temperature before opening the cooling circuit.
  • Page 13 Workshop manual RemOVING THe eNGINe fROm THe fRame - Completely remove the clutch rod (arrow). Note: Oil should never be poured down the drain or discharged into the environment. - Detach the retaining ring (1) from the output sprocket using retaining ring pliers.
  • Page 14 Workshop manual RemOVING THe eNGINe fROm THe fRame - Extract the screws (arrows) that secure the engine to the frame at the bottom. - Extract the nut (1), remove the shaft from the swinging arm and move it back- wards. - Properly position the engine for extraction and remove it.
  • Page 15 Workshop manual fITTING THe eNGINe TO THe fRame - Fit the engine to the frame and position it correctly on the brackets. - Align the swinging arm with the engine and frame, grease the swinging arm shaft and fit it. - Fasten the engine fixing screws to their brackets.
  • Page 16 Workshop manual fITTING THe eNGINe TO THe fRame - Position the output sprocket (2) on the secondary shaft and fit the retaining ring (1). - Insert the clutch rod (arrow). - Position the hydraulic clutch clamp with a new gasket, fit the output sprocket guard and tighten the screws (arrows).
  • Page 17 Workshop manual fITTING THe eNGINe TO THe fRame - Remove the oil filler cap (arrow) and refill with new transmission oil. Viscosity: 5W40 Capacity: 900 cc - Fit the oil filler cap with a new gasket and tighten. - Activate the kick-start pedal 3 or 4 times and check the oil level with the gauge (arrow).
  • Page 18 Workshop manual fITTING THe eNGINe TO THe fRame - Fit the kick-start pedal lever, apply Loctite 243 to the screw (arrow) and then tighten it. - Tightening torque: 20 Nm. - Fit the fuel tank and breather pipe. - Check the condition of the air filter. If damaged, replace it with a new one. If not damaged, clean and reattach it (see user manual).
  • Page 19 Workshop manual Dismantling the engine Preliminary instructions: Note:  W hendismantlingtheengine,keeppairsofpartstogether.Thisincludes gears,cylinders,pistonsandotherpartssubjectedtonaturalwearintheir pairs. Pairsofpartsshouldalwaysbereplacedtogether.  D uringdismantling,cleanallpartsandplacethemintraysinorderof disassembly.Thiswillspeedupreassemblyandensurethatallpartsare properlyfitted. Partsshouldbekeptawayfromanyfiresource. Allgaskets,sealsandO-ringsmustbereplacedeverytimetheengineis partiallyorcompletelydismantled. - Thoroughly clean the engine before placing it on the bedplate. - Place the engine on the bedplate. - Remove the spark plug from the cylinder head.
  • Page 20 Workshop manual Dismantling the engine - Insert extractor ref. ME25634045 into the internal thread of the magnetic flywheel. - Remove the magnetic flywheel by holding the extractor with a spanner while turning the screw. - Remove the cotter pin from the cone of the crankshaft. - Extract the screws (arrows) from the ignition stator and remove it together with the wiring.
  • Page 21 Workshop manual Dismantling the engine - Block the rotation of the water pump turbine (1). - Extract the fixing screw (2) and remove the water pump turbine. - Extract the entire water pump seal (arrows). REMOVING THE CYLINDER HEAD AND CYLINDER - Extract the screws (1) from the clutch disc cover and remove it.
  • Page 22 Workshop manual Dismantling the engine - Extract the fixing screws (1) from the centrifuge cam holder. - Extract the exhaust valve ball joint pin clip (2). - Loosen the screws of the cylinder head (1) in a diagonal sequence and remove it from the cylinder.
  • Page 23 Workshop manual Dismantling the engine - Remove the nuts (arrows) that fix the cylinder to the semi-crankcases on both sides of the engine. - Detach the cylinder by moving it upwards. - Remove the gasket from the cylinder. Note: Theremaybemorethanonegasket. - Mark the orientation of the piston towards the exhaust port using an indelible marker.
  • Page 24 Workshop manual Dismantling the engine - Extract the screws (1) by loosening them in a diagonal sequence. - Remove the clutch springs and pusher bushings. - Detach the clutch press (2) - Extract the clutch disc assembly from the basket. - Open the safety (1) on the fixing nut of the clutch hub (2).
  • Page 25 Workshop manual Dismantling the engine REMOVING THE EXHAUST VALVE CENTRIFUGAL DRIVE SYSTEM - Extract the screws (arrows) and remove the bracket (1) from the exhaust valve control shaft. - Detach the exhaust valve centrifugal drive (2). REMOVING THE KICK-START SPROCKET ASSEMBLY - Remove the spring (1) with a pair of pliers and detach the kick-start sprocket assembly.
  • Page 26 Workshop manual Dismantling the engine REMOVING THE CRANKSHAFT SPROCKET Attention: Thecrankshaftlockingnutloosenstotheright! - Block the rotation of the crankshaft sprocket and loosen the nut (arrow) (the 200 cc engine features a hexagon screw). Note: The200ccenginedoesnotfeatureaninertialflywheel. - Remove the nut, bevelled washer, crankshaft sprocket, flywheel and crankshaft cotter pin.
  • Page 27 Workshop manual Dismantling the engine - Install extractor ref. ME25950000 by turning the legs in the housing openings of the ignition stator as shown in the picture. Note: Theextractorlegscanbeheightadjusted;theymustbeparalleltothesurface of the semi-crankcase. - Use the extractor to completely separate the left-hand semi-crankcase from the right-hand semi-crankcase.
  • Page 28 Workshop manual Dismantling the engine REMOVING THE CRANKSHAFT - Remove the crankshaft assembly (arrow) by pulling it upwards. Note:  I fthecrankshaftdoesnotcomeouteasily,tapitwithaplasticmallet alternatelyonbothshafts. -28-...
  • Page 29 Workshop manual 1. Washer 2. Connecting rod pin 3. Connecting rod end bearing 4. Connecting rod 5. Crankshaft assembly 6. Cylinder 7. Hexagon screw with washer 6x14 8. Viton exhaust duct O-ring 44x3 9. Exhaust duct 10. Exhaust gasket 11. Breather 12.
  • Page 30 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS CONNECTING ROD Note:  T hebearingoftheconnectingrodheadshouldbereplacedalongwiththe crankshaftstump,connectingrodandspacerwashers. - Check the connecting rod end bearing and housing for jamming marks, grooves and gaps. - Measure the clearance of the connecting rod head by pushing it to one side and inserting a thickness gauge on the opposite side.
  • Page 31 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Piston: ring end opening - Insert a piston ring into the cylinder approximately 20 mm from the upper end. - Using a thickness gauge, measure the distance between the ends of ring -A- Ring end opening 200 cc: STD: 0.3 mm...
  • Page 32 Workshop manual 1. Lever assembly 30. Water pump gaskets 2. Washer 5x12x1.5 31. Water pump impeller 3. Self-locking nut 32. Impeller sprocket 4. Impeller lever shaft 33. Screw M6x16 5. Screw M5x6 34. Water pump washer 25.8x17.5x0.5 6. Impeller external lever 35.
  • Page 33 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS CYLINDER HEAD - Check that the cylinder head support surface is not deformed with respect to the cylinder. - Carefully clean the inside of the cylinder head; it must be free of carbon. REMOVE - Remove the screws - Extract the bearings with an extractor along with the washer and the left-hand...
  • Page 34 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Valve control shaft bracket - Check that the centrifugal lever shaft moves freely inside the bracket. Exhaust valve bearings - Check that the exhaust valve bearings show no signs of jamming or hardness when rotating.
  • Page 35 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS 21. Screw 1. Clutch cover gasket 22. Screw ULS 2. Central crankcase gasket 23. Washer 6x10x1.5 3. Water inlet valve 24. Screw 4. Hollow head screw 25. Screw 6. Cylinder bolt 26. Allen screw 7.
  • Page 36 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS RIGHT-HAND SEMI-CRANKCASE, INNER SIDE - Remove centring bushings -1- and selector spring centring screw -2- - Before performing any repairs to the right-hand semi-crankcase, check for any deformation around its circumference with a thickness gauge, both inside and outside.
  • Page 37 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Dislodge the bearings from the right-hand semi-crankcase. Crankshaft bearing -1- - Remove the ball bearing from the crankshaft by pressing from the outside of the semi-crankcase inwards. - Place the new ball bearing in the semi-crankcase housing. The stamped side of the bearing must be orientated towards the inside of the semi-crankcase.
  • Page 38 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Press on the bearing until it is fully encased in the right-hand semi-crankcase housing. Attention: Whenremovingandfittingtheneedlerollerbearing,becarefulnottoapply excessivepressuretothebearinghousingarea.Ifthepressureisexcessive, thesemi-crankcasemaybecomedamaged! - Check the lubrication hole of the crankshaft bearing (arrow). It should be clean and free of obstructions.
  • Page 39 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Centrifugal bearing -1- - Remove the ball bearing from the centrifugal shaft using a bearing extractor (maximum diameter 8 mm) from the outside of the semi-crankcase. - Place the new ball bearing in the semi-crankcase housing. The closed side of the bearing must be orientated towards the inside of the housing opening.
  • Page 40 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS LEFT-HAND SEMI-CRANKCASE, INNER SIDE - Before performing any repairs to the left-hand semi-crankcase, check inside for any deformation around its circumference with a thickness gauge. Maximum semi-crankcase deformation 0.05 mm Note: Toremovethebearingsfromtheleft-handsemi-crankcase,itisnecessaryto heatittoapproximately150°Cusingaheatingplate,stoveorsimilar.Onceit ishot,simplyuseanordinaryextractortoolorasoftmetalorwoodenpusher tocompletelyremovethebearings.Inexceptionalcases,itmaybenecessary...
  • Page 41 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Place the new ball bearing in the semi-crankcase housing. The stamped side of the bearing must be orientated towards the outside of the semi-crankcase. - Press on the bearing until it is fully encased in the left-hand semi-crankcase housing.
  • Page 42 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Check the lubrication hole of the crankshaft bearing (arrow). It should be clean and free of obstructions. LEFT-HAND SEMI-CRANKCASE, OUTER SIDE Note: Allgaskets,sealsandO-ringsmustbereplacedeverytimetheengineis partiallyorcompletelydismantled. Crankshaft seal -1- - Place the new crankshaft seal in the semi-crankcase housing. The sealing lip must be orientated towards the outside of the semi-crankcase.
  • Page 43 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS CLUTCH COVER - Before performing any repairs to the clutch cover, check inside for any deformation with a thickness gauge. Maximum clutch cover deformation 0.05 mm Note: Toremovethebearingsfromtheclutchcover,itisnecessarytoheatitto approximately150°Cusingaheatingplate,stoveorsimilar.Onceitishot, simplyuseanordinaryextractortoolorasoftmetalorwoodenpusherto removethebearingscompletely.Inexceptionalcases,itmaybenecessaryto use a press to dislodge the bearings. - Remove the seals from the clutch cover using a seal extractor or by carefully prying with a screwdriver.
  • Page 44 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Water pump sprocket shaft bearing -2- - Remove the ball bearing from the water pump sprocket shaft using a bearing extractor (maximum diameter 10 mm) from the inside of the clutch cover. - Place the new ball bearing in the clutch cover housing.
  • Page 45 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS 1. Clutch basket washer 22.1x42x2.8 21. Allen screw M6x20 2. Clutch sprocket washer 22. Bevelled washer 20/125 3. Silentblock rubber 23. Crankshaft sprocket locking nut 4. Clutch basket rivets 24. Clutch primary sprocket O-ring 5.
  • Page 46 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Clutch spring - Check the condition of the springs and their length. Length of the springs Min. 45.7 mm. Limit: 44 mm. Note: All of the clutch springs should be replaced. Clutch press - Check condition and clutch disc contact surface for scratches and excessive wear.
  • Page 47 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Check the thickness of the iron clutch disc. Clutch disc thickness STD: 1.45 to 1.55 mm. Limit: 1.40 mm. Clutch rod - Check the clutch rod for deformation. Maximum clutch rod deformation 0.05 mm.
  • Page 48 Workshop manual 1. Fork assembly 3. Short fork shaft 4. Long fork shaft 5. Desmodromic valve 6. Gear selector 7. Gear selector bushing 8. Gear selector spring 9. Flat washer 6x16x1.5 10. Special screw 11. Desmodromic valve bearing 12. Desmodromic valve bearing 13.
  • Page 49 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Check that the selector shaft bushing is in good condition and has no excess play. Scorpion guide bushing - Check that the guide bushing is not excessively worn in the scorpion contact area.
  • Page 50 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Check the clearance between the fork and its housing on the sprocket. Clearance between the fork and its housing STD: 0.15 mm. on the sprocket Limit: 0.25 mm. -50-...
  • Page 51 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS 1. Gear change washer 18x31.5x0.7 21. Circlip D.25 t=2 2. Primary 2nd sprocket 22. Output sprocket Z13 3. Circlip DIN 471 23. Gear change seal collar 4. Grooved washer 31.5x1 24. O-ring 25x2 NBR 5.
  • Page 52 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS - Check the bearing contact surface for jamming marks, grooves and gaps. - Check the sprocket teeth for wear or breakage. - Check for dirt on the sprockets and their movement grooves. - Check that the lubrication grooves contained on some sprockets are free of dirt and metal particles.
  • Page 53 Workshop manual 1. Kick-start ratchet spring 2. Kick-start ratchet 3. Kick-start Seeger 20 4. Kick-start shaft 5. Washer 27x20.2x1 6. Kick-start sprocket 7. Kick-start intermediate sprocket 8. Kick-start washer 20x40x1 9. Kick-start sprocket washer 24x15.15x0.8 10. Clutch shaft Seeger 15 11.
  • Page 54 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Kick-start shaft - Check that the teeth of the kick-start shaft show no signs of excessive wear or contact marks. - Check the clearance of the shaft in the casing housing. - Check that the lubrication channels are clean and free of debris. Ratchet - Check that the ratchet teeth show no signs of excessive wear.
  • Page 55 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS 1. Reed block assembly 2. Reed block clamp 3. Reed block rubber 4. Pipe 5. Special screw M6x25 6. Crankcase reed block gasket 7. Pipe reed block gasket 8. Intake reed set -55-...
  • Page 56 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Reeds - Check that the reeds are free of cracks and signs of ageing. - Check that the reeds are firmly laying on each other and are watertight. Reed spacer bracket - Check that none of the surfaces of the spacer are deformed. Reed block - Check that the support surfaces of the reeds are in perfect condition.
  • Page 57 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS 21. Bearing 61902-2Z C4 2. Screw UFK 22. Seeger DIN 472 D28x1.2 3. Magnetic flywheel 23. Bendix cover gasket 4. Electric starter sprocket 24. Needle D3x9.8 5. Screw ULS Torx M5x8 25. Screw M6x25 6.
  • Page 58 Workshop manual SeRVICING aND RePaIRING THe eNGINe’S COmPONeNTS Rubber ignition cap - Check that the rubber ignition cap is in good condition. Idria magnetic flywheel - Perform the following checks using a multitester. Measurement Wire colours Resistance Impulse coils Red-green 100 +/- 20% Exciter Black/Red - Red/White...
  • Page 59 Workshop manual aSSemBlING THe eNGINe Note:  A llenginepartsmustbecompletelycleanandinoptimumconditionbefore beginningassembly.Beforeassembly,applyengineoiltoallmovingand sliding parts. - Place the right-hand semi-crankcase on the bedplate. FITTING THE CRANKSHAFT - Lubricate the crankshaft bearing in the semi-crankcase. - Insert the crankshaft into the semi-crankcase bearing. - On the opposite side of the semi-crankcase, fit the O-ring and then the crankcase seal bushing with the recessed side facing outwards.
  • Page 60 Workshop manual aSSemBlING THe eNGINe - Carefully fit the gear shafts of primary shaft -1- and secondary shaft -2- at the same time. - Fit 2nd gear sprocket -1- and adjusting washer -2- to the primary shaft. - Fit the desmodromic valve to the semi-crankcase making sure that it is aligned with the marks (arrows) made during the dismantling.
  • Page 61 Workshop manual aSSemBlING THe eNGINe Note: Remembertopositionthesmallgasketonthetopofthesemi-crankcase (arrow). - Fit the screws in the position shown in the picture. Screws -1- : 70 mm. Screws -2- : 60 mm. Screws -3- : 65 mm. - Slightly adjust all of the screws and then tighten them diagonally, starting at the centre.
  • Page 62 Workshop manual aSSemBlING THe eNGINe - Block the rotation of the crankshaft sprocket and tighten the nut (arrow). Tightening torque: 40 Nm. FITTING THE GEAR SELECTOR ASSEMBLY - Fit the gear selector assembly with the spring (arrow) untensioned and tighten screw -1- Use threadlocker.
  • Page 63 Workshop manual aSSemBlING THe eNGINe FITTING THE KICK-START SPROCKET ASSEMBLY - Lubricate the kick-start shaft housing on the semi-crankcase. - Insert the kick-start assembly, making sure that the ratchet is located between the bracket and casing. - Fit spring -1- into the semi-crankcase opening with pliers. - Check that the kick-start spring centring bushing is in the correct position.
  • Page 64 Workshop manual aSSemBlING THe eNGINe - Fit the clutch hub, new sealing washer and fixing nut. - Hold the clutch hub and tighten the fixing nut. Use threadlocker. Tightening torque: 40 Nm. - Close the safety of sealing washer -1-. - Check that the clutch discs are completely clean and lubricate all of the discs.
  • Page 65 Workshop manual aSSemBlING THe eNGINe - Fit the centrifuge cam holder. Replace nuts -1- with new ones and tighten them. Tightening torque: 8 Nm - Fit exhaust valve ball joint pin clip -2-. - Check the functioning of the entire exhaust valve system. Note:  I fnecessary,makeadjustments,loosenthecentrifugaldriveleverscrewand positionthelever-rodassemblyinthedesiredposition.
  • Page 66 Workshop manual aSSemBlING THe eNGINe FITTING THE CLUTCH COVER - Fit the new clutch cover gasket. - Fit the clutch cover and tighten the screws diagonally. Screws -1- : 30 mm. Screws -2- : 35 mm. Screws -3- : 55 mm. Tightening torque: 10 Nm.
  • Page 67 Workshop manual aSSemBlING THe eNGINe FITTING THE IGNITION - Fit the crankshaft cotter pin. - Position the ignition stator and screws (arrows) - Tighten the screws (arrows). Use threadlocker. Tightening torque: 8 Nm. - Make sure rubber cap -2- is correctly positioned. - Fit the magnetic flywheel and tighten nut -1-.
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This manual is also suitable for:

Enduro 2t 200ccEnduro 2t 250ccEnduro 2t 300cc

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