GAS GAS Enduro Series Gebrauchsanweisung

2017 GAS GAS

Reprinng and reproducon of any kind, either in whole or in part, is prohibited without the wrien permission

of the copyright holder.

The company has the right, without prior noce, to change the technical content of the products.

The models in the images may appear with special equipment that does not come with the standard model.

Edion 01/08/2017

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INTRODUCTION

This manual was created by TORROT ELECTRIC EUROPA S.L. to be used by ocial 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 instrucons for carrying out all

repairs, as well as the necessary technical data to perform maintenance on the motorcycles.

It also has extensive informaon about special GG tools that will be of great help to opmise each repair process.

Through successive edions, we will keep it updated with all upgrades and evoluons of the engines of this family.

Parcularly important informaon in this manual is preceded by the following signs:

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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 .............................................................................................................................................................. 68

Contents

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This page has been le blank intenonally.

GENERAL INFORMATION

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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 ames in the work area. Petrol is extremely ammable and can be explosive under certain condions.

- Use appropriate cleaning products for each task, making sure that they are approved.

- Wear eye protecon whenever using electric tools such as drills, sanders or recers.

- Use a protecve cream on the hands before starng disassembly work to protect the skin from infecons and make subsequent cleaning

easier. Make sure hands are not slippery.

- Remember that prolonged contact of engine oil with the skin may be harmful to health.

- Keep loose clothing away from moving parts.

- Do not wear rings, wristwatches, etc., while performing tasks on the engine, especially the electrical system.

- Keep the work area dy to prevent tripping over objects le on the oor.

- Do not allow oils, grease or other uids to remain on the oor of the work area as they are a slipping hazard.

- Use appropriate tools to compress or decompress springs to prevent them from violently recoiling.

- Take special precauons to avoid breathing dust from parts containing asbestos (e.g. clutch discs), as this product is extremely harmful to

health.

- Avoid breathing vapours from petrol or cleaning uids, as these can be extremely toxic. Make sure that the work area is venlated.

MAINTENANCE

- Always use original GG spare parts and lubricants recommended by the manufacturer. Non-original spare parts can damage the engine.

- Only use tools specically designed for this vehicle.

- Always replace gaskets, seals and O-rings during servicing and assembly.

- Aer disassembly, clean the components with non-ammable solvents.

- Lubricate all work surfaces prior to assembly, excluding conical couplings.

- Apply oil to all pairs of parts and bearings during assembly.

- Only use tools with metric measurements during disassembling, servicing and assembling operaons. Metric screws, nuts and bolts are

not interchangeable with connecng elements with English measurements.

- All surfaces that receive gaskets, seals and O-rings must be cleaned with special care.

- Carefully examine all retaining rings prior to assembly and replace any deformed ones. Always replace piston pin retaining rings aer each

use.

- Aer assembly, check that all components have been properly ed and that all mechanisms work correctly.

GENERAL TIGHTENING TORQUES

The following table species ghtening torques for nuts or screws with ISO threads.

Tightening torques for special components or assemblies are indicated in the respecve repair processes of this manual.

To prevent deformaon, ghten the assemblies with several nuts or screws progressively and in a diagonal or alternang sequence unl

the specied torque is reached.

Threads have to be clean and dry to apply the ghtening torques described below. Components should be at room temperature.

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*(A) NUT *(B) SCREW GENERAL TIGHTENING TORQUES

Nm Kgf.m Ft.lb

10 mm 6 mm 6 0.6 4.3

12 mm 8 mm 15 1.5 11

14 mm 10 mm 30 3.0 22

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 26 mm 130 13.0 94

*A: Distance between the planes of the nut.

*B: External diameter of the screw thread.

ENGINE IDENTIFICATION

- The engine serial number is stamped on the boom of the le-hand semi-

crankcase.

- Always quote the engine serial number when ordering an original GG spare

part for the engine.

GENERAL INFORMATION

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GENERAL INFORMATION

- This tool will be needed to ghten or loosen the fork bars.

Ref: BE21105GG-CLJ-1

- These tools are used to t 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 t the fork seal and dust cover.

Ref: BE20235GG-CLJ-1

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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 t the cranksha into the crankcase.

Ref: ME25950000

- This tool is used to separate the crankcases and open the engine.

Ref: ME25950005

- With this tool, the spokes can be ghtened or loosened.

Ref: BE55100CT2509

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TECHNICAL DATA TABLE

ENGINE

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

Carbureor Dell’Orto PHBG 21 (Keihin PWKS 38 compeon model)

Intake type V-Force 4 reed valve system

Lubricaon system Fuel mix

Starter system Kick-starter/Electric starter on E-START models

Ignion system Digital CDI-Euro 4

Pre-ignion set-up

Spark plug DENSO W24ESR-U and NGK BR8EG

Distance between electrodes 0.7/0.8 mm

TRANSMISSION

Primary reducon 3.31 (63/19)

Gearbox 6 speeds, cascade

Gear rao

1ª 2.07 (14/29)

2ª 1.63 (16/26)

3ª 1.33 (18/24)

4ª 1.10 (20/22)

5ª 0.91 (23/21)

6ª 0.79 (24/19)

Secondary transmission By chain

Secondary reducon 3.67 (13/49) EC 200-250 // 3.69 (13/48) EC300

Compeon models only

3.30 (13/42) EC 200-250-

300

Chain 110 Links // 5/8 "x 1/4" with seals (112 links) compeon model only

Type of clutch Mul-disc oil bath with hydraulic drive

Clutch drive Hydraulic

Lubricaon Medium Oil

Capacity 900cc

FRAME

Type Central backbone frame in 25 CrMo 4 steel, aluminium alloy subframe

Tyre and rim

measurements

Front Excel 1.6 x 21 - 90/90 - 21 M/C 54R MICHELIN ENDURO MEDIUM F TT

Rear Excel 2.15 x 18 - 140/80 - 18 70R MICHELIN ENDURO MEDIUM R TT

Tyre pressure Front 1.0 bar

Rear 1.0 bar

Suspension

Front KYB fork ø48 mm AOS System (Air Oil Separated), closed cartridge, with spring and

compression and rebound

Rear Progressive system with KYB single shock absorber with adjustable high and low speed

compression and rebound

Suspension travel

Front 300mm (KYB)

Rear 131 mm (KYB)

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