User manual GAS GAS EC 300

[. . . ] WORKSHOP MANUAL / WERKSTATTHANDBUCH MOTOR EC Enducross 200 / 250 / 300 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. [. . . ] - 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-. It should be free of obstruction and clean. 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. - Fit the new ball bearing in the crankcase housing. 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. - Fit the new ball bearing in the crankcase housing. 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. The seal lip should face the outside of the crankcase. - 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-. - Replace non-existent centring bushings where necessary. 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. [. . . ] - Fit the four cylinder nuts and adjust slightly. - Adjust the four nuts at the foot of the cylinder in diagonal pairs. Tightening torque: 25 Nm - Place the exhaust valve operating rod -1-. Replace the nuts -2- with new ones and tighten them. [. . . ]