GAS GAS Enduro Series Instruction manual

2017 GAS GAS
All rights reserved
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

Workshop manual
-3-
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:

Workshop manual
-4-
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

Workshop manual
-5-
This page has been le blank intenonally.
GENERAL INFORMATION

Workshop manual
-6-
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.

Workshop manual
-7-
*(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

Workshop manual
-8-
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

Workshop manual
-9-
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

Workshop manual
-10-
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)

Workshop manual
-11-
REMOVING THE ENGINE FROM THE FRAME
Note:
The cylinder head, cylinder, clutch and ignion 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.
- Remove the kick-start pedal lever (arrow)
- Loosen the springs that hold the exhaust pipe to the cylinder piping.
- Remove the enre exhaust system.

Workshop manual
-12-
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 uid.
Danger:
Make sure that the coolant is not at a high temperature before opening the
cooling circuit.
Note:
Drain the coolant into a clean container for later use.
- Remove the radiator cap.
- Unscrew the coolant drain screw on the water pump and allow the uid to
drain into a container.
- Wipe away any uid that falls on the engine, frame or wheels.
- Detach the spark plug connector (arrow) and disconnect the coolant pipes on
both sides of the engine.
- Remove the rear brake pedal and the rear brake pump guard and set to one
side.
- Remove the screws (arrows) and detach the output sprocket guard and the
hydraulic clutch clamp with the gasket.
- Loosen the chain.

Workshop manual
-13-
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.
- Remove the output sprocket (2) from the secondary sha.
- Detach the gear lever (3).
- Release the wiring of the magnec ywheel from its aachments to the frame
and uncouple the connector on the control unit (CDI) and the other wiring
connectors.
- Remove the carbureor (4)
- Extract the screws (arrows) that secure the engine to the frame.
- Loosen the 3 screws (arrows) that secure the cylinder head bracket to the
frame.
1
2
3
4

Workshop manual
-14-
- Extract the screws (arrows) that secure the engine to the frame at the boom.
- Extract the nut (1), remove the sha from the swinging arm and move it back-
wards.
- Properly posion the engine for extracon and remove it.
REMOVING THE ENGINE FROM THE FRAME
1

Workshop manual
-15-
FITTING THE ENGINE TO THE FRAME
- Fit the engine to the frame and posion it correctly on the brackets.
- Align the swinging arm with the engine and frame, grease the swinging arm
sha and t it.
- Fasten the engine xing screws to their brackets.
Note:
The self-locking nuts that hold the engine must be replaced with new ones.
- Lightly ghten all of the nuts and then to the specied torque:
Nuts Tightening torque
A60 Nm
B 25 Nm
C 60 Nm
D 80 Nm
- Fit the carbureor.
- Fit the magnec ywheel wiring to the frame and x correctly.
- Aach the control unit connector and the other wiring connectors.
- Fit the gear change lever.
Tightening torque: 15 Nm.
Note:
Theoutputsprocketmustbeplacedinthesameposionfromwhereitwas
removedtoachievethesameweardirecon.
A
C
D
B

Workshop manual
-16-
- Posion the output sprocket (2) on the secondary sha and t the retaining
ring (1).
- Insert the clutch rod (arrow).
- Posion the hydraulic clutch clamp with a new gasket, t the output sprocket
guard and ghten the screws (arrows).
Tightening torque: 6 Nm.
- Tense the chain.
- Fit the rear brake pedal and the rear brake pump guard.
Tightening torque: 29 Nm.
Note:
Check that the coolant pipes are not cut or damaged.
- Aach the spark plug connector (arrow) and connect the coolant pipes on both
sides of the engine.
Note:
- Makesurethatthecoolantdrainscrewonthewaterpumpisghtandhas
a new gasket.
Tightening torque: 9 Nm.
- Disconnect the coolant recirculaon tube.
- Rell the coolant system through the le-hand radiator cap.
Mixture of anfreeze and dislled water: 1:1 (anfreeze 50%, dislled water 50%).
Capacity: 1.1 litres.
Note:
-Makesurethatthetransmissionoildrainplugisghtandhasanewgasket.
Tightening torque: 20 Nm.
FITTING THE ENGINE TO THE FRAME
1
2

Workshop manual
-17-
- Remove the oil ller cap (arrow) and rell with new transmission oil.
Viscosity: 5W40
Capacity: 900 cc
- Fit the oil ller cap with a new gasket and ghten.
- Acvate the kick-start pedal 3 or 4 mes and check the oil level with the gauge
(arrow).
- Posion the enre exhaust system and lightly ghten the screws.
- Check the condion of the O-rings on the exhaust pipe and replace any that are
damaged.
- Correctly posion the springs that hold the exhaust pipe to the cylinder piping.
- Tighten the exhaust system screws.
Tightening torque: 6 Nm.
FITTING THE ENGINE TO THE FRAME

Workshop manual
-18-
- Fit the kick-start pedal lever, apply Locte 243 to the screw (arrow) and then
ghten it.
- Tightening torque: 20 Nm.
- Fit the fuel tank and breather pipe.
- Check the condion of the air lter. If damaged, replace it with a new one. If
not damaged, clean and reaach it (see user manual).
- Fit the fuel tank together with the two side covers, seat and frame side guards.
Note:
Aercarryingoutarstphaseofbreaking-in,checktheoilandcoolant
levels,chaintensionandperformageneralinspecon.
- Check that there is no leakage of coolant through the radiator pipes.
FITTING THE ENGINE TO THE FRAME

Workshop manual
-19-
Dismantling the engine
Preliminary instrucons:
Note:
Whendismantlingtheengine,keeppairsofpartstogether.Thisincludes
gears,cylinders,pistonsandotherpartssubjectedtonaturalwearintheir
pairs.
Pairsofpartsshouldalwaysbereplacedtogether.
Duringdismantling,cleanallpartsandplacethemintraysinorderof
disassembly.Thiswillspeedupreassemblyandensurethatallpartsare
properlyed.
Partsshouldbekeptawayfromanyresource.
Allgaskets,sealsandO-ringsmustbereplacedeverymetheengineis
parallyorcompletelydismantled.
- Thoroughly clean the engine before placing it on the bedplate.
- Place the engine on the bedplate.
- Remove the spark plug from the cylinder head.
DISMANTLING THE IGNITION
- Remove the screws (arrows) from the ignion cover.
- Block the rotaon of the magnec ywheel.
- Remove the nut (1).
Aenon:
Themagnecywheelnutloosenstothele!
1

Workshop manual
-20-
Dismantling the engine
- Insert extractor ref. ME25634045 into the internal thread of the magnec
ywheel.
- Remove the magnec ywheel by holding the extractor with a spanner while
turning the screw.
- Remove the coer pin from the cone of the cranksha.
- Extract the screws (arrows) from the ignion stator and remove it together
with the wiring.
REMOVING THE WATER PUMP
- Extract the screws (arrows) from the water pump cover.