GAS GAS Enduro 2T 200CC, Workshop Manual

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Workshop manual
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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 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.
- Wear eye protection whenever using electric tools such as drills, sanders or rectifiers.
- Use a protective cream on the hands before starting disassembly work to protect the skin from infections 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 tidy to prevent tripping over objects left on the floor.
- Do not allow oils, grease or other fluids to remain on the floor 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 precautions 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 fluids, as these can be extremely toxic. Make sure that the work area is ventilated.
MAINTENANCE
- Always use original GG spare parts and lubricants recommended by the manufacturer. Non-original spare parts can damage the engine.
- Only use tools specifically designed for this vehicle.
- Always replace gaskets, seals and O-rings during servicing and assembly.
- After disassembly, clean the components with non-flammable 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 operations. Metric screws, nuts and bolts are
not interchangeable with connecting 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 after each
use.
- After assembly, check that all components have been properly fitted and that all mechanisms work correctly.
GENERAL TIGHTENING TORQUES
The following table specifies tightening torques for nuts or screws with ISO threads.
Tightening torques for special components or assemblies are indicated in the respective repair processes of this manual.
To prevent deformation, tighten the assemblies with several nuts or screws progressively and in a diagonal or alternating sequence until
the specified torque is reached.
Threads have to be clean and dry to apply the tightening torques described below. Components should be at room temperature.