GAS GAS Enduro Series, Workshop Manual

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Workshop manual
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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.
- Insert the iron discs and lined discs alternately into the clutch hub, starting
and ending with a lined disc.
- Lubricate the pusher bearing and fit clutch press -2-.
- Position screws -1- with their bushings and springs and tighten them in stages
diagonally. Use threadlocker.
Tightening torque: 10 Nm
FITTING THE CYLINDER AND CYLINDER HEAD
- Check that the piston and pin are clean.
- Lubricate the connecting rod end bearing.
- Position the piston with the arrow marked on the head towards the exhaust
port.
Note:
Before fitting the pin retaining ring, cover the crankcase opening with a clean
cloth.
- Insert the pin through the piston and connecting rod end bearing and then fit
the new retaining ring (arrow).
- Fit the piston rings with the manufacturer markings facing upwards.
- Fit the gaskets to the base of the cylinder.
- Position the cylinder carefully, ensuring that the rings are centred with the
locking pins of the piston grooves.
- Position the four cylinder nuts and lightly tighten them.
- Tighten the four nuts at the base of the cylinder diagonally.
Tightening torque: 25 Nm.
1
1
1
1
2
1
1
2
1