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Workshop manual

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aSSemBlING THe eNGINe

FITTING THE CLUTCH COVER

- Fit the new clutch cover gasket.
- Fit the clutch cover and tighten the screws diagonally.
Screws -1- : 30 mm.
Screws -2- : 35 mm.
Screws -3- : 55 mm.
Tightening torque: 10 Nm.
- Fit a new gasket to the clutch disc cover and tighten the screws diagonally.
Screws 4: 25 mm.
Screws 5: 75 mm.
Tightening torque: 10 Nm.

FITTING THE WATER PUMP

- Fit the new water pump seal (arrow) to the clutch cover.

- Position water pump turbine -1- and insert fixing screw -2-.
- Block the rotation of the turbine and tighten screw -2-. Use threadlocker.

Tightening torque: 6 Nm.

- Fit the water pump cover and tighten the screws (arrows).
Tightening torque: 6 Nm.

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Содержание Enduro Series

Страница 1: ......

Страница 2: ...in part is prohibited without the written permission of the copyright holder The company has the right without prior notice to change the technical content of the products The models in the images may...

Страница 3: ...tains precise instructions for carrying out all repairs as well as the necessary technical data to perform maintenance on the motorcycles It also has extensive information about special GG tools that...

Страница 4: ...ATION 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 ENGI...

Страница 5: ...Workshop manual 5 This page has been left blank intentionally General information...

Страница 6: ...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...

Страница 7: ...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...

Страница 8: ...en or loosen the fork bars Ref BE21105GG CLJ 1 These tools are used to fit 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...

Страница 9: ...014 This tool will be needed to remove the stator Ref ME25634045 This tool is used to fit the crankshaft into the crankcase Ref ME25950000 This tool is used to separate the crankcases and open the eng...

Страница 10: ...79 24 19 Secondary transmission By chain Secondary reduction 3 67 13 49 EC 200 250 3 69 13 48 EC300 Competition models only 3 30 13 42 EC 200 250 300 Chain 110 Links 5 8 x 1 4 with seals 112 links com...

Страница 11: ...ame 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 cover...

Страница 12: ...oling 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 fluid to drain into a container Wipe a...

Страница 13: ...retaining ring pliers Remove the output sprocket 2 from the secondary shaft Detach the gear lever 3 Release the wiring of the magnetic flywheel from its attachments to the frame and uncouple the conne...

Страница 14: ...ws arrows that secure the engine to the frame at the bottom Extract the nut 1 remove the shaft from the swinging arm and move it back wards Properly position the engine for extraction and remove it RE...

Страница 15: ...ld the engine must be replaced with new ones Lightly tighten all of the nuts and then to the specified torque Nuts Tightening torque A 60 Nm B 25 Nm C 60 Nm D 80 Nm Fit the carburettor Fit the magneti...

Страница 16: ...nt pipes are not cut or damaged Attach 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 tight a...

Страница 17: ...art pedal 3 or 4 times and check the oil level with the gauge arrow Position the entire exhaust system and lightly tighten the screws Check the condition of the O rings on the exhaust pipe and replace...

Страница 18: ...If damaged replace it with a new one If not damaged clean and reattach it see user manual Fit the fuel tank together with the two side covers seat and frame side guards Note After carrying out a firs...

Страница 19: ...s will speed up reassembly and ensure that all parts are properly fitted Parts should be kept away from any fire source All gaskets seals and O rings must be replaced every time the engine is partiall...

Страница 20: ...wheel Remove the magnetic flywheel by holding the extractor with a spanner while turning the screw Remove the cotter pin from the cone of the crankshaft Extract the screws arrows from the ignition sta...

Страница 21: ...pump turbine Extract the entire water pump seal arrows REMOVING THE CYLINDER HEAD AND CYLINDER Extract the screws 1 from the clutch disc cover and remove it Extract the screws 2 from the clutch cover...

Страница 22: ...the screws of the cylinder head 1 in a diagonal sequence and remove it from the cylinder Note If the cylinder head does not come out easily tap it with a plastic mallet Remove the inner and outer O ri...

Страница 23: ...of the piston towards the exhaust port using an indelible marker Place a clean cloth at the base of the cylinder to prevent the retaining ring from falling into the crankcase Remove one retaining rin...

Страница 24: ...osen the nut by holding the clutch hub Attention The clutch hub nut loosens to the left Remove the sealing washer and detach the clutch hub Note The clutch hub has a fitting position relative to the p...

Страница 25: ...t valve centrifugal drive 2 REMOVING THE KICK START SPROCKET ASSEMBLY Remove the spring 1 with a pair of pliers and detach the kick start sprocket assembly Extract the retaining ring 2 remove the spac...

Страница 26: ...ngine does not feature an inertial flywheel Remove the nut bevelled washer crankshaft sprocket flywheel and crankshaft cotter pin REMOVING THE REED BLOCK Remove the screws arrow and detach the reed bl...

Страница 27: ...er bushing from the output sprocket arrow located on the shaft Attention Do not use screwdrivers or levers to separate the semi crankcases REMOVING THE GEAR SELECTOR AND ASSEMBLY Remove the fork shaft...

Страница 28: ...l 28 REMOVING THE CRANKSHAFT Remove the crankshaft assembly arrow by pulling it upwards Note If the crankshaft does not come out easily tap it with a plastic mallet alternately on both shafts Dismantl...

Страница 29: ...d end bearing 4 Connecting rod 5 Crankshaft assembly 6 Cylinder 7 Hexagon screw with washer 6x14 8 Viton exhaust duct O ring 44x3 9 Exhaust duct 10 Exhaust gasket 11 Breather 12 Piston pin retaining r...

Страница 30: ...or scratches jamming marks and deformation due to overheating Check the grooves of the rings cleanliness absence of deposits of carbon breakage etc If necessary clean them with a wire brush that does...

Страница 31: ...8 mm PIN Check the pin for jamming marks grooves and overheating Measure the pin bore with a micrometre at three different points Pin bore STD 17 994 mm Limit 17 98 mm CYLINDER Cylinder internal measu...

Страница 32: ...24 Impeller balls 25 O ring 26 Adjustable spring seal 27 Water pump sprocket shaft 28 Water pump bearing 29 Seeger water pump 30 Water pump gaskets 31 Water pump impeller 32 Impeller sprocket 33 Scre...

Страница 33: ...the exhaust port of the cylinder Note To remove the centrifuge simply compress spring 19 to the pin and remove it CHECK Centrifugal shaft Check that the centrifugal shaft does not show signs of jammin...

Страница 34: ...right hand exhaust valves Check the valves for cracks jamming marks or deformation due to overheating Clean the valves to remove any carbon deposits with a wire brush that does not damage their surfa...

Страница 35: ...Centrifugal regulating cap 31 Crankcase assembly 1 Clutch cover gasket 2 Central crankcase gasket 3 Water inlet valve 4 Hollow head screw 6 Cylinder bolt 7 Crankcase bushing 9 Friction bushing 10 Oil...

Страница 36: ...C using a heating plate stove or similar Once it is hot simply use an ordinary extractor tool or a soft metal or wooden pusher to remove the bearings completely In exceptional cases it may be necessar...

Страница 37: ...aring be careful not to apply excessive pressure to the bearing housing area If the pressure is excessive the semi crankcase may become damaged Secondary shaft bearing 3 Remove the ball bearing from t...

Страница 38: ...eating plate stove or similar Once it is hot simply use an ordinary extractor tool or a soft metal or wooden pusher to remove the bearings completely In exceptional cases it may be necessary to use a...

Страница 39: ...s the inside of the housing opening Press on the bearing until it is fully encased in the right hand semi crankcase housing Crankshaft seal 3 Place the new crankshaft seal in the semi crankcase housin...

Страница 40: ...rings must be replaced every time the engine is partially or completely dismantled Place the left hand semi crankcase on a heating plate and heat it to approximately 150 C Danger When handling the sem...

Страница 41: ...g until it is fully encased in the right hand semi crankcase housing Attention When removing and fitting the needle roller bearing be careful not to apply excessive pressure to the bearing housing are...

Страница 42: ...eful not to damage the sealing lip Output shaft seal 2 Place the new crankshaft seal in the semi crankcase housing The sealing lip must be orientated towards the outside of the semi crankcase Press on...

Страница 43: ...with a screwdriver Note All gaskets seals and O rings must be replaced every time the engine is partially or completely dismantled Place the clutch cover on a heating plate and heat it to approximate...

Страница 44: ...rientated towards the outside of the housing opening Press on the bearing until it is fully encased in the clutch cover housing Kick start shaft seal 1 Fit the new kick start shaft seal to the clutch...

Страница 45: ...ch hub assembly 1 Clutch basket washer 22 1x42x2 8 2 Clutch sprocket washer 3 Silentblock rubber 4 Clutch basket rivets 5 Complete clutch basket 6 Clutch basket bearing 7 Clutch basket bushing 8 Clutc...

Страница 46: ...ch press Check condition and clutch disc contact surface for scratches and excessive wear Bearing and pusher Check the clutch bearing and pusher for jamming marks grooves and gaps Lined clutch discs C...

Страница 47: ...1 for scratches and excessive wear Check that oil circulation holes 2 are free of dirt and metal particles Clutch basket sprocket Check the contact surface of bearing 1 for jamming marks grooves and g...

Страница 48: ...elector spring 9 Flat washer 6x16x1 5 10 Special screw 11 Desmodromic valve bearing 12 Desmodromic valve bearing 13 Selector seal 12 22 7 14 Selector spring centring screw 15 Scorpion spring 16 Scorpi...

Страница 49: ...e ends of the scorpion spring into the selector shaft and scorpion brackets Gear selector Check that the bearing on the end of the selector is in good condition that it turns easily and that there is...

Страница 50: ...anual 50 SERVICING AND REPAIRING THE ENGINE S COMPONENTS Check the clearance between the fork and its housing on the sprocket Clearance between the fork and its housing on the sprocket STD 0 15 mm Lim...

Страница 51: ...change unit 1 Gear change washer 18x31 5x0 7 2 Primary 2nd sprocket 3 Circlip DIN 471 4 Grooved washer 31 5x1 5 Primary 6th sprocket 6 Primary 3rd and 4th sprocket 7 Washer 25 2x31 5x1 8 Primary 5th s...

Страница 52: ...some sprockets are free of dirt and metal particles Once the shaft elements have been removed clean them thoroughly and replace all of the retaining rings Primary shaft Properly lubricate all of the...

Страница 53: ...k start sprocket 7 Kick start intermediate sprocket 8 Kick start washer 20x40x1 9 Kick start sprocket washer 24x15 15x0 8 10 Clutch shaft Seeger 15 11 Kick start spring 12 Kick start spring centring b...

Страница 54: ...free of debris Ratchet Check that the ratchet teeth show no signs of excessive wear Kick start sprocket Check that the sprocket shows no signs of excessive wear or gaps Check that the teeth of the ki...

Страница 55: ...55 SERVICING AND REPAIRING THE ENGINE S COMPONENTS 1 Reed block assembly 2 Reed block clamp 3 Reed block rubber 4 Pipe 5 Special screw M6x25 6 Crankcase reed block gasket 7 Pipe reed block gasket 8 I...

Страница 56: ...t the reeds are free of cracks and signs of ageing Check that the reeds are firmly laying on each other and are watertight Reed spacer bracket Check that none of the surfaces of the spacer are deforme...

Страница 57: ...er 6x12x1 5 31 Electric motor cover 2 Screw UFK 3 Magnetic flywheel 4 Electric starter sprocket 5 Screw ULS Torx M5x8 6 Hexagon screw 10x25 7 Ignition cover 8 Hexagon screw 6x40 9 Hexagon screw 5x15 1...

Страница 58: ...20 Exciter Black Red Red White 12 7 20 Charging coil Yellow Earth 0 67 20 White Yellow 0 16 20 Note All measurements should be taken at a temperature of 20 C Otherwise significant errors can be produ...

Страница 59: ...rankcase Insert the crankshaft into the semi crankcase bearing On the opposite side of the semi crankcase fit the O ring and then the crankcase seal bushing with the recessed side facing outwards FITT...

Страница 60: ...nd 3 long through the forks to their housings on the semi crankcase Note Check that the transmission functions correctly by turning the desmodromic valve by hand Position the transmission gears in neu...

Страница 61: ...haft Replace the nut that fixes the engine to the bedplate Check that no semi crankcase gasket debris is left on the support surface of the cylinder FITTING THE REED BLOCK Remove any semi crankcase ga...

Страница 62: ...HE GEAR SELECTOR ASSEMBLY Fit the gear selector assembly with the spring arrow untensioned and tighten screw 1 Use threadlocker Tightening torque 6 Nm Position the spring arrow with a pair of pliers F...

Страница 63: ...TTING THE EXHAUST VALVE CENTRIFUGAL DRIVE SYSTEM Lubricate the semi crankcase centrifugal shaft bearing Fit centrifugal drive 2 to the semi crankcase Fit bracket 1 making sure that the output lever is...

Страница 64: ...0 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 p...

Страница 65: ...e lever screw and position the lever rod assembly in the desired position Fit the new O rings to the top of the cylinder Check that the cylinder head support surface is completely clean Insert the cyl...

Страница 66: ...to the clutch disc cover and tighten the screws diagonally Screws 4 25 mm Screws 5 75 mm Tightening torque 10 Nm FITTING THE WATER PUMP Fit the new water pump seal arrow to the clutch cover Position w...

Страница 67: ...m Make sure rubber cap 2 is correctly positioned Fit the magnetic flywheel and tighten nut 1 Use threadlocker Tightening torque 40 Nm Fit a new gasket to the ignition cover and tighten the screws arro...

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