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EC 200
GAS GAS EC 200 User Manual
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WORKSHOP MANUAL /
WERKSTATTHANDBUCH
200 / 250 / 300
200 / 250 / 300
MOTOR EC Enducross
MOTOR EC Enducross
WORKSHOP MANUAL /
WERKSTATTHANDBUCH
2
Table of Contents
Table of Contents
5
Safety
6
Maintenance
6
General Information
6
General Tightening Torques
7
Engine Serial Number
7
Table of Technical Data
8
Removing the Engine from the Chassis
9
Fitting the Engine on the Chassis
13
Dismantling the Ignition
17
Dismounting Engine
17
Dismantling the Water Pump
18
Removing Cylinder Head and Cylinder
19
Dismantling the Clutch
21
Dismount the Centrifugal Operating System of the Exhaust Valve
23
Dismantling the Starter Pinion Unit
23
Dismantling the Gear Selector Unit
23
Dismantling Crankshaft Flywheel
24
Dismounting the Reed Valve
24
Removing the Half Crankcases
25
Removing the Crankshaft
26
Crankshaft - Piston - Cylinder Diagram
27
Service and Repair of the Engine Components
27
Crankshaft
28
Connecting Rod
29
Piston
29
Piston: Opening at the End of the Ring
30
Piston Pin
30
Cylinder: Interior Measurement
30
Cylinder Head
30
Operation of the Exhaust Valve
31
Exhaust Valve Dismantling
32
Exhaust Valve Testing
32
Centrifugal Pinion
32
Centrifugal Balls
32
Short Exhaust Valve Shaft
33
Left Exhaust Valve
33
Exhaust Valve Bearings
33
Valve Control Shaft Support
33
Crankcase Diagram
34
Right Half Crankcase, Inner Side
35
Crankshaft Bearing
36
Primary Cam Bearing
36
Secondary Cam Bearing
36
Desmodromic Bearing
36
Centrifugal Shaft Bearing
38
Pinion Shaft Bearing of Water Pump
38
Crankshaft Seal
38
Starter Ratchet Plate
38
Left Half Crankcase, Inner Side
39
Centring Bushings
39
Left Crankcase, Outer Side
41
Output Shaft Seal
42
Selector Shaft Seal
42
Clutch Cover
42
Starter Shaft Seal
44
Clutch Diagram
45
Clutch Spring
46
Clutch Press
46
Clutch Bearing
46
Clutch Discs
46
Clutch Housing Bearings
47
Clutch Hub
47
Clutch Housing Crown
47
Clutch Rod
47
Gearshift Mechanism Diagram
48
Selector Shaft
49
Scorpion Guide Bushing
49
Selector Shaft Assembly
49
Gear Lock
49
Gears Diagram
51
Primary Cam
52
Secondary Cam
52
Starter Mechanism Diagram
53
Interior Pinion
54
Ratchet
54
Starter Pinion
54
Starter Shaft
54
Reed Valve Diagram
55
Reeds
56
Reed Spacer Plate
56
Reed Valve
56
Ignition Diagram
57
Ignition Rubber Top
58
Magnetic Flywheel Kokusan
58
Spark Plug
58
Assembling the Crankshaft
59
Assembling the Engine
59
Joining the Crankcases
60
Fitting the Reed Valve
61
Assembling the Gear Selector Unit
62
Assembling the Starter Pinion Unit
63
Assembling the Centrifugal Operating System of the Exhaust Valve
63
Assembling the Clutch
63
Assembling the Cylinder and Cylinder Head
64
Fitting the Clutch Cover
66
Assembling the Water Pump
66
Assembling the Ignition
67
Electrical Diagrams
69
Electrical Schemas
69
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Service Manual
80 pages
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GAS GAS EC 200 Specifications
General
Transmission
6-speed
Seat Height
960 mm
Cooling System
Liquid
Starter
Kick
Front Brake
Disc
Rear Brake
Disc
Front Suspension
Kayaba forks
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