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GAS GAS Enduro Series User Manual

GAS GAS Enduro Series
72 pages
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Table of Contents

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GAS GAS Enduro Series Specifications

General IconGeneral
Transmission6-speed
CategoryEnduro
Cooling SystemLiquid-cooled
StarterElectric
Fuel Tank Capacity9.5 liters
Fuel SystemElectronic fuel injection
Fuel Capacity9.5 liters

Summary

Removing the Engine from the Frame

Fitting the Engine to the Frame

Dismantling the Engine

Preliminary Instructions and Ignition Dismantling

Provides crucial pre-dismantling advice and steps for removing the ignition cover and magnetic flywheel.

Magnetic Flywheel Removal and Stator Extraction

Details using an extractor to remove the magnetic flywheel and extracting the ignition stator.

Cylinder Head Removal and O-ring Replacement

Covers loosening cylinder head screws, removing it, and replacing O-rings.

Cylinder Removal and Gasket Replacement

Details removing cylinder nuts, detaching the cylinder, and removing the gasket.

Clutch Spring and Pusher Bushing Removal

Covers loosening screws, removing clutch springs, pusher bushings, and clutch press.

Clutch Hub and Basket Removal

Details opening safety, loosening clutch hub nut, removing washer, and detaching the clutch basket.

Crankshaft Sprocket Removal

Details blocking crankshaft rotation, loosening the nut, and removing the crankshaft sprocket and flywheel.

Reed Block and Semi-Crankcases Separation

Explains removing reed block screws and separating the semi-crankcases.

Semi-Crankcase Separation Procedure

Covers installing extractor, separating semi-crankcases, and detaching spacer bushing.

Gear Selector and Assembly Removal

Details removing fork shafts, forks, desmodromic valve, adjusting washer, and gear shafts.

Crankshaft Assembly Removal

Provides instructions on how to remove the crankshaft assembly by pulling it upwards.

Servicing and Repairing Engine Components

Connecting Rod Checks and Measurements

Details checking the connecting rod end bearing and measuring connecting rod head clearance.

Piston Condition and Fitting Clearance

Covers checking piston for damage, grooves, and measuring piston fitting clearance.

Cylinder Head Checks and Removal

Covers checking cylinder head support surface and removing components like bearings and shafts.

Crankshaft, Primary, and Secondary Shaft Bearing Installation

Details installing bearings for crankshaft, primary, and secondary shafts into the semi-crankcase.

Bearing Installation in Left-Hand Semi-Crankcase

Covers removing and installing crankshaft and primary shaft bearings into the left-hand semi-crankcase.

Secondary Shaft and Desmodromic Valve Bearing Installation

Details installing secondary shaft and desmodromic valve bearings into the left-hand semi-crankcase.

Clutch Spring and Clutch Press Checks

Covers checking clutch spring condition, length, and clutch press contact surface.

Assembling the Engine

Crankshaft Installation in Semi-Crankcase

Covers lubricating the crankshaft bearing and inserting the crankshaft into the semi-crankcase.

Gear Selector and Assembly Lubrication and Fitting

Details lubricating gear shaft bearings and fitting gears, bearings, and washers.

Gear Shafts and Desmodromic Valve Alignment

Covers fitting primary and secondary gear shafts and aligning the desmodromic valve.

Transmission Forks and Semi-Crankcase Joining

Details fitting forks, sliding shafts, and joining the semi-crankcases with gasket and mallet.

Semi-Crankcase Screw Tightening and Gasket Check

Covers fitting and tightening semi-crankcase screws, checking for gasket debris.

Reed Block and Crankshaft Flywheel Fitting

Details fitting the reed block with new gaskets and fitting the crankshaft flywheel components.

Crankshaft Sprocket Nut Tightening

Covers blocking crankshaft rotation and tightening the crankshaft sprocket nut.

Gear Selector Assembly Fitting and Screw Tightening

Details fitting the gear selector assembly, spring, and centring screw.

Kick-Start Sprocket Assembly and Exhaust Valve System Fitting

Covers fitting the kick-start assembly, spring, and exhaust valve centrifugal drive bracket.

Piston and Cylinder Head Installation

Details lubricating piston/pin, positioning piston, and installing cylinder and head with nuts.

Ignition Stator, Flywheel, and Spark Plug Fitting

Covers fitting ignition stator, magnetic flywheel, and spark plug with correct torque.

Wiring Diagram

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