Ed: 07/05

- Remove the drain plug -arrow- and drain the transmission oil. Danger: Make sure that the coolant fluid is not hot before opening the coolant circuit.
Note: Place the coolant in a clean container, it may be reused later.
- Remove the radiator cap. - Unscrew the coolant drain plug in the water pump and allow the fluid to drain into the containert. - Clean any fluid which falls on the engine, chassis or wheels.
- Disconnect the spark plug connector -1- and disconnect the coolant pipes on both sides of the engine. - Remove the back brake pedal and the back brake pump guard, setting them to one side.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 REMOVING THE ENGINE FROM THE CHASSIS 01-03
- Undo the screws -arrows-, remove the chain pinion and the hydraulic clutch calliper with the gasket. - Loosen the chain.
- Extract the clutch rod -arrow- entirely.
Note: The position of the chain pinion before removing. It should be replaced in the same position to ensure the same direction of wear.
- Remove the circlip -1- of the chain pinion using circlip pliers. - Remove the chain pinion -2- from the secondary shaft. - Remove the gear lever. - Release the magnetic flywheel wiring from its fastening on the chassis; disconnect the connector on the control unit (CDI) and the remaining wiring connectors.
- Remove the carburettor.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 01-04 REMOVING THE ENGINE FROM THE CHASSIS Ed: 07/05
- Remove the screws -arrows- fastening the engine to the chassis. - Loosen the screw fastening the cylinder head support to the chassis.
- Remove the screw -arrow- fastening the engine to the lower chassis. - Remove the nut -1-, remove swing arm and move backwards. - Position the engine ready for removal and then take off.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 FITTING THE ENGINE ON THE CHASSIS 02-01
- Fit the engine on the chassis and correctly position on the supports. - Line up swing arm with the engine and chassis, grease swing arm and fit. - Place engine fastening screws in supports. Note: The self-locking fastening nuts of the engine must be replaced with new nuts.
- Tighten all the nuts slightly and then to the specified torque: Nuts A B C D Tightening torque 38 to 48 Nm 24 to 29 Nm 38 to 48 Nm 66 Nm

- Replace the plastic covers on both sides of the motorcycle. - Fit the seat. Note: After the first stage of running in, check the oil and coolant levels, the chain tension and generally inspect the engine.
- Check no coolant is leaking from the radiator hoses.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 DISMOUNTING ENGINE
Prior instructions: Note: When dismounting the engine keep all the paired parts together. This includes gears, cylinders, pistons and other parts subject to natural wear in pairs. Paired components must always be replaced together. During the disassembly, clean all the parts and place them on trays in the order they are removed. This will accelerate assembly and ensure the correct installation of all the parts. Parts should be kept away from any source of fire. All gaskets, seals and O-rings should be replaced whenever the engine is dismounted partially or completely.
- Thoroughly clean engine before placing on work bench. - Place the motor on the bench. - Remove spark plug from cylinder head.
Dismantling the ignition - Undo the screws -arrows- of the ignition cover.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 03-02 DISMOUNTING ENGINE
- Block the magnetic flywheel. - Remove the nut -1-. Warning: The magnetic flywheel nut is loosened by turning to the left!
- Insert the extractor ref. ME25634045 on the internal thread of the magnetic flywheel. - Remove the magnetic flywheel by holding the extractor with a wrench while threading the screw. - Remove the pin from the crankshaft.
- Undo the screws -arrows- from the ignition stator and remove it with the wiring.
Dismantling the water pump - Undo the screws -arrows- of the water pump cover.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 DISMOUNTING ENGINE 03-03
- Block the turbine -1- of the water pump. - Undo the fastening screw -2- and remove the turbine from the water pump.

- Remove the complete seal -arrow- from the water pump.
Removing cylinder head and cylinder - Undo bolts -1- on the clutch disc cover and remove cover. - Undo bolts -2- on the clutch cover and remove cover. - Remove the clutch cover gasket.
- Undo the screws -arrows- of the exhaust valve right-hand cover.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 03-04 DISMOUNTING ENGINE Ed: 07/05
- Remove the fastening nut -1- from the operating lever and the nut -2- from the exhaust valve rod.
- Loosen screws -1- and remove thermostat cover. - Loosen cylinder head screws -2- in diagonal pairs and remove cover from cylinder. Note: If the cylinder head does not come off easily hit lightly with a plastic hammer.
- Remove inner and outer O-rings of the cylinder head.
- Undo the screws -arrows- of the exhaust valve left-hand cover.
- Remove the fastening nuts -arrows- from the cylinder to the crankcase, on both sides of the engine. - Remove the cylinder by lifting upwards. Note: If the cylinder does not come off easily hit lightly with a plastic hammer.
- Remove the cylinder gasket.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 DISMOUNTING ENGINE 03-05
Note: There may be more than one gasket.
- Mark the orientation of the piston towards the exhaust port using a permanent marker. - Place a clean cloth at the base of the cylinder to prevent the circlip from falling in the crankcase.
- Remove a circlip from the pin and take out the pin by pushing from the opposite end. Note: If necessary, gently tap the pin using a suitable tappet.
Dismantling the clutch Note: If the clutch is being removed in order to, for example, replace the discs, it is not necessary to remove the complete clutch cover. To access the clutch discs it is only necessary to remove the clutch disc cover.
Remove the screws -1- undoing in diagonal pairs. Remove the clutch springs and the rod bushings. Remove the clutch press -2-. Remove the set of clutch discs from the housing.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 03-06 DISMOUNTING ENGINE Ed: 07/05
- Open the safety catch -1- of the fastening nut of the clutch hub -2-. - Loosen the nut by holding the clutch hub. Warning: The clutch hub nut is loosened by turning to the left!
- Remove the lock washer and take out the clutch hub.
Note: The clutch hub has an assembly position with respect to the primary shaft. Mark the position using a permanent marker on the grease ring.
- Remove the clutch housing washer. - Remove the clutch housing.
- Remove the clutch housing bearings -1-, the bushing -2and the washer -3-.

- Immediately fit the inner ring of the bearing on the crankshaft, ensuring that the lower lip of the inner ring faces downwards. - Press on the inner ring until it is completely fitted onto the crankshaft. Crankshaft: outer dimension - Measure the distance between the crankshaft counterweights at opposite points. Maximum difference between faces 0.05 mm
Crankshaft: eccentricity - Measure the eccentricity of the crankshaft by placing it on the bench to check the crankshaft run out ref. MFS450450025. Maximum eccentricity 0.05 mm
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-03
Connecting rod Note: The bearing of the connecting rod big-end is replaced together with the crankshaft journal, the connecting rod and the spacer washers.
- Check the connecting rod small-end bearing and housing for seizure, signs of rolling and play.
- Measure the play of the connecting rod big-end by pushing it to one side and inserting a feeler gauge on the opposite side. Connecting rod big-end play STD: 0.80 mm Limit: 1.00 mm
Piston - Check the piston for scratches, signs of seizure and damage from overheating. - Check the grooves of the rings (cleanliness, absence of carbon deposits, breakage, etc). If necessary, clean with a wire brush that will not damage the piston surface. - Check that the locking pins of the rings are in their housing and are firmly seated. - Check that there is no excess play between the rings and the piston grooves. Piston: assembly play Note: The play at assembly of the piston is determined by subtracting the smallest cylinder diameter from the largest piston diameter.
Play of the piston at assembly

200 cc: 250 cc: 300 cc:

STD: 0.05 mm Limit: 0.10 mm STD: 0.055 mm Limit: 0.10 mm STD: 0.06 mm Limit: 0.10 mm
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-04 SERVICE AND REPAIR OF THE ENGINE COMPONENTS
Piston: opening at the end of the ring - Insert a piston ring in the cylinder, approximately 20 mm from the upper end. - Measure the distance between the ends of the ring -A- with a feeler gauge. Opening at the end of the ring 200 cc: 250 cc: 300 cc: STD: 0.3 mm Limit: 0.6 mm STD: 0.4 mm Limit: 0.7 mm STD: 0.5 mm Limit: 0.8 mm
Piston pin - Check the piston pin for seizure, signs of rolling and overheating. - Measure the diameter of the piston with a micrometer at three different points. Diameter of the piston pin STD: 17.994 mm Limit: 17.98 mm
Cylinder Cylinder: interior measurement - Check the cylinder for scratches, signs of seizure, notches or breakage in the intake or exhaust port. - Measure the diameter of the cylinder, approximately 20 mm from the upper end and in different places, in order to obtain an exact idea of the possible ovality of the cylinder. Cylinder diameter 200 cc: 250 cc: 300 cc: STD: 62.50 mm Limit: 62.60 mm STD: 66.38 mm Limit: 66.50 mm STD: 71.99 mm Limit: 72.10 mm

Cylinder Head - Check the cylinder support surface of the cylinder head is not damaged. - Thoroughly clean the interior of the cylinder head, which should be free of carbon deposits.
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-05
Operation of the exhaust valve
1. Screw aTightening torque: 6 Nm 2. Bearings 3. Washer 4. Left exhaust valve 5. Screw aTightening torque: 6 Nm 6. Exhaust valve lever 7. Exhaust valve bearing separator 8. Bearings 9. Exhaust valve bearing spacer 10. Right exhaust valve 11. Screw aTightening torque: 6 Nm 12. Short exhaust valve shaft 13. Central exhaust valve 14. Long exhaust valve shaft 15. Circlip 16. Pin 17. Centrifugal shaft 18. Centrifugal pinion
19. Centrifugal spring 20. Bearing plate 21. Exhaust valve needle cage 22. Centrifugal separator bearing 23. Needle bearing plate 24. Centrifugal hood 25. Centrifugal balls 26. O-ring 27. Centrifugal star 28. Pin 29. Bolts aTightening torque: 6 Nm 30. Rod and lever unit 31. Centrifugal lever shaft 32. Control shaft support 33. Centrifugal output lever 34. Screw aTightening torque: 6 Nm 35. Needle
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-06 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Dismantling - Undo screws -1- and -11-. - Take out the bearings -2- using an extractor tool together with the washer -3- and the left-side exhaust valve -4-. - Remove the long exhaust valve shaft -12-. - Release the right exhaust valve through the casing of the left exhaust valve -10-, the spacer -9- and the bearing -8tapping gently with a tappet. - Remove the short exhaust valve shaft -14- tapping the inside of the screw hole gently with a tappet either -1- or -11-. - Remove the central exhaust valve through the cylinder exhaust port. Note: To dismantle the centrifugal mechanism, first compress the spring -19- until the pin is released -16- and then remove the mechanism.
Testing Centrifugal shaft -17- Check that the centrifugal shaft does not show signs of seizure or rust. The housing -24- should slide along the shaft easily. Centrifugal pinion -18- Check that the pinion does not show signs of wear in the contact area of the teeth. Exhaust valve needle cage -21- Check that the needle cage does not show signs of seizure or stiffness on turning and that the plates -23- do not show signs of rolling. Centrifugal balls -25- Check the condition of the centrifugal balls. They should be spherical and should not show signs of wear or contact. Diameter of the centrifugal balls 8 mm

Needle -35- Check that it is firmly fastened to the centrifugal output lever -33-. Centrifugal output lever -33- Check that it is firmly fitted on the shaft of the centrifugal lever -31-. - If it is necessary to remove it, mark its position with respect to the shaft of the centrifugal lever -31-, e.g. with a permanent marker.
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-07
Valve control shaft support -32- Check that the shaft of the centrifugal lever -31- moves freely within the support. Exhaust valve bearings -2- and -11- Check that the exhaust valve bearings do not show signs of seizure or stiffness on turning. Note: The exhaust valve bearings must be replaced together.
Left exhaust valve -4-, central -13- and right -10- Check the valves for cracks, signs of seizure or damage from overheating. - Clean the valves of carbon deposits using a wire brush that does not damage the surface of the valves. Short exhaust valve shaft -14- and long shaft -12- Check the shafts for cracks, signs of seizure or damage from overheating. - Clean the shafts of carbon deposits using a wire brush that does not damage the surface of the valves.
Central exhaust valve assembly position -13- Fit the central exhaust valve with the curved surface facing the inside of the exhaust port.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-08 SERVICE AND REPAIR OF THE ENGINE COMPONENTS

Crankcase

1. Allen key 6x70 aTightening torque: 6 Nm 2. Left crankcase (outer side) 3. Cylinder studs 4. Crankcase centring bushing 5. Water intake sump plug 6. Fibre washer 14x20x2 7. Oil filler cap 8. Copper washer 9. Left crankcase (inner side) 10. Central crankcase gasket 11. Copper washer 8x12x1 12. Allen key 8x14 aTightening torque: 15 Nm 13. Oil cap O-ring 12x2 14. Oil drain cap with magnet aTightening torque: 9 Nm 15. Right crankcase 16. Clutch cover gasket 17. Clutch cover 18. Allen key 6x25 aTightening torque: 6 Nm
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-09
Right half crankcase, inner side - Remove the centring bushings -1- and the centring pin of the selector spring -2-.
- Before making any repairs to the right half crankcase, check the deformation to the same in the entire perimeter using a feeler gauge, both on the inside and the outside. Maximum deformation of half crankcase 0.05 mm
Note: To remove the bearings of the right half crankcase it should be heated to approximately 150 C using a heating plate, oven or similar. When it is hot, only a standard extractor tool is required, a soft metal or wooden rod, to completely remove the bearings. In exceptional cases it may be necessary to use a press to dislodge the bearings.

- Check the opening for lubricating the crankshaft bearing -arrow-. It should be free of obstruction and clean. Right half crankcase, outer side
- Take out the right crankcase seals using a seal extractor or by carefully levering with a screwdriver.
Note: All gaskets, seals and O-rings should be replaced whenever the engine is dismounted partially or completely.
- Place the right half crankcase on a heating plate and heat to approximately 150 C.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-12 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Danger: When handling the crankcase after heating it, heat-resistant gloves should be used to protect hands.
Centrifugal shaft bearing -1- Remove the ball bearing from the centrifugal pinion using a bearing extractor ( max. 8mm) from outside the half crankcase. - Fit the new ball bearing in the crankcase housing. The closed face of the bearing should face the inside of the opening of the casing. - Press down on the bearing until it fits completely in the right crankcase housing. Pinion shaft bearing of water pump -2- Remove the ball bearing from the water pump pinion shaft using a bearing extractor ( max. 8mm) from outside the half crankcase. - Fit the new ball bearing in the crankcase housing. The closed face of the bearing should face the inside of the opening of the casing. - Press down on the bearing until it fits completely in the right crankcase housing. Crankshaft seal -3- Fit the new crankshaft seal in the crankcase housing. The seal lip should face the outside of the crankcase. - Press down on the seal with a rod until it fits completely in the right crankcase housing. Warning: When fitting the seal take care not to damage the seal lip!
Starter ratchet plate -4- Remove the starter ratchet plate by undoing the screws -5-.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/3 2
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-13
- Fit the plate by applying thread-lock on the screws -5Centring bushings -6- Check the existence and condition of the centring bushings -6-. - Replace non-existent centring bushings where necessary. Note: If there are no centring bushings, a correct seal is not guaranteed when the crankcases are fitted.

Short -9- and long -11-fork shaft - Check the fork shafts for deformation. - Check the shafts for signs of wear or grooving. The forks should slide easily across the shafts. Maximum deformation of the fork shafts 0.05 mm
Forks -8- and -12- Check that the fork is neither damaged nor bent. - Check that the interior of the fork ride opening shows no signs of wear or grooving.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-24 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
- Check the play between the fork and its housing in the pinion. Play between the fork and. its housing in the pinion STD: 0.15 mm Limit: 0.25 mm
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-25
1. Primary shaft 2. Needle bearing K25-29-10 3. Primary pinion V 4. Washer 25.2x31.5x1 5. Circlip D25 recessed 6. Primary pinion III and IV 7. Primary pinion VI 8. Serrated washer 31.5x1 9. Primary gear II 10. Shift washer 18x31.5x0.7 11. Circlip D25 12. Secondary pinion II 13. Secondary shaft 14. Needle cage bearings KD22x25x9.8 15. Secondary pinion VI 16. Secondary pinion III 17. Secondary pinion IV 18. Secondary pinion V 19. Washer 20.8x29x1 20. Secondary pinion I 21. Needle bearings K20-24-10
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-26 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
- Check the contact surface of the bearings for seizure, signs of rolling and play. - Check the pinion teeth for wear or breakage. - Check the pinions and tracks are free of dirt. - Check that the lubrication grooves which include some pinions are free of dirt and metal particles. - After dismounting the parts of the cams, clean thoroughly and replace all the circlips.

VI III / IV

Primary cam -1- Thoroughly lubricate all the bearings when assembling.
Note: The assembly order of the pinions is: V - III / IV - VI speeds

VI III IV

Secondary cam -16- Thoroughly lubricate all the bearings when assembling. Note: The assembly order of the pinions is: II - VI III - IV speeds
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-27

Starter mechanism

1. Circlip D15 2. Washer 24x15.15x0.8 3. Interior starter pinion 4. Starter ratchet plate 5. Allen screws 5x15 aTightening torque: 6 Nm 6. Starter ratchet spring 7. Starter ratchet 8. Circlip D20 9. Stop washer 27x20.2x1 10. Starter pinion 11. Starter shaft 12. Washer 20x40x1 13. Starter spring 14. Starter shaft centring bushing
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-28 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Starter shaft -11- Check that the starter shaft teeth show no signs of excessive wear or contact marks. - Check the play of the shaft in the casing housing. - Check that the interior lubrication openings are clean and free of particles. Ratchet -7- Check that the ratchet teeth do not show signs of excessive wear. Starter pinion -10- Check that the pinion does not show signs of excessive wear or play. - Check that the starter pinion teeth show no signs of excessive wear or contact marks. Interior pinion -3- Check that the pinion does not show signs of excessive wear or play. - Check that the lubrication channels are clean and free of particles. - Check that the interior bushing of the pinion shows no signs of scratching or excessive wear.

SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-29

Reed valve

1. Allen screws 6x16 aTightening torque 6 Nm 2. Lower reed 3. Upper reed 4. Screws 5. Reed support 6. Reed valve gaskets 7. Reed spacing plate 8. Reed valve
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-30 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Reeds -2- and -3- Check the reeds for cracks or splitting and for signs of ageing. - Check that the reeds sit firmly one on top of another and are dry. Reed spacer plate -7- Check that the spacer -7- does not have any deformed surfaces. Reed valve -8 - Check that the supporting surfaces of the reeds are in perfect condition.
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-31

Ignition

1. Ignition rubber top 2. Allen screw 5x20 aTightening torque: 6 Nm 3. Flat washer 5x12x1.5 4. Magnetic flywheel Kokusan FP-8009 Multispark 5. Ignition Centring 6. Spark plug
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-32 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Ignition rubber top -1- Check that the ignition rubber top is in good condition. Magnetic flywheel Kokusan -4- Carry out the following tests using a multi-tester. Measurement Impulse coil Exciter Charge coil Colour of wires Red - Green Yellow - Earth White - Yellow Resistance 100 0.67 0.16 +/- 20% +/- 20% +/- 20% +/- 20%
Black/Red - Red/White 12.7
Note: All measurements must be taken at a temperature of 20 C. Otherwise significant errors may occur in the measurement values.
Spark plug -6- Check that the spark plug shows no signs of knocks or cracks - Check that the spark plug is free of carbon deposits and particles. - Check that the electrode is not over worn or burnt - Check the electrode distance with a feeler gauge. Electrode distance 0.7 to 0.8 mm
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 ASSEMBLING THE ENGINE 05-01
Notes: All the engine parts must be perfectly clean and in optimum conditions for commencing assembly. Before assembly, apply engine oil to all the moving and sliding parts.
- Place the right half crankcase on the workbench. Assembling the crankshaft - Lubricate the crankshaft bearing in the crankcase. - Insert the crankshaft in the crankcase bearing. - On the opposite side of the crankcase fit the O-ring and then the crankshaft seal bushing with the recessed side facing outwards. Assembling the selector rod and gears from the gearbox - Lubricate the bearings of the gear cams and of the desmodromic in the crankcase.

- Place the pinions of I and V gear -arrows-, the needle bearing and the adjustment washers in the crankcase.
Note: The 1st gear pinion should be positioned with the four notches -arrows- facing the crankcase.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 05-02 ASSEMBLING THE ENGINE 2 Ed: 07/05
- Carefully place together the gear cams of the primary -1and secondary -2- shafts.
- Place the pinion of 2nd gear -1- and the adjustment washer -2- on the primary gear cam. - Fit the desmodromic in the crankcase lining it up with the marks -arrows- made when dismounting.
- Position the forks -1- in the grooves of the gears and at the same time in the desmodromic grooves. - Next slide the shafts -2- (short) and -3- (long) across the forks to their housing in the crankcase.
Note: Check the transmission works correctly by turning the desmodromic by hand. Place the transmission gears in neutral position.
Joining the crankcases - Turn the bench so that the left-hand half of the crankcase is facing upwards and remove the nut fastening the engine to the bench. - Check that the contact surfaces of the left and right crankcases are perfectly clean - Fit the centring bushings in the left crankcase. - Position the new gasket. - Fit the right crankcase and gently tap with a plastic hammer until the two surfaces are joined together.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/1 ASSEMBLING THE ENGINE 05-03
Note: Remember to place the small gasket in the upper part of the crankcase -arrow-.
- Place the screws in the position shown in the diagram. Screws -1-: 70 mm Screws -2-: 60 mm Screws -3-: 65 mm - Adjust all the screws slightly and then tighten in diagonal pairs, starting at the centre. Tightening torque: 10 Nm - Check that the crankshaft and the transmission shaft turn smoothly, if this is not the case try to release the turn by tapping them with a plastic hammer. - Fit the chain pinion hub on the shaft. - Put the nut fastening the engine to the bench back again. - Check that there are no traces of the half crankcase sealant on the cylinder support surface.
Fitting the reed valve - Remove the remains of the crankcase gasket on the support surface of the reed box. - Place the reed box in its housing with the new gaskets. - Tighten the screws -arrows-. Tightening torque: 10 Nm Fit the dual-mass flywheel of the crankshaft

Note: The 200 cc engine is not fitted with a flywheel. The crankshaft pinion is fastened with a hexagonal screw.
- Fit the crankshaft pin, the flywheel, the crankshaft pinion, the bevelled washer and the nut on the crankshaft.
Note: The locking nut of the crankshaft is tightened to the left!
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 05-04 ASSEMBLING THE ENGINE Ed: 07/05
- Lock the rotation of the crankshaft pinion and tighten the nut -arrow-. Tightening torque: 40 Nm
Assembling the gear selector unit - Place the gear locking unit with the spring -arrow- slack and tighten the arrow -1 -. Use thread lock. Tightening torque: 6 Nm
- Position the spring -arrow- using pliers. - Fit the centring screw of the selector shaft -2-. Use thread lock. Tightening torque: 15 Nm
- Insert the selector shaft bushing and fit the complete selector shaft -arrow-.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/ASSEMBLING THE ENGINE 05-05
Assembling the starter pinion unit - Lubricate the housing of the starter shaft in the crankcase. - Insert the starter unit, ensuring that the ratchet is located between the plate and the casing. - Place the spring -1- in the opening in the crankcase using pliers. - Check that the centring bushing of the starter spring is positioned correctly. - Lubricate the bearing of the inner pinion of the starter. - Fit the inner pinion of the starter, the spacing washer and the circlip -2-.
Assembling the centrifugal operating system of the exhaust valve - Lubricate the centrifugal shaft bearing in the crankcase. - Fit the centrifugal mechanism -2- in the crankcase. - Fit the support -1- ensuring that the output lever is correctly located in the groove of the mechanism. - Tighten the screws -arrows-. Use thread lock. Tightening torque: 10 Nm - Fit the water pump shaft and pinion.
Assembling the clutch - Check that the primary shaft is clean and particle-free. - Fit the washer -3-, the bushing -2- and the clutch housing bearings -1-. - Lubricate the clutch housing bearings.
- Fit the clutch housing and then the washer -arrow-. Note: When fitting the clutch hub note the assembly position with respect to the mark made when dismounting.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 05-06 ASSEMBLING THE ENGINE Ed: 07/05
- Fit the clutch hub, the new lock washer and the fastening nut. - Hold the clutch hub down and tighten the fastening nut. Use thread lock. Tightening torque: 40 Nm
- Close the catch of the lock washer -1-. - Check that the clutch discs are perfectly clean and lubricate all the discs. - Insert the iron discs and the covered discs alternately in the clutch hub, beginning and ending with a covered disc.

- Lubricate the rod bearing and fit the clutch press -2-. - Place the screws -1- with their bushings and springs and tighten them in stages in diagonal pairs. Use thread lock. Tightening torque: 10 Nm Assembling the cylinder and cylinder head - Check that the piston and pin are clean. - Lubricate the connecting rod small-end bearing. - Position the piston with the arrow marked on the head facing the exhaust port.
Note: Before fitting the pin circlip cover the crankcase opening with a clean cloth.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 ASSEMBLING THE ENGINE 05-07
- Insert the pin through the piston and the bearing of the connecting rod small-end, and then fit the new circlip -arrow-. - Fit the piston rings with the manufacturers inscription facing upwards. - Fit the gaskets at the foot of the cylinder. - Carefully fit the cylinder, making sure that the rings are centred with the locking pins of the piston grooves. - Fit the four cylinder nuts and adjust slightly. - Adjust the four nuts at the foot of the cylinder in diagonal pairs. Tightening torque: 25 Nm - Place the exhaust valve operating rod -1-. Replace the nuts -2- with new ones and tighten them. Tightening torque: 8 Nm - Test the working of the entire exhaust valve system. Note: If it is necessary to make adjustments, loosen the screw of the centrifugal mechanism lever -3- and place the lever-rod unit in the desired position.
- Fit the new O-rings on the upper part of the cylinder. - Check that the support surface of the cylinder head is perfectly clean.
- Place the cylinder head and tighten the screws -2- in diagonal pairs. Use thread lock. Tightening torque: 25 Nm - Check that the support surface of the thermostat cover is perfectly clean. - Fit the thermostat cover with a new gasket and tighten the screws -1-. Use thread lock. Tightening torque: 10 Nm
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 05-08 ASSEMBLING THE ENGINE Ed: 07/05
- Fit the right cover of the exhaust valve with a new gasket and tighten the screws -arrows-. Tightening torque: 8 Nm

- Fit the left cover of the exhaust valve and tighten the screws -arrows-. Tightening torque: 8 Nm
Fitting the clutch cover - Fit the new gasket of the clutch cover. - Fit the clutch cover and tighten the screws in diagonal pairs. Screws -1-: 30 mm Screws -2-: 35 mm Screws -3-: 55 mm Tightening torque: 10 Nm - Fit the clutch disc cover with a new gasket and tighten the screws in diagonal pairs. Screws 4: 25 mm Screws 5: 75 mm Tightening torque: 10 Nm Assembling the water pump - Fit the new seal of the water pump -arrow- on the clutch cover.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 ASSEMBLING THE ENGINE 05-09
- Position the turbine -1- of the water pump and fit the fastening screw -2-. - Block the rotation of the turbine and tighten the screw -2-. Use thread lock. Tightening torque: 6 Nm
- Fit the cover of the water pump and tighten the screws -arrows-. Tightening torque: 6 Nm
Assembling the ignition - Fit the pin from the crankshaft. - Position the ignition stator and the screws -arrows-, noting the location of the ignition centring washer -1-. - Tighten the screws -arrows-. Use thread lock. Tightening torque: 8 Nm - Ensure that the rubber tops -2- are correctly fitted.
- Fit the magnetic flywheel and tighten the nut -1-. Use thread lock. Tightening torque: 40 Nm
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 05-10 ASSEMBLING THE ENGINE Ed: 07/05
- Fit the ignition cover with a new gasket and tighten the screws -arrows-. - Fit the spark plug in the cylinder head. Warning: The spark plug should always be handthreaded to the limit and then adjusted with a spark plug wrench without over-tightening! Tightening torque: 27 Nm
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 ELECTRICAL SCHEMAS 06-01
C/ Unicef, 17 - Polgon Industrial Torremirona - 1719 Salt (Girona) SPAIN TEL +54 / FAX + 60

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