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GAS GAS Ec 300

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Comments to date: 8. Page 1 of 1. Average Rating:
mdkmemphis 3:18am on Thursday, September 9th, 2010 
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matcauthron 8:03pm on Tuesday, June 1st, 2010 
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nich008 2:27pm on Saturday, May 22nd, 2010 
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sharr 11:27pm on Saturday, April 3rd, 2010 
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Documents

doc0

WORKSHOP MANUAL / WERKSTATTHANDBUCH

MOTOR EC Enducross

200 / 250 / 300

INTRODUCTION

This manual was created by GAS GAS Motos, S.A. for the use of official GAS GAS services. It is principally directed at operators with a basic knowledge of the principles of mechanics and repair techniques. It contains precise instructions for making all the repairs, in addition to the necessary technical data to carry out the maintenance of the motorbikes. There is also considerable information about the special GAS GAS tools and equipment that will be of great help in optimising repair processes. In successive editions, we will keep you informed of all the updates and evolution of the motorbikes in this family. Particularly important information in the manual is preceded by one of the following symbols.
Note: indicates points of particular interest for more efficient and convenient operation. Warning: indicates special instructions or procedures which should be followed to the letter to avoid damaging the equipment. Danger: indicates special instructions or procedures which must be followed to the letter to avoid physical injury to the operators.

GAS GAS Motos, S.A

CONTENTS
Sect. P. IV VI GENERAL INFORMATION TABLE OF TECHNICAL DATA REMOVING THE ENGINE FROM THE CHASSIS FITTING THE ENGINE ON THE CHASSIS DISMOUNTING ENGINE SERVICE AND REPAIR OF THE ENGINE COMPONENTS ASSEMBLING THE ENGINE ELECTRICAL SCHEMAS
GENERAL INFORMATION Certain safety and maintenance norms should be remembered when carrying out repairs to the vehicles. Some of the more important norms are listed below: Safety - Do not smoke or cause sparks or naked flames in the work area. Petrol is highly inflammable and may be explosive in certain conditions. - Use cleaning products appropriate to each task, ensuring that they have been approved. - Always wear protective eye equipment when using electric tools such as drills, sanders or grinders. - Apply a protective hand cream before commencing dismantling work. This protects the skin from infection and makes subsequent cleaning easier. Ensure that hands are not slippery. - Remember that prolonged contact of the skin with engine oil can be damaging to health. - Keep loose clothing away from moving parts. - Do not wear rings, wristwatches, etc while working on the engine, especially the electrical system. - Keep the work area tidy, it is easy to trip over elements left on the floor. - Avoid leaving oils, grease or other fluids on the floor of the work area to avoid slipping on them. - Use suitable tools for compressing or decompressing springs to prevent these from escaping suddenly. - Take special care not to inhale dust from parts containing asbestos (for example: clutch discs), this product is extremely dangerous for your health. - Avoid inhaling fumes from petrol or cleaning fluids, these can be highly toxic. Ensure that the work area is well-ventilated. Maintenance - Always use original GAS GAS spare parts and lubricants recommended by the manufacturer. Other spare parts may damage the engine. - Only use the tools specified for this vehicle. - Always replace all the gaskets, seals and O-rings during service and assembly. - After dismounting, clean components with non-inflammable dissolvent. - Lubricate all work surfaces before assembly, except the conical couplings. - Oil all the paired parts and bearings when assembling. - When removing, servicing and assembling parts, only use metric-sized tools. Metric screws, nuts and bolts are not interchangeable with parts with Imperial measurements. - All the surfaces receiving gaskets, seals and O-rings must be carefully cleaned. - Carefully examine all the circlips before assembly and replace any which are damaged. Always replace the piston pin circlip after each use. - After assembly check all the components are correctly fitted and the mechanisms are working perfectly.
General tightening torques The following table specifies tightening torques for nuts or bolts with ISO threads. Tightening torques for components or special units are given in the relevant repair process described in this manual. To avoid damage, tighten units with various nuts or bolts progressively and in diagonal or alternate pairs, until obtaining the specified torque. To apply the tightening torques described below, clean, dry threads are necessary. Components should be at room temperature. GENERAL TIGHTENING TORQUES Nm 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 26 mm Kgf.m 0,6 1,5 3,0 5,5 8,5 13,0 Ft.lb 4,61 94

*(A) NUT

*(B) BOLT
*A: Distance between the nut faces. *B: External diameter of screw thread. Engine serial number The engine serial number is stamped on the lower part of the left crankcase.
Remember to quote the engine serial number each time you place an order for an original GAS GAS spare part for said engine.
TABLE OF TECHNICAL DATA Engine Definition Mono-cylindrical 2-stroke engine, liquid-cooled, intake to crankcase Displacement in cubic centimetres 200 Engine: 199.4cc 250 Engine: 249.3cc 300 Engine: 294.7cc Fuel RON / SUPER-LEAD-FREE 95-98 octane. Mixed with SYNTHETIC 2T oil Mixture ratio 100% synthetic oil: petrol 50: oil 1 (2%) Petrol / oil semi-synthetic oil: petrol 40: oil 1 (2.5 %) Bore and stroke 200 Engine: 62.5 x 65 mm 250 Engine: 66.4 x 72 mm 300 Engine: 72 x 72 mm Spark plug NGK BR8EG Electrode separation 0.7 - 0.8 mm Ignition timing 1 mm BTDC Piston rings: quantity 2 rings Starter system Kick-start pedal System Circuit capacity Mix ratio Liquid-cooled, with impulse pump 1.1 litres Distilled water: 50% Antifreeze: 50 % Carburetion KEIHIN PWK litres Gravity Dry air filter CDI system 12 V / 110 W 6-speed cascade Oil bath, multi-disk hydraulic action By chain 2.071 (29/14) 1.625 (26/16) 1.333 (24/18) 1.100 (22/20) 0.913 (21/23) 0.791 (19/24) 200 cc: 3.22 (58/18); 250 - 300 cc: 2.85 (57/20) 3.615 (47/13) 200 cc: 9.21; 250 - 300 cc: 8.149 10W30 API SF or SG 900 cc
System Carburettor Fuel tank Fuel supply Air filter Ignition system Voltage / Power Transmission Clutch Secondary transmission Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Primary reduction ratio Final reduction ratio Overall drive ratio (6th gear) Oil type Oil capacity
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 REMOVING THE ENGINE FROM THE CHASSIS 01-01
Note: The cylinder head, the cylinder, the clutch and the ignition, can be removed without dismounting the engine from the chassis.
- Thoroughly clean the motorcycle before starting to dismantle the engine. - Place the motorcycle on a support suitable for work. - Remove the seat.
- Dismantle the plastic covers on both sides. - Remove the fuel tank.
- Remove the lever from the kick-start pedal - arrow-.

- 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
- Assemble the carburettor. - Place the magnetic flywheel on the chassis and fasten correctly. - Connect the control unit connector and the remaining wiring connectors.
- Assemble the gear lever. Tightening torque: 15 Nm Note: The chain pinion must be fitted in the same position as when it was removed to ensure the same direction of wear.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 02-02 FITTING THE ENGINE ON THE CHASSIS Ed: 07/05
- Place the chain pinion -2- on the secondary shaft and fit the circlip -1-. - Fit the clutch rod -arrow-.
- Fit the hydraulic clutch calliper with a new gasket, fit the chain pinion guard and tighten screws -arrows-. Tightening torque: 6 Nm - Tension the chain. - Assemble the back brake pedal and the back brake pump guard. Tightening torque: 29 Nm Note: Check that the coolant pipes are not cut or worn.
- Connect the spark plug connector -arrow- and connect the coolant pipes on both sides of the engine. Note: Ensure that the coolant drain plug in the water pump is screwed in tightly and has a new seal.
Tightening torque: 9 Nm - Disconnect the coolant recirculation pipe. - Fill the coolant system through the left radiator cap. Mixture of coolant and distilled water: 1:1 (antifreeze 50%, distilled water 50%). Capacity 1.1 litres. Note: Ensure that the transmission oil drain plug is tightened and has a new gasket.

Tightening torque: 20 Nm

Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 FITTING THE ENGINE ON THE CHASSIS 02-03
- Remove the oil filler cap -arrow- and fill with new transmission oil. Viscosity: 10W30 Capacity 900 cc - Fit the oil filler cap with a new gasket and tighten.
- Pump the starter pedal 3 or 4 times and check the oil level through the indicator -arrow-. - Apply Nural 29 to the exhaust system unions.
- Fit the complete exhaust system and tighten screws slightly.
- Check the condition of the O-rings of the exhaust; if they are deteriorated, replace them. - Correctly fit the springs holding the exhaust pipe to the cylinder pipe. - Tighten the exhaust system screws. Tightening torque: 6 Nm
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 02-04 FITTING THE ENGINE ON THE CHASSIS Ed: 07/05
- Fit the kick-start pedal lever, apply Loctite 243 to the screw -arrow- and then tighten. - Tightening torque: 20 Nm - Fit the fuel tank and the vent hose. - Check the condition of the air filter. If it is damaged, replace with a new one. If it is undamaged, clean and refit (see user manual).

- 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.

- 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

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.
- 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. Danger: When handling the crankcase after heating it, heat-resistant gloves should be used to protect hands.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-10 SERVICE AND REPAIR OF THE ENGINE COMPONENTS
- Remove the right crankcase bearings.
Crankshaft bearing -1- Remove the ball bearing from the crankshaft by pressing from the outside of the crankcase inwards. - Fit the new ball bearing in the crankcase housing. The stamped face of the bearing should face the inside of the crankcase. - Press on the new ball bearing until it fits level with the inner surface of the crankcase.
Primary cam bearing -2- Remove the ball bearing from the primary cam by pressing from the outside of the crankcase inwards. - Fit the new ball bearing in the crankcase housing. The closed face of the bearing should face the outside of the crankcase. - Press down on the bearing until it fits completely in the right crankcase housing.
Warning: When removing and fitting the ball bearing take care not to apply excessive pressure on the casing area of the bearings. If too much pressure is applied the crankcase may be damaged!
Secondary cam bearing -3- Remove the ball bearing from the secondary cam by pressing from the outside of the crankcase inwards. - Fit the new ball bearing in the crankcase housing. The stamped face of the bearing should face the inside of the crankcase. - Press down on the bearing until it fits completely in the right crankcase housing.
Desmodromic bearing -4- Remove the needle bearing from the desmodromic by pressing from the outside of the crankcase inwards. - Fit the new needle bearing in the crankcase housing. The stamped face of the bearing should face the inside of the crankcase. - Press down on the bearing until it fits completely in the right
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-11

crankcase housing.

Warning: Be careful when removing and fitting the needle bearings so as not to put too much pressure on the bearing housings. If too much pressure is applied, the crankcase could be damaged!
- Check the opening for lubricating the crankshaft bearing -arrow-. It should be free of obstruction and clean. Right half crankcase, outer side

Left half crankcase, inner side - Before making any repairs to the left half crankcase, check the deformation to the same in the entire perimeter on the inside using a feeler gauge. Maximum deformation of half crankcase 0.05 mm
Note: To remove the bearings of the left 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.
- Take out the left 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 left half crankcase on a heating plate and heat to approximately 150 C.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-14 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
- Remove the left crankcase bearings.
Crankshaft bearing -1- Remove the ball bearing from the crankshaft using a bearing extractor (max. 38 mm) from the inside of the crankcase inwards. - Fit the new ball bearing in the crankcase housing. The stamped face of the bearing should face the inside of the crankcase. - Press on the new ball bearing until it fits level with the inner surface of the crankcase. Primary cam bearing -2- Remove the ball bearing from the primary cam by pressing from the outside of the crankcase inwards. - Fit the new ball bearing in the crankcase housing. The stamped face of the bearing should face the outside of the crankcase. - Press down on the bearing until it fits completely in the left crankcase housing. Warning: When removing and fitting the ball bearing take care not to apply excessive pressure on the casing area of the bearings. If too much pressure is applied the crankcase may be damaged!
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-15

Warning: Be careful when removing and fitting the needle bearings so as not to put too much pressure on the bearing housings. If too much pressure is applied, the half crankcase could get damaged!
Desmodromic bearing -4- Remove the needle bearing from the desmodromic using a bearing extractor ( max. 25 mm) from the inside of the crankcase inwards. - Fit the new needle bearing in the crankcase housing. The stamped 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 left crankcase housing.
Warning: When removing and fitting the needle bearing take care not to apply excessive pressure on the casing area of the bearings. If too much pressure is applied the crankcase may be damaged!
- Check the opening for lubricating the crankshaft bearing arrow-. It should be free of obstruction and clean. Left crankcase, outer side Note: All gaskets, seals and O-rings should be replaced whenever the engine is dismounted partially or completely.
Crankshaft seal -1- 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 left crankcase housing. Warning: When fitting the seal take care not to damage the seal lip!
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-16 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Output shaft seal -2- 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 flat in the left crankcase housing. Warning: When fitting the seal take care not to damage the seal lip!
Selector shaft seal -3- Fit the new selector shaft 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 left crankcase housing. Warning: When fitting the seal take care not to damage the seal lip!
Clutch cover - Before any repairs to the clutch cover check the deformation on the inside using a feeler gauge. Maximum deformation of clutch cover 0.05 mm
Note: To remove the bearings of the clutch cover 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.
- Take out the clutch cover seals using a seal extractor or by carefully levering with a screwdriver.
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-17

Covered clutch discs -17- Check the thickness of the covered clutch discs. Thickness of the covered clutch disc STD: 2.75 to 2.85 mm Limit: 2.68 mm
Iron clutch discs -18- Check the condition of the clutch disc for scratches and warping or deformation. Maximum deformation of the iron clutch plate 0.05 mm
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-21
- Check the thickness of the iron clutch disc. Thickness of the clutch disc Limit: 1.45 to 1.55 mm Limit: 1.40 mm
Clutch rod -7- Check the clutch rod deformation. Maximum deformation of the clutch rod 0.05 mm
Clutch hub -8- Check that the clutch disc housings -arrow- are not out of line due to excessive wear. - Check the condition and the contact surface -1- with the clutch discs for scratches and excessive wear. - Check that the oil circulation openings -2- are free from dirt and metal particles.
Clutch housing crown -13- Check the contact surface of the bearing -1- for seizure, signs of rolling and play. - Check on both sides that the lubrication grooves -2- are free from dirt and metal particles. - Check there is no play between the housing -3- and the crown -4-. - Check that the clutch disc housings -arrow- are not out of line due to excessive wear. Clutch housing bearings -12- Check the clutch housing bearings and the bushing for seizure, signs of rolling and play.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-22 SERVICE AND REPAIR OF THE ENGINE COMPONENTS

Gearshift mechanism

1. Desmodromic bearing 2. Allen key 6x25x8.8 aTightening torque: 6 Nm 3. Flat washer 6x16x1.5 4. Gear locking spring 5. Gear lock plate bushing 6. Gear lock 7. Desmodromic 8. Fork V-VI 9. Short fork shaft 10. Desmodromic bearing HK3512 11. Long fork shaft 12. Forks I-II-III-IV 13. Centring pin selector shaft 14. Selector shaft bushing 15. Selector shaft 16. Scorpion spring 17. Scorpion 18. Scorpion guide bushing 19. Selector spring
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-23
Selector shaft -15- Check that the selector shaft shows no signs of excessive wear or contact marks. - Check that the selector rod bushing -14- is in good condition and without excess play. Scorpion guide bushing -18- Check that the guide bushing does not show signs of excess wear in the contact area with the scorpion -17-.

Selector shaft assembly - Insert the selector shaft bushing -14- at the end. The assembly position should be with the conical side -arrow- facing the side opposite the scorpion -17-. - Insert the scorpion guide bushing -18- in the end of the selector shaft -15-. - Insert the scorpion -17- in the selector shaft guide. - Place the selector spring -19- on the shaft support and support the lower foot (straight foot) on the end. - Using pliers, pass the upper foot (curved foot) over the end until it is supported on the opposite side to the lower foot. - Insert the ends of the scorpion spring -16- on the supports of the selector shaft -15-and of the scorpion -17-. Gear lock -6- Check that the bearing at the end of the lock is in good condition, turns easily and does not show signs of excess play. Desmodromic -7- Check the rolling tracks of the desmodromic bearings -1for seizure, signs of rolling and play. - Check the inside of the desmodromic channels for dirt and particles and make sure the channels are not excessively worn.
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.

- 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

www.gasgasmotos.es

PU010638016

doc1

DESPIECE PART LIST

ENDUCROSS EC/MC/SM

250 300

Manillar / Handlebar

EC/MC/SM 2006

Elctricos / Electric

Plsticos / Plastics

EC/SM 2006
Plsticos / Plastics MC 2006
Chasis / Frame EC/MC/SM 2006
Filtro de aire / Air filter EC/MC/SM 2006
Basculante / Swingarm EC/MC/SM 2006
Tubo escape / Exhaust EC/MC/SM 2006
Adhesivos / Decals EC/MC 2006

Adhesivos / Decals

SM 2006

Depsiot / Fuel tank

Rueda delantera / Front Wheel
Rueda delantera / Front Wheel SM 2006
Rueda trasera / Rear Wheel EC/MC 2006
Rueda trasera / Rear Wheel SM 2006
Suspensin MARZOCCHI MARZOCCHI Fork
EC/MC/SM 2006 Suspensin HLINS / HLINS Fork EC/MC/SM 2006
Suspensin MARZOCCHI MARZOCCHI Fork 50

CROSS 250

21 21A

/ 9A 8

26A / 26B

4A 9 9A 16 16A A 26 B 33

DESCRIPCIN / DESCRIPTION
JUEGO DE EMPUADURAS / C798HANDLEBAR GRIP (PAIR) PUO DE GAS / TWIST GRIP CABLE DE GAS / THROTTLE CABLE MANILLAR COMPLETO / STEERING HANDLEBAR SET MANILLAR DIMETRO VARIABLE / VARIABLE DIAMETER HANDLEBAR TAPA BOMBA FRENO / BRAKE PUMP COVER TORNILLO TAPA BOMBA / BRAKE PUMP SCREW GOMA ANTIESPUMANTE / NO-FOAM RUBBER TORNILLO ESPECIAL / SPECIAL SCREW MANETA FRENO DELANTERO / FRONT BRAKE LEVER MANETA FRENO TT 250 / FRONT BRAKE TT 250 TENSOR MANETA BOMBA / PUMP LEVER TENSOR GUARDAPOLVO / DUST COVER TORNILLO ALLEN 6X35 / 6X35 ALLEN SCREW ARANDELA LATIGUILLO 10X14X1 / HOSE WASHER 10X14X1 LATIGUILLO FRENO DELANTERO / FRONT BRAKE HOSE INTERRUPTOR STOP BOMBA / PUMP STOP SWITCH BRIDA SUJECIN MANILLAR INFERIOR / HANDLEBAR CLAMP (LOWER) CTO. SOP. MANILLAR DIMETRO VARIABLE / VARIABLE DIAMETER HANDLEBAR SUP. SET KIT PISTN BOMBA FRENO A / A BRAKE PUMP PISTON KIT TORNILLO ESPECIAL 10X45 / 10X45 SPECIAL BOLT DISTANCIADOR BRIDA INFERIOR MANILLAR EC2003 / CLAMP HANDLEBAR SPACER TUERCA CILINDRO 8.8 ESP. 10/150C13 / NUT CYLINDER M10 CONMUTADOR LUZ / LIGHT SWITCH LATIGUILLO EMBRAGUE / CLUTCH HOSE ARANDELA / WASHER TORNILLO REGULACIN MANETA / ADJUSTING LEVER SCREW SOPORTE BOMBA EMBRAGUE / CLUTCH PUMP CLAMP MANETA EMBRAGUE CORTA / SHORT CLUTCH LEVER MANETA EMBRAGUE LARGA (SERIE) / LONG CLUTCH LEVER (STANDARD) TUERCA M6 BAJA / M6 LOW NUT BOMBA EMBRAGUE HIDRULICO / HYDRAULIC CLUTCH PUMP KIT TAPA BOMBA FRENO EMBRAGUE / CLUTCH BRAKE PUMP COVER KIT ESPEJO RETROVISOR / REAR-VIEW MIRROR BRIDA SUJECIN MANILLAR SUPERIOR / HANDLEBAR CLAMP (UPPER) TORNILLO SUJECIN BRIDA MANILLAR 8X30 / CLAMP SCREW 8X30 BOMBA FRENO DELANTERO / FRONT BRAKE PUMP SET
BE250236002 BE25724007 BE25724008 BE250624001 BE250524001RC BC25922210 BC25922217 BC25922216 BC25922212 BC250022045 BC250022045R BC25922218 BC25922213 BE25622007 BE250422002 BE250334003 BE250614013 BE250514012RC BC25922219 T0201045 BE250314035 M01613001 BE250534001 BE250522003 BT27922046 BE250022211 BT27922040 E200701 T2006001 BE250522009 BE250522210 L300760 BE250614012 T0308030 BC25922008
BE250122045SM T0306035 BE250522002SM T4006018 BE250122008SM

Chasis 1

33A 43A 50
BOMBA FRENO DELANTERO PURGADA / FRONT BRAKE PUMP SET KIT REPARACIN / REPARATION KIT ABRAZADERA MUELLE / S PRING CLAMP BRIDA / CLAMP BRIDA GRANDE / BIG CLAMP BRIDA PEQUEA / LITTLE CLAMP GUARDAPOLVO CABLE GAS / DUST COVER THROTTLE CABLE TUBO LQUIDO FRENO A BOMBA / BRAKE TO PUMP LIQUID HOSE DEPSITO LIQUIDO FRENOS SM / SM BRAKE FLUID TANK CASQUILLO TAPA RADIADOR ALUMINIO / ALUMINIUM RADIATOR COVER BUSHING CTO. EMBRAGUE ACEITE COMPLETO C18 / COMPLETE OIL CLUTCH PUMP CTO. EMBRAGUE ACEITE COMPLETO / COMPLETE OIL CLUTCH PUMP BRIDA UNEX CORTA 2221-0 2.5X98 / SHORT UNEX CLAMP 2221-0 2.5X98 ARANDELA 10X14X2.3 / WASHER 10X14X2.3 PROTECTOR MANILLAR DIMETRO VARIABLE / VARIABLE DIAMETER HANDLEBAR PROTECTOR GOMA SUJECIN CABLEADO / CABLED RUBBER HOLDER INTERRUPTOR CDI / CDI SWITCH
BE250422108 BT27722208 BC25922211 BE25634009 BE25634010 G600000 BE250622005 BE120622005 BE25634010 T4001014 BE250524004RC BFS450320067 BE250634007
BE250522108SM BT27710120 R361700 BFS400310116SM BE250110016SM BE250026000 BE250634007
Solo Motocross MC / Only Motocross MC bike

15 21A 33A 50

RACORD 10X125 / 10X125 RACORD BOTN DE PARO KE9B / KE9B STOP BUTTON CTO. BOMBA FRENO DELANTERO / FRONT BRAKE PUMP SET PROTECCIN MANILLAR / HANDLEBAR STEERING PROTECTION BRIDAS SERRETAS / CLAMP INTERRUPTOR CDI / CDI SWITCH
BC25722006 BC250334055 BC250422108 BE250624004 BE25634007 BE250634007

Elctrico / Electric

13 / 13A 19 24

1 1A 13A 36

CTO. MULTIFUNCIN ENDURO / ENDURO MULTIFUNCTION SET CTO. MULTIFUNCIN SM / SM MULTIFUNCTION SET PASACABLES CTA. KMS. / SPEED CABLE HOSE BOMBILLA 12V1,2-9W / BULB 12V1.2-9W PTICA HALGENA / HALOGEN OPTIC BOMBILLA HALGENA HS1 12V35- 35W / HS1 12V35-35W HALOGEN BULB INTERMITENTE IZQUIERDO DELANTERO / LEFT FRONT INDICATOR INSTALACIN ENDURO 2005 / 2005 ENDURO INSTALLATION INSTALACIN XC / XC INSTALLATION ESPUMA PROTECTOR CDI EC 2005 / EC 2005 CDI PROTECTOR FOAM PIPA BUJA LBMH / SPARK PLUG CAP LBMH BOBINA KOKUSAN / KOKUSAN IGNITION COIL CRISTAL FARO TRASERO / REAR LIGHT CAP BOMBILLA 12V5-21W / 12V5-21W BULB CASQUILLO BOBINA / I GNITION COIL BUSHING INTERMITENTE DERECHO TRASERO / RIGHT REAR INDICATOR TUERCA AUTOBLOCANTE BAJA M6 / SELF-LOCKING M6 NUT CLAXON / HORN CAJA INTERMITENCIAS / I NTERMITENT BOX BRIDA UNEX 4,8X20 / UNEX CLAMP 4.8X20 CDI KOKUSAN / KOKUSAN CDI FARO PILOTO / REAR LIGHT SET GOMA SUJECIN CDI / CDI ELASTIC BAND TORNILLO CHAPA / SPECIAL SCREW SOPORTE INTERMITENTE DEL. DER. / RIGHT FRONT INDICATOR HOLDER SOPORTE INTERMITENTE DEL. IZDO / LEFT FRONT INDICATOR HOLDER BRIDA UNEX CORTA 2221-0 2.5X98 / SHORT CLAMP 2221-0 2.5X98 TORNILLO ESPECIAL 6X25 VALONA 11mm / SPECIAL SCREW 6X25 TORNILLO 6X30 / SCREW 6X30 BUJA W24ESRU / PLUG W24ESRU ADAPTADOR CALBE CDI / CDI CABLE ADAPTOR BOMBILLA LUZ POSICIN / SIDELIGHT BULB

BE250228031 BE250128025 BE250128027

Chasis 4

UERCA HEXAGONAL REMACHABLE M6 / REVITABLE M6 NUT JUEGO PARAMANOS HP20 / HANDS-PROTECTOR SET TORNILLO ESPECIAL 6X25 / 6X25 SPECIAL SCREW ARANDELA PLACAS RADIADOR EC 2005 / EC 2005 RADIATOR PLATE WASHER GOMAS RADIADOR A CHASIS / RADIATOR RUBBER MUELLE DZUS / DZUS SPRING
T2706000 BTL400220034GC T0206025 BE250511002 G200000 BE250528047

Chasis / Frame

7 60A 9 / 9A 30 6A 14 36

6A 9 9A 36

TUERCA DIRECCIN / STEERING SHAFT NUT ALLEN 7X30 / 7X30 ALLEN BOLT BRIDA SUSPENSIN SUPERIOR / FORK CLAMP (UPPER) TUERCA DIRECCIN INFE. / LOWER STEERING SHAFT NUT GUARDAPOLVO COJINETE DIRECCIN / BEARING DUST COVER COJINETE DIRECCIN / STEERING BEARING COJINETE DIRECCIN / STEERING BEARING TRICA DIRECCIN 50X5 / STEERING ORING PROTECTOR CHASIS DERECHO / RIGHT FRAME PROTECTION BRIDA SUSPENSIN INFERIOR MZ / MZ FORK CLAMP (LOWER) BRIDA SUSPENSIN INFERIOR OH / OH FORK CLAMP (LOWER) TIJA DIRECCIN / STEERING SHAFT PASADOR DIN 660 6X22 / DIN 660 6X22 BRAKE PIN MUELLE PUNTERA PEDAL RETRCTIL / BRAKE PEDAL END SPRING PUNTERA PEDAL FRENO / BRAKE PEDAL END PROTECTOR CHASIS IZQUIERDO / LEFT FRAME PROTECTION MUELLE PEDAL FRENO / BRAKE PEDAL SPRING TUERCA AUTOBLOC. ARANDELA M8 / M8 SELF-LOCKING NUT WITH WASHER TIRANTE CULATA / CYLINDER HEAD BRACE TORNILLO ESPECIAL 8X65 FIL.20 8.8 / 8X65 SPECIAL SCREW TORNILLO ESPECIAL 8X70 FIL.20 / 8 X 70 SPECIAL SCREW GLACIER PEDAL FRENO / BRAKE PEDAL BEARING TRICA PEDAL ARRANQUE D 11X2 / 11X2 KICKSTART ORING TORNILLO MOTOR 10X118 / 10X118 ENGINE BOLT ESTRIBO DERECHO / RIGHT FOOTREST MUELLE ESTRIBO DERECHO / RIGHT FOOTREST SPRING MUELLE ESTRIBO IZQUIERDO / LEFT FOOTREST SPRING CASQUILLO ESTRIBO / FOOTREST BUSHING CLAVILLA ZINC 3X35 / 3X35 ZINC PIN CHASIS ENDURO EC2005 / ENDURO FRAME TORNILLO ESPECIAL 8X25 / 8X25 SPECIAL SCREW TUERCA AUTOBLOCANTE M8 BAJA / LOW M8 SELF-LOCKING NUT TORNILLO ESPECIAL 8X20 / SPECIAL SCREW 8X20 MUELLE EXTERIOR CAVALLETE / SUPPORT OUTER SPRING CASQUILLO ANTIRROBO EJE DIRECCIN / STEERING AXLE ANTI-THEFT BUSHING FUNDA CLIP 1X70 CHASIS / CHASSIS CLIP SLEEVE 1X70 BRIDA UNEX 2274 4.8X20 / 2274 UNEX CLAMP 4.8X20 BRIDA UNEX 2274 4.8X36 / 2274 UNEX CLAMP 4.8X36

BE120610000 -

BE200510050 -

250 / 250 / 300

BE25610030 T0307030 BE250414001 BE25610029 BE25610126 BE25610008 BE250610008 BE25610012 BE250520030 BE250614002 BE250414002OH BE250614003 BE25922018 ME25636029 BT27922017 BE250520031 BE25610023 T2208002 BE25910050 T0208065 T0208070 BE250010009 ME250036063 T0210118 BE250010002 BE25610037 BE25610038 BE25610006 BE25622022 BE250610000 T02080255 T2108001 T0208020 BE250510039 BE25910072 BE250411000 BE25634009 BE25634007

Chasis 5

60A 69
TORNILLO PRISIONERO M6X8 / SET SCREW M6X8 CASQUILLO CROSS 125 / CROSS 125 BUSHING COLA CHASIS / FRAME TAIL TORNILLO ESPECIAL 8X45 / 8X45 SPECIAL SCREW ARANDELA 8X20X1,5 / 8X20X1.5 WASHER RODILLO GUIA CAD. SUP. / UPPER CHAIN ROLL CASQUILLO ROD. 6,25X12X25 / 6.25X12X25 BUSHING RODILLO GUIA CADENA 13,5X32X23,5 / LOWER CHAIN ROLL SOPORTE CABALLETE / SIDE STAND HOLDER ULS 8X30 / 8X30 ULS BOLT ESTRIBO IZQUIERDO / LEFT FOOTREST CABALLETE EC2005 / EC2005 SIDE STAND BRACKET TUERCA ENJAULADA / CAGED NUT MUELLE CABALLETE / SIDE STAND BRACKET SPRING TORNILLO ESPECIAL 6X25 / 6X25 SPECIAL SCREW TUERCA AUTOBLOCANTE M6 ALTA / M6 SELF-LOCKING NUT HIGH COLN SOPORTE GUARDABARRO TRAS. ALUMINIO / ALUMINIUM REAR FENDER SUP. CTO. PEDAL FRENO / BRAKE PEDAL SET ANTIRROBO / STEERING LOCK CTO. REMACHE ANTIRROBO / STEERING LOCK RIVET ARANDELA 10.5x19X2 / 10.5x19X2 WASHER GOMA SUJECIN CDI / CDI RUBBER HOLDER TUERCA REMACHABLE / RIVETABLE NUT ARANDELA DIRECCIN / STEERING WASHER ARANDELA DIRECCIN INFERIOR / LOWER STEERING WASHER CAZOLETA DIRECCIN / STEERING CAP CASQUILLO SOPORTE PEDAL FRENO EC250 / BRAKE PEDAL SUP. BUSHING CASQUILLO CABALLETE EC2001 / SIDE STAND HOLDER BUSHING TORNILLO ULS 6X16 / 6X16 ULS TUERCA AUTOBLOCANTE M10 PASO 1.25 PLATA / M10 SELF-LOCKING NUT TIRA ADHESIVA DEPSITO / FUEL TANK BAND STICKER TORNILLO HEXAGONAL 6X25 / 6X25 HEXAGONAL SCREW TUERCA ARAND M-6 AUTOBL. / M-6 SELF-LOCKING WASHER NUT ARANDELA PLANA 6X12X1.5 / 6X12X1.5 WASHER

BE120110065 -

200 /250 / 300
BE250310073 BE250010001 T0208045 T4008020 BE25610014 BE25612016 BE25610032 BE250212023 T0508030 BE250010003 BE250512010 T2606000 BE250410039 T0206025 T2106002 BE250010018 BE250522016CT BE250010075 BE250010076 T4001019 BE250034100 BE250010070 BE25610028 BE250610028 BE250610026 BE250210916 BE250112011 T0506016 T3110002 BE25638018 T0106025 T2206001 T4006012
ULS 6X25 CON ARANDELA ZINCADO / ULS 6X25 WITH ZINC WASHER TORNILLO ESPECIAL 6X20 / 6X20 SPECIAL SCREW ALLEN 8X20 / 8X20 ALLEN BOLT TUERCA TOPE DIRECCIN M8X13X8 ZINCADO / ZINC STEERING STOPNUT M8X13X8
T0556025 T0606020 T0308020 T2008002
BRIDA SUPERIOR 58 SUSP.CROSS 2004 / 2004 CROSS SUSP. UPPER CLAMP 58 BRIDA INFERIOR 61 SUSP. CROSS / CROSS SUSP. LOWER CLAMP 61 CHASIS CROSS 2005 / CROSS FRAME 2005 TUERCA AUTOBLOCANTE M8 BAJA / LOW M8 SELF-LOCKING NUT CASQUILLO CROSS 125 / CROSS 125 BUSHING TUERCA ENJAULADA / CAGED NUT BC120610000 BE120110065 -
BC250414001 BC250414002 BC250610000 T2108001 T2606000
Solo SUPERMOTARD SM / Only SUPERMOTAR SM
COLA CHASIS CON ESTRIBOS SM 2004 / SM 2004 FRAME TAIL WITH FOOTRESTS CAVALLETE EC-2005 SUPERMOTARD / SUPERMOTARD EC-2005 SUPPORT ESTRIBO TRASERO DERECHO / REAR RIGHT FOOTREST ESTRIBO TRASERO IZQUIERDO / REAR LEFT FOOTREST MUELLE ESTRIBO TRASERO / REAR FOOTRE+B353ST SPRING CASQUILLO GUA ESTRIBO TRASERO / REAR FOOTREST GUIDE BUSHING TORNILLO / SCREW ARANDELA / WASHER BE250410001SM BE250512010SM BE250410102SM BE250410103SM BIE500110037 BIE500110104 T0308045 T4008017

BE250022039 BE25634007 BE25622026 BE25622027 BE250522010 BE250334003 BE25622007 C180700 BE250318055 BE250018025 BE25618020 T0106016 BE250022090 BE250022096 BE250022055 BE250022060 BE250522004 BE250022068 BE250422012 BE250118015SM BE250118014SM BE250118004SM BE250118028SM BE250022120 BE250022034 BE250022093 BE250322001 BE250022094 BE250022095 BE250118005SM T0556020 BE250118011SM BE250318027 R575700 C160001 BE250318021 BE250118034SM

Chasis 15

TUERCA AUTOBLOCANTE M8 ALTA CORONA / M8 HIGH SELF-LOCKING SPROCKET NUT ALLEN CNICO 8X30 / 8X30 CONIC ALLEN BOLT TUERCA AUTOBLOCANTE RUEDA TRASERA / REAR WHEEL SELF-LOCKING NUT CADENA 108 / 108 CHAIN TUERCA RADIO TRASERA / REAR SPOKE NUT RETN / SEAL PLATINA (B) SUJECCIN PASTILLAS TRASERAS / REAR BRAKE PADS HOLDER BRACKET (B) PISTN PINZA FRENO TRASERA / REAR BRAKE CALIPER PISTON RETN PISTN PINZA FRENO TRASERA / REAR BRAKE CALIPER PISTON ORING TRICA PISTN PINZA FRENO TRASERA / REAR BRAKE CALIPER PISTON SEAL CTO. FRENO TRASERO PURGADO / REAR BRAKE SET RUEDA TRASERA SM / SM REAR WHEEL SET ARANDELA 8X16X1 / 8X16X1 WASHER BRIDA UNEX CORTA 2,5X98 / 2,5X98 SHORT CLAMP ARANDELA INTERIOR CUBO / INTERIOR HUB WASHER COJINETE RUEDA 6005-25R1 C3 / WHEEL BEARING RACORD SUJ. LATIGUILLO 10X1,25 / HOSE HOLDER RACORD 10X1.25
T2108002 T0408030 BE25618023 BE250110036SM BE250118016SM C160710 BE250022091 BE250022044 BE250022047 BE250022048 BE250522118 BE250518100SM T4008018 BE25634010 BE250318056 BE250318054 BC25722006
Suspensin MARZOCCHI / MARZOCCHI Fork

25/25A

16 / 16A

16A 25 25A 28 29

BASE HORQUILLA IZQUIERDA / LEFT FORK BASE BASE HORQUILLA DERECHA / RIGHT FORK BASE GLACIER BOTELLA 538103 50x45x15 / OUTER TUBE BUSHING ANILLO DE CIERRE / RETAINING CUP RETN SUSPENSIN 45X58X11 / OIL SEAL ANILLO DE CIERRE / STOP RING GUARDAPOLVO / DUST SEAL CTO. BARRA SUSPENSIN / OUTER TUBE UNIT TORNILLO Y JUNTA TRICA / SCREW+ O'RING TRICA TAPN REGULACIN / SET SCREW MUELLE TAPN REGULACIN / REBOUND SPRING TORNILLO PEQUEO TAPN REGULACIN / SCREW TRICA TAPN REGULACIN / REGULATION CAP ORING CASQUILLO REGULACIN / PIN + O'RING CASQUILLO GUIA MUELLE / SPRING GUIDE BUSHING CUP MUELLE K=4.2 / SPRING K=4.2 KIT MUELLE Y CASQUILLO K:4.0 / SPRINGS K=4.0 + SLEEVES ARANDELA 22X8.1X0.3 / SHIM 22X8.1X0.3 TUERCA BLOQUEADOR M12X25 / LOCK NUT TUBO GUIA MUELLE / SPRING GUIDE TOPE PRECARGA / PRELOAD SLEEVE TOPE DE FONDO / NUT ANILLO RETENCIN / STOP RING TOPE FONDO HUG D45 / FOOT NUT TOPE FONDO USD D45 / FOOT NUT CUP CARTUCHO AMORTIGUADOR / CARTRIDGE BODY CARTUCHO AMORTIGUADOR / CARTRIDGE BODY VARILLA INTERNA / INNER ROD CTO. VARILLA / DAMPING SHAFT UNIT MUELLE / REBOUND SPRING BRIDA UNEX 2244 16/02 4.8X30 / UNEX CLAMP 2244 16/02 4.8X30

BE250114228 BE120514109 -
BE250414143 BE250414142 BE250314131 BE250114133 C240701 BE25714132 BE25714131 BE250514110 BE25714103 BE250114225 BE250114226 BE250114227 BE250114104 BE250114112 BE250114107 BE250114268 BE250514235 BE250114242 BE250514229 BE250514109 BE250114230 BE250114231 BE250514232 BE250114233 BE250514114 BE250114234 BE250514116 BE250114118 BE25634007
BE250114143SM BE250114142SM BE250314110 BE250114245 BE250314229SM BE250314109SM BE250314232SM BE250314114SM BE250314116SM BE250114116 -
SEGMENTO PISTN / PISTON RING PISTN SUSPENSIN / REBOUND PISTON

250 / 300 + cross 125

BE250114120 BE250514119

BE250314119SM

Chasis 16
33 33A 33B 33C 42 42A 42B 42C 42D 42E 42F 48A 48B 48C 53
BE250114238 BE250114239 BE250114240 BE250114241 BE250114126 BE250114128 BE250114144 BE250514124 BE250514244 BE250514235 BE250114246 BE250514247 BE250514248 BE250114248-1 BE250114248-3 BE250514248-4 BE250514248-5 BE250514248-6 BE250514248-7 BE250514249 BE250514105 BE250114250 BE250114248-3 BE250514000MZ BC120514040 BC250514040 BC300514040 BE250114040SM BC250014050 BC250014155 BC250014156 T0206016 T0316012
ARANDELA SUSPENSIN 15X8.1X0.1 / SHIM 15X8.1X0.1 ARANDELA SUSPENSIN 19X8.1X0.1 / SHIM 19X8.1X0.1 ARANDELA SUSPENSIN 17X8.1X0.1 / COMPRESSION DAMPING WASHER ARANDELA SUSPENSIN 21X8.1X0.1 / REED VALVE VLVULA BASE / NUT CASQUILLO INTERIOR BOTELLA / LOWER BUSH TORNILLO 6X30 DIN 6921 8.8 / SCREW 6X30 GRUPO AMORTIGUADOR / VALVE UNIT TORNILLO BL. VLVULA / VALVE SCREW JUNTA 22X8.1X0.3 C72 BLU / SHIM 22X8.1X0.3 TRICA 2087 D21.95 S1.78 / O`RING 2087 PISTN D.26 SINTER. / COMPRESSION PISTON JUNTA 15X8.1X0.2 / COMPRESSION DAMPING WASHER BE250114248-1 (19X8.1X0.1) JUNTA 19X8.1X0.1 / SHIM 19X8.1X0.1 BE250114248-3 (17X8.1X0.1) JUNTA 17X8.1X0.1 / COMPRESSION DAMPING WASHER BE250514248-5 (11X8.1X0.1) JUNTA 16X8.1X0.2 / SHIM 16X8.1X0.2 BE250514248-6 (13X8.1X0.2) JUNTA 11X8.1X0.1 / SHIM 11X8.1X0.1 BE250514248-7 (14X8.1X0.2) JUNTA 13X8.1X0.2 / SHIM 13X8.1X0.2 BE120514248 (15X8.1X0.15) JUNTA 14X8.1X0.2 / SHIM 14X8.1X0.2 BE120514248-1 (16X8.1X0.15) VLVULA DE AJUSTE / ADJUSTING VALVE CTO. TAPN REGULACIN / PLUG UNIT TRICA 2100 D25.1 S1.78 / ORING 2100 ARANDELA SUSPENSIN 21X0.8X0.1 / REED VALVE BE250114241 (21X8.1X0.1) CTO. SUSPENSIN DELANTERA MARZOCCHI / MARZOCCHI FRONT SUSP. BE120514000MZ JUEGO PROTEC. HORQ. INV. AMARILLO / YELLOW REV. FORK PROT. SET JUEGO PROTEC. HORQUILLA INVERTIDA ROJO / RED REV. FORK PROT. SET JUEGO PROTEC. HORQUILLA INVERTIDA AZUL / BLUE REV. FORK PROT. SET JUEGO PROTEC. HORQUILLA INVERTIDA SM / SM REV. FORK PROT. SET CASQUILLO PROTECTOR HORQUILLA / FORK PROTECTORS BUSHING FIJACIN IZQUIERDA LATIGUILLO / LEFT HOSE HOLDER FIJACIN DERECHA LATIGUILLO / RIGHT HOSE HOLDER TORNILLO ESPECIAL 6X16 8.8 ZINCADO / 6X16 8.8 SPECIAL SCREW TORNILLO ESPECIAL 6X12 / 6X12 SPECIAL SCREW -

BE250314124SM BE250114244 BE250114245 BE250314247SM BE250114248-5X4 BE250514248-5X4 BE250314248 BE120514248 BE250314248-1 BE250114249 BE250114105 BE250514248-6 BE250114000 -
Suspensin HLINS / HILNS Fork

53/53A/53B

TORNILLO 00828-01 / SCREW RODILLO REGULACIN 00820-01 / ADJUSTMENT KNOB CIRCLIP 01473-06 / CIRCLIP TRICA 00338-79 / ORING TORNILLO DE AJUSTE 02405-01 / ADJUSTMENT SCREW BOLA 00884-01 / BALL MUELLE 00883-01 / SPRING TORNILLO 01050-01 / SCREW TRICA 00338-59 / ORING VARILLA DE AJUSTE 02366-13 / ADJUSTMENT ROD TRICA 00438-61 / O-RING GUA VARILLA 02402-01 / NEEDLE HOUSING GUA FUNDA 02430-01 / GUIDING SLEEVE CIRCLIP 01499-02 / CIRCLIP CENTRADOR 02399-48 / CYLINDER TUBE CAP GLACIER 00110-03 / BUSHING ARANDELA 02340-01 / WASHER EJE 02393-01 / SHAFT MUELLE 02063-02 / SPRING TRICA 00438-31 / O-RING AGUJA DE EXTENSIN 02356-03 / REBOUND NEEDLE MUELLE 02322-01 / SPRING SOPORTE PISTN 02320-03 / PISTON HOLDER ARANDELA REGLAJE 00530-18 / SHIM WASHER ARANDELA ONDULADA 01149-01 / WAVE WASHER PISTN REGLAJE 02335-01 / REBOUND PISTON ARO DEL PISTN 01447-02 / PISTON RING ARANDELA ONDULADA 04105-01 / WAVE WASHER ARANDELA 00153-01 / WASHER TUERCA CIERRE 00430-05 / LOCK NUT CIRCLIP 01473-02 / CIRCLIP TRICA 00338-53 / O-RING TRICA 00438-02 / O-RING "POPPET" VLVULA 02414-01 / POPPET VALVE 02414-01 TRICA 00438-52 / ORING ASIENTO VLVULA 02415-01 / VALVE SEAT TRICA 00438-03 / ORING
BE250314100OH BE250314101OH BE250314224OH BE250314103OH BE250314112OH BE250314250OH BE250314226OH BE250114100OH BE250114104OH BE250314116OH BE250414104OH BE250314220OH BE250414230OH BE250114252OH BE250314219OH BE250114253OH BE250114216OH BE250314178OH BE250114254OH BE250114255OH BE250114112OH BE250114256OH BE250114195OH BE250114202OH BE250114203OH BE250114200OH BE250114207OH BE250314203OH BE250114213OH BE250114202OH BE250114214OH BE250114257OH BE250114259OH BE250314248OH BE250314264OH BE250314247OH BE250314261OH

Chasis 17

53/53A/53B 71

53A 53B 70 71

SOPORTE DEL MUELLE 02436-04 / SPRING SUPPORT MUELLE HORQUILLA DELANTERA 02428-41 / SPRING FRONT FORK BOTELLA 02425-01 / FORK LEG OUTER ADH. PROTECTOR HLINS 02332-05 / COVER STICKER HLINS GUA SEPARADOR 02409-02 / GUIDE SLEEVE GLACIER BOTELLA 02427-02 / TUBE BUSHING 02427-02 SEPARADOR 02431-01 / SLEEVE CIRCLIP 05009-12 / CIRCLIP ARANDELA 02412-01 / WASHER RETN 02410-02 / SEAL CIRCLIP 02015-01 / CIRCLIP GUARDAPOLVO 02411-02 / SCRAPER CARTUCHO CILINDRICO 02339-01 / CILINDER TUBE CARTRIDGE GLACIER BARRA 02429-02 / BAR BUSHING 02429-02 BARRA SUSPENSIN 02426-01 / FORK LEG INNER PROTECTORES HORQUILLA AMARILLOS / YELLOW FORK PROTECTORS PROTECTORES HORQUILLA ROJOS / RED FORK PROTECTORS PROTECTORES HORQUILLA AZULES / BLUE FORK PROTECTORS TRICA 00438-16 / O-RING TORNILLO BASE HORQUILLA 02314-02 / BOLT FORK BOTTOM BASE BOTELLA IZQUIERDA 02372-27 / FORK BOTTOM LEFT BASE BOTELLA DERECHA 02372-28 / FORK BOTTOM RIGHT CTO. REGULACIN EXTENSIN / BASE VALVE ASSY TAPN 02397-48 / TOP CAP CTO. REGULACIN COMPRESIN / COMPRESSION REGULATOR SET / BUMP RUBBER 02400-01 / SLIDE WASHER 02403-01 ARANDELA 00520-23 / SHIM CTO. SUSPENSIN OHLINS 2004 / 2004 OHLINS SUSPENSION SET BOLA 00884-04 / BALL MUELLE 01248-01 / SPRING TORNILLO 6X12 HELLA TORC ESPECIAL ZI / ZI SPECIAL TORC HELLA 6X12 SCREW CASQUILLO PROTECTOR SUSP. INVERTIDA / REVERSED SUSPENSION PROTECTOR BUSHING FIJACIN LATIGUILLO CROSS / CROSS HOSE HOLDER FJACIN LATIGUILLO CROSS CON TUERCA / CROSS HOSE HOLDER TORNILLO ESPECIAL 6X16 8.8 ZINCADO / SPECIAL ZINC SCREW 6X16 8.8

BE250414262OH BE250414108OH BE250414206OH BE250338042OH BE250314182OH BE250414134OH BE250414109OH BE250414202OH BE250414133OH BE250414212OH BE250114132OH BE250414131OH BE250114114OH BE250414111OH BE250414110OH BC120514040 BC250414040 BC300414040 BE250414263OH BE250114209OH BE250414143OH BE250414142OH BE250314267OH BE250414105OH BE250314268OH BE250314265OH BE250314266OH BE250314245OH BE250414000OH BE250114250OH BE250114226OH T0316012 BC250014050 BC250014155 BC250014156 T0206016
Suspensin MARZOCCHI / MARZOCCHI Fork 50

CROSS 250 2006

33 33A 33B 33C 34
BASE HORQUILLA IZQUIERDA / LEFT FORK BASE BASE HORQUILLA DERECHA / RIGHT FORK BASE GLACIER BOTELLA 538103 50x45x15 / UPPER BUSH ANILLO DE CIERRE / CLOSE RING RETN SUSPENSIN 45X58X11 / SUSPENSION SEAL ANILLO DE CIERRE / CLOSE RING GUARDAPOLVO / DUSTKEEPER CTO. BARRA SUSPENSIN / FORK SET TORNILLO / SCREW TRICA 2087 / O'RING TRICA 2015 / O'RING TORNILLO PEQUEO TAPN REGULACIN / SMALL BOLT TRICA TAPN REGULACIN / REGULATION CAP ORING CASQUILLO REGULACIN / REGULATION BUSHING ARANDELA / WAHER MUELLE 4.5 / SPRING GRUPO VLVULA / PLUG UNIT TUERCA BLOQUEADOR M12X25 / LOCKER NUT TUERCA + ARANDELA / NUT+SHIMS KIT VARILLA INTERNA / INNER ROO TRICA 3193 / O'RING ARANDELA 36X30.1X3 / WASHER TRICA 2106 / O'RING TORNILLO DE APRIETE / REBOONO ADJ. CARTUCHO AMORTIGUADOR COMPLETO / OUMPING UNIT TUERCA INFERIOR / FOOT NUT VARILLA / SHAFT MUELLE / SPRING CLIP 30.5X1 / STOP RING JUNTA 22X8.1X0.3 / STOP RING SEGMENTO PISTN / PISTON SEGMENT PISTN SUSPENSIN / SUPENSION PISTON ARANDELA SUSPENSIN 15X8.1X0.1 / SUSPENSION WASHER ARANDELA SUSPENSIN 19X8.1X0.1 / SUSPENSION WASHER ARANDELA SUSPENSIN 17X8.1X0.1 / SUSPENSION WASHER ARANDELA SUSPENSIN 21X8.1X0.1 / SUSPENSION WASHER VLVULA BASE / BASE VALVE
BC250414143 BC250414142 S700761 BC250414133 BC250414212 BC25814132 G280701 BC250514110 BC250414103 BE250114246 BC250414104 BC250414227 BC250414104 BC250414112 BC250414107 BC250414228 BC250514249 BC250414242 BC250514253 BC250414117 BC250414187 BC250414254 BC250414255 BC250414214 BC250414192 BC250414314 BC250514116 BE250114118 BC250414256 BE250514235 BE250114120 BE250514118 BE250114248 BE250114248-1 BE250114248-3 BE250114241 BE250114126

 

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