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.

- 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).
- 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-.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05 DISMOUNTING ENGINE 03-07
Dismount the centrifugal operating system of the exhaust valve - Take the shaft and pinion off the water pump. - Undo the screws -arrows- and remove the support -1- from the exhaust valve control shaft. - Remove the centrifugal mechanism from the exhaust valve -2-.

Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 03-10 DISMOUNTING ENGINE Ed: 07/05
- Remove the pinions of V and I gear -arrows-, the needle bearing and the adjustment washers.
Removing the crankshaft - Remove the crankshaft unit -arrow- by pulling upwards. Note: If the crankshaft does not come off easily alternately tap the two shafts gently with a plastic hammer.
- On the side opposite the dismounted half crankcase, first remove the bushing -arrow- from the crankshaft seal and then the O-ring. Note: All gaskets, seals and O-rings should be replaced whenever the engine is dismounted partially or completely.
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL Ed: 07/05
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-01
Crankshaft- Piston - Cylinder
1. Nylon counterweight 2. Nylon counterweight screws 3. Washer 4. Connecting rod piston pin 5. Connecting rod small end bearing 18x22x22 6. Connecting rod 7. Crankshaft unit 8. Cylinder 9. Hexagonal bolt with 6x14 washer 10. Viton exhaust duct O-ring 44x3 11. Exhaust duct 12. Exhaust gasket 13. Vent 14. Piston pin circlip 15. Piston 16. Set of rings 17. Piston pin 18. Cylinder head O-ring gaskets
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-02 SERVICE AND REPAIR OF THE ENGINE COMPONENTS
Crankshaft Note: The crankshaft bearings must be completely replaced, for example, when replacing the outer piston the inner ring should also be replaced.
- Remove the inner ring of the crankshaft bearing -arrowusing an extractor tool. Place the extractor claws below the lower lip of the inner ring. Warning: Do not fix the crankshaft in a bench vice by the counterweights!
- Thoroughly clean the surface where the new inner ring of the bearing will be fitted. - Heat the inner ring of the new bearing on a heating plate, oven or similar to approx. 150 C. Danger: When fitting the inner ring of the crankshaft bearing, heat-resistant gloves must be worn.
- 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

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

- 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.

Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-18 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Starter shaft seal -1- Fit the new starter shaft seal in the clutch cover housing. The seal lip should face the outside of the clutch cover. - Press down on the seal with a rod until it fits completely in the clutch cover housing. Warning: When fitting the seal take care not to damage the seal lip!
SERVICE AND REPAIR OF THE ENGINE COMPONENTS 04-19

Clutch

1. Screw 6x20 aTightening torque: 6 Nm 2. Clutch pump O-ring 3. Hydraulic clutch calliper 4. Line washer 5. Bleeder 6. Bleeder cap 7. Clutch rod 8. Clutch hub 9. Washer 10. Clutch housing bushing 11. Clutch housing rivets 12. Clutch housing bearing 13. Clutch housing crown 14. Rubber silentblock 15. Washer clutch crown 16. Clutch housing washer 22.1x42x2.8 17. Covered clutch disc 18. Iron clutch disc 19. Clutch rod 20. Needle bearing 21. Needle plate 22. Clutch press 23. Circlip 15 24. Allen key 6x20 aTightening torque: 6 Nm 25. Clutch spring bushing 26. Clutch spring
Engine 200 cc / 250 cc / 300 cc EC ENDUCROSS WORKSHOP MANUAL 04-20 SERVICE AND REPAIR OF THE ENGINE COMPONENTS Ed: 07/05
Clutch spring -26- Check the condition of the springs and their length. Length of the springs Min. 45.7 mm Limit: 44 mm
Note: The clutch springs are replaced as a set.
Clutch press -22- Check the condition and the contact surface with the clutch discs for scratches and excessive wear. Bearing -20- and rod -19- Check the clutch bearing and the rod for seizure, signs of rolling and play.
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

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.

- 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

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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

ME120534007

200 / 250 / 300
BE250634005 BE2506340055M BE250334053 L300123 BE250520024 L300125 BE250634019 BE250634014 BX250534014 BE250534109 BE25934000 ME250434006 BP25734115 L300116 BT120222097 BE250634021 T2106001 BE25634020 L300720 BE25634009 ME250634007 BE250234015 BE250034100 T0706316 BE250134017 BE250134020 BE25634010 T0206025 T0506030 ME25934000 ME250534017 L300126

ME120134000 -

Chasis 2
ULS 6X16 NEGRO / 6X16 ULS BLACK BOLT TUERCA CON ARANDELA M6 / NUT WITH WASHER M6 INTERMITENTE IZQUIERDO TRASERO / LEFT REAR INDICATOR INTERMITENTE DERECHO DELANTERO / RIGHT FRONT INDICATOR BOMBILLA / LAMP CRISTAL INTERMITENTE / INDICATOR COVER REGULADOR / REGULATOR BRIDA NYLON 3.6X140 / NYLON CLAMP 3,6X140 ULS 6X14 CON ARANDELA PLATA / 6X12 ULS WITH WASHER TORNILLO PHILIPS CABOTA ANCHA 6X13 / 6X13 PHILIPS SCREW CABLE MULTIFUNCIN TT 2003 / 2003 TT MULTIFUNCTION HOSE SOPORTE CDI EC 2005 / EC 2005 CDI SUPPORT ULS 6X10 / 6X10 ULS BOLT SOPORTE MULTIFUNCIN / MULTIFUNCTION SUPPORT Solo Motocross MC / Only Motocross MC bike

125 am- red

BC120620020CT BE120620012 BC120620004 BE120620007 BC120620005 BE120620013 BE120620006 -

MC 2006

250 rojo - red
BC250620020CT BC250220009 T0506016 BE250220039 T0506020 BE250420063/2 BE250620012 T2206000 T0206016 BE250032060 BE25610017 BE250014118 BE250510015 T0606020 BC250620004 BE250620007 BE250520016 BC250620005 BE250620013 BE250620006 T0206020 T06065017 BE250510055 BE250010019 BE250010020 BC250220032 BE250128026 BE250128028 T4005010
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

Tubo escape / Exhaust

6 / 6A 22 14

6 / 6A

200/250/300

6A 31 32

HEXAGONAL 6X15 / HEXAGONAL ARANDELA 6X18X1,5 / 6X18X1.5 WASHER ARANDELA KLINGERIT / KLINGERIT WASHER SILENTBLOCK ESCAPE / EXHAUST SILENTBLOCK TUERCA AUTOBLOCANTE BAJA M6 / LOW SELF-LOKING NUT M6 TUBO ESCAPE / EXHAUST PIPE TUBO ESCAPE CATALIZADO / CATALYZED EXHAUST PIPE SILENTBLOCK ESCAPE / EXHAUST SILENTBLOCK BRIDA UNEX 4,8X36 / UNEX CLAMP 4.8X36 JUNTA ESCAPE / EXHAUST GASKET MUELLE ESCAPE / EXHAUST SPRING TRICA TUBERA ESCAPE 44X3 FP / EXHAUST ORING TUBERA ESCAPE / EXHAUST PIPE SILENCIOSO / SILENCER TUERCA AUTOBLOC. DIN-6926 M6 C/ARAN. / SELF-BLOCKING NUT WITH WAS. SILENTBLOCK SILENCIADOR / SILENTBLOCK SILENCER CASQUILLO SILENTBLOCK SILENCIOSO / SILENTBLOCK SILENCER BUSHING ALLEN 6X30 / ALLEN BOLT 6X30 CAZOLETA FINAL / SILENCER END CAP REMACHE D.4 SILENCIOSO / SILENCER RIVET D4 TORNILLO HEXAGONAL CON ARANDELA 6X14 / HEXAGONAL WITH WASHER TUERCA RAPIDA NUT M6 / M6 FAST NUT TORNILLO ESPIRAL 6X16 / SCREW ALLEN 6X50 / 6X50 BOLT CTO. CAZOLETA POSTERIOR / REAR CAP SET CATALIZADOR 125 / 125 CATALYST FILTRO AIRE SECUNDARIO / SECONDARY AIR FILTER TUBO GOMA ESCAPE A VLVULA / EXHAUST TO VALVE RUBBER TUBE TUBO GOMA VLVULA A FILTRO / VALVE TO FILTER RUBBER TUBE ABRAZADERA 8X15 / 8X15 CLAMP PROTECTOR ESCAPE HOMOLOGADO / ACCREDITED EXHAUST PROTECTOR ABRAZADERA 50-70 / 50-70 CLAMP ABRAZADERA 70-90 / 70-90 CLAMP
BE120326001 BE120626001H BE12626003 ME120316019 BE120626002H BE120326120 BE120326100 BE120126250 BE120626062 -
BE250326001 BE200326002 BT280626059 BE250626061 BE250626062 BC300214157 BE250626254 BE250328033 BE250626255
T0106015 T4006018 T4006725 BE25626007 T2106001 BE250326001 BE250626001H BE25626004 BE25634007 BE25626003 BE25610042 BE250526006 ME250516019 BE250326002 T2206002 BE250026005 BE250026000 T0306030 BE250326120 BE250026032 T0206014 T2606000 T0206016 T0306050 BE250126100 BT280626059 BE250626061 BE250626062 BC300214157 BE250626254 BE250328033 BE250626255
BE250326001 BT280626059 BE250626061 BE250626062 BC300214157 BE250626254 BE250328033 BE250626255

Chasis 8

TUBO ESCAPE CROSS / EXHAUST PIPE SILENCIOSO CROSS / CROSS SILENCER CAZOLETA FINAL / END CAP CTO. CAZOLETA POSTERIOR / REAR CAP SET Solo SUPERMOTARD SM / Only SUPERMOTARD SM
BE120326001 BC120326002 BE120326120 BE120326100
BC250326001 BC250326002 BE120326120 BE120326100
TUBO ESCAPE SUPERMOTARD / EXHAUST PIPE BE120226001SM BC250226001SM

EC/MC 2006

1 1A 1B 1C 1D 1E 1F 2 2A 2B 2C 2D 2E 2F 2G 2H 2J 2K 2L 2M 2N 5 5A 5B 11
CTO. ADH. EC-/ EC-2006 STICKERS SET CTO. ADH. EC-/ EC-2006 STICKERS SET CTO. ADH. EC-/ EC-2006 STICKERS SET CTO. ADH. EC-250 AZUL 2006 / EC-2006 STICKERS SET CTO. ADH. EC-/ EC-2006 STICKERS SET CTO. ADH. MC-/ MC-125 - 2006 STICKERS SET CTO. ADH. MC-/ MC- 250 - 2006 STICKERS SET ADH. 2T BASCULANTE IZQ. EC 125/ EC 125 LEFT 2T STICKER ARM ADH. 2T BASCULANTE DER. EC 125/ EC 125 RIGHT 2T STICKER ARM ADH. 2T BASCULANTE IZQ. EC 200/ EC 200 LEFT 2T STICKER ARM ADH. 2T BASCULANTE DER. EC 200/ EC 200 RIGHT 2T STICKER ARM ADH. 2T BASCULANTE IZQ. EC 250/ EC 250 LEFT 2T STICKER ARM ADH. 2T BASCULANTE DER. EC 250/ EC 250 RIGHT 2T STICKER ARM ADH. 2T BASCULANTE IZQ. EC 250/ EC 250 LEFT 2T STICKER ARM ADH. 2T BASCULANTE DER. EC 250/ EC 250 RIGHT 2T STICKER ARM ADH. 2T BASCULANTE IZQ. EC 300/ EC 2300 LEFT 2T STICKER ARM ADH. 2T BASCULANTE DER. EC 300/ EC 300 RIGHT 2T STICKER ARM ADH. 2T BASCULANTE IZQ. MC 125/ MC 125 LEFT 2T STICKER ARM ADH. 2T BASCULANTE DER. MC 125/ MC 125 RIGHT 2T STICKER ARM ADH. 2T BASCULANTE IZQ. MC 250/ MC 250 LEFT 2T STICKER ARM ADH. 2T BASCULANTE DER. MC 250/ MC 250 RIGHT 2T STICKER ARM ADH. TAPA FILTRO 125-200/ 125-200 FILTER COVER STICKER ADH. TAPA FILTRO 250 / 250 FILTER COVER STICKER ADH. TAPA FILTRO 250-300 / 250-300 FILTER COVER STICKER ADH. MICHELN HORQUILLA / FRONT FORK MICHELIN STICKER

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

Chasis 18

42A 42B 42C 42D 42E 42F 42G 42H 45 46
CASQUILLO INTERIOR VOTELLA / INNER BUSHING TORNILLO 6X25 DIN 6921 8.8 / BOLT 6X25 TOPE / CUP CASQUILLO M6X0.75 / BUSHING PISTN SINTER. / PISTON JUNTA 23X8.1X0.1 / GASKET 23X8.1X0.1 JUNTA 20X8.1X0.1 / GASKET 20X8.1X0.1 JUNTA 22X8.1X0.1 / GASKET 22X8.1X0.1 JUNTA 11X8.1X0.1 / GASKET 11X8.1X0.1 JUNTA 11X8.1X0.2 / GASKET 11X8.1X0.2 JUNTA 16X8.1X0.1 / GASKET 16X8.1X0.1 JUNTA 18X8.1X0.1 / GASKET 18X8.1X0.1 JUNTA 13X8.1X0.15 / GASKET 13X8.1X0.15 JUNTA 14X8.1X0.15 / SHIM 14X8.1X0.15 VLVULA DE AJUSTE / AJUSTING VALVE CONJUNTI HIDRULICO / BODY UNIT TRICA S125 31.4X1.78 / O'RING 2125 CTO. SUPENCIN DELANTERA MARZOCCHI CROSS 250 /