GASGAS 2023 Motocross Models Break Cover Owner’s Manual
- June 13, 2024
- GASGAS
Table of Contents
2023 Motocross Models Break Cover
Product Information: GASGAS Motorcycle MC 250
The GASGAS Motorcycle MC 250 is a state-of-the-art sports
vehicle designed to provide an exceptional riding experience. With
proper care and maintenance, this motorcycle will deliver
long-lasting pleasure.
The Owner’s Manual contains the latest information for this
model series at the time of publication. Please note that minor
differences in design may exist due to further developments.
This document is valid for the following models: MC 250
(F0301W0, F0301W1)
Table of Contents
- Means of Representation
- Symbols used
- Formats used
- Safety Advice
- Important Notes
- View of Vehicle
- Serial Numbers
- Controls
- Preparing for Use
- Riding Instructions
Product Usage Instructions
1. Means of Representation
The symbols and formats used in this manual are important for
understanding and following the instructions. Familiarize yourself
with them before using the motorcycle.
2. Safety Advice
Prioritize your safety while riding the GASGAS motorcycle. This
section provides essential safety advice that should be followed at
all times.
3. Important Notes
This section covers important information regarding manufacturer
warranty, fuel and auxiliary substances, spare parts and
accessories, service, figures, and customer service. Read this
section carefully to ensure proper usage and maintenance.
4. View of Vehicle
Get acquainted with the different views of the vehicle,
including front left and rear right, as illustrated in this
section.
5. Serial Numbers
Learn about the various serial numbers associated with the
motorcycle, such as the vehicle identification number, type label,
engine number, fork part number, and shock absorber article
number.
6. Controls
This section provides detailed information on the various
controls present on the GASGAS motorcycle. Understand their
functions and operation before riding.
7. Preparing for Use
Follow the advice given in this section to properly prepare the
motorcycle for its first use, running in the engine, and various
operating conditions such as dry sand, wet sand, wet and muddy
circuits, high temperatures, low temperatures, or snow.
8. Riding Instructions
Find detailed riding instructions that cover various aspects of
operating the GASGAS motorcycle. Follow these instructions to
ensure a safe and enjoyable riding experience.
For more detailed information, please refer to the complete
Owner’s Manual.
OWNER’S MANUAL 2023
MC 250 Art. no. 3215095en
DEAR GASGAS CUSTOMER
Congratulations DEARGASGASCUSTOMER on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports vehicle which, with appropriate care, will bring you pleasure for a long time to come.
We wish you good and safe riding at all times!
Enter the serial numbers of your vehicle below. Vehicle identification number ( p. 12)
Dealer’s stamp
Engine number ( p. 12)
The Owner’s Manual contained the latest information for this model series at
the time of publication. However, minor differences due to further
developments in design cannot be ruled out completely.
All specifications contained herein are non-binding. GASGAS Motorcycles GmbH
specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without
prior notice and without specifying reasons, to adapt these to local
conditions, as well as to stop production of a particular model without prior
notice. GASGAS Motorcycles accepts no liability for delivery options,
deviations from figures and descriptions, as well as misprints and other
errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2022 GASGAS Motorcycles GmbH, Mattighofen Austria All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only
with the express written permission of the copyright owner.
ISO 9001(12 100 6061) GASGAS Motorcycles applies quality assurance processes
that lead to the highest possible product quality as defined in the ISO 9001
international quality management standard. Issued by: TÜV Management Service
GASGAS Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen, Austria
This document is valid for the following models: MC 250 (F0301W0, F0301W1)
3215095en
3215095en 31.08.2022
TABLE OF CONTENTS
1TABLEOFCONTENTS MEANS OF REPRESENTATION ………………………………. 5
1.1 Symbols used…………………………………………. 5 1.2 Formats used…………………………………………. 5
2 SAFETY ADVICE …………………………………………………… 6
2.1 Use definition intended use………………….. 6 2.2 Misuse…………………………………………………… 6
2.3 Safety advice………………………………………….. 6 2.4 Degrees of risk and symbols
……………………. 6 2.5 Tampering warning ………………………………… 6 2.6 Safe operation
……………………………………….. 7 2.7 Protective clothing …………………………………. 7 2.8 Work rules
…………………………………………….. 8 2.9 Environment ………………………………………….. 8 2.10 Owner’s Manual
…………………………………….. 8
3 IMPORTANT NOTES …………………………………………….. 9
3.1 Manufacturer warranty, implied warranty ……………………………………………….. 9
3.2 Fuel, auxiliary substances………………………… 9 3.3 Spare parts, accessories
………………………….. 9 3.4 Service ………………………………………………….. 9 3.5 Figures
………………………………………………….. 9 3.6 Customer service……………………………………. 9
4 VIEW OF VEHICLE ……………………………………………… 10
4.1 View of vehicle, front left (example) ………. 10 4.2 View of vehicle, rear
right (example)………. 11
5 SERIAL NUMBERS………………………………………………. 12
5.1 Vehicle identification number………………… 12 5.2 Type label …………………………………………….
12 5.3 Engine number …………………………………….. 12 5.4 Fork part number ………………………………….
12 5.5 Shock absorber article number………………. 13
6 CONTROLS………………………………………………………… 14
6.1 Clutch lever………………………………………….. 14 6.2 Hand brake lever ………………………………….. 14
6.3 Throttle grip…………………………………………. 14 6.4 Stop button………………………………………….. 14 6.5
Opening the fuel tank filler cap………………. 15 6.6 Closing the fuel tank filler
cap………………… 15 6.7 Fuel tap……………………………………………….. 16 6.8
Choke………………………………………………….. 16 6.9 Shift lever…………………………………………….. 16 6.10 Kick
starter lever…………………………………… 17 6.11 Foot brake lever …………………………………… 17 6.12
Plug-in stand………………………………………… 17
7 PREPARING FOR USE …………………………………………. 18
7.1 Advice on preparing for first use ……………. 18 7.2 Running in the engine
…………………………… 19 7.3 Preparing the vehicle for difficult
operating conditions …………………………….. 19 7.4 Preparing the vehicle for rides on
dry
sand ……………………………………………………. 20
7.5 Preparing the vehicle for rides on wet sand ……………………………………………………. 21
7.6 Preparing the vehicle for rides on wet and muddy circuits ………………………………..
22
7.7 Preparing vehicle for high temperatures or slow riding……………………………………….. 23
7.8 Preparing the vehicle for low temperatures or snow ………………………….. 24
8 RIDING INSTRUCTIONS ………………………………………. 25
8.1 Checks and maintenance measures when preparing for use…………………………. 25
8.2 Starting ……………………………………………….. 25 8.3 Starting off…………………………………………… 26 8.4
Shifting, riding ……………………………………… 26 8.5 Braking………………………………………………… 27 8.6
Stopping, parking………………………………….. 27 8.7 Transporting ………………………………………… 28 8.8
Refueling……………………………………………… 28
9 SERVICE SCHEDULE……………………………………………. 30
9.1 Additional information ………………………….. 30 9.2 Required work ……………………………………… 30 9.3 Recommended work …………………………….. 31
10 TUNING THE CHASSIS ………………………………………… 32
10.1
10.2 10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.11 10.12 10.13 10.14
10.15
10.16 10.17
Checking the basic chassis setting with the rider’s weight …………………………………. 32 Air suspension XACT 5448……………………… 32 Compression damping of the shock absorber ……………………………………………… 33 Adjusting the low-speed compression damping of the shock absorber ……………… 33 Adjusting the high-speed compression damping of the shock absorber ……………… 33 Adjusting the rebound damping of the shock absorber …………………………………….. 34 Measuring the dimension of the rear wheel unloaded……………………………………. 34 Checking the static sag of the shock absorber ……………………………………………… 35 Checking the riding sag of the shock absorber ……………………………………………… 36 Adjusting the spring preload of the shock absorber …………………………………. 36 Adjusting the riding sag ……………………… 37 Checking the basic setting of the fork …….. 38 Adjusting the fork air pressure……………….. 38 Adjusting the compression damping of the fork ……………………………………………….. 39 Adjusting the rebound damping of the fork……………………………………………………… 40 Handlebar position……………………………….. 40 Adjusting the handlebar position ……….. 40
11 SERVICE WORK ON THE CHASSIS ………………………… 42
11.1 Raising the motorcycle with a lift stand ….. 42 11.2 Removing the
motorcycle from the lift
stand …………………………………………………… 42
2
TABLE OF CONTENTS
11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16
11.17 11.18 11.19 11.20 11.21 11.22 11.23 11.24 11.25
11.26 11.27
11.28 11.29 11.30
11.31 11.32 11.33 11.34 11.35 11.36 11.37
11.38 11.39 11.40 11.41 11.42
11.43
11.44
Bleeding the fork legs……………………………. 42 Cleaning the dust boots of the fork legs….. 43 Removing the fork legs ……………………… 44 Installing the fork legs ……………………….. 44 Removing the fork protector …………………. 45 Installing the fork protector …………………… 45 Removing the lower triple clamp ………… 45 Installing the lower triple clamp …………. 46 Checking the steering head bearing play … 48 Adjusting steering head bearing play ….. 49 Lubricating the steering head bearing …. 49 Removing the start number plate…………… 49 Installing the start number plate ……………. 50 Removing front fender………………………….. 50 Installing front fender …………………………… 50 Removing the shock absorber ……………. 50 Installing the shock absorber ……………… 52 Removing the seat………………………………… 54 Mounting the seat………………………………… 54 Removing the air filter box cover……………. 55 Installing the air filter box cover …………….. 56 Removing the air filter ………………………. 56 Cleaning the air filter and air filter box ………………………………………………….. 57 Installing the air filter ………………………… 58 Preparing air filter box cover for securing …………………………………………… 58 Removing the main silencer…………………… 58 Installing the main silencer ……………………. 59 Changing the glass fiber yarn filling in the main silencer ………………………………. 59 Removing the fuel tank ……………………… 60 Installing the fuel tank ……………………….. 61 Checking the chain for dirt…………………….. 62 Cleaning the chain………………………………… 63 Checking the chain tension ……………………. 63 Adjusting the chain tension …………………… 64 Checking the chain, rear sprocket, engine sprocket, and chain guide …………… 65 Checking the frame …………………………… 67 Checking the link fork ………………………… 67 Checking the throttle cable routing………… 67 Checking the rubber grip ………………………. 68 Adjusting the basic position of the clutch lever ……………………………………………………. 69 Checking/correcting the fluid level of hydraulic clutch ……………………………………. 69 Changing the hydraulic clutch fluid …….. 70
12 BRAKE SYSTEM………………………………………………….. 72
12.1 Checking the free travel of the hand brake lever…………………………………………… 72
12.2 Adjusting the basic position of the hand brake lever…………………………………………… 72
12.3 Checking the brake discs……………………….. 72 12.4 Checking the front brake
fluid level………… 73 12.5 Adding front brake fluid …………………….. 73 12.6 Checking
the front brake linings …………….. 75
12.7
12.8
12.9
12.10 12.11 12.12
12.13
Changing the brake linings of the front brake ……………………………………………….. 75 Checking the free travel of foot brake lever ……………………………………………………. 78 Adjusting the basic position of the foot brake lever ……………………………………….. 78 Checking the rear brake fluid level …………. 79 Adding rear brake fluid ……………………… 79 Checking the brake linings of the rear brake…………………………………………………… 80 Changing the rear brake linings ………….. 81
13 WHEELS, TIRES………………………………………………….. 83
13.1 Removing the front wheel …………………. 83 13.2 Installing the front wheel …………………… 84 13.3 Removing the rear wheel …………………… 84 13.4 Installing the rear wheel ……………………. 85 13.5 Checking the tire condition……………………. 87 13.6 Checking tire pressure…………………………… 87 13.7 Checking spoke tension…………………………. 88
14 COOLING SYSTEM ……………………………………………… 89
14.1 Cooling system …………………………………….. 89 14.2 Checking the antifreeze and
coolant
level…………………………………………………….. 89 14.3 Checking the coolant level …………………….. 90
14.4 Draining the coolant ………………………….. 90 14.5 Refilling with coolant
…………………………. 91 14.6 Changing the coolant ………………………… 93
15 TUNING THE ENGINE…………………………………………. 95
15.1 15.2
15.3 15.4 15.5 15.6
15.7 15.8
15.9
15.10 15.11
Checking the play in the throttle cable……. 95 Adjusting the play in the throttle cable ……………………………………………….. 95 Carburetor tuning…………………………………. 96 Carburetor idle setting ……………………….. 98 Carburetor adjusting the idle speed …. 99 Plug-in connector of ignition timing map adjustment ………………………………………….. 99 Changing the ignition timing map………… 100 Checking the basic position of the shift lever …………………………………………………. 100 Adjusting the basic position of the shift lever ……………………………………………… 100 Engine characteristic auxiliary spring…. 101 Engine characteristic adjusting the auxiliary spring ………………………………. 101
16 SERVICE WORK ON THE ENGINE ………………………. 103
16.1 Emptying the carburetor float chamber ……………………………………….. 103
16.2 Checking the gear oil level ………………….. 104 16.3 Changing the gear oil
……………………… 104 16.4 Adding the gear oil …………………………. 105
17 CLEANING, CARE…………………………………………….. 107
17.1 Cleaning the motorcycle …………………….. 107
3
TABLE OF CONTENTS
18 STORAGE……………………………………………………….. 109
18.1 Storage……………………………………………… 109 18.2 Preparing for use after storage……………. 110
19 TROUBLESHOOTING ……………………………………….. 111
20 TECHNICAL DATA……………………………………………. 113
20.1 20.2 20.3 20.3.1 20.3.2
20.4 20.4.1 20.4.2 20.4.3 20.5 20.6 20.7 20.8 20.9
Engine ………………………………………………. 113 Engine tightening torques…………………… 113
Carburetor ………………………………………… 115
Carburetor tuning …………………………. 115 Basic carburetor setting for sandy surfaces
……………………………………….. 116 Capacities………………………………………….. 116 Gear oil
………………………………………… 116 Coolant ………………………………………… 116 Fuel ……………………………………………… 116
Chassis ……………………………………………… 116 Tires …………………………………………………. 117 Fork
………………………………………………….. 117 Shock absorber………………………………….. 118 Chassis tightening
torques ………………….. 118
21 SUBSTANCES ………………………………………………….. 121
22 AUXILIARY SUBSTANCES ………………………………….. 123
23 STANDARDS …………………………………………………… 125
24 LIST OF ABBREVIATIONS………………………………….. 126
INDEX ……………………………………………………………………. 127
4
MEANS OF REPRESENTATION 1
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g., of a work step or a function).
Indicates an unexpected reaction (e.g., of a work step or a function).
Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have this work performed by an authorized GASGAS Motorcycles workshop. Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required. Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential reworking.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name
Indicates a proprietary name.
Name®
Indicates a protected name.
BrandTM
Indicates a brand available on the open market.
Underlined terms
Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.
5
2 SAFETY ADVICE
2.1
Use definition intended use
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.
Info Only operate this vehicle in closed-off areas remote from public road traffic.
2.2
Misuse
The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended. Any use of the vehicle beyond the intended and defined use constitutes misuse. Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.
2.3
Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.
2.4
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or
serious permanent injury if the appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the
appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate
measures are not taken. Note Identifies a danger that will lead to
considerable machine and material damage if the appropriate measures are not
taken.
Note Indicates a danger that will lead to environmental damage if the
appropriate measures are not taken.
2.5
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
6
SAFETY ADVICE 2
1 The removal or rendering inoperative by any person other than for purposes
of servicing, repair, or replacement, of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been
removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencers, baffles, header pipes or any
other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system. 3 Lack of proper
maintenance. 4 Replacing moving parts of the vehicle, or parts of the exhaust
system or intake system, with parts other than those
specified by the manufacturer.
2.6
Safe operation
Danger
Danger of accidentsA rider who is not fit to ride poses a danger to him or
herself and others. Do not operate the vehicle if you are not fit to ride
due to alcohol, drugs or medication. Do not operate the vehicle if you are
physically or mentally impaired.
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result in
unconsciousness and death. Always make sure there is sufficient ventilation
when running the engine. Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Warning
Danger of burnsSome vehicle components become very hot when the vehicle is
operated. Do not touch any parts such as the exhaust system, radiator,
engine, shock absorber, or brake system before
the vehicle parts have cooled down. Let the vehicle parts cool down before
you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety immediately eliminated by an authorized GASGAS Motorcycles workshop. Adhere to the information and warning labels on the vehicle.
2.7
Protective clothing
Warning
Risk of injuryMissing or poor protective clothing presents an increased safety
risk. Wear appropriate protective clothing such as helmet, boots, gloves as
well as trousers and a jacket with pro-
tectors on all rides. Always wear protective clothing that is in good
condition and meets the legal regulations.
In the interest of your own safety, GASGAS Motorcycles recommends that you
only operate the vehicle while wearing protective clothing.
7
2 SAFETY ADVICE
2.8
Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key). Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000) Unless otherwise noted, normal conditions apply to all tasks and descriptions.
Ambient temperature Ambient air pressure Relative air humidity
20 °C (68 °F) 1,013 mbar (14.69 psi) 60 ± 5 %
During assembly, use new parts to replace parts which cannot be reused (e.g.
self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings,
pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required.
Observe the manufacturer’s instructions. If thread locker (e.g., Precote®) has
already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for
damage and wear. Change damaged or worn parts.
After completing a repair or service work, check the operating safety of the
vehicle.
2.9
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of others. When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country. Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles dealer will be glad to advise you.
2.10 Owner’s Manual
Read this owner’s manual carefully and completely before making your first
trip. The Owner’s Manual contains useful information and many tips on how to
operate, handle, and service your motorcycle. This is the only way to find out
how best to customize the vehicle for your own use and how you can protect
yourself from injury.
Tip Store the Owner’s Manual on your terminal device, for example, so that you can read it whenever you need to.
If you would like to know more about the vehicle or have questions on the
material you read, please contact an authorized GASGAS Motorcycles dealer. The
Owner’s Manual is an important component of the vehicle. If the vehicle is
sold, the Owner’s Manual must be downloaded again by the new owner. The
Owner’s Manual can be downloaded several times using the QR code or the link
on the delivery certificate.
The Owner’s Manual is available for download from your authorized GASGAS
Motorcycles dealer and on the GASGAS Motorcycles website. A printed copy can
also be ordered from your authorized GASGAS Motorcycles dealer. International
GASGAS Motorcycles website: http://www.gasgas.com
8
IMPORTANT NOTES 3
3.1
Manufacturer warranty, implied warranty
The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2
Fuel, auxiliary substances
Note Environmental hazardImproper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner’s Manual and specification.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by GASGAS Motorcycles and have them installed by an authorized GASGAS Motorcycles workshop. GASGAS Motorcycles accepts no liability for other products and any resulting damage or loss. Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized GASGAS Motorcycles dealer will be glad to advise you.
The latest news GASGAS Technical Accessories on your vehicle can be found on the GASGAS Motorcycles website. International GASGAS Motorcycles website: http://www.gasgas.com
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner’s Manual. An incorrect suspension setting can lead to damage and breakage of chassis components. Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle. The relevant mileage or time interval is whichever occurs first.
3.5
Figures
The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized GASGAS Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and GASGAS Motorcycles.
A list of authorized GASGAS Motorcycles dealers can be found on the GASGAS Motorcycles website. International GASGAS Motorcycles website: http://www.gasgas.com
9
4 VIEW OF VEHICLE
4.1
View of vehicle, front left (example)
1 Hand brake lever ( p. 14) 2 Clutch lever ( p. 14) 3 Air filter box cover 4 Plug-in stand ( p. 17) 5 Shift lever ( p. 16) 6 Choke ( p. 16) 7 Fuel tap
V02471-10
10
4.2
View of vehicle, rear right (example)
VIEW OF VEHICLE 4
1 Seat 2 Fuel tank filler cap 3 Stop button ( p. 14) 4 Throttle grip ( p. 14) 5 Kick starter lever ( p. 17) 6 Foot brake lever ( p. 17) 7 Shock absorber compression adjuster 8 Shock absorber rebound adjuster 9 Level viewer for brake fluid, rear
V02470-10
11
5 SERIAL NUMBERS
5.1
Vehicle identification number
1 The vehicle identification number is stamped on the right side of the
steering head.
5.2
Type label
401945-10
1 The type label is fixed to the front of the steering head.
401946-10
5.3
Engine number
1 Engine number is embossed on the left side of the engine above the
engine sprocket.
H01047-10
5.4
Fork part number
1 The fork part number is stamped on the inside of the axle clamp.
401947-10
12
SERIAL NUMBERS 5
5.5
Shock absorber article number
1 Shock absorber article number is stamped on the top of the shock
absorber above the adjusting ring towards the engine side.
401948-10
13
6 CONTROLS
6.1
Clutch lever
1 Clutch lever is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
J00075-10
6.2
Hand brake lever
1 Hand brake lever is located on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3
Throttle grip
J00077-10
1 The throttle grip is fitted on the right side of the handlebar.
6.4
Stop button
J00076-10
1 The stop button is fitted on the left side of the handlebar.
Possible states · The stop button is in the basic position In this position,
the
ignition circuit is closed and the engine can be started. · Stop button
pressed In this position, the ignition circuit is inter-
rupted, a running engine stops, and a non-running engine will not start.
S04519-10
14
CONTROLS 6
6.5
Opening the fuel tank filler cap
Danger
Fire hazardFuel is highly flammable. The fuel in the fuel tank expands when
warm and can escape if overfilled.
Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
Switch off the engine for refueling. Make sure that no fuel is spilled;
particularly not on hot parts of the vehicle. If any fuel is spilled, wipe
it off immediately. Observe the specifications for refueling.
Warning
Danger of poisoningFuel is harmful to health. Avoid skin, eye and clothing
contact with fuel. Immediately consult a doctor if you swallow fuel. Do
not inhale fuel vapors. Rinse the affected area immediately with plenty of
water in the event of contact with the skin. Rinse the eyes thoroughly with
water, and consult a doctor in case of fuel contact with the eyes. Change
your clothing if fuel spills on them. Keep fuels correctly in a suitable
canister, and out of the reach of children.
Note Environmental hazardImproper handling of fuel is a danger to the
environment. Do not allow fuel to enter the groundwater, the soil, or the
sewage system.
1 Turn fuel tank filler cap counterclockwise and lift it off.
S04520-10
6.6
Closing the fuel tank filler cap
1 Mount fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed.
Info
2 Route fuel tank breather hose without kinks.
S04520-11
15
6 CONTROLS
6.7
Fuel tap
6.8
Choke
6.9
Shift lever
V02460-10
The fuel tap is on the left side of the fuel tank.
1 Open or close the fuel supply to the carburetor using knurled screw
on the fuel tap.
Possible states · Fuel tap is closed Fuel cannot flow from the fuel tank to
the car-
buretor. · Fuel tap is open Fuel can flow from the fuel tank to the carbure-
tor. The fuel tank empties completely.
1 Choke is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through
which the engine can draw extra fuel. This results in a richer fuel-air
mixture, which is needed for a cold start.
Info If the engine is warm, the choke function must be deactivated.
V02461-10
Possible states · Choke function activated The choke lever is pulled out to
the
stop. · Choke function deactivated The choke lever is pushed in to the
stop.
1 Shift lever is mounted on the left of the engine.
401950-10
The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.
401950-13
16
CONTROLS 6
6.10 Kick starter lever
1 Kick starter lever is fitted on the right side of the engine.
The kick starter lever can be swiveled.
Info Before riding, swing the kick starter lever inwards towards the engine.
6.11
Foot brake lever
401954-10
1 Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
6.12 Plug-in stand
401956-10
1 The holder for the plug-in stand is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle. The plug-in stand is used as
a fork locker when transporting the motorcycle.
Info Remove the plug-in stand before riding.
H02629-10
17
7 PREPARING FOR USE
7.1
Advice on preparing for first use
Danger
Danger of accidentsA rider who is not fit to ride poses a danger to him or
herself and others. Do not operate the vehicle if you are not fit to ride
due to alcohol, drugs or medication. Do not operate the vehicle if you are
physically or mentally impaired.
Warning
Risk of injuryMissing or poor protective clothing presents an increased safety
risk. Wear appropriate protective clothing such as helmet, boots, gloves as
well as trousers and a jacket with pro-
tectors on all rides. Always wear protective clothing that is in good
condition and meets the legal regulations.
Warning
Danger of crashingDifferent tire tread patterns on the front and rear wheel
impair the handling characteristic. Different tire tread patterns can make the
vehicle significantly more difficult to control. Make sure that only tires
with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidentsAn unadapted riding style impairs the handling
characteristic. Adapt your riding speed to the road conditions and your
riding ability.
Warning
Danger of accidentsThe vehicle is not designed to carry passengers. Do not
ride with a passenger.
Warning
Danger of accidentsThe brake system fails in the event of overheating. If the
foot brake lever is not released, the brake linings drag continuously. Take
your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidentsTotal weight and axle loads influence the handling
characteristic. Do not exceed the maximum permissible overall weight or the
axle loads.
Warning
Risk of injuryPeople who act without authorization may not be familiar with
the vehicle. Do not leave the vehicle unattended if the engine is running.
Protect the vehicle against access by unauthorized persons.
Info When using your motorcycle, remember that others may feel disturbed by
excessive noise.
Make sure that the pre-sales inspection work has been carried out by an
authorized GASGAS Motorcycles workshop. You will receive a delivery
certificate when the vehicle is handed over.
Before riding for the first time, read the entire Owner’s Manual carefully.
Get to know the controls. Adjust basic position of the clutch lever. ( p.
69) Adjust the basic position of the hand brake lever. ( p. 72) Adjust the
basic position of the foot brake lever. ( p. 78) Adjust the basic position
of the shift lever. ( p. 100)
18
PREPARING FOR USE 7
Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.
Info Your motorcycle is not approved for use on public roads. When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.
Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle. Do not make any off-road trips that exceed your ability and experience. Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. Do not take luggage along.
Do not exceed the maximum permissible weight and the maximum permissible axle loads. Guideline
Maximum permissible overall weight
335 kg (739 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
Check the spoke tension. ( p. 88)
Info The spoke tension must be checked after half an hour of operation. Run the engine in. ( p. 19)
7.2
Running in the engine
During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours
< 70 %
During the first 5 operating hours
< 100 %
Info The use of a service hour counter is recommended in order to be able to check the mileage at any time. Avoid fully opening the throttle.
7.3
Preparing the vehicle for difficult operating conditions
Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
Prepare air filter box cover for securing. ( p. 58) Clean the air filter and air filter box. ( p. 57)
Info Check the air filter approx. every 30 minutes.
Check the electrical connector for humidity and corrosion and to ensure it
is firmly seated. » If humidity, corrosion, or damage is found: Clean and
dry the connector, or change it if necessary.
19
7 PREPARING FOR USE
Difficult operating conditions are: Rides on dry sand. ( p. 20) Rides on wet sand. ( p. 21) Rides on wet and muddy circuits. ( p. 22) Riding at high temperatures or slow riding. ( p. 23) Riding at low temperatures and in snow. ( p. 24)
7.4
Preparing the vehicle for rides on dry sand
Check the radiator cap.
Value on the radiator cap
1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
M01129-01
Warning
Danger of scaldingDuring motorcycle operation, the coolant gets very hot and
is under pressure. Do not open the radiator, the radiator hoses or
other cooling system components if the engine or the cooling system are at
operating temperature. Allow the cooling system and the engine to cool down
before you open the radiator, the radiator hoses or other components of the
cooling system. In the event of scalding, rinse the area affected
immediately with lukewarm water.
Change the radiator cap. Mount the air filter dust cover.
Air filter dust cover (79006920000)
Info Observe the fitting instructions for GASGAS Technical Accessories.
M01104-01
Mount the air filter sand cover. Air filter sand cover (79006922000)
Info Observe the fitting instructions for GASGAS Technical Accessories.
M01105-01
20
PREPARING FOR USE 7
Adjust the carburetor jetting and setting. Info The recommended carburetor
tuning is available from your authorized GASGAS Motorcycles workshop.
M01107-01 600868-01
Clean the chain.
Chain cleaner ( p. 123)
Mount the steel sprocket. Grease the chain.
Universal oil spray ( p. 124)
Clean the radiator fins. Straighten the bent radiator fins carefully.
Condition
Regular use in sand Change the piston every 10 operating hours.
7.5
Preparing the vehicle for rides on wet sand
Check the radiator cap.
Value on the radiator cap
1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
M01129-01
Warning
Danger of scaldingDuring motorcycle operation, the coolant gets very hot and
is under pressure. Do not open the radiator, the radiator hoses or
other cooling system components if the engine or the cooling system are at
operating temperature. Allow the cooling system and the engine to cool down
before you open the radiator, the radiator hoses or other components of the
cooling system. In the event of scalding, rinse the area affected
immediately with lukewarm water.
Change the radiator cap.
21
7 PREPARING FOR USE
Mount the air filter rain cover. Air filter rain cover (79006921000)
Info Observe the fitting instructions for GASGAS Technical Accessories.
M01106-01
Adjust the carburetor jetting and setting.
Info The recommended carburetor tuning is available from your authorized GASGAS Motorcycles workshop.
M01107-01 600868-01
Clean the chain.
Chain cleaner ( p. 123)
Mount the steel sprocket. Grease the chain.
Universal oil spray ( p. 124)
Clean the radiator fins. Straighten the bent radiator fins carefully.
Condition
Regular use in sand Change the piston every 10 operating hours.
7.6
Preparing the vehicle for rides on wet and muddy circuits
Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info Observe the fitting instructions for GASGAS Technical Accessories.
M01106-01
22
PREPARING FOR USE 7
Adjust the carburetor jetting and setting. Info The recommended carburetor
tuning is available from your authorized GASGAS Motorcycles workshop.
M01107-01
Mount the steel sprocket. Clean the motorcycle. ( p. 107) Straighten the bent radiator fins carefully.
600868-01
7.7
Preparing vehicle for high temperatures or slow riding
Check the radiator cap.
Value on the radiator cap
1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
M01129-01
Warning
Danger of scaldingDuring motorcycle operation, the coolant gets very hot and
is under pressure. Do not open the radiator, the radiator hoses or
other cooling system components if the engine or the cooling system are at
operating temperature. Allow the cooling system and the engine to cool down
before you open the radiator, the radiator hoses or other components of the
cooling system. In the event of scalding, rinse the area affected
immediately with lukewarm water.
600868-01
Change the radiator cap. Adjust the secondary drive to the road
conditions.
Info The engine oil heats up quickly when the clutch is operated frequently
due to an excessively high secondary ratio.
Clean the chain. Chain cleaner ( p. 123)
Clean the radiator fins. Straighten the bent radiator fins carefully.
Check the coolant level. ( p. 90)
23
7 PREPARING FOR USE
7.8
Preparing the vehicle for low temperatures or snow
Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info Observe the fitting instructions for GASGAS Technical Accessories.
M01106-01
Adjust the carburetor jetting and setting.
Info The recommended carburetor tuning is available from your authorized GASGAS Motorcycles workshop.
M01107-01
24
RIDING INSTRUCTIONS 8
8.1
Checks and maintenance measures when preparing for use
Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated.
H02217-01
Check the gear oil level. ( p. 104) Check the front brake fluid level. (
p. 73) Check the rear brake fluid level. ( p. 79) Check the front brake
linings. ( p. 75) Check the brake linings of the rear brake. ( p. 80)
Check that the brake system is functioning properly. Check the coolant
level. ( p. 90) Check the chain for dirt. ( p. 62) Check the chain, rear
sprocket, engine sprocket, and chain guide.
( p. 65) Check the chain tension. ( p. 63) Check the tire condition. ( p.
87) Check tire pressure. ( p. 87) Check the spoke tension. ( p. 88)
Info The spoke tension must be checked regularly as incorrect spoke tension
will strongly impair riding safety.
Clean the dust boots of the fork legs. ( p. 43) Bleed the fork legs. ( p.
42) Check the air filter. Check the settings of all controls and ensure
that they can be oper-
ated smoothly. Check all screws, nuts, and hose clamps regularly for
tightness. Check the fuel level.
8.2
Starting
Danger
Danger of poisoningExhaust gases are toxic and inhaling them may result in
unconsciousness and death. Always make sure there is sufficient ventilation
when running the engine. Use effective exhaust extraction when starting or
running the engine in an enclosed space.
Note Engine damageHigh revving speed with a cold engine negatively impacts the
lifespan of the engine. Always run the engine warm at a low speed.
Info If the motorcycle is unwilling to start, the cause can be old fuel in the
float chamber. The flammable elements of the fuel evaporate after a long time
of standing. If the float chamber is filled with fresh fuel, the engine starts
immediately.
The motorcycle has been out of use for more than 1 week Empty the carburetor
float chamber. ( p. 103)
25
8 RIDING INSTRUCTIONS
H02629-10
Turn the knurled screw on the fuel tap all the way counterclockwise. Fuel
can flow from the fuel tank to the carburetor.
1 Remove plug-in stand .
Shift the transmission into neutral. Condition
The engine is cold Pull the choke lever out as far as possible. Press the
kick starter lever robustly through its full range.
Info Do not open the throttle.
8.3
Starting off
Info The plug-in stand must be removed before riding. When you are riding, the side stand must be folded up and secured with the rubber strap.
Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.
8.4
Shifting, riding
Warning
Danger of accidentsIf you change down at high engine speed, the rear wheel
blocks and the engine races. Do not change into a low gear at high engine
speed.
Info If you hear unusual noises while riding, stop immediately, switch off the
engine, and contact an authorized GASGAS Motorcycles workshop. First-gear is
used for starting off and for steep inclines.
Shift into a higher gear when conditions allow (incline, road situation,
etc.). To do so, release the throttle while simultaneously pulling the clutch
lever, shift into the next gear, release the clutch lever and open the
throttle.
If the choke function has been activated, deactivate it after the engine has
warmed up. After reaching maximum speed by fully opening the throttle grip,
turn the throttle back so it is ¾ open. This will barely
reduce the speed, but fuel consumption will be considerably lower. Always
open the throttle only as much as the engine can handle abrupt throttle
opening increases fuel consumption. To shift down, apply the brakes and
close the throttle at the same time. Pull the clutch lever and shift into a
lower gear, release the clutch lever slowly, and either open the throttle or
shift
again. Switch off the engine if running at idle speed or stationary for a
long time.
Guideline 2 min
Avoid frequent or lengthy slipping of the clutch. This causes the gear oil,
engine and cooling system to heat up. Ride at a low engine speed instead of
at a high engine speed with a slipping clutch.
26
RIDING INSTRUCTIONS 8
8.5
Braking
Warning
Danger of accidentsExcessively forceful application of the brakes blocks the
wheels. Adjust application of the brakes to the respective riding situation
and riding surface conditions.
Warning
Danger of accidentsA spongy pressure point on the front or rear brake reduces
braking efficiency. Check the brake system and do not continue riding until
the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidentsMoisture and dirt impair the brake system. Brake
carefully several times to dry out and remove dirt from the brake linings and
the brake discs.
On sandy, wet, or slippery surfaces, use mostly the rear brake. Always
finish braking before the going into a bend. Shift down to a lower gear
appropriate to your speed. Use the braking effect of the engine on long
downhill stretches. Shift back one or two gears, but do not overrev the
engine when doing so. This means that significantly less braking is required
and the brake system does not overheat.
8.6
Stopping, parking
Warning
Risk of injuryPeople who act without authorization may not be familiar with
the vehicle. Do not leave the vehicle unattended if the engine is running.
Protect the vehicle against access by unauthorized persons.
Warning
Danger of burnsSome vehicle components become very hot when the vehicle is
operated. Do not touch any parts such as the exhaust system, radiator,
engine, shock absorber, or brake system before
the vehicle parts have cooled down. Let the vehicle parts cool down before
you perform any work on the vehicle.
Note Fire hazardHot vehicle components pose a fire hazard and explosion risk.
Do not park the vehicle near to materials which are highly flammable or
explosive. Allow the vehicle to cool down before covering it.
Note Material damageThe vehicle may be damaged by incorrect procedure when
parking. Significant damage may be caused if the vehicle rolls away or falls
over. The components for parking the vehicle are designed only for the weight
of the vehicle. Park the vehicle on a firm and level surface. Ensure that
nobody sits on the vehicle when the vehicle is parked on a stand.
Apply the brakes on the motorcycle. Shift the transmission to neutral
position. Press and hold the stop button while the engine is idling until
the engine stops. Turn the knurled screw on the fuel tap all the way
clockwise. Rest the vehicle on the plug-in stand.
27
8 RIDING INSTRUCTIONS
8.7
Transporting
Note Danger of damageThe parked vehicle can roll away or fall over. Park the
vehicle on a firm and level surface.
Note Fire hazardHot vehicle components pose a fire hazard and explosion risk.
Do not park the vehicle near to materials which are highly flammable or
explosive. Allow the vehicle to cool down before covering it.
Switch off the engine. Mount plug-in stand on the fork legs.
Plug-in stand (79029094000)
H02628-01
Info The plug-in stand is included. Make sure the brake line runs in front of
the plug-in stand and does not become wedged.
Use tension belts or other suitable devices to secure the motorcycle against
falling over or rolling away.
Info Only tighten the tension belts to the point that the plug-in stand is firmly in contact with the fender and the tires. Pay attention to the alignment of the plug-in stand to the fender.
8.8
Refueling
401475-01
Danger
Fire hazardFuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
Switch off the engine for refueling. Make sure that no fuel is spilled;
particularly not on hot parts of the vehicle. If any fuel is spilled, wipe
it off immediately. Observe the specifications for refueling.
Warning
Danger of poisoningFuel is harmful to health. Avoid skin, eye and clothing
contact with fuel. Immediately consult a doctor if you swallow fuel. Do
not inhale fuel vapors. Rinse the affected area immediately with plenty of
water in the event of contact with the skin. Rinse the eyes thoroughly with
water, and consult a doctor in case of fuel contact with the eyes. Change
your clothing if fuel spills on them.
28
RIDING INSTRUCTIONS 8
Note Environmental hazardImproper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system.
400382-10
Switch off the engine. Open the fuel tank filler cap. ( p. 15)
A Fill the fuel tank with fuel up to measurement .
Guideline
A Measurement of
35 mm (1.38 in)
Total fuel tank capacity, approx.
7.5 l (1.98 US gal)
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) ( p. 122)
Engine oil, 2-stroke ( p. 121) Close the fuel tank filler cap. ( p. 15)
29
9 SERVICE SCHEDULE
9.1
Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on GASGAS Motorcycles Dealer.net. Your authorized GASGAS Motorcycles dealer will be glad to advise you. The use of a service hour counter is recommended in order to be able to check the mileage at any time. Service hour counter (A54012920000)
9.2
Required work
after every race
Every 40 operating hours
Every 20 operating hours
Every 10 operating hours
After 5 operating hours
After 1 operating hour
Change the gear oil. ( p. 104) Check the front brake linings. ( p. 75) Check the brake linings of the rear brake. ( p. 80) Check the brake discs. ( p. 72) Check the brake lines for damage and leakage. Check the rear brake fluid level. ( p. 79) Check the free travel of the foot brake lever. ( p. 78) Check the frame. ( p. 67) Check the link fork. ( p. 67) Check the fork bearing for play. Check the shock absorber heim joint for play. Check the shock absorber linkage. Check the tire condition. ( p. 87) Check tire pressure. ( p. 87) Check the wheel bearing for play. Check the wheel hubs. Check the rim run-out. Check the spoke tension. ( p. 88) Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 65) Check the chain tension. ( p. 63) Grease all moving parts (e.g., hand lever, chain, …) and check for smooth operation. Check/correct the fluid level of hydraulic clutch. ( p. 69) Check the front brake fluid level. ( p. 73) Check the free travel of the hand brake lever. ( p. 72)
Check the steering head bearing for play. ( p. 48)
Change the spark plug and spark plug connector.
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks,
and incorrect routing.
Check the antifreeze and coolant level. ( p. 89) Check the cables for damage and for routing without kinks.
30
SERVICE SCHEDULE 9
after every race
Every 40 operating hours
Every 20 operating hours
Every 10 operating hours
After 5 operating hours
After 1 operating hour
Check that the throttle cables are undamaged, routed without sharp bends, and set cor-
rectly.
Clean the air filter and air filter box. ( p. 57) Change the glass fiber yarn filling in the main silencer. ( p. 59) Service the fork. Perform the shock absorber service. Check the tightness of the easily accessible, safety- relevant screws and nuts. Check the idle speed. Final check: Check the vehicle for operating safety and take for a test ride. Make a service entry in GASGAS Motorcycles Dealer.net.
One-time interval Periodic interval
9.3
Recommended work
every 48 months
every 12 months
Every 40 operating hours
After 20 operating hours / Every 20 operating hours
After 10 operating hours / Every 10 operating hours
Change the front brake fluid. Change the rear brake fluid. Change the hydraulic clutch fluid. ( p. 70) Lubricate the steering head bearing. ( p. 49) Service the fork. Perform the shock absorber service. Check/set the carburetor components. Change the needle jet. Change the coolant. ( p. 93) Perform minor engine service. (Check the reed valve housing, reed valve, and intake flange. Check the clutch. Under difficult operating conditions: Change the piston and check the cylinder and Z dimension.)
Perform the intermediate engine service. (Change the piston and check the cylinder and Z dimension. Check the exhaust control for functioning and smooth operation.)
Perform major engine service including removing and installing the engine. (Change the
connecting rod, conrod bearing, and crank pin. Check the transmission and shift mechanism.
Change all engine bearings.)
One-time interval Periodic interval
31
10 TUNING THE CHASSIS
10.1 Checking the basic chassis setting with the rider’s weight Info
When adjusting the basic chassis setting, first adjust the shock absorber and
then the fork.
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider’s weight.
As delivered, GASGAS offroad motorcycles are adjusted for an average rider’s weight (with full protective clothing).
Guideline
Standard rider weight
75 … 85 kg (165 … 187 lb.)
If the rider’s weight is above or below this range, the basic setting of the
suspension components must be adjusted accordingly.
Small weight differences can be compensated by adjusting the spring preload,
but in the case of large weight differences, the springs must be replaced.
10.2
401030-01
Air suspension XACT 5448
Air suspension WP Suspension XACT 5448 is used in the fork. In this system,
suspension is located in the left fork leg and damping in the right fork leg.
As fork springs are no longer required, a significant weight advantage is
achieved when compared to conventional forks. The response on slightly uneven
surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air cushion.
A steel spring is located in the left fork leg as an end stop.
M01110-01
Info If the fork is frequently overloaded, then the air pressure in the fork
must be increased to avoid damage to the fork and frame.
The air pressure in the fork can be quickly adjusted to the rider’s weight,
surface conditions and the rider’s preference using a fork airpump. The fork
does not have to be dismantled. The time consuming mounting of harder or
softer fork springs is not required. If the air chamber loses air due to a
damaged seal, the fork will still not sag. In this case the air is retained in
the fork. The suspension travel is maintained as far as possible. The damping
becomes harder and the riding comfort reduces. As with a conventional fork,
the damping can be adjusted in rebound and compression stages. The rebound
adjuster is located at the lower end of the right fork leg. The compression
adjuster is located at the upper end of the right fork leg.
32
TUNING THE CHASSIS 10
10.3 Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges:
high-speed and low-speed. High-speed and low-speed refer to the compression
speed of the rear wheel suspension and not to the vehicle speed. The high-
speed compression adjuster has an effect, for example, when landing after a
jump: the rear wheel suspension compresses quickly. The low-speed compression
adjuster has an effect, for example, when riding over long ground swells: the
rear wheel suspension compresses slowly. These two ranges can be adjusted
separately, although the transition between high-speed and low-speed is
gradual. Thus, modifications in the high-speed range affect the compression
damping in the low-speed range and vice versa.
10.4 Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injuryParts of the shock absorber will move around if the shock
absorber is detached incorrectly. The shock absorber is filled with highly
compressed nitrogen. Please follow the description provided. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.
1 Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click.
S04522-10
Info
2 Do not loosen fitting !
Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Lowspeed compression damping
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.5 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injuryParts of the shock absorber will move around if the shock
absorber is detached incorrectly. The shock absorber is filled with highly
compressed nitrogen. Please follow the description provided. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
Info The effect of the high speed compression adjuster can be seen in the fast
compression of the shock absorber.
33
10 TUNING THE CHASSIS
1 Turn adjusting screw all the way clockwise with a socket wrench.
S04523-10
Info
2 Do not loosen fitting !
Turn counterclockwise by the number of turns corresponding to the shock absorber type.
Guideline
Highspeed compression damping
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.6 Adjusting the rebound damping of the shock absorber
Caution
Risk of injuryParts of the shock absorber will move around if the shock
absorber is detached incorrectly. The shock absorber is filled with highly
compressed nitrogen. Please follow the description provided. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
S04524-10
1 Turn adjusting screw clockwise up to the last perceptible click.
Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Rebound damping
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.7
Measuring the dimension of the rear wheel unloaded
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
34
TUNING THE CHASSIS 10
Main work Position the sag gage in the rear axle and measure the distance to
marking SAG on the rear fender. Sag gage (00029090200)
A Note the value as dimension .
402415-10
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
10.8
Checking the static sag of the shock absorber
A Measure dimension of rear wheel unloaded. ( p. 34)
Hold the motorcycle upright with aid of an assistant. Measure the distance
again between the rear axle and marking SAG
on the rear fender using the sag gage.
B Note the value as dimension .
Info
A The static sag is the difference between measurements and B.
Check the static sag.
Static sag
35 mm (1.38 in)
» If the static sag is less or more than the specified value: Adjust the spring preload of the shock absorber. ( p. 36)
402416-10
35
10 TUNING THE CHASSIS
10.9
Checking the riding sag of the shock absorber
A Measure dimension of rear wheel unloaded. ( p. 34)
With another person holding the motorcycle, the rider, wearing full
protective clothing, sits on the seat in a normal sitting position (feet on
footrests) and bounces up and down a few times. The rear wheel suspension
levels out.
Another person again measures the distance between the rear axle and marking
SAG on the rear fender using the sag gage.
C Note the value as dimension .
402417-10
Info
A The riding sag is the difference between measurements and C.
Check riding sag. Guideline Riding sag
105 mm (4.13 in)
» If the riding sag differs from the specified measurement: Adjust the riding sag. ( p. 37)
10.10 Adjusting the spring preload of the shock absorber
Caution
Risk of injuryParts of the shock absorber will move around if the shock
absorber is detached incorrectly. The shock absorber is filled with highly
compressed nitrogen. Please follow the description provided. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
Info Before changing the spring preload, make a note of the present setting,
e.g., by measuring the spring length.
Preparatory work Raise the motorcycle with a lift stand. ( p. 42) Remove
the shock absorber. ( p. 50) After removing the shock absorber, clean it
thoroughly.
36
TUNING THE CHASSIS 10
Main work
1 Loosen screw . 2 Turn adjusting ring until the spring is no longer under
tension.
Hook wrench (90129051000)
Info If the spring cannot be fully released, the spring must be removed to accurately measure the spring length.
Measure the total spring length while the spring is not under tension.
2 Tension the spring by turning adjusting ring to specified dimension A.
Guideline
Spring preload
7 mm (0.28 in)
402659-10
Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.
1 Tighten screw .
Guideline Screw, shock absorber M5 adjusting ring
5 Nm (3.7 lbf ft)
Finishing work Install the shock absorber. ( p. 52)
Remove the motorcycle from the lift stand. (
p. 42)
10.11
Adjusting the riding sag
B00292-10
Preparatory work Raise the motorcycle with a lift stand. ( p. 42) Remove
the shock absorber. ( p. 50) After removing the shock absorber, clean it
thoroughly.
Main work Choose and mount a suitable spring.
Guideline Spring rate Weight of rider: 65 … 75 kg 39 N/mm (223 lb/in) (143 …
165 lb.) Weight of rider: 75 … 85 kg 42 N/mm (240 lb/in) (165 … 187 lb.)
Weight of rider: 85 … 95 kg 45 N/mm (257 lb/in) (187 … 209 lb.)
Info The spring rate is shown on the outside of the spring.
Finishing work Install the shock absorber. ( p. 52)
Remove the motorcycle from the lift stand. (
Check the static sag of the shock absorber. (
p. 42) p. 35)
37
10 TUNING THE CHASSIS
Check the riding sag of the shock absorber. ( p. 36) Adjust the rebound damping of the shock absorber. ( p. 34)
10.12 Checking the basic setting of the fork
Info For various reasons, no exact riding sag can be determined for the fork.
Smaller differences in the rider’s weight can be compensated for by the fork
air pressure.
However, if the fork frequently bottoms out (hard end stop on compression),
the fork air pressure must be increased, within the specified values, to avoid
damage to the fork and frame.
If the fork feels unusually hard after extended periods of operation, the
fork legs need to be bled.
401000-01
10.13 Adjusting the fork air pressure
Warning
Danger of accidentsModifications to the suspension setting may seriously alter
the handling characteristic. Modifications which are not coordinated with
others to the suspension setting may cause a serious deterioration in the
handling characteristic and overload components. Only make adjustments
within the recommended range. Ride slowly to start with after making
adjustments to get the feel of the new handling characteristic.
Info Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine. The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
Preparatory work Raise the motorcycle with a lift stand. (
Main work
1 Remove protection cap . 2 Push together fork airpump fully.
Fork airpump (79412966100)
p. 42)
S04525-10
Info The fork airpump is included as part of the motorcycle’s accessory pack.
Connect the fork airpump to the left fork leg. The fork airpump indicator
switches on automatically. A little air escapes from the fork leg when
connecting.
38
TUNING THE CHASSIS 10
Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying GASGAS Technical Accessories instructions.
Adjust the air pressure as specified.
Guideline
Air pressure
10.4 bar (151 psi)
Gradual changing of the air pressure in steps of
0.2 bar (3 psi)
Minimum air pressure
7 bar (102 psi)
Maximum air pressure
12 bar (174 psi)
Info Never adjust the air pressure to a value outside the stated range.
Disconnect the fork airpump from the left fork leg. When disconnecting,
excess pressure will escape from the hose the fork leg itself does not lose
any air. The fork airpump indicator switches off automatically after 80
seconds.
Mount the protection cap.
Info Only mount the protection cap by hand.
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
10.14 Adjusting the compression damping of the fork Info
The hydraulic compression damping determines the fork suspension behavior.
1 Turn adjuster clockwise all the way to the stop.
S04526-10
Info
1 Adjuster is located at the upper end of the right fork leg.
Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Info Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
39
10 TUNING THE CHASSIS
10.15 Adjusting the rebound damping of the fork Info
The hydraulic rebound damping determines the fork suspension behavior.
1 Turn adjuster clockwise all the way to the stop.
Z01370-10
Info
1 Adjuster is located at the lower end of the right fork leg.
Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort
23 clicks
Standard
18 clicks
Sport
13 clicks
Info Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.16 Handlebar position
A The holes on the handlebar supports are placed at a distance of
from the center.
Hole distance A
3.5 mm (0.138 in)
The handlebar can be mounted in 2 different positions. In this way, the handlebar can be mounted in the most comfortable position for the rider.
H01188-10
10.17 Adjusting the handlebar position
Warning
Danger of accidentsA repaired handlebar poses a safety risk. If the handlebar
is bent or straightened, the material becomes fatigued. The handlebar may
break as a result. Change the handlebar if the handlebar is damaged or bent.
Preparatory work Remove the handlebar cushion.
40
TUNING THE CHASSIS 10
Main work
1 Remove screws . Remove the handlebar clamp. Remove the handlebar and lay
it to one side.
Info Cover the components to protect them against damage. Do not kink the
cables and lines.
2 3 Remove screws . Take off handlebar supports . 4 5 Position rubber
bushings and push through nuts from
below. Place the handlebar supports in the required position.
H01189-10
Info The handlebar supports are longer and higher on one side. Position the left and right handlebar supports evenly.
2 Mount and tighten screws .
Guideline Screw, handlebar M10 support
Position the handlebar.
40 Nm (29.5 lbf ft) Loctite®243TM
Info Make sure the cables and wiring are positioned correctly.
Position the handlebar clamp.
1 Mount screws but do not tighten yet.
1 First bolt the handlebar clamp with screws onto the longer, higher side of the handlebar supports so that both parts touch. Guideline
Screw, handlebar
M8
clamp
20 Nm (14.8 lbf ft)
1 Tighten screws evenly.
Guideline
Screw, handlebar
M8
clamp
20 Nm (14.8 lbf ft)
Finishing work Mount the handlebar cushion.
41
11 SERVICE WORK ON THE CHASSIS
11.1 Raising the motorcycle with a lift stand
Note Material damageThe vehicle may be damaged by incorrect procedure when
parking. Significant damage may be caused if the vehicle rolls away or falls
over. The components for parking the vehicle are designed only for the weight
of the vehicle. Park the vehicle on a firm and level surface. Ensure that
nobody sits on the vehicle when the vehicle is parked on a stand.
Raise the motorcycle at the frame underneath the engine. Lift stand
(A54029955100) Neither wheel is in contact with the ground.
Secure the motorcycle against falling over.
401942-01
11.2 Removing the motorcycle from the lift stand
Note Material damageThe vehicle may be damaged by incorrect procedure when
parking. Significant damage may be caused if the vehicle rolls away or falls
over. The components for parking the vehicle are designed only for the weight
of the vehicle. Park the vehicle on a firm and level surface. Ensure that
nobody sits on the vehicle when the vehicle is parked on a stand.
Remove the motorcycle from the lift stand. Remove the lift stand.
1 To park the motorcycle, insert plug-in stand into the left side of the
wheel spindle.
Info Remove the plug-in stand before riding.
11.3
H02629-10
Bleeding the fork legs
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
42
SERVICE WORK ON THE CHASSIS 11
Main work
1 Release bleeder screws .
Any excess pressure escapes from the interior of the fork. Tighten the
bleeder screws.
H01182-12
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
11.4
Cleaning the dust boots of the fork legs
Preparatory work Raise the motorcycle with a lift stand. (
Remove the fork protector. ( p. 45)
p. 42)
Main work
1 Push dust boots of both fork legs downward.
Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
M01134-10
Warning
Danger of accidentsOil or grease on the brake discs reduces the braking
effect. Always keep the brake discs free of oil and grease. Clean the
brake discs with brake cleaner when neces-
sary.
Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray ( p. 124)
Press the dust boots back into their normal position. Remove excess oil.
Finishing work Install the fork protector. ( p. 45)
Remove the motorcycle from the lift stand. (
p. 42)
43
11 SERVICE WORK ON THE CHASSIS
11.5
Removing the fork legs
I00182-10
Preparatory work Raise the motorcycle with a lift stand. (
Remove the front wheel. ( p. 83)
p. 42)
Main work
1 Remove screws and take off the clamp.
2 Remove screws and take off the brake caliper.
Allow the brake caliper and brake line to hang loosely to the side.
Info Do not actuate the hand brake lever when the front wheel is removed.
3 Loosen screws . Remove the left fork leg. 4 Loosen screws . Remove the right fork leg.
11.6
S04528-10
Installing the fork legs
Main work Position the fork legs.
1 Air bleeder screw of the right fork leg is positioned to the
front.
A Valve of the left fork leg faces the front.
H01182-10
Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp. The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
S04528-11
2 Tighten screws .
Guideline Screw, top triple clamp M8
3 Tighten screws .
Guideline Screw, bottom triple M8 clamp
20 Nm (14.8 lbf ft) 15 Nm (11.1 lbf ft)
44
SERVICE WORK ON THE CHASSIS 11
4 Position the brake caliper. Mount and tighten screws .
Guideline
Screw, front
M8
brake caliper
25 Nm (18.4 lbf ft) Loctite®243TM
Position the brake line and the clamp. Mount and tighten
5 screws .
I00182-11
Finishing work Install the front wheel. ( p. 84)
11.7
Removing the fork protector
1 Remove screws . Remove the clamp. 2 Remove screws . Take off the left
fork protector. 3 Remove screws . Take off the right fork protector.
11.8
F00024-10
Installing the fork protector
F00024-11
Position the fork protection on the left fork leg. Mount and tighten
1 screws .
Guideline
Remaining screws,
M6
chassis
10 Nm (7.4 lbf ft)
2 Position the brake line and clamp. Mount and tighten screws .
Position the fork protector on the right fork leg. Mount and tighten
3 screws .
Guideline
Remaining screws,
M6
chassis
10 Nm (7.4 lbf ft)
11.9
Removing the lower triple clamp
Preparatory work Raise the motorcycle with a lift stand. ( p. 42) Remove
the front wheel. ( p. 83) Remove the fork legs. ( p. 44) Remove the start
number plate. ( p. 49) Remove front fender. ( p. 50) Remove the handlebar
cushion.
45
11 SERVICE WORK ON THE CHASSIS
Main work
1 Remove screw .
2 Remove screw .
Take off the upper triple clamp with the handlebar and hang them to the
side.
S04530-10
Info Cover the components to protect them against damage. Do not kink the
cables and lines.
3 4 Remove O-ring . Remove protective ring .
Take off the lower triple clamp with the steering stem. Remove the upper
steering head bearing.
M01117-10
11.10
Installing the lower triple clamp
Main work Clean the bearing and sealing elements, check for damage, and
grease. High viscosity grease ( p. 123)
Insert the lower triple clamp with the steering stem. Mount upper steering
head bearing.
1 Check whether upper steering head seal is correctly positioned. 2 3
Slide on protective ring and O-ring .
102146-10
Position the upper triple clamp with the handlebar.
4 Mount screw , but do not tighten yet.
S04531-10
46
SERVICE WORK ON THE CHASSIS 11
Position the fork legs.
5 Air bleeder screw of the right fork leg is positioned to the
front.
A Valve of the left fork leg faces the front.
H01182-11
Info The air suspension AER valve is located in the left fork leg. Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.
6 Tighten screws .
Guideline Screw, bottom triple M8 clamp
15 Nm (11.1 lbf ft)
S04532-10
4 Tighten screw .
Guideline Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
S04533-10
7 Mount and tighten screw .
Guideline Screw, top steer- M8 ing stem
20 Nm (14.8 lbf ft) Loctite®243TM
S04533-11
8 Tighten screws .
Guideline Screw, top triple clamp M8
20 Nm (14.8 lbf ft)
S04532-11
47
11 SERVICE WORK ON THE CHASSIS
9 Position the brake caliper. Mount and tighten screws .
Guideline
Screw, front
M8
brake caliper
25 Nm (18.4 lbf ft) Loctite®243TM
Position the brake line and the clamp. Mount and tighten
screws bk.
I00182-12
Finishing work Check that the wiring harness, throttle cables, and brake and
clutch
lines can move freely and are routed correctly.
Install front fender. ( p. 50) Install the front wheel. ( p. 84) Check
the steering head bearing for play. ( p. 48) Remove the motorcycle from the
lift stand. ( p. 42) Install the start number plate. ( p. 50) Mount the
handlebar cushion.
11.11 Checking the steering head bearing play
Warning
Danger of accidentsIncorrect steering head bearing play impairs the handling
characteristic and damages components. Correct incorrect steering head
bearing play immediately. (Your authorized GASGAS Motorcycles workshop will
be glad to help.)
Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
H01167-01
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
Main work Move the handlebar to the straight-ahead position. Move the fork
legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play: Adjust steering head bearing play. ( p. 49)
Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire steering
range. There should be no detectable detent positions.
» If detent positions are detected: Adjust steering head bearing play. ( p.
49) Check the steering head bearing and change if necessary.
Check the steering stop bolts for correct adjustment and locking.
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
48
SERVICE WORK ON THE CHASSIS 11
11.12
Adjusting steering head bearing play
S04534-10
Preparatory work Raise the motorcycle with a lift stand. (
Remove the handlebar cushion.
p. 42)
Main work
1 Loosen screws .
2 Remove screw .
3 Loosen and retighten screw .
Guideline
Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
1 Tighten screws .
Guideline
Screw, top triple clamp M8
20 Nm (14.8 lbf ft)
2 Mount and tighten screw .
Guideline Screw, top steer- M8 ing stem
20 Nm (14.8 lbf ft) Loctite®243TM
Finishing work Check the steering head bearing for play. ( p. 48)
Remove the motorcycle from the lift stand. ( p. 42)
Mount the handlebar cushion.
11.13
Lubricating the steering head bearing
Remove the lower triple clamp. ( p. 45) Install the lower triple clamp. (
p. 46)
Info The steering head bearing is cleaned and lubricated in the course of
removal and installation.
H02387-01
11.14
Removing the start number plate
1 Remove screw .
Disconnect the brake line at the start number plate. Take off the start
number plate.
S04535-10
49
11 SERVICE WORK ON THE CHASSIS
11.15
Installing the start number plate
Connect the brake line at the start number plate. Position the start
number plate.
The holding lugs engage in the fender.
1 Mount and tighten screw .
S04536-10
11.16 Removing front fender
Preparatory work Remove the start number plate. ( p. 49)
Main work
1 2 Remove screws and . Remove front fender.
S04537-10
11.17 Installing front fender
Main work
1 2 Position front fender. Mount and tighten screws and .
Guideline
Remaining screws,
M6
chassis
10 Nm (7.4 lbf ft)
S04537-10
Finishing work Install the start number plate. ( p. 50)
11.18
Removing the shock absorber
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
50
SERVICE WORK ON THE CHASSIS 11
Main work Remove the cable ties.
1 Remove screws along with the washers.
Take off the left frame protector. Push the right frame protector to the
front and take off at the bot-
tom.
S04538-10
2 Remove screw . 3 Remove fitting .
Info Raise the wheel slightly to be able to remove the screws more easily.
S04569-10
4 Press angle lever toward the rear. 5 Press linkage lever downward.
S04570-10
6 Remove screws and pull foot brake cylinder off the push rod.
I01022-10
Remove the connecting link of the chain. Take off the chain.
Info Cover the components to protect them against damage.
M01149-01
51
11 SERVICE WORK ON THE CHASSIS
7 Remove nut and pull out the swingarm pivot.
Push the link fork back and secure it against falling over.
S04571-10
8 Hold the shock absorber and remove screw .
S04541-10
Remove the shock absorber carefully at the bottom.
S04542-01
11.19
Installing the shock absorber
Main work Carefully position the shock absorber into the vehicle from the
bot-
tom.
S04543-01
1 Mount and tighten screw .
Guideline Screw, top shock M10 absorber
60 Nm (44.3 lbf ft) Loctite®2701TM
S04541-11
52
SERVICE WORK ON THE CHASSIS 11
V01527-10
Position the link fork and mount the swingarm pivot.
Info
A Pay attention to flat area .
2 Mount and tighten nut .
Guideline
Nut, fork pivot
M16x1.5
100 Nm (73.8 lbf ft)
Mount the chain. Connect the chain with the connecting link.
Guideline
The closed side of the chain joint lock must face in the direction of travel.
M01149-01
Position the foot brake cylinder.
3 Push rod engages in the foot brake cylinder.
The dust boot is correctly positioned.
4 Mount and tighten screws .
Guideline
Remaining screws,
M6
chassis
10 Nm (7.4 lbf ft)
I01023-10
Position the angle lever and linkage lever.
5 Mount and tighten fitting .
Guideline
Nut, linkage lever on angle lever
M14x1.5
60 Nm (44.3 lbf ft)
K00864-10
Info
B Pay attention to flat area .
6 Mount and tighten screw .
Guideline Screw, bottom M10 shock absorber
60 Nm (44.3 lbf ft) Loctite®2701TM
Info Raise the wheel slightly to be able to mount the screw more easily.
53
11 SERVICE WORK ON THE CHASSIS
Position the left frame protector.
Insert the right frame protector from below and push it to the rear.
7 Mount and tighten screws with the washers.
Guideline
Screw, frame protector M5
3 Nm (2.2 lbf ft)
Mount the new cable ties.
S04538-11
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
11.20 Removing the seat
1 Remove screw .
S04544-10
Raise the rear of the seat, pull the seat back, and lift it off.
H02218-10
11.21 Mounting the seat
Mount the front of the seat on the collar bushing of the fuel tank, lower
the seat at the rear, and push the seat forward.
Make sure that the seat is locked in correctly.
H02218-11
54
SERVICE WORK ON THE CHASSIS 11
1 Mount and tighten screw .
Guideline
Remaining screws,
M6
chassis
10 Nm (7.4 lbf ft)
S04544-10
11.22
Removing the air filter box cover
Condition The air filter box cover is secured. Remove the seat. ( p. 54)
1 Remove screw .
S04545-10
A Pull off the air filter box cover in area sideways and take off toward the front.
S04546-10
Condition The air filter box cover is not secured.
A Pull off the air filter box cover in area sideways and take off toward the
front.
S04547-10
55
11 SERVICE WORK ON THE CHASSIS
11.23
Installing the air filter box cover
Condition The air filter box cover is secured.
A B Insert the air filter box cover in area and clip it into area .
S04546-11
1 Mount and tighten screw .
Guideline
Screw, air filter box cover
EJOT PT® K60x20-Z
Mount the seat. ( p. 54)
3 Nm (2.2 lbf ft)
S04546-12
Condition The air filter box cover is not secured.
A B Insert the air filter box cover in area and clip it into area .
S04547-11
11.24 Removing the air filter
Note Engine damageUnfiltered intake air has a negative effect on the service
life of the engine. Dust and dirt will enter the engine without an air filter.
Only operate the vehicle if it is equipped with an air filter.
Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.,
correctly and in compliance with the appli-
cable regulations.
Preparatory work Remove the air filter box cover. ( p. 55)
56
SERVICE WORK ON THE CHASSIS 11
Main work
1 Detach retaining tab . Remove air filter with air filter support.
Take off air filter from air filter support.
S04548-10
11.25 Cleaning the air filter and air filter box
Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.,
correctly and in compliance with the appli-
cable regulations.
Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work Remove the air filter box cover. ( p. 55) Remove the air
filter. ( p. 56)
Main work Wash the air filter thoroughly in special cleaning liquid and
allow it
to dry properly.
Air filter cleaner ( p. 123)
K00518-01
Info Only press the air filter to dry it, never wring it out.
Oil the dry air filter with a high-grade air filter oil. Oil for foam air
filter ( p. 123)
Clean the air filter box. Clean the intake flange and check it for damage
and tightness.
Finishing work Install the air filter. ( p. 58) Install the air filter box
cover. ( p. 56)
57
11 SERVICE WORK ON THE CHASSIS
11.26 Installing the air filter
Main work Mount the clean air filter on the air filter support.
A Grease the air filter in area .
Long-life grease ( p. 123)
102178-10
1 Insert the air filter and position the top retaining pin in bushing B.
The air filter is correctly positioned.
2 Secure the bottom retaining pin with holding tab .
S04549-10
Info If the air filter is not mounted correctly, dust and dirt may enter the
engine and result in damage.
Finishing work Install the air filter box cover. ( p. 56)
11.27
Preparing air filter box cover for securing
Preparatory work Remove the air filter box cover. ( p. 55)
Main work
A Drill a hole at marking .
Guideline Diameter
6 mm (0.24 in)
S02308-10
Finishing work Install the air filter box cover. ( p. 56)
11.28 Removing the main silencer
Warning
Danger of burnsThe exhaust system gets very hot when the vehicle is driven.
Allow the exhaust system to cool down before performing any work on the
vehicle.
58
SERVICE WORK ON THE CHASSIS 11
1 Remove screws with the washers. 2 Pull off the main silencer from the
manifold at exhaust sleeve .
V02462-10
11.29
Installing the main silencer
1 Position the main silencer in exhaust sleeve .
2 Mount and tighten screws with the washers.
Guideline
Remaining screws,
M6
chassis
10 Nm (7.4 lbf ft)
V02463-10
11.30 Changing the glass fiber yarn filling in the main silencer
Warning
Danger of burnsThe exhaust system gets very hot when the vehicle is driven.
Allow the exhaust system to cool down before performing any work on the
vehicle.
Info Over time, the fibers of the rock wool escape into the air, and the main
silencer “burns out”. Not only is the noise level higher, the performance
characteristic changes.
Preparatory work Remove the main silencer. ( p. 58)
59
11 SERVICE WORK ON THE CHASSIS
Main work
1 2 Remove screws . Pull out inner tube .
3 Remove the glass fiber yarn filling from the inner tube.
Clean the parts that need to be reinstalled and check for damage.
3 Fit the new glass fiber yarn filling into the inner tube.
4 Slide outer tube over the inner tube with the new glass fiber yarn filling.
1 Mount and tighten all screws .
Guideline
Screws on main
M5
silencer
7 Nm (5.2 lbf ft)
H01759-10
Finishing work Install the main silencer. ( p. 59)
11.31 Removing the fuel tank
Danger
Fire hazardFuel is highly flammable. The fuel in the fuel tank expands when
warm and can escape if overfilled. Do not fuel the vehicle in the vicinity
of open flames or lit cigarettes. Switch off the engine for refueling.
Make sure that no fuel is spilled; particularly not on hot parts of the
vehicle. If any fuel is spilled, wipe it off immediately. Observe the
specifications for refueling.
Warning
Danger of poisoningFuel is harmful to health. Avoid skin, eye and clothing
contact with fuel. Immediately consult a doctor if you swallow fuel. Do
not inhale fuel vapors. Rinse the affected area immediately with plenty of
water in the event of contact with the skin. Rinse the eyes thoroughly with
water, and consult a doctor in case of fuel contact with the eyes. Change
your clothing if fuel spills on them. Keep fuels correctly in a suitable
canister, and out of the reach of children.
Preparatory work Remove the seat. ( p. 54) Turn the knurled screw on the
fuel tap all the way clockwise.
60
SERVICE WORK ON THE CHASSIS 11
Main work Pull off the fuel hose.
Info Remaining fuel may flow out of the fuel hose.
1 Remove screws .
S04552-10
2 Remove screw with the rubber bushing.
Pull the fuel tank breather hose off the fuel tank lid.
S04553-10
Pull both spoilers laterally off the radiator and take off the fuel tank upwards.
S04554-10
11.32 Installing the fuel tank
Danger
Fire hazardFuel is highly flammable. The fuel in the fuel tank expands when
warm and can escape if overfilled. Do not fuel the vehicle in the vicinity
of open flames or lit cigarettes. Switch off the engine for refueling.
Make sure that no fuel is spilled; particularly not on hot parts of the
vehicle. If any fuel is spilled, wipe it off immediately. Observe the
specifications for refueling.
Warning
Danger of poisoningFuel is harmful to health. Avoid skin, eye and clothing
contact with fuel. Immediately consult a doctor if you swallow fuel. Do
not inhale fuel vapors. Rinse the affected area immediately with plenty of
water in the event of contact with the skin. Rinse the eyes thoroughly with
water, and consult a doctor in case of fuel contact with the eyes. Change
your clothing if fuel spills on them.
61
11 SERVICE WORK ON THE CHASSIS
Main work Check the throttle cable routing. ( p. 67) Position the fuel
tank and fit the two spoilers laterally to the radia-
tor. Make sure that no cables or throttle cables are trapped or damaged.
S04554-11
Attach the fuel tank breather hose.
1 Mount and tighten screw with the rubber bushing.
Guideline
Remaining screws,
M6
chassis
10 Nm (7.4 lbf ft)
S04553-11
2 Mount and tighten screws .
Guideline
Remaining screws,
M6
chassis
Connect the fuel hose.
10 Nm (7.4 lbf ft)
S04552-11
Finishing work Mount the seat. ( p. 54)
11.33
Checking the chain for dirt
Check the chain for heavy soiling. » If the chain is very dirty: Clean the chain. ( p. 63)
400678-01
62
SERVICE WORK ON THE CHASSIS 11
11.34 Cleaning the chain
Warning
Danger of accidentsLubricants on the tires reduces the road grip. Remove
lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidentsOil or grease on the brake discs reduces the braking
effect. Always keep the brake discs free of oil and grease. Clean the
brake discs with brake cleaner when necessary.
Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.,
correctly and in compliance with the appli-
cable regulations.
Info The service life of the chain depends largely on its maintenance.
Preparatory work Raise the motorcycle with a lift stand. ( p. 42) Main work
Rinse off loose dirt with a soft jet of water. Remove old grease residue
with chain cleaner.
Chain cleaner ( p. 123) After drying, apply chain spray.
Off-road chain spray ( p. 123)
400725-01
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
11.35 Checking the chain tension
Warning
Danger of accidentsIncorrect chain tension damages components and results in
accidents. If the chain is tensioned too much, the chain, engine sprocket,
rear sprocket, transmission and rear wheel bearings wear more quickly. Some
components may break if overloaded. If the chain is too loose, the chain may
fall off the engine sprocket or the rear sprocket. As a result, the rear wheel
locks or the engine will be damaged. Check the chain tension regularly.
Set the chain tension in accordance with the specification.
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
63
11 SERVICE WORK ON THE CHASSIS
Main work Pull the chain at the end of the chain sliding piece upward to
mea-
A sure chain tension .
Guideline
1 Lower chain section must be taut.
K01197-10
Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
Chain tension
55 … 58 mm (2.17 … 2.28 in)
» If the chain tension does not meet the specification: Adjust the chain tension. ( p. 64)
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
11.36 Adjusting the chain tension
Warning
Danger of accidentsIncorrect chain tension damages components and results in
accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket,
transmission and rear wheel bearings wear more quickly. Some components may
break if overloaded. If the chain is too loose, the chain may fall off the
engine sprocket or the rear sprocket. As a result, the rear wheel locks or the
engine will be damaged.
Check the chain tension regularly. Set the chain tension in accordance
with the specification.
I01018-10
Preparatory work Raise the motorcycle with a lift stand. (
Check the chain tension. ( p. 63)
p. 42)
Main work
1 Loosen nut .
2 Loosen nuts .
3 Adjust the chain tension by turning adjusting screws left and right. Guideline
Chain tension
55 … 58 mm (2.17 … 2.28 in)
3 Turn adjusting screws on the left and right so that the mark-
ings on the left and right chain adjusters are in the same position
A relative to reference marks . The rear wheel is then correctly
aligned.
2 Tighten nuts .
4 Make sure that chain adjusters are fitted correctly on adjusting 3 screws .
1 Tighten nut .
Guideline
Nut, rear wheel spindle M25x1.5
80 Nm (59 lbf ft)
64
SERVICE WORK ON THE CHASSIS 11
Info The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary ratios with the same chain length.
4 Chain adjusters can be turned by 180°.
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
11.37
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
Main work Shift the transmission into neutral. Check the chain, rear
sprocket and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn: Change the
drivetrain kit.
400227-01
Info The engine sprocket, rear sprocket and chain should always be replaced together.
A Pull on the top section of the chain with the specified weight .
Guideline
Weight, chain wear measurement
10 … 15 kg (22 … 33 lb.)
B Measure distance of 18 chain rollers in the lower chain section.
Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
B Maximum distance from
18 chain rollers at the longest chain section
272 mm (10.71 in)
B » If distance is greater than the specified measurement:
Change the drivetrain kit.
400987-10
Info When a new chain is mounted, the rear sprocket and the engine sprocket should also be changed. New chains wear out faster on an old, worn rear sprocket or engine sprocket.
65
11 SERVICE WORK ON THE CHASSIS
Check the chain sliding guard for wear.
» If the lower edge of the chain pins is in line with, or below, the chain sliding guard:
Change the chain sliding guard.
Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
Tighten screws on the chain sliding guard.
Guideline
Screw, chain M6 sliding guard
6 Nm (4.4 lbf ft) Loctite®243TM
V01528-10
Check the chain sliding piece for wear.
» If the lower edge of the chain pins is in line with or below the chain sliding piece:
Change the chain sliding piece.
Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
Tighten screw on the chain sliding piece.
Guideline
Screw, chain sliding M8 piece
15 Nm (11.1 lbf ft)
K01199-10
C Check the chain guide with a slide gage for dimension .
C Minimum thickness of the 6 mm (0.24 in)
chain guide » If the measured value is less than the specified value:
Change the chain guide.
402421-10
66
SERVICE WORK ON THE CHASSIS 11
102192-01
Check that the chain guide is firmly seated.
» If the chain guide is loose:
Tighten the screws on the chain guide.
Guideline
Screw, chain guide on link fork at the front
M6x45
10 Nm (7.4 lbf ft)
Screw, chain M6x19 guide on link fork at the rear
10 Nm (7.4 lbf ft) Loctite®243TM
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
11.38 Checking the frame
Check the frame for damage, cracks, and deformation. » If the frame shows signs of damage, cracks, or deformation: Change the frame. Guideline Repairs on the frame are not permitted.
S02306-01
11.39 Checking the link fork
Check the link fork for damage, cracks, and deformation. » If the link fork shows signs of damage, cracks, or deformation: Change the link fork. Guideline Repairs on the link fork are not permitted.
S02305-01
11.40 Checking the throttle cable routing
Warning
Danger of accidentsThe throttle cable can become kinked, trapped or blocked if
it is not routed correctly. If the throttle cable is kinked, trapped or
blocked, the speed can no longer be controlled. Make sure that the throttle
cable routing and the play in throttle cable complies with the specification.
Preparatory work Remove the seat. ( p. 54) Turn the knurled screw on the
fuel tap all the way clockwise. Remove the fuel tank. ( p. 60)
67
11 SERVICE WORK ON THE CHASSIS
Main work Check the throttle cable routing.
The throttle cable must be routed along the back of the handlebar, to the
right of the frame, above the fuel tank bracket, and to the carburetor. The
throttle cable must be secured on the fuel tank bracket with a rubber strap. »
If the throttle cable is not routed as specified:
Correct the throttle cable routing.
V02474-01
Finishing work Install the fuel tank. ( p. 61)
Mount the seat. ( p. 54)
11.41 Checking the rubber grip
Check the rubber grips on the handlebar for damage, wear, and looseness.
401197-01
Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar. The rubber grip can only be replaced with the sleeve or the throttle tube.
» If a rubber grip is damaged or worn: Change the rubber grip.
1 Check that screw is firmly seated.
Guideline
Screw, fixed grip M4
5 Nm (3.7 lbf ft)
Loctite®243TM
A Diamond must be located at the top.
102245-10
68
SERVICE WORK ON THE CHASSIS 11
11.42
Adjusting the basic position of the clutch lever
Adjust the basic position of the clutch lever to your hand size by
1 turning adjusting screw .
J00081-10
Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding.
11.43 Checking/correcting the fluid level of hydraulic clutch
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of
the reach of children. Wear suitable protective clothing and safety glasses.
Do not allow brake fluid to come into contact with the skin, the eyes or
clothing. Consult a doctor immediately if brake fluid has been swallowed.
Rinse the affected area with plenty of water in the event of contact with the
skin. Rinse eyes thoroughly with water immediately and consult a doctor if
brake fluid comes into contact with the
eyes. If brake fluid spills on to your clothing, change the clothing.
Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint. Only use clean brake fluid from a sealed container.
H04933-01
Move the hydraulic clutch fluid reservoir mounted on the handlebar into a
horizontal position.
1 Remove screws . 2 3 Take off cover with membrane .
Check the fluid level. Fluid level below container rim 4 mm (0.16 in)
» If the fluid level does not meet specifications: Correct the fluid level
of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 ( p. 121)
Position the cover with the membrane. Mount and tighten the screws.
Info Use water to immediately clean up any brake fluid that has overflowed or spilled.
69
11 SERVICE WORK ON THE CHASSIS
11.44 Changing the hydraulic clutch fluid
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of
the reach of children. Wear suitable protective clothing and safety glasses.
Do not allow brake fluid to come into contact with the skin, the eyes or
clothing. Consult a doctor immediately if brake fluid has been swallowed.
Rinse the affected area with plenty of water in the event of contact with the
skin. Rinse eyes thoroughly with water immediately and consult a doctor if
brake fluid comes into contact with the
eyes. If brake fluid spills on to your clothing, change the clothing.
Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.,
correctly and in compliance with the appli-
cable regulations.
Info Never use DOT 5 brake fluid. It is silicone-based and purple in color.
Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid
contact between brake fluid and painted parts. Brake fluid corrodes paint.
Only use clean brake fluid from a sealed container.
Move the hydraulic clutch fluid reservoir mounted on the handlebar into a
horizontal position.
1 Remove screws . 2 3 Take off cover with membrane .
H04933-01
4 Fill bleeding syringe with the appropriate hydraulic fluid.
Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 121)
5 On the clutch slave cylinder, remove bleeder screw and mount 4 bleeding
syringe .
H04934-01
70
SERVICE WORK ON THE CHASSIS 11
H04932-01
6 Now press the fluid into the system until it emerges from hole of the
master cylinder without bubbles. Occasionally extract the fluid from the
master cylinder reservoir to
prevent overflowing. Remove the bleeding syringe. Mount and tighten the
bleeder screw. Correct the fluid level of the hydraulic clutch.
Guideline Fluid level below container rim 4 mm (0.16 in)
Position the cover with the membrane. Mount and tighten the screws.
Info Use water to immediately clean up any brake fluid that has overflowed or spilled.
71
12 BRAKE SYSTEM
12.1 Checking the free travel of the hand brake lever
Warning
Danger of accidentsThe brake system fails in the event of overheating. If
there is no free travel on the hand brake lever, pressure builds up on the
front brake circuit. Set the free travel on the hand brake lever in
accordance with the specification.
A Push the hand brake lever forward and check free travel .
Free travel of hand brake lever 3 mm ( 0.12 in) » If the free travel does not
match the specification:
Check brake system for damage.
12.2
I01020-10
Adjusting the basic position of the hand brake lever
Check the free travel of the hand brake lever. ( p. 72) Adjust the basic
position of the hand brake lever to your hand size
1 by turning adjusting screw .
I01021-10
Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar. The range of adjustment is limited. Only turn the adjusting screw by hand, and do not use force. Do not make any adjustments while riding.
12.3 Checking the brake discs
Warning
Danger of accidentsWorn-out brake discs reduce the braking effect. Make sure
that worn-out brake discs are replaced immediately. (Your authorized GASGAS
Motorcycles work-
shop will be glad to help.)
Check the front and rear brake disc thickness at multiple points for
A the dimension .
H00938-10
Info Wear reduces the thickness of the brake disc around the contact surface of the brake linings.
Brake discs – wear limit front rear
2.5 mm (0.098 in) 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
72
BRAKE SYSTEM 12
Change the front brake disc. Change the rear brake disc. Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc exhibits damage, cracking, or deformation: Change the front brake disc. Change the rear brake disc.
12.4 Checking the front brake fluid level
Warning
Danger of accidentsAn insufficient brake fluid level will cause the brake
system to fail. If the brake fluid level drops below the specified marking or
the specified value, the brake system is leaking or the brake linings are worn
down. Check the brake system and do not continue riding until the problem is
eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidentsOld brake fluid reduces the braking effect. Make sure
that brake fluid for the front and rear brake is changed in accordance with
the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Preparatory work Check the front brake linings. ( p. 75) Main work Move
the brake reservoir mounted on the handlebar to a horizontal
position.
1 Check the brake fluid level in level viewer . A » If the brake fluid level
has dropped below the marking :
Add front brake fluid. ( p. 73)
12.5
S04558-10
Adding front brake fluid
Warning
Danger of accidentsAn insufficient brake fluid level will cause the brake
system to fail. If the brake fluid level drops below the specified marking or
the specified value, the brake system is leaking or the brake linings are worn
down. Check the brake system and do not continue riding until the problem is
eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
73
12 BRAKE SYSTEM
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of
the reach of children. Wear suitable protective clothing and safety glasses.
Do not allow brake fluid to come into contact with the skin, the eyes or
clothing. Consult a doctor immediately if brake fluid has been swallowed.
Rinse the affected area with plenty of water in the event of contact with the
skin. Rinse eyes thoroughly with water immediately and consult a doctor if
brake fluid comes into contact with the
eyes. If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidentsOld brake fluid reduces the braking effect. Make sure
that brake fluid for the front and rear brake is changed in accordance with
the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.,
correctly and in compliance with the appli-
cable regulations.
Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint. Only use clean brake fluid from a sealed container.
Preparatory work Check the front brake linings. ( p. 75)
Main work Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
1 Remove screws .
2 3 Take off cover with membrane .
A Add brake fluid to level .
Guideline
A Level (brake fluid level
below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 121)
2 3 Position cover with membrane . Mount and tighten 1 screws .
Info Use water to immediately clean up any brake fluid that has overflowed or spilled.
I00180-10
74
BRAKE SYSTEM 12
12.6 Checking the front brake linings
Warning
Danger of accidentsWorn-out brake linings reduce the braking effect. Ensure
that worn-out brake linings are replaced immediately. (Your authorized GASGAS
Motorcycles workshop
will be glad to help.)
12.7
I01025-10
A Check the brake linings for minimum thickness .
A Minimum thickness
1 mm ( 0.04 in)
» If the minimum thickness is less than specified: Change the brake linings
of the front brake. ( p. 75)
Check the brake linings for damage and cracking. » If damage or wear is
encountered: Change the brake linings of the front brake. ( p. 75)
Changing the brake linings of the front brake
Warning
Danger of accidentsIncorrect servicing will cause the brake system to fail.
Ensure that service work and repairs are performed professionally. (Your
authorized GASGAS Motorcy-
cles workshop will be glad to help.)
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of
the reach of children. Wear suitable protective clothing and safety glasses.
Do not allow brake fluid to come into contact with the skin, the eyes or
clothing. Consult a doctor immediately if brake fluid has been swallowed.
Rinse the affected area with plenty of water in the event of contact with the
skin. Rinse eyes thoroughly with water immediately and consult a doctor if
brake fluid comes into contact with the
eyes. If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidentsOld brake fluid reduces the braking effect. Make sure
that brake fluid for the front and rear brake is changed in accordance with
the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidentsOil or grease on the brake discs reduces the braking
effect. Always keep the brake discs free of oil and grease. Clean the
brake discs with brake cleaner when necessary.
75
12 BRAKE SYSTEM
Warning
Danger of accidentsBrake linings which have not been approved alter the
braking efficiency. Not all brake linings are tested and approved for GASGAS
motorcycles. The structure and friction coefficient of the brake linings, and
thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance
with the original homologation is not guaranteed. In this case, the vehicle no
longer corresponds to its condition at delivery and the manufacturer warranty
shall be void. Only use brake linings approved and recommended by GASGAS
Motorcycles.
Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.,
correctly and in compliance with the appli-
cable regulations.
Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint. Only use clean brake fluid from a sealed container.
Move the brake fluid reservoir mounted on the handlebar to a horizontal
position.
1 Remove screws . 2 3 Take off cover with membrane .
Manually press the brake caliper toward the brake disc to push back the
brake pistons. Ensure that brake fluid does not flow out of the brake fluid
reservoir, extract some if necessary.
A00829-10
Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.
4 5 Remove cotter pins , pull out pin , and remove the brake linings. Clean the brake caliper and the brake caliper bracket.
J00078-10
76
BRAKE SYSTEM 12
6 Check that spring plate in the brake caliper and brake pad slid7 ing plate
in the brake caliper bracket are seated correctly.
100397-01
5 Insert the new brake linings, insert pin , and mount cotter pins 4.
Guideline
Mount the outer cotter pins from the front to the rear.
Mount the inner cotter pins from the rear to the front.
Info Always change the brake linings in pairs. Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
J00079-10
A Correct the brake fluid level to level .
Guideline
A Level (brake fluid level
below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 121)
2 3 Position cover with membrane . Mount and tighten 1 screws .
Info Use water to immediately clean up any brake fluid that has overflowed or spilled.
A00855-10
77
12 BRAKE SYSTEM
12.8 Checking the free travel of foot brake lever
Warning
Danger of accidentsThe brake system fails in the event of overheating. If
there is no free travel on the foot brake lever, pressure builds up in the
brake system on the rear brake. Set the free travel on the foot brake lever
in accordance with the specification.
402026-10
1 Disconnect spring .
Move the foot brake lever back and forth between the end stop and the
contact to the foot brake cylinder piston and check free
A travel .
Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not meet specifications: Adjust the basic position
of the foot brake lever. ( p. 78)
1 Reconnect spring .
12.9 Adjusting the basic position of the foot brake lever
Warning
Danger of accidentsThe brake system fails in the event of overheating. If
there is no free travel on the foot brake lever, pressure builds up in the
brake system on the rear brake. Set the free travel on the foot brake lever
in accordance with the specification.
1 Detach spring .
2 3 Loosen nut and, with push rod , turn it back until you have maximum free
travel. To adjust the basic position of the foot brake lever to individual
4 5 requirements, loosen nut and turn screw accordingly.
Info The range of adjustment is limited.
J00118-10
3 A Turn push rod accordingly until you have free travel . If necessary, adjust the basic position of the foot brake lever. Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
3 2 Hold push rod and tighten nut .
Guideline Remaining nuts, chas- M6 sis
10 Nm (7.4 lbf ft)
5 4 Hold screw and tighten nut .
Guideline Nut, foot brake lever M8 stop
20 Nm (14.8 lbf ft)
1 Attach spring .
78
BRAKE SYSTEM 12
12.10 Checking the rear brake fluid level
Warning
Danger of accidentsAn insufficient brake fluid level will cause the brake
system to fail. If the brake fluid level drops below the specified marking or
the specified value, the brake system is leaking or the brake linings are worn
down. Check the brake system and do not continue riding until the problem is
eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidentsOld brake fluid reduces the braking effect. Make sure
that brake fluid for the front and rear brake is changed in accordance with
the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Preparatory work Check the brake linings of the rear brake. ( p. 80) Main
work Stand the vehicle upright.
1 Check the brake fluid level in level viewer . A » If the brake fluid has
dropped below marking :
Add rear brake fluid. ( p. 79)
S04559-10
12.11 Adding rear brake fluid
Warning
Danger of accidentsAn insufficient brake fluid level will cause the brake
system to fail. If the brake fluid level drops below the specified marking or
the specified value, the brake system is leaking or the brake linings are worn
down. Check the brake system and do not continue riding until the problem is
eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of
the reach of children. Wear suitable protective clothing and safety glasses.
Do not allow brake fluid to come into contact with the skin, the eyes or
clothing. Consult a doctor immediately if brake fluid has been swallowed.
Rinse the affected area with plenty of water in the event of contact with the
skin. Rinse eyes thoroughly with water immediately and consult a doctor if
brake fluid comes into contact with the
eyes. If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidentsOld brake fluid reduces the braking effect. Make sure
that brake fluid for the front and rear brake is changed in accordance with
the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
79
12 BRAKE SYSTEM
Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc.,
correctly and in compliance with the appli-
cable regulations.
Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
S04561-10
Preparatory work Check the brake linings of the rear brake. ( p. 80)
Main work Stand the vehicle upright.
1 2 Remove screw cap with membrane and the O-ring. A Add brake fluid to
level .
Brake fluid DOT 4 / DOT 5.1 ( p. 121) Mount the screw cap with the membrane
and the O-ring.
Info Clean up overflowed or spilled brake fluid immediately with water.
12.12 Checking the brake linings of the rear brake
Warning
Danger of accidentsWorn-out brake linings reduce the braking effect. Ensure
that worn-out brake linings are replaced immediately. (Your authorized GASGAS
Motorcycles workshop
will be glad to help.)
J00083-10
A Check the brake linings for minimum thickness .
A Minimum thickness
1 mm ( 0.04 in)
» If the minimum thickness is less than specified: Change the rear brake
linings. ( p. 81)
Check the brake linings for damage and cracking. » If damage or wear is
encountered: Change the rear brake linings. ( p. 81)
80
BRAKE SYSTEM 12
12.13 Changing the rear brake linings Warning
Danger of accidentsIncorrect servicing will cause the brake system to fail.
Ensure that service work and repairs are performed professionally. (Your
authorized GASGAS Motorcy-
cles workshop will be glad to help.)
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of
the reach of children. Wear suitable protective clothing and safety glasses.
Do not allow brake fluid to come into contact with the skin, the eyes or
clothing. Consult a doctor immediately if brake fluid has been swallowed.
Rinse the affected area with plenty of water in the event of contact with the
skin. Rinse eyes thoroughly with water immediately and consult a doctor if
brake fluid comes into contact with the
eyes. If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidentsOld brake fluid reduces the braking effect. Make sure
that brake fluid for the front and rear brake is changed in accordance with
the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.) Note
Environmental hazardHazardous substances cause environmental damage. Dispose
of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly
and in compliance with the appli-
cable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and
purple in color. Oil seals and brake lines are not designed for DOT 5 brake
fluid. Avoid contact between brake fluid and painted parts. Brake fluid
corrodes paint. Only use clean brake fluid from a sealed container.
Stand the vehicle upright.
1 2 Remove screw cap with membrane and the O-ring.
S04560-10
81
12 BRAKE SYSTEM
Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.
J00084-10
Info Make sure that you do not press the brake caliper against the spokes when
pushing back the brake piston.
3 4 Remove cotter pins , pull out pin , and remove the brake linings.
Clean the brake caliper and the brake caliper bracket.
5 Check that spring plate in the brake caliper and brake pad slid6 ing plate
in the brake caliper bracket are seated correctly.
Info The arrow on the spring plate points in the direction of rotation of the brake disc.
J00085-10
4 Insert the new brake linings, insert pin , and mount cotter pins 3.
Info Always change the brake linings in pairs.
7 Make sure that decoupling plate is mounted on the pis-
ton side brake lining.
Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
J00088-10
A Correct brake fluid level to marking .
Brake fluid DOT 4 / DOT 5.1 ( p. 121)
1 2 Mount and tighten screw cap with membrane and the Oring.
K01185-10
Info Use water to immediately clean up any brake fluid that has overflowed or spilled.
82
WHEELS, TIRES 13
13.1
Removing the front wheel
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
Main work Manually press the brake caliper toward the brake disc to push
back
the brake pistons.
Info Make sure that you do not press the brake caliper against the spokes when
pushing back the brake pistons.
J00082-10
1 Loosen screw by several rotations. 2 Loosen screws . 1 Press on screw to push the wheel spindle out of the axle clamp. 1 Remove screw .
K00454-10
Warning
Danger of accidentsDamaged brake discs reduce the braking effect. Always lay
the wheel down in such a way that the brake
disc is not damaged.
H01340-10
Hold front wheel and remove wheel spindle. Take the front wheel out of the fork. Info Do not actuate the hand brake lever when the front wheel is removed.
3 Remove spacers .
H00934-10
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13 WHEELS, TIRES
13.2 Installing the front wheel
Warning
Danger of accidentsOil or grease on the brake discs reduces the braking
effect. Always keep the brake discs free of oil and grease. Clean the
brake discs with brake cleaner when necessary.
H00935-10 K00454-11
Check the wheel bearing for damage and wear. » If the wheel bearing is
damaged or worn: Change front wheel bearing.
1 A Clean and grease shaft seal rings and contact surfaces of the spacers.
Long-life grease ( p. 123)
Insert the spacers. Clean and grease the wheel spindle.
Long-life grease ( p. 123)
Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned.
2 Mount and tighten screw .
Guideline
Screw, front wheel spindle
M20x1.5
35 Nm (25.8 lbf ft)
Operate the hand brake lever several times until the brake linings are
seated correctly against the brake disc.
Remove the motorcycle from the lift stand. ( p. 42) Operate the front
brake and compress the fork a few times firmly.
The fork legs straighten.
3 Tighten screws .
Guideline
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
13.3
Removing the rear wheel
Preparatory work Raise the motorcycle with a lift stand. ( p. 42)
84
WHEELS, TIRES 13
Main work Manually press the brake caliper toward the brake disc to push
back
the brake piston.
Info Make sure that you do not press the brake caliper against the spokes when
pushing back the brake piston.
1 Remove nut . 2 3 Take off chain adjuster . Pull out wheel spindle far
enough to
allow the rear wheel to be pushed forward. Push the rear wheel forward as
far as possible. Remove the chain
from the rear sprocket.
Info Cover the components to protect them against damage.
I01016-10
Warning
Danger of accidentsDamaged brake discs reduce the braking effect. Always lay
the wheel down in such a way that the brake
disc is not damaged.
Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.
Info Do not operate the foot brake lever when the rear wheel is removed.
4 Remove spacers .
13.4
H03002-10
Installing the rear wheel
Warning
Danger of accidentsOil or grease on the brake discs reduces the braking
effect. Always keep the brake discs free of oil and grease. Clean the
brake discs with brake cleaner when necessary.
85
13 WHEELS, TIRES
H03001-10
Main work Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn: Change the rear wheel bearing.
1 A Clean and grease shaft seal rings and contact surfaces of the spacers.
Long-life grease ( p. 123)
Insert the spacers. Clean and grease the wheel spindle.
Long-life grease ( p. 123)
2 Position rear wheel and insert wheel spindle .
The brake linings are correctly positioned. Mount the chain.
H00006-10
3 4 Position chain adjuster . Mount nut , but do not tighten it yet.
3 Make sure that chain adjusters are fitted correctly on adjusting 5 screws .
Check the chain tension. ( p. 63)
4 Tighten nut .
Guideline
Nut, rear wheel spindle M25x1.5
80 Nm (59 lbf ft)
Info The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary ratios with the same chain length.
3 Chain adjusters can be turned by 180°.
Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
I01017-10
Finishing work Remove the motorcycle from the lift stand. ( p. 42)
86
WHEELS, TIRES 13
13.5 Checking the tire condition
Info Only mount tires approved and/or recommended by GASGAS Motorcycles. Other
tires could have a negative effect on handling characteristics. The type,
condition, and pressure of the tires all have a major impact on the handling
characteristic of the motorcycle. The tires mounted on the front and rear
wheels must have a similar profile. Worn tires have a negative effect on
handling characteristics, especially on wet surfaces.
Check the front and rear tires for cuts, embedded objects, and other damage.
» If the tires have cuts, run-in objects, or other damage: Change the tires.
400602-10 H01144-01
Check the tire age.
Info The tire date of manufacture is usually contained in the tire label and
is indicated by the last four digits of the DOT number. The first two digits
indicate the week of manufacture and the last two digits the year of
manufacture. GASGAS Motorcycles recommends that the tires be changed after
five years at the latest, regardless of the actual wear.
» If the tires are more than five years old: Change the tires.
13.6 Checking tire pressure
Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures optimal riding comfort and maximum tire service life.
400695-01
Remove the protection cap. Check the tire pressure when the tires are cold.
Offroad tire pressure front rear
1.0 bar (15 psi) 1.0 bar (15 psi)
» If the tire pressure does not meet specifications: Correct the tire
pressure.
Mount the protection cap.
87
13 WHEELS, TIRES
13.7 Checking spoke tension
Warning
Danger of accidentsIncorrectly tensioned spokes impair the handling
characteristic and result in secondary damage. The spokes break due to being
overloaded if they are too tightly tensioned. If the tension in the spokes is
too low, then lateral and radial run-out will form in the wheel. Other spokes
will become looser as a result. Check spoke tension regularly, and in
particular on a new vehicle. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
400694-01
Strike each spoke briefly using a screwdriver blade.
Info The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
You should hear a high note.
» If the spoke tension differs:
Correct the spoke tension.
Check the spoke torque.
Guideline
Spoke nipple, front wheel
M4.5
Spoke nipple, rear wheel
M4.5
Torque wrench kit (58429094000)
6 Nm (4.4 lbf ft) 6 Nm (4