GASGAS TXT RACING 125 / TXT RACING 250 / TXT RACING 280 / TXT RACING 300 / TXT GP 250 / TXT GP 300. OWNER'S MANUAL (2024)

TABLE OF CONTENTS

MEANS OF REPRESENTATION

6.19

Side stand

6.20

Locking the steering (Option:

1.1

Symbols used

Homologized)

1.2

Formats used

6.21

Unlocking the steering (Option:

SAFETY ADVICE

Homologized)

6.22

Opening the fuel tank filler cap

2.1

Use definition - intended use

6.23

Closing the fuel tank filler cap

2.2

Misuse

COMBINATION INSTRUMENT (OPTION:

2.3

Safety advice

HOMOLOGIZED)

2.4

Degrees of risk and symbols

2.5

Tampering warning

7.1

Overview

2.6

Safe operation

7.2

Activation

2.7

Protective clothing

7.3

Messages on the combination

2.8

Work rules

instrument

2.9

Environment

7.4

Setting the combination instrument

2.10

Owner's Manual

7.5

Setting kilometers or miles

7.6

Setting the clock

IMPORTANT NOTES

7.7

Setting the service display

3.1

Manufacturer and implied warranty

7.8

Speed, time, and DST distance 1

3.2

Fuel, auxiliary substances

7.9

Speed, time, and DST2 distance 2

3.3

Spare parts, accessories

7.10

AVG average speed, ART operating

3.4

Service

hours, and ODO total distance covered

3.5

Figures

PREPARING FOR USE

3.6

Customer service

8.1

Advice on preparing for first use

VIEW OF VEHICLE

8.2

Running in the engine

4.1

View of vehicle, front left (example)

8.3

Preparing the vehicle for difficult

4.2

View of vehicle, rear right (example)

operating conditions

SERIAL NUMBERS

RIDING INSTRUCTIONS

5.1

Vehicle identification number

9.1

Checks and maintenance measures

5.2

Type label

when preparing for use

5.3

Engine number

9.2

Starting

5.4

Fork article number

9.3

Starting off

9.4

Shifting, riding

CONTROLS

9.5

Braking

6.1

Clutch lever

9.6

Stopping, parking

6.2

Hand brake lever

9.7

Transporting

6.3

Throttle grip

9.8

Refueling

6.4

Magnetic switch (Option: Not

SERVICE SCHEDULE

homologized)

6.5

Stop button (Option: Homologized)

10.1

Additional information

6.6

Light switch (Option: Not homologized)

10.2

Service schedule

6.7

Light switch (Option: Homologized)

TUNING THE CHASSIS

6.8

Horn button (Option: Homologized)

6.9

Turn signal switch (Option:

11.1

Checking the basic chassis setting with

Homologized)

the rider's weight

6.10

Map switch (Option: Not homologized)

11.2

Adjusting the rebound damping of the

6.11

Overview of indicator lights (Option:

shock absorber

Homologized)

11.3

Adjusting the compression damping of

6.12

Steering lock (Option: Homologized)

the shock absorber (All GP models)

6.13

Fuel tap

11.4

Measuring the dimension of the rear

6.14

Choke button (Option: Not

wheel unloaded

homologized)

11.5

Checking the static sag of the shock

6.15

Choke lever (Option: Homologized)

absorber

6.16

Shift lever

11.6

Adjusting the spring preload of the

6.17

Kick starter lever

shock absorber

6.18

Foot brake lever

TABLE OF CONTENTS

11.7

Checking the riding sag of the shock

12.41

Adjusting the free travel of the clutch

absorber

lever

11.8

Adjusting the riding sag

12.42

Adjusting the basic position of the clutch

11.9

Basic setting of the fork

lever

11.10

Adjusting the rebound damping of the

12.43

Checking/correcting the fluid level of

fork

hydraulic clutch

11.11

Adjusting the compression damping of

12.44

Changing the hydraulic clutch fluid

the fork (All GP models)

BRAKE SYSTEM

11.12

Adjusting the spring preload of the fork

11.13

Adjusting fork fluid barrier

13.1

Checking the free travel of the hand

brake lever

SERVICE WORK ON THE CHASSIS

13.2

Adjusting the free travel of the hand

12.1

Raising the motorcycle with a lift stand

brake lever

12.2

Removing the motorcycle from the lift

13.3

Adjusting the basic position of the hand

stand

brake lever

12.3

Cleaning the dust boots of the fork legs

13.4

Removing front brake disc guard

12.4

Removing the fork legs

13.5

Installing the front brake disc guard

12.5

Installing the fork legs

13.6

Removing front brake caliper

12.6

Removing the lower triple clamp

13.7

Installing the front brake caliper

12.7

Installing the lower triple clamp

13.8

Checking the front brake fluid level

12.8

Checking the steering head bearing play ... 47

13.9

Adding front brake fluid

12.9

Adjusting the steering head bearing

13.10

Checking that the brake linings of the

play

front brake are secured

12.10

Lubricating the steering head bearing

13.11

Changing the brake linings of the front

brake

12.11

Removing the headlight mask

12.12

Installing the headlight mask

13.12

Checking brake discs

13.13

Checking the free travel of the foot

12.13

Checking the headlight setting (Option:

Homologized)

brake lever

12.14

Removing the front fender

13.14

Adjusting the basic position of the foot

brake lever

12.15

Installing the front fender

13.15

Checking the rear brake fluid level

12.16

Removing the rear fender

13.16

Adding rear brake fluid

12.17

Installing the rear fender

13.17

Checking that the brake linings of the

12.18

Removing the shock absorber

rear brake are secured

12.19

Installing the shock absorber

13.18

Changing the rear brake linings

12.20

Removing the air filter box

12.21

Installing the air filter box

WHEELS, TIRES

12.22

Removing the air filter

14.1

Removing the front wheel

12.23

Installing the air filter

14.2

Installing the front wheel

12.24

Cleaning the air filter and air filter box

14.3

Removing the rear wheel

12.25

Removing the manifold

14.4

Installing the rear wheel

12.26

Installing the manifold

14.5

Checking the tire condition

12.27

Removing the main silencer

14.6

Checking tire pressure

12.28

Installing the main silencer

14.7

Checking the spoke tension

12.29

Changing the glass fiber yarn filling of

the main silencer

ELECTRICAL SYSTEM

12.30

Removing the fuel tank

15.1

Diagnostics connector

12.31

Installing the fuel tank

15.2

Changing the headlight bulb (Option:

12.32

Checking the chain for dirt

Homologized)

12.33

Cleaning the chain

15.3

Changing the position light lamp

12.34

Checking the chain tension

(Option: Homologized)

12.35

Adjusting the chain tension

15.4

Changing the turn signal bulb (Option:

12.36

Checking the chain, rear sprocket,

Homologized)

engine sprocket, and chain guide

12.37

Checking the frame

COOLING SYSTEM

12.38

Checking the link fork

16.1

Cooling system

12.39

Checking the rubber grip

16.2

Checking the coolant level

12.40

Checking the free travel of the clutch

16.3

Checking the antifreeze and coolant

lever

level

TABLE OF CONTENTS

16.4

Draining the coolant

INDEX OF SPECIAL TERMS

129

16.5

Refilling with coolant

100

LIST OF ABBREVIATIONS

130

16.6

Changing the coolant

101

LIST OF SYMBOLS

131

TUNING THE ENGINE

103

28.1

Yellow and orange symbols

131

17.1

Checking the play in the throttle cable....

103

28.2

Green and blue symbols

131

17.2

Adjusting the play in the throttle

cable

103

INDEX

132

17.3

Carburetor tuning

104

17.4

Carburettor - idle speed

106

17.5

Carburetor - adjusting the idle

speed

106

17.6

Checking the basic position of the shift

lever

107

17.7

Adjusting the basic position of the shift

lever

107

SERVICE WORK ON THE ENGINE

108

18.1

Emptying the carburetor

float chamber (Option: Not

homologized)

108

18.2

Checking the gear oil level

109

18.3

Adding the gear oil

109

18.4

Changing the gear oil

109

CLEANING, CARE

111

19.1

Cleaning the motorcycle

111

STORAGE

113

20.1

Storage

113

20.2

Preparing for use after storage

114

TROUBLESHOOTING

115

TECHNICAL SPECIFICATIONS

117

22.1

Engine

117

22.2

Engine tightening torques

117

22.3

Carburetor

118

22.3.1

Option: Homologized

118

22.3.2

Option: Not homologized

118

22.4

Capacities

119

22.4.1

Gear oil

119

22.4.2

Coolant

119

22.4.3

Fuel

119

22.5

Chassis

119

22.6

Electrical system

120

22.7

Tires

120

22.8

Fork

120

22.8.1

All RACING models

120

22.8.2

All GP models

121

22.9

Shock absorber

121

22.9.1

All RACING models

121

22.9.2

All GP models

121

22.10

Chassis tightening torques

122

SUBSTANCES

124

AUXILIARY SUBSTANCES

126

STANDARDS

128

MEANS OF REPRESENTATION

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.

Denotes 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.

Brand™

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.

SAFETY ADVICE

2.1

Use definition - intended use

(All EU models)

This vehicle has been designed and built to withstand the normal stresses and strains of trial use.

Info

This vehicle is only authorized for operation on public roads in the homologated (restricted) version.

The derestricted version of this vehicle must only be operated in closed off areas away from public highway

traffic.

This vehicle has been designed for trial use and not for motocross.

(All US models)

This vehicle has been designed and built to withstand the normal stresses and strains of trial use.

Info

This vehicle is not approved for use on public roads.

This vehicle has been designed for trial use and not for motocross.

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 respec-

tive 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.

SAFETY ADVICE

2.5

Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

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

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:

Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust

gases.

Removal or puncturing of parts of the intake system.

Lack of proper maintenance.

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 accidents A 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 poisoning Exhaust 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 burns Some vehicle components become hot when the vehicle is operated.

- Do not touch any parts such as the exhaust system, radiator, engine, damper, or brake system before the vehi-

cle 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. An appropriate driver's license is needed to drive the vehicle on public

roads.

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 injury Missing 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 pro-

tective clothing.

SAFETY ADVICE

2.8

Work rules

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with transpon-

der key) or the motor must be at a standstill (models without ignition lock or transponder 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

20 °C (68 °F)

Ambient air pressure

1,013 mbar (14.69 psi)

Relative air humidity

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, used components, and, if applicable, the end-of-life motor-

cycle, comply with the respective laws and regulations of the respective country.

2.10

Owner's Manual

Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful infor-

mation 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 down-

loaded 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 also available for download from your authorized GASGAS Motorcycles dealer and on the GAS-

GAS Motorcycles website. A printed copy can also be ordered from your authorized GASGAS Motorcycles dealer.

International GASGAS Motorcycles website: http://www.gasgas.com

IMPORTANT NOTES

3.1

Manufacturer and 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 dam-

age caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

3.2

Fuel, auxiliary substances

Note

Environmental hazard Improper 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 current accessories for 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 neces-

sary 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

CONTROLS

6.1

Clutch lever

Clutch lever 1 is fitted on the handlebar on the left.

The clutch is activated hydraulically and adjusts itself automatically.

I00086-10

6.2

Hand brake lever

The hand brake lever 1 is located on the right side of the handlebar.

The front brake is engaged using the hand brake lever.

I00087-10

6.3

Throttle grip

The throttle grip 1 is fitted on the right side of the handlebar.

I00087-11

6.4

Magnetic switch (Option: Not homologized)

The holder for the magnetic switch 1 is located on the left side of the

handlebar.

Possible states

• Magnetic switch mounted - When the magnetic switch is

mounted, the vehicle can be started and ridden.

• Magnetic switch removed - When the magnetic switch is

removed, the vehicle cannot be started or ridden.

I00086-11

Warning

Risk of injury If the magnetic switch remains in the holder

during a fall, the vehicle is not immediately deactivated.

- Make sure that the loop of the magnetic switch is securely

attached to the user’s protective clothing or wrist so that

the magnetic switch is disconnected from the holder in the

event of a fall.

CONTROLS

If the red magnetic switch on the handlebar is disconnected from the

holder, e.g., in the event of a fall, the vehicle is switched off.

By removing the magnetic switch from the handlebar, the vehicle can be

quickly switched off in any operating state.

6.5

Stop button (Option: Homologized)

The stop button 1 is located on the right 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.

I00140-10

6.6

Light switch (Option: Not homologized)

The light switch 1 is mounted on the frame on the left behind the

steering head.

Info

The light switch has no function in the homologated (restricted)

condition of the motorcycle.

Possible states

Light on - Light switch is tilted to the rear. In this position,

I00088-10

the front light and the tail light are switched on.

Light off - Light switch is tilted to the front. In this position,

the front light and the tail light are switched off.

6.7

Light switch (Option: Homologized)

Light switch 1 is fitted on the left side of the handlebar.

Possible states

Low beam on - Light switch is in the central position. In

this position, the low beam and tail light are switched on.

High beam on - Light switch is turned to the left. In this

position, the high beam and the tail light are switched on.

I00141-10

CONTROLS

6.8

Horn button (Option: Homologized)

Horn button 1 is fitted on the left side of the handlebar.

Possible states

• The horn button is in the basic position

• The horn button is pressed - The horn is operated in this posi-

tion.

I00141-11

6.9

Turn signal switch (Option: Homologized)

Turn signal switch 1 is fitted on the left side of the handlebar

Possible states

• Turn signal off - The turn signal switch is in the central position.

• Right turn signal, on - The turn signal switch is turned to the right.

• Left turn signal, on - The turn signal switch is turned to the left.

I00141-12

6.10

Map switch (Option: Not homologized)

The map switch 1 is mounted on the frame on the right behind the

steering head.

Possible states

Map switch tilted backwards. - The ignition timing

map Performance is active in this position.

Map switch tilted forwards. - The ignition timing map Soft

is active in this position.

The engine characteristic can be altered with the map switch.

I00089-10

Info

The map switch has no function in the homologated (restricted)

condition of the motorcycle.

6.11

Overview of indicator lights (Option: Homologized)

Possible states

The high beam indicator lamp lights up blue - The high

beam is switched on.

Malfunction indicator lamp lights up/flashes yellow - The

OBD has detected an error in the vehicle electronics. Come

safely to a halt, and contact an authorized GASGAS Motor-

cycles workshop.

Turn signal indicator lamp flashes green - The turn signal is

switched on.

I00149-10

CONTROLS

6.12

Steering lock (Option: Homologized)

Steering lock 1 is located below the upper triple clamp.

The steering lock is used to lock the steering. Steering, and therefore

riding, is no longer possible.

I00142-10

6.13

Fuel tap

The fuel tap is on the left side of the fuel tank.

Open or close the fuel supply to the carburetor using tap handle 1 on

the fuel tap.

Possible states

• Fuel supply closed OFF, tap handle faces the rear - No fuel can flow

from the fuel tank to the carburetor.

• Fuel supply open ON, tap handle faces downward - Fuel can flow

from the fuel tank to the carburetor. The fuel tank empties down

to the reserve level.

I00090-10

• Fuel reserve open RES, fuel tap faces the front - Fuel can flow from

the fuel tank to the carburetor. The fuel tank empties completely.

6.14

Choke button (Option: Not homologized)

Choke 1 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 mix-

ture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

I00118-10

• Choke function activated - The choke lever is pulled out to the

stop.

• Choke function deactivated - The choke lever is pushed in to the

stop.

6.15

Choke lever (Option: Homologized)

The choke lever 1 is fitted on the left side of the handlebar.

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 mix-

ture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

I00141-14

• Choke function activated - Choke lever pulled out all the way.

CONTROLS

6.19

Side stand

The side stand 1 is located on the right of the vehicle.

E01323-01

The side stand 1 is used for parking the motorcycle.

Info

The side stand 1 must be folded up during motorcycle use.

E01322-01

6.20

Locking the steering (Option: Homologized)

Preparatory work

- Stop and park. ( p. 29)

Main work

- Turn handlebar as far as possible to the right.

- Insert the key for the steering lock into the steering lock, turn it to

the left, press it in, and turn it to the right. Pull out the key for the

steering lock.

Steering is no longer possible.

Info

Never leave the key for the steering lock in the steering lock.

400732-01

6.21

Unlocking the steering (Option: Homologized)

- Insert the key for the steering lock into the steering lock, turn it to

the left, pull it out, and turn it to the right. Pull out the key for the

steering lock.

The handlebar can now be moved again.

Info

Never leave the key for the steering lock in the steering lock.

400731-01

CONTROLS

6.22

Opening the fuel tank filler cap

Danger

Fire hazard Fuel 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 poisoning Fuel 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 hazard Improper handling of fuel is a danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

- Fold up fuel tank quick release 1, turn it counterclockwise and

take it off by pulling it upward.

I00091-10

6.23

Closing the fuel tank filler cap

- Put on the fuel tank quick release 1 with the label GASGAS facing

upward and turn it clockwise until the fuel tank is firmly closed.

Guideline

Route vent hose free of kinks.

I00091-10

COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED)

7.1

Overview

1 Overview of indicator lights ( p. 15)

2 Left button

3 Display

4 Right button

402819-10

7.2

Activation

Activating combination instrument

The combination instrument is activated when one of the buttons is

pressed or an impulse comes from the wheel speed sensor.

402819-01

7.3

Messages on the combination instrument

Possible states

Battery voltage of the combination instrument - The bat-

tery voltage of the combination instrument is too low.

Change combination instrument battery.

Service - A service is due. Contact an authorized GAS-

GAS Motorcycles workshop.

401901-01

7.4

Setting the combination instrument

Condition

The motorcycle is stationary.

- Press both buttons for 3-5 seconds.

The Setup menu is displayed. The UNIT display flashes.

- Press one of the buttons to select UNIT for the speed in kilometers

KM/H or miles M/H.

401909-01

COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED)

- Wait for 5 seconds.

The combination instrument changes to the next menu item.

The

symbol flashes.

– Press one of the buttons to select the 24 h display or 12 h display for

the clock.

401911-01

- Wait for 5 seconds.

The combination instrument changes to the next menu item.

The

symbol flashes.

Resetting the time

- Press the left button.

The value decreases.

Advancing the time

- Press the right button.

The value increases.

401912-01

- Wait for 5 seconds.

The combination instrument changes to the next menu item.

The

symbol flashes.

– Set the service.

Shortening the service interval

- Press the left button.

The value decreases.

Extending the service interval

- Press the right button.

401913-01

The value increases.

Switching off the service interval display

- Press and hold the left button.

off appears in the display.

401914-01

7.5

Setting kilometers or miles

Info

If the unit is changed, value ODO is retained and converted accordingly.

Condition

The motorcycle is stationary.

COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED)

- Press both buttons for 3-5 seconds.

The Setup menu is displayed. The UNIT display flashes.

- Press one of the buttons to select UNIT for the speed in kilometers

KM/H or miles M/H.

401909-01

7.6

Setting the clock

Condition

The motorcycle is stationary.

- Press both buttons for 3-5 seconds.

The Setup menu is displayed. The UNIT display flashes.

- Wait for the menu of the clock to flash.

- Press one of the buttons to select the 24 h display or 12 h display for

the clock.

401911-01

- Wait for 5 seconds.

The combination instrument changes to the next menu item.

The

symbol flashes.

Resetting the time

- Press the left button.

The value decreases.

Advancing the time

- Press the right button.

The value increases.

401912-01

7.7

Setting the service display

Condition

The motorcycle is stationary.

- Press both buttons for 3-5 seconds.

The Setup menu is displayed. The UNIT display flashes.

- Wait for the menu of the service display to flash.

- Set the service.

Shortening the service interval

- Press the left button.

The value decreases.

Extending the service interval

401913-01

- Press the right button.

The value increases.

COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED)

Switching off the service interval display

- Press and hold the left button.

off appears in the display.

401914-01

7.8

Speed, time, and DST distance 1

- Press one of the buttons until DST appears on the combination

instrument.

KM/H or M/H shows the speed.

shows the time.

DST displays the distance since the last reset, e. g. between two refuel-

ing stops.

Info

If the value of 39999.9 is exceeded, DST is automatically reset to

401901-01

0.0.

Press the left

Next display mode

button briefly.

Press the left

DST can be preset to a value between 0.0 and

button for 3 - 5

39999.9 by pressing the buttons.

seconds.

Press the right

Next display mode

button briefly.

Press the right

DST is reset to 0.0.

button for 3 - 5

seconds.

7.9

Speed, time, and DST2 distance 2

- Press one of the buttons until DST2 appears on the combination

instrument.

KM/H or M/H shows the speed.

shows the time.

DST2 shows distance 2 since the last reset, e. g. between two refueling

stops.

Info

If the value of 39999.9 is exceeded, DST2 is automatically reset

401902-01

to 0.0.

Press the left

Next display mode

button briefly.

Press the left

DST2 can be preset to a value between 0.0 and

button for 3 - 5

39999.9 by pressing the buttons.

seconds.

Press the right

Next display mode

button briefly.

PREPARING FOR USE

8.1

Advice on preparing for first use

Danger

Danger of accidents A 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 injury Missing 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 crashing Different 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 accidents An unadapted riding style impairs the handling characteristic.

- Adapt your riding speed to the road conditions and your riding ability.

Warning

Danger of accidents The vehicle is not designed to carry passengers.

- Do not ride with a passenger.

Warning

Danger of accidents The 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 accidents Total weight and axle loads influence the handling characteristic.

- Do not exceed the maximum permissible overall weight or the axle loads.

Warning

Risk of injury People 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 the motorcycle, remember that others may be disturbed by excessive noise.

Ensure that the pre-sale inspection work has been carried out by an authorized GASGAS Motorcycles workshop.

–

Read the entire Owner's Manual before riding for the first time.

–

Get to know the controls.

–

Adjust basic position of the clutch lever.

(

p. 70)

–

Adjust basic position of the hand brake lever.

(

p. 73)

–

Adjust the basic position of the foot brake lever.

(

p. 80)

–

Adjust the basic position of the shift lever.

(

p. 107)

PREPARING FOR USE

- Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more challenging

ride.

Info

When offroad, it is recommended that you are accompanied by another person on another vehicle so that you

can help each other.

- Also, ride as slowly as possible and in a standing position to get a better feel for the motorcycle.

- Do not undertake 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 carry the luggage.

- The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded.

- Check the spoke tension. ( p. 91)

Guideline

The spoke tension must be checked after half an hour of operation.

- Run the engine in. ( p. 26)

8.2

Running in the engine

– During the running-in phase, do not exceed the specified engine performance.

Guideline

Maximum engine performance

During the first three operating hours

< 70 %

During the first five operating hours

< 100 %

– Avoid fully opening the throttle!

- Check the idle speed regularly.

Guideline

Idle speed

900 … 1,100 rpm

Info

The idle speed may change during the run-in time.

» If the idle speed changes:

- Carburetor - adjust the idle speed.

(

p. 106)

8.3

Preparing the vehicle for difficult operating conditions

Info

Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces/offroad, can

result in significantly increased wear of components, such as the air filter, drive train, brake system, or suspension

components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

- Clean the air filter and air filter box. ( p. 58)

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.

RIDING INSTRUCTIONS

9.1

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.

- Check the gear oil level. ( p. 109)

- Check the electrical system.

- Check the front brake fluid level. ( p. 75)

- Check the rear brake fluid level. ( p. 81)

- Check that the brake linings of the front brake are secured.

(

p. 77)

– Check that the brake linings of the rear brake are secured. ( p. 83)

- Check that the brake system is functioning properly.

H02217-01

- Check the coolant level. ( p. 97)

- Check the chain for dirt. ( p. 66)

- Check the chain tension. ( p. 67)

- Check the tire condition. ( p. 90)

- Check the tire pressure. ( p. 91)

- Check the spoke tension. ( p. 91)

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. 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 clips regularly for tightness.

- Check the fuel level.

9.2

Starting

Danger

Danger of poisoning Exhaust 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 damage High 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

(Option: Not homologized)

- Empty the carburetor float chamber.

(

p. 108)

RIDING INSTRUCTIONS

- Turn the tap handle of the fuel tap to the position ON facing down-

ward.

Fuel can flow from the fuel tank to the carburetor.

- Swing up the side stand 1.

- Shift the transmission into neutral.

Condition

The engine is cold

(Option: Not homologized)

- Pull the choke lever out as far as possible.

(Option: Homologized)

- Pull the choke lever all the way to the stop.

E01322-01

- Press the kick starter lever robustly through its full range.

Info

Do not open the throttle.

9.3

Starting off

Info

Switch on the light before riding so you are easily visible.

The side stand must be folded up during motorcycle use.

- Pull the clutch lever, shift into first-gear, release the clutch lever slowly and at the same time open the throttle care-

fully.

9.4

Shifting, riding

Warning

Danger of accidents If 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 GAS-

GAS 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 simulta-

neously 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.

- Only open the throttle as much as the engine can handle - abrupt throttle grip 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 you are likely to be 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.

RIDING INSTRUCTIONS

– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

9.5

Braking

Warning

Danger of accidents Excessively 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 accidents A 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 accidents Moisture 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 the rear brake.

- Always finish braking before you go into a bend. Shift down to a lower gear appropriate to your speed.

9.6

Stopping, parking

Warning

Risk of injury People 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 burns Some vehicle components become hot when the vehicle is operated.

- Do not touch any parts such as the exhaust system, radiator, engine, damper, or brake system before the vehi-

cle parts have cooled down.

- Let the vehicle parts cool down before you perform any work on the vehicle.

Note

Material damage The 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.

Note

Fire hazard Hot 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.

- Apply the brakes on the motorcycle.

- Shift the transmission into neutral.

(Option: Not homologized)

- While the engine is idling, remove the magnetic switch from the holder on the handlebars.

RIDING INSTRUCTIONS

(Option: Homologized)

- Press and hold the stop button while the engine is idling until the engine stops.

- Park the motorcycle on firm ground.

9.7

Transporting

Note

Danger of damage The parked vehicle can roll away or fall over.

- Park the vehicle on a firm and level surface.

Note

Fire hazard Hot 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.

- Use tension belts or other suitable devices to secure the motorcycle

against falling over or rolling away.

401475-01

9.8

Refueling

Danger

Fire hazard Fuel 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 poisoning Fuel 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.

Note

Environmental hazard Improper handling of fuel is a danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

- Switch off the engine.

- Open the fuel tank filler cap. ( p. 19)

SERVICE SCHEDULE

10.1

Additional information

Any further work that results from the service 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.

10.2

Service schedule

every 24 months

after every race

Every 120 operating hours

Every 60 operating hours

Every 20 operating hours

After 3 operating hours

Check that the brake linings of the front brake are secured. ( p. 77)

●

Check that the brake linings of the rear brake are secured. ( p. 83)

●

Check brake discs. ( p. 79)

●

Check the brake lines for damage and tightness.

●

Check the front brake fluid level. ( p. 75)

●

Change the front brake fluid.

●

Check the rear brake fluid level. ( p. 81)

●

Change the rear brake fluid.

●

Check the free travel of the hand brake lever. ( p. 73)

●

Check the free travel of the foot brake lever. ( p. 80)

●

Change the needle jet and check/adjust the carburetor components.

●

Check/adjust the carburetor components.

●

Check the reed valve housing, reed valve and intake flange.

●

Check the idle speed.

●

Check/correct the fluid level of hydraulic clutch. ( p. 71)

●

Change the hydraulic clutch fluid.

(

p. 71)

●

Check the clutch.

●

Check that the radiator fan is functioning properly.

●

Check the antifreeze and coolant level. ( p. 98)

●

Change the coolant.

(

p. 101)

●

Change the gear oil.

(

p. 109)

○

●

Change the spark plug and spark plug connector.

●

Check/measure the piston, check/measure the cylinder and check the cylinder head.

●

Perform engine service including removing and installing the engine. (Change the connect-

●

ing rod, conrod bearing, and crank pin. Change the piston. Check the transmission and the

shift mechanism. Change all engine bearings. Change all gear bearings.)

Change the glass fiber yarn filling of the main silencer.

(

p. 62)

●

Check the frame.

(

p. 69)

●

Grease all moving parts (e.g., hand lever, chain,...) and check for smooth operation.

●

Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves for cracking,

●

tightness, and correct routing.

Check the cables for damage and for routing without kinks.

●

Check that the throttle cables are undamaged, routed without kinks, and set correctly.

●

Check the tightness of the safety-relevant screws and nuts which are easily accessible.

●

SERVICE SCHEDULE

every 24 months

after every race

Every 120 operating hours

Every 60 operating hours

Every 20 operating hours

After 3 operating hours

Check the headlight setting. (Option: Homologized) ( p. 52)

●

Check the link fork.

(

p. 69)

●

Check the fork bearing for play.

●

Check the heim joint for play.

●

Check the shock absorber linkage.

●

Check the shock absorber for tightness.

●

Change the damping rubber on the shock absorber.

●

Service the fork.

●

Check the steering head bearing play. ( p. 47)

●

Lubricate the steering head bearing.

(

p. 50)

●

Check the tire condition. ( p. 90)

●

Check the tire pressure. ( p. 91)

●

Check the wheel bearing for play.

●

Check the wheel hubs.

●

Check the rim run-out.

●

Check the spoke tension. ( p. 91)

●

Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 69)

●

Check the chain tension. ( p. 67)

●

Clean the air filter and air filter box. ( p. 58)

●

Final check: check vehicle for operating safety.

○

●

Take a test ride.

○

●

Make a service entry in GASGAS Motorcycles Dealer.net.

○

●

○ One-time interval

● Periodic interval

TUNING THE CHASSIS

11.1

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.

- This vehicle is delivered pre-set for a standard 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.

401030-01

11.2

Adjusting the rebound damping of the shock absorber

Caution

Risk of injury Parts 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.)

Preparatory work

- Remove the rear fender. ( p. 53)

- Remove the air filter box.

(

p. 55)

Main work

- Turn adjusting screw 1 clockwise up to the last perceptible click.

- Turn counterclockwise by the appropriate number of clicks.

Guideline

Rebound damping (All RACING models)

Standard

12 clicks

Rebound damping (All GP models)

Standard

12 clicks

I00096-10

Info

Turn clockwise to increase damping; turn counterclockwise

to reduce damping.

Finishing work

- Install the air filter box.

(

p. 56)

TUNING THE CHASSIS

– Install the rear fender. ( p. 54)

11.3

Adjusting the compression damping of the shock absorber (All GP models)

Caution

Risk of injury Parts 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.)

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove the rear fender. ( p. 53)

- Remove the air filter box.

(

p. 55)

– Remove main silencer. ( p. 61)

- Remove the shock absorber.

(

p. 54)

Main work

- Turn adjusting screw 1 clockwise up to the last perceptible click.

- Turn counterclockwise by the appropriate number of clicks.

Guideline

Compression damping

Standard

12 clicks

Info

I00150-10

Turn clockwise to increase damping; turn counterclockwise

to reduce damping.

Finishing work

- Install the shock absorber.

(

p. 54)

– Install the main silencer. ( p. 61)

- Install the air filter box.

(

p. 56)

– Install the rear fender. ( p. 54)

- Remove the motorcycle from the lift stand. ( p. 42)

11.4

Measuring the dimension of the rear wheel unloaded

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

Main work

- Position the sag gage in the rear axle and measure the distance to

the rear fender.

- Note the value as dimension A.

402415-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

TUNING THE CHASSIS

11.5

Checking the static sag of the shock absorber

- Measure dimension A of rear wheel unloaded. ( p. 35)

- Hold the motorcycle upright with aid of an assistant.

- Measure the distance again between the rear axle and the rear

fender using the sag gage.

- Note the value as dimension B.

Info

The static sag is the difference between measurements A

and B.

- Check the static sag.

Static sag (All RACING models)

10 … 15 mm (0.39 … 0.59 in)

Static sag (All GP models)

10 … 15 mm (0.39 … 0.59 in)

» If the static sag is less or more than the specified value:

- Adjust the spring pretension of the shock absorber.

(

p. 36)

402416-10

11.6

Adjusting the spring preload of the shock absorber

Caution

Risk of injury Parts 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

Note the current adjustment before changing the spring preload - e.g. measure the spring length.

Info

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove the rear fender. ( p. 53)

- Remove the air filter box.

(

p. 55)

– Remove main silencer. ( p. 61)

- Remove the shock absorber.

(

p. 54)

Main work

(All RACING models)

- Loosen grub screws 1 but do not remove.

- Adjust the spring preload by turning adjusting ring 2 using the

special tool.

Guideline

Spring preload

8.5 mm (0.335 in)

Hook wrench (A53529051000)

I00150-11

TUNING THE CHASSIS

Info

Turn counterclockwise to increase the spring preload.

Turning clockwise reduces the spring preload.

- Tighten grub screws 1.

Guideline

Grub screw, shock

2 Nm (1.5 lbf ft)

absorber

(All GP models)

- Loosen grub screws 1 but do not remove.

- Adjust the spring preload by turning adjusting ring 1 using the

special tool.

Guideline

Spring preload

8.5 mm (0.335 in)

Hook wrench (A53529051000)

Info

Turn counterclockwise to increase the spring preload.

Turning clockwise reduces the spring preload.

- Tighten grub screws 1.

Guideline

Grub screw, shock

2 Nm (1.5 lbf ft)

absorber

Finishing work

- Install the shock absorber.

(

p. 54)

– Install the main silencer. ( p. 61)

- Install the air filter box.

(

p. 56)

– Install the rear fender. ( p. 54)

- Remove the motorcycle from the lift stand. ( p. 42)

TUNING THE CHASSIS

11.7

Checking the riding sag of the shock absorber

- Measure dimension A of rear wheel unloaded. ( p. 35)

- With another person holding the motorcycle, the rider, wearing full

protective clothing, sits on the seat in a normal riding 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 the rear fender using the sag gage.

- Note the value as dimension C.

Info

The riding sag is the difference between measurements A

and C.

- Check riding sag.

Guideline

Riding sag (All RACING models)

70 … 75 mm (2.76 … 2.95 in)

Riding sag (All GP models)

70 … 75 mm (2.76 … 2.95 in)

» If the riding sag differs from the specified measurement:

402417-10

- Adjust the riding sag.

(

p. 38)

11.8

Adjusting the riding sag

Caution

Risk of injury Parts 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.)

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove the rear fender. ( p. 53)

- Remove the air filter box.

(

p. 55)

– Remove main silencer. ( p. 61)

- Remove the shock absorber.

(

p. 54)

– After removing the shock absorber, clean it thoroughly.

Main work

- Select and mount a suitable spring.

Guideline

Spring rate (All RACING models)

Standard

68.7 N/mm (392.3 lb/in)

Spring rate (All GP models)

Standard

73.6 N/mm (420.3 lb/in)

B00292-10

Finishing work

- Install the shock absorber.

(

p. 54)

– Install the main silencer. ( p. 61)

- Remove the motorcycle from the lift stand. ( p. 42)

- Check the static sag of the shock absorber. ( p. 36)

TUNING THE CHASSIS

– Check the riding sag of the shock absorber. ( p. 38)

- Adjust the rebound damping of the shock absorber. ( p. 34)

- Install the air filter box.

(

p. 56)

– Install the rear fender. ( p. 54)

11.9

Basic setting of the fork

For various reasons, no exact riding sag can be determined for the fork.

As with the shock absorber, smaller differences in the rider's weight can

be compensated by the spring preload.

However, if the fork frequently bottoms out (hard end stop on com-

pression), harder springs must be fitted 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

11.10

Adjusting the rebound damping of the fork

- Turn adjusting screw 1 clockwise all the way.

Info

Adjusting screw 1 is located at the upper end of the right

fork leg.

- Turn counterclockwise by the appropriate number of clicks.

Guideline

Rebound damping (All RACING models)

I00098-10

Standard

19 clicks

Rebound damping (All GP models)

Standard

19 clicks

Info

Turn clockwise to increase damping; turn counterclockwise

to reduce damping.

11.11

Adjusting the compression damping of the fork (All GP models)

Info

The hydraulic compression damping determines the fork suspension behavior.

- Turn adjusting screw 1 clockwise all the way.

Info

Adjusting screw 1 is located at the lower end of the right

fork leg.

- Turn counterclockwise by the number of rotations corresponding to

the fork type.

I00151-10

TUNING THE CHASSIS

Guideline

Compression damping

Standard

1.75 turns

Info

Turn clockwise to increase damping; turn counterclockwise

to reduce damping during compression.

11.12

Adjusting the spring preload of the fork

- Turn adjusting screw 1 counterclockwise all the way.

Info

Adjusting screw 1 is located at the upper end of the left

fork leg.

- Turn clockwise by the appropriate number of turns.

Guideline

Spring preload (All RACING models)

I00100-10

Standard

5.5 turns

Spring preload (All GP models)

Standard

5.5 turns

Info

Turn clockwise to increase the spring preload; turn counter-

clockwise to reduce the spring preload.

Adjusting the spring preload has no influence on the absorp-

tion setting of the rebound.

Basically, however, you should set the rebound damping

higher with a higher spring preload.

11.13

Adjusting fork fluid barrier

Info

The fluid barrier determines the behavior of the end position damping and the puncture resistance of the fork.

Preparatory work

- Remove front brake disc guard.

(

p. 74)

Main work

- Turn the adjusting screw 1 clockwise as far as it will go.

Info

The adjusting screw 1 is located on the underside of the

left fork leg.

- Turn counterclockwise by the appropriate number of clicks.

I00101-10

SERVICE WORK ON THE CHASSIS

12.1

Raising the motorcycle with a lift stand

Note

Material damage The 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.

Neither wheel is in contact with the ground.

- Secure the motorcycle against falling over.

401942-01

12.2

Removing the motorcycle from the lift stand

Note

Material damage The 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.

- To park the motorcycle, press side stand 1 to the ground with

your foot and lean the motorcycle on it.

Info

The side stand must be folded up during motorcycle use.

E01323-01

12.3

Cleaning the dust boots of the fork legs

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

SERVICE WORK ON THE CHASSIS

Main work

- Push dust boots 1 of both fork legs upwards.

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.

I00116-10

Warning

Danger of accidents Oil 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 inside fork tubes of both fork legs.

Universal oil spray ( p. 127)

- Press the dust boots back into the installation position.

- Remove the excess oil.

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

12.4

Removing the fork legs

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove front brake disc guard.

(

p. 74)

– Remove front brake caliper.

(

p. 74)

– Remove the front wheel.

(

p. 87)

– Remove the headlight mask. ( p. 50)

- Remove the front fender. ( p. 53)

Main work

- Loosen screws 1. Remove the fork leg on the left while carefully

sliding the brake line guide 2 from the fork leg.

- Loosen screws 3. Remove the right fork leg.

I00108-10

SERVICE WORK ON THE CHASSIS

12.5

Installing the fork legs

Main work

- Position the left fork leg while carefully pushing the brake line

guide 1 onto the fork leg.

- Tighten screw 2.

Guideline

Screw, top triple clamp

12 Nm (8.9 lbf ft)

– Tighten screws 3.

Guideline

I00108-11

Screw, bottom triple

10 Nm (7.4 lbf ft)

clamp

- Position the right fork leg.

- Tighten screw 4.

Guideline

Screw, top triple clamp

12 Nm (8.9 lbf ft)

– Tighten screws 5.

Guideline

Screw, bottom triple

10 Nm (7.4 lbf ft)

clamp

Info

Grooves are milled into the side of the upper end of the fork

legs. The first milled groove (from the top) must be flush

with the upper edge of the upper triple clamp.

The suspension is located in the left fork leg. The rebound

damping is located in the right fork leg.

Finishing work

- Install the front wheel.

(

p. 87)

– Install the front brake caliper.

(

p. 74)

– Install the brake disc guard at the front.

(

p. 74)

– Install the front fender. ( p. 53)

- Install the headlight mask. ( p. 51)

- Remove the motorcycle from the lift stand. ( p. 42)

12.6

Removing the lower triple clamp

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove front brake disc guard.

(

p. 74)

– Remove front brake caliper.

(

p. 74)

– Remove the front wheel.

(

p. 87)

– Remove the headlight mask. ( p. 50)

- Remove the front fender. ( p. 53)

- Remove the fork legs.

(

p. 43)

SERVICE WORK ON THE CHASSIS

12.7

Installing the lower triple clamp

Main work

- Clean the bearing and sealing elements, check for damage, and

grease.

Long-life grease ( p. 126)

- Insert the lower triple clamp with steering stem 1.

- Mount upper steering head bearing 2.

- Mount protective ring 3.

I00173-10

Position the upper triple clamp.

–

Mount steering head nut 4, but do not tighten yet.

Guideline

Nut, steering head

M16

20 Nm (14.8 lbf ft)

–

Mount screw 5, but do not tighten yet.

Guideline

Screw, steering stem

12 Nm (8.9 lbf ft)

I01047-10

Position the fork legs with the brake line guide.

Info

Make sure the cables and wiring are routed correctly.

Grooves are milled into the side of the upper end of the fork

legs. The first milled groove (from the top) must be flush

with the upper edge of the upper triple clamp.

The suspension is located in the left fork leg. The rebound

damping is located in the right fork leg.

I01053-10

Tighten screws 6.

Guideline

Screw, bottom triple

10 Nm (7.4 lbf ft)

clamp

Tighten steering head nut 4.

Guideline

Nut, steering head

M16

20 Nm (14.8 lbf ft)

–

Tighten screw 5.

Guideline

Screw, steering stem

12 Nm (8.9 lbf ft)

SERVICE WORK ON THE CHASSIS

– Using a plastic hammer, tap lightly on the upper triple clamp to

avoid stresses.

- Tighten screw 7.

Guideline

Screw, top triple clamp

12 Nm (8.9 lbf ft)

– Position the handlebar.

- Position the handlebar clamps. Mount screws 8 and tighten

evenly.

Guideline

Screw, handlebar

20 Nm (14.8 lbf ft)

clamp

Info

The markings on the handlebar should be at the center of

I01043-10

the handlebar clamps.

Keep the installed gap widths equal when tightening.

- Mount handlebar cushion 9.

I01041-10

Finishing work

- Check the wiring harness, throttle cables, and brake and clutch lines

for freedom of movement and correct routing.

- Install the front wheel.

(

p. 87)

– Install the front brake caliper.

(

p. 74)

– Install the brake disc guard at the front.

(

p. 74)

– Install the front fender. ( p. 53)

- Install the headlight mask. ( p. 51)

- Remove the motorcycle from the lift stand. ( p. 42)

12.8

Checking the steering head bearing play

Warning

Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages com-

ponents.

- Correct incorrect steering head bearing play immediately. (Your authorized GASGAS Motorcycles workshop will

be glad to help.)

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

SERVICE WORK ON THE CHASSIS

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 the steering head bearing play.

(

p. 48)

– Move the handlebar to and fro over the entire steering range.

It must be possible to move the handlebar easily over the entire

H01167-01

steering range. There should be no detectable detent positions.

» If detent positions are detected:

- Adjust the steering head bearing play.

(

p. 48)

– Check the steering head bearing and change if necessary.

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

12.9

Adjusting the steering head bearing play

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

Main work

- Remove handlebar cushion 1.

I00186-10

- Remove screws 2.

- Take off handlebar and place carefully to the front.

Info

Cover the components to protect them against damage.

Do not kink the cables or lines.

I00152-10

- Loosen screw 3.

- Loosen steering head screw 4.

I00153-10

SERVICE WORK ON THE CHASSIS

– Loosen screws 5.

I00154-10

- Tighten steering head screw 4.

Guideline

Nut, steering head

M16

20 Nm (14.8 lbf ft)

– Tighten screw 3.

Guideline

Screw, steering stem

12 Nm (8.9 lbf ft)

– Using a plastic hammer, tap lightly on the upper triple clamp to

I00153-10

avoid stresses.

- Tighten screws 5.

Guideline

Screw, top triple clamp

12 Nm (8.9 lbf ft)

I00154-10

- Position the handlebar with handlebar clamps.

- Mount screws 2, but do not tighten yet.

- First bolt the handlebar clamp with screws 2 onto the rear side of

the handlebar supports so that both parts touch.

- Tighten screws 2 evenly.

Guideline

Screw, handlebar

20 Nm (14.8 lbf ft)

clamp

I00152-10

- Mount handlebar cushion 1.

I00186-10

Finishing work

- Check the wiring harness, cables, and brake and clutch lines for free-

dom of movement and correct routing.

- Check the steering head bearing play. ( p. 47)

SERVICE WORK ON THE CHASSIS

(Option: Homologized)

Info

Plug in connector according to the noted cable colors.

- Plug in connector 1 of the turn signal indicator lamp.

- Plug in connector 2 of the horn.

- Plug in connector 3 of the speedometer.

I00159-11

- Plug in connector 4 of the headlight bulb and the parking

light.

- Plug in connector 5 of the turn signal lamps.

- Position the headlight mask.

- Secure the headlight mask to the fork legs with cable ties 6.

I00158-11

12.13

Checking the headlight setting (Option: Homologized)

- Park the vehicle on a horizontal surface in front of a light-colored

wall and make a mark at the height of the center of the low beam

headlight.

- Make another mark at a distance B under the first marking.

Guideline

5 cm (2 in)

Distance B

– Position the vehicle vertically at a distance A away from the wall.

Guideline

400726-10

5 m (16 ft)

Distance A

– The rider now sits down on the motorcycle.

- Switch on the low beam.

- Check the headlight setting.

The boundary between light and dark must be exactly on the

lower mark for a motorcycle with rider.

» If the boundary between light and dark does not meet specifica-

tions:

- Correct the headlight setting.

SERVICE WORK ON THE CHASSIS

12.17

Installing the rear fender

- Insert the rear fender in area A and engage it in area B.

I00093-11

- Mount and tighten screw 1.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

I00092-10

12.18

Removing the shock absorber

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove the rear fender. ( p. 53)

- Remove the air filter box.

(

p. 55)

– Remove main silencer. ( p. 61)

Main work

- The rear wheel must hang down.

- Remove screw 1.

- Remove the shock absorber from the top carefully.

Z03155-10

12.19

Installing the shock absorber

Main work

- Position the shock absorber carefully from above.

- Mount and tighten screw 1.

Guideline

Screw, bottom shock

M10

45 Nm (33.2 lbf ft)

absorber

Z03155-10

Finishing work

- Install the main silencer. ( p. 61)

- Install the air filter box.

(

p. 56)

SERVICE WORK ON THE CHASSIS

12.21

Installing the air filter box

Main work

- Carefully position the air filter box on the frame, sliding the inlet

sleeve onto the carburetor.

- Mount and tighten screws 1.

Guideline

Screw, air filter box

6 Nm (4.4 lbf ft)

I00094-11

- Position and tighten hose clamp 2.

I00095-11

Finishing work

- Install the rear fender. ( p. 54)

12.22

Removing the air filter

Note

Engine damage Unfiltered 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 hazard Hazardous 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 rear fender. ( p. 53)

SERVICE WORK ON THE CHASSIS

12.24

Cleaning the air filter and air filter box

Note

Environmental hazard Hazardous 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 rear fender. ( p. 53)

- 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. 126)

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.

I00119-12

Oil for foam air filter ( p. 126)

- Clean the air filter box.

- Remove screws 1.

- Take off the splash protector.

- Check if the drainage channel is blocked.

Info

This drainage channel allows liquids to drain.

- Position the splash protector and mount and tighten with

screws 1.

Guideline

Screw, lower part of air

EJOT DELTA PT^®

1.5 Nm (1.11 lbf ft)

filter box

K40x12

Finishing work

- Install the air filter. ( p. 57)

- Install the rear fender. ( p. 54)

SERVICE WORK ON THE CHASSIS

(Option: Not homologized)

- Mount gasket 1.

I00145-11

- Position the manifold.

- Mount and tighten screws 2.

Guideline

Screw, manifold

12 Nm (8.9 lbf ft)

Loctite^®243™

Z03094-11

12.27

Removing the main silencer

Warning

Danger of burns The exhaust system gets hot when the vehicle is driven.

- Allow the exhaust system to cool down before performing any work on the vehicle.

Preparatory work

- Remove the rear fender. ( p. 53)

- Remove the air filter box.

(

p. 55)

Main work

- Remove screw 1.

- Remove screws 2.

- Carefully take off the main silencer to the rear.

I00120-10

12.28

Installing the main silencer

Main work

- Position the main silencer.

- Position the shock absorber and mount screw 1, but do not

tighten it yet.

- Mount screws 2, but do not tighten yet.

- Shake the main silencer slightly to avoid strain.

- Tighten screws 2.

Guideline

I00120-10

Screw, main silencer

14 Nm (10.3 lbf ft)

on frame

SERVICE WORK ON THE CHASSIS

- Tighten screw 1.

Guideline

Screw, top shock

M10

50 Nm (36.9 lbf ft)

absorber

Finishing work

- Install the air filter box.

(

p. 56)

– Install the rear fender. ( p. 54)

12.29

Changing the glass fiber yarn filling of the main silencer

Warning

Danger of burns The exhaust system gets 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 glass fiber yarn filling escape and the damper "burns" out.

Not only is the noise level higher, but the performance characteristics change.

Preparatory work

- Remove the rear fender. ( p. 53)

- Remove the air filter box.

(

p. 55)

Main work

- Remove screws 1.

- Remove silencer cap holder 2.

I00166-10

- Remove screws 3.

- Remove silencer cap 4.

I00167-10

- Pull out inner tube 5 with glass fiber yarn filling.

- Remove the remaining glass fiber yarn filling from the main silencer

and silencer cap.

- Clean the parts that need to be reinstalled and check for damage.

- Mount new inner tube 5 with glass fiber yarn filling in the main

silencer.

Guideline

The side of the inner tube with the larger inside diameter must be

I00168-10

positioned in the silencer cap.

SERVICE WORK ON THE CHASSIS

- Position glass fiber yarn filling 8 over inner tube 5 in silencer

cap 4.

- Position glass fiber yarn filling 9 under the inner tube in the

silencer cap.

I00171-10

- Position silencer cap holder 2.

- Mount and tighten screws 1.

I00166-10

Finishing work

- Install the air filter box.

(

p. 56)

– Install the rear fender. ( p. 54)

12.30

Removing the fuel tank

Danger

Fire hazard Fuel 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 poisoning Fuel 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.

SERVICE WORK ON THE CHASSIS

– Turn the tap handle of the fuel tap to the position OFF toward the

rear.

- Push hose clamp 1 toward the rear and pull off the fuel hose.

Info

Remaining fuel may flow out of the fuel hose.

I01037-11

- Remove screw 2.

- Pull off vent hose 3.

- Remove screw 4.

- Lift the fuel tank at the front and remove it from the frame.

I00122-10

12.31

Installing the fuel tank

Danger

Fire hazard Fuel 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 poisoning Fuel 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.

Main work

- Position the fuel tank in the frame, mount and tighten screw 1.

Guideline

Screw, fuel tank fasten-

6 Nm (4.4 lbf ft)

ing

- Mount and tighten screw 2.

Guideline

Screw, fuel tank fasten-

6 Nm (4.4 lbf ft)

I00122-11

ing

- Attach vent hose 3.

SERVICE WORK ON THE CHASSIS

Guideline

Route vent hose free of kinks.

- Attach fuel hose and secure with hose clamp 4.

I01037-10

Finishing work

- Check the throttle cable routing.

12.32

Checking the chain for dirt

- Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

- Clean the chain. ( p. 66)

400678-01

12.33

Cleaning the chain

Warning

Danger of accidents Lubricants on the tires reduces the road grip.

- Remove lubricants from the tires using a suitable cleaning agent.

Warning

Danger of accidents Oil 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 hazard Hazardous 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)

SERVICE WORK ON THE CHASSIS

Main work

- Rinse off the loose dirt with a gentle jet of water.

- Remove old grease residue with chain cleaner.

Chain cleaner ( p. 126)

- After drying, apply chain spray.

Off-road chain spray ( p. 126)

400725-01

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

12.34

Checking the chain tension

Warning

Danger of accidents Incorrect 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 bear-

ings 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)

Main work

- Determine distance A between link fork and chain adjuster.

Info

The vehicle has a spring preloaded chain adjuster.

Chain wear is not always even, so you should repeat this

measurement at different chain positions.

Chain tension

10 … 20 mm (0.39 … 0.79 in)

I00112-10

» If the chain tension does not meet the specification:

- Adjust the chain tension. ( p. 68)

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

SERVICE WORK ON THE CHASSIS

12.35

Adjusting the chain tension

Warning

Danger of accidents Incorrect 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 bear-

ings 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)

- Check the chain tension. ( p. 67)

Main work

- Loosen screw 1.

I00113-10

- Adjust the chain tension by turning eccentrics 2 left and right.

Guideline

Chain tension

10 … 20 mm (0.39 … 0.79 in)

Turn eccentrics left and right so that the eccentrics are on the

same detent. The rear wheel is then correctly aligned.

- Tighten screw 1.

Guideline

Screw, rear wheel spin-

M10

50 Nm (36.9 lbf ft)

dle

I00114-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

SERVICE WORK ON THE CHASSIS

12.36

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.

Info

The engine sprocket, the rear sprocket, and the

chain should always be replaced together.

400227-01

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

12.37

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.

Z03613-10

12.38

Checking the link fork

- Check the link fork for damage, cracking, and deformation.

» If the link fork shows signs of damage, cracking, or deformation:

- Change the link fork.

Info

Always replace a damaged link fork. GASGAS Motor-

cycles does not permit repairing link forks.

E01406-01

12.39

Checking the rubber grip

- Check the rubber grips on the handlebar for damage, wear, and

looseness.

» If a rubber grip is damaged, worn, or loose:

- Change and secure the rubber grip.

Rubber grip adhesive (00062030051) ( p. 126)

401197-01

SERVICE WORK ON THE CHASSIS

12.40

Checking the free travel of the clutch lever

- Pull the clutch lever and check free travel A.

Free travel of clutch lever

≥ 3 mm (≥ 0.12 in)

» If the free travel does not match the specification:

- Set the free travel of the clutch lever.

(

p. 70)

I00086-12

12.41

Adjusting the free travel of the clutch lever

- Check the free travel of the clutch lever. ( p. 70)

- Loosen nut 1.

- Adjust the free travel of the clutch lever with adjusting screw 2.

Info

Turn the adjusting screw clockwise to reduce free travel. The

pressure point moves away from the handlebar.

Turn the adjusting screw counterclockwise to increase free

travel. The pressure point moves towards the handlebar.

I00086-13

The range of adjustment is limited.

Do not use force.

Do not make any adjustments while riding.

- Hold adjusting screw 2 and tighten nut 1.

12.42

Adjusting the basic position of the clutch lever

Main work

- Adjust the basic position of the clutch lever to your hand size by

turning adjusting screw 1.

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.

I00086-14

The range of adjustment is limited.

Do not use force.

Do not make any adjustments while riding.

Finishing work

- Check the free travel of the clutch lever. ( p. 70)

SERVICE WORK ON THE CHASSIS

12.43

Checking/correcting the fluid level of hydraulic clutch

Note

Environmental hazard Hazardous 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 fluid level rises with increasing wear of the clutch facing discs.

Do not use brake fluid.

- Move the hydraulic clutch fluid reservoir mounted on the handlebar

into a horizontal position.

- Remove screws 1.

- Take off cover 2 with membrane.

- Check the fluid level.

Fluid level below container rim

4 mm (0.16 in)

» If the level of the fluid does not meet specifications:

I01040-10

- Correct the fluid level of the hydraulic clutch.

Hydraulic fluid (15) ( p. 125)

- Position cover 2 with the membrane. Mount and tighten

screws 1.

12.44

Changing the hydraulic clutch fluid

Note

Environmental hazard Hazardous 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 use brake fluid.

- Move the hydraulic clutch fluid reservoir mounted on the handlebar

into a horizontal position.

- Remove screws 1.

- Take off cover 2 with membrane.

I01040-10

BRAKE SYSTEM

13.1

Checking the free travel of the hand brake lever

- Pull the hand brake lever and check the free travel A.

Free travel of hand brake lever

≥ 3 mm (≥ 0.12 in)

» If the free travel does not match the specification:

- Set the free travel of the hand brake lever.

(

p. 73)

I00087-12

13.2

Adjusting the free travel of the hand brake lever

- Check the free travel of the hand brake lever. ( p. 73)

- Loosen nut 1.

- Adjust the free travel of the hand brake lever with adjusting

screw 2.

Info

Turn the adjusting screw clockwise to reduce free travel. The

pressure point moves away from the handlebar.

Turn the adjusting screw counterclockwise to increase free

I00117-10

travel. The pressure point moves towards the handlebar.

The range of adjustment is limited.

Do not use force.

Do not make any adjustments while riding.

- Hold adjusting screw 2 and tighten nut 1.

13.3

Adjusting the basic position of the hand brake lever

Main work

- Adjust basic position of the hand brake lever to your hand size by

turning adjusting screw 1.

Info

Turn the adjusting screw clockwise to decrease the distance

between the hand brake lever and the handlebar.

Turn the adjusting screw counterclockwise to increase the

distance between the hand brake lever and the handlebar.

I00087-13

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.

Finishing work

- Check the free travel of the hand brake lever. ( p. 73)

BRAKE SYSTEM

13.4

Removing front brake disc guard

- Remove screws 1 and take off the brake disc guard to the rear.

I00103-10

13.5

Installing the front brake disc guard

- Position the brake disc guard at the front.

- Mount and tighten screws 1.

Guideline

Screw, front brake

25 Nm (18.4 lbf ft)

caliper

I00103-10

13.6

Removing front brake caliper

Preparatory work

- Remove front brake disc guard.

(

p. 74)

Main work

- Press back the brake linings by slightly tilting the brake caliper later-

ally on the brake disc.

- Pull the brake caliper carefully up from the brake disc and hang to

the side.

Info

Cover the components to protect them against damage.

I00104-10

13.7

Installing the front brake caliper

Warning

Danger of accidents Oil 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.

BRAKE SYSTEM

Main work

- Position the brake caliper on the brake disc carefully.

I00104-10

Finishing work

- Install the brake disc guard at the front.

(

p. 74)

13.8

Checking the front brake fluid level

Warning

Danger of accidents An 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 accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.

- 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.)

- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-

GAS Motorcycles workshop will be glad to help.)

- Move the brake fluid reservoir mounted on the handlebar to a hori-

zontal position.

- Check the brake fluid level in level viewer 1.

» If an air bubble is visible in upper range of the level viewer A:

- Add front brake fluid.

(

p. 75)

I00126-10

13.9

Adding front brake fluid

Warning

Danger of accidents An 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.)

BRAKE SYSTEM

Warning

Skin irritation Brake fluid is a harmful substance.

- 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 accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.

- 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.)

- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-

GAS Motorcycles workshop will be glad to help.)

Note

Environmental hazard Hazardous 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

Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.

Preparatory work

- Check that the brake linings of the front brake are secured.

(

p. 77)

Main work

- Move the brake fluid reservoir mounted on the handlebar to a hori-

zontal position.

- Remove screws 1.

- Take off cover 2 with membrane.

- Add brake fluid to level A.

Guideline

5 mm (0.2 in)

Level A (brake fluid level

below reservoir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 124)

- Position cover 2 with the membrane. Mount and tighten

screws 1.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

I00127-11

BRAKE SYSTEM

13.10

Checking that the brake linings of the front brake are secured

Warning

Danger of accidents Worn-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.)

- Check the brake linings for minimum thickness A.

≥ 1 mm (≥ 0.04 in)

Minimum thickness A

» If the minimum thickness is less than specified:

- Change the brake linings of the front brake.

(

p. 77)

– Check the brake linings for damage and cracking.

» If damage or wear is encountered:

- Change the brake linings of the front brake.

(

p. 77)

I00155-10

- Check that the brake linings are secured.

» If the brake linings are not secured correctly:

- Secure brake linings, replace with new parts if necessary.

13.11

Changing the brake linings of the front brake

Warning

Danger of accidents Incorrect 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 irritation Brake fluid is a harmful substance.

- 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 accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.

- 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.)

- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-

GAS Motorcycles workshop will be glad to help.)

Warning

Danger of accidents Oil 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.

BRAKE SYSTEM

Warning

Danger of accidents Brake 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 warranty shall be

void.

- Only use brake linings approved and recommended by GASGAS Motorcycles.

Note

Environmental hazard Hazardous 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

Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.

Preparatory work

- Remove front brake disc guard.

(

p. 74)

– Remove front brake caliper.

(

p. 74)

Main work

- Move the brake fluid reservoir mounted on the handlebar to a hori-

zontal position.

- Remove screws 1.

- Take off cover 2 with membrane.

I00127-10

- Take off lock washer 3 and remove screw 4.

- Take off retainer spring 5 and remove the brake linings.

- Clean the brake caliper.

- Position the new brake linings.

Info

Always change the brake linings in pairs.

- Position retaining spring 5.

- Mount and tighten screw 4.

Info

To make it easier to mount the screw, push the retainer

spring down.

Make sure the retainer spring is seated correctly.

- Mount lock washer 3.

- Add brake fluid to level A.

I01039-10

Guideline

5 mm (0.2 in)

Level A (brake fluid level

below reservoir rim)

BRAKE SYSTEM

Brake fluid DOT 4 / DOT 5.1 ( p. 124)

- Position cover 2 with the membrane. Mount and tighten

screws 1.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

Finishing work

- Install the front brake caliper.

(

p. 74)

– Install the brake disc guard at the front.

(

p. 74)

13.12

Checking brake discs

Warning

Danger of accidents Worn-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.)

Condition

Preparatory work

- Remove front brake disc guard.

(

p. 74)

Main work

- Check front and rear brake disc thickness at multiple points for the

dimension A.

Info

Wear reduces the thickness of the brake disc around the

contact surface of the brake linings.

Brake discs - wear limit

400257-10

front

2.7 mm (0.106 in)

rear

2.7 mm (0.106 in)

» If the brake disc thickness is less than the specified value:

- Change the front brake disc.

- Change the rear brake disc.

- Check front and rear brake discs for damage, cracking, and deforma-

tion.

» If the brake disc exhibits damage, cracking, or deformation:

- Change the front brake disc.

- Change the rear brake disc.

Finishing work

- Install the brake disc guard at the front.

(

p. 74)

BRAKE SYSTEM

13.13

Checking the free travel of the foot brake lever

Warning

Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.

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.

- Ensure that the adjustment steps are performed properly. (Your authorized GASGAS Motorcycles workshop

will be glad to help.)

- Move the foot brake lever back and forth between the end stop

and the contact to the foot brake cylinder piston and check free

travel A.

Guideline

Free travel at foot brake lever

3 … 5 mm (0.12 … 0.2 in)

» If the free travel does not match the specification:

- Adjust the basic position of the foot brake lever.

(

p. 80)

E01373-10

13.14

Adjusting the basic position of the foot brake lever

Warning

Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.

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.

- Ensure that the adjustment steps are performed properly. (Your authorized GASGAS Motorcycles workshop

will be glad to help.)

- Loosen nut 1 and, with push rod 2, turn it back until you have

maximum free travel.

- To adjust the basic position of the foot brake lever to individual

requirements, loosen nut 3 and turn screw 4 accordingly.

Info

The range of adjustment is limited.

- Turn push rod 2 accordingly until you have free travel A. If nec-

essary, adjust the basic position of the foot brake lever.

Guideline

Free travel at foot brake lever

3 … 5 mm (0.12 … 0.2 in)

– Hold screw 4 and tighten nut 3.

- Hold push rod 2 and tighten nut 1.

I00128-10

BRAKE SYSTEM

13.15

Checking the rear brake fluid level

Warning

Danger of accidents An 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 accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.

- 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.)

- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-

GAS Motorcycles workshop will be glad to help.)

- Position the vehicle upright.

- Check the brake fluid level in level viewer 1.

» If the brake fluid level has dropped below the marking A:

- Add rear brake fluid.

(

p. 81)

I00129-10

13.16

Adding rear brake fluid

Warning

Danger of accidents An 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 irritation Brake fluid is a harmful substance.

- 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.

BRAKE SYSTEM

Warning

Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.

- 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.)

- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-

GAS Motorcycles workshop will be glad to help.)

Note

Environmental hazard Hazardous 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

Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.

Preparatory work

- Check that the brake linings of the rear brake are secured. ( p. 83)

Main work

- Remove screw 1 with nut 2.

- Pull the push rod out of the foot brake cylinder and remove the foot

brake lever to the front.

I01035-10

- Remove screws 3.

- Carefully take off the brake cylinder and hold it vertically.

I00132-10

- Remove screws 4 and cover 5 with membrane 6.

I00133-10

BRAKE SYSTEM

– Add brake fluid up to the marking A.

Brake fluid DOT 4 / DOT 5.1 ( p. 124)

- Position cover 5 with membrane 6 and mount and tighten

screws 4.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

I00134-10

- Position the foot brake cylinder.

- Mount and tighten screws 3.

Guideline

Screw, foot brake cylin-

10 Nm (7.4 lbf ft)

der

I00132-10

- Position the foot brake lever; insert the push rod into the foot brake

cylinder.

- Mount and tighten screw 1 with nut 2.

Guideline

Screw, foot brake

25 Nm (18.4 lbf ft)

lever

Loctite^®243™

I01035-10

13.17

Checking that the brake linings of the rear brake are secured

Warning

Danger of accidents Worn-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.)

- Check the brake linings for minimum thickness A.

≥ 1 mm (≥ 0.04 in)

Minimum thickness A

» If the minimum thickness is less than specified:

- Change the rear brake linings.

(

p. 84)

– Check the brake linings for damage and cracking.

» If damage or wear is encountered:

- Change the rear brake linings.

(

p. 84)

I00130-10

- Check that the brake linings are secured.

» If the brake linings are not secured correctly:

- Secure brake linings, replace with new parts if necessary.

BRAKE SYSTEM

13.18

Changing the rear brake linings

Warning

Danger of accidents Incorrect 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 irritation Brake fluid is a harmful substance.

- 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 accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.

- 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.)

- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-

GAS Motorcycles workshop will be glad to help.)

Note

Environmental hazard Hazardous 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

Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove the rear wheel.

(

p. 88)

Main work

- Remove screw 1 with nut 2.

- Pull the push rod out of the foot brake cylinder and remove the foot

brake lever to the front.

I01035-10

BRAKE SYSTEM

- Position the brake caliper on the link fork and mount and tighten

screw 7.

Guideline

Screw, rear brake

12 Nm (8.9 lbf ft)

caliper

Loctite^®243™

I01012-10

- Correct brake fluid level to marking B.

Brake fluid DOT 4 / DOT 5.1 ( p. 124)

I00134-11

- Position cover 5 with membrane 6 and mount and tighten

screws 4.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

I00133-10

- Position the foot brake cylinder.

- Mount and tighten screws 3.

Guideline

Screw, foot brake cylin-

10 Nm (7.4 lbf ft)

der

I00132-10

- Position the foot brake lever; insert the push rod into the foot brake

cylinder.

- Mount and tighten screw 1 with nut 2.

Guideline

Screw, foot brake

25 Nm (18.4 lbf ft)

lever

Loctite^®243™

I01035-10

WHEELS, TIRES

14.1

Removing the front wheel

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

- Remove front brake disc guard.

(

p. 74)

– Remove front brake caliper.

(

p. 74)

Main work

- Loosen screw 1 by several rotations.

- Loosen wheel spindle 2.

- Press the left-hand side of wheel spindle 2 to push the wheel spin-

dle out of the axle clamp.

Warning

Danger of accidents Damaged brake discs reduce the

Z03073-11

braking effect.

- Always lay the wheel down in such a way that the brake

disc is not damaged.

- 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.

14.2

Installing the front wheel

Warning

Danger of accidents Oil 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.

- Check wheel bearing 1 for damage and wear.

» If the wheel bearing is damaged or worn:

- Change front wheel bearing.

- Clean and lightly grease the wheel spindle.

Long-life grease ( p. 126)

- Jack up the front wheel into the fork, position it, and insert the

wheel spindle.

H00935-18

WHEELS, TIRES

- Tighten wheel spindle 2.

Guideline

Wheel spindle, front

M18

50 Nm (36.9 lbf ft)

– Install the front brake caliper.

(

p. 74)

The brake linings are correctly positioned.

- Install the brake disc guard at the front.

(

p. 74)

– Operate the hand brake lever several times until the brake linings

are seated correctly against the brake disc.

Z03073-10

- 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.

- Tighten screw 3.

Guideline

Screw, fork shoe

15 Nm (11.1 lbf ft)

14.3

Removing the rear wheel

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 42)

Main work

- Remove screw 1 with spacer 2.

I00135-10

- Turn eccentrics 3 so that the greatest possible chain play is

present.

- 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.

I00136-10

Warning

Danger of accidents Damaged brake discs reduce the

braking effect.

- Always lay the wheel down in such a way that the brake

disc is not damaged.

- Holding the rear wheel, withdraw the wheel spindle to the right.

Take the rear wheel out of the link fork.

Info

Do not operate the foot brake lever when the rear wheel is

removed.

WHEELS, TIRES

– Remove eccentrics 3 and spacers 4.

E01387-12

14.4

Installing the rear wheel

Warning

Danger of accidents Oil 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.

Main work

- Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

- Change the rear wheel bearing.

- Clean and grease shaft seal rings 1 and contact surfaces A of the

spacers.

Long-life grease ( p. 126)

- Insert the spacers.

H03001-10

- Lift the rear wheel into the link fork, position it, and insert wheel

spindle 2 with eccentric 3.

- Mount the chain.

The brake linings are correctly positioned.

E01387-11

- Mount screw 4 with spacer 5, but do not tighten yet.

- Operate the foot brake lever repeatedly until the brake linings are in

contact with the brake disc and there is a pressure point.

I00135-11

WHEELS, TIRES

- Make sure that eccentrics 3 are fitted correctly to the screws of

link fork 6.

- Adjust the chain tension. ( p. 68)

- Tighten screw 4.

Guideline

Screw, rear wheel spin-

M10

50 Nm (36.9 lbf ft)

dle

I00156-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 42)

14.5

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 motorcy-

cle.

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.

- Check tread depth.

Info

Adhere to the legally required minimum tread depth.

400602-10

Minimum tread depth

≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum tread depth:

- Change the tires.

WHEELS, TIRES

– 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 num-

ber. 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.

H01144-01

» If the tires are more than five years old:

- Change the tires.

14.6

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.

- Remove protection cap.

- Check tire pressure when the tires are cold.

Street tire pressure (Option: Homologized)

front

1.2 bar (17 psi)

rear

1.2 bar (17 psi)

Offroad tire pressure

front

0.42 bar (6.1 psi)

400695-01

rear

0.30 bar (4.4 psi)

» If the tire pressure does not meet specifications:

- Correct tire pressure.

- Mount the protection cap.

14.7

Checking the spoke tension

Warning

Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam-

age.

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.)

ELECTRICAL SYSTEM

15.1

Diagnostics connector

Diagnostics connector 1 is located on the right-hand side below the

fuel tank in the voltage regulator retaining bracket.

I00157-10

15.2

Changing the headlight bulb (Option: Homologized)

Note

Impairments to reflectors and lamps Grease on the reflector reduces the emitted light.

Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

Grease residue on the bulb reduces heat dissipation and increases the heat of the bulb, thus reducing its service life.

- Clean and degrease the bulbs before mounting.

- Do not touch the bulbs with your bare hands.

Preparatory work

- Remove the headlight mask. ( p. 50)

Main work

- Remove headlight bulb connector 1.

- Pull off protection cap 2 downwards.

I01004-10

- Pull out bulb socket 3 with headlight bulb.

I01005-10

ELECTRICAL SYSTEM

- Carefully push down headlight bulb 4 and turn counterclockwise

until it is released.

- Remove the headlight bulb.

- Insert the new headlight bulb.

Low beam/high beam (BILUX bulb / socket BA20D) ( p. 120)

- Carefully push down headlight bulb 4 and turn clockwise until it

engages.

I01006-10

- Insert the bulb socket 3 and headlight bulb in the reflector.

I01005-10

- Mount protection cap 2.

- Plug in connector of headlight bulb 1.

I01004-10

Finishing work

- Install the headlight mask. ( p. 51)

15.3

Changing the position light lamp (Option: Homologized)

Note

Impairments to reflectors and lamps Grease on the reflector reduces the emitted light.

Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

Grease residue on the bulb reduces heat dissipation and increases the heat of the bulb, thus reducing its service life.

- Clean and degrease the bulbs before mounting.

- Do not touch the bulbs with your bare hands.

Preparatory work

- Remove the headlight mask. ( p. 50)

ELECTRICAL SYSTEM

Main work

- Carefully pull position light socket 1 out of the housing.

- Remove bulb 2.

- Position a new bulb 2 in the socket.

Position light (T5W/socket BA9s) ( p. 120)

- Carefully position position light socket 1 in the housing.

I01010-10

Finishing work

- Install the headlight mask. ( p. 51)

15.4

Changing the turn signal bulb (Option: Homologized)

Note

Impairments to reflectors and lamps Grease on the reflector reduces the emitted light.

Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

Grease residue on the bulb reduces heat dissipation and increases the heat of the bulb, thus reducing its service life.

- Clean and degrease the bulbs before mounting.

- Do not touch the bulbs with your bare hands.

Main work

- Remove the screw on the rear of the turn signal housing.

- Carefully remove turn signal glass 1.

- Lightly squeeze orange cap 2 in the area of the holding lugs and

take it off.

- Press the turn signal bulb lightly into the socket, turn it counter-

clockwise by about 30°, and pull it out of the socket.

Info

Do not touch the reflector with your fingers and keep it free

from grease.

- Press the new turn signal bulb carefully into the socket and turn it

clockwise until it stops.

Turn signal (R10W / socket BA15s) ( p. 120)

- Mount the orange cap.

- Position the turn signal glass.

- Insert the screw and first turn counterclockwise until it engages in

the thread with a small jerk. Tighten the screw lightly.

E00360-10

COOLING SYSTEM

16.1

Cooling system

Water pump 1 in the engine ensures forced circulation of the coolant.

The pressure in the cooling system resulting from heat is regulated by a

valve 2 in the radiator.

I00147-10

16.2

Checking the coolant level

Warning

Danger of scalding During motorcycle operation, the coolant gets 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.

Warning

Danger of poisoning Coolant is harmful to health.

- Keep coolant out of the reach of children.

- Do not allow coolant to come into contact with the skin, the eyes and clothing.

- Consult a doctor immediately if coolant is swallowed.

- Rinse the affected area immediately with plenty of water in the event of contact with the skin.

- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

- Change clothing if coolant spills onto your clothing.

Condition

The engine is cold.

- Stand the motorcycle upright on a horizontal surface.

- Remove radiator cap screw 1.

I00146-11

COOLING SYSTEM

- Check the coolant level in the radiator.

5 mm (0.2 in)

Coolant level A above the

radiator fins

» If the coolant level does not match the specified value:

- Correct the coolant level.

- Mount and tighten radiator cap screw 1.

400243-10

16.3

Checking the antifreeze and coolant level

Warning

Danger of scalding During motorcycle operation, the coolant gets 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.

Warning

Danger of poisoning Coolant is harmful to health.

- Keep coolant out of the reach of children.

- Do not allow coolant to come into contact with the skin, the eyes and clothing.

- Consult a doctor immediately if coolant is swallowed.

- Rinse the affected area immediately with plenty of water in the event of contact with the skin.

- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

- Change clothing if coolant spills onto your clothing.

Condition

The engine is cold.

- Stand the motorcycle upright on a horizontal surface.

- Remove radiator cap screw 1.

- Check the antifreeze in the coolant.

-25 … -45 °C (-13 … -49 °F)

» If the antifreeze in the coolant does not match the specified

value:

- Correct the antifreeze in the coolant.

I00146-11

- Check the coolant level in the radiator.

5 mm (0.2 in)

Coolant level A above the

radiator fins

» If the coolant level does not match the specified value:

- Correct the coolant level.

- Mount and tighten radiator cap screw 1.

400243-10

COOLING SYSTEM

16.4

Draining the coolant

Warning

Danger of scalding During motorcycle operation, the coolant gets 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.

Warning

Danger of poisoning Coolant is harmful to health.

- Keep coolant out of the reach of children.

- Do not allow coolant to come into contact with the skin, the eyes and clothing.

- Consult a doctor immediately if coolant is swallowed.

- Rinse the affected area immediately with plenty of water in the event of contact with the skin.

- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

- Change clothing if coolant spills onto your clothing.

Condition

The engine is cold.

- Position the motorcycle upright.

- Place an appropriate container under the water pump cover.

- Remove radiator cap screw 1.

- Remove screw 2.

- Completely drain the coolant.

- Mount and tighten screw 2 with a new seal ring.

Guideline

Coolant drain plug

15 Nm (11.1 lbf ft)

I00146-10

COOLING SYSTEM

16.5

Refilling with coolant

Warning

Danger of poisoning Coolant is harmful to health.

- Keep coolant out of the reach of children.

- Do not allow coolant to come into contact with the skin, the eyes and clothing.

- Consult a doctor immediately if coolant is swallowed.

- Rinse the affected area immediately with plenty of water in the event of contact with the skin.

- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

- Change clothing if coolant spills onto your clothing.

- Make sure that screw 1 is tightened.

- Position the motorcycle upright.

I00146-12

- Unscrew bleeder screw 2 to the last thread.

- Fill the radiator with coolant until coolant escapes at bleeder

screw 2.

Coolant ( p. 124)

- Tighten bleeder screw 2.

I00165-10

- Completely fill the radiator with coolant and mount and tighten radi-

ator cap screw 3.

Danger

Danger of poisoning Exhaust 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 run-

I00146-14

ning the engine in an enclosed space.

- Allow the engine to warm up and cool down again.

- Check the antifreeze and coolant level. ( p. 98)

100

COOLING SYSTEM

16.6

Changing the coolant

Warning

Danger of scalding During motorcycle operation, the coolant gets 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.

Warning

Danger of poisoning Coolant is harmful to health.

- Keep coolant out of the reach of children.

- Do not allow coolant to come into contact with the skin, the eyes and clothing.

- Consult a doctor immediately if coolant is swallowed.

- Rinse the affected area immediately with plenty of water in the event of contact with the skin.

- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

- Change clothing if coolant spills onto your clothing.

Condition

The engine is cold.

- Position the motorcycle upright.

- Place an appropriate container under the water pump cover.

- Remove radiator cap screw 1.

- Remove screw 2.

- Completely drain the coolant.

- Mount and tighten screw 2 with a new seal ring.

Guideline

Coolant drain plug

15 Nm (11.1 lbf ft)

I00146-10

- Unscrew bleeder screw 3 to the last thread.

- Fill the radiator with coolant until coolant escapes at bleeder

screw 3.

Coolant ( p. 124)

- Tighten bleeder screw 3.

- Completely fill the radiator with coolant and mount and tighten radi-

ator cap screw 1.

I00165-11

Coolant ( p. 124)

101

TUNING THE ENGINE

17.1

Checking the play in the throttle cable

- Check the throttle grip for smooth operation.

- Move the handlebar to the straight-ahead position. Turn the throt-

tle grip back and forth slightly and determine the play in throttle

cable A.

Play in throttle cable

2 … 3 mm (0.08 … 0.12 in)

» If the throttle cable play does not meet the specified value:

- Adjust the play in the throttle cable.

(

p. 103)

400192-11

Danger

Danger of poisoning Exhaust 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 run-

ning the engine in an enclosed space.

- Start the engine and let it run at idle speed. Move the handlebar to

and fro over the entire steering range.

The idle speed must not change.

» If the idle speed changes:

- Adjust the play in the throttle cable.

(

p. 103)

17.2

Adjusting the play in the throttle cable

Main work

- Move the handlebar to the straight-ahead position.

- Push back sleeve 1.

- Loosen nut 2.

I00137-10

- Turn barrel adjuster 3 so that there is play A in the throttle

cable at the throttle grip.

Guideline

Play in throttle cable

2 … 3 mm (0.08 … 0.12 in)

– Tighten nut 2.

- Slide on sleeve 1.

400192-11

Finishing work

- Check the throttle grip for smooth operation.

- Check the play in the throttle cable. ( p. 103)

103

TUNING THE ENGINE

17.3

Carburetor tuning

Effects of carburetor tuning

H01400-01

The different carburetor components must be tuned both to one another and for the use intended.

Main jet MJ

The main jet MJ has the greatest influence with the throttle slide open (full throttle).

If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger

main jet needs to be used. If the insulator is dark brown or sooty, a smaller main jet needs to be used.

Needle position POS

The needle position has the greatest influence in the mid throttle slide range.

If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine

knocks when accelerating at the full power rpm range, the jet needle must be raised.

Cylindrical part of the needle CYL

The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.

Idling jet IJ

The idling jet has the greatest influence in the low to mid throttle slide range.

If the engine stutters at idle speed or when accelerating with a partially open throttle slide, a smaller idling jet must be

used. If the engine knocks in this power range, then a larger idling jet must be used.

Idle air adjusting screw open ASO

The idle air adjusting screw has the greatest influence at idle speed.

104

TUNING THE ENGINE

Influence of throttle slide adjustment

K00495-01

The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip

position have only minimal influence.

When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the great-

est influence.

K00496-01

When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first

cylindrical part of the needle is less.

When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and

the idling jet is only minimal.

K00497-01

When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only

minimal influence.

When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only

minimal influence.

Clip position

1... 5

Clip position from above

The five possible clip positions are shown here.

The carburetor tuning depends on the defined ambient and operating

conditions.

B00075-10

105

TUNING THE ENGINE

17.4

Carburettor - idle speed

The idle setting of the carburetor significantly influences the vehicle’s

starting behavior, the stability of the idle speed, and the vehicle’s

response when accelerating. An engine with a correctly set idle speed

will be easier to start than one with an incorrectly set idle speed.

The idle mixture is adjusted using the idle air adjusting screw 1.

The idle speed is adjusted with adjusting screw 2.

402799-11

17.5

Carburetor - adjusting the idle speed

Screw in idle air adjusting screw 1 all the way and turn it to the

specified basic setting.

Guideline

Idle air adjusting screw (TXT RACING 280 EU)

open

1 turn

Idle air adjusting screw (All 125/250/300 models)

open

1.25 turns

–

Run the engine until warm.

I00138-10

Guideline

Warming-up phase

≥ 5 min

Danger

Danger of poisoning Exhaust 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 run-

ning the engine in an enclosed space.

Adjust the idle speed with adjusting screw 2.

Guideline

Choke function deactivated - The choke lever is pushed in to the

stop. (Option: Not homologized) ( p. 16)

Choke function deactivated - Choke lever in basic position.

(Option: Homologized) ( p. 17)

Idle speed

900 … 1,100 rpm

–

Turn idle air adjusting screw 1 slowly in a clockwise direction until

the idle speed begins to fall.

Note the position and turn the idle air adjusting screw slowly coun-

terclockwise until the idle speed again begins to fall.

Adjust to the point between these two positions with the highest

idle speed.

106

TUNING THE ENGINE

Info

If there is a big engine speed rise, reduce the idle speed to a

normal level and repeat the above steps.

If the procedure described here does not lead to satisfactory

results, the cause may be a wrongly dimensioned idling jet.

If you can turn the idle air adjusting screw to the end with-

out any change of engine speed, mount a smaller idling jet.

After changing the idling jet, start from the beginning with

the adjusting steps.

Following extreme air temperature or altitude changes,

adjust the idle speed again.

17.6

Checking the basic position of the shift lever

Info

When driving, the shift lever must not touch the rider's boot when in the basic position.

When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

- Sit on the vehicle in the riding position and determine distance A

between the upper edge of your boot and the shift lever.

Distance between shift lever

10 … 20 mm (0.39 … 0.79 in)

and upper edge of boot

» If the distance does not meet specifications:

- Adjust the basic position of the shift lever.

(

p. 107)

400692-10

17.7

Adjusting the basic position of the shift lever

- Remove screw 1 and take off shift lever 2.

401950-12

- Clean gear teeth A of the shift lever and shift shaft.

- Mount the shift lever on the shift shaft in the required position and

engage gearing.

Info

The range of adjustment is limited.

The shift lever must not come into contact with any other

vehicle components during the shift procedure.

401951-10

- Mount and tighten screw 1.

Guideline

Screw, shift lever

8 Nm (5.9 lbf ft)

107

SERVICE WORK ON THE ENGINE

18.1

Emptying the carburetor float chamber (Option: Not homologized)

Danger

Fire hazard Fuel 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 poisoning Fuel 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 hazard Improper handling of fuel is a danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Info

Water in the float chamber results in malfunctioning.

Condition

The engine is cold.

Preparatory work

- Turn the tap handle of the fuel tap to the position OFF toward the

rear.

Fuel no longer flows from the fuel tank to the carburetor.

Main work

- Place a cloth under the carburetor to capture the draining fuel.

- Remove screw plug 1.

- Fully drain the fuel.

- Mount and tighten screw plug 1.

I00139-10

108

SERVICE WORK ON THE ENGINE

18.2

Checking the gear oil level

Condition

Engine stopped a few minutes ago.

Preparatory work

- Stand the motorcycle upright on a horizontal surface.

Main work

- Check the gear oil level in level viewer 1.

The gear oil level is between the upper A edge of the level

viewer and the bottom B edge of the level viewer.

» If the gear oil level is below the bottom B edge of the level

viewer:

- Add the gear oil. ( p. 109)

Z03154-10

18.3

Adding the gear oil

Info

Too little gear oil or poor-quality gear oil results in premature wear to the transmission.

Gear oil must only be topped up when the engine is cold.

Preparatory work

- Park the motorcycle on a level surface.

Main work

- Remove filler plug 1.

- Add gear oil until the gear oil level in level viewer 2 is between the

upper A and lower B edge.

Gear oil (API GL-4, SAE 75W) ( p. 124)

- Mount and tighten filler plug 1.

Z03154-11

18.4

Changing the gear oil

Warning

Danger of scalding Engine and gear oil get hot when the motorcycle is operated.

- Wear suitable protective clothing and safety gloves.

- In the event of scalding, rinse the area affected immediately with lukewarm water.

Note

Environmental hazard Hazardous 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 gear oil drain plug is located on the left side of the underside of the engine.

To facilitate draining, there is a hole in the engine guard at the level of the gear oil drain plug.

109

SERVICE WORK ON THE ENGINE

Condition

The engine is at operating temperature.

Preparatory work

- Park the motorcycle on a level surface.

- Position an appropriate container under the engine.

Main work

- Remove gear oil drain plug 1.

- Let the gear oil drain fully.

- Thoroughly clean the gear oil drain plug.

- Clean the sealing surface on the engine.

- Mount and tighten gear oil drain plug 1 with a new seal ring.

Guideline

Drain plug for gear oil

M12

15 Nm (11.1 lbf ft)

I00148-10

- Remove filler plug 2 and fill up with gear oil.

Gear oil

0.37 l (0.39 qt.)

Gear oil (API GL-4,

SAE 75W) ( p. 124)

- Mount and tighten filler plug 2.

Danger

Danger of poisoning Exhaust gases are toxic and inhaling

them may result in unconsciousness and death.

Z03153-10

- Always make sure there is sufficient ventilation when

running the engine.

- Use effective exhaust extraction when starting or run-

ning the engine in an enclosed space.

- Start the engine and check it for leaks.

Finishing work

- Check the gear oil level. ( p. 109)

110

CLEANING, CARE

19.1

Cleaning the motorcycle

Note

Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.

The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.

Pressure which is too high causes malfunctions and destroys components.

- Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.

- Maintain a minimum distance between the nozzle of the pressure cleaner and the component.

Minimum clearance

60 cm (23.6 in)

Note

Environmental hazard Hazardous 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

To maintain the value and appearance of the motorcycle over a long period, clean it regularly.

Avoid direct sunshine when cleaning the motorcycle.

- Close off exhaust system to keep water from entering.

- Remove the coarse dirt particles with a gentle water jet.

- Spray the heavily soiled parts with a normal commercial motorcycle

cleaner and clean using a brush.

Motorcycle cleaner ( p. 126)

Info

Use warm water containing normal motorcycle cleaner and

401061-01

a soft sponge.

Never apply motorcycle cleaner to a dry vehicle; always

rinse the vehicle with water first.

- After rinsing the motorcycle with a gentle spray of water, allow it to

dry thoroughly.

(Option: Not homologized)

- Empty the carburetor float chamber.

(

p. 108)

– Remove the closure of the exhaust system.

Warning

Danger of accidents Moisture and dirt impair the brake

system.

- Brake carefully several times to dry out and remove dirt

from the brake linings and the brake discs.

- After cleaning, ride the vehicle a short distance until the engine

warms up.

Info

The heat produced causes water at inaccessible locations in

the engine and on the brake system to evaporate.

- After the motorcycle has cooled down, lubricate all moving parts

and pivot points.

- Clean the chain. ( p. 66)

111

STORAGE

20.1

Storage

Warning

Danger of poisoning Fuel 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.

Info

If the motorcycle is not being used for an extended length of time, additional measures are recommended.

Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are neces-

sary, you should do this during the storage period (less workshop overload). This allows you to avoid long waiting

periods when the next season starts.

- When refueling for the last time before taking the motorcycle out of

service, add fuel additive.

Fuel additive ( p. 126)

- Refuel. ( p. 30)

Tip

Fill the fuel tank completely as specified, using fuel with the

lowest possible ethanol content.

401058-01

- Clean the motorcycle. ( p. 111)

- Change the gear oil.

(

p. 109)

– Check the antifreeze and coolant level. ( p. 98)

(Option: Not homologized)

- Empty the carburetor float chamber.

(

p. 108)

– Check the tire pressure. ( p. 91)

- Store the vehicle in a dry location that is not subject to large fluctua-

tions in temperature.

Info

GASGAS Motorcycles recommends jacking up the motorcy-

cle.

- Raise the motorcycle with a lift stand. ( p. 42)

- Cover the vehicle with a tarp or a similar cover that is permeable to

air.

Info

Do not use non-porous materials since they prevent humid-

ity from escaping, thus causing corrosion.

Avoid running the engine for a short time only. Because the

engine will not warm up sufficiently, the water vapor pro-

duced during combustion will condense, causing engine

parts and the exhaust system to rust.

113

TROUBLESHOOTING

Faults

Possible cause

Action

Engine does not start

Operating error

- Carry out start procedure. ( p. 27)

The motorcycle has been in disuse

(Option: Not homologized)

for an extended period and old

- Empty the carburetor float cham-

fuel is in the float chamber

ber.

(

p. 108)

Fuel supply interrupted

Check the fuel tank breather.

–

Clean the fuel tap.

–

Check/adjust the carburetor components.

Spark plug sooty or wet

Clean and dry the spark plug and spark

plug connector, or change if necessary.

Plug gap of spark plug too wide

Adjust plug gap.

Guideline

Spark plug gap

0.7 … 0.8 mm (0.028 … 0.031 in)

Fault in ignition system

Check the ignition system.

Magnetic switch cable in the

Check magnetic switch.

wiring harness chafed; magnetic

switch defective

Connector or ignition coil loose or

Clean the connector and treat with con-

oxidized

tact spray.

Water in carburetor or jets

Check/adjust the carburetor components.

blocked

The engine has no idle speed

Idling jet blocked

Check/adjust the carburetor components.

Adjusting screws on the carbu-

Carburetor - adjust the idle speed.

retor are in turned to the wrong

(

p. 106)

position

Faulty spark plug

Change the spark plug.

Faulty ignition

Check the ignition coil.

–

Check the spark plug connector.

Engine has too little power

Fuel supply interrupted

Check the fuel tank breather.

–

Clean the fuel tap.

–

Check/adjust the carburetor components.

Air filter is very dirty

Clean the air filter and air filter box.

(

p. 58)

Exhaust system leaking or

Check exhaust system for damage.

deformed

Fault in ignition system

Check the ignition system.

Damaged membrane or reed valve

Check the membrane and reed valve hous-

housing

ing.

The engine stutters or there is

Lack of fuel

Turn the tap handle of the fuel tap to the

backfiring through the carburetor

position ON facing downward.

Turn the tap handle of the fuel tap to the

position RES toward the front.

Refuel. ( p. 30)

The engine takes in false air

Check the intake flange and carburetor for

firm seating.

Connector or ignition coil loose or

Clean the connector and treat with con-

oxidized

tact spray.

Engine overheats

Too little coolant in cooling system

Check the cooling system for tightness.

–

Check the antifreeze and coolant level.

(

p. 98)

115

TROUBLESHOOTING

Faults

Possible cause

Action

Engine overheats

Too little air stream

- Switch off the engine when standing.

Radiator fins very dirty

- Clean the radiator fins.

Foam formation in the cooling

- Drain the coolant.

(

p. 99)

system

- Refill with coolant. ( p. 100)

Damaged cylinder head or cylin-

- Check the cylinder head and cylinder head

der head gasket

gasket.

Bent radiator hose

- Change the radiator hose.

White smoke development (steam

Damaged cylinder head or cylin-

- Check the cylinder head and cylinder head

in the exhaust gas)

der head gasket

gasket.

Gear oil emerges from the vent

Too much gear oil added

- Check the gear oil level. ( p. 109)

hose

Water in the gear oil

Damaged radial shaft seal ring or

- Check the radial shaft seal ring and the

water pump

water pump.

116

TECHNICAL SPECIFICATIONS

22.1

Engine

Design

1-cylinder 2-stroke gasoline engine, water-cooled, with

membrane inlet

Displacement (TXT RACING 125 EU)

125 cm³ (7.63 cu in)

Displacement (All 250 models)

247.7 cm³ (15.116 cu in)

Displacement (TXT RACING 280 EU)

272.2 cm³ (16.611 cu in)

Displacement (All 300 models)

294.1 cm³ (17.947 cu in)

Stroke (TXT RACING 125 EU)

54.5 mm (2.146 in)

Stroke (All 250 models)

60 mm (2.36 in)

Stroke (TXT RACING 280 EU)

60 mm (2.36 in)

Stroke (All 300 models)

60 mm (2.36 in)

Hole (TXT RACING 125 EU)

54 mm (2.13 in)

Hole (All 250 models)

72.5 mm (2.854 in)

Hole (TXT RACING 280 EU)

76 mm (2.99 in)

Hole (All 300 models)

79 mm (3.11 in)

Primary transmission

27:75

Clutch

Multidisc clutch in oil bath/hydraulically operated

Transmission

6-gear transmission, GASGAS*Four / Six System

Transmission ratio

first-gear

24x27x23x28x15x33

second-gear

14:36

third-gear

15:33

fourth-gear

28x23x27x24x14x36

fifth-gear

14:27

sixth-gear

28:23

Ignition system

Contactless controlled fully electronic ignition with digital

ignition adjustment

Spark plug

NGK BPR5 ES

Spark plug gap

0.7 … 0.8 mm (0.028 … 0.031 in)

Starting aid

Kick starter system

22.2

Engine tightening torques

Screw, clutch spring

4 Nm (3 lbf ft)

Screw for shift shaft spring

7 Nm (5.2 lbf ft)

Screw for spring shift lock

7 Nm (5.2 lbf ft)

Screw, alternator cover

8 Nm (5.9 lbf ft)

Screw, clutch cover

8 Nm (5.9 lbf ft)

Screw, crankshaft speed sensor

8 Nm (5.9 lbf ft)

Screw, engine case

8 Nm (5.9 lbf ft)

Screw, inner clutch hub

8 Nm (5.9 lbf ft)

Screw, kick starter stop

8 Nm (5.9 lbf ft)

Screw, membrane fixation

8 Nm (5.9 lbf ft)

Screw, shift drum locating unit

8 Nm (5.9 lbf ft)

Screw, shift lever

8 Nm (5.9 lbf ft)

Screw, shift shaft, tightening bearing

8 Nm (5.9 lbf ft)

Screw, stator

8 Nm (5.9 lbf ft)

117

TECHNICAL SPECIFICATIONS

Screw, water pump impeller

8 Nm (5.9 lbf ft)

Coolant drain plug

15 Nm (11.1 lbf ft)

Screw, cylinder head

15 Nm (11.1 lbf ft)

Screw, kick starter lever

10 Nm (7.4 lbf ft)

Loctite^®243™

Bleeder screw, cylinder head

15 Nm (11.1 lbf ft)

Nut, cylinder base

M10

30 Nm (22.1 lbf ft)

Stud, cylinder

M10

6 Nm (4.4 lbf ft)

Screw, rotor

M10x1.25

50 Nm (36.9 lbf ft)

Drain plug for gear oil

M12

15 Nm (11.1 lbf ft)

Filler plug

M12

15 Nm (11.1 lbf ft)

Spark plug

M14x1.25

27 Nm (19.9 lbf ft)

Nut, primary gear wheel

M23LHx1

50 Nm (36.9 lbf ft)

Loctite^®243™

22.3

Carburetor

22.3.1

Option: Homologized

Carburetor type

Dell’Orto PHBG 21BS

Needle position (TXT RACING 125 EU)

2nd position from top

Needle position (All 250 models)

1st position from top

Needle position (All 280/300 models)

3rd position from top

Jet needle

Main jet (TXT RACING 125 EU)

Main jet (All 250/280/300 models)

Idling jet (All 250 models)

Idling jet (All 125/280/300 models)

Idle air adjusting screw (TXT RACING 125 EU)

open

1 turn

Idle air adjusting screw (All 250 models)

open

0.5 turns

Idle air adjusting screw (All 280/300 models)

open

1.25 turns

22.3.2

Option: Not homologized

Carburetor type

KEIHIN PWK 28

Needle position (All 300 models)

Fourth position from top

Needle position (All 125/250/280 models)

3rd position from top

Jet needle

JJH

Main jet (TXT RACING 125 EU)

125

Main jet (All 250 models)

125

Main jet (TXT RACING 280 EU)

125

Main jet (All 300 models)

125

Idling jet (TXT RACING 125 EU)

Idling jet (All 250 models)

Idling jet (TXT RACING 280 EU)

Idling jet (All 300 models)

118

TECHNICAL SPECIFICATIONS

Idle air adjusting screw (TXT RACING 280 EU)

open

1 turn

Idle air adjusting screw (All 125/250/300 models)

open

1.25 turns

22.4

Capacities

22.4.1

Gear oil

0.37 l (0.39 qt.)

Gear oil (API GL-4, SAE 75W)

(

p. 124)

22.4.2

Coolant

0.4 l (0.4 qt.)

Coolant ( p. 124)

22.4.3

Fuel

Total fuel tank capacity, approx.

2.2 l (2.3 qt.)

Super unleaded (98 octane) mixed with

2-stroke engine oil (1:67) ( p. 125)

Fuel reserve, approx.

0.15 l (0.16 qt.)

22.5

Chassis

Frame

Tubular frame made of chrome molybdenum steel

Fork (All RACING models)

Tech 39 mm

Fork (All GP models)

Tech 39 mm

Suspension travel (All RACING models)

front

159.5 mm (6.28 in)

rear

174 mm (6.85 in)

Suspension travel (All GP models)

front

159.5 mm (6.28 in)

rear

174 mm (6.85 in)

Shock absorber (All RACING models)

Tech 2V

Shock absorber (All GP models)

Tech 3V

Brake system

front

Disc brake with axially mounted 4-piston brake caliper

rear

Disc brake with 2-piston brake caliper

Brake discs - diameter

front

185 mm (7.28 in)

rear

150 mm (5.91 in)

Brake discs - wear limit

front

2.7 mm (0.106 in)

rear

2.7 mm (0.106 in)

Street tire pressure (Option: Homologized)

front

1.2 bar (17 psi)

rear

1.2 bar (17 psi)

Offroad tire pressure

front

0.42 bar (6.1 psi)

rear

0.30 bar (4.4 psi)

119

TECHNICAL SPECIFICATIONS

Secondary drive ratio (TXT RACING 125 EU)

09:48

Secondary drive ratio (All 250/280/300 models)

10:39

Chain

5/8 x 1/4"

Wheelbase

1,320 ± 10 mm (51.97 ± 0.39 in)

Seat height unloaded

630 mm (24.8 in)

Ground clearance unloaded

325 mm (12.8 in)

Weight when ready for racing without fuel approx.

69.3 kg (152.8 lb.)

Homologated weight without fuel approx.

72.2 kg (159.2 lb.)

Maximum permissible front axle load

97 kg (214 lb.)

Maximum permissible rear axle load

127 kg (280 lb.)

Maximum permissible overall weight

224 kg (494 lb.)

22.6

Electrical system

Combination instrument battery

CR 2032

Battery voltage: 3 V

Low beam/high beam (Option:

BILUX bulb / socket BA20D

12 V

Homologized)

35/35 W

Position light (Option: Homologized)

T5W/socket BA9s

12 V

Turn signal (Option: Homologized)

R10W / socket BA15s

12 V

10 W

Brake/tail light (Option: Homologized)

LED

License plate lamp (Option: Homolo-

LED

gized)

22.7

Tires

Front tire

Rear tire

2.75 - 21 M/C 45M TT

4.00 R 18 M/C 64M TL

Michelin Trial Competition X11

The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an

authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical

specifications must be observed. Additional information is available in the Service section under:

http://www.gasgas.com

22.8

Fork

22.8.1

All RACING models

Fork article number

A53501000044

Fork

Tech 39 mm

Rebound damping

Standard

19 clicks

Fluid barrier

Standard

2.5 turns

Spring preload

Standard

5.5 turns

Air chamber length

Air chamber length, left

125 mm

Air chamber length, right

70 mm

120

TECHNICAL SPECIFICATIONS

22.8.2

All GP models

Fork article number

A53501100044

Fork

Tech 39 mm

Rebound damping

Standard

19 clicks

Compression damping

Standard

1.75 turns

Fluid barrier

Standard

2.5 turns

Spring preload

Standard

5.5 turns

Air chamber length

Air chamber length, left

125 mm

Air chamber length, right

70 mm

22.9

Shock absorber

22.9.1

All RACING models

Shock absorber article number

A53504010044

Shock absorber

Tech 2V

Rebound damping

Standard

12 clicks

Spring preload

8.5 mm (0.335 in)

Spring rate

Standard

68.7 N/mm (392.3 lb/in)

Static sag

10 … 15 mm (0.39 … 0.59 in)

Riding sag

70 … 75 mm (2.76 … 2.95 in)

Gas pressure

10 bar (145 psi)

22.9.2

All GP models

Shock absorber article number

A53504110144

Shock absorber

Tech 3V

Rebound damping

Standard

12 clicks

Compression damping

Standard

12 clicks

Spring preload

8.5 mm (0.335 in)

Spring rate

Standard

73.6 N/mm (420.3 lb/in)

Static sag

10 … 15 mm (0.39 … 0.59 in)

Riding sag

70 … 75 mm (2.76 … 2.95 in)

Gas pressure

10 bar (145 psi)

121

TECHNICAL SPECIFICATIONS

22.10

Chassis tightening torques

Remaining EJOT screws

EJOT DELTA PT^® K40

1 Nm (0.7 lbf ft)

Remaining EJOT screws

EJOT DELTA PT^® K50

2 Nm (1.5 lbf ft)

Screw, brake hose guide clamp

EJOT DELTA PT^® K40x12

0.5 Nm (0.37 lbf ft)

Screw, combination instrument

EJOT DELTA PT^® 45x12-Z

2 Nm (1.5 lbf ft)

(Option: Homologized)

Screw, headlight (Option: Homolo-

EJOT PT^® K50x18 T20

3 Nm (2.2 lbf ft)

gized)

Screw, license plate holder (Option:

EJOT DELTA PT^® K45x12 T20

2 Nm (1.5 lbf ft)

Homologized)

Screw, lower part of air filter box

EJOT DELTA PT^® K40x12

1.5 Nm (1.11 lbf ft)

Screw, sprocket cover (Option:

EJOT DELTA PT^® K40x12

0.5 Nm (0.37 lbf ft)

Homologized)

Screw, rear brake line guide

5 Nm (3.7 lbf ft)

Screw, turn signal switch adapter

6 Nm (4.4 lbf ft)

(Option: Homologized)

Spoke nipple, front wheel

M4.5

2 Nm (1.5 lbf ft)

Spoke nipple, rear wheel

M4.5

3 Nm (2.2 lbf ft)

Remaining nuts, chassis

5 Nm (3.7 lbf ft)

Remaining screws, chassis

5 Nm (3.7 lbf ft)

Screw, chain sprocket guard

1.2 Nm (0.89 lbf ft)

Screw, chain sprocket guard

3 Nm (2.2 lbf ft)

Screw, clutch assembly clamp

6 Nm (4.4 lbf ft)

Screw, clutch master cylinder

5 Nm (3.7 lbf ft)

Screw, cylinder head cable holder

6 Nm (4.4 lbf ft)

Screw, engine case cable retainer

8 Nm (5.9 lbf ft)

Screw, hand brake cylinder

6 Nm (4.4 lbf ft)

Screw, headlamp mask (Option:

6 Nm (4.4 lbf ft)

Homologized (not available))

Screw, link fork, chain guard

1.2 Nm (0.89 lbf ft)

Screw, throttle grip

3 Nm (2.2 lbf ft)

Front fender

12 Nm (8.9 lbf ft)

Loctite^®243™

Remaining nuts, chassis

10 Nm (7.4 lbf ft)

Remaining screws, chassis

10 Nm (7.4 lbf ft)

Screw, air filter box

6 Nm (4.4 lbf ft)

Screw, bottom triple clamp

10 Nm (7.4 lbf ft)

Screw, brake disc

12 Nm (8.9 lbf ft)

Screw, brake disc guard, rear wheel

3 Nm (2.2 lbf ft)

Screw, chain guard on frame

12 Nm (8.9 lbf ft)

Screw, electrics compartment

6 Nm (4.4 lbf ft)

Screw, foot brake cylinder

10 Nm (7.4 lbf ft)

Screw, fuel tank fastening

6 Nm (4.4 lbf ft)

Screw, handlebar stop, frame

6 Nm (4.4 lbf ft)

Screw, main silencer on Clipsmutter

12 Nm (8.9 lbf ft)

Screw, main silencer on frame

14 Nm (10.3 lbf ft)

Screw, radiator bracket

10 Nm (7.4 lbf ft)

122

TECHNICAL SPECIFICATIONS

Screw, rear brake caliper

12 Nm (8.9 lbf ft)

Loctite^®243™

Screw, rear fender

6 Nm (4.4 lbf ft)

Screw, sensor magnet (Option:

12 Nm (8.9 lbf ft)

Homologized)

Screw, side stand fixing on link fork

12 Nm (8.9 lbf ft)

Screw, steering stem

12 Nm (8.9 lbf ft)

Screw, top triple clamp

12 Nm (8.9 lbf ft)

Screw, voltage regulator

6 Nm (4.4 lbf ft)

Remaining nuts, chassis

25 Nm (18.4 lbf ft)

Remaining screws, chassis

25 Nm (18.4 lbf ft)

Screw, brake cable guiding

25 Nm (18.4 lbf ft)

Loctite^®243™

Screw, chain adjuster

20 Nm (14.8 lbf ft)

Loctite^®243™

Screw, eccentric stop

17 Nm (12.5 lbf ft)

Screw, engine brace on frame

35 Nm (25.8 lbf ft)

Screw, engine fixing arm, top

30 Nm (22.1 lbf ft)

Screw, engine guard

25 Nm (18.4 lbf ft)

Screw, foot brake lever

25 Nm (18.4 lbf ft)

Loctite^®243™

Screw, fork shoe

15 Nm (11.1 lbf ft)

Screw, front brake caliper

25 Nm (18.4 lbf ft)

Screw, handlebar clamp

20 Nm (14.8 lbf ft)

Screw, handlebar support

25 Nm (18.4 lbf ft)

Screw, manifold

12 Nm (8.9 lbf ft)

Loctite^®243™

Screw, pull rod on frame

30 Nm (22.1 lbf ft)

Screw, radiator safety valve

8 Nm (5.9 lbf ft)

Screw, side stand

25 Nm (18.4 lbf ft)

Loctite^®243™

Banjo bolt, clutch master cylinder

M10

14 Nm (10.3 lbf ft)

Banjo bolt,.clutch slave cylinder

M10

20 Nm (14.8 lbf ft)

Lock nut, engine bearer, bottom

M10

50 Nm (36.9 lbf ft)

Remaining nuts, chassis

M10

45 Nm (33.2 lbf ft)

Remaining screws, chassis

M10

45 Nm (33.2 lbf ft)

Screw, bell crank

M10

45 Nm (33.2 lbf ft)

Screw, bottom shock absorber

M10

45 Nm (33.2 lbf ft)

Screw, engine mounting bracket

M10

50 Nm (36.9 lbf ft)

Screw, pull rod on bell crank

M10

45 Nm (33.2 lbf ft)

Screw, rear wheel spindle

M10

50 Nm (36.9 lbf ft)

Screw, top shock absorber

M10

50 Nm (36.9 lbf ft)

Nut, swingarm pivot

M12x1

50 Nm (36.9 lbf ft)

Screw, link fork

M14

50 Nm (36.9 lbf ft)

Nut, steering head

M16

20 Nm (14.8 lbf ft)

Wheel spindle, front

M18

50 Nm (36.9 lbf ft)

123

SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

Standard/classification

- DOT

Guideline

- Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the

corresponding properties.

Recommended supplier

Castrol

- REACT PERFORMANCE DOT 4

MOTOREX^®

- Brake Fluid DOT 5.1

Coolant

Guideline

- Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuit-

able antifreeze causes corrosion, deposits and frothing.

- Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and

lubrication properties.

- Only use coolant that complies with the requirements stated (see specifications on the container) and that has the rele-

vant properties.

Antifreeze protection to at least

-25 °C (-13 °F)

The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be

diluted.

The use of premixed coolant is recommended.

Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other

coolants.

Recommended supplier

MOTOREX^®

- COOLANT M3.0

Engine oil, 2-stroke

Standard/classification

- JASO FD ( p. 128)

Guideline

- Only use high-grade 2-stroke engine oil from a reputable brand.

fully synthetic

Recommended supplier

MOTOREX^®

- Cross Power 2T

Gear oil (API GL-4, SAE 75W)

Standard/classification

- API (API GL-4)

- SAE ( p. 128) (SAE 75W)

Guideline

- Use only gear oils that comply with the specified standards (see specifications on the container) and that exhibit the

required properties.

Fully synthetic gear oil

124

AUXILIARY SUBSTANCES

Air filter cleaner

Recommended supplier

MOTOREX^®

- Racing Bio Dirt Remover

Chain cleaner

Recommended supplier

MOTOREX^®

- Chain Clean

Fuel additive

Recommended supplier

MOTOREX^®

- Fuel Stabilizer

Long-life grease

Recommended supplier

MOTOREX^®

- Bike Grease 2000

Motorcycle cleaner

Recommended supplier

MOTOREX^®

- Moto Clean

Off-road chain spray

Recommended supplier

MOTOREX^®

- Chainlube Offroad

Oil for foam air filter

Recommended supplier

MOTOREX^®

- Racing Bio Liquid Power

Preserving materials for paints, metal and rubber

Recommended supplier

MOTOREX^®

- Moto Protect

Rubber grip adhesive (00062030051)

Recommended supplier

KTM AG

- GRIP GLUE

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces

Recommended supplier

MOTOREX^®

- Quick Cleaner

126

INDEX

Choke lever

Clutch

Accessories

fluid level, checking/correcting

Air filter

fluid, changing

cleaning

Clutch lever

installing

basic position, adjusting

removing

free travel, adjusting

Air filter box

free travel, checking

cleaning

Combination instrument

installing

adjusting

removing

message

Antifreeze

overview

checking

service display, setting

setting kilometers or miles

Auxiliary substances

setting the clock

Compression damping

Basic chassis setting

adjusting the fork

rider's weight, checking with

adjusting the shock absorber

Brake discs

Coolant

checking

changing

101

Brake fluid

draining

front brake, adding

refilling

100

rear brake, adding

Coolant level

Brake fluid level

checking

97-98

of front brake, checking

Cooling system

of rear brake, checking

Customer service

Brake lining retainers

of front brake, checking

Defined use

of rear brake, checking

Diagnostics connector

Brake linings

Difficult operating conditions

of front brake, changing

of front brake, checking

of rear brake, checking

Engine

rear brake, changing

running in

Engine number

Engine sprocket

Capacity

checking

coolant

119

fuel

31,

119

Environment

Gear oil

110,

119

Carburetor

Figures

float chamber, emptying

108

Fluid barrier

Idle speed

106

adjusting the fork

idle speed, adjusting

106

Foot brake lever

Carburetor tuning

104

basic position, adjusting

Chain

free travel, checking

checking

Fork

cleaning

article number

Chain guide

basic setting

checking

Fork legs

Chain tension

dust boots, cleaning

adjusting

installing

checking

removing

Choke button

132

INDEX

Frame

removing

checking

Front brake caliper

Magnetic switch

installing

Main silencer

removing

glass fiber yarn filling, changing

Front brake disc guard

installing

removing

Manifold

Front fender

installing

removing

Manufacturer warranty

Front wheel

Map switch

installing

Misuse

removing

Motorcycle

Fuel tank

cleaning

111

installing

from lift stand, removing

removing

lift stand, raising with

Fuel tank filler cap

closing

Overview of indicator lights

opening

Owner's Manual

Fuel tap

Fuel, oils, etc

Play in throttle cable

adjusting

103

Gear oil

checking

103

adding

109

Position light lamp

changing

109

changing

level, checking

109

Preparing for use

advice on preparing for first use

Hand brake lever

after storage

114

basic position, adjusting

checks and maintenance measures when preparing

free travel, adjusting

for use

free travel, checking

Protective clothing

Headlight bulb

changing

Rear fender

Headlight mask

installing

removing

Rear sprocket

Headlight setting

checking

Rear wheel

Horn button

installing

removing

Implied warranty

Rebound damping

Intended use

adjusting the fork

adjusting the shock absorber

Kick starter lever

Refueling

fuel

Riding sag

Light switch

adjusting

Link fork

Rubber grip

checking

Lower triple clamp

installing

133

INDEX

Type label

Safe operation

Service

Vehicle identification number

Service schedule

32-33

View of vehicle

Shift lever

front left

adjusting the basic position

107

rear right

basic position, checking

107

Shock absorber

Work rules

checking static sag

installing

removing

riding sag, checking

spring preload, adjusting

Side stand

Spare parts

Spoke tension

checking

Spring preload

adjusting the fork

Starting

Steering

locking

unlocking

Steering head bearing

lubricating

Steering head bearing play

adjusting

checking

Steering lock

Stop button

Storage

113

Technical specifications

capacities

119

carburetor

118

chassis

119

chassis tightening torques

122

electrical system

120

engine

117

engine tightening torques

117

fork

120

shock absorber

121

tires

120

Throttle grip

Tire condition

checking

Tire pressure

checking

Transporting

Turn signal bulb

changing

Turn signal switch

134