GASGAS EC 450F / EC 500F / EW 500F. OWNER'S MANUAL (2024)

TABLE OF CONTENTS

MEANS OF REPRESENTATION

6.18

Foot brake lever

6.19

Side stand

1.1

Symbols used

6.20

Steering lock

1.2

Formats used

6.21

Locking the steering (All EU models)

SAFETY ADVICE

6.22

Unlocking the steering

2.1

Use definition - intended use

COMBINATION INSTRUMENT

2.2

Misuse

7.1

Combination instrument overview

2.3

Safety advice

7.2

Activation

2.4

Degrees of risk and symbols

7.3

Message on the combination

2.5

Tampering warning

instrument

2.6

Safe operation

7.4

Setting the combination instrument

2.7

Protective clothing

7.5

Setting kilometers or miles

2.8

Work rules

7.6

Setting the clock

2.9

Environment

7.7

Setting the service display

2.10

Owner's Manual

7.8

Speed, time, and DST distance 1

IMPORTANT NOTES

7.9

Speed, time, and DST2 distance 2

7.10

AVG average speed, ART operating

3.1

Manufacturer warranty, implied

hours, and ODO total distance covered

warranty

3.2

Fuel, auxiliary substances

PREPARING FOR USE

3.3

Spare parts, accessories

8.1

Advice on preparing for first use

3.4

Service

8.2

Running in the engine

3.5

Figures

8.3

Starting power of lithium-ion batteries

3.6

Customer service

at low temperatures

8.4

Preparing the vehicle for difficult

VIEW OF VEHICLE

operating conditions

4.1

View of vehicle, front left (example)

8.5

Preparing the vehicle for rides on dry

4.2

View of vehicle, rear right (example)

sand

8.6

Preparing the vehicle for rides on wet

SERIAL NUMBERS

sand

5.1

Vehicle identification number

8.7

Preparing the vehicle for rides on wet

5.2

Type label

and muddy circuits

5.3

Key number

8.8

Preparing vehicle for high temperatures

5.4

Engine number

or slow riding

5.5

Fork part number

8.9

Preparing the vehicle for low

5.6

Shock absorber article number

temperatures or snow

CONTROLS

RIDING INSTRUCTIONS

6.1

Clutch lever

9.1

Checks and maintenance measures

6.2

Hand brake lever

when preparing for use

6.3

Throttle grip

9.2

Starting the vehicle

6.4

Horn button (All EU models)

9.3

Activating traction control (optional)

6.5

Light switch (All EU models)

9.4

Starting off

6.6

Light switch (All US models)

9.5

Quickshifter (optional)

6.7

Turn signal switch (All EU models)

9.6

Activating the quickshifter (optional)

6.8

Start button

9.7

Shifting, riding

6.9

Stop button

9.8

Braking

6.10

Combination switch (optional)

9.9

Stopping, parking

6.11

Overview of indicator lamps (All EU

9.10

Transporting

models)

9.11

Refueling

6.12

Indicator lamps overview (All US

SERVICE SCHEDULE

models)

6.13

Opening fuel tank filler cap

10.1

Additional information

6.14

Closing the fuel tank filler cap

10.2

Service schedule

6.15

Cold start button

6.16

Idle speed adjusting screw

6.17

Shift lever

TABLE OF CONTENTS

TUNING THE CHASSIS

12.27

Preparing air filter box cover for

securing

11.1

Checking the basic chassis setting with

12.28

Removing the main silencer

the rider's weight

12.29

Installing the main silencer

11.2

Compression damping of the shock

12.30

Cleaning spark arrestor (EW 500F US)....

absorber

12.31

Changing the glass fiber yarn filling in

11.3

Adjusting the low-speed compression

the main silencer

damping of the shock absorber

12.32

Removing the fuel tank

11.4

Adjusting the high-speed compression

12.33

Installing the fuel tank

damping of the shock absorber

12.34

Checking for chain dirt accumulation

11.5

Adjusting the rebound damping of the

12.35

Cleaning the chain

shock absorber

12.36

Checking the chain tension

11.6

Measuring the dimension of the rear

12.37

Adjusting the chain tension

wheel unloaded

11.7

Checking the static sag of the shock

12.38

Checking the chain, rear sprocket,

engine sprocket, and chain guide

absorber

12.39

Checking the frame

11.8

Checking the rider sag of the shock

absorber

12.40

Checking the link fork

11.9

Adjusting the spring preload of the

12.41

Checking the throttle cable routing

shock absorber

12.42

Checking the rubber grip

11.10

Adjusting the rider sag

12.43

Programming the Quickshifter

11.11

Checking the basic setting of the fork

(optional)

11.12

Adjusting the compression damping of

12.44

Adjusting the basic position of the clutch

the fork

lever

11.13

Adjusting the rebound damping of the

12.45

Checking/correcting the fluid level of

fork

hydraulic clutch

11.14

Handlebar position

12.46

Changing the hydraulic clutch fluid

11.15

Adjusting the handlebar position

BRAKE SYSTEM

SERVICE WORK ON THE CHASSIS

13.1

Adjusting the basic position of the hand

12.1

Raising the motorcycle with a lift stand

brake lever

13.2

Checking the brake discs

12.2

Removing the motorcycle from the lift

stand

13.3

Checking the front brake fluid level

12.3

Bleeding the fork legs

13.4

Adding front brake fluid

12.4

Cleaning the dust boots of the fork legs

13.5

Checking that the brake linings of the

front brake are secured

12.5

Removing the fork protector

13.6

Changing the brake linings of the front

12.6

Installing the fork protector

brake

12.7

Removing the fork legs

13.7

Checking the free travel of foot brake

12.8

Installing the fork legs

lever

12.9

Removing the frame protector

13.8

Adjusting the basic position of the foot

12.10

Installing the frame protector

brake lever

12.11

Removing the lower triple clamp

13.9

Checking the rear brake fluid level

12.12

Installing the lower triple clamp

13.10

Adding rear brake fluid

12.13

Checking the steering head bearing play ... 57

13.11

Checking that the brake linings of the

12.14

Adjusting the steering head bearing

rear brake are secured

play

13.12

Changing the rear brake linings

12.15

Lubricating the steering head bearing

12.16

Removing the front fender

WHEELS, TIRES

12.17

Installing the front fender

14.1

Removing the front wheel

12.18

Removing the shock absorber

14.2

Installing the front wheel

12.19

Installing the shock absorber

14.3

Removing the rear wheel

12.20

Removing the seat

14.4

Installing the rear wheel

12.21

Mounting the seat

14.5

Checking the tire condition

12.22

Removing the air filter box cover

14.6

Checking tire pressure

12.23

Installing the air filter box cover

14.7

Checking spoke tension

100

12.24

Removing the air filter

12.25

Installing the air filter

ELECTRICAL SYSTEM

101

12.26

Cleaning the air filter and air filter

15.1

Removing the 12-V battery

101

box

TABLE OF CONTENTS

15.2

Installing the 12-V battery

102

BLINK CODE

132

15.3

Charging the 12-V battery

102

TECHNICAL SPECIFICATIONS

134

15.4

Changing the main fuse

104

15.5

Removing the headlight mask with the

23.1

Engine

134

headlight

105

23.2

Engine tightening torques

135

15.6

Installing the headlight mask with the

23.3

Capacities

136

headlight

106

23.3.1

Engine oil

136

15.7

Changing the headlight bulb

107

23.3.2

Coolant

136

15.8

Checking the headlight setting

107

23.3.3

Fuel

136

15.9

Adjusting the headlight range

108

23.4

Chassis

136

15.10

Changing the turn signal bulb (All EU

23.5

Electrical system

137

models)

108

23.6

Tires

138

15.11

Changing the combination instrument

23.7

Fork

138

battery

109

23.8

Shock absorber

138

15.12

Diagnostics connector

110

23.9

Chassis tightening torques

139

15.13

OCU

110

SUBSTANCES

142

COOLING SYSTEM

111

AUXILIARY SUBSTANCES

144

16.1

Cooling system

111

STANDARDS

146

16.2

Checking the antifreeze and coolant

level

111

INDEX OF SPECIAL TERMS

147

16.3

Checking the coolant level

112

LIST OF ABBREVIATIONS

148

16.4

Draining the coolant

112

16.5

Refilling coolant

113

LIST OF SYMBOLS

149

16.6

Changing the coolant

114

29.1

Yellow and orange symbols

149

TUNING THE ENGINE

115

29.2

Green and blue symbols

149

17.1

Checking the play in the throttle cable....

115

INDEX

150

17.2

Adjusting the play in the throttle

cable

115

17.3

Adjusting the characteristic map of the

throttle response

116

17.4

Changing the mapping (optional)

117

17.5

Adjusting the idle speed

118

17.6

Programming the throttle valve

position

119

17.7

Checking the basic position of the shift

lever

119

17.8

Adjusting the basic position of the shift

lever

120

SERVICE WORK ON THE ENGINE

121

18.1

Changing the fuel screen

121

18.2

Checking the engine oil level

122

18.3

Changing the engine oil and oil filter,

cleaning the oil screen

122

18.4

Adding engine oil

125

CLEANING, CARE

126

19.1

Cleaning the motorcycle

126

19.2

Checks and maintenance steps for

winter operation

127

STORAGE

128

20.1

Storage

128

20.2

Preparing for use after storage

129

TROUBLESHOOTING

130

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.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates 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 racing. This vehicle complies

with the currently valid regulations and categories of the top international motorsports organizations.

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 is designed for use in offroad endurance competition, and not primarily for use in motocross.

(EC 450F US)

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

Info

This vehicle is homologated and approved for use on public roads.

No homologation-relevant components may be removed or modified.

(EW 500F US)

This vehicle has been designed and built to withstand the normal stresses and strains of offroad leisure use. Addition-

ally, it fulfills the CARB (California Air Resources Board) guidelines of the Green Sticker program.

Info

This vehicle is not approved for use on public roads.

No homologation-relevant components may be removed or modified.

This vehicle is not designed for use in racing on closed circuits or for Motocross use.

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.

SAFETY ADVICE

2.4

Degrees of risk and symbols

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate

measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Note

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.5

Tampering warning

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

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, manifolds or any other components which conduct emissions.

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.

(EW 500F US)

An add-on or modified part must be compliant with applicable ARB evaporative emission control standards. A violation

of this requirement is punishable by civil and/or criminal punishment.

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.

SAFETY ADVICE

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.

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.

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, and used components, comply with the laws and regula-

tions of the respective country.

Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regu-

lations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles dealer will be glad to

advise you.

SAFETY ADVICE

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 available for download from your authorized GASGAS Motorcycles dealer and on the

GASGAS Motorcycles website.

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

IMPORTANT NOTES

3.1

Manufacturer warranty, implied warranty

The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and

confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary 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 latest news GASGAS Technical Accessories on your vehicle can be found on the GASGAS Motorcycles website.

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

3.4

Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the

engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to

damage and breakage of chassis components.

Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces, can result in significantly

increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it

may be necessary to inspect or replace parts before the next scheduled service.

It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will

ensure a much longer service life for your motorcycle.

The relevant mileage or time interval is whichever occurs first.

3.5

Figures

The figures contained in the manual may depict special equipment.

In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always 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

6.5

Light switch (All EU models)

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.

A01315-10

6.6

Light switch (All US models)

The button 1 is located to the left of the combination instrument.

Possible states

• Light off - Button is in the basic position, the light is switched off.

• Light on - Button is pressed in until it engages. Low beam and tail

light are switched on.

T04626-01

6.7

Turn signal switch (All EU models)

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.

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

left.

Right turn signal, on - The turn signal switch is turned to

the right.

A01317-10

6.8

Start button

Start button 1 is fitted on the right side of the handlebar.

Possible states

• The start button is in the basic position

• The start button is pressed - The starter motor is actuated in this

position.

W00296-11

CONTROLS

6.9

Stop button

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.

W00296-10

6.10

Combination switch (optional)

The combination switch is fitted on the left side of the handlebar.

Possible states

STANDARD - STANDARD mapping is activated when the

indicator lamp A lights up.

1 TC

STANDARD with TC - STANDARD mapping with traction

control is activated when the indicator lamp A and the

TC indicator lamp light up.

ADVANCED - ADVANCED mapping is activated when the

indicator lamp B lights up.

2 TC

ADVANCED with TC - ADVANCED mapping with traction

control is activated when the indicator lamp B and the

TC indicator lamp light up.

Caution

Voiding of the government approval for road use and the

insurance coverage If the combination switch is mounted,

the vehicle’s road permit, if any, expires.

- Only operate the vehicle in closed-off areas remote from

public road traffic if the combination switch is installed.

F03761-10

The engine characteristic can be changed using button 1 and but-

ton 2 on the combination switch.

Traction control can be activated using the TC button 3 on the combi-

nation switch.

The quick shifter can also be activated via the combination switch.

6.11

Overview of indicator lamps (All EU models)

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 dealer.

The fuel level warning lamp lights up yellow - The fuel level

has reached the reserve mark.

A01319-10

Turn signal indicator lamp flashes green - The turn signal is

switched on.

CONTROLS

6.12

Indicator lamps overview (All US models)

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 KTM workshop.

The fuel level warning lamp lights up yellow - The fuel level

has reached the reserve mark.

T04628-01

6.13

Opening 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.

- Press release button 1, turn the fuel tank filler cap counterclock-

wise, and lift it off.

A01320-20

CONTROLS

6.14

Closing the fuel tank filler cap

- Mount fuel tank filler cap and turn it clockwise until the release but-

ton 1 engages.

Info

Route fuel tank breather hose 2 without kinks.

A01320-10

6.15

Cold start button

The cold start button 1 is fitted to the bottom of the throttle valve

body.

The electronic fuel injection system extends the injection time if the

engine is cold and the ambient temperature is low. To help the engine

burn the increased fuel quantity, it must be supplied with additional

oxygen by pushing the cold start button.

After briefly opening up the throttle and then releasing the throttle grip

again, or turning the throttle grip towards the front, the cold start but-

ton returns to its original position.

Info

Check whether the cold start button has returned to its basic

position.

Possible states

• The cold start button is activated - The cold start button is pushed

in all the way.

• The cold start button is deactivated - The cold start button is in its

basic position.

A01321-10

CONTROLS

6.16

Idle speed adjusting screw

The idle setting of the throttle valve body substantially influences

the vehicle’s starting behavior, a stable idle speed, and the vehicle’s

response when the throttle is opened.

An engine with a correctly set idle speed is easier to start than an engine

with the idle speed set incorrectly.

The idle speed is adjusted using the idle speed adjusting screw 1.

Increase the idle speed by turning the idle speed adjusting screw clock-

wise.

Decrease the idle speed by turning the idle speed adjusting screw coun-

terclockwise.

R06539-10

6.17

Shift lever

Shift lever 1 is mounted on the left of the engine.

401950-10

The gear positions can be seen in the figure.

The neutral or idle position is between the first and second gears.

401950-11

CONTROLS

6.21

Locking the steering (All EU models)

Note

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

- Park the vehicle on a firm and level surface.

- Park the vehicle.

- Turn handlebar as far as possible to the right.

- Lubricate the steering lock regularly.

Universal oil spray ( p. 145)

- Insert the key for the steering lock into the steering lock ( p. 21),

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

for the steering lock.

Steering is no longer possible.

400732-01

Info

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

6.22

Unlocking the steering

- Insert the key for the steering lock into thesteering lock ( p. 21),

turn it to the left, pull it out, 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

COMBINATION INSTRUMENT

7.1

Combination instrument overview

1 Overview of indicator lamps ( p. 17) (All EU models)

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

Message on the combination instrument

Possible states

Battery voltage of the combination instrument - Battery

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 and hold 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

- Wait for 5 seconds.

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.

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.

Combination instrument changes to the next menu item. The

symbol flashes.

Shortening the service interval

- Press the left button.

The value decreases.

Extending the service interval

- Press the right button.

The value increases.

401913-01

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, the value ODO is retained and converted accordingly.

Condition

The motorcycle is stationary.

COMBINATION INSTRUMENT

– Press and hold 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 and hold 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.

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 and hold 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.

Shortening the service interval

- Press the left button.

The value decreases.

Extending the service interval

- Press the right button.

401913-01

The value increases.

COMBINATION INSTRUMENT

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 shows the distance since the last reset, such as 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 the distance 2 since the last reset, such as 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 your motorcycle, remember that others may feel disturbed by excessive noise.

Make sure that the pre-sales inspection work has been carried out by an authorized GASGAS Motorcycles workshop.

You will receive a delivery certificate when the vehicle is handed over.

Before riding for the first time, read the entire Owner's Manual carefully.

–

Get to know the controls.

–

Adjust basic position of the clutch lever. ( p. 80)

–

Adjust basic position of the hand brake lever. ( p. 84)

–

Adjust the basic position of the foot brake lever.

(

p. 89)

–

Adjust the basic position of the shift lever.

(

p. 120)

PREPARING FOR USE

– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging

trips.

Info

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

can help each other.

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

- Do not make any off-road trips that exceed your ability and experience.

- Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

- If you carry any luggage, make sure you fix it firmly as close as possible to the center of the vehicle and ensure even

weight distribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

- Do not exceed the maximum permissible weight and maximum permissible axle loads.

Guideline

Maximum permissible overall weight

335 kg (739 lb.)

Maximum permissible front axle load

145 kg (320 lb.)

Maximum permissible rear axle load

190 kg (419 lb.)

– Check the spoke tension. ( p. 100)

Info

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

- Run the engine in. ( p. 29)

8.2

Running in the engine

– Do not exceed the specified engine speed and load during the running-in time.

Guideline

Maximum engine speed

During the first operating hour

7,000 rpm

Maximum engine performance

During the first 3 operating hours

≤ 75 %

– Avoid fully opening the throttle.

8.3

Starting power of lithium-ion batteries at low temperatures

Lithium-ion batteries are far lighter than lead batteries, have a low self-

discharge rate, and have more starting power at temperatures over 6 °C

(43 °F).

Several attempts to start may be required. Press the start button for

5 seconds, and wait 15 seconds between attempts. At low tempera-

tures, wait for 30 seconds. The pauses are necessary so that the heat

created can distribute through the lithium-ion battery and the lithium-

ion battery is not damaged.

The starting power increases as the battery warms up.

Always make sure the lithium-ion battery is charged to that there is

402555-01

enough power to spare for starting at low temperatures.

After 6 unsuccessful starting attempts, do not try again, and check the

vehicle for other errors instead.

PREPARING FOR USE

8.4

Preparing the vehicle for difficult operating conditions

Info

Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in signifi-

cantly increased wear of components, such as the drive train, brake system, or suspension components. For this

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

- Clean the air filter and air filter box.

(

p. 65)

Info

Check the air filter approx. every 30 minutes.

- Check the 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.

Difficult operating conditions are:

- Rides on dry sand. ( p. 30)

- Rides on wet sand. ( p. 31)

- Rides on wet and muddy circuits. ( p. 31)

- Rides at high temperatures or slow riding. ( p. 32)

- Riding at low temperatures and in snow. ( p. 32)

8.5

Preparing the vehicle for rides on dry sand

- Mount the air filter dust cover.

Air filter dust cover (79006920000)

Info

Observe the fitting instructions for GASGAS Techni-

cal Accessories.

102136-01

- Mount the air filter sand cover.

Air filter sand cover (79006922000)

Info

Observe the fitting instructions for GASGAS Techni-

cal Accessories.

102138-01

PREPARING FOR USE

– Clean the chain.

Chain cleaner ( p. 144)

- Mount the steel sprocket.

- Grease the chain.

Universal oil spray ( p. 145)

- Clean the radiator fins.

- Straighten the bent radiator fins carefully.

600868-01

8.6

Preparing the vehicle for rides on wet sand

- Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info

Observe the fitting instructions for GASGAS Techni-

cal Accessories.

102137-01

- Clean the chain.

Chain cleaner ( p. 144)

- Mount the steel sprocket.

- Grease the chain.

Universal oil spray ( p. 145)

- Clean the radiator fins.

- Straighten the bent radiator fins carefully.

600868-01

8.7

Preparing the vehicle for rides on wet and muddy circuits

- Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info

Observe the fitting instructions for GASGAS Techni-

cal Accessories.

102137-01

- Mount the steel sprocket.

- Clean the motorcycle. ( p. 126)

- Straighten the bent radiator fins carefully.

600868-01

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 engine oil level. ( p. 122)

–

Check the electrical system.

–

Check the front brake fluid level. ( p. 84)

–

Check the rear brake fluid level. ( p. 90)

–

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

(

p. 86)

–

Check that the brake linings of the rear brake are secured. ( p. 92)

–

Check that the brake system is functioning properly.

H02217-01

Check the coolant level. ( p. 112)

–

Check for chain dirt accumulation. ( p. 73)

–

Check the chain, rear sprocket, engine sprocket, and chain guide.

(

p. 75)

–

Check the chain tension. ( p. 74)

–

Check the tire condition. ( p. 99)

–

Check the tire pressure. ( p. 99)

–

Check the spoke tension. ( p. 100)

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. 51)

–

Bleed the fork legs. ( p. 50)

–

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 the vehicle

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.

RIDING INSTRUCTIONS

- Take the motorcycle off side stand 1 and secure the side stand

with rubber strap 2.

- Shift the transmission into neutral.

Condition

Ambient temperature: < 20 °C (< 68 °F)

- Push the cold start button in all the way.

401944-10

- Press the start button.

Info

Press the start button for a maximum of 5 seconds. Wait for

15 seconds before a further attempt at starting.

At low temperatures, wait for 30 seconds.

At temperatures below 6 °C (43 °F), several attempts at

starting may be necessary to warm-up the lithium-ion bat-

tery and thereby increase the starting power.

After 6 unsuccessful starting attempts, do not try again, and

400733-01

check the vehicle for other errors instead.

During the starting process, the malfunction indicator lamp

lights up.

9.3

Activating traction control (optional)

Caution

Voiding of the government approval for road use and the insurance coverage If the combination switch is

mounted, the vehicle’s road permit, if any, expires.

- Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch is

installed.

Info

The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion, particularly in

wet conditions.

When traction control is switched off, the rear wheel may spin more during high acceleration and on surfaces with

low grip.

Traction control can be switched on or off during the ride.

The setting most recently selected is activated again when restarting.

- Press the TC button 1 to switch traction control on or off.

Guideline

Engine speed

≤ 4,000 rpm

The TC LED lights up when the traction control is activated.

F03760-11

RIDING INSTRUCTIONS

9.4

Starting off

Info

When you are riding, the side stand must be folded up and secured with the rubber strap.

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

9.5

Quickshifter (optional)

When the quickshifter is activated, you can shift up without actuating

the clutch.

Info

The quickshifter is not activated when shifting up from first to

second gear, and the clutch lever must be used when shifting up

instead.

Even if the quickshifter is activated, you need to use the clutch

lever to shift down.

Because there is no need to close the throttle grip, uninterrupted gear

shifts are possible.

The quickshifter uses the shifter shaft position to check whether or not a

shift should be initiated, and sends a corresponding signal to the engine

control.

If the quickshifter is deactivated, the clutch needs to be actuated in the

normal way for each shift.

S05784-10

9.6

Activating the quickshifter (optional)

- Press the QS button 1 to switch the quickshifter on or off.

The QS indicator lamp lights up when the quickshifter is acti-

vated.

Info

The quickshifter is not activated when shifting up from first

to second gear, and the clutch lever must be used when

shifting up instead.

Even if the quickshifter is activated, you need to use the

F03760-12

clutch lever to shift down.

RIDING INSTRUCTIONS

9.7

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.

- After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely

reduce the speed, but fuel consumption will be considerably lower.

- Always open the throttle only as much as the engine can handle - abrupt throttle opening increases fuel consumption.

- To shift down, apply the brakes and close the throttle at the same time.

- Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift

again.

- Switch off the engine if running at idle speed or stationary for a long time.

Guideline

≥ 2 min

- Avoid frequent and lengthy slipping of the clutch. This causes the engine oil, engine and cooling system to heat up.

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

9.8

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. Change down to a lower gear appropriate to your road speed.

- Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the

engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.

RIDING INSTRUCTIONS

9.9

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

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.

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.

- Apply the brakes on the motorcycle.

- Shift the transmission into neutral.

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

- Park the motorcycle on firm ground.

9.10

Transporting

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.

RIDING INSTRUCTIONS

- Switch off the engine.

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

against falling over or rolling away.

401475-01

9.11

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

Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.

In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems

with the fuel system.

- Refuel only with clean fuel that meets the specified standards. (Your authorized GASGAS Motorcycles workshop will be

glad to help.)

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 fuel tank filler cap. ( p. 18)

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

Every 90 operating hours

Every 45 operating hours

Every 15 operating hours

After 1 operating hour

Read out the fault memory using the GASGAS Motorcycles diagnostics tool.

○

●

Program the gear position sensor.

●

Check that the electrical system is functioning properly.

○

●

Check and charge the 12-V battery.

●

Check that the brake linings of the front brake are secured. ( p. 86)

●

Check that the brake linings of the rear brake are secured. ( p. 92)

●

Check the brake discs. ( p. 84)

●

Check the brake lines for damage and tightness.

●

Check the front brake fluid level. ( p. 84)

●

Change the front brake fluid.

●

Check the rear brake fluid level. ( p. 90)

●

Change the rear brake fluid.

●

Check/correct the fluid level of hydraulic clutch. ( p. 81)

●

Change the hydraulic clutch fluid.

(

p. 82)

●

Check the free travel of the hand brake lever.

○

●

Check the free travel of the foot brake lever. ( p. 89)

●

Check the idle speed.

○

●

Change the engine oil and oil filter, clean the oil screen.

(

p. 122)

○

●

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

○

●

ness, and correct routing.

Check the cables for damage and that there are no kinks in the routing.

●

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

●

Check the frame.

(

p. 78)

●

Check the link fork.

(

p. 78)

●

Check the fork bearing for play.

●

Check the shock absorber heim joint for play.

●

Check the shock absorber linkage.

●

Check the tire condition. ( p. 99)

●

Check the tire pressure. ( p. 99)

●

Check the wheel bearing for play.

●

Check the wheel hubs.

●

Check the rim run-out.

○

●

Check the spoke tension. ( p. 100)

○

●

Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 75)

○

●

SERVICE SCHEDULE

every 24 months

Every 90 operating hours

Every 45 operating hours

Every 15 operating hours

After 1 operating hour

Check the chain tension. ( p. 74)

○

●

Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth opera-

○

●

tion.

Check the valve clearance.

○

●

Change the fuel filter.

●

Check the clutch.

●

Clean the air filter and air filter box.

(

p. 65)

●

Check the funnel in the inlet sleeve in the air filter box. (All EC models)

●

Check the inlet membrane. (EW 500F US)

●

Change the glass fiber yarn filling in the main silencer.

(

p. 69)

●

Service the fork.

●

Perform the shock absorber service.

●

Check all screws, nuts, and hose clips for a tight fit.

○

●

Change the fuel screen.

(

p. 121)

○

●

Check the fuel pressure.

○

●

Check the antifreeze and coolant level. ( p. 111)

●

Check the coolant level. ( p. 112)

○

●

Change the coolant. ( p. 114)

●

Check that the radiator fan is functioning properly.

○

●

Check the steering head bearing for play. ( p. 57)

○

●

Lubricate the steering head bearing.

(

p. 58)

●

Check the headlight setting. ( p. 107)

●

Clean spark arrestor. (EW 500F US)

(

p. 67)

●

Perform engine service including removing and installing the engine. (Change the spark plug

●

and spark plug connector. Change the piston. Check/measure the cylinder. Check the cylin-

der head. Change the valves, valve springs, valve spring retainers and valve spring seats. Check

the camshaft, rocker arm and rocker arm shafts. Change the connecting rod, conrod bearing

and crank pin. Check the transmission and the shift mechanism. Check the oil pressure control

valve. Change the suction pump. Check the force pump and lubrication system. Check the timing

assembly. Change the timing chain. Change all engine bearings and all gaskets. Change the free-

wheel.)

Final check: Check the vehicle is roadworthy and take a test ride.

○

●

Read out the fault memory after the test ride using the GASGAS Motorcycles diagnostics tool.

○

●

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.

- As delivered, GASGAS offroad motorcycles are adjusted for an aver-

age 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

Compression damping of the shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.

High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.

The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension

compresses quickly.

The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel sus-

pension compresses slowly.

These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus,

modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.

11.3

Adjusting the low-speed compression 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.)

Info

The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock

absorber.

TUNING THE CHASSIS

– Turn adjuster 1 clockwise up to the last perceptible click.

- Turn counterclockwise by the number of clicks corresponding to the

shock absorber type.

Guideline

Info

Turn clockwise to increase damping; turn counterclockwise

to reduce damping during compression.

A01323-10

11.4

Adjusting the high-speed compression 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.)

Info

The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber.

- Turn adjuster 1 clockwise up to the last perceptible click.

- Turn counterclockwise by the number of turns corresponding to the

shock absorber type.

Guideline

Info

Turn clockwise to increase damping; turn counterclockwise

to reduce damping during compression.

A01324-10

11.5

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.)

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

- Turn counterclockwise by the number of clicks corresponding to the

shock absorber type.

Guideline

Info

Turn clockwise to increase the damping; turn counterclock-

wise to reduce damping when the shock absorber rebounds.

S05733-10

TUNING THE CHASSIS

11.6

Measuring the dimension of the rear wheel unloaded

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

Main work

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

the marking on the rear fender.

Sag gauge (00029090100)

Pin, sag scale (00029990010)

- Note the value as dimension A.

F03178-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

11.7

Checking the static sag of the shock absorber

- Measure dimension A of rear wheel unloaded. ( p. 44)

- Hold the motorcycle upright with aid of an assistant.

- Remeasure the distance between the rear axle and the marking on

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.

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

- Adjust the spring preload of the shock absorber.

(

p. 45)

402416-10

TUNING THE CHASSIS

11.8

Checking the rider sag of the shock absorber

- Measure dimension A of rear wheel unloaded. ( p. 44)

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

protective clothing, sits on the seat in a normal sitting position (feet

on footrests) and bounces up and down a few times.

The rear wheel suspension levels out.

- Another person now remeasures the distance between the rear axle

and the marking on the rear fender using the sag gage.

- Note the value as dimension C.

Info

The rider sag is the difference between measurements A

and C.

- Check the rider sag.

» If the rider sag differs from the specified measurement:

- Adjust the rider sag.

(

p. 46)

402417-10

11.9

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

Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

- Remove the frame protector. ( p. 53)

- Remove the shock absorber.

(

p. 59)

– After removing the shock absorber, clean it thoroughly.

TUNING THE CHASSIS

Main work

- Loosen screw 1.

- Turn adjusting ring 2 until the spring is no longer under tension.

Hook wrench (90129051000)

Info

If the spring cannot be fully released, the spring must be

removed to accurately measure the spring length.

- Measure the total spring length while the spring is not under ten-

sion.

- Tension the spring by turning adjusting ring 2 to specified dimen-

sion A.

Guideline

Info

Depending on the static sag and/or the rider sag, it may be

necessary to increase or decrease the spring preload.

402659-10

- Tighten screw 1.

Guideline

Screw, shock absorber

5 Nm (3.7 lbf ft)

adjusting ring

Finishing work

- Install the shock absorber.

(

p. 60)

– Check the free travel of the foot brake lever. ( p. 89)

- Install the frame protector. ( p. 54)

- Remove the motorcycle from the lift stand. ( p. 50)

11.10

Adjusting the rider sag

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

- Remove the frame protector. ( p. 53)

- Remove the shock absorber.

(

p. 59)

– After removing the shock absorber, clean it thoroughly.

Main work

- Select and mount a suitable spring.

Guideline

Info

The spring rate is shown on the outside of the spring.

Smaller weight differences can be compensated by changing

the spring preload.

B00292-10

Finishing work

- Install the shock absorber.

(

p. 60)

– Check the free travel of the foot brake lever. ( p. 89)

- Install the frame protector. ( p. 54)

- Remove the motorcycle from the lift stand. ( p. 50)

- Check the static sag of the shock absorber. ( p. 44)

TUNING THE CHASSIS

– Check the rider sag of the shock absorber. ( p. 45)

- Adjust the rebound damping of the shock absorber. ( p. 43)

11.11

Checking the basic setting of the fork

Info

For various reasons, no exact rider 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

11.12

Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

- Turn white adjuster 1 clockwise as far as it will go.

Info

Adjuster 1 is located at the upper end of the left fork leg.

The compression damping is located in left fork leg COMP

(white adjuster). The rebound damping is located in right

fork leg REB (red adjuster).

- Turn counterclockwise by the number of clicks corresponding to the

F03174-10

fork type.

Guideline

Compression damping

Comfort

18 clicks

Standard

15 clicks

Sport

12 clicks

Info

Turn clockwise to increase damping; turn counterclockwise

to reduce damping during compression.

TUNING THE CHASSIS

11.13

Adjusting the rebound damping of the fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

- Turn red adjuster 1 clockwise as far as it will go.

Info

Adjuster 1 is located at the upper end of the right fork leg.

The rebound damping is located in right fork leg REB (red

adjuster). The compression damping is located in left fork

leg COMP (white adjuster).

- Turn counterclockwise by the number of clicks corresponding to the

F03175-10

fork type.

Guideline

Rebound damping

Comfort

18 clicks

Standard

15 clicks

Sport

12 clicks

Info

Turn clockwise to increase the damping; turn counterclock-

wise to reduce damping when the shock absorber rebounds.

11.14

Handlebar position

The holes on the handlebar support are placed at a distance of A from

the center.

3.5 mm (0.138 in)

Hole distance A

The handlebar support can be mounted in two different positions.

W00321-10

TUNING THE CHASSIS

11.15

Adjusting the handlebar position

Warning

Danger of accidents A repaired handlebar poses a safety risk.

If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.

- Change the handlebar if the handlebar is damaged or bent.

Preparatory work

- Take off the handlebar cushion.

Main work

- Remove screws 1. Take off the handlebar clamp. Take off the han-

dlebar and lay it to one side.

Info

Cover the components to protect them against damage.

Do not kink the cables or lines.

- Remove screws 2. Take off the handlebar support.

- Place the handlebar support in the required position. Mount and

tighten screws 2.

Guideline

Screw, handlebar

M10

40 Nm (29.5 lbf ft)

holder

Loctite^®243™

– Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

W00324-10

- Position the handlebar clamp. Mount screws 1 and tighten evenly.

Guideline

Screw, handlebar

20 Nm (14.8 lbf ft)

clamp

Info

Make sure the installed gap widths are even.

Finishing work

- Mount the handlebar cushion.

SERVICE WORK ON THE CHASSIS

12.1

Raising the motorcycle with a lift stand

Note

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

- Park the vehicle on a firm and level surface.

- Raise the motorcycle at the frame underneath the engine.

Lift stand (A54029955100)

Neither wheel is in contact with the ground.

401942-01

- Secure the motorcycle against falling over.

12.2

Removing the motorcycle from the lift stand

Note

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

- Park the vehicle on a firm and level surface.

- 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

When you are riding, the side stand must be folded up and

secured with rubber strap.

401943-10

12.3

Bleeding the fork legs

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

Main work

- Release bleeder screws 1.

Any excess pressure escapes from the interior of the fork.

- Tighten the bleeder screws.

W00297-11

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

SERVICE WORK ON THE CHASSIS

12.4

Cleaning the dust boots of the fork legs

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

- Remove the fork protector. ( p. 51)

Main work

- Push dust boots 1 of both fork legs downward.

Info

The dust boots remove dust and coarse dirt particles from

the inside fork tubes. Over time, dirt can accumulate behind

the dust boots. If this dirt is not removed, the oil seals

behind can start to leak.

H03152-10

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. 145)

- Press the dust boots back into the installation position.

- Remove the excess oil.

Finishing work

- Install the fork protector. ( p. 52)

- Remove the motorcycle from the lift stand. ( p. 50)

12.5

Removing the fork protector

- Remove screws 1 and take off the clamp.

- Remove screws 2 on the left fork leg and take off the left fork pro-

tector.

- Remove screws 3 on the right fork leg and take off the right fork

protector.

F03179-10

SERVICE WORK ON THE CHASSIS

12.6

Installing the fork protector

- Position the fork protector on left fork leg. Mount and tighten

screws 1.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

- Position the brake line, the wiring harness, and the clamp. Mount

and tighten screws 2.

Guideline

F03179-11

Screw, brake line

EJOT

1.7 Nm (1.25 lbf ft)

holder

- Position the fork protector on the right fork leg. Mount and tighten

screws 3.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

12.7

Removing the fork legs

Preparatory work

- Remove the headlight mask with the headlight. ( p. 105)

- Raise the motorcycle with a lift stand. ( p. 50)

- Remove the front wheel.

(

p. 95)

Main work

- Remove screws 1 and take off the clamp.

- Remove the cable ties.

- Remove screws 2 and take off the brake caliper.

- Allow the brake caliper and the brake line to hang loosely to the

side.

F03180-10

- Loosen screws 3. Remove the left fork leg.

- Loosen screws 4. Remove the right fork leg.

F03182-10

SERVICE WORK ON THE CHASSIS

12.8

Installing the fork legs

Main work

- Position the fork legs.

Bleeder screws 1 are positioned toward the front.

Info

The rebound damping is located in right fork leg REB (red

adjuster). The compression damping is located in left fork

leg COM (white adjuster).

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

W00297-11

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

with the upper edge of the upper triple clamp.

- Tighten screws 2.

Guideline

Screw, top triple clamp

20 Nm (14.8 lbf ft)

– Tighten screws 3.

Guideline

Screw, bottom triple

15 Nm (11.1 lbf ft)

clamp

F03182-11

- Position the brake caliper, and mount and tighten screws 4.

Guideline

Screw, front

25 Nm (18.4 lbf ft)

brake caliper

Loctite^®243™

– Mount the cable ties.

- Position the brake line, the wiring harness, and the clamp. Mount

and tighten screws 5.

Guideline

F03181-10

Screw, brake line

EJOT

1.7 Nm (1.25 lbf ft)

holder

Finishing work

- Install the front wheel.

(

p. 96)

– Install the headlight mask with the headlight. ( p. 106)

- Check the headlight setting. ( p. 107)

12.9

Removing the frame protector

- Remove the cable ties.

- Remove screws 1 with the bushings.

- Take off the left frame protector.

- Push the right frame protector to the front and take off at the bot-

tom.

A01373-10

SERVICE WORK ON THE CHASSIS

12.10

Installing the frame protector

- Position the left frame protector.

- Insert the right frame protector from below and push it to the rear.

- Mount screws 1 with the bushings and tighten.

Guideline

Screw, frame protector

3 Nm (2.2 lbf ft)

– Secure the frame protector with cable ties.

A01374-10

12.11

Removing the lower triple clamp

Preparatory work

- Remove the headlight mask with the headlight. ( p. 105)

- Raise the motorcycle with a lift stand. ( p. 50)

- Remove the front wheel.

(

p. 95)

– Remove the fork legs.

(

p. 52)

– Remove the front fender. ( p. 58)

- Take off the handlebar cushion.

Main work

- Remove screw 1.

- Remove screw 2.

- Take off the upper triple clamp with the handlebar and set it aside.

Info

Cover the components to protect them against damage.

Do not kink the cables or lines.

W00353-10

- Remove protective ring 3.

- Take off the lower triple clamp with the steering stem.

- Remove the upper steering head bearing.

W00354-10

SERVICE WORK ON THE CHASSIS

12.12

Installing the lower triple clamp

Main work

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

grease.

High viscosity grease ( p. 144)

- Insert the lower triple clamp with the steering stem. Mount upper

steering head bearing.

- Push on protective ring 1.

W00319-11

(All EU models)

- Pay attention to the correct positioning of the steering lock in

area A.

The catch on the steering lock engages in the notch of the

triple clamp.

W00549-10

- Position the upper triple clamp and handlebar.

- Mount screw 2, but do not tighten it yet.

W00353-11

- Position the fork legs.

Bleeder screws 3 are positioned toward the front.

Info

The rebound damping is located in right fork leg REB (red

adjuster).

The compression damping is located in left fork leg COMP

(white adjuster).

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

W00297-13

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

with the upper edge of the upper triple clamp.

SERVICE WORK ON THE CHASSIS

- Tighten screws 4.

Guideline

Screw, bottom triple

15 Nm (11.1 lbf ft)

clamp

A01357-10

- Tighten screw 2.

Guideline

Screw, top steering

M20x1.5

12 Nm (8.9 lbf ft)

head

- Mount and tighten screw 5.

Guideline

Screw, top steer-

20 Nm (14.8 lbf ft)

ing stem

Loctite^®243™

T04629-01

- Tighten screws 6.

Guideline

Screw, top triple clamp

20 Nm (14.8 lbf ft)

A01359-10

- Position the brake caliper, and mount and tighten screws 7.

Guideline

Screw, front

25 Nm (18.4 lbf ft)

brake caliper

Loctite^®243™

– Mount the cable ties.

- Position the brake line, the wiring harness, and the clamp. Mount

and tighten screws 8.

A01360-10

Finishing work

- Mount the handlebar cushion.

- Install the front fender. ( p. 59)

- Install the front wheel.

(

p. 96)

– Install the headlight mask with the headlight. ( p. 106)

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

dom of movement and correct routing.

- Check the steering head bearing for play. ( p. 57)

- Remove the motorcycle from the lift stand. ( p. 50)

- Check the headlight setting. ( p. 107)

SERVICE WORK ON THE CHASSIS

12.13

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.)

Info

If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing

seats in the frame can become damaged over time.

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

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. 57)

– 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. 57)

– Check the steering head bearing and replace if necessary.

- Check the steering stop bolts for correct adjustment and locking.

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

12.14

Adjusting the steering head bearing play

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

Main work

- Loosen screws 1.

- Remove screw 2.

- Loosen and retighten screw 3.

Guideline

Screw, top steering

M20x1.5

12 Nm (8.9 lbf ft)

head

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

W00339-10

avoid stresses.

- Mount and tighten screw 2.

Guideline

Screw, top steer-

20 Nm (14.8 lbf ft)

ing stem

Loctite^®243™

– Tighten screws 1.

SERVICE WORK ON THE CHASSIS

– Position the link fork and mount the swingarm pivot.

Info

Pay attention to flat area A.

- Mount and tighten nut 2.

Guideline

Nut, fork pivot

M16x1.5

100 Nm (73.8 lbf ft)

F03198-10

- Mount the chain.

- Connect the chain with connecting link 3.

Guideline

The closed side of the chain joint lock must face in the direction

of travel.

F03702-12

- Join plug-in connector of the brake light switch.

F03193-10

- Position the rear brake cylinder.

Push rod 4 engages in the rear brake cylinder.

The dust boot is correctly positioned.

- Mount and tighten screws 5.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

W00052-10

- Position the angle lever and linkage lever.

- Mount and tighten fitting 6.

Guideline

Nut, linkage lever on

M16x1.5

80 Nm (59 lbf ft)

angle lever

Info

Pay attention to flat area B.

S05741-10

- Mount and tighten screw 7.

Guideline

Screw, bottom

M12

80 Nm (59 lbf ft)

shock absorber

Loctite^®2701™

SERVICE WORK ON THE CHASSIS

12.23

Installing the air filter box cover

Condition

The air filter box cover is secured.

- Insert the air filter box cover in area B and clip it into area A.

A01329-10

- Mount and tighten screw 1.

Guideline

Screw, air filter box

EJOT PT^®

3 Nm (2.2 lbf ft)

cover

K60x20-Z

– Mount the seat. ( p. 62)

A01328-10

Condition

The air filter box cover is not secured.

- Insert the air filter box cover in area B and clip it into area A.

A01329-10

12.24

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 air filter box cover. ( p. 63)

SERVICE WORK ON THE CHASSIS

Main work

- Detach retaining tab 1. Remove air filter with air filter support.

- Remove air filter from air filter support.

W00216-10

12.25

Installing the air filter

Main work

- Mount the clean air filter on the air filter support.

- Grease the air filter in area A.

Long-life grease ( p. 144)

W00457-10

- Insert air filter and position retaining pin 1 in bushing B.

The air filter is correctly positioned.

- Insert retaining tab 2.

Retaining pin 3 is secured by retaining tab 2.

Info

If the air filter is not mounted correctly, dust and dirt may

enter the engine and result in damage.

W00217-10

Finishing work

- Install the air filter box cover. ( p. 64)

12.26

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 air filter box cover. ( p. 63)

- Remove the air filter.

(

p. 64)

SERVICE WORK ON THE CHASSIS

Main work

- Wash the air filter thoroughly in special cleaning liquid and allow it

to dry properly.

Air filter cleaner ( p. 144)

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.

F03685-01

Oil for foam air filter ( p. 144)

- Clean the air filter box.

- Check the intake flange for damage and looseness.

Finishing work

- Install the air filter.

(

p. 65)

– Install the air filter box cover. ( p. 64)

12.27

Preparing air filter box cover for securing

Preparatory work

- Remove the air filter box cover. ( p. 63)

Main work

- Drill a hole at marking A.

Guideline

Diameter

6 mm (0.24 in)

A01375-10

Finishing work

- Install the air filter box cover. ( p. 64)

12.28

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.

(All EU models)

- Detach spring 1.

Spring hook (50305017000C1)

- Remove screws 2 and take off the main silencer with the cat-

alytic converter.

(All US models)

- Detach spring 1.

A01330-10

Spring hook (50305017000C1)

- Remove screws 2 and take off the main silencer.

SERVICE WORK ON THE CHASSIS

12.31

Changing the glass fiber yarn filling in 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 main silencer. ( p. 66)

Main work

(EW 500F US)

- Remove screws 1.

- Take off silencer cap 2 with O-ring 3.

- Remove the old glass fiber yarn filling.

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

age.

- Fit new glass fiber yarn filling 4 into the main silencer.

- Mount the O-ring on the silencer cap.

- Position the silencer cap.

- Mount and tighten all of the screws.

Guideline

Screws on main

7 Nm (5.2 lbf ft)

silencer

V01735-10

(All EC models)

- Remove screws 1.

- Take off silencer cap 2 with O-ring 3.

- Remove the old glass fiber yarn filling.

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

age.

- Fit new glass fiber yarn filling 4 into the main silencer.

- Mount the O-ring on the silencer cap.

- Position the silencer cap.

- Mount and tighten all of the screws.

Guideline

Screws on main

7 Nm (5.2 lbf ft)

silencer

V01734-10

SERVICE WORK ON THE CHASSIS

Finishing work

- Install the main silencer. ( p. 67)

12.32

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.

Preparatory work

- Remove the air filter box cover. ( p. 63)

- Remove the seat. ( p. 62)

Main work

- Clean quick release coupling 1 thoroughly with compressed air.

Info

Under no circumstances should dirt enter into the fuel line.

Dirt in the fuel line clogs the injection valve!

- Disconnect the quick release coupling.

W00346-10

Info

Remaining fuel may flow out of the fuel line.

- Mount wash cap set 2.

Wash cap set (81212016100)

SERVICE WORK ON THE CHASSIS

– Unplug fuel pump connector 3.

- Remove screw 4 with the rubber bushing.

W00342-10

- Remove screws 5.

- Hang the horn and horn bracket to one side.

A01349-10

- Pull both spoilers laterally off the radiator and lift off the fuel tank.

F03212-10

12.33

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.

SERVICE WORK ON THE CHASSIS

Main work

- Check the throttle cable routing. ( p. 78)

- Position the fuel tank and fit the two spoilers to the sides in front of

the radiator bracket.

- Make sure that no cables or throttle cables are trapped or damaged.

F03212-11

- Attach the fuel tank breather hose.

- Mount and tighten screw 1 with the rubber bushing.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

- Plug in fuel pump connector 2.

W00342-11

- Position the horn with the horn bracket.

- Mount and tighten screws 3.

Guideline

Screw, fuel tank spoiler

6 Nm (4.4 lbf ft)

on radiator

A01350-10

- Remove the wash cap set.

- Clean the quick release coupling thoroughly with compressed air.

Info

Under no circumstances should dirt enter into the fuel line.

Dirt in the fuel line clogs the injection valve!

- Spray silicone spray onto a lint-free cleaning cloth and lightly lubri-

cate the O-ring of the quick-release coupling.

W00348-10

Silicone spray ( p. 144)

- Join quick release coupling 4.

Info

Route the cable and fuel line at a safe distance from the

exhaust system.

Finishing work

- Mount the seat. ( p. 62)

- Install the air filter box cover. ( p. 64)

SERVICE WORK ON THE CHASSIS

12.34

Checking for chain dirt accumulation

- Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

- Clean the chain. ( p. 73)

400678-01

12.35

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. 50)

Main work

- Rinse off loose dirt with a soft jet of water.

- Remove old grease residue with chain cleaner.

Chain cleaner ( p. 144)

- After drying, apply chain spray.

Off-road chain spray ( p. 144)

400725-01

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

SERVICE WORK ON THE CHASSIS

12.36

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. 50)

Main work

- Pull the chain at the end of the chain sliding piece upward to mea-

sure chain tension A.

Info

Lower chain section 1 must be taut.

When the chain guard is mounted, it must be possible to

pull up the chain at least to the point where it makes contact

with chain guard B.

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

measurement at different chain positions.

Chain tension

55 … 58 mm (2.17 … 2.28 in)

» If the chain tension does not meet the specification:

- Adjust the chain tension. ( p. 74)

F03213-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

12.37

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. 50)

- Check the chain tension. ( p. 74)

SERVICE WORK ON THE CHASSIS

Main work

- Loosen nut 1.

- Loosen nuts 2.

- Adjust the chain tension by turning adjusting screws 3 left and

right.

Guideline

Chain tension

55 … 58 mm (2.17 … 2.28 in)

Turn adjusting screws 3 on the left and right so that the mark-

ings on the left and right chain adjusters are in the same position

relative to reference marks A. The rear wheel is then correctly

aligned.

- Tighten nuts 2.

- Make sure that chain adjusters 4 are fitted correctly on adjusting

screws 3.

- Tighten nut 1.

Guideline

Nut, wheel spindle,

M22x1.5

80 Nm (59 lbf ft)

F03214-10

rear

Info

The wide adjustment range of the chain adjusters (32 mm

(1.26 in)) enables different secondary ratios with the same

chain length.

Chain adjusters 4 can be turned by 180°.

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

12.38

Checking the chain, rear sprocket, engine sprocket, and chain guide

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

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, rear sprocket, and chain

should always be replaced together.

400227-01

SERVICE WORK ON THE CHASSIS

- Pull on the top section of the chain with the specified weight A.

Guideline

Weight of chain wear measure-

10 … 15 kg (22 … 33 lb.)

ment

- Measure distance B of 18 chain rollers in the lower chain section.

Info

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

measurement at different chain positions.

272 mm (10.71 in)

Maximum distance B from

18 chain rollers at the longest

chain section

» If distance B is greater than the specified measurement:

- Change the drivetrain kit.

Info

When a new chain is mounted, the rear sprocket

400987-10

and engine sprocket should also be changed.

New chains wear out faster on old, worn sprockets.

- Check the chain sliding guard for wear.

» If the lower edge of the chain pins is in line with, or below, the

chain sliding guard:

- Change the chain sliding guard.

- Check that the chain sliding guard is firmly seated.

» If the chain sliding guard is loose:

- Tighten screws on the chain sliding guard.

Guideline

Screw, chain

6 Nm (4.4 lbf ft)

sliding guard

Loctite^®243™

W00303-10

SERVICE WORK ON THE CHASSIS

– Check chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the

chain sliding piece:

- Change the chain sliding piece.

- Check that the chain sliding piece is firmly seated.

» If the chain sliding piece is loose:

- Tighten the screw of the chain sliding piece.

Guideline

Screw, chain sliding

15 Nm (11.1 lbf ft)

piece

W00304-10

- Check the chain guide for wear.

Info

Wear can be seen on the front of the chain guide.

» If the light part of the chain guide is worn:

- Change the chain guide.

401760-01

- Check that the chain guide is firmly seated.

» If the chain guide is loose:

- Tighten the screws on the chain guide.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

Remaining nuts,

10 Nm (7.4 lbf ft)

chassis

W00305-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

SERVICE WORK ON THE CHASSIS

Main work

- Check the throttle cable routing.

Both throttle cables must be routed to the throttle valve body

side by side on the back of the handlebars and above the fuel

tank roller. Both throttle cables must be secured behind the rub-

ber strap of the fuel tank support.

» If the throttle cable routing is not as specified:

- Correct the throttle cable routing.

F03220-01

Finishing work

- Install the fuel tank.

(

p. 71)

– Mount the seat. ( p. 62)

- Install the air filter box cover. ( p. 64)

12.42

Checking the rubber grip

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

looseness.

Info

The rubber grips are vulcanized onto a sleeve on the left and

onto the handle tube of the throttle grip on the right. The

left sleeve is clamped onto the handlebar.

The rubber grip can only be replaced with the sleeve or the

throttle tube.

401197-01

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

- Change the rubber grip.

(All EU models)

- Check that screw 1 is firmly seated.

Guideline

Screw, fixed grip

5 Nm (3.7 lbf ft)

Loctite^®243™

Diamond A must be positioned visibly as shown in the fig-

ure.

W00325-10

SERVICE WORK ON THE CHASSIS

(All US models)

- Check that screw 1 is firmly seated.

Guideline

Screw, fixed grip

5 Nm (3.7 lbf ft)

Loctite^®243™

Diamond A must be positioned visibly as shown in the fig-

ure.

W00326-10

12.43

Programming the Quickshifter (optional)

Info

If the shifting performance of the Quickshifter starts to decrease, it must be reprogrammed.

- Carry out start procedure. ( p. 33)

- Press and hold the QS button 1 for at least 10 seconds.

The QS indicator lamp flashes.

- Pull the clutch lever, engage first-gear and hold the shift lever all the

way down.

- Briefly press the QS button 1.

The QS indicator lamp lights up blue, the teaching procedure

was successful.

F03760-12

Info

If the quickshifter cannot be activated, the teaching proce-

dure was unsuccessful and must be repeated.

12.44

Adjusting the basic position of the clutch lever

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

turning adjusting screw 1.

Info

Turn the adjusting screw clockwise to increase the distance

between the clutch lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the

distance between the clutch lever and the handlebar.

The range of adjustment is limited.

A01332-10

Turn the adjusting screw by hand only, and do not apply any

force.

Do not make any adjustments while riding.

SERVICE WORK ON THE CHASSIS

12.45

Checking/correcting the fluid level of hydraulic clutch

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.

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.

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

- Move the hydraulic clutch fluid reservoir mounted on the handlebar

into a horizontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

- Check the fluid level.

Fluid level below container rim

4 mm (0.16 in)

» If the fluid level does not meet specifications:

F03222-10

- Correct the fluid level of the hydraulic clutch.

Brake fluid DOT 4 / DOT 5.1 ( p. 142)

- Position the cover with the membrane. Mount and tighten the

screws.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

SERVICE WORK ON THE CHASSIS

12.46

Changing the hydraulic clutch fluid

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.

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.

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

- Move the hydraulic clutch fluid reservoir mounted on the handlebar

into a horizontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

F03222-10

- Fill bleeding syringe 4 with the appropriate hydraulic fluid.

Syringe (50329050000)

Brake fluid DOT 4 / DOT 5.1 ( p. 142)

- On the clutch slave cylinder, remove the protection cap, remove

bleeder screw 5 and mount bleeding syringe 4.

H04934-10

- Now inject fluid into the system until it escapes from the openings

6 of the master cylinder without bubbles.

- Occasionally extract the fluid from the master cylinder reservoir to

prevent overflowing.

- Remove the bleeding syringe. Mount and tighten the bleeder screw.

Mount the protection cap.

- Correct the fluid level of the hydraulic clutch.

Guideline

Fluid level below container rim

4 mm (0.16 in)

F03223-10

BRAKE SYSTEM

13.1

Adjusting the basic position of the hand brake lever

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

turning adjusting screw 1.

Info

Turn the adjusting screw clockwise to increase the distance

between the hand brake lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the

distance between the hand brake lever and the handlebar.

The range of adjustment is limited.

Turn the adjusting screw by hand only, and do not apply any

F03161-11

force.

Do not make any adjustments while riding.

13.2

Checking the 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.)

- Check the 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

front

2.5 mm (0.098 in)

400257-10

rear

3.5 mm (0.138 in)

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

- Change the front brake disc.

- Change the rear brake disc.

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

deformation.

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

- Change the front brake disc.

- Change the rear brake disc.

13.3

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 MIN marking, 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

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 the brake fluid level has dropped below the MIN marking A:

- Add front brake fluid.

(

p. 85)

F03262-10

13.4

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.)

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.

BRAKE SYSTEM

Preparatory work

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

(

p. 86)

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 3.

- 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. 142)

- Position the cover with the membrane. Mount and tighten the

screws.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

T04631-01

13.5

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 lining thickness A.

≥ 1 mm (≥ 0.04 in)

Minimum thickness A

» If it is less than the minimum thickness:

- Change the brake linings of the front brake.

(

p. 87)

– Check the brake linings for damage and cracking.

» If there is damage or cracking:

- Change the brake linings of the front brake.

(

p. 87)

F03227-10

- 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

13.6

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.

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 manufacturer

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.

BRAKE SYSTEM

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

zontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

A01333-10

- Manually press the brake caliper toward the brake disc to push back

the brake pistons. Ensure that brake fluid does not flow out of the

brake fluid reservoir; extract some if necessary.

Info

Make sure that you do not press the brake caliper against

the spokes when pushing back the brake pistons.

- Remove cotter pin 4.

S05112-10

- Pull out pin 5.

- Remove the brake linings.

- Clean the brake caliper and the brake caliper bracket.

- Check that spring plate 6 in the brake caliper and brake pad slid-

ing plate 7 in the brake caliper bracket are seated correctly.

S04465-10

- Insert the new brake linings.

- Mount pin 5.

Spring plate 6 engages in the groove on the pin.

Info

Always change the brake linings in pairs.

- Mount cotter pins 4.

Guideline

Mount the outer cotter pins from the front to the rear.

Mount the inner cotter pins from the rear to the front.

- Operate the hand brake lever repeatedly until the brake linings are

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

S05113-10

BRAKE SYSTEM

– Correct the brake fluid level 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. 142)

- Position cover 2 with membrane 3.

- Mount and tighten screws 1.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

A01334-10

13.7

Checking the free travel of 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.)

- Disconnect spring 1.

- 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 meet specifications:

- Adjust the basic position of the foot brake lever.

402026-10

(

p. 89)

– Reconnect spring 1.

13.8

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.)

BRAKE SYSTEM

- Detach spring 1.

- Loosen nut 4 and, with push rod 5, turn it back until you have

maximum free travel.

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

requirements, loosen nut 2 and turn screw 3 accordingly.

Info

The range of adjustment is limited.

- Turn push rod 5 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 3 and tighten nut 2.

Guideline

Rear brake lever stop

20 Nm (14.8 lbf ft)

nut

F03229-10

- Hold push rod 5 and tighten nut 4.

Guideline

Remaining nuts, chas-

10 Nm (7.4 lbf ft)

sis

- Attach spring 1.

13.9

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 MIN marking, 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 MIN marking A:

- Add rear brake fluid.

(

p. 91)

F03230-10

BRAKE SYSTEM

13.10

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.

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. 92)

- Remove the frame protector. ( p. 53)

Main work

- Stand the vehicle upright.

- Remove screw cap 1 with membrane 2 and the O-ring.

- Add brake fluid up to the marking A.

Brake fluid DOT 4 / DOT 5.1 ( p. 142)

- Mount and tighten the screw cap with the membrane and O-ring.

Info

A01384-10

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

Finishing work

- Install the frame protector. ( p. 54)

BRAKE SYSTEM

13.11

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 lining thickness A.

≥ 1 mm (≥ 0.04 in)

Minimum thickness A

» If it is less than the minimum thickness:

- Change the rear brake linings.

(

p. 92)

– Check the brake linings for damage and cracking.

» If there is damage or cracking:

- Change the rear brake linings.

(

p. 92)

F03232-10

- Check that the brake linings are secured.

» If the brake linings are not secured correctly:

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

13.12

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.)

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 manufacturer

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 the frame protector. ( p. 53)

Main work

- Stand the vehicle upright.

- Remove screw cap 1 with membrane 2 and the O-ring.

- Press the brake piston back into the basic position and ensure that

brake fluid does not flow out of the brake fluid reservoir; extract

some if necessary.

Info

Make sure that you do not press the brake caliper against

A01382-10

the spokes when pushing back the brake piston.

- Remove cotter pin 3, pull out pin 4, and remove the brake lin-

ings.

- Clean the brake caliper and the brake caliper bracket.

F03234-10

- Check that spring plate 5 in the brake caliper and brake pad slid-

ing plate 6 in the brake caliper bracket are seated correctly.

F03235-10

WHEELS, TIRES

14.1

Removing the front wheel

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

Main work

- Manually press the brake caliper toward the brake disc to push back

the brake pistons.

Info

Make sure that you do not press the brake caliper against

the spokes when pushing back the brake pistons.

S04473-01

- Loosen screw 1 by several rotations.

- Loosen screws 2.

- Press on screw 1 to push the wheel spindle out of the axle clamp.

- Remove screw 1.

S04474-10

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.

- Hold front wheel and remove wheel spindle. Take front wheel out of

the fork.

S04475-01

Info

Do not actuate the hand brake lever when the front wheel is

removed.

- Remove spacers 3.

H00934-10

WHEELS, TIRES

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 the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:

- Change front wheel bearing.

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

spacers.

Long-life grease ( p. 144)

- Insert the spacers.

- Clean and grease the wheel spindle.

H00935-10

Long-life grease ( p. 144)

- Position the front wheel and insert the wheel spindle.

The brake linings are correctly positioned.

- Mount and tighten screw 2.

Guideline

Screw, front wheel

M20x1.5

35 Nm (25.8 lbf ft)

spindle

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

are seated correctly against the brake disc.

- Remove the motorcycle from the lift stand. ( p. 50)

- Operate the front brake and compress the fork a few times firmly.

S04474-11

The fork legs straighten.

- Tighten screws 3.

Guideline

Screw, fork stub

15 Nm (11.1 lbf ft)

14.3

Removing the rear wheel

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 50)

WHEELS, TIRES

Main work

- Manually press the brake caliper toward the brake disc to push back

the brake piston.

Info

Make sure that you do not press the brake caliper against

the spokes when pushing back the brake piston.

- Remove nut 1.

- Take off chain adjuster 2. Pull out wheel spindle 3 far enough to

allow the rear wheel to be pushed forward.

- Push the rear wheel forward as far as possible. Remove the chain

from the rear sprocket.

Info

Cover the components to protect them against damage.

Warning

Danger of accidents Damaged brake discs reduce the

F03238-10

braking effect.

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

disc is not damaged.

- Hold the rear wheel and remove the wheel spindle. Take the rear

wheel out of the link fork.

Info

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

removed.

- Remove spacers 4.

H03002-10

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.

WHEELS, TIRES

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. 144)

- Insert the spacers.

H03001-10

- Clean and grease the wheel spindle.

Long-life grease ( p. 144)

- Position rear wheel and insert wheel spindle 2.

The brake linings are correctly positioned.

- Mount the chain.

F03237-10

- Position chain adjuster 3. Mount nut 4, but do not tighten it yet.

- Make sure that chain adjusters 3 are fitted correctly on adjusting

screws 5.

- Check the chain tension. ( p. 74)

- Tighten nut 4.

Guideline

Nut, wheel spindle,

M22x1.5

80 Nm (59 lbf ft)

rear

Info

The wide adjustment range of the chain adjusters (32 mm

(1.26 in)) enables different secondary ratios with the same

chain length.

Chain adjusters 3 can be turned by 180°.

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

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

F03214-11

Finishing work

- Remove the motorcycle from the lift stand. ( p. 50)

WHEELS, TIRES

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.

- 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 the protection cap.

- Check tire pressure when the tires are cold.

Offroad tire pressure

front

1.0 bar (15 psi)

rear

1.0 bar (15 psi)

Street tire pressure

front

2.0 bar (29 psi)

400695-01

rear

2.0 bar (29 psi)

» If the tire pressure does not meet specifications:

- Correct tire pressure.

WHEELS, TIRES

- Mount the protection cap.

14.7

Checking 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.)

- Strike each spoke briefly using a screwdriver blade.

Info

The frequency of the sound depends on the spoke length

and spoke diameter.

If you hear different tone frequencies from different spokes

of equal length and diameter, this is an indication of differ-

ent spoke tensions.

You should hear a high note.

400694-01

» If the spoke tension differs:

- Correct the spoke tension.

- Check the spoke torque.

Guideline

Spoke nipple, front

M4.5

6 Nm (4.4 lbf ft)

wheel

Spoke nipple, rear

M4.5

6 Nm (4.4 lbf ft)

wheel

Torque wrench kit (58429094000)

100

ELECTRICAL SYSTEM

15.1

Removing the 12-V battery

Note

Environmental hazard

12 V batteries contain environmentally hazardous materials.

– Do not dispose of 12 V batteries as household waste.

- Dispose of 12 V batteries at a collection point for used batteries.

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 air filter box cover. ( p. 63)

- Remove the seat. ( p. 62)

Main work

Warning

Risk of injury

12 V batteries contain harmful substances.

– Keep 12 V batteries out of the reach of children.

- Keep sparks and open flames away from 12 V batteries.

- Only charge 12 V batteries in well-ventilated rooms.

- Maintain a minimum clearance from inflammable

materials when charging 12 V batteries.

Minimum clearance

1 m (3 ft)

– Do not charge deeply discharged 12 V batteries if the

charge is already below the minimum voltage.

Minimum voltage before 9 V

the start of the charge

- Dispose of 12 V batteries correctly if they have less than

the minimum voltage.

- Disconnect negative cable 1 from the 12-V battery.

A01339-10

- Pull back positive terminal cover and disconnect positive cable 2

from the 12-V battery.

- Pull off starter relay 3 and OCU 4 and hang to the side.

- Unscrew battery holding bracket screw 5.

- Push battery holding bracket to the side and detach.

- Lift out the 12-V battery.

A01340-10

101

ELECTRICAL SYSTEM

15.2

Installing the 12-V battery

Main work

- Insert the 12-V battery into the battery compartment with the ter-

minals facing forward and secure with holding bracket.

12-V battery (HJTZ5S-FP-C) ( p. 137)

A01341-10

- Screw battery holding bracket screw 1 tight.

- Attach starter relay 2 and OCU 3 to the holding bracket.

- Connect positive cable 4 to the 12-V battery.

Guideline

Screw, battery terminal

2.5 Nm (1.84 lbf ft)

– Connect negative cable 5 to the 12 V battery.

Guideline

Screw, battery terminal

2.5 Nm (1.84 lbf ft)

A01343-10

Finishing work

- Mount the seat. ( p. 62)

- Install the air filter box cover. ( p. 64)

15.3

Charging the 12-V battery

Note

Environmental hazard

12 V batteries contain environmentally hazardous materials.

– Do not dispose of 12 V batteries as household waste.

- Dispose of 12 V batteries at a collection point for used batteries.

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.

102

ELECTRICAL SYSTEM

Info

Even when there is no load on the 12-V battery, it discharges steadily each day.

The charging level and the method of charging are very important for the service life of the 12-V battery.

Rapid recharging with a high charging current shortens the service life of the battery.

If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.

If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and suffer a

loss of capacity, destroying the battery.

Preparatory work

- Remove the air filter box cover. ( p. 63)

- Remove the seat. ( p. 62)

- Remove the 12-V battery.

(

p. 101)

Main work

Warning

Risk of injury

12 V batteries contain harmful substances.

– Keep 12 V batteries out of the reach of children.

- Keep sparks and open flames away from 12 V batteries.

- Only charge 12 V batteries in well-ventilated rooms.

- Maintain a minimum clearance from inflammable

F01568-10

materials when charging 12 V batteries.

Minimum clearance

1 m (3 ft)

– Do not charge deeply discharged 12 V batteries if the

charge is already below the minimum voltage.

Minimum voltage before 9 V

the start of the charge

- Dispose of 12 V batteries correctly if they have less than

the minimum voltage.

- Check the battery voltage.

» Battery voltage: < 9 V

- Do not charge the 12-V battery.

- Replace the 12-V battery and dispose of the old 12-V bat-

tery properly.

» If the specifications have been met:

Battery voltage: ≥ 9 V

- Connect a battery charger to the 12-V battery. Switch on

the battery charger.

Guideline

Maximum charging voltage

14.4 V

Maximum charging current

3.0 A

Maximum charging time

12 h

Recharge the 12-V battery

6 months

regularly when the motor-

cycle is not being used

Ideal charging and storage

10 … 20 °C (50 … 68 °F)

temperature of the lithium-

ion battery

Battery charger (79629974000)

This battery charger tests whether the 12-V battery retains

its voltage. It is also impossible to overcharge the 12-V bat-

103

ELECTRICAL SYSTEM

tery with this battery charger. The charging time may be

longer at low temperatures.

This battery charger is only suitable for lithium iron phos-

phate batteries. Read the accompanying GASGAS Techni-

cal Accessories instructions.

Info

If the charging current, charging voltage, or

charging time is exceeded, the 12-V battery will be

destroyed.

If the 12-V battery is left in a discharged state for an

extended period, it will become deeply discharged

and suffer a loss of capacity, destroying the battery.

The 12-V battery is maintenance-free.

Never remove cover 1.

- Switch off the battery charger after charging and disconnect from

the 12-V battery.

Finishing work

- Install the 12-V battery.

(

p. 102)

– Mount the seat. ( p. 62)

- Install the air filter box cover. ( p. 64)

15.4

Changing the main fuse

Warning

Fire hazard Incorrect fuses overload the electrical system.

- Only use fuses with the required ampere value.

- Do not bypass or repair fuses.

Info

The main fuse protects all electrical power consumers of the vehicle.

Preparatory work

- Remove the air filter box cover. ( p. 63)

- Remove the seat. ( p. 62)

- Remove the fuel tank.

(

p. 70)

104

ELECTRICAL SYSTEM

Main work

- Take off protection caps 1.

- Remove faulty main fuse 2.

Info

A faulty fuse has a burned-out fuse wire A.

A spare fuse 3 is located in the starter relay.

- Insert a new main fuse.

Fuse (58011109120) ( p. 137)

- Check that the electrical system is functioning properly.

Tip

Insert a spare fuse so that it is available if needed.

- Mount the protection caps.

- Mount the starter relay onto the holder and route the cable.

A01380-10

Finishing work

- Install the fuel tank.

(

p. 71)

– Mount the seat. ( p. 62)

- Install the air filter box cover. ( p. 64)

15.5

Removing the headlight mask with the headlight

- Release screws 1.

- Slide the headlight mask up and swing it forward.

- Detach the brake line and wiring harness from the headlight mask.

T04630-01

(All US models)

- Disconnect plug-in connector 2 and take off the headlight

mask together with the headlight.

W00351-10

105

ELECTRICAL SYSTEM

15.7

Changing the headlight bulb

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 with the headlight. ( p. 105)

Main work

- Turn LED unit 1 counterclockwise all the way and take it out of the

reflector.

I00431-10

- Insert the LED unit into the reflector and turn it clockwise all the

way.

Headlight (LED)

Info

Ensure that O-ring 2 is seated properly.

I00432-10

Finishing work

- Install the headlight mask with the headlight. ( p. 106)

- Check the headlight setting. ( p. 107)

15.8

Checking the headlight setting

- Position the vehicle upright on a horizontal surface in front of a light

wall and make a marking 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.

107

ELECTRICAL SYSTEM

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:

- Adjust headlight range. ( p. 108)

15.9

Adjusting the headlight range

Preparatory work

- Check the headlight setting. ( p. 107)

Main work

- Loosen screw 1.

- Adjust the headlight range by pivoting the headlight.

Guideline

The boundary between light and dark must be exactly on the

lower mark for a motorcycle with rider (instructions on how to

apply the mark: Checking the headlight setting).

V00369-10

Info

A change in weight on the vehicle may require a correction

of the headlight range.

- Tighten screw 1.

Finishing work

- Check the headlight setting. ( p. 107)

15.10

Changing the turn signal bulb (All EU models)

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.

108

ELECTRICAL SYSTEM

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. 137)

- 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

Finishing work

- Check that the turn signal system is functioning properly.

15.11

Changing the combination instrument battery

Preparatory work

- Remove the headlight mask with the headlight. ( p. 105)

Main work

- Remove screws 1 along with the washers.

- Pull the combination instrument upward out of the holder.

F03251-10

- Using a coin, turn protection cap 2 all the way counterclockwise

and take it off.

- Remove combination instrument battery 3.

- Insert the combination instrument with the label facing upward.

Combination instrument battery (CR 2430) ( p. 137)

- Check the O-ring of the protection cap for correct seating.

F03252-10

109

ELECTRICAL SYSTEM

- Position protection cap 2 and turn all the way clockwise using a

coin.

- Press any button on the combination instrument.

The combination instrument is activated.

- Position the combination instrument in the holder.

- Mount and tighten the screws with washers.

F03253-10

Finishing work

- Install the headlight mask with the headlight. ( p. 106)

- Check the headlight setting. ( p. 107)

- Set the combination instrument. ( p. 23)

15.12

Diagnostics connector

Diagnostics connector 1 is located under the seat.

F03736-10

15.13

OCU

OCU 1 is located under the seat.

The OCU replaces the electronic fuses and relays.

All outputs are switched depending on the signals of the voltage regula-

tor and ECU.

The outputs are deactivated individually in the event of overcurrent.

This enables easy error detection because the status of each output is

indicated via LED lights.

The OCU monitors the electronics system completely independently.

As soon as an indicated error is rectified, the status light of the OCU

W00331-10

changes from red to green.

Overview

Ignition

Light

Brake light + horn

Fuel pump

Radiator fan

110

COOLING SYSTEM

16.1

Cooling system

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

The pressure resulting from the warming of the cooling system is reg-

ulated by a valve in radiator cap 2. This ensures that operating the

vehicle at the specified coolant temperature will not result in a risk of

malfunctions.

120 °C (248 °F)

Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also

reduce the cooling effect.

F03739-10

Additional cooling is provided by the radiator fan, which is activated on a

temperature-dependent basis.

16.2

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 the radiator cap.

- 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.

- Check the coolant level in the radiator.

400243-10

10 mm (0.39 in)

Coolant level A above the

radiator fins

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

- Correct the coolant level.

Coolant ( p. 142)

- Mount the radiator cap.

111

COOLING SYSTEM

16.3

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 the radiator cap.

- Check the coolant level in the radiator.

10 mm (0.39 in)

Coolant level A above the

radiator fins

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

- Correct the coolant level.

400243-10

Coolant ( p. 142)

- Mount the radiator cap.

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.

112

COOLING SYSTEM

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 screw 1. Take off radiator cap 2.

- Completely drain the coolant.

- Mount and tighten screw 1 with a new seal ring.

Guideline

Screw, water pump

10 Nm (7.4 lbf ft)

cover

F03739-10

16.5

Refilling 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.

Main work

- Make sure that the screw 1 is tightened.

- Stand the vehicle upright.

- Pour coolant in up to measurement A above the radiator fins.

Guideline

10 mm (0.39 in)

Coolant

0.95 l (1 qt.)

Coolant ( p. 142)

F03255-10

- Refit the radiator cap.

Finishing work

- Take a short test ride.

- Check the coolant level. ( p. 112)

113

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.

Main work

- Position the motorcycle upright.

- Place an appropriate container under the water pump cover.

- Remove screw 1. Take off radiator cap 2.

- Completely drain the coolant.

F03739-10

- Mount and tighten screw 1 with a new seal ring.

Guideline

Screw, water pump

10 Nm (7.4 lbf ft)

cover

- Pour coolant in up to level A above the radiator fins.

Guideline

10 mm (0.39 in)

F03255-10

Coolant

0.95 l (1 qt.)

Coolant ( p. 142)

– Mount radiator cap 2.

Finishing work

- Go for a short test ride.

- Check the coolant level. ( p. 112)

114

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

3 … 5 mm (0.12 … 0.2 in)

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

- Adjust the play in the throttle cable.

(

p. 115)

– Push the cold start button in all the way.

400192-11

When the throttle grip is turned forward, the cold start button

returns to its original position.

» If the cold start button does not return to its original position:

- Adjust the play in the throttle cable.

(

p. 115)

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. 115)

17.2

Adjusting the play in the throttle cable

Info

If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be removed.

Preparatory work

- Remove the air filter box cover. ( p. 63)

- Remove the seat. ( p. 62)

- Remove the fuel tank.

(

p. 70)

– Check the throttle cable routing. ( p. 78)

115

TUNING THE ENGINE

Main work

- Move the handlebar to the straight-ahead position.

- Push back sleeve 1.

- Loosen nut 2.

- Turn adjusting screw 3 in as far as possible.

- Loosen nut 4.

- Push cold start button 6 all the way to the stop.

- Turn adjusting screw 5 so that the cold start button moves to the

basic position when the throttle grip is turned to the front.

- Tighten nut 4.

- Turn adjusting screw 3 so that there is play in the throttle cable at

the throttle grip.

Guideline

Play in throttle cable

3 … 5 mm (0.12 … 0.2 in)

– Tighten nut 2.

- Slide on sleeve 1.

A01346-10

- Check the throttle grip for smooth operation.

Finishing work

- Check the play in the throttle cable. ( p. 115)

17.3

Adjusting the characteristic map of the throttle response

Info

On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate.

A guide plate with a different characteristic map is supplied.

Main work

- Push back sleeve 1.

- Remove screws 2 and half-shells 3.

- Detach the throttle cables and take off the grip tube.

A01348-10

116

TUNING THE ENGINE

– Remove guide plate 4 from handle tube 5.

- Position the required guide plate on the grip tube.

Guideline

The label OUTSIDE must be visible. Marking A must be posi-

tioned at marking B.

Grey guide plate (79002014000)

Alternative 1

Black guide plate (79002014100)

Info

The gray guide plate opens the throttle valve more slowly.

The black guide plate opens the throttle valve more quickly.

The gray guide plate is mounted upon delivery.

102246-10

- Clean the outside of the handlebar and the inside of the grip tube.

Mount the grip tube on the handlebar.

- Attach the throttle cables to the guide plate and route correctly.

- Position half-shells 3, mount and tighten screws 2.

Guideline

Screw, throttle grip

5 Nm (3.7 lbf ft)

– Slide on sleeve 1 and check the throttle grip for ease of move-

ment.

A01344-10

Finishing work

- Check the play in the throttle cable. ( p. 115)

17.4

Changing the mapping (optional)

Caution

Voiding of the government approval for road use and the insurance coverage If the combination switch is

mounted, the vehicle’s road permit, if any, expires.

- Only operate the vehicle in closed-off areas remote from public road traffic if the combination switch is

installed.

Info

Traction control can be activated additionally using button TC.

The mapping can also be changed during the ride.

117

TUNING THE ENGINE

Activating STANDARD mapping:

- Press button 1.

Guideline

Engine speed

< 4,000 rpm

The indicator lamp A lights up.

STANDARD - balanced response

Info

F03762-10

Traction control can be activated additionally using TC

button 3.

Activating ADVANCED mapping:

- Press button 2.

Guideline

Engine speed

< 4,000 rpm

The indicator lamp B lights up.

ADVANCED - direct response

Info

F03763-10

Traction control can be activated additionally using TC

button 3.

17.5

Adjusting the idle speed

Warning

Danger of accidents The engine may go out spontaneously if the idle speed is set too low.

- Set the idle speed to the specified value. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

- Run the engine until warm.

The cold start button is deactivated - The cold start button is in

its basic position. ( p. 19)

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 by turning idle speed adjusting screw 1.

Guideline

Idle speed

1,800 … 1,900 rpm

Service hour counter with revolution counter (A54012920100)

Info

R06539-10

Turning counterclockwise lowers the idle speed.

Turning clockwise raises the idle speed.

118

TUNING THE ENGINE

17.6

Programming the throttle valve position

Info

If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed, then the mal-

function indicator lamp flashes 2x per second.

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.

- Allow the vehicle to run at idle speed.

The malfunction indicator lamp stops flashing once program-

ming is completed.

Info

If the engine becomes too warm, perform a cool-down ride

at medium speed.

After this, do not switch off the engine, but leave it running

at idle speed until the programming is finished.

H02263-10

17.7

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.

Gap between the shift lever

10 … 20 mm (0.39 … 0.79 in)

and the top of the boot

» If the distance does not meet specifications:

- Adjust the basic position of the shift lever.

(

p. 120)

400692-10

119

SERVICE WORK ON THE ENGINE

18.1

Changing the fuel screen

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.

- Clean quick release coupling 1 thoroughly with compressed air.

Info

Under no circumstances should dirt enter into the fuel line.

Dirt in the fuel line clogs the injection valve!

- Disconnect the quick release coupling.

Info

Remaining fuel may flow out of the fuel hose.

- Pull fuel screen 2 out of the connecting piece.

- Insert the new fuel screen all the way into the connecting piece.

- Spray silicone spray onto a lint-free cleaning cloth and lightly lubri-

cate the O-ring of the quick-release coupling.

Silicone spray ( p. 144)

- Join the quick release coupling.

Danger

A01353-10

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 check the response.

121

SERVICE WORK ON THE ENGINE

18.2

Checking the engine oil level

Preparatory work

- Stand the motorcycle upright on a horizontal surface.

Condition

The engine is at operating temperature.

- Check the engine oil level.

Info

After switching off the engine, wait one minute before

checking the level.

The engine oil is at a level between the lower edge A and

F03260-10

the middle of the level viewer B.

» If the engine oil is not up to the lower edge A of the level

viewer:

- Add engine oil. ( p. 125)

18.3

Changing the engine oil and oil filter, cleaning the oil screen

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

Drain the engine oil with the engine at operating temperature.

Preparatory work

- Park the motorcycle on a level surface.

Main work

- Position an appropriate container under the engine.

- Remove oil drain plug 1 with the magnet and seal ring.

F03774-10

122

SERVICE WORK ON THE ENGINE

– Remove screw plug 2 with the O-ring.

Info

Do not remove screw A.

F03775-10

- Remove screw plug 3 with the long oil screen 4 and the O-rings.

- Allow the engine oil to drain completely.

- Thoroughly clean the parts and the sealing surfaces.

H05063-10

- Mount and tighten screw plug 2 with new O-ring.

Guideline

Screw plug, crankcase

M16x1.5

15 Nm (11.1 lbf ft)

F03775-11

- Position long oil screen 4 with the O-rings on a pin wrench.

- Position the pin wrench through the drill hole of the screw plug in

the opposite section of the engine case.

- Push the oil screen all the way into the engine case.

F03776-10

- Mount and tighten screw plug 3 with the O-ring.

Guideline

Screw plug, oil screen

M20x1.5

15 Nm (11.1 lbf ft)

– Mount and tighten oil drain plug 1 with the magnet and a new

seal ring.

Guideline

Oil drain plug with

M12x1.5

20 Nm (14.8 lbf ft)

magnet

H05065-10

123

SERVICE WORK ON THE ENGINE

- Remove screws 5. Take off the oil filter cover with the O-ring.

H05066-10

- Pull oil filter 6 out of the oil filter housing.

Lock ring plier (51012011000)

- Allow the engine oil to drain completely.

- Thoroughly clean the parts and the sealing surface.

H05067-10

- Lay the motorcycle on its side and fill the oil filter housing to about

⅓ full with engine oil.

- Insert the new oil filter into the oil filter housing.

- Oil the O-ring of the oil filter cover and mount it together with oil

filter cover 7.

- Mount and tighten the screws.

Guideline

Screw, oil filter cover

M6x16

10 Nm (7.4 lbf ft)

H05068-10

- Stand the motorcycle upright.

- Remove filler plug 8 with the O-ring, and fill up with engine oil.

Engine oil

1.2 l (1.3 qt.)

Engine oil (SAE

10W/50) ( p. 142)

Info

Too little engine oil or poor-quality engine oil will result in

premature wear of the engine.

- Mount and tighten the filler plug together with the O-ring.

H01713-10

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 check it for leaks.

Finishing work

- Check the engine oil level. ( p. 122)

124

SERVICE WORK ON THE ENGINE

18.4

Adding engine oil

Info

Too little engine oil or poor-quality engine oil will result in premature wear of the engine.

Main work

- Remove oil filler plug 1 with the O-ring from the clutch cover.

- Fill engine oil to the middle A of the level viewer.

Engine oil (SAE 10W/50) ( p. 142)

Info

In order to achieve optimal engine oil performance, it is not

advisable to mix different engine oils.

GASGAS Motorcycles recommends changing the engine oil,

if necessary.

- Mount and tighten the filler plug together with the O-ring.

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-

F03261-10

ning the engine in an enclosed space.

- Start the engine and check for leaks.

Finishing work

- Check the engine oil level. ( p. 122)

125

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 the 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. 144)

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.

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. 73)

–

Treat bare metal (except for brake discs and the exhaust system)

with a corrosion inhibitor.

126

CLEANING, CARE

Preserving materials for paints, metal and rubber ( p. 144)

- Treat all plastic parts and powder-coated parts with a mild cleaning

and care product.

Special cleaner for glossy and matte paint finishes, metal and

plastic surfaces ( p. 145)

19.2

Checks and maintenance steps for winter operation

Info

If you use the vehicle in winter, you must expect salt on the roads. You should therefore take precautions against

aggressive road salt.

If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corro-

sive effects of salt.

- Clean the motorcycle. ( p. 126)

- Clean brake system.

Info

After EVERY trip on salted roads, thoroughly clean the brake

calipers and brake linings, after they have cooled down and

without removing them, with cold water and dry them care-

fully.

After riding on salted roads, thoroughly clean the vehicle

401060-01

with cold water and dry it well.

- Treat the engine, link fork, and all other bare or zinc-plated parts

(except the brake discs) with a wax-based corrosion inhibitor.

Info

Corrosion inhibitor must not come in contact with the brake

discs as this would greatly reduce the braking force.

- Clean the chain. ( p. 73)

127

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 you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.

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). In this way, you can avoid long work-

shop waiting times at the start of the new season.

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

service, add fuel additive.

Fuel additive ( p. 144)

- Refuel. ( p. 38)

Tip

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

lowest possible ethanol content.

401058-01

- Clean the motorcycle. ( p. 126)

- Change the engine oil and oil filter, clean the oil screen.

(

p. 122)

– Check the antifreeze and coolant level. ( p. 111)

- Check the tire pressure. ( p. 99)

- Remove the 12-V battery.

(

p. 101)

– Charge the 12-V battery.

(

p. 102)

Guideline

Storage temperature of the

0 … 35 °C (32 … 95 °F)

12-V battery without direct

sunlight

- 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. 50)

- Preferably cover the motorcycle with a tarp or similar cover that is

permeable to air. Do not use non-porous materials since they pre-

vent humidity from escaping, thus causing corrosion.

128

TROUBLESHOOTING

Faults

Possible cause

Action

The engine cannot be cranked

Operating error

Carry out start procedure. ( p. 33)

(starter motor)

12-V battery discharged

Charge the 12-V battery.

(

p. 102)

–

Check the charging voltage.

–

Check the open-circuit current.

–

Check the stator winding of the alterna-

tor.

Main fuse blown

Change the main fuse. ( p. 104)

Starter relay defective

Check the starter relay.

Starter motor defective

Check the starter motor.

The engine turns but does not

Operating error

Carry out start procedure. ( p. 33)

start

Quick release coupling not joined

Join quick release coupling.

Fuse 1 blown

Change the fuses of individual electrical

power consumers.

Fuse 4 blown

Change the fuses of individual electrical

power consumers.

Idle speed is not set correctly

Adjust the idle speed.

(

p. 118)

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 electrode gap

1.0 mm (0.039 in)

Ignition system defective

Check the ignition system.

Short-circuit cable in wiring har-

Check the wiring harness. (visual check)

ness frayed, stop button or emer-

–

Check the electrical system.

gency OFF switch faulty

Error in the electronic fuel injec-

Read out the fault memory using the GAS-

tion

GAS Motorcycles diagnostics tool.

Engine does not speed up

Error in the electronic fuel injec-

Read out the fault memory using the GAS-

tion

GAS Motorcycles diagnostics tool.

Ignition system defective

Ignition coil - check the secondary wind-

ing.

Check the spark plug connector.

–

Check the stator winding of the alterna-

tor.

Engine has too little power

Air filter heavily contaminated

Clean the air filter and air filter box.

(

p. 65)

Fuel filter is very dirty

Change the fuel filter.

Fuel screen is very dirty

Change the fuel screen.

(

p. 121)

Error in the electronic fuel injec-

Read out the fault memory using the GAS-

tion

GAS Motorcycles diagnostics tool.

Exhaust system leaky, deformed

Check exhaust system for damage.

or too little glass fiber yarn filling

–

Change the glass fiber yarn filling in the

in the main silencer

main silencer.

(

p. 69)

Valve clearance too little

Adjust the valve clearance.

Ignition system defective

Ignition coil - check the secondary wind-

ing.

Check the spark plug connector.

–

Check the stator winding of the alterna-

tor.

130

TROUBLESHOOTING

Faults

Possible cause

Action

The engine dies during the trip

Lack of fuel

Refuel. ( p. 38)

Fuse 1 blown

Change the fuses of individual electrical

power consumers.

Fuse 4 blown

Change the fuses of individual electrical

power consumers.

Engine overheats

Coolant level low in cooling sys-

Check the cooling system for leaks.

tem

Check the coolant level. ( p. 112)

Insufficient airflow

Switch off engine when stationary.

Radiator fins very dirty

Clean radiator fins.

Foam formation in cooling system

Drain the coolant.

(

p. 112)

–

Refill the coolant.

(

p. 113)

Bent radiator hose

Change the radiator hose.

Thermostat defective

Check the thermostat.

Guideline

Opening temperature: 70 °C (158 °F)

Defect in radiator fan system

Check the radiator fan fuse.

–

Check fuse 4.

–

Check the radiator fan.

Malfunction indicator lamp lights

Error in the electronic fuel injec-

Check wiring for damage and electrical

up or flashes

tion

plug-in connectors for corrosion and dam-

age.

Read out the fault memory using the GAS-

GAS Motorcycles diagnostics tool.

High oil consumption

Engine vent hose bent

Route the vent hose without bends or

replace it if necessary.

Engine oil level too high

Check the engine oil level. ( p. 122)

Engine oil too thin (low viscosity)

Change the engine oil and oil filter, clean

the oil screen.

(

p. 122)

Piston and cylinder worn

Measure the piston/cylinder mounting

clearance.

12-V battery discharged

The 12-V battery is not being

Check the charging voltage.

charged by the alternator

Check the stator winding of the alterna-

tor.

Unwanted electrical power con-

Check the open-circuit current.

sumer

Values in combination instrument

The combination instrument bat-

Change combination instrument battery.

deleted (time, stop watch, lap

tery is empty

(

p. 109)

times)

The high beam, low beam, tail

Fuse 2 blown

Change the fuses of individual electrical

light, position light, and license

power consumers.

plate lamp are not working

The horn, brake light, turn signal,

Fuse 3 blown

Change the fuses of individual electrical

and radiator fan are not working

power consumers.

131

BLINK CODE

Info

The blink codes are only displayed by the derestricted version of the vehicle.

Blink code for malfunction

indicator lamp

02a Malfunction indicator lamp flashes 2x per second

Error level condition

Throttle valve position programming necessary

Blink code for malfunction

indicator lamp

02 Malfunction indicator lamp flashes 2x short

Error level condition

Crankshaft speed sensor - circuit fault

Blink code for malfunction

indicator lamp

06 Malfunction indicator lamp flashes 6x short

Error level condition

Throttle valve position sensor circuit A - input signal too low

Throttle valve position sensor circuit A - input signal too high

Blink code for malfunction

indicator lamp

09 Malfunction indicator lamp flashes 9x short

Error level condition

Induction manifold pressure sensor, cylinder 1 - input signal too low

Induction manifold pressure sensor cylinder 1 - input signal too high

Blink code for malfunction

indicator lamp

12 Malfunction indicator lamp flashes 1x long, 2x short

Error level condition

Coolant temperature sensor - input signal too low

Coolant temperature sensor - input signal too high

Blink code for malfunction

indicator lamp

13 Malfunction indicator lamp flashes 1x long, 3x short

Error level condition

Intake air temperature sensor - input signal too low

Intake air temperature sensor - input signal too high

Blink code for malfunction

indicator lamp

15 Malfunction indicator lamp flashes 1x long, 5x short

Error level condition

Tilt sensor - input signal too low

Tilt sensor - input signal too high

Blink code for malfunction

indicator lamp

21 Malfunction indicator lamp flashes 2x long, 1x short

Error level condition

Battery voltage - input voltage too high

132

TECHNICAL SPECIFICATIONS

23.1

Engine

Design

1-cylinder 4-stroke engine, water-cooled

Displacement (All 450 models)

449.9 cm³ (27.455 cu in)

Displacement (All 500 models)

510.9 cm³ (31.177 cu in)

Stroke (All 450 models)

63.4 mm (2.496 in)

Stroke (All 500 models)

72 mm (2.83 in)

Bore

95 mm (3.74 in)

Compression ratio

12.75:1

Idle speed

1,800 … 1,900 rpm

Control

OHC, 4 valves controlled via rocker arm

Valve diameter, intake

40 mm (1.57 in)

Valve diameter, exhaust

33 mm (1.3 in)

Valve clearance

Intake at: 20 °C (68 °F)

0.10 … 0.15 mm (0.0039 … 0.0059 in)

Exhaust at: 20 °C (68 °F)

0.12 … 0.17 mm (0.0047 … 0.0067 in)

Crankshaft bearing

2 cylinder roller bearing

Conrod bearing

Slide bearing

Piston pin bearing

Bearing bush

Pistons

Forged light alloy

Piston rings

1 compression ring, 1 oil scraper ring

Engine lubrication

Pressure circulation lubrication with 2 trochoidal pumps

Primary transmission

29:72

Clutch

Multidisc clutch in oil bath, hydraulically activated

Gearbox

6-gear transmission, claw shifted

Transmission ratio

first-gear