GASGAS ES 700. OWNER'S MANUAL (2023)
TABLE OF CONTENTS
TABLE OF CONTENTS
1
MEANS OF REPRESENTATION
5
6.20
Closing the fuel tank filler cap
20
6.21
Combination instrument
20
1.1
Symbols used
5
6.21.1
Overview
20
1.2
Formats used
5
6.21.2
Activation and test
21
2
SAFETY ADVICE
6
6.21.3
Setting the combination instrument
21
6.21.4
Setting kilometers or miles
21
2.1
Use definition - intended use
6
6.21.5
Setting the clock
22
2.2
Misuse
6
6.21.6
Setting the service interval
22
2.3
Safety advice
6
6.21.7
Distance 1
23
2.4
Degrees of risk and symbols
6
6.21.8
Distance 2
23
2.5
Tampering warning
7
6.21.9
Average speed 1
23
2.6
Safe operation
7
6.21.10
Average speed 2
24
2.7
Protective clothing
7
6.21.11
Riding time 1
24
2.8
Work rules
8
6.21.12
Riding time 2
24
2.9
Environment
8
6.21.13
Service hour counter
24
2.10
Owner's Manual
8
6.21.14
Clock
25
3
IMPORTANT NOTES
9
6.21.15
Service interval display
25
6.21.16
Tachometer
25
3.1
Manufacturer warranty, implied
6.21.17
Odometer
26
warranty
9
6.21.18
Gear display
26
3.2
Fuel, auxiliary substances
9
6.21.19
Service display
26
3.3
Spare parts, technical accessories
9
6.21.20
Distance fuel reserve
26
3.4
Service
9
3.5
Figures
9
7
PREPARING FOR USE
27
3.6
Customer service
9
7.1
Advice on preparing for first use
27
4
VIEW OF VEHICLE
10
7.2
Running in the engine
28
7.3
Loading the vehicle
28
4.1
View of vehicle, front left (example)
10
4.2
View of vehicle, rear right (example)
11
8
RIDING INSTRUCTIONS
30
5
SERIAL NUMBERS
12
8.1
Checks and maintenance measures
when preparing for use
30
5.1
Vehicle identification number
12
8.2
Starting the vehicle
30
5.2
Type label
12
8.3
Starting off
32
5.3
Key number
12
8.4
Shifting, riding
32
5.4
Engine number
12
8.5
Quickshifter +
34
5.5
Fork part number
13
8.6
Motorcycle traction control
35
5.6
Shock absorber article number
13
8.7
Braking
35
6
CONTROLS
14
8.8
Stopping, parking
36
8.9
Transport
37
6.1
Clutch lever
14
8.10
Towing in the event of a breakdown
37
6.2
Hand brake lever
14
8.11
Refueling
38
6.3
Throttle grip
14
6.4
Horn button
14
9
SERVICE SCHEDULE
40
6.5
Light switch
15
9.1
Additional information
40
6.6
Turn signal switch
15
9.2
Service schedule
40
6.7
Emergency OFF switch
15
6.8
Start button
15
10
TUNING THE CHASSIS
42
6.9
ABS button
16
10.1
Fork/shock absorber
42
6.10
Combination switch
16
10.2
Adjusting the compression damping of
6.11
Ignition and steering lock
17
the fork
42
6.12
Overview of indicator lights
17
10.3
Adjusting the rebound damping of the
6.13
Seat release
18
fork
42
6.14
Grab handles
18
10.4
Compression damping of the shock
6.15
Passenger foot pegs
18
absorber
43
6.16
Shift lever
18
10.5
Adjusting the low-speed compression
6.17
Foot brake lever
19
damping of the shock absorber
43
6.18
Side stand
19
10.6
Adjusting the high-speed compression
6.19
Opening the fuel tank filler cap
19
damping of the shock absorber
44
2
TABLE OF CONTENTS
10.7
Adjusting the rebound damping of the
12.11
Adding rear brake fluid
72
shock absorber
45
12.12
Checking that the brake linings of the
10.8
Handlebar position
45
rear brake are secured
73
10.9
Adjusting the handlebar position
45
12.13
Changing the rear brake linings
73
11
SERVICE WORK ON THE CHASSIS
47
13
WHEELS, TIRES
76
11.1
Raising the motorcycle with rear lifting
13.1
Removing the front wheel
76
gear
47
13.2
Installing the front wheel
77
11.2
Taking the motorcycle off of the rear
13.3
Removing the rear wheel
77
wheel stand
47
13.4
Installing the rear wheel
78
11.3
Raising the motorcycle with a lift stand
47
13.5
Checking the rear hub damping rubber
11.4
Removing the motorcycle from the lift
pieces
80
stand
48
13.6
Checking the tire condition
81
11.5
Cleaning the dust boots of the fork legs
48
13.7
Checking tire pressure
82
11.6
Removing fork protector
49
13.8
Checking the spoke tension
82
11.7
Installing the fork protector
49
13.9
Using tire repair spray
83
11.8
Bleeding the fork legs
49
14
ELECTRICAL SYSTEM
84
11.9
Removing the seat
50
11.10
Mounting the seat
50
14.1
Removing the 12-V battery
84
11.11
Removing the tool set
50
14.2
Installing the 12-V battery
84
11.12
Storing the tool set
51
14.3
Charging the 12-V battery
85
11.13
Take off the side cover
52
14.4
Changing the main fuse
86
11.14
Mounting side cover
53
14.5
Changing the ABS fuses
87
11.15
Removing the front fender
54
14.6
Changing the fuses of individual
11.16
Installing the front fender
54
electrical power consumers
88
11.17
Removing the air filter
54
14.7
Removing the headlight mask with the
11.18
Installing the air filter
55
headlight
89
11.19
Checking the chain for dirt
55
14.8
Installing the headlight mask with the
11.20
Cleaning the chain
56
headlight
90
11.21
Checking the chain tension
56
14.9
Changing the headlight bulb
91
11.22
Adjusting the chain tension
57
14.10
Changing the position light lamp
91
11.23
Checking the chain, rear sprocket,
14.11
Checking the headlight setting
92
engine sprocket, and chain guide
58
14.12
Adjusting the headlight range
93
11.24
Adjusting chain guide
61
14.13
ACC1 and ACC2
93
11.25
Checking the rubber grip
61
14.14
Diagnostics connector
93
11.26
Adjusting the basic position of the clutch
15
COOLING SYSTEM
94
lever
62
11.27
Checking/correcting the fluid level of
15.1
Cooling system
94
hydraulic clutch
62
15.2
Checking the antifreeze and coolant
11.28
Removing engine guard
63
level
94
11.29
Installing the engine guard
63
15.3
Checking the coolant level
95
15.4
Draining the coolant
96
12
BRAKE SYSTEM
64
15.5
Filling/bleeding the cooling system
97
12.1
Anti-lock braking system (ABS)
64
15.6
Changing the coolant
98
12.2
Adjusting the basic position of the hand
16
TUNING THE ENGINE
100
brake lever
65
12.3
Checking the brake discs
65
16.1
Changing the riding mode
100
12.4
Checking the front brake fluid level
66
16.2
Adjusting traction control
100
12.5
Adding the front brake fluid
66
16.3
Checking the basic position of the shift
12.6
Checking that the brake linings of the
lever
101
front brake are secured
67
16.4
Adjusting the basic position of the shift
12.7
Changing the brake linings of the front
lever
101
brake
68
17
SERVICE WORK ON THE ENGINE
102
12.8
Checking the free travel of foot brake
lever
70
17.1
Checking the engine oil level
102
12.9
Adjusting the basic position of the foot
17.2
Changing the engine oil and oil filter,
brake lever
70
cleaning the oil screens
102
12.10
Checking the rear brake fluid level
71
17.3
Adding engine oil
105
3
TABLE OF CONTENTS
18
CLEANING, CARE
106
18.1
Cleaning the motorcycle
106
18.2
Checks and maintenance steps for
winter operation
107
19
STORAGE
108
19.1
Storage
108
19.2
Preparing for use after storage
109
20
TROUBLESHOOTING
110
21
TECHNICAL DATA
112
21.1
Engine
112
21.2
Engine tightening torques
113
21.3
Capacities
115
21.3.1
Engine oil
115
21.3.2
Coolant
115
21.3.3
Fuel
116
21.4
Chassis
116
21.5
Electrical system
117
21.6
Tires
117
21.7
Fork
117
21.8
Shock absorber
118
21.9
Chassis tightening torques
119
22
SUBSTANCES
123
23
AUXILIARY SUBSTANCES
125
24
STANDARDS
126
25
INDEX OF SPECIAL TERMS
127
26
LIST OF ABBREVIATIONS
128
27
LIST OF SYMBOLS
129
27.1
Red symbols
129
27.2
Yellow and orange symbols
129
27.3
Green and blue symbols
129
INDEX
130
4
MEANS OF REPRESENTATION
1
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g., of a work step or a function).
Indicates an unexpected reaction (e.g., of a work step or a function).
Indicates work that requires expert knowledge and technical understanding. In the interest of your own
safety, have this work performed by an authorized GASGAS Motorcycles workshop. Your motorcycle will
be cared for there to the highest degree by specially trained experts using the special tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates 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.
5
2
SAFETY ADVICE
2.1
Use definition - intended use
The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on gentle terrain (un-
paved roads).
This vehicle is not suitable for use on race tracks.
Info
This vehicle is only authorized for operation on public roads in its homologated version.
When used in a dusty environment, it may be necessary to use air filter protection. Your authorized GASGAS Motor-
cycles dealer will be glad to advise you.
2.2
Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respec-
tive use.
2.3
Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction
and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the
relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do not
remove any information or warning labels. If they are missing, you or others may not recognize dangers and may
therefore be injured.
2.4
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate
measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
6
SAFETY ADVICE
2
2.5
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1
The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of
any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
2
the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1
Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust
gases.
2
Removal or puncturing of parts of the intake system.
3
Lack of proper maintenance.
4
Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those
specified by the manufacturer.
2.6
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
- Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
- Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when running the engine.
- Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
- Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before
the vehicle parts have cooled down.
- Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and
environmentally compatible manner.
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.
7
2
SAFETY ADVICE
2.8
Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote
key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the
number in parentheses. Example: bearing puller (15112017000)
Unless otherwise noted, normal conditions apply to all tasks and descriptions.
Ambient temperature
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 guidelines
of the country in which you are disposing of them.
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.
2.10
Owner's Manual
Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful infor-
mation and many tips on how to operate, handle, and service your motorcycle. This is the only way to find out how best to
customize the vehicle for your own use and how you can protect yourself from injury.
Tip
Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need to.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized
GASGAS Motorcycles dealer.
The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be down-
loaded again by the new owner.
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate.
The Owner's Manual is also available for download from your authorized GASGAS Motorcycles dealer and on the GAS-
GAS Motorcycles website. A printed copy can also be ordered from your authorized GASGAS Motorcycles dealer.
International GASGAS Motorcycles website: http://www.gasgas.com
8
IMPORTANT NOTES
3
3.1
Manufacturer warranty, implied warranty
The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and
confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary 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, technical accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by
GASGAS Motorcycles and have them mounted 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 dusty environments, heavy rain, high heat or with a heavy load, can
lead to considerably more rapid wear of components such as the air filter, drive train, brake system, or suspension compo-
nents. 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
9
4
VIEW OF VEHICLE
4.1
View of vehicle, front left (example)
W00172-10
1 Hand brake lever ( p. 14)
2 Clutch lever ( p. 14)
3 Fuel tank filler cap
3 Seat release ( p. 18)
4 Side stand ( p. 19)
5 Compression damping of the shock absorber ( p. 43)
6 Shift lever ( p. 18)
7 Tool set
10
VIEW OF VEHICLE
4
4.2
View of vehicle, rear right (example)
V02689-10
1 Ignition and steering lock ( p. 17)
2 Fork compression adjuster
3 Light switch ( p. 15)
3 Turn signal switch ( p. 15)
3 Horn button ( p. 14)
4 Combination switch ( p. 16)
5 Emergency OFF switch ( p. 15)
5 Start button ( p. 15)
6 Throttle grip ( p. 14)
7 Fork rebound adjustment
8 Vehicle identification number ( p. 12)
9 Foot brake lever ( p. 19)
11
5
SERIAL NUMBERS
5.1
Vehicle identification number
The vehicle identification number 1 is stamped on the right side of the
steering head.
401945-10
5.2
Type label
The Europe type label 1 is located on the right side of the frame.
V02700-10
5.3
Key number
The key number 1 can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep
the KEYCODECARD in a safe place.
V02729-10
5.4
Engine number
The engine number 1 is stamped on the left side of the engine under
the engine sprocket.
401949-10
12
SERIAL NUMBERS
5
5.5
Fork part number
The fork part number 1 is stamped on the inner side of the fork stub.
401947-10
5.6
Shock absorber article number
The shock absorber article number 1 is on the left side of the shock
absorber.
402025-10
13
6
CONTROLS
6.1
Clutch lever
Clutch lever 1 is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
V02701-10
6.2
Hand brake lever
The hand break lever 1 is fitted on the right side of the handlebar.
The hand brake lever operates the front brake.
V02702-10
6.3
Throttle grip
The throttle grip 1 is fitted on the right side of the handlebar.
V02703-10
6.4
Horn button
Horn button 1 is fitted on the left side of the handlebar.
Possible states
• The horn button is in the basic position
• The horn button is pressed - The horn is operated in this posi-
tion.
V02704-10
14
CONTROLS
6
6.5
Light switch
The light switch 1 is fitted on the left side of the handlebar.
Possible states
Low beam on - Light switch is turned downward. In this
position, the low beam and tail light are switched on.
High beam on - Light switch is turned upward. In this posi-
tion, the high beam and tail light are switched on.
V02704-11
6.6
Turn signal switch
The turn signal switch 1 is fitted on the left side of the handlebar.
Possible states
Turn signal off
Turn signal light, left, on - Turn signal switch pressed to
the left. The turn signal switch returns automatically to the
central position after use.
Turn signal light, right, on - Turn signal switch pressed to
the right. The turn signal switch returns automatically to
the central position after use.
V02704-12
To switch off the turn signal light, press the turn signal switch towards
the switch case.
6.7
Emergency OFF switch
The emergency OFF switch 1 is fitted on the right side of the handle-
bar.
Possible states
Emergency OFF switch off - In this position, the ignition
circuit is interrupted, a running engine stops, and the
engine cannot be started.
Emergency OFF switch on - This position is necessary for
operation as the ignition circuit is closed.
V02705-11
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 - In this position, the starter motor is
actuated.
V02705-10
15
6
CONTROLS
6.9
ABS button
The ABS button 1 is fitted next to the combination instrument on the
left.
Info
The ABS button is also used as the ABS warning lamp ( p. 64).
S04356-10
6.10
Combination switch
The combination switch is fitted on the left side of the handlebar.
Possible states
1
STREET - Riding mode STREET and traction control are
activated when LED 1 lights up.
1 TC
STREET without TC - When LEDs 1 and TC light up, riding
mode STREET is active and traction control is deactivated.
2
SPORT - If LED 2 is lit up, riding mode SPORT, a subse-
quently active traction control and ABS mode Offroad are
activated.
V02706-10
2 TC
SPORT without TC - If LEDs 2 and TC are lit up, riding
mode SPORT and ABS mode Offroad are active. The
traction control is deactivated.
The combination switch displays the current riding mode and traction
control setting.
Press button MAP on the combination switch to change the riding
mode, the traction control and the ABS mode.
The traction control is activated or deactivated using button TC on the
combination switch.
Info
Each time the ignition is switched on, all three switch LEDs light
up for a function check.
If all three LEDs light up during operation, a malfunction has
been detected by the engine control unit. Contact an authorized
GASGAS Motorcycles workshop immediately.
H02887-01
16
CONTROLS
6
6.11
Ignition and steering lock
The ignition and steering lock is located in front of the seat.
Possible states
Ignition off - In this position, the ignition circuit is inter-
rupted, a running engine stops, and a non-running engine
will not start. The ignition key can be removed.
Ignition on - In this position, the ignition circuit is closed
and the engine can be started.
Steering locked - In this position, the ignition circuit is
interrupted and the steering locked. The ignition key can
S03271-01
be removed.
6.12
Overview of indicator lights
Possible states
ABS warning lamp lights up/flashes yellow - If the
ABS warning lamp lights up, the ABS is not active. The ABS
warning lamp also lights up if a malfunction is detected.
Contact an authorized GASGAS Motorcycles workshop. If
the ABS warning lamp flashes slowly, ABS mode Offroad is
active.
The high beam indicator lamp lights up blue - The high
beam is switched on.
Fuel level warning lamp lights up orange - The fuel level
has reached the reserve mark.
Malfunction indicator lamp lights up orange - The OBD has
detected a malfunction in the vehicle electronics. Come
safely to a halt, and contact an authorized GASGAS Motor-
cycles workshop.
The coolant temperature warning lamp lights up red - The
coolant temperature has reached a critical value. Stop
immediately (taking care not to endanger yourself or other
road users in the process), switch off the engine, allow it to
S04357-01
cool down and check the coolant level.
The idle indicator lamp lights up green - The transmission
is in the neutral position.
Turn signal indicator lamp flashes green - The turn signal is
switched on.
The oil pressure warning lamp lights up red - The oil
pressure is too low. Stop immediately, taking care not to
endanger yourself or other road users in the process, and
switch off the engine.
TC indicator lamp lights up/flashes yellow - If the TC indi-
cator lamp lights up, the cornering MTC ( p. 35) is not
active. If the TC indicator light and both ride mode lamps
light up at same time, a malfunction has been detected.
Contact an authorized GASGAS Motorcycles workshop.
The TC indicator lamp flashes if the cornering MTC actively
engages.
17
6
CONTROLS
6.13
Seat release
The loop 1 unlocks the seat.
Info
The loop for unlocking the seat is located under the fuel tank
cap.
V02707-10
6.14
Grab handles
The grab handles 1 are used for moving the motorcycle around.
If you carry a passenger, the passenger can hold onto the grab handles
during the trip.
V02717-10
6.15
Passenger foot pegs
The passenger foot pegs can be folded up and down.
Possible states
• Passenger foot pegs folded up - For operation without a passen-
ger.
• Passenger foot pegs folded down - For operation with a passenger.
V02708-10
6.16
Shift lever
The shift lever 1 is mounted on the left side of the engine.
401950-10
18
CONTROLS
6
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
401950-11
6.17
Foot brake lever
Foot brake lever 1 is located in front of the right footrest.
The rear brake is engaged with the foot brake lever.
401956-10
6.18
Side stand
The side stand 1 is located on the left of the vehicle.
The side stand is used for parking the motorcycle.
Info
The side stand must be folded up during motorcycle use.
The side stand is coupled with the safety starting system - see
the riding instructions.
Possible states
401943-10
• Side stand folded out - The vehicle can be supported on the side
stand. The safety starting system is active.
• Side stand folded in - This position is mandatory when riding the
motorcycle. The safety starting system is inactive.
6.19
Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
19
6
CONTROLS
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.
- Lift cover 1 of fuel tank filler cap and insert the ignition key.
- Turn the ignition key 90° counterclockwise and take off the fuel tank
filler cap.
Info
The fuel tank filler cap has a fuel tank breather.
V02709-10
6.20
Closing the fuel tank filler cap
- Put the fuel tank filler cap back on and turn the ignition key 90°
clockwise.
- Remove the ignition key and close the cover.
V02710-01
6.21
Combination instrument
6.21.1
Overview
1 + button
2 Service display ( p. 26)
3 Speedometer
4 Display
5 Overview of indicator lights ( p. 17)
6 Gear display ( p. 26)
- button
7
S04376-01
20
CONTROLS
6
6.21.2
Activation and test
Activating combination instrument
The combination instrument is activated when the ignition is switched
on.
Display test
To enable you to check that the display is functioning properly, all dis-
play segments light up briefly.
S04360-01
6.21.3
Setting the combination instrument
Condition
The motorcycle is stationary.
- Press and hold both buttons for 3 - 5 seconds.
The Setup menu is displayed.
Info
In the setup menu, all the indicators can be activated and
deactivated.
S04366-01
- Press the + button to select the desired indicator.
- Press the - button to activate or deactivate the selected indicator.
Info
An activated indicator flashes quickly.
A deactivated indicator flashes slowly.
- Press the + button repeatedly until the setup menu is closed.
S04362-01
Info
When the setup menu is closed, you can press the + or -
button to switch between the activated indicators.
6.21.4
Setting kilometers or miles
Info
If the unit is changed, the value is retained and converted accordingly.
Make the setting according to the country.
Condition
The motorcycle is stationary.
21
6
CONTROLS
- Press and hold both buttons for 3 - 5 seconds.
The Setup menu is displayed.
- Press the + button repeatedly until kmor mp flashes on the indica-
tor.
- Press the - button to change from km to mp or from mp to km.
- Press the + button.
The settings are adopted and the setup menu is closed.
S04361-01
6.21.5
Setting the clock
Condition
The motorcycle is stationary.
- Press the + or - button until the indicator CLK appears in the combi-
nation instrument.
- Press and hold the - button for 3-5 seconds.
The combination instrument switches to the clock setting
mode.
- Press the - button to select the 24 h display or 12 h display for the
clock.
- Confirm the selection using the + button.
The setting is adopted and the combination instrument
S04363-01
changes to the next menu item.
- Press the - button to set the hour.
- Confirm the selection using the + button.
The setting is adopted and the combination instrument
changes to the next menu item.
- Press the - button to set the minute.
- Confirm the selection using the + button.
The setting is adopted and the setting mode is closed.
S04367-01
6.21.6
Setting the service interval
Condition
The motorcycle is stationary.
- Press the + or - button repeatedly until SER is shown on the combi-
nation instrument.
- Press the - button repeatedly until the service interval display starts
flashing.
- Press the - button repeatedly until the desired service interval is
displayed.
Info
The indicator can be set within the range of 500 to 10,000.
S04375-01
- Press and hold the - button for 3-5 seconds until the indicator is no
longer flashing.
22
CONTROLS
6
6.21.7
Distance 1
- Press the + or - button repeatedly until TR1 is shown on the combi-
nation instrument.
TR1 shows the distance 1 since the last reset, such as between two refu-
eling stops.
Info
If the value of 9999.9 is exceeded, TR1 is automatically reset to
0.0.
S04369-01
Briefly press
Next display mode
the button
Briefly press
Next display mode
the button
Press the but-
TR1 is reset to 0.0.
ton for 2-3
seconds.
6.21.8
Distance 2
- Press the + or - button repeatedly until TR2 is shown on the combi-
nation instrument.
TR2 shows the distance 2 since the last reset, such as between two refu-
eling stops.
Info
If the value of 9999.9 is exceeded, TR2 is automatically reset to
0.0.
S04370-01
Briefly press
Next display mode
the button
Briefly press
Next display mode
the button
Press the but-
TR2 is reset to 0.0.
ton for 2-3
seconds.
6.21.9
Average speed 1
- Press the + or - button repeatedly until A1 is shown on the combina-
tion instrument.
A1 shows average speed 1 since the last reset.
Briefly press
Next display mode
the button
Briefly press
Next display mode
the button
Press the but-
A1 is reset to 0.0.
S04371-01
ton for 2-3
seconds.
23
6
CONTROLS
6.21.10
Average speed 2
- Press the + or - button repeatedly until A2 is shown on the combina-
tion instrument.
A2 shows average speed 2 since the last reset.
Briefly press
Next display mode
the button
Briefly press
Next display mode
the button
Press the but-
A2 is reset to 0.0.
S04372-01
ton for 2-3
seconds.
6.21.11
Riding time 1
- Press the + or - button repeatedly until T1 is shown on the combina-
tion instrument.
T1 shows riding time 1 since the last reset.
Briefly press
Next display mode
the button
Briefly press
Next display mode
the button
Press the but-
T1 is reset to 0.0.
S04373-01
ton for 2-3
seconds.
6.21.12
Riding time 2
- Press the + or - button repeatedly until T2 is shown on the combina-
tion instrument.
T2 shows riding time 2 since the last reset.
Briefly press
Next display mode
the button
Briefly press
Next display mode
the button
Press the but-
T2 is reset to 0.0.
S04374-01
ton for 2-3
seconds.
6.21.13
Service hour counter
- Press the + or - button repeatedly until ART is shown on the combi-
nation instrument.
ART shows the motorcycle's operating hours
S04365-01
24
CONTROLS
6
6.21.14
Clock
- Press the + or - button repeatedly until CLK is shown on the combi-
nation instrument.
CLK shows the time.
S04377-01
6.21.15
Service interval display
- Press the + or - button repeatedly until SER is shown on the combi-
nation instrument.
SER shows the remaining kilometers until the next service is due.
S04394-10
6.21.16
Tachometer
- Press the + or - button repeatedly until RPM is shown on the combi-
nation instrument.
Guideline
Speed per symbol approx.
8
1,000 rpm
88
3,000 rpm
888
4,000 rpm
8888
5,000 rpm
S04399-01
88888
7,000 rpm
888888
9,000 rpm
RPM shows the current engine speed.
Info
Before the first service, the tachometer always flashes with
a slow frequency (5 Hz) when the engine speed reaches
6500 rpm.
The tachometer flashes with a slow frequency (5 Hz) in the
following cases: The coolant temperature is lower than 35 °C
and the engine speed has reached 6500 rpm, or the recom-
mended shift speed of 8000 rpm has been reached.
The tachometer flashes with a fast frequency (10 Hz) when
the maximum engine speed is reached.
25
6
CONTROLS
6.21.17
Odometer
- Press the + or - button repeatedly until ODO is shown on the combi-
nation instrument.
ODO shows the motorcycle's total mileage.
S04379-01
6.21.18
Gear display
The gear display shows the engaged gear.
Info
The gear display is at the left of the display.
S04380-01
6.21.19
Service display
The service display is at the top left of the display.
Info
If the service display appears, a service is due. Contact an autho-
rized GASGAS Motorcycles workshop.
S04382-01
6.21.20
Distance fuel reserve
When the fuel level has reached the reserve mark, TR1 F appears on the
display, and the fuel level warning lamp 1 lights up.
This indicator can be closed by pressing the + or - button.
Info
This indicator shows the distance traveled since the beginning of
the fuel reserve.
When the indicator is closed, the fuel level warning lamp
remains lit.
S04395-10
After refueling, the display can be reset with the + or - button.
26
PREPARING FOR USE
7
7.1
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 Non-approved or non-recommended tires and wheels impact the handling characteristic.
- Only use tires/wheels approved by GASGAS Motorcycles with the corresponding speed index.
Warning
Danger of accidents New tires have reduced road grip.
The contact surface on new tires is not yet roughened.
- Run in new tires with moderate riding at alternating angles.
Running-in phase
200 km (124 mi)
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.
Info
When using your vehicle, 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. 62)
–
Adjust basic position of the hand brake lever. ( p. 65)
–
Adjust the basic position of the foot brake lever.
(
p. 70)
–
Get used to the handling characteristic of the motorcycle in a suitable area before making a longer trip. 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 trips that exceed your ability and experience.
–
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–
Run the engine in. ( p. 28)
27
7
PREPARING FOR USE
7.2
Running in the engine
– During the run-in phase, do not exceed the specified vehicle speed in the respective gear.
Guideline
During the first
1,000 km (620 mi)
Maximum speed per gear
First gear
45 km/h (28 mph)
Second gear
65 km/h (40.4 mph)
Third gear
85 km/h (52.8 mph)
Fourth gear
105 km/h (65.2 mph)
Fifth gear
120 km/h (74.6 mph)
Sixth gear
130 km/h (80.8 mph)
– Avoid fully opening the throttle!
7.3
Loading the vehicle
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
The total weight consists of: operational motorcycle with a full tank, rider and, if necessary, a passenger with pro-
tective clothing and helmet, and, if necessary, mounted luggage.
- Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Danger of accidents Improper mounting of cases, tank rucksacks or other luggage impairs the handling charac-
teristics.
Luggage mounted incorrectly can slip while the vehicle is in motion.
- Mount and secure all luggage according to the manufacturer's instructions.
- Check that your luggage is fixed properly at regular intervals.
Warning
Danger of accidents Carrying luggage alters handling characteristics at high speed.
- Adapt your speed to your payload.
- Ride more slowly if your motorcycle is loaded with cases or other luggage.
Maximum speed with baggage
130 km/h (80.8 mph)
Warning
Danger of accidents The luggage system will be damaged if it is overloaded.
- Read the manufacturer information on maximum payload when mounting cases.
Warning
Danger of accidents Luggage which has slipped impairs visibility.
If the tail light is covered, you are less visible to traffic behind you, especially when it is dark.
- Check that your luggage is fixed properly at regular intervals.
Warning
Danger of accidents A high payload alters the handling characteristic and increases the stopping distance.
- Adapt your speed to your payload.
28
PREPARING FOR USE
7
Warning
Fire hazard The hot exhaust system may burn luggage.
- Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system.
- If luggage is carried, ensure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight
distribution between the front and rear wheels.
- Do not exceed the maximum permissible weight and maximum permissible axle loads.
Guideline
Maximum permissible overall weight
350 kg (772 lb.)
Maximum permissible front axle load
150 kg (331 lb.)
Maximum permissible rear axle load
200 kg (441 lb.)
29
8
RIDING INSTRUCTIONS
8.1
Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is roadworthy.
The vehicle must be in perfect technical condition when it is being operated.
- Check the engine oil level. ( p. 102)
- Check the front brake fluid level. ( p. 66)
- Check the rear brake fluid level. ( p. 71)
- Check that the brake linings of the front brake are secured.
(
p. 67)
– Check that the brake linings of the rear brake are secured. ( p. 73)
- Check that the brake system is functioning properly.
- Check the coolant level. ( p. 95)
H02217-01
- Check the chain for dirt. ( p. 55)
- Check the chain tension. ( p. 56)
- Check the tire condition. ( p. 81)
- Check tire pressure. ( p. 82)
- Check the settings of all controls and ensure that they can be oper-
ated smoothly.
- Check that the electrical system is functioning properly.
- Check that luggage is properly secured.
- Sit on the motorcycle and check the rear mirror setting.
- Check the fuel level.
8.2
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.
Caution
Danger of accidents Electronic components and safety devices will be damaged if the 12-V battery is discharged
or missing.
If the 12-V battery is discharged or defective, malfunctions in the vehicle electronics can occur, especially when
starting.
- Never operate the vehicle with a discharged 12-V battery or without a 12-V battery.
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.
30
RIDING INSTRUCTIONS
8
– Turn the emergency OFF switch to the position
– Switch on the ignition by turning the ignition key to the position
Guideline
To avoid malfunctions in the control unit communication, do not
switch the ignition off and on in rapid succession.
After you switch on the ignition, you can hear the fuel pump
operating for about two seconds. The function check of the
combination instrument is run at the same time.
B00103-10
The ABS warning lamp lights up and goes out again after start-
ing off.
- Shift the transmission to neutral position.
Green idle indicator lamp N lights up.
- Press start button
Info
Do not press the start button until the combination instru-
ment function check has finished.
Do not open the throttle to start.
If the starting attempt is unsuccessful, wait for 15 seconds
before making another attempt at starting.
After 6 unsuccessful starting attempts, do not try again, and
check the vehicle for other malfunctions instead.
This motorcycle is equipped with a safety starting system.
You can only start the engine if the transmission is in neutral
or if the clutch lever is pulled when a gear is engaged. If the
side stand is folded out and you shift into gear and release
the clutch lever, the engine stops.
- Take the weight off the side stand and swing it back up with your
foot as far as it will go.
Switching off the ABS
GASGAS Motorcycles recommends riding with ABS at all times. How-
ever, situations may arise in which ABS is not advantageous.
Condition
The motorcycle is stationary.
Riding mode SPORT - direct response
Vehicle speed before stopping: ≥ 5 km/h (≥ 3.1 mph)
Note
Voiding of the government approval for road use and the
insurance coverage If the ABS is switched off completely,
the vehicle's approval for road use is invalidated.
S04356-10
- Only operate the vehicle in closed-off areas remote
from public road traffic if the ABS is switched off com-
pletely.
- Press and hold the button 1 for 3 - 5 seconds.
The ABS warning lamp lights up; the ABS is deactivated.
31
8
RIDING INSTRUCTIONS
8.3
Starting off
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
8.4
Shifting, riding
Warning
Danger of accidents Abrupt load alterations can cause the vehicle to get out of control.
- Avoid abrupt load alterations and sudden braking actions.
- Adapt your speed to the road conditions.
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.
Warning
Danger of accidents An incorrect ignition key position causes malfunctions.
- Do not change the ignition key position while driving.
Warning
Danger of accidents Adjustments to the vehicle distract attention from traffic activity.
- Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injury The passenger may fall from the motorcycle if they conduct themselves incorrectly.
- Ensure that the passenger sits correctly on the passenger seat, places his or her feet on the passenger foot
pegs and holds on to the rider or the grab handles.
- Note the regulations governing the minimum age of passengers in your country.
Warning
Danger of accidents A risky riding style constitutes a major risk.
- Comply with traffic regulations and ride defensively and with foresight to detect sources of danger as early as
possible.
Warning
Danger of accidents Cold tires have reduced road grip.
- Ride the first miles carefully on every journey at moderate speed until the tires reach operating temperature.
Warning
Danger of accidents New tires have reduced road grip.
The contact surface on new tires is not yet roughened.
- Run in new tires with moderate riding at alternating angles.
Running-in phase
200 km (124 mi)
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
The total weight consists of: operational motorcycle with a full tank, rider and, if necessary, a passenger with pro-
tective clothing and helmet, and, if necessary, mounted luggage.
- Do not exceed the maximum permissible overall weight or the axle loads.
32
RIDING INSTRUCTIONS
8
Warning
Danger of accidents Improper mounting of cases, tank rucksacks or other luggage impairs the handling charac-
teristics.
Luggage mounted incorrectly can slip while the vehicle is in motion.
- Mount and secure all luggage according to the manufacturer's instructions.
- Check that your luggage is fixed properly at regular intervals.
Warning
Danger of accidents A fall can damage the vehicle more seriously than it may first appear.
- Check the vehicle after a fall as you do when preparing for use.
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
Engine failure Overheating damages the engine.
- If the coolant temperature warning is displayed, stop immediately and take care not to endanger yourself or other traf-
fic participants in the process.
- Allow the engine and cooling system to cool down.
- Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state.
Info
If unusual noises occur while riding, stop safely immediately, switch off the engine, and contact an authorized GAS-
GAS Motorcycles workshop.
- Shift into a higher gear when conditions allow (incline, road situa-
tion, etc.).
- Release the throttle while simultaneously pulling the clutch lever,
shift into the next gear, release the clutch lever, and open the throt-
tle.
Info
The gear positions can be seen in the figure. The neutral or
idle position is between the first and second gears. First gear
401950-11
is used for starting off or for steep inclines.
- 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.
- Accelerate only up to a speed suitable for the road surface and
weather conditions. Particularly in bends, do not shift, and accel-
erate very carefully.
- Brake if necessary and close the throttle at the same time in order
to shift down.
- Pull clutch lever and shift into a lower gear, release the clutch lever
slowly, and open the throttle or shift again.
- If the engine stalls (e.g. at an intersection), just pull the clutch lever
and press the start button. The transmission must not be shifted
into neutral.
- Switch off the engine if you are likely to be running at idle speed or
stationary for a long time.
33
8
RIDING INSTRUCTIONS
- 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.
- If the oil pressure warning lamp lights up, stop immediately, tak-
ing care not to endanger yourself or other road users in the process,
and switch off the engine. Contact an authorized GASGAS Motorcy-
cles workshop.
- If the malfunction indicator lamp lights up during a trip, please
contact an authorized GASGAS Motorcycles workshop as soon as
possible.
- Quickshifter + allows you to shift up in the speed range shown with-
out pulling the clutch lever.
Guideline
Minimum speed before gear change
First gear to second gear
30 km/h (18.6 mph)
Second gear to third gear
40 km/h (24.9 mph)
Third gear to fourth gear
45 km/h (28 mph)
Fourth gear to fifth gear
50 km/h (31.1 mph)
Fifth gear to sixth gear
55 km/h (34.2 mph)
– Quickshifter + allows you to shift down in the speed range shown
without pulling the clutch lever.
Guideline
Maximum speed before gear change
Sixth gear to fifth gear
165 km/h (102.5 mph)
Fifth gear to fourth gear
145 km/h (90.1 mph)
Fourth gear to third gear
120 km/h (74.6 mph)
Third gear to second gear
90 km/h (55.9 mph)
Second gear to first gear
60 km/h (37.3 mph)
8.5
Quickshifter +
If the quickshifter + is activated, you can shift up and down without actu-
ating the clutch.
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.
V01270-10
34
RIDING INSTRUCTIONS
8
8.6
Motorcycle traction control
The motorcycle traction control (cornering MTC) lowers the engine
torque in case of loss of traction in the rear wheel. Depending on the
riding mode, different amounts of slip are allowed when the traction
control is activated.
Info
When motorcycle traction control is switched off, the rear wheel
may spin during strong acceleration and on surfaces with low
grip, resulting in a risk of crashing.
After the ignition is switched on, motorcycle traction control is
H02885-01
enabled again.
The motorcycle traction control MTC is switched on and off on the left
combination switch using the TC button.
Info
When the motorcycle traction control is active, the TC indica-
tor lamp flashes.
When motorcycle traction control is switched off, the TC indica-
tor lamp lights up.
8.7
Braking
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.
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 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 Higher total weight increases the stopping distance.
- Take the longer stopping distance into account when carrying a passenger or luggage with you.
Warning
Danger of accidents Salt on the roads impairs the brake system.
- Brake carefully several times to remove salt from the brake linings and the brake discs.
Warning
Danger of accidents ABS may increase the stopping distance in certain situations.
- Adjust application of the brakes to the respective riding situation and riding surface conditions.
35
8
RIDING INSTRUCTIONS
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
The ABS effectiveness is only ensured if it is switched on.
- Leave the ABS switched on in order to benefit from the protective effect.
Warning
Danger of accidents The rear wheel can lock due to the engine braking effect.
- Pull in the clutch, if you perform emergency or full braking, or if you brake on a slippery ground.
- To brake release the throttle and apply the front and rear brakes at the same time.
Info
When the ABS is enabled, you can achieve maximum braking power even on low grip surfaces such as sandy,
wet, or slippery terrain without the danger of the wheels locking.
Warning
Danger of accidents Banked or laterally sloping ground reduces the maximum possible delay.
- If possible finish braking before going into a bend.
- 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.
8.8
Stopping, parking
Warning
Risk of injury People who act without authorization endanger themselves and others.
- Do not leave the vehicle unattended if the engine is running.
- Protect the vehicle against access by unauthorized persons.
- Lock the steering and remove the ignition key if you leave the vehicle unattended.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
- Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before
the vehicle parts have cooled down.
- Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
- Park the vehicle on a firm and level surface.
- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
- Do not park the vehicle near to materials which are highly flammable or explosive.
- Allow the vehicle to cool down before covering it.
- Apply the brakes on the motorcycle.
- Shift the transmission to neutral position.
36
RIDING INSTRUCTIONS
8
– Switch off the ignition by turning the ignition key to the position
Info
If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition
lock, power continues to flow to most power consumers. This discharges the 12-V battery. You should therefore
always switch off the engine with the ignition lock - the emergency OFF switch is intended for emergencies
only.
- Park the motorcycle on a firm surface.
- Swing side stand forward with your foot as far as it will go and lean the vehicle on it.
- Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to the position and turn-
ing it to the position . To make the steering lock engage more easily, move the handlebar a little to the left and right.
Remove the ignition key.
8.9
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
- Do not park the vehicle near to materials which are highly flammable or explosive.
- Allow the vehicle to cool down before covering it.
- Switch off the engine and remove the ignition key.
- Use tension belts or other suitable devices to secure the motorcycle
against accidents or falling over.
401448-01
8.10
Towing in the event of a breakdown
Note
Danger of damage Towing away using a towing vehicle is not an appropriate vehicle recovery method.
Damage to the drive train or transmission may occur during towing.
- Do not use towing equipment where the wheels of the broken down vehicle remain on the road and rotate as it is
towed.
- Always transport a broken down vehicle on a trailer or on the loading area of a transport vehicle.
37
8
RIDING INSTRUCTIONS
- Ensure that the broken down vehicle is properly secured on the
trailer or transport vehicle.
- Observe local regulations for the recovery of broken down vehicles.
H04927-01
8.11
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.
38
RIDING INSTRUCTIONS
8
– Switch off the engine.
- Open the fuel tank filler cap. ( p. 19)
- Fill the fuel tank with fuel up to level A.
Guideline
20 mm (0.79 in)
Dimension A
Fuel tank capacity,
13.3 l
Super unleaded (ROZ
approx.
(3.51 US gal)
95) ( p. 124)
– Close the fuel tank filler cap. ( p. 20)
S03345-10
39
9
SERVICE SCHEDULE
9.1
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.
9.2
Service schedule
every 48 months
every 24 months
every 12 months
every 30,000 km (18,600 mi)
every 20,000 km (12,400 mi)
every 10,000 km (6,200 mi)
after 1,000 km (620 mi)
Read out the fault memory using the GASGAS Motorcycles diagnostics tool.
○
●
●
●
●
●
●
Program the shift shaft sensor.
○
●
●
●
●
●
●
Check that the electrical system is functioning properly.
○
●
●
●
●
●
●
Check that the brake linings of the front brake are secured. ( p. 67)
○
●
●
●
●
●
●
Check that the brake linings of the rear brake are secured. ( p. 73)
○
●
●
●
●
●
●
Check the brake discs. ( p. 65)
○
●
●
●
●
●
●
Check the brake lines for damage and tightness.
○
●
●
●
●
●
●
Check the front brake fluid level. ( p. 66)
○
●
●
●
●
Change the front brake fluid.
●
●
Check the rear brake fluid level. ( p. 71)
○
●
●
●
●
Change the rear brake fluid.
●
●
Check/correct the fluid level of hydraulic clutch. ( p. 62)
●
●
●
●
Change the hydraulic clutch fluid.
●
●
Check the free travel of the foot brake lever. ( p. 70)
○
●
●
●
●
●
●
Change the engine oil and the oil filter, clean the oil screens.
(
p. 102)
○
●
●
●
●
●
●
Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves for crack-
●
●
●
●
●
●
ing, tightness, and correct routing.
Empty the drainage hoses.
○
●
●
●
●
●
●
Check the cables for damage and for routing without kinks.
●
●
●
●
●
●
Check the frame.
●
Check the link fork.
●
Check the fork bearing for play.
●
●
●
Check the steering head bearing for play.
○
●
●
●
●
●
●
Check the wheel bearing for play.
○
●
●
●
●
●
●
Check the shock absorber and fork for leaks. Perform a fork service and shock
○
●
●
●
●
●
●
absorber service as needed and depending on how the vehicle is used.
Check the tire condition. ( p. 81)
○
●
●
●
●
●
●
Check tire pressure. ( p. 82)
○
●
●
●
●
●
●
Check the rim run-out.
○
●
●
●
●
●
●
Retighten the spokes.
○
Check the spoke tension. ( p. 82)
○
●
●
●
●
●
●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 58)
●
●
●
●
●
●
40
SERVICE SCHEDULE
9
every 48 months
every 24 months
every 12 months
every 30,000 km (18,600 mi)
every 20,000 km (12,400 mi)
every 10,000 km (6,200 mi)
after 1,000 km (620 mi)
Check the chain tension. ( p. 56)
○
●
●
●
●
●
●
Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth
○
●
●
●
●
●
●
operation.
Change the spark plugs.
●
Check the valve clearance.
●
●
●
Change the air filter. Clean the air filter box.
●
●
●
Change the fuel screen.
○
Change the fuel screen, and check the fuel pressure.
●
●
●
●
●
●
Check the headlight setting. ( p. 92)
○
●
●
●
Check the tightness of the safety-relevant screws and nuts which are easily accessi-
○
●
●
●
●
●
●
ble.
Clean the dust boots of the fork legs. ( p. 48)
●
●
●
Check that the radiator fan is functioning properly.
○
●
●
●
●
●
●
Check the antifreeze and coolant level. ( p. 94)
○
●
●
●
●
●
Change the coolant.
(
p. 98)
●
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 diagnos-
○
●
●
●
●
●
●
tics tool.
Set the service interval. ( p. 22)
○
●
●
●
●
●
●
Make a service entry in GASGAS Motorcycles Dealer.net.
○
●
●
●
●
●
●
○ One-time interval
● Periodic interval
41
10
TUNING THE CHASSIS
10.1
Fork/shock absorber
The fork and the shock absorber offer many options for adapting the
chassis to the riding style and the payload.
Info
The recommendations for the suspension setting are shown
in table 1. The table is located on the underside of the front
rider's seat.
These adjustments should be understood as a guideline and should
always be the basis for one’s own personal suspension setting. Do not
V02711-10
change the adjustments at random, as otherwise the riding characteris-
tics could deteriorate, particularly at high speeds.
10.2
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
- Turn white adjusting screw 1 clockwise as far as it will go.
Info
The adjusting screw 1 is located at the upper end of the
left fork leg.
The compression damping is located in left fork leg COMP
(white adjusting screw). The rebound damping is located in
right fork leg REB (red adjusting screw).
S04313-10
- Turn counterclockwise by the number of clicks corresponding to the
fork type.
Guideline
Compression damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping during compression.
10.3
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
42
TUNING THE CHASSIS
10
– Turn red adjusting screw 1 clockwise as far as it will go.
Info
Adjusting screw 1 is located at the upper end of the right
fork leg.
The rebound damping is located in right fork leg REB (red
adjusting screw). The compression damping is located in left
fork leg COMP (white adjusting screw).
S04313-11
- Turn counterclockwise by the number of clicks corresponding to the
fork type.
Guideline
Rebound damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Turn clockwise to increase the damping; turn counterclock-
wise to reduce damping when the shock absorber rebounds.
10.4
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, for example, has an effect when riding over an asphalt edge: the rear wheel suspen-
sion 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.
10.5
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.
43
10
TUNING THE CHASSIS
- Turn adjusting screw 1 clockwise with a screwdriver as far as the
last perceptible click.
Info
Do not loosen fitting 2!
- Turn counterclockwise by the number of clicks corresponding to the
shock absorber type.
Guideline
V02712-10
Low-speed compression damping
Comfort
25 clicks
Standard
20 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
10.6
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 fast compression of the shock absorber.
- Turn adjusting screw 1 all the way clockwise with a socket wrench.
Info
Do not loosen fitting 2!
- Turn counterclockwise by the number of turns corresponding to the
shock absorber type.
Guideline
High-speed compression damping
V02712-11
Comfort
2.5 turns
Standard
2 turns
Sport
1 turn
Full payload
1 turn
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
44
TUNING THE CHASSIS
10
10.7
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
Rebound damping
Comfort
23 clicks
Standard
20 clicks
Sport
10 clicks
V02713-10
Full payload
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
10.8
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 can be mounted in 2 different positions. This allows the
handlebar to be mounted in the most comfortable position for the rider.
S02163-10
10.9
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.
45
10
TUNING THE CHASSIS
-
Remove screws 1. Take off the handlebar clamp. Remove the han-
dlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
-
Remove screws 2. Remove handlebar support 3.
–
Position rubber bushings 4 and push through nuts 5 from
below.
-
Place the handlebar support in the required position.
Info
The handlebar supports are longer and higher on one side.
Position the left and right handlebar supports evenly.
-
Mount and tighten screws 2.
Guideline
Screw, handlebar
M10
45 Nm (33.2 lbf ft)
S02164-10
support
Loctite®243™
–
Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
-
Position the handlebar clamp.
–
Mount screws 1, but do not tighten yet.
Handlebar clamp marking A is aligned with centre line B of
the handlebar scale.
S04388-10
-
First bolt the handlebar clamp with screws 1 onto the longer,
higher side of the handlebar supports so that both parts touch.
-
Tighten screws 1 evenly.
Guideline
Screw, handlebar
M8
20 Nm (14.8 lbf ft)
clamp
46
SERVICE WORK ON THE CHASSIS
11
11.1
Raising the motorcycle with rear lifting gear
Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.
- Insert the adapter in a suitable lifting gear and screw into the link
fork on both sides.
- Position the motorcycle vertically, align the lifting gear, and raise the
motorcycle.
402346-01
11.2
Taking the motorcycle off of the rear wheel stand
Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.
- Secure the motorcycle against falling over.
- Remove the rear wheel stand and lean the vehicle on the side stand.
11.3
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.
- Use the motor guard underneath the motor to raise the vehicle.
Neither wheel is in contact with the ground.
- Secure the motorcycle against falling over.
401942-01
47
11
SERVICE WORK ON THE CHASSIS
11.4
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 and rest it on side
stand 1.
- Remove the lift stand.
401943-10
11.5
Cleaning the dust boots of the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 47)
- Remove fork protector. ( p. 49)
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.
S03371-10
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 inner fork tubes of both fork legs.
Universal oil spray ( p. 125)
- Press the dust boots back into the installation position.
- Remove the excess oil.
Finishing work
- Install the fork protector. ( p. 49)
- Remove the motorcycle from the lift stand. ( p. 48)
48
SERVICE WORK ON THE CHASSIS
11
11.6
Removing fork protector
- Remove screws 1 and take off the clamp.
- Remove screws 2 on the left fork leg. Take off the fork protector.
- Remove screws 2 on the right fork leg. Take off the fork protector.
V02714-10
11.7
Installing the fork protector
- Position the left fork protector. Mount and tighten screws 1.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Position brake line, wiring harness, and clamp. Mount and tighten
screws 2.
- Position the right fork protector. Mount and tighten screws 1.
Guideline
V02714-11
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
11.8
Bleeding the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 47)
Main work
- Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
Info
Carry out this operation on both fork legs.
S04313-12
Finishing work
- Remove the motorcycle from the lift stand. ( p. 48)
49
11
SERVICE WORK ON THE CHASSIS
11.9
Removing the seat
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
Main work
- Pull on loop 1 and raise the rear of the seat.
- Pull the seat back and lift it off.
V02707-10
Finishing work
- Close the fuel tank filler cap. ( p. 20)
11.10
Mounting the seat
- Hook the seat using holding lugs 1 on to bushings 2, lower the
seat at the rear and push it forward.
- Push locking pin 3 into lock housing 4 and push the back of the
seat down until the locking pin locks in place with an audible click.
- Check that the seat is correctly mounted.
V02715-10
11.11
Removing the tool set
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
50
SERVICE WORK ON THE CHASSIS
11
Main work
- Take the hexagon socket wrench for loosening and mounting
screws 1 from bracket A on the underside of the seat.
- Remove screws 1.
- Take off the left side cover.
V02730-10
- Open the tool set compartment and take out tool set 2.
V02731-10
11.12
Storing the tool set
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
51
11
SERVICE WORK ON THE CHASSIS
Main work
- Remove screws 1.
Info
A tool for removing and mounting these screws is located in
holder A on the underside of the seat.
- Take off the left side cover.
V02730-10
- Open the tool set compartment and store tool set 2.
- Close the tool set compartment.
- Position the left side cover.
- Mount and tighten screws 1.
Guideline
Screw, radiator shield
M6x20
4.5 Nm (3.32 lbf ft)
– Make sure the tool is reinserted in holder A.
V02731-10
Finishing work
- Mount the seat. ( p. 50)
11.13
Take off the side cover
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
52
SERVICE WORK ON THE CHASSIS
11
Main work
- Remove screws 1.
- Pull the left side cover out from the rubber bushing in area A.
- Pull off the left side cover upwards from the special screw in
area B.
- Take off the left side cover from upwards.
- Repeat these steps on the opposite side.
V02733-10
11.14
Mounting side cover
Main work
- Position the left side cover with holding lug 1 on special screw 2
and push downwards.
- Press the left side cover into rubber bushing 4 with pin 3.
V02734-10
- Mount and tighten screws 5.
Guideline
Screw, radiator shield
M6x20
4.5 Nm (3.32 lbf ft)
– Repeat these steps on the opposite side.
V02735-11
53
11
SERVICE WORK ON THE CHASSIS
Finishing work
- Mount the seat. ( p. 50)
11.15
Removing the front fender
Preparatory work
- Remove the headlight mask with the headlight. ( p. 89)
Main work
- Remove screws 1.
- Remove screws 2 and take off the fender.
S03291-10
11.16
Installing the front fender
Main work
- Position the front fender. Mount and tighten screws 1.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Mount and tighten screws 2.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
S03292-10
chassis
Finishing work
- Install the headlight mask with the headlight. ( p. 90)
- Check the headlight setting. ( p. 92)
11.17
Removing the air filter
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
Main work
- Remove screws 1.
- Remove the upper part of the air filter box 2.
V02718-10
54
SERVICE WORK ON THE CHASSIS
11
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.
- Remove air filter 3.
V02719-10
11.18
Installing the air filter
Main work
- Clean the air filter box.
- Mount air filter 1.
Info
The air filter must lie flush against the air filter box along the
entire sealing surface A.
If the air filter is not mounted correctly, dust and dirt may
enter the engine and result in damage.
V02719-11
- Hook air filter box top 2 into the front of the air filter box and
swing down.
- Mount and tighten screws 3.
Guideline
Screw, upper part of
M6
2 Nm (1.5 lbf ft)
the air filter box
V02718-11
Finishing work
- Mount the seat. ( p. 50)
11.19
Checking the chain for dirt
- Check the chain for heavy soiling.
» If the chain is very dirty:
- Clean the chain. ( p. 56)
400678-01
55
11
SERVICE WORK ON THE CHASSIS
11.20
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. 47)
Main work
- Rinse off loose dirt with a soft jet of water.
- Remove old grease residue with chain cleaner.
Chain cleaner ( p. 125)
- After drying, apply chain spray.
Off-road chain spray ( p. 125)
400725-01
Finishing work
- Remove the motorcycle from the lift stand. ( p. 48)
11.21
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.
56
SERVICE WORK ON THE CHASSIS
11
– Raise the motorcycle with the rear lifting gear. ( p. 47)
Info
The check is also possible when the motorcycle is resting on
the side stand.
- Shift the transmission to neutral position.
- Push the chain upward at a distance B from the chain sliding
guard and determine chain tension A.
Info
The top part of chain C must be taut.
Chain wear is not always even. Repeat this measurement at
different chain positions.
Chain tension
5 mm (0.2 in)
Distance to chain sliding guard
30 mm (1.18 in)
» If the chain tension does not meet the specification:
- Adjust the chain tension. ( p. 57)
S02193-10
- Take the motorcycle off of the rear wheel stand. ( p. 47)
11.22
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
- Check the chain tension. ( p. 56)
57
11
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
5 mm (0.2 in)
Turn the adjusting screws 3 on the left and right so that the
markings on the left and right chain adjusters 4 are in the same
position relative to the reference marks A. The rear wheel is
then correctly aligned.
Info
The top chain section must be taut.
Chain wear is not always even. Repeat this measurement at
different chain positions.
- Tighten nuts 2.
V00509-10
- Make sure that chain adjusters 4 are fitted correctly on adjusting
screws 3.
- Tighten nut 1.
Guideline
Nut, rear wheel spindle
M25x1.5
90 Nm (66.4 lbf ft)
11.23
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 47)
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.
100132-10
58
SERVICE WORK ON THE CHASSIS
11
–
Pull on the top section of the chain with the specified weight A.
Guideline
Weight of chain wear measure-
15 kg (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 an old, worn rear
sprocket or engine sprocket.
-
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:
- Replace the chain sliding guard.
-
Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
- Tighten screws on the chain sliding guard.
Guideline
Screw, chain
M6
10 Nm (7.4 lbf ft)
sliding guard
Loctite®243™
S02194-01
59
11
SERVICE WORK ON THE CHASSIS
- Check the chain sliding piece for wear.
» If the lower edge of the chain pins is in line with or below the
chain sliding piece:
- Change the chain sliding piece.
- Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
- Tighten screw on the chain sliding piece.
Guideline
Screw, chain
M8
15 Nm (11.1 lbf ft)
sliding piece
Loctite®243™
S02195-01
- 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.
400985-01
- Check that the chain guide is firmly seated.
» If the chain guide is loose:
- Tighten the screws on the chain guide.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
101068-01
Finishing work
- Remove the motorcycle from the lift stand. ( p. 48)
60
SERVICE WORK ON THE CHASSIS
11
11.24
Adjusting chain guide
- Remove screws 1 and 2. Take off the chain guide.
Condition
Number of teeth: ≤ 44 teeth
- Insert nut 3 in hole A. Position the chain guide.
- Mount and tighten screws 1 and 2.
Guideline
Screw, chain guide
M6
10 Nm (7.4 lbf ft)
Condition
Number of teeth: ≥ 45 teeth
- Insert nut 3 in hole B. Position the chain guide.
- Mount and tighten screws 1 and 2.
Guideline
Screw, chain guide
M6
10 Nm (7.4 lbf ft)
S02196-10
11.25
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 or worn:
- Change the rubber grip.
- Check that screw 1 is firmly seated.
Guideline
Screw, fixed grip
M4
5 Nm (3.7 lbf ft)
Loctite®243™
Diamond A must be located at the top.
W00116-10
61
11
SERVICE WORK ON THE CHASSIS
11.26
Adjusting the basic position of the clutch lever
- Adjust basic position of the clutch lever to your hand size by turning
adjusting screw 1.
Info
Do not make any adjustments while riding.
Push the clutch lever forward and turn the adjusting wheel.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
V02720-10
- When adjusting the clutch lever, make sure to leave a minimum
clearance to other parts of the vehicle.
Guideline
Minimum clearance
5 mm (0.2 in)
11.27
Checking/correcting the fluid level of hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Note
Environmental 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.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
- Move the clutch fluid reservoir mounted on the handlebar to a hori-
zontal position.
62
SERVICE WORK ON THE CHASSIS
11
– 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:
- Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 123)
V02721-10
- Position the cover with the membrane. Mount and tighten the
screws.
Info
Clean up the overflowed or spilled brake fluid immediately
with water.
11.28
Removing engine guard
- Remove screws 1 on both sides.
- Pull the engine guard forward out of the holders and remove it.
V02695-10
11.29
Installing the engine guard
- Slide the engine guard into holders 1 at the rear.
- Position the engine guard. Mount and tighten screws 2 on both
sides.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
V02695-11
63
12
BRAKE SYSTEM
12.1
Anti-lock braking system (ABS)
The ABS module 1, consisting of a hydraulic unit, an ABS control unit,
and a return pump, is located under the seat. One wheel speed sen-
sor 2 is located in each case on the front and the rear wheel.
Warning
Danger of accidents Changes to the vehicle impair the func-
tion of the ABS.
- Do not make any changes to the suspension travel.
- Only use spare parts on the brake system which have been
approved and recommended by GASGAS Motorcycles.
- Only use tires/wheels approved by GASGAS Motorcycles
with the corresponding speed index.
- Maintain the specified tire pressure.
- Ensure that service work and repairs are performed profes-
sionally. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
ABS is a safety system that prevents locking of the wheels when driving
straight ahead without the influence of lateral forces.
Warning
Danger of accidents Driving aids can reduce the probability of
a fall only within physical limits.
It is not always possible to compensate for extreme riding sit-
uations, for example with luggage loaded with a high center
of gravity, varying road surfaces, steep descents or full braking
H01077-10
without disengaging the gear.
- Adapt your riding style to the road conditions and your driv-
ing ability.
Warning
Danger of accidents An incorrectly selected ABS mode makes
control of the vehicle considerably more difficult.
The ABS modes are each only suitable for certain conditions.
- Always select an ABS mode that is compatible with the sur-
face of the ground.
ABS has two operating modes: the Street and Offroad ABS modes.
In ABS mode Street, the ABS controls both wheels.
In ABS mode Offroad, the ABS only controls the front wheel. There is no
ABS control on the rear wheel. The ABS warning lamp 3 flashes slowly
to remind you that the Offroad ABS mode is enabled.
Info
In the Offroad ABS mode, the rear wheel may lock and there is a
risk of falling.
ABS mode Offroad is only available in riding mode SPORT.
The ABS operates with two independent brake circuits (front and rear
brakes). When the ABS control unit detects a locking tendency in a
wheel, ABS begins regulating the brake pressure. The control function
causes a slight pulsing of the hand and foot brake levers.
64
BRAKE SYSTEM
12
The ABS warning lamp 3 must light up after the ignition is switched
on and go out after starting off. If it does not go out after starting off
or if it lights up while riding, this indicates a malfunction in the ABS. In
this case, the ABS is no longer enabled and the wheels may lock during
braking. The brake system itself stays functional; only ABS control is not
available.
The ABS warning lamp may also light up if the rotating speeds of the
front and rear wheels differ greatly under extreme riding conditions, for
example when making "wheelies" or if the rear wheel spins. This causes
the ABS to switch off.
To reactivate the ABS, the vehicle must be stopped and the ignition
switched off. The ABS is reactivated when the vehicle is switched on
again. The ABS warning lamp goes out when you start off.
Info
The motorcycle has an additional 5-D sensor. The 5-D sensor
makes the ABS control dependent on the angle of inclination and
pitch. This can prevent locking and slipping of the wheels during
braking when the vehicle is inclined (when cornering) within the
physical limitations.
12.2
Adjusting the basic position of the hand brake lever
- Adjust the basic position of the hand brake lever to your hand size
by turning adjusting wheel 1.
Info
Do not make any adjustments while riding.
Push the hand brake lever forward and turn the adjusting
wheel.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
V02722-10
- When adjusting the brake lever, maintain a minimum clearance to
other parts of the vehicle.
Guideline
Minimum clearance
5 mm (0.2 in)
12.3
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 will reduce the thickness of the brake disc at contact
surface 1 of the brake linings.
Brake discs - wear limit
front
4.5 mm (0.177 in)
400406-10
rear
4.5 mm (0.177 in)
65
12
BRAKE SYSTEM
» If the brake disc thickness is less than the specified value.
- Change the 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 brake disc.
12.4
Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Move the brake reservoir mounted on the handlebar to a horizontal
position.
- Check the brake fluid level in the viewer.
» If the brake fluid level has dropped below the marking A:
- Add the front brake fluid.
(
p. 66)
V02723-10
12.5
Adding the 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 causes skin irritation.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
66
BRAKE SYSTEM
12
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note
Environmental 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
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
- Check that the brake linings of the front brake are secured.
(
p. 67)
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
V02724-10
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 123)
- Position the cover with the membrane. Mount and tighten the
screws.
Info
Clean up the overflowed or spilled brake fluid immediately
with water.
12.6
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.)
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a conse-
quence, the braking effect is greatly reduced and the brake discs are destroyed.
- Check the brake linings regularly.
67
12
BRAKE SYSTEM
- 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. 68)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the brake linings of the front brake.
(
p. 68)
B01959-01
- Check that the brake linings are secured.
» If the brake linings are not secured correctly:
- Secure brake linings, replace with new parts if necessary.
12.7
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 causes skin irritation.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Warning
Danger of 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.
68
BRAKE SYSTEM
12
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
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Only use clean brake fluid from a sealed container.
- Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
- Remove screws 1.
- Take off cover 2 with membrane 3.
- 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
V02724-11
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake pistons.
- Remove cotter pin 4, remove pin 5 toward the right by striking
it, and remove the brake linings.
- Clean the brake caliper and the brake caliper bracket.
400418-11
- Check that spring plate 6 in the brake caliper and brake pad slid-
ing plate 7 in the brake caliper bracket are seated correctly.
- Insert the new brake linings, insert the pin, and mount the cotter
pins.
Guideline
Always change the brake linings in pairs.
- Operate the hand brake lever repeatedly until the brake linings are
in contact with the brake disc and there is a pressure point.
400418-10
- Correct the brake fluid level to level A.
Guideline
5 mm (0.2 in)
Dimension A
Brake fluid DOT 4 / DOT 5.1 ( p. 123)
- Position the cover with the membrane. Mount and tighten the
screws.
V02724-12
69
12
BRAKE SYSTEM
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
12.8
Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
- 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)
Info
You will know that contact has been made with the foot
brake cylinder piston when there is increased resistance
402027-10
when you activate the foot brake lever.
» If the free travel does not meet specifications:
- Adjust the basic position of the foot brake lever.
(
p. 70)
12.9
Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
70
BRAKE SYSTEM
12
– Loosen fittings 3 on foot brake cylinder 4.
- To adjust the basic position of the foot brake lever to individual
requirements, loosen nut 1 and turn screw 2 accordingly.
Info
The range of adjustment is limited. The screw must be
screwed into the footrest bracket by at least four turns.
- Position foot brake cylinder 4 so that the foot brake lever has the
necessary free travel.
- Mount and tighten fittings 3.
Guideline
Screw connection, foot
M6
10 Nm (7.4 lbf ft)
brake cylinder
- Check the free travel of the foot brake lever. ( p. 70)
- Tighten nut 1.
V02725-10
12.10
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 Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Stand the vehicle upright.
- Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the MIN marking 1:
- Add rear brake fluid.
(
p. 72)
V02726-10
71
12
BRAKE SYSTEM
12.11
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 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
Skin irritation Brake fluid causes skin irritation.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note
Environmental 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
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
- Check that the brake linings of the rear brake are secured. ( p. 73)
Main work
- Position the vehicle vertically.
- Remove screw cap 1 with the washer and membrane 2.
- Add brake fluid up to the MAX marking.
Brake fluid DOT 4 / DOT 5.1 ( p. 123)
- Mount screw cap with washer and membrane.
Info
V02727-10
Clean up the overflowed or spilled brake fluid immediately
with water.
72
BRAKE SYSTEM
12
12.12
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.)
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a conse-
quence, the braking effect is greatly reduced and the brake discs are destroyed.
- Check the brake linings regularly.
- 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. 73)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the rear brake linings.
(
p. 73)
B01962-01
- Check that the brake linings are secured.
» If the brake linings are not secured correctly:
- Secure brake linings, replace with new parts if necessary.
12.13
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 causes skin irritation.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
73
12
BRAKE SYSTEM
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
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Only use clean brake fluid from a sealed container.
- Stand the vehicle upright.
- Remove screw cap 1 with the washer and membrane 2.
- Manually press the brake caliper toward the brake disc to push back
the brake piston. Ensure that brake fluid does not flow out of the
brake fluid reservoir; extract some if necessary.
Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake piston.
V02727-10
- Remove cotter pin 3, remove pin 4 toward the left by striking it,
and remove the brake linings.
- Clean the brake caliper and the brake caliper bracket.
B01962-10
74
BRAKE SYSTEM
12
– Check that spring plate 5 in the brake caliper and brake pad slid-
ing plate 6 in the brake caliper bracket are seated correctly.
- Insert the new brake linings, insert the pin, and mount the cotter
pins.
Info
Always change the brake linings in pairs.
- Operate the foot brake lever repeatedly until the brake linings are in
400419-11
contact with the brake disc and there is a pressure point.
- Correct the brake fluid level to marking MAX.
Brake fluid DOT 4 / DOT 5.1 ( p. 123)
- Mount the screw cover with washer and the membrane.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
75
13
WHEELS, TIRES
13.1
Removing the front wheel
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 47)
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.
V02728-10
- 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.
V02736-10
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 the front wheel and remove the wheel spindle. Take the front
wheel out of the fork.
V02736-11
Info
Do not actuate the hand brake lever when the front wheel is
removed.
- Remove spacers 3.
S03368-10
76
WHEELS, TIRES
13
13.2
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. 125)
- Insert the spacers.
H00935-10
- Clean and grease the wheel spindle.
Long-life grease ( p. 125)
- Jack up the front wheel into the fork, position it, and insert the
wheel spindle.
The brake linings are correctly positioned.
- Mount and tighten screw 2.
Guideline
Screw, front wheel
M24x1.5
45 Nm (33.2 lbf ft)
V02736-12
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. 48)
- Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
- Tighten screws 3.
Guideline
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
13.3
Removing the rear wheel
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 47)
Main work
- Take the brake line out of the guide.
V02737-10
77
13
WHEELS, TIRES
- Manually press the brake caliper toward the brake disc to push back
the brake piston.
- Remove screw 1 and pull wheel speed sensor 2 out of the hole.
- Remove nut 3. Take off chain adjuster 4.
- Pull out wheel spindle 5 to the point where the chain adjuster is
no longer in contact with the adjusting screw.
- Push the rear wheel forward as far as possible and take the chain off
the rear sprocket.
Info
Cover the components to protect them against damage.
- Hold the rear wheel and remove the wheel spindle.
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.
V00509-11
- Take the rear wheel out of the link fork.
Info
Do not operate the foot brake when the rear wheel is
removed.
- Remove spacer 6.
R04972-10
13.4
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.
Warning
Danger of accidents There is no braking effect to start with at the rear brake after installing the rear wheel.
- Actuate the foot brake several times before going on a ride until you can feel a firm pressure point.
Main work
- Check the rear hub damping rubber pieces.
(
p. 80)
78
WHEELS, TIRES
13
–
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 ring 1 and contact surface A of the
spacer.
Long-life grease ( p. 125)
-
Insert a spacer.
V01510-10
-
Clean and grease the thread of the wheel spindle and nut 2.
Long-life grease ( p. 125)
-
Clean and grease the wheel spindle.
Long-life grease ( p. 125)
-
Mount the damping rubber and rear sprocket carrier in the rear
wheel.
-
Position the rear wheel.
The brake linings are correctly positioned.
-
Push the rear wheel forward as far as possible and lay the chain on
the rear sprocket.
-
Mount wheel spindle 3 and chain adjuster 4. Mount nut 2,
but do not tighten yet.
-
Make sure that chain adjusters 4 are fitted correctly on adjusting
screws 5.
Guideline
In order for the rear wheel to be correctly aligned, the markings
on the left and right chain adjusters must be in the same position
V00510-10
relative to reference markings B.
Info
Mount left and right chain adjusters 4 in the same posi-
tion.
-
Tighten nut 2.
Guideline
Nut, rear wheel spindle
M25x1.5
90 Nm (66.4 lbf ft)
–
Position wheel speed sensor 6 in the hole.
–
Mount and tighten screw 7.
Guideline
Screw, wheel
M6
6 Nm (4.4 lbf ft)
speed sensor
Loctite®243™
79
13
WHEELS, TIRES
- Position the brake line in the guide.
- Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
V02737-10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 48)
- Check the chain tension. ( p. 56)
13.5
Checking the rear hub damping rubber pieces
Info
The engine power is transmitted from the rear sprocket to the rear wheel via the 6 damping rubber pieces. They
eventually wear out during operation. If the damping rubber pieces are not changed in time, the rear sprocket car-
rier and the rear hub will be damaged.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 47)
- Remove the rear wheel.
(
p. 77)
Main work
- Check bearing 1.
» If the bearing is damaged or worn:
- Change the bearing of the rear sprocket carrier.
- Check damping rubber pieces 2 of the rear hub for damage and
wear.
» If the damping rubber pieces of the rear hub are damaged or
worn:
V02738-10
- Change all the damping rubber pieces of the rear hub.
- Lay the rear wheel on a workbench with the rear sprocket facing
upwards and insert the wheel spindle in the hub.
- To check play A, hold the rear wheel tight and try to turn the rear
sprocket with your hand.
Info
Measure the play on the outside of the rear sprocket.
Play of damping rubber pieces
≤ 5 mm (≤ 0.2 in)
V00511-10
on rear wheel
» If clearance A is larger than the specified value:
- Change all the damping rubber pieces of the rear hub.
Finishing work
- Install the rear wheel.
(
p. 78)
– Remove the motorcycle from the lift stand. ( p. 48)
- Check the chain tension. ( p. 56)
80
WHEELS, TIRES
13
13.6
Checking the tire condition
Warning
Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable.
- Ensure that damaged or worn tires are replaced immediately. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
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 Non-approved or non-recommended tires and wheels impact the handling characteristic.
- Only use tires/wheels approved by GASGAS Motorcycles with the corresponding speed index.
Warning
Danger of accidents New tires have reduced road grip.
The contact surface on new tires is not yet roughened.
- Run in new tires with moderate riding at alternating angles.
Running-in phase
200 km (124 mi)
Info
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcy-
cle.
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.
H01144-10
» If the tires are more than five years old:
- Change the tires.
81
13
WHEELS, TIRES
13.7
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 the tire pressure when the tires are cold.
Tire pressure, offroad, solo
front
1.5 bar (22 psi)
rear
1.5 bar (22 psi)
Tire pressure, road, solo
front
1.8 bar (26 psi)
400695-01
rear
1.8 bar (26 psi)
Tire pressure with passenger / full payload
front
2.2 bar (32 psi)
rear
2.2 bar (32 psi)
» If the tire pressure does not meet specifications:
- Correct the tire pressure.
- Mount the protection cap.
13.8
Checking the spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam-
age.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low,
then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
- Check spoke tension regularly, and in particular on a new vehicle. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
- Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length
and spoke diameter.
If spokes of the same length and diameter vibrate with a
different tone, this is an indication that the spoke tensions
differ.
You should hear a high note.
400694-01
» If the spoke tension differs:
- Correct the spoke tension.
82
WHEELS, TIRES
13
13.9
Using tire repair spray
Warning
Danger of accidents Incorrect use of tire repair spray will
result in the repaired tire losing pressure.
Tire repair spray cannot be used for all types of damage.
- Observe the instructions and specifications of the manufac-
turer of the tire repair spray.
- After repairing a tire with tire repair spray, ride slowly and
carefully.
H03319-01
- Ride no further than to the nearest workshop and have the
tire changed.
Tire repair spray should only be used in an emergency.
We recommend transporting the broken down vehicle to the nearest
workshop instead of using tire repair spray.
83
14
ELECTRICAL SYSTEM
14.1
Removing the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
- Keep 12 V batteries out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Avoid contact with battery acid and battery gases.
- Keep sparks or open flames away from the 12 V battery.
- Only charge 12 V batteries in well-ventilated rooms.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery
gases get into the eyes.
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
Main work
- Remove screws 1.
- Push the retaining bracket toward the rear and remove it.
- Take off positive terminal cover 2.
- Disconnect negative cable 3 from the 12-V battery.
- Disconnect positive cable 4 from the 12-V battery.
- Lift out the 12-V battery.
V02748-10
Info
Never operate the motorcycle with a discharged 12-V bat-
tery or without a 12-V battery. In both cases, electrical com-
ponents and safety devices can be damaged. The vehicle will
therefore no longer be roadworthy.
14.2
Installing the 12-V battery
Main work
- Insert the 12-V battery into the battery compartment with the ter-
minals facing to the rear.
12-V battery (YTZ10S) ( p. 117)
V02749-10
84
ELECTRICAL SYSTEM
14
– Position positive cable 1 with washer 2.
- Position negative cable 3 with washer 2.
- Mount and tighten the screw.
Guideline
Screw, battery terminal
M6
4.5 Nm (3.32 lbf ft)
V02750-10
- Position positive terminal cover 4.
- Position retaining bracket and mount and tighten screws 5.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
V02751-10
Finishing work
- Mount the seat. ( p. 50)
- Set the clock. ( p. 22)
14.3
Charging the 12-V battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
- Keep 12 V batteries out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Avoid contact with battery acid and battery gases.
- Keep sparks or open flames away from the 12 V battery.
- Only charge 12 V batteries in well-ventilated rooms.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes with water for at least 15 minutes and consult a doctor immediately if battery acid and battery
gases get into the eyes.
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.
85
14
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 charging current, charging voltage, or charging time is exceeded, electrolyte escapes through the safety
valves. This reduces the capacity of the 12-V battery.
If the 12-V battery is discharged by repeated starting, charge the 12-V battery immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and sulfat-
ing occurs, thus destroying the battery.
The 12-V battery is maintenance-free. The acid level does not have to be checked.
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
- Remove the 12-V battery.
(
p. 84)
Main work
- Connect a battery charger to the 12-V battery. Switch on the battery
charger.
Guideline
The battery charger must be suitable for the 12-V battery.
Info
Never remove cover 1.
Charge the 12-V battery to a maximum of 10% of the capac-
V02752-10
ity specified on battery housing 2.
- Switch off the battery charger after charging and disconnect from
the 12-V battery.
Guideline
The charging current, charging voltage, and charging time must
not be exceeded.
Recharge the 12-V battery reg-
3 months
ularly when the motorcycle is
not being used
Finishing work
- Install the 12-V battery.
(
p. 84)
– Mount the seat. ( p. 50)
- Set the clock. ( p. 22)
14.4
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. It is in the housing of the starter relay next to
the 12-V battery.
86
ELECTRICAL SYSTEM
14
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
Main work
- Pull off engine control unit 1 from the holder and hang to the
side.
V02739-10
- Take off protection caps 2.
- Remove a defective main fuse 3 with needle nose pliers.
Info
A faulty fuse has a burned-out fuse wire A.
A spare fuse 4 is located in the starter relay.
- Insert a new main fuse.
Fuse (58011109130) ( p. 117)
Info
Insert a new spare fuse into the starter relay to have it avail-
able when needed.
- Check that the electrical system is functioning properly.
- Mount the protection caps.
- Position the engine control unit.
S04580-10
Finishing work
- Mount the seat. ( p. 50)
- Set the clock. ( p. 22)
14.5
Changing the ABS fuses
Warning
Fire hazard Incorrect fuses overload the electrical system.
- Only use fuses with the required ampere value.
- Do not bypass or repair fuses.
Info
Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the
ABS. The third fuse, which protects the ABS control unit, is located in the fuse box.
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
- Pull off the engine control unit from the holder and hang to the side.
87
14
ELECTRICAL SYSTEM
To change the fuse of the ABS hydraulic unit:
- Take off protection cap 1.
- Remove the fuse 2 of the ABS hydraulic unit.
- Insert a new fuse.
Fuse (75011088010) ( p. 117)
- Mount the protection cap.
To change the fuse of the ABS return pump:
- Take off protection cap 1.
- Remove the fuse 3 of the ABS return pump.
- Insert a new fuse.
Fuse (75011088025) ( p. 117)
- Mount the protection cap.
S04582-10
Finishing work
- Position the engine control unit.
- Mount the seat. ( p. 50)
14.6
Changing the fuses of individual electrical power consumers
Info
The fuse box containing the fuses of individual electrical power consumers is located under the seat.
Preparatory work
- Open the fuel tank filler cap. ( p. 19)
- Remove the seat. ( p. 50)
- Pull off the engine control unit from the holder and hang to the side.
Main work
- Open fuse box cover 1.
S04584-10
88
ELECTRICAL SYSTEM
14
– Remove the faulty fuse.
Guideline
Fuse 1 - 10 A - ignition, combination instrument, clock, engine
control unit
Fuse 2 - 10A - ignition, combination instrument, engine control
unit
Fuse 3 - 10 A - fuel pump
Fuse 4 - 10 A - radiator fan
S04583-10
Fuse 5 - 10A - horn, brake light, turn signal
Fuse 6 - 15 A - high beam, low beam, position light, tail light,
license plate lamp
Fuse 7 - 10 A - for auxiliary equipment ACC 1 (permanent positive)
Fuse 8 - 10 A - for auxiliary equipment ACC 2 (ignition plus)
Fuse 9 - 10 A - ABS
Fuse 10 - not assigned
Fuse SPARE - 10A/15A - spare fuses
Info
A faulty fuse has a burned-out fuse wire A.
Warning
Fire hazard Incorrect fuses overload the electrical system.
- Only use fuses with the required ampere value.
- Do not bypass or repair fuses.
- Insert the spare fuse with the correct rating.
Fuse (75011088010) ( p. 117)
Fuse (75011088015) ( p. 117)
Tip
Put a spare fuse in the fuse box so that it is available if
needed.
- Check the function of the electrical power consumer.
- Close the fuse box cover.
Finishing work
- Mount the seat. ( p. 50)
14.7
Removing the headlight mask with the headlight
- Cover the fender with a cloth.
- Remove screws 1 on both sides.
- Tip the headlight mask forward.
V02740-10
89
14
ELECTRICAL SYSTEM
- Disconnect plug-in connector 2 of the headlight.
- Take off the headlight mask.
S03304-10
14.8
Installing the headlight mask with the headlight
Main work
- Connect plug-in connector 1 of the headlight.
- Check that the lighting is functioning properly.
S03304-11
- Remove the cloth from the fender and position the headlight mask.
Headlight mask engages in the fender on the bushings 2.
S03305-10
- Position the headlight mask.
Info
Pay attention to routing of the brake line.
- Mount and tighten screws 3.
Guideline
Screw, headlight mask
M5
2 Nm (1.5 lbf ft)
V02740-11
Finishing work
- Check the headlight setting. ( p. 92)
90
ELECTRICAL SYSTEM
14
14.9
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. 89)
Main work
- Unplug connector 1.
- Take off protection cap 2 of the headlight bulb.
V02741-10
- Detach spring bar 3.
- Remove headlight bulb 4.
- Insert a new headlight bulb into the headlight housing.
Headlight (H4/socket P43t) ( p. 117)
- Fix the headlight bulb in the headlight using the spring bar.
- Mount the protection cap. Plug in the connector.
V02742-10
Finishing work
- Install the headlight mask with the headlight. ( p. 90)
- Check the headlight setting. ( p. 92)
14.10
Changing the position light lamp
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. 89)
91
14
ELECTRICAL SYSTEM
Main work
- Remove bulb socket 1.
V02741-11
- Pull position light lamp 2 out of the bulb socket.
- Insert a new position light lamp in the bulb socket.
Position light (W5W / socket W2.1x9.5d) ( p. 117)
- Insert the bulb socket in the reflector.
V02743-10
Finishing work
- Install the headlight mask with the headlight. ( p. 90)
- Check the headlight setting. ( p. 92)
14.11
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 mounts the motorcycle with luggage and passenger if
applicable.
- Switch on the low beam.
- Check the headlight setting.
The light-dark boundary must be exactly on the lower mark-
ing when the motorcycle is ready to be operated with the rider
mounted along with any luggage and a passenger if applicable.
» If the boundary between light and dark does not meet specifica-
tions:
- Adjust headlight range. ( p. 93)
92
ELECTRICAL SYSTEM
14
14.12
Adjusting the headlight range
Preparatory work
- Check the headlight setting. ( p. 92)
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).
Info
V02744-10
If you have a payload, you may have to correct the headlight
range.
- Tighten screw 1.
14.13
ACC1 and ACC2
Installation location
- The power supplies ACC1 1 and ACC2 2 are located behind the
headlight mask.
S03334-10
14.14
Diagnostics connector
Diagnostics connector 1 is located under the engine control unit.
V02745-10
93
15
COOLING SYSTEM
15.1
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. Heat expansion causes excess
coolant to flow into compensating tank 3. When the temperature
falls, this surplus coolant is sucked back into the cooling system. This
ensures that operating the vehicle at the specified coolant temperature
will not result in a risk of malfunctions.
125 °C (257 °F)
V02696-10
The coolant is cooled by the air stream and radiator fan 4, which is
activated depending on the temperature.
The lower the speed, the less the cooling effect. Dirty cooling fins also
reduce the cooling effect.
400407-10
15.2
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
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.
94
COOLING SYSTEM
15
–
Place the motorcycle on a horizontal surface using the side stand.
–
Remove the cover of compensating tank 1.
–
Check the antifreeze in the coolant.
-25 … -45 °C (-13 … -49 °F)
» If the antifreeze in the coolant does not match the specified
value:
- Correct the antifreeze in the coolant.
-
Check the coolant level in the compensating tank.
V02746-10
The coolant level must be between the two markings.
» If the coolant level does not match the specified value:
- Correct the coolant level.
Coolant ( p. 123)
-
Mount the cover of the compensating tank.
–
Remove radiator cap 2.
–
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.
V02747-10
The radiator must be filled completely.
» If the coolant level does not match the specified value:
- Check the coolant level and the reason for the loss.
Coolant ( p. 123)
-
Mount the radiator cap.
15.3
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
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.
95
15
COOLING SYSTEM
Condition
The engine is cold.
- Place the motorcycle on a horizontal surface using the side stand.
- Check the coolant level in compensating tank 1.
The coolant level must be between the two markings.
» If the coolant level does not match the specified value:
- Correct the coolant level.
Coolant ( p. 123)
V02746-10
- Remove radiator cap 2 and check the coolant level in the radiator.
The radiator must be filled completely.
» If the coolant level does not match the specified value:
- Check the coolant level and the reason for the loss.
Coolant ( p. 123)
- Mount the radiator cap.
V02747-10
15.4
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
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.
Preparatory work
- Remove engine guard. ( p. 63)
96
COOLING SYSTEM
15
Main work
- Position the motorcycle upright.
- Position an appropriate container under the engine.
- Remove screw 1. Take off the radiator cap.
- Completely drain the coolant.
- Mount and tighten screw 1 with a new seal ring.
Guideline
Screw plug, water
M10x1
15 Nm (11.1 lbf ft)
600616-10
pump drain hole
15.5
Filling/bleeding the 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.
Main work
- Place the motorcycle on a horizontal surface using the side stand.
- Remove radiator cap 1.
- Refill with coolant.
Coolant ( p. 123)
- Completely fill the radiator with coolant.
- Mount radiator cap 1.
V02747-11
- Remove the cover of the compensating tank.
- Add coolant up to the marking A.
- Mount the cover of the compensating tank.
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
V02746-11
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and let it warm up.
- Stop the engine and allow it to cool down.
- Check the coolant level. ( p. 95)
Finishing work
- Install the engine guard. ( p. 63)
97
15
COOLING SYSTEM
15.6
Changing the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
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.
Preparatory work
- Remove engine guard. ( p. 63)
Main work
- Position the motorcycle upright.
- Position an appropriate container under the engine.
- Remove screw 1 with the seal ring.
600616-10
- Remove radiator cap 2.
- Completely drain the coolant.
V02747-10
98
COOLING SYSTEM
15
– Mount and tighten screw 1 with a new seal ring.
Guideline
Screw plug, water
M10x1
15 Nm (11.1 lbf ft)
pump drain hole
600616-10
- Stand the motorcycle on a level surface using the side stand.
- Refill with coolant.
Coolant
1.20 l (1.27 qt.)
Coolant ( p. 123)
– Completely fill the radiator with coolant.
- Mount radiator cap 2.
S03317-10
- Remove compensating tank cover 3.
- Add coolant to the top marking.
- Mount the cover of the compensating tank.
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
V02746-12
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and allow it to warm up.
- Stop the engine and allow it to cool down.
Finishing work
- Check the coolant level. ( p. 95)
- Install the engine guard. ( p. 63)
99
16
TUNING THE ENGINE
16.1
Changing the riding mode
Info
The desired riding mode can be activated via the MAP button on the combination switch.
The setting most recently selected is activated again when restarting.
The riding mode can also be changed during the ride.
Condition
Throttle grip closed.
- Press MAP button until the LED displays the desired riding
mode. Riding mode 1 is STREET and riding mode 2 is SPORT.
Riding mode STREET - balanced response
Riding mode SPORT - direct response
Info
The riding mode only influences the throttle response.
H02886-01
The homologated performance is available in both riding
modes.
In riding mode 2, the traction control allows more slip
and rise of the front wheel.
In riding mode 2, the ABS switches to ABS
mode Offroad.
16.2
Adjusting traction control
Info
Traction control is activated when the ignition is switched on.
The traction control lowers the tightening torque in case of loss of traction in the rear wheel.
When traction control is switched off, the rear wheel may spin during high acceleration and on surfaces with low
grip, resulting in a risk of crashing.
Traction control can also be adjusted during the ride.
Traction control cannot be deactivated until a minimum speed has previously been reached and the self test is com-
plete.
Deactivating traction control:
Condition
Throttle grip closed.
Speed before deactivation: ≥ 4 km/h (≥ 2.5 mph)
- Press and hold the TC button for five seconds.
The TC LED lights up when the traction control is deac-
tivated.
Activating the traction control:
Condition
S03255-01
Throttle grip closed.
- Press and hold the TC button for five seconds.
The TC LED does not light up when the traction control
is activated.
Info
If the TC indicator lamp and both riding mode
lamps light up at same time, a malfunction has
been detected in the traction control. Contact an
authorized GASGAS Motorcycles workshop.
100
TUNING THE ENGINE
16
16.3
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.
If the shift lever is permanently touching the boot, the transmission will be subject to excessive load; this can cause
a malfunction of the quickshifter (optional).
- Sit on the vehicle in the riding position and determine distance A
between the upper edge of your boot and the shift lever.
Distance between shift lever
10 … 20 mm (0.39 … 0.79 in)
and upper edge of boot
» If the distance does not meet specifications:
- Adjust the basic position of the shift lever.
(
p. 101)
400692-10
16.4
Adjusting the basic position of the shift lever
- Remove screw 1 with the washers and take off shift lever 2.
401950-12
- Clean gear teeth A of the shift lever and shift shaft.
- Mount shift lever 2 on the shift shaft in the required position and
engage the gearing.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other
vehicle components during the shift procedure.
401951-10
- Mount and tighten screw 1 with washers.
Guideline
Screw, shift lever
M6
14 Nm (10.3 lbf ft)
Loctite®243™
101
17
SERVICE WORK ON THE ENGINE
17.1
Checking the engine oil level
Info
The engine oil level must be checked when the engine is warm.
Condition
The engine is at operating temperature.
Preparatory work
- Stand the motorcycle upright on a horizontal surface.
Main work
- Check the engine oil level.
Info
After switching off the engine, wait one minute before
checking the level.
The engine oil must be between the lower and upper edge of the
oil level viewer.
V02697-10
» If the engine oil level is not at the specified level:
- Add engine oil. ( p. 105)
17.2
Changing the engine oil and oil filter, cleaning the oil screens
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
- 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 while the engine is at operating temperature.
Preparatory work
- Remove engine guard. ( p. 63)
Main work
- Position an appropriate container under the engine.
- Remove oil drain plug 1 with the magnet and seal ring.
- Allow the engine oil to drain completely.
S02210-10
102
SERVICE WORK ON THE ENGINE
17
– Thoroughly clean the oil drain plug with magnet.
- Mount the oil drain plug with the magnet and seal ring and tighten
it.
Guideline
Oil drain plug with
M12x1.5
20 Nm (14.8 lbf ft)
magnet
S02209-01
- Remove screws 2. Take off oil filter cover 3 with the O-ring.
- Pull oil filter 4 out of the oil filter housing.
Lock ring plier (51012011000)
S03320-10
- Remove screws 5. Take off oil filter cover 6 with the O-ring.
- Pull oil filter 7 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.
S03321-10
- Remove screw plug 8 with oil screen 9 and the O-rings.
S03322-10
- Remove screw plug bk with oil screen bl and the O-rings.
- Allow the engine oil to drain completely.
- Thoroughly clean the parts and the sealing surface.
S03323-10
103
17
SERVICE WORK ON THE ENGINE
- Position oil screen bm with the O-rings.
- Mount and tighten screw plug bn with the O-ring.
Guideline
Plug, oil screen
M20x1.5
15 Nm (11.1 lbf ft)
S03324-10
- Position oil screen bo with the O-rings.
- Mount and tighten screw plug bp with the O-ring.
Guideline
Plug, oil screen
M20x1.5
15 Nm (11.1 lbf ft)
S03325-10
- Insert oil filters bq and br.
- Oil the O-rings of the oil filter covers. Mount oil filter covers bs
and bt.
- Mount and tighten the screws.
Guideline
Screw, oil filter cover
M5
6 Nm (4.4 lbf ft)
S03326-10
- Remove filler plug ck with the O-ring, and fill up with engine oil.
Engine oil
1.70 l (1.8 qt.)
Engine oil (SAE
10W/50) ( p. 123)
- Mount and tighten filler plug ck with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
S03327-10
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and check it for leaks.
Finishing work
- Install the engine guard. ( p. 63)
104
SERVICE WORK ON THE ENGINE
17
17.3
Adding engine oil
Info
Too little engine oil or poor-quality engine oil will result in premature wear of the engine.
Main work
- Remove filler plug 1 with the O-ring, and fill up with engine oil.
- Fill engine oil to the middle of the level viewer.
Engine oil (SAE 10W/50) ( p. 123)
Info
In order to achieve optimal engine oil performance, it is not
advisable to mix different engine oils.
H01066-10
GASGAS Motorcycles recommends changing the engine oil,
if necessary.
- Mount and tighten filler plug 1 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-
ning the engine in an enclosed space.
- Start the engine and check it for leaks.
Finishing work
- Check the engine oil level. ( p. 102)
105
18
CLEANING, CARE
18.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
- Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
- Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance
60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
-
Close off exhaust system to keep water from entering.
–
Remove loose dirt first with a soft jet of water.
–
Spray the heavily soiled parts with a normal commercial motorcycle
cleaner and clean using a brush.
Motorcycle cleaner ( p. 125)
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.
If the vehicle was operated in road salt, clean it with cold
water. Warm water would enhance the corrosive effects of
salt.
-
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.
-
Push back the protection caps of the handlebar controls to allow any
water that has penetrated to evaporate.
106
CLEANING, CARE
18
– After the motorcycle has cooled down, lubricate all moving parts
and pivot points.
- Clean the chain. ( p. 56)
- Treat bare metal (except for brake discs and the exhaust system)
with a corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 125)
- Treat all painted parts with a mild paint care product.
Perfect finish and high gloss polish for paints ( p. 125)
Info
Do not polish parts that were matte when delivered as this
would strongly impair the material quality.
- 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. 125)
- Lubricate the ignition/steering lock.
Universal oil spray ( p. 125)
18.2
Checks and maintenance steps for winter operation
Info
If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precautions
against aggressive road salt.
After riding on salted roads, thoroughly clean the vehicle with cold water and dry it well. Warm water enhances the
corrosive effects of salt.
- Clean the motorcycle. ( p. 106)
- Clean the 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 motorcy-
401060-01
cle with cold water and dry it well.
- Treat the engine, the swingarm, 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. 56)
107
19
STORAGE
19.1
Storage
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If the motorcycle is not being used for an extended length of time, additional measures are recommended.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are neces-
sary, you should do this during the storage period (less workshop overload). This allows you to avoid long waiting
periods when the next season starts.
-
When refueling for the last time before taking the motorcycle out of
service, add fuel additive.
Fuel additive ( p. 125)
-
Refuel. ( p. 38)
–
Clean the motorcycle. ( p. 106)
–
Change the engine oil and the oil filter, clean the oil screens.
(
p. 102)
–
Check the antifreeze and coolant level. ( p. 94)
401058-01
-
Check tire pressure. ( p. 82)
–
Remove the 12-V battery.
(
p. 84)
–
Charge the 12-V battery.
(
p. 85)
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. 47)
–
Cover the motorcycle with a tarp or cover that is permeable to air.
Info
Do not use non-porous materials since they prevent humid-
ity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since the
engine cannot warm up properly, the water vapor produced
during combustion condenses and causes valves and the
exhaust system to rust.
108
STORAGE
19
19.2
Preparing for use after storage
- Remove the motorcycle from the lift stand. ( p. 48)
- Charge the 12-V battery.
(
p. 85)
– Install the 12-V battery.
(
p. 84)
– Set the clock. ( p. 22)
- Perform checks and maintenance measures when preparing for use.
(
p. 30)
– Take a test ride.
401059-01
109
20
TROUBLESHOOTING
Faults
Possible cause
Action
The engine does not turn when
Operating error
-
Carry out start procedure. ( p. 30)
the start button is pressed
12 V battery discharged
-
Charge the 12-V battery.
(
p. 85)
–
Check the open-circuit current.
Fuse 1, 2 or 3 blown
-
Change the fuses of individual electrical
power consumers. ( p. 88)
Main fuse blown
-
Change the main fuse. ( p. 86)
No ground connection present
-
Check the ground connection.
Engine turns only if the clutch
The vehicle is in gear
-
Shift the transmission to neutral position.
lever is drawn
The vehicle is in gear and the side
-
Shift the transmission to neutral position.
stand is folded out
Engine turns but does not start.
Operating error
-
Carry out start procedure. ( p. 30)
Fuse 3 blown
-
Change the fuses of individual electrical
power consumers. ( p. 88)
Quick release coupling not joined
-
Join quick release coupling.
Malfunction in the electronic fuel
-
Read out the fault memory using the GAS-
injection
GAS Motorcycles diagnostics tool.
Throttle opened while starting
-
When starting, DO NOT open the throttle.
–
Carry out start procedure. ( p. 30)
Engine has too little power
Air filter is very dirty
-
Remove the air filter.
(
p. 54)
–
Install the air filter.
(
p. 55)
Fuel screen is very dirty
-
Change the fuel screen.
Fuel filter is very dirty
-
Check the fuel pressure.
Malfunction in the electronic fuel
-
Read out the fault memory using the GAS-
injection
GAS Motorcycles diagnostics tool.
Engine overheats.
Too little coolant in cooling system
-
Check the cooling system for leakage.
–
Check the coolant level. ( p. 95)
Radiator fins very dirty
-
Clean radiator fins.
Foam formation in cooling system
-
Drain the coolant.
(
p. 96)
–
Fill/bleed the cooling system.
(
p. 97)
Buckled or damaged radiator hose
-
Change the radiator hose.
Thermostat is faulty
-
Check the thermostat.
Fuse 4 blown
-
Change the fuses of individual electrical
power consumers. ( p. 88)
Defect in radiator fan system
-
Check the radiator fan system.
Air in cooling system
-
Fill/bleed the cooling system.
(
p. 97)
Malfunction indicator lamp lights
Malfunction in the electronic fuel
-
Read out the fault memory using the GAS-
up
injection
GAS Motorcycles diagnostics tool.
Engine dies during the journey
Lack of fuel
-
Refuel. ( p. 38)
Fuse 1, 2 or 3 blown
-
Change the fuses of individual electrical
power consumers. ( p. 88)
ABS warning lamp lights up
ABS fuse blown
-
Change the ABS fuses. ( p. 87)
Large difference in wheel speeds
-
Stop the vehicle, switch off the ignition,
of the front and rear wheels
and start it again.
Malfunction in ABS
-
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
change it if necessary.
Engine oil level too high
-
Check the engine oil level. ( p. 102)
110
TROUBLESHOOTING
20
Faults
Possible cause
Action
High oil consumption
Engine oil too thin (low viscosity)
- Change the engine oil and the oil filter,
clean the oil screens.
(
p. 102)
Headlight and parking light are not
Fuse 6 blown
- Change the fuses of individual electrical
functioning
power consumers. ( p. 88)
Turn signal, brake light and horn
Fuse 5 blown
- Change the fuses of individual electrical
not functioning
power consumers. ( p. 88)
Time is not (correctly) displayed
Fuse 1 blown
- Change the fuses of individual electrical
power consumers. ( p. 88)
- Set the clock. ( p. 22)
12 V battery discharged
Ignition not switched off when
- Charge the 12-V battery.
(
p. 85)
vehicle was parked
The 12-V battery is not being
- Check the charging voltage.
charged by the alternator
- Check the open-circuit current.
Combination instrument shows
Fuse 1 or 2 blown
- Change the fuses of individual electrical
nothing in the display
power consumers. ( p. 88)
- Set the clock. ( p. 22)
Speedometer in combination
Speedometer wiring harness is
- Check the wiring harness and plug-in con-
instrument not functioning
damaged or plug-in connection is
nection.
oxidized
111
21
TECHNICAL DATA
21.1
Engine
Design
1-cylinder 4-stroke engine, water-cooled
Displacement
692.7 cm³ (42.271 cu in)
Stroke
80 mm (3.15 in)
Bore
105 mm (4.13 in)
Compression ratio
12.7:1
Idle speed
Coolant temperature: ≥ 70 °C (≥ 158 °F)
1,650 ± 50 rpm
Control
OHC, intake with cam levers, exhaust controlled by rocker
arm, chain drive
Valve diameter, intake
42 mm (1.65 in)
Valve diameter, exhaust
34 mm (1.34 in)
Valve play, cold
Intake at: 20 °C (68 °F)
0.10 … 0.15 mm (0.0039 … 0.0059 in)
Exhaust at: 20 °C (68 °F)
0.22 … 0.27 mm (0.0087 … 0.0106 in)
Crankshaft bearing
2 roller bearings
Conrod bearing
Slide bearing
Piston pin bearing
Piston pin with DLC coating
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 lower compression ring, 1 oil ring
with spring expander
Engine lubrication
Semi-dry sump lubrication system with two trochoid
pumps
Primary transmission
36:79
Clutch
APTC™ antihopping clutch in oil bath/hydraulically oper-
ated
Transmission
6-gear transmission, claw shifted
Transmission ratio
First gear
14:35
Second gear
16:28
Third gear
20:27
Fourth gear
21:23
Fifth gear
23:22
Sixth gear
23:20
Mixture preparation
Electronic fuel injection
Ignition
Contactless controlled fully electronic ignition with digital
ignition adjustment
Alternator
12 V, 300 W
Spark plug
Inside spark plug
NGK LKAR9BI-10
Outside spark plug
NGK LMAR7DI-10
Spark plug electrode gap
1.0 mm (0.039 in)
Cooling
Water cooling, permanent circulation of coolant by water
pump
Starting aid
Starter motor, automatic decompression
112
TECHNICAL DATA
21
21.2
Engine tightening torques
Screw, membrane fixation
M3
2 Nm (1.5 lbf ft)
Loctite®243™
Hose clamp, intake flange
M4
2.5 Nm (1.84 lbf ft)
Oil nozzle for clutch lubrication
M4
0.4 Nm (0.3 lbf ft)
Oil nozzle for conrod bearing lubrica-
M4
0.8 Nm (0.59 lbf ft)
tion
Locking screw for bearing
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Oil nozzle in cylinder head
M5
2 Nm (1.5 lbf ft)
Remaining screws, engine
M5
6 Nm (4.4 lbf ft)
Screw, axial lock of camshaft and bal-
M5
6 Nm (4.4 lbf ft)
ancer shaft
Loctite®243™
Screw, clutch spring
M5
6 Nm (4.4 lbf ft)
Screw, cover plate for oil return line
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, gear sensor
M5
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, oil filter cover
M5
6 Nm (4.4 lbf ft)
Screw, oil pump cover
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, oil pump cover, top
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, retaining bracket
M5
8 Nm (5.9 lbf ft)
Loctite®243™
Screw, shift shaft sensor
M5
5 Nm (3.7 lbf ft)
Loctite®243™
Remaining screws, engine
M6
10 Nm (7.4 lbf ft)
Screw, alternator cover
M6x25
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, alternator cover
M6x30
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, alternator cover (timing chain
M6
10 Nm (7.4 lbf ft)
shaft through-hole)
Loctite®243™
Screw, camshaft bearing bridge
M6
10 Nm (7.4 lbf ft)
Screw, camshaft bearing support
M6x80
10 Nm (7.4 lbf ft)
Screw, camshaft bearing support
M6x90
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6x25
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6x30
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6x35
10 Nm (7.4 lbf ft)
Screw, clutch slave cylinder
M6x20
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, crankshaft speed sensor
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, cylinder (timing chain shaft) on
M6
10 Nm (7.4 lbf ft)
housing
Loctite®243™
Screw, cylinder head
M6
10 Nm (7.4 lbf ft)
Loctite®243™
113
21
TECHNICAL DATA
Screw, engine case
M6
10 Nm (7.4 lbf ft)
Screw, engine case
M6x25
10 Nm (7.4 lbf ft)
Screw, engine case
M6x30
10 Nm (7.4 lbf ft)
Screw, engine case
M6x70
10 Nm (7.4 lbf ft)
Screw, engine case
M6x80
10 Nm (7.4 lbf ft)
Screw, engine sprocket cover and
M6x35
10 Nm (7.4 lbf ft)
slave cylinder of the clutch
Screw, guide rail
M6x30
10 Nm (7.4 lbf ft)
Loctite®2701™
Screw, guide rail
M6x20
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, ignition coil
M6
10 Nm (7.4 lbf ft)
Screw, locking lever
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, resonator
M6
10 Nm (7.4 lbf ft)
Screw, secondary air system cover
M6x12
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift drum locating
M6
15 Nm (11.1 lbf ft)
Loctite®243™
Screw, shift lever
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter motor
M6
10 Nm (7.4 lbf ft)
Screw, stator
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, tensioning rail
M6x30
10 Nm (7.4 lbf ft)
Loctite®2701™
Screw, thermostat case
M6
10 Nm (7.4 lbf ft)
Screw, timing chain shaft
M6
10 Nm (7.4 lbf ft)
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
Screw, water pump wheel
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Intake channel vacuum connection
M6x0.75
2.5 Nm (1.84 lbf ft)
Loctite®2701™
Oil nozzle for piston cooling
M6x0.75
4 Nm (3 lbf ft)
Screw plug, locking screw
M8
15 Nm (11.1 lbf ft)
Screw, rocker arm shaft
M8x40
15 Nm (11.1 lbf ft)
Screw, rocker arm shaft
M8x55
15 Nm (11.1 lbf ft)
Setscrew, camshaft bearing bridge
M8
6 Nm (4.4 lbf ft)
Loctite®243™
Stud, exhaust flange
M8
15 Nm (11.1 lbf ft)
Loctite®243™
114
TECHNICAL DATA
21
Screw, cylinder head
M10
Tightening sequence:
Tighten diagonally, beginning with the
rear screw on the timing chain shaft.
1st stage
15 Nm (11.1 lbf ft)
2nd stage
30 Nm (22.1 lbf ft)
3rd stage
45 Nm (33.2 lbf ft)
4th stage
60 Nm (44.3 lbf ft)
Thread greased
Screw, engine sprocket
M10
60 Nm (44.3 lbf ft)
Loctite®243™
Screw plug, oil channel
M10x1
15 Nm (11.1 lbf ft)
Loctite®243™
Screw plug, water pump drain hole
M10x1
15 Nm (11.1 lbf ft)
Screw, oil line
M10x1
10 Nm (7.4 lbf ft)
Screw, unlocking for timing chain ten-
M10x1
8 Nm (5.9 lbf ft)
sioner
Spark plug outside
M10x1
11 Nm (8.1 lbf ft)
Spark plug inside
M12x1.25
18 Nm (13.3 lbf ft)
Coolant temperature sensor on the
M12x1.5
12 Nm (8.9 lbf ft)
cylinder head
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
Screw plug, oil pressure control valve
M12x1.5
20 Nm (14.8 lbf ft)
Screw plug, oil channel
M14x1.5
15 Nm (11.1 lbf ft)
Loctite®243™
Engine case stud
M16x1.5
25 Nm (18.4 lbf ft)
Loctite®243™
Nut, rotor
M18x1.5
100 Nm (73.8 lbf ft)
Loctite®243™
Nut, inner clutch hub
M20x1.5
120 Nm (88.5 lbf ft)
Loctite®243™
Nut, primary gear wheel
M20LHx1.5
90 Nm (66.4 lbf ft)
Loctite®243™
Plug, oil screen
M20x1.5
15 Nm (11.1 lbf ft)
Plug, oil thermostat
M24x1.5
15 Nm (11.1 lbf ft)
Plug, timing chain tensioner
M24x1.5
25 Nm (18.4 lbf ft)
Screw plug, alternator cover
M24x1.5
8 Nm (5.9 lbf ft)
21.3
Capacities
21.3.1
Engine oil
Engine oil
1.70 l (1.8 qt.)
Engine oil (SAE 10W/50) ( p. 123)
21.3.2
Coolant
Coolant
1.20 l (1.27 qt.)
Coolant ( p. 123)
115
21
TECHNICAL DATA
21.3.3
Fuel
Please observe the labels on EU fuel pumps.
A00420-10
Fuel tank capacity, approx.
13.3 l (3.51 US gal)
Super unleaded (ROZ 95) ( p. 124)
Fuel reserve, approx.
1.4 l (1.5 qt.)
21.4
Chassis
Frame
Lattice frame made of chrome molybdenum steel tubing,
powder-coated
Fork
WP SuspensionXPLOR 5348
Shock absorber
WP SuspensionXPLOR 5746
Suspension travel
front
250 mm (9.84 in)
rear
250 mm (9.84 in)
Brake system
front
Disc brake with dual-piston brake caliper, floating
rear
Disc brake with single-piston brake caliper, floating
Brake discs - diameter
front
300 mm (11.81 in)
rear
240 mm (9.45 in)
Brake discs - wear limit
front
4.5 mm (0.177 in)
rear
4.5 mm (0.177 in)
Tire pressure, road, solo
front
1.8 bar (26 psi)
rear
1.8 bar (26 psi)
Tire pressure with passenger / full payload
front
2.2 bar (32 psi)
rear
2.2 bar (32 psi)
Tire pressure, offroad, solo
front
1.5 bar (22 psi)
rear
1.5 bar (22 psi)
Secondary drive ratio
15:46
Chain
5/8 x 1/4” X-ring
Steering head angle
62.3°
Wheelbase
1,506 ± 15 mm (59.29 ± 0.59 in)
Seat height unloaded
935 mm (36.81 in)
Ground clearance unloaded
269 mm (10.59 in)
Weight without fuel, approx.
147.8 kg (325.8 lb.)
116
TECHNICAL DATA
21
Maximum permissible front axle load
150 kg (331 lb.)
Maximum permissible rear axle load
200 kg (441 lb.)
Maximum permissible overall weight
350 kg (772 lb.)
21.5
Electrical system
12-V battery
YTZ10S
Battery voltage: 12 V
Nominal capacity: 8.6 Ah
Maintenance-free
Fuse
58011109130
30 A
Fuse
75011088015
15 A
Fuse
75011088010
10 A
Fuse
75011088025
25 A
Headlight
H4/socket P43t
12 V
60/55 W
Position light
W5W / socket W2.1x9.5d
12 V
5W
Combination instrument lighting and
LED
indicator lamps
Turn signal
LED
Brake/tail light
LED
License plate lamp
LED
21.6
Tires
Front tire
Rear tire
90/90 - 21 M/C 54S M+S TT
140/80 - 18 M/C 70R M+S TT
Continental TKC 80 Twinduro
Continental TKC 80 Twinduro
The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an
authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical
specifications must be observed. Additional information is available in the Service section under:
21.7
Fork
Fork article number
14.18.8S.10
Fork
WP SuspensionXPLOR 5348
Compression damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Rebound damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Spring length with preload spacer(s)
435 mm (17.13 in)
Spring rate
Soft
5.3 N/mm (30.3 lb/in)
117
21
TECHNICAL DATA
Medium (standard)
5.9 N/mm (33.7 lb/in)
Hard
6.5 N/mm (37.1 lb/in)
Fork length
895 mm (35.24 in)
Fork oil per fork leg
640 ml (21.64 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 123)
21.8
Shock absorber
Shock absorber article number
15.18.7S.10
Shock absorber
WP SuspensionXPLOR 5746
High-speed compression damping
Comfort
2.5 turns
Standard
2 turns
Sport
1 turn
Full payload
1 turn
Low-speed compression damping
Comfort
25 clicks
Standard
20 clicks
Sport
10 clicks
Full payload
10 clicks
Rebound damping
Comfort
23 clicks
Standard
20 clicks
Sport
10 clicks
Full payload
10 clicks
Spring preload
Comfort
18 mm (0.71 in)
Standard
18 mm (0.71 in)
Sport
18 mm (0.71 in)
Full payload
25 mm (0.98 in)
Spring rate
Soft
66 N/mm (377 lb/in)
Medium (standard)
72 N/mm (411 lb/in)
Hard
81 N/mm (463 lb/in)
Spring length
225 mm (8.86 in)
Gas pressure
10 bar (145 psi)
Fitted length
395 mm (15.55 in)
Shock absorber fluid ( p. 124)
SAE 2.5
118
TECHNICAL DATA
21
21.9
Chassis tightening torques
Screw, chain guard
EJOT
1.5 Nm (1.11 lbf ft)
Screw, combination instrument
EJOT
1 Nm (0.7 lbf ft)
Screw, combination switch
EJOT PT® K50x18 T20
2 Nm (1.5 lbf ft)
Screw, radiator guard
EJOT PT® K50x14 T20
2 Nm (1.5 lbf ft)
Screw, side stand sensor
EJOT
1 Nm (0.7 lbf ft)
Screw, tail light
EJOT PT® K45x12-Z
1.5 Nm (1.11 lbf ft)
Fitting, side stand sensor
M4
2 Nm (1.5 lbf ft)
Screw, fixed grip
M4
5 Nm (3.7 lbf ft)
Loctite®243™
Spoke nipple, front wheel
M4.5
4 Nm (3 lbf ft)
Spoke nipple, rear wheel
M4.5
4 Nm (3 lbf ft)
Remaining nuts, chassis
M5
5 Nm (3.7 lbf ft)
Remaining screws, chassis
M5
5 Nm (3.7 lbf ft)
Screw, brake line holder on link fork
M5
5 Nm (3.7 lbf ft)
Screw, cable on starter motor
M5
3 Nm (2.2 lbf ft)
Screw, combination switch, left
M5
3.5 Nm (2.58 lbf ft)
Screw, electrical holder
M5
3 Nm (2.2 lbf ft)
Screw, exhaust heat shield
M5
8 Nm (5.9 lbf ft)
Screw, foot brake lever stub
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, fuel hose clamp on fuel tank
M5
5 Nm (3.7 lbf ft)
Screw, fuel level sensor
M5
3 Nm (2.2 lbf ft)
Screw, fuel pump
M5
4 Nm (3 lbf ft)
Screw, fuel tank closure flange
M5
2.5 Nm (1.84 lbf ft)
Screw, headlight mask
M5
2 Nm (1.5 lbf ft)
Screw, heat guard on fuel tank cover
M5x12
3.5 Nm (2.58 lbf ft)
Screw, pressure regulator
M5
4 Nm (3 lbf ft)
Screw, radiator fan cover
M5
3.2 Nm (2.36 lbf ft)
Screw, radiator guard
M5
3.5 Nm (2.58 lbf ft)
Screw, seat lock cable
M5
3 Nm (2.2 lbf ft)
Screw, throttle grip
M5
3.5 Nm (2.58 lbf ft)
Screw, upper fuel tank cover
M5x20
2 Nm (1.5 lbf ft)
Screw. rear wiring harness
M5
2 Nm (1.5 lbf ft)
Remaining nuts, chassis
M6
10 Nm (7.4 lbf ft)
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Screw connection, foot brake cylinder
M6
10 Nm (7.4 lbf ft)
Screw, ABS control unit
M6
5 Nm (3.7 lbf ft)
Screw, ABS module retaining bracket
M6
10 Nm (7.4 lbf ft)
on frame
Screw, air filter box, on frame
M6
6 Nm (4.4 lbf ft)
Screw, ball joint of push rod on foot
M6
10 Nm (7.4 lbf ft)
brake cylinder
Loctite®243™
Screw, battery cable to starter motor
M6
6 Nm (4.4 lbf ft)
Screw, battery terminal
M6
4.5 Nm (3.32 lbf ft)
Screw, brake assembly
M6
5 Nm (3.7 lbf ft)
119
21
TECHNICAL DATA
Screw, brake fluid reservoir for rear
M6
5 Nm (3.7 lbf ft)
brake
Screw, brake line holder on frame
M6x12
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, chain guard
M6
2 Nm (1.5 lbf ft)
Loctite®243™
Screw, chain guide
M6
10 Nm (7.4 lbf ft)
Screw, chain sliding guard
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, clutch assembly
M6
5 Nm (3.7 lbf ft)
Screw, combination instrument
M6x8
5 Nm (3.7 lbf ft)
holder on triple clamp
Screw, compensating tank radiator
M6
2 Nm (1.5 lbf ft)
Screw, electrical holder in fuel tank
M6
2 Nm (1.5 lbf ft)
Screw, electrical holder under 12-V
M6
10 Nm (7.4 lbf ft)
battery
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, ignition lock
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, inertial measurement unit
M6
8 Nm (5.9 lbf ft)
Screw, license plate holder, bottom
M6
8 Nm (5.9 lbf ft)
Screw, license plate holder, bottom
M6x14
5 Nm (3.7 lbf ft)
Screw, license plate holder, top
M6
8 Nm (5.9 lbf ft)
Screw, lower right fuel tank cover
M6x12
5 Nm (3.7 lbf ft)
Screw, magnetic holder on side stand
M6
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, radiator bleeding
M6
8 Nm (5.9 lbf ft)
Screw, radiator bracket, bottom
M6
8 Nm (5.9 lbf ft)
Screw, radiator bracket, top
M6
10 Nm (7.4 lbf ft)
Screw, radiator shield
M6x20
4.5 Nm (3.32 lbf ft)
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, SAS valve
M6
4 Nm (3 lbf ft)
Screw, seat lock
M6
5 Nm (3.7 lbf ft)
Screw, seat support, center
M6x12
5 Nm (3.7 lbf ft)
Screw, seat support, front
M6x14
6 Nm (4.4 lbf ft)
Screw, side fuel tank cover
M6x11
3 Nm (2.2 lbf ft)
Screw, tool set compartment on
M6x12
5 Nm (3.7 lbf ft)
frame
Screw, tool set compartment on
M6x24
5 Nm (3.7 lbf ft)
frame
Screw, upper part of the air filter box
M6
2 Nm (1.5 lbf ft)
Screw, voltage regulator
M6
8 Nm (5.9 lbf ft)
Screw, wheel speed sensor
M6
6 Nm (4.4 lbf ft)
Loctite®243™
Nut, manifold on cylinder head
M8
Tighten the nuts evenly. The plate
should not be bent.
≤ 15 Nm (≤ 11.1 lbf ft)
Copper paste
120
TECHNICAL DATA
21
Nut, rear sprocket screw
M8
35 Nm (25.8 lbf ft)
Loctite®2701™
Remaining nuts, chassis
M8
25 Nm (18.4 lbf ft)
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
Screw, bottom triple clamp
M8
12 Nm (8.9 lbf ft)
Screw, chain sliding piece
M8
15 Nm (11.1 lbf ft)
Loctite®243™
Screw, connection lever on frame
M8
30 Nm (22.1 lbf ft)
Loctite®243™
Screw, engine sprocket cover
M8
15 Nm (11.1 lbf ft)
Screw, foot brake lever
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, front footrest bracket
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, fuel tank bracket
M8
15 Nm (11.1 lbf ft)
Screw, fuel tank, bottom
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, fuel tank, top
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, grab handle
M8
10 Nm (7.4 lbf ft)
Screw, handlebar clamp
M8
20 Nm (14.8 lbf ft)
Screw, heel protector
M8x12
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, main silencer clamp
M8
12 Nm (8.9 lbf ft)
Screw, main silencer holder
M8
25 Nm (18.4 lbf ft)
Screw, main silencer holder on fuel
M8
25 Nm (18.4 lbf ft)
tank
Screw, rear footrest bracket
M8x16
25 Nm (18.4 lbf ft)
Screw, side stand bracket
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, spring holder plate on side
M8
25 Nm (18.4 lbf ft)
stand bracket
Loctite®243™
Screw, steering stem
M8
20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp
M8
17 Nm (12.5 lbf ft)
Engine carrying screw
M10
45 Nm (33.2 lbf ft)
Loctite®243™
Remaining nuts, chassis
M10
45 Nm (33.2 lbf ft)
Remaining screws, chassis
M10
45 Nm (33.2 lbf ft)
Screw, bottom shock absorber
M10
45 Nm (33.2 lbf ft)
Loctite®243™
Screw, engine bearer on frame
M10
45 Nm (33.2 lbf ft)
Screw, handlebar support
M10
45 Nm (33.2 lbf ft)
Loctite®243™
Screw, side stand
M10
35 Nm (25.8 lbf ft)
Loctite®243™
121
21
TECHNICAL DATA
Screw, top shock absorber
M10
45 Nm (33.2 lbf ft)
Loctite®243™
Banjo bolt, brake line
M10x1
25 Nm (18.4 lbf ft)
Lambda sensor
M12x1.25
25 Nm (18.4 lbf ft)
Copper paste
Screw, swingarm pivot
M12x1.5
80 Nm (59 lbf ft)
Nut, angle lever to link fork
M14x1.5
100 Nm (73.8 lbf ft)
Nut, linkage lever to rocker arm
M14x1.5
100 Nm (73.8 lbf ft)
Screw, radiator temperature sensor
M18
20 Nm (14.8 lbf ft)
Screw, bottom steering head
M20x1.5
60 Nm (44.3 lbf ft)
Loctite®243™
Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
Screw, front wheel spindle
M24x1.5
45 Nm (33.2 lbf ft)
Nut, rear wheel spindle
M25x1.5
90 Nm (66.4 lbf ft)
122
SUBSTANCES
22
Brake fluid DOT 4 / DOT 5.1
Standard/classification
- DOT
Guideline
- Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the
corresponding properties.
Recommended supplier
Castrol
- REACT PERFORMANCE DOT 4
MOTOREX®
- Brake Fluid DOT 5.1
Coolant
Guideline
- Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuit-
able antifreeze causes corrosion, deposits and frothing.
- Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and
lubrication properties.
- Only use coolant that complies with the requirements stated (see specifications on the container) and that has the rele-
vant properties.
Antifreeze protection to at least
-25 °C (-13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be
diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other
coolants.
Recommended supplier
MOTOREX®
- COOLANT M3.0
Engine oil (SAE 10W/50)
Standard/classification
- JASO T903 MA2 ( p. 126)
- SAE ( p. 126) (SAE 10W/50)
Guideline
- Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the
corresponding properties.
Fully synthetic engine oil
Recommended supplier
MOTOREX®
- Power Synt 4T
Fork oil (SAE 4) (48601166S1)
Standard/classification
- SAE ( p. 126) (SAE 4)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre-
sponding properties.
123
22
SUBSTANCES
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
- SAE ( p. 126) (SAE 2.5)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre-
sponding properties.
Super unleaded (ROZ 95)
Standard/classification
- DIN EN 228 (ROZ 95)
Guideline
- Only use super unleaded fuel that matches or is equivalent to the specified standard.
- Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15, E25, E85,
E100).
124
AUXILIARY SUBSTANCES
23
Chain cleaner
Recommended supplier
MOTOREX®
- Chain Clean
Fuel additive
Recommended supplier
MOTOREX®
- Fuel Stabilizer
Long-life grease
Recommended supplier
MOTOREX®
- Bike Grease 2000
Motorcycle cleaner
Recommended supplier
MOTOREX®
- Moto Clean
Off-road chain spray
Recommended supplier
MOTOREX®
- Chainlube Offroad
Perfect finish and high gloss polish for paints
Recommended supplier
MOTOREX®
- Moto Shine
Preserving materials for paints, metal and rubber
Recommended supplier
MOTOREX®
- Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX®
- Quick Cleaner
Universal oil spray
Recommended supplier
MOTOREX®
- Joker 440 Synthetic
125
24
STANDARDS
JASO T903 MA2
Different technical development directions required a separate specification for motorcycles - the JASO T903 MA2 stan-
dard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle
specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high perfor-
mance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to
their viscosity. The viscosity describes only one property of oil and says nothing about quality.
126
INDEX OF SPECIAL TERMS
25
ABS
Anti-lock braking system
Safety system that prevents locking of the wheels when
driving straight ahead without the influence of lateral
forces
MTC
Motorcycle Traction Control
Auxiliary function of the motor control that reduces engine
torque with spinning rear wheel
OBD
On-board diagnosis
Vehicle system, which monitors the specified parameters
of the vehicle electronics
-
Quickshifter +
Engine electronics function for shifting up and down with-
out clutch actuation
127
26
LIST OF ABBREVIATIONS
Art. no.
Article number
ca.
circa
cf.
compare
e.g.
for example
etc.
et cetera
i.a.
inter alia
no.
number
poss.
possibly
128
LIST OF SYMBOLS
27
27.1
Red symbols
Red symbols indicate an error condition that requires immediate intervention.
The coolant temperature warning lamp lights up red - The coolant temperature has reached a criti-
cal value. Stop immediately (taking care not to endanger yourself or other road users in the process),
switch off the engine, allow it to cool down and check the coolant level.
The oil pressure warning lamp lights up red - The oil pressure is too low. Stop immediately, taking care
not to endanger yourself or other road users in the process, and switch off the engine.
27.2
Yellow and orange symbols
Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also repre-
sented by yellow or orange symbols.
ABS warning lamp lights up/flashes yellow - If the ABS warning lamp lights up, the ABS is not
active. The ABS warning lamp also lights up if a malfunction is detected. Contact an authorized
GASGAS Motorcycles workshop. If the ABS warning lamp flashes slowly, ABS mode Offroad is active.
Fuel level warning lamp lights up orange - The fuel level has reached the reserve mark.
Malfunction indicator lamp lights up orange - The OBD has detected a malfunction in the vehicle elec-
tronics. Come safely to a halt, and contact an authorized GASGAS Motorcycles workshop.
TC indicator lamp lights up/flashes yellow - If the TC indicator lamp lights up, the cornering MTC
(
p. 35) is not active. If the TC indicator light and both ride mode lamps light up at same time,
a malfunction has been detected. Contact an authorized GASGAS Motorcycles workshop. The TC
indicator lamp flashes if the cornering MTC actively engages.
27.3
Green and blue symbols
Green and blue symbols reflect information.
The high beam indicator lamp lights up blue - The high beam is switched on.
The idle indicator lamp lights up green - The transmission is in the neutral position.
Turn signal indicator lamp flashes green - The turn signal is switched on.
129
INDEX
INDEX
Chain guide
1
adjusting
61
checking
58
12-V battery
charging
85
Chain tension
installing
84
adjusting
57
removing
84
checking
56
A
Changing the headlight bulb
91
ABS
64
Clutch
ABS button
16
fluid level, checking/correcting
62
ABS fuses
Clutch lever
14
changing
87
basic position, adjusting
62
ACC1
Combination instrument
front
93
adjusting
21
clock, setting
22
ACC2
overview
20
front
93
setting kilometers or miles
21
Air filter
setting the service interval
22
installing
55
Coolant
removing
54
antifreeze and coolant level, checking
94
Anti-lock braking system
64
changing
98
Auxiliary substances
9
draining
96
B
level, checking
95
Brake discs
Cooling system
94
checking
65
filling/bleeding
97
Brake fluid
Cornering MTC
35
front brake, adding
66
Customer service
9
of rear brake, adding
72
D
Brake fluid level
Defined use
6
front brake, checking
66
Diagnostics connector
93
rear brake, checking
71
E
Brake lining retainers
Emergency OFF switch
15
of front brake, checking
67
Engine
of rear brake, checking
73
running in
28
Brake linings
Engine guard
of front brake, changing
68
installing
63
of front brake, checking
67
removing
63
of rear brake, checking
73
of the rear brake, changing
73
Engine number
12
Brakes
35
Engine oil
Braking
35
adding
105
changing
102
Breakdown
towing
37
Engine oil level
checking
102
C
Engine sprocket
Capacity
checking
58
coolant
99,
115
Environment
8
engine oil
104,
115
fuel
39,
116
F
Chain
Figures
9
checking
58
Foot brake lever
19
cleaning
56
basic position, adjusting
70
dirt, checking for
55
free travel, checking
70
130
INDEX
Fork
42
Motorcycle
compression damping, adjusting
42
cleaning
106
dust boots, cleaning
48
lift stand, raising with
47
fork legs, bleeding
49
removing from lift stand
48
rebound, adjusting
42
taking off of the rear wheel stand
47
with lifting gear at rear, raising
47
Fork part number
13
Motorcycle traction control
35
Fork protector
installing
49
O
removing
49
Oil filter
Front fender
changing
102
installing
54
Oil screens
removing
54
cleaning
102
Front wheel
Overview of indicator lights
17
installing
77
Owner's Manual
8
removing
76
P
Fuel tank filler cap
closing
20
Parking
36
opening
19
Passenger foot pegs
18
Fuel, oils, etc
9
Position light lamp
changing
91
Fuse
of individual electrical power consumers, changing
88
Preparing for use
advice on preparing for first use
27
G
after storage
109
Grab handles
18
checks and maintenance measures when preparing
H
for use
30
Protective clothing
7
Hand brake lever
14
basic position, adjusting
65
Q
Handlebar position
45
Quickshifter +
34
adjusting
45
R
Headlight
Rear hub damping rubber pieces
range, adjusting
93
checking
80
setting, checking
92
Rear sprocket
Headlight mask with headlight
checking
58
installing
90
Rear wheel
removing
89
installing
78
Horn button
14
removing
77
I
Refueling
Ignition lock
17
fuel
38
Implied warranty
9
Riding
32
Intended use
6
starting off
32
K
Riding mode
Key number
12
changing
100
L
Rubber grip
Light switch
15
checking
61
Loading the vehicle
28
S
Luggage
28
Safe operation
7
M
Seat
Main fuse
mounting
50
changing
86
removing
50
unlocking
18
Manufacturer warranty
9
Misuse
6
Service
9
131
INDEX
Service schedule
40-41
V
Shift lever
18
Vehicle identification number
12
basic position, adjusting
101
View of vehicle
basic position, checking
101
front left
10
Shifting
32
rear right
11
Shock absorber
42
W
compression damping, general
43
Winter operation
high-speed compression damping, adjusting
44
checks and maintenance steps
107
low-speed compression damping, adjusting
43
Work rules
8
rebound damping, adjusting
45
Shock absorber article number
13
Side cover
mounting
53
removing
52
Side stand
19
Spare parts
9
Spoke tension
checking
82
Start button
15
Starting
30
Steering lock
17
Stopping
36
Storage
108
T
Technical accessories
9
Technical data
capacities
115
chassis
116
chassis tightening torques
119
electrical system
117
engine
112
engine tightening torques
113
fork
117
shock absorber
118
tires
117
Throttle grip
14
Tire condition
checking
81
Tire pressure
checking
82
Tire repair spray
using
83
Tool set
removing
50
storing
51
Towing
37
Traction control
adjusting
100
Transport
37
Troubleshooting
110-111
Turn signal switch
15
Type label
12
132