GASGAS MC 50. OWNER'S MANUAL (2024)
TABLE OF CONTENTS
TABLE OF CONTENTS
1
MEANS OF REPRESENTATION
5
8.4
Riding
21
8.5
Braking
21
1.1
Symbols used
5
8.6
Stopping, parking
22
1.2
Formats used
5
8.7
Transporting
22
2
SAFETY ADVICE
6
8.8
Refueling
23
2.1
Use definition - intended use
6
9
SERVICE SCHEDULE
24
2.2
Misuse
6
9.1
Additional information
24
2.3
Safety advice
6
9.2
Service schedule
24
2.4
Degrees of risk and symbols
6
2.5
Tampering warning
6
10
TUNING THE CHASSIS
26
2.6
Safe operation
7
10.1
Checking the basic chassis setting with
2.7
Protective clothing
7
rider's weight
26
2.8
Work rules
8
10.2
Air suspension XACT 5235
26
2.9
Environment
8
10.3
Compression damping of the shock
2.10
Owner's Manual
8
absorber
27
3
IMPORTANT NOTES
9
10.4
Adjusting the low-speed compression
damping of the shock absorber
27
3.1
Manufacturer warranty, implied
10.5
Adjusting the high-speed compression
warranty
9
damping of the shock absorber
27
3.2
Fuel, auxiliary substances
9
10.6
Adjusting the rebound damping of the
3.3
Spare parts, accessories
9
shock absorber
28
3.4
Service
9
10.7
Measuring the dimension of the rear
3.5
Figures
9
wheel unloaded
29
3.6
Customer service
9
10.8
Checking the static sag of the shock
absorber
29
4
VIEW OF VEHICLE
10
10.9
Checking the rider sag of the shock
4.1
View of vehicle, left side (example)
10
absorber
30
4.2
View of vehicle, right side (example)
11
10.10
Adjusting the spring preload of the
shock absorber
30
5
SERIAL NUMBERS
12
10.11
Adjusting the riding sag
31
5.1
Vehicle identification number
12
10.12
Checking the basic setting of the fork
32
5.2
Frame label
12
10.13
Adjusting the fork air pressure
32
5.3
Engine number
12
10.14
Adjusting the rebound damping of the
5.4
Fork article number
12
fork
34
5.5
Shock absorber article number
13
10.15
Handlebar position
34
10.16
Adjusting the handlebar position
34
6
CONTROLS
14
11
SEAT HEIGHT
36
6.1
Hand brake lever
14
6.2
Throttle grip
14
11.1
Seat height adjustment options
36
6.3
Stop button
14
11.2
Adjusting the seat height on the shock
6.4
Opening the fuel tank filler cap
14
absorber
36
6.5
Closing the fuel tank filler cap
15
11.3
Adjusting the seat height on the fork
37
6.6
Fuel tap
15
11.4
Adjusting the seat height on the
frame
38
6.7
Choke
16
6.8
Kick starter lever
16
12
SERVICE WORK ON THE CHASSIS
41
6.9
Foot brake lever
16
12.1
Raising the motorcycle with a lift stand
41
6.10
Plug-in stand
16
12.2
Removing the motorcycle from the lift
7
PREPARING FOR USE
17
stand
41
12.3
Bleeding the fork legs
41
7.1
Advice on preparing for first use
17
12.4
Cleaning the dust boots of the fork legs
42
7.2
Running in the engine
18
12.5
Removing the fork protector
43
8
RIDING INSTRUCTIONS
20
12.6
Installing the fork protector
43
12.7
Removing the fork legs
44
8.1
Checks and maintenance measures
12.8
Installing the fork legs
44
when preparing for use
20
12.9
Removing the lower triple clamp
45
8.2
Starting the vehicle
20
12.10
Installing the lower triple clamp
46
8.3
Starting off
21
2
TABLE OF CONTENTS
12.11
Checking the steering head bearing play ... 48
13.11
Adding rear brake fluid
77
12.12
Adjusting the steering head bearing
13.12
Checking that the brake linings of the
play
48
rear brake are secured
78
12.13
Lubricating the steering head bearing
49
13.13
Changing the rear brake linings
78
12.14
Removing the fuel tank
49
14
WHEELS, TIRES
82
12.15
Installing the fuel tank
50
12.16
Removing the start number plate
52
14.1
Removing the front wheel
82
12.17
Installing the start number plate
52
14.2
Installing the front wheel
82
12.18
Removing front fender
52
14.3
Removing the rear wheel
83
12.19
Installing the front fender
53
14.4
Installing the rear wheel
84
12.20
Removing the left side cover
53
14.5
Checking the tire condition
85
12.21
Installing the left side cover
54
14.6
Checking tire pressure
86
12.22
Removing the right side cover
54
14.7
Checking the spoke tension
86
12.23
Installing the right side cover
55
15
COOLING SYSTEM
88
12.24
Removing the shock absorber
55
12.25
Installing the shock absorber
55
15.1
Cooling system
88
12.26
Removing the seat
56
15.2
Checking the antifreeze and coolant
12.27
Mounting the seat
56
level
88
12.28
Removing the frame protector
57
15.3
Checking the coolant level
89
12.29
Installing the frame protector
57
15.4
Draining the coolant
89
12.30
Removing the air filter
57
15.5
Refilling with coolant
90
12.31
Installing the air filter
58
15.6
Changing the coolant
91
12.32
Cleaning the air filter and air filter
16
TUNING THE ENGINE
93
box
58
12.33
Removing the main silencer
59
16.1
Checking the play in the throttle cable
93
12.34
Installing the main silencer
60
16.2
Adjusting the play in the throttle
12.35
Changing the rock wool on the main
cable
93
silencer
60
16.3
Carburettor - idle speed
94
12.36
Removing the engine sprocket cover
61
16.4
Carburetor - adjusting the idle speed
94
12.37
Installing the engine sprocket cover
61
16.5
Checking the clutch setting
95
12.38
Checking the chain for dirt
61
16.6
Removing the clutch cover
96
12.39
Cleaning the chain
62
16.7
Adjusting the clutch
96
12.40
Checking the chain tension
62
16.8
Installing the clutch cover
99
12.41
Adjusting the chain tension
63
17
SERVICE WORK ON THE ENGINE
100
12.42
Checking the chain, rear sprocket,
engine sprocket, and chain guide
64
17.1
Checking the gear oil level
100
12.43
Adjusting the chain guide
66
17.2
Changing the gear oil
100
12.44
Checking the frame
66
17.3
Adding the gear oil
101
12.45
Checking the link fork
66
18
CARBURETOR
103
12.46
Checking the throttle cable routing
66
12.47
Checking the rubber grip
67
18.1
Removing the carburetor
103
18.2
Installing the carburetor
105
13
BRAKE SYSTEM
68
19
CLEANING, CARE
108
13.1
Adjusting the basic position of the hand
brake lever
68
19.1
Cleaning the motorcycle
108
13.2
Checking the brake discs
68
20
STORAGE
110
13.3
Checking the front brake fluid level
69
13.4
Adding front brake fluid
70
20.1
Storage
110
13.5
Checking that the brake linings of the
20.2
Preparing for use after storage
111
front brake are secured
71
21
TROUBLESHOOTING
112
13.6
Changing the front brake linings
71
13.7
Checking the free travel of the foot
22
TECHNICAL SPECIFICATIONS
114
brake lever
74
22.1
Engine
114
13.8
Adjusting the free travel of the foot
22.2
Engine tightening torques
114
brake lever
75
22.3
Carburetor with carburetor tuning
115
13.9
Adjusting the basic position of the foot
brake lever
75
22.3.1
Carburetor tuning (Option: Low seat
position)
115
13.10
Checking the rear brake fluid level
76
3
TABLE OF CONTENTS
22.3.2
Carburetor tuning (Option: High
seat position)
116
22.4
Capacities
117
22.4.1
Gear oil
117
22.4.2
Coolant
117
22.4.3
Fuel
117
22.5
Chassis
117
22.6
Tires
118
22.7
Fork
118
22.8
Shock absorber
119
22.9
Chassis tightening torques
119
23
SUBSTANCES
122
24
AUXILIARY SUBSTANCES
124
25
STANDARDS
126
26
LIST OF ABBREVIATIONS
127
INDEX
128
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 the safety
of your child, have these jobs performed in an authorized GASGAS Motorcycles workshop. Your motor-
cycle 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.
Indicates a voltage measurement.
Indicates a current measurement.
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
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with
the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
2.2
Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the 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.
2.5
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
6
SAFETY ADVICE
2
1
The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of
any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
2
the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1
Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust
gases.
2
Removal or puncturing of parts of the intake system.
3
Lack of proper maintenance.
4
Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those
specified by the manufacturer.
2.6
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
- Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
- Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when running the engine.
- Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become hot when the vehicle is operated.
- Do not touch any parts such as the exhaust system, radiator, engine, damper, or brake system before the vehi-
cle parts have cooled down.
- Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and
environmentally compatible manner.
The vehicle should only be used by trained persons.
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.
- Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as trousers and a
jacket with protectors on all rides.
- Alway use protective clothing for your child that is in good condition and meets the legal requirements.
- When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
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 transpon-
der key) or the motor must be at a standstill (models without ignition lock or transponder key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the
number in parentheses. Example: bearing puller (15112017000)
Unless otherwise noted, normal conditions apply to all tasks and descriptions.
Ambient temperature
20 °C (68 °F)
Ambient air pressure
1,013 mbar (14.69 psi)
Relative air humidity
60 ± 5 %
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion
screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instructions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn
parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of
the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of
others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regula-
tions of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regu-
lations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles dealer will be glad to
advise you.
2.10
Owner's Manual
It is important that you read this Owner's Manual carefully and completely before your child makes his or her first trip. The
Owner's Manual contains useful information and many tips for you and your child on how to operate, handle, and service
your motorcycle. This is the only way for you to find out how to ideally tune the vehicle and how to protect your child 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, accessories
For the safety of your child, only use spare parts and accessory products that are approved and/or recommended by GAS-
GAS Motorcycles and have them installed by an authorized GASGAS Motorcycles workshop. GASGAS Motorcycles accepts
no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized
GASGAS Motorcycles dealer will be glad to advise you.
The latest news GASGAS Technical Accessories on your vehicle can be found on the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the
engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to
damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces, can result in significantly
increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it
may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always neces-
sary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized GASGAS Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle
and GASGAS Motorcycles.
A list of authorized GASGAS Motorcycles dealers can be found on the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
9
4
VIEW OF VEHICLE
4.1
View of vehicle, left side (example)
K01479-10
1 Valve for fork airpump
2 Stop button ( p. 14)
3 Fuel tank filler cap
4 Fuel tap ( p. 15)
5 Quick release of seat
6 Shock absorber compression adjustment
7 Choke
10
VIEW OF VEHICLE
4
4.2
View of vehicle, right side (example)
K01480-10
1 Fork rebound adjustment
2 Throttle grip ( p. 14)
3 Hand brake lever ( p. 14)
4 Vehicle identification number ( p. 12)
5 Clutch adjuster
6 Foot brake lever ( p. 16)
7 Kick starter lever ( p. 16)
8 Shock absorber rebound adjuster
9 Level viewer for brake fluid, rear
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
Frame label
Frame label 1 is located on the front frame tube.
402154-10
5.3
Engine number
The engine number 1 is located on the left side of the engine under
the engine sprocket.
401949-11
5.4
Fork article number
The fork article number 1 is stamped on the outside of the axle clamp.
401947-10
12
SERIAL NUMBERS
5
5.5
Shock absorber article number
The shock absorber article number 1 is stamped on the bottom of the
shock absorber toward the right-hand side.
H01186-10
13
6
CONTROLS
6.1
Hand brake lever
Hand brake lever 1 is fitted on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
F02966-10
6.2
Throttle grip
Throttle grip 1 is fitted on the right side of the handlebar.
F02966-11
6.3
Stop button
The stop button 1 is fitted on the left side of the handlebar.
Possible states
• The stop button is in the basic position - In this position, the
ignition circuit is closed and the engine can be started.
• Stop button pressed - In this position, the ignition circuit is inter-
rupted, a running engine stops, and a non-running engine will not
start.
F02967-10
6.4
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.
14
CONTROLS
6
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.
- Turn fuel tank filler cap 1 counterclockwise and lift it off.
F02968-10
6.5
Closing the fuel tank filler cap
- Mount fuel tank filler cap 1 and turn it clockwise until the fuel
tank is tightly closed.
Info
Route fuel tank breather hose 2 without kinks.
F02968-11
6.6
Fuel tap
Fuel tap 1 is on the left of the fuel tank.
Possible states
• Fuel tap is closed - The knurled screw is turned all the way clock-
wise. Fuel cannot flow out of the fuel tank.
• Fuel tap is open - The knurled screw is turned all the way counter-
clockwise. Fuel can flow out of the fuel tank.
F02969-10
15
6
CONTROLS
6.7
Choke
Choke 1 is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through
which the engine can draw extra fuel. This results in a richer fuel-air mix-
ture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
F02970-10
• Choke function activated - The choke lever is pulled out to the
stop.
• Choke function deactivated - The choke lever is pushed in to the
stop.
6.8
Kick starter lever
Kick starter lever 1 is fitted on the right side of the engine.
The kick starter lever can be swiveled.
Info
Before riding, swing the kick starter lever inwards towards the
engine.
H01184-10
6.9
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
6.10
Plug-in stand
The fixture for plug-in stand 1 is located on the frame on the left side
of the vehicle.
The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before riding.
402581-10
16
PREPARING FOR USE
7
7.1
Advice on preparing for first use
Warning
Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk.
Children often underestimate or fail to recognize dangerous situations.
- Your child must already be able to ride a bicycle.
- Your child must be able to put the vehicle upright independently after a fall.
- Your child must understand that regulations and instructions from you or from other guardians must be fol-
lowed.
- Make it clear to your child that they should not, under any circumstances, operate the vehicle without supervi-
sion.
- Make it clear to your child that he or she may only drive at speeds corresponding to the child's riding abilities
and the road conditions.
- Do not ask too much of your child.
Make sure that their stamina, riding technique and motivation are at the necessary levels.
- Only let your child ride on the vehicle if they are physically and mentally ready.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
- Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as trousers and a
jacket with protectors on all rides.
- Alway use protective clothing for your child that is in good condition and meets the legal requirements.
- When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
- Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style constitutes a major risk.
- Ensure that your child adapts the riding speed to the road conditions and to his or her riding abilities.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
- Make it clear to your child that he or she must not carry a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
- Ensure that your child raises his or her foot from the foot brake lever if he or she does not want to brake.
Warning
Danger of accidents The suspension components will become damaged or destroyed if overloaded.
- Do not exceed the maximum permissible weight of the rider.
Warning
Risk of injury People who act without authorization may not be familiar with the vehicle.
- Do not leave the vehicle unattended if the engine is running.
- Protect the vehicle against access by unauthorized persons.
17
7
PREPARING FOR USE
Info
When using the motorcycle, remember that others may be disturbed by excessive noise.
-
Ensure that the pre-sale inspection work has been carried out by an authorized GASGAS Motorcycles workshop.
You will receive a delivery certificate when the vehicle is handed over.
-
Read through the entire Owner's Manual together with your child before riding for the first time.
Info
Pay special attention to the safety instructions and to the risk of injury.
Explain to your child the techniques of riding and falling, e.g., how shifting weight can influence handling charac-
teristics.
-
Familiarize your child with the controls.
–
Adjust basic position of the hand brake lever. ( p. 68)
–
Adjust the basic position of the foot brake lever.
(
p. 75)
–
Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the weight of
your child.
-
Allow your child to become accustomed to the handling of the motorcycle on suitable terrain, preferably on a large,
open meadow.
Info
To give your child a feeling for the brake system, you should push your child at first. Do not start the engine
until your child is able to apply the necessary front brake pressure.
Initially, let your child ride to another person who can help your child stop and turn.
-
Erect obstacles for your child to navigate around so that your child becomes accustomed to handling the vehicle.
–
Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for the motorcy-
cle.
-
Your child should not ride on terrain that exceeds your child's capabilities and experience.
–
Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding.
–
Make sure the maximum permissible weight of the rider is not exceeded.
Guideline
Maximum rider weight
45 kg (99 lb.)
Maximum rider size
< 130 cm (< 51.2 in)
–
Check the spoke tension. ( p. 86)
Info
The spoke tension must be checked after half an hour of operation.
-
Run the engine in. ( p. 18)
7.2
Running in the engine
– During the running-in time, do not exceed the specified engine load.
Guideline
Maximum engine performance
During the first 3 operating hours
< 70 %
During the first 5 operating hours
< 100 %
Info
The use of a service hour counter is recommended in order to be able to check the mileage at any time.
18
PREPARING FOR USE
7
– Avoid fully opening the throttle.
19
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 safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
- Check the gear oil level. ( p. 100)
- Check the front brake fluid level. ( p. 69)
- Check the rear brake fluid level. ( p. 76)
- Check that the brake linings of the front brake are secured.
(
p. 71)
– Check that the brake linings of the rear brake are secured. ( p. 78)
- Check that the brake system is functioning properly.
- Check the coolant level. ( p. 89)
H02217-01
- Check the chain for dirt. ( p. 61)
- Check the chain, rear sprocket, engine sprocket, and chain guide.
(
p. 64)
– Check the chain tension. ( p. 62)
- Check the tire condition. ( p. 85)
- Check tire pressure. ( p. 86)
- Check the spoke tension. ( p. 86)
Info
The spoke tension must be checked regularly as incorrect
spoke tension will strongly impair riding safety.
- Clean the dust boots of the fork legs. ( p. 42)
- Bleed the fork legs. ( p. 41)
- Check the air filter.
- Check the settings of all controls and ensure that they can be oper-
ated smoothly.
- Check all screws, nuts, and hose clips regularly for tightness.
- Check the fuel level.
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.
Note
Engine failure High rpm with a cold engine negatively impacts the lifespan of the engine.
- Ensure that the engine is always warmed up at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the
fuel evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
20
RIDING INSTRUCTIONS
8
Preliminary work
- Raise the motorcycle with a lift stand. ( p. 41)
The motorcycle has been out of use for more than 1 week
- Empty the carburetor float chamber.
- Turn the knurled screw on the fuel tap all the way counterclockwise.
Fuel can flow from the fuel tank to the carburetor.
The engine is cold
- Pull the choke knob up all the way to the stop and turn it by a max. ¼ turn.
- Press the kick starter lever robustly through its full range.
Info
Do not open the throttle.
Final steps
- Remove the motorcycle from the lift stand. ( p. 41)
8.3
Starting off
Info
The plug-in stand must be removed before riding.
- Open the throttle carefully.
8.4
Riding
Info
If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized
GASGAS Motorcycles workshop.
- If the choke function has been activated, deactivate it after the engine has warmed up.
- After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely
reduce the speed, but fuel consumption will be considerably lower.
- Your child should always open the throttle only as much as the engine can handle - abruptly opening the throttle
increases fuel consumption.
- Your child should switch off the engine if prolonged operation at idle speed or while stationary is imminent.
Guideline
≥ 2 min
8.5
Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
- Explain to your child that he or she must adapt the braking to the traffic situation and the road conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
- Check the brake system and do not allow your child to continue riding until the problem is eliminated. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
21
8
RIDING INSTRUCTIONS
Warning
Danger of accidents Moisture and dirt impair the brake system.
- Explain to your child that he or she must brake carefully several times to dry out and remove dirt from the
brake linings and the brake discs.
- On sandy, wet, or slippery surfaces, use mostly the rear brake if possible.
- Try to complete the braking procedure before riding into a curve.
8.6
Stopping, parking
Warning
Risk of injury People who act without authorization may not be familiar with the vehicle.
- Do not leave the vehicle unattended if the engine is running.
- Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become hot when the vehicle is operated.
- Do not touch any parts such as the exhaust system, radiator, engine, damper, or brake system before the vehi-
cle parts have cooled down.
- Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
- Park the vehicle on a firm and level surface.
- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
- Do not park the vehicle near to materials which are highly flammable or explosive.
- Allow the vehicle to cool down before covering it.
- Apply the brakes on the motorcycle.
- Press and hold the stop button while the engine is idling until the engine stops.
- Turn the knurled screw on the fuel tap all the way clockwise.
- Park the motorcycle on firm ground.
8.7
Transporting
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
- Park the vehicle on a firm and level surface.
- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
22
RIDING INSTRUCTIONS
8
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
- Do not park the vehicle near to materials which are highly flammable or explosive.
- Allow the vehicle to cool down before covering it.
- Switch off the engine.
- Use tension belts or other suitable devices to secure the motorcycle
against falling over or rolling away.
401475-01
8.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
- Switch off the engine.
- Open the fuel tank filler cap. ( p. 14)
- Fill the fuel tank with fuel up to a maximum of level A.
Guideline
35 mm (1.38 in)
Dimension A
Fuel tank capacity,
2.3 l (2.4 qt.)
Super unleaded (95
approx.
octane) mixed with
2-stroke engine oil
(1:60) ( p. 123)
- Close the fuel tank filler cap. ( p. 15)
400214-10
23
9
SERVICE SCHEDULE
9.1
Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and
invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service
schedule can always be found on GASGAS Motorcycles Dealer.net. Your authorized GASGAS Motorcycles dealer will be glad
to advise you.
The use of a service hour counter is recommended in order to be able to check the mileage at any time.
Service hour counter (A54012920000)
9.2
Service schedule
every 24 months
Every 90 operating hours
Every 45 operating hours
Every 15 operating hours
After 1 operating hour
Check that the brake linings of the front brake are secured. ( p. 71)
○
●
●
●
●
Check that the brake linings of the rear brake are secured. ( p. 78)
○
●
●
●
●
Check the brake discs. ( p. 68)
○
●
●
●
●
Check the brake lines for damage and tightness.
○
●
●
●
●
Check the front brake fluid level. ( p. 69)
○
●
●
Change the front brake fluid.
●
●
Check the rear brake fluid level. ( p. 76)
○
●
●
Change the rear brake fluid.
●
●
Check the play of the handbrake lever.
○
●
●
●
●
Check the free travel of the foot brake lever. ( p. 74)
○
●
●
●
●
Check the idle speed.
○
●
●
●
●
Change the gear oil.
(
p. 100)
○
●
●
●
●
Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves for cracking, tight-
○
●
●
●
●
ness, and correct routing.
Check the cables for damage and that there are no kinks in the routing.
○
●
●
●
●
Check that the throttle cables are undamaged, routed without kinks, and set correctly.
○
●
●
●
●
Check the frame.
(
p. 66)
●
●
●
Check the link fork.
(
p. 66)
●
●
●
Check the fork bearing for play.
●
●
●
Check the shock absorber heim joint for play.
●
●
●
Check the tire condition. ( p. 85)
○
●
●
●
●
Check tire pressure. ( p. 86)
○
●
●
●
●
Check the wheel bearing for play.
●
●
●
Check the wheel hubs.
●
●
●
Check the rim run-out.
○
●
●
●
Check the spoke tension. ( p. 86)
○
●
●
●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 64)
○
●
●
●
Check the chain tension. ( p. 62)
○
●
●
●
●
Grease all moving parts (e.g., hand lever, chain, etc.) and check for smooth operation.
○
●
●
●
●
Change the spark plug and spark plug connector.
●
●
●
Clean the air filter and air filter box.
(
p. 58)
○
●
●
●
●
Change the rock wool on the main silencer.
(
p. 60)
●
●
24
SERVICE SCHEDULE
9
every 24 months
Every 90 operating hours
Every 45 operating hours
Every 15 operating hours
After 1 operating hour
Service the fork.
●
●
Perform the shock absorber service.
●
●
Check all screws, nuts, and hose clips for a tight fit.
○
●
●
●
●
Check the clutch setting.
●
●
●
Check the antifreeze and coolant level. ( p. 88)
○
●
●
●
Change the coolant.
(
p. 91)
●
Check the steering head bearing play. ( p. 48)
○
●
Lubricate the steering head bearing.
(
p. 49)
●
●
●
Check/adjust the carburetor components.
●
●
●
Check the cylinder and piston.
●
●
●
Perform minor engine service. (Check the clutch. Check the inlet membrane. Change the pis-
●
●
ton.)
Perform major engine service including removing and installing the engine. (Change the con-
●
necting rod, conrod bearing, and crank pin. Check the transmission. Change the crankshaft bear-
ing. Change the intake flange. Change all engine bearings.)
Final check: check the operating safety of the vehicle and take for a test ride.
○
●
●
●
●
Make a service entry in GASGAS Motorcycles Dealer.net.
○
●
●
●
●
○ One-time interval
● Periodic interval
25
10
TUNING THE CHASSIS
10.1
Checking the basic chassis setting with rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
- For optimal motorcycle riding characteristics and to avoid damage
to forks, shock absorbers, link fork and frame, the basic settings of
the suspension components must match the rider's weight.
- This vehicle is delivered pre-set for a standard rider's weight (with
full protective clothing).
Guideline
Standard rider weight
25 … 35 kg (55 … 77 lb.)
– If the rider's weight is above or below this range, the basic setting of
the suspension components must be adjusted accordingly.
- Small weight differences can be compensated by adjusting the
spring preload, but in the case of large weight differences, the
springs must be replaced.
401030-01
10.2
Air suspension XACT 5235
Air suspension WP XACT 5235 is used in the fork.
In this system, suspension is located in the left fork leg and damping in the right fork leg.
As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks. The
response on slightly uneven surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air cushion. A steel spring is located in the left fork leg as
an end stop.
Info
If the fork is frequently overloaded, then the air pressure in the fork must be increased to avoid damage to the fork
and frame.
The air pressure in the fork can be quickly adjusted to the rider's weight, surface conditions and the rider's preference using
a fork airpump. The fork does not have to be dismantled. The time consuming mounting of harder or softer fork springs is
not required.
If the air chamber loses air due to a damaged seal, the fork will still not sag. In this case the air is retained in the fork. The
suspension travel is maintained as far as possible. The damping becomes harder and the riding comfort reduces.
The rebound damping can be adjusted.
The rebound adjustment is located at the upper end of the right fork leg.
26
TUNING THE CHASSIS
10
10.3
Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension
compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel 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.
10.4
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.
- 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
F02184-10
Low-speed compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
10.5
Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber.
27
10
TUNING THE CHASSIS
- Push the splash protector to the side.
- Using an open end wrench, turn adjusting screw 1 clockwise all
the way.
Info
Do not loosen fitting 2!
- Turn counterclockwise by the number of turns corresponding to the
shock absorber type.
F02184-11
Guideline
High-speed compression damping
Comfort
2.5 turns
Standard
2 turns
Sport
1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
- Position the splash protector.
10.6
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
18 clicks
Standard
15 clicks
Sport
12 clicks
F02185-10
Info
Turn clockwise to increase the damping; turn counterclock-
wise to reduce damping when the shock absorber rebounds.
28
TUNING THE CHASSIS
10
10.7
Measuring the dimension of the rear wheel unloaded
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
Main work
- Measure the vertical distance between the rear axle and a fixed
point, such as a marking on the side cover.
- Note the value as dimension A.
400988-10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
10.8
Checking the static sag of the shock absorber
- Measure dimension A of rear wheel unloaded. ( p. 29)
- Hold the motorcycle upright with aid of an assistant.
- Measure the distance between rear axle and fixed point again.
- Note the value as dimension B.
Info
The static sag is the difference between measurements A
and B.
- Check the static sag.
Static sag
12 mm (0.47 in)
» If the static sag is less or more than the specified value:
- Adjust the spring preload of the shock absorber.
(
p. 30)
400989-10
29
10
TUNING THE CHASSIS
10.9
Checking the rider sag of the shock absorber
- Measure dimension A of rear wheel unloaded. ( p. 29)
- With another person holding the motorcycle, the rider, wearing full
protective clothing, sits on the seat in a normal sitting position (feet
on footrests) and bounces up and down a few times.
The rear wheel suspension levels out.
- Another person now measures the distance between the rear axle
and the fixed point.
- Note the value as dimension C.
Info
The rider sag is the difference between measurements A
and C.
- Check the rider sag.
Rider sag
80 mm (3.15 in)
» If the rider sag differs from the specified measurement:
- Adjust the rider sag.
(
p. 31)
400990-10
10.10
Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the right side cover. ( p. 54)
- Remove the shock absorber.
(
p. 55)
– After removing the shock absorber, clean it thoroughly.
30
TUNING THE CHASSIS
10
Main work
- Measure the full spring length while it is under tension and note
down the value.
- Loosen retaining ring 1.
- Turn adjusting ring 2 until the spring is no longer under tension.
Hook wrench (T304)
Hook wrench (T1533)
Info
If the spring cannot be fully released, the spring must be
removed to accurately measure the spring length.
- Measure the total spring length while the spring is not under ten-
sion.
- Tension the spring by turning adjusting ring 2 to specified dimen-
sion A.
Guideline
Spring preload
5 mm (0.2 in)
F03048-10
Info
The spring preload is the difference between the relaxed
spring length and the tensioned spring length.
Depending on the static sag and/or the rider sag, it may be
necessary to increase or decrease the spring preload.
- Tighten retaining ring 1.
Finishing work
- Install the shock absorber.
(
p. 55)
– Install the right side cover. ( p. 55)
- Remove the motorcycle from the lift stand. ( p. 41)
10.11
Adjusting the riding sag
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the right side cover. ( p. 54)
- Remove the shock absorber.
(
p. 55)
– After removing the shock absorber, clean it thoroughly.
Main work
- Select and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 15 … 25 kg
25 N/mm (143 lb/in)
(33 … 55 lb.)
Weight of rider (standard):
30 N/mm (171 lb/in)
25 … 35 kg (55 … 77 lb.)
Weight of rider: 35 … 45 kg
35 N/mm (200 lb/in)
B00292-10
(77 … 99 lb.)
31
10
TUNING THE CHASSIS
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing
the spring preload.
Finishing work
- Install the shock absorber.
(
p. 55)
– Install the right side cover. ( p. 55)
- Remove the motorcycle from the lift stand. ( p. 41)
- Check the static sag of the shock absorber. ( p. 29)
- Check the rider sag of the shock absorber. ( p. 30)
- Adjust the rebound damping of the shock absorber. ( p. 28)
10.12
Checking the basic setting of the fork
Info
For various reasons, no exact rider sag can be determined for the fork.
- Smaller differences in the rider's weight can be compensated for by
the fork air pressure.
- However, if the fork frequently bottoms out (hard end stop on com-
pression), the fork air pressure must be increased, within the speci-
fied values, to avoid damage to the fork and frame.
401000-01
10.13
Adjusting the fork air pressure
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic.
Modifications which are not coordinated with others to the suspension setting may cause a serious deterioration
in the handling characteristic and overload components.
- Only make adjustments within the recommended range.
- Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the
new handling characteristic.
Info
Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine.
The air suspension is located in the left fork leg. The rebound damping is located in the right fork leg.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
32
TUNING THE CHASSIS
10
Main work
- Remove protection cap 1.
- Push together fork airpump 2 fully.
Fork airpump (79412966100)
Info
The fork airpump is included as part of the motorcycle's
accessory pack.
F02971-10
- Connect the fork airpump to the left fork leg.
The fork airpump indicator switches on automatically.
A little air escapes from the fork leg when connecting.
Info
This is due to the volume of the hose and not due to a
defect in the fork airpump or the fork.
Observe the accompanying instructions for GASGAS techni-
cal accessories.
- Adjust the air pressure as specified.
Guideline
Air pressure
2 bar (29 psi)
Gradual changing of the air
0.2 bar (3 psi)
pressure in steps of
Minimum air pressure
1.4 bar (20 psi)
Maximum air pressure
4 bar (58 psi)
Info
Never adjust the air pressure to a value outside the stated
range.
- Disconnect the fork airpump from the left fork leg.
When disconnecting, excess pressure will escape from the hose
- the fork leg itself does not lose any air.
The fork airpump indicator switches off automatically after
80 seconds.
- Mount the protection cap.
Info
Only mount the protection cap by hand.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
33
10
TUNING THE CHASSIS
10.14
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
- Turn adjuster 1 clockwise all the way.
Info
Adjuster 1 is located at the upper end of the right fork leg.
- Turn counterclockwise by the number of clicks corresponding to the
fork type.
Guideline
Rebound damping
F02972-10
Comfort
15 clicks
Standard
12 clicks
Sport
10 clicks
Info
Turn clockwise to increase the damping; turn counterclock-
wise to reduce damping when the shock absorber rebounds.
10.15
Handlebar position
On the upper triple clamp, there are 2 holes at a distance of A to each
other.
15 mm (0.59 in)
Hole distance A
The holes on the handlebar supports are placed at a distance of B
from the center.
3.5 mm (0.138 in)
Hole distance B
The handlebar supports can be mounted in four different positions. This
C00248-10
allows the handlebar to be mounted in the most comfortable position
for the rider.
10.16
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.
34
TUNING THE CHASSIS
10
– Remove screws 1. Take off the handlebar clamps. Remove the
handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
- Remove screws 2. Take off handlebar supports.
- Place handlebar supports in required position. Mount and tighten
C00249-10
screws 2.
Guideline
Screw, handlebar
M10
40 Nm (29.5 lbf ft)
support
Loctite®243™
– Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
- Position the handlebar clamps. Mount screws 1 and tighten
evenly.
Guideline
Screw, handlebar
M8
20 Nm (14.8 lbf ft)
clamp
Info
Make sure the installed gaps are even.
35
11
SEAT HEIGHT
11.1
Seat height adjustment options
This vehicle offers several options for adjusting the seat height to the
rider's height.
The seat height can be changed with the mounting position of the fork,
shock absorber, and frame.
Info
When adjusting the seat height on the fork and shock absorber,
make sure that the vehicle is as straight as possible after com-
pleting the work.
If the seat height on the shock absorber is set low, the fork
should be pushed through further and vice versa.
H03605-01
11.2
Adjusting the seat height on the shock absorber
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic.
- Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the
new handling characteristic.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the right side cover. ( p. 54)
Main work
- Hold the rear wheel with the link fork and remove screw 1.
- Position the shock absorber according to the required seat height.
Guideline
High seat position
A
Low seat position
B
– Mount and tighten screw 1.
K01485-10
Guideline
Screw, top shock
M10
45 Nm (33.2 lbf ft)
absorber
Loctite®243™
Finishing work
- Install the right side cover. ( p. 55)
- Remove the motorcycle from the lift stand. ( p. 41)
36
SEAT HEIGHT
11
11.3
Adjusting the seat height on the fork
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic.
- Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the
new handling characteristic.
Info
The seat height can be infinitely adjusted by pushing the fork legs through.
If the seat height is adjusted on the fork, the seat height should also be adjusted on the shock absorber.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the front wheel.
(
p. 82)
Main work
- Loosen screw 1.
- Loosen screw 2.
- Position the fork leg according to the required seat height.
Guideline
Condition
Seat position as low as possible, fork fully inserted
18 mm (0.71 in)
Maximum distance A
between lower edge of screw
cap and upper edge of triple
clamp
Condition
Seat position as high as possible, fork pulled out completely
Bottom edge of screw cap B closes flush with the upper
edge of the triple clamp
Position the fork leg only within the described range.
S05939-10
– Tighten screw 2.
Guideline
Screw, bottom triple
M8
15 Nm (11.1 lbf ft)
clamp
- Tighten screw 1.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
– Repeat the procedure on the other fork leg.
Guideline
Position both fork legs equally.
Finishing work
- Install the front wheel.
(
p. 82)
37
11
SEAT HEIGHT
11.4
Adjusting the seat height on the frame
Preparatory work
- Remove the seat. ( p. 56)
- Turn the knurled screw on the fuel tap all the way clockwise.
- Remove the fuel tank.
(
p. 49)
– Remove the right side cover. ( p. 54)
- Remove main silencer. ( p. 59)
Main work
- Loosen hose clip 1.
I00665-10
- Remove screws 2 on the right and left side.
- Remove subframe with air filter box.
I00666-10
- Loosen hose clip 3 and slide the intake snorkel to the desired posi-
tion.
Guideline
High seat position
Position A
Low seat position
Position B
I00667-10
38
SEAT HEIGHT
11
Condition
Low seat position
- Position subframe in position C with screws 2 on the right
and left side and tighten.
Guideline
Screw, tail
M8
30 Nm (22.1 lbf ft)
assembly
Loctite®2701™
I00668-10
Condition
High seat position
- Position subframe in position D with screws 2 on the right
and left side and tighten.
Guideline
Screw, tail
M8
30 Nm (22.1 lbf ft)
assembly
Loctite®2701™
I00669-10
- Position the intake flange on the carburetor and tighten hose clip
1.
Guideline
Hose clip, carburetor
-
2.8 Nm (2.07 lbf ft)
I00671-10
39
11
SEAT HEIGHT
Condition
High seat position
- Make sure that tank extension 4 is fitted.
Condition
Low seat position
- Make sure that tank extension 4 is removed.
I00670-10
Finishing work
- Install the main silencer. ( p. 60)
- Install the fuel tank.
(
p. 50)
– Mount the seat. ( p. 56)
40
SERVICE WORK ON THE CHASSIS
12
12.1
Raising the motorcycle with a lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
- Park the vehicle on a firm and level surface.
- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
- Raise the motorcycle at the frame underneath the engine.
Neither wheel is in contact with the ground.
- Secure the motorcycle against falling over.
401942-01
12.2
Removing the motorcycle from the lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
- Park the vehicle on a firm and level surface.
- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
- Remove the motorcycle from the lift stand.
- Remove the lift stand.
- To park the motorcycle, insert plug-in stand 1 into the plug-in
stand bracket on the left side of the vehicle.
Info
Remove the plug-in stand before riding.
402581-10
12.3
Bleeding the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
41
12
SERVICE WORK ON THE CHASSIS
Main work
- Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
F02179-10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
12.4
Cleaning the dust boots of the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the fork protector. ( p. 43)
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 seals rings
behind can start to leak.
F02975-10
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when neces-
sary.
- Clean and oil the dust boots and inside fork tubes of both fork legs.
Universal oil spray ( p. 125)
- Press the dust boots back into the installation position.
- Remove the excess oil.
Finishing work
- Install the fork protector. ( p. 43)
- Remove the motorcycle from the lift stand. ( p. 41)
42
SERVICE WORK ON THE CHASSIS
12
12.5
Removing the fork protector
- Remove screws 1 and take off the clamp.
- Remove screws 2 on the left fork leg. Take off the fork protector.
F02976-10
- Remove screws 3 on the right fork leg. Take off the fork protector.
F02977-10
12.6
Installing the fork protector
- Position fork protector on the right fork leg. Mount and tighten
screws 1.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
F02977-11
- Position fork protector on left fork leg. Mount and tighten
screws 2.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Position the brake line and the clamp. Mount and tighten
screws 3.
Guideline
F02976-11
Screw, brake hose
EJOT PT
2 Nm (1.5 lbf ft)
bracket
K60x20-Z
43
12
SERVICE WORK ON THE CHASSIS
12.7
Removing the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the front wheel.
(
p. 82)
Main work
- Remove screws 1 and take off the clamp.
- Remove screws 2 and take off the brake caliper.
- Allow the brake caliper and the brake line to hang loosely to the
side.
Info
Do not kink the brake line.
F03020-10
- Loosen screws 3. Remove the left fork leg.
- Loosen screws 4. Remove the right fork leg.
F03022-10
12.8
Installing the fork legs
Main work
- Position the fork legs.
Bleeder screws 1 are positioned toward the rear.
Info
The second milled groove in the fork leg must be flush with
the upper edge of the upper triple clamp.
F02179-10
- Tighten screws 2.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom triple
M8
15 Nm (11.1 lbf ft)
clamp
F03022-11
44
SERVICE WORK ON THE CHASSIS
12
– Position the brake caliper, mount screw 4, and tighten.
Guideline
Screw, front
M8x60
20 Nm (14.8 lbf ft)
brake caliper
Loctite®243™
– Mount and tighten screw 5.
Guideline
Screw, front
M8x40
20 Nm (14.8 lbf ft)
brake caliper
Loctite®243™
F03021-10
- Position the brake line and the clamp. Mount and tighten
screws 6.
Guideline
Screw, brake hose
EJOT PT
2 Nm (1.5 lbf ft)
bracket
K60x20-Z
Finishing work
- Install the front wheel.
(
p. 82)
12.9
Removing the lower triple clamp
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the front wheel.
(
p. 82)
– Remove the fork legs.
(
p. 44)
– Remove the start number plate. ( p. 52)
- Remove front fender. ( p. 52)
Main work
- Pull fuel tank breather 1 out of the steering stem.
- Remove nut 2.
- Release screw 3, take off the upper triple clamp with the handle-
bar and set aside.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
F03025-10
- Remove protective ring 4.
- Remove the lower triple clamp with the steering stem.
- Remove the upper steering head bearing.
I00655-10
45
12
SERVICE WORK ON THE CHASSIS
12.10
Installing the lower triple clamp
Main work
- Clean the bearing and sealing elements, check for damage, and
grease.
High viscosity grease ( p. 124)
- Insert the lower triple clamp with the steering stem. Mount upper
steering head bearing 1.
- Push on protective ring 2.
I00656-10
- Position the upper triple clamp and handlebar.
- Mount nut 3, but do not tighten yet.
I00657-10
- Position the fork legs.
Bleeder screws 4 are positioned toward the rear.
Info
The upper milled groove in the fork leg must be flush with
the upper edge of the upper triple clamp.
I00658-10
46
SERVICE WORK ON THE CHASSIS
12
– Tighten screws 5.
Guideline
Screw, bottom triple
M8
15 Nm (11.1 lbf ft)
clamp
K01481-10
- Tighten nut 3.
Guideline
Nut, steering head
M20x1.5
10 Nm (7.4 lbf ft)
– Position the fuel tank breather 6 in the steering stem.
K01482-10
- Tighten bolt 7.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to
avoid stresses.
- Tighten screws 8.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
K01483-10
- Position the brake caliper, mount screw 9, and tighten.
Guideline
Screw, front
M8x60
20 Nm (14.8 lbf ft)
brake caliper
Loctite®243™
– Mount and tighten screw bk.
Guideline
Screw, front
M8x40
20 Nm (14.8 lbf ft)
brake caliper
Loctite®243™
K01484-10
- Position the brake line and the clamp. Mount and tighten
screws bl.
Guideline
Screw, brake hose
EJOT PT
2 Nm (1.5 lbf ft)
bracket
K60x20-Z
Finishing work
- Check that the wiring harness, cables, brake line have the necessary
freedom of movement and are correctly routed.
- Install the front fender. ( p. 53)
- Install the start number plate. ( p. 52)
- Check the wiring harness, cables, and brake and clutch lines for free-
dom of movement and correct routing.
- Install the front wheel.
(
p. 82)
– Check the steering head bearing play. ( p. 48)
47
12
SERVICE WORK ON THE CHASSIS
- Remove the motorcycle from the lift stand. ( p. 41)
12.11
Checking the steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages com-
ponents.
- Correct incorrect steering head bearing play immediately. (Your authorized GASGAS Motorcycles workshop will
be glad to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing
seats in the frame can become damaged over time.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
Main work
- Move the handlebar to the straight-ahead position. Move the fork
legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
- Adjust the steering head bearing play.
(
p. 48)
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire
H01167-01
steering range. There should be no detectable detent positions.
» If detent positions are detected:
- Adjust the steering head bearing play.
(
p. 48)
– Check the steering head bearing and replace if required.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
12.12
Adjusting the steering head bearing play
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
Main work
- Pull fuel tank breather 1 out of the steering stem.
- Loosen screws 2.
- Loosen screw 3.
- Loosen and retighten nut 4.
Guideline
Nut, steering head
M20x1.5
10 Nm (7.4 lbf ft)
F03028-11
- Using a plastic hammer, tap lightly on the upper triple clamp to
avoid stresses.
- Tighten screw 3.
Guideline
Screw, steering stem
M8
20 Nm (14.8 lbf ft)
48
SERVICE WORK ON THE CHASSIS
12
– Tighten screws 2.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
– Position the fuel tank breather 1 in the steering stem.
Finishing work
- Check the steering head bearing play. ( p. 48)
- Remove the motorcycle from the lift stand. ( p. 41)
12.13
Lubricating the steering head bearing
- Remove the lower triple clamp.
(
p. 45)
– Install the lower triple clamp.
(
p. 46)
Info
The steering head bearing is cleaned and lubricated in the
course of removal and installation of the lower triple clamp.
H02387-01
12.14
Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
- Remove the seat. ( p. 56)
- Turn the knurled screw on the fuel tap all the way clockwise.
49
12
SERVICE WORK ON THE CHASSIS
Main work
- Pull fuel tank breather 1 out of the steering stem.
- Remove screw 2.
K01461-10
- Pull off fuel hose 3.
Info
Remaining fuel may flow out of the fuel hose.
K01462-10
- Pull the fuel tank guard out of rubber bushing 4.
- Raise the fuel tank.
- Take off the fuel tank.
K01463-10
12.15
Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
50
SERVICE WORK ON THE CHASSIS
12
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.
Main work
- Position the fuel tank.
- Make sure that no cables or throttle cables are trapped or damaged.
- Press fuel tank guard into rubber bushing 1.
- Check the throttle cable routing. ( p. 66)
K01463-11
- Mount and tighten screw 2.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Position the fuel tank breather 3 in the steering stem.
K01461-11
- Mount fuel hose 4.
K01462-11
Finishing work
- Mount the seat. ( p. 56)
51
12
SERVICE WORK ON THE CHASSIS
12.16
Removing the start number plate
- Remove the service hour counter and hang it to one side.
- Remove screw 1.
- Unhook the start number plate from the brake line and remove it.
S06035-10
12.17
Installing the start number plate
- Attach the start number plate to the brake line.
- Position the start number plate.
Holding lugs 1 engage in the fender.
S06036-10
- Mount and tighten screw 2.
Guideline
Screw, start number
M6
4 Nm (3 lbf ft)
plate
- Install service hour counter.
S06035-11
12.18
Removing front fender
- Remove screws 1. Take off the front fender.
S05958-10
52
SERVICE WORK ON THE CHASSIS
12
12.19
Installing the front fender
- Position start number plate on the fender.
The holding lugs of the start number plate engage in drill
holes 1 of the fender.
S06011-10
- Position fender on the lower triple clamp, mount and tighten
screws 2.
Guideline
Screw, fender
M6
6 Nm (4.4 lbf ft)
S05958-11
12.20
Removing the left side cover
- Remove left side cover from the rubber bushings in the areas A
and B.
- Take off the left side cover.
K01464-10
53
12
SERVICE WORK ON THE CHASSIS
12.21
Installing the left side cover
- Press the left side cover in area A into rubber bushing 1 and
press into rubber bushing B in area 2.
K01486-10
12.22
Removing the right side cover
- Remove the side cover from the rubber bushings in areas A and
B.
- Remove the right side cover.
K01465-10
54
SERVICE WORK ON THE CHASSIS
12
12.23
Installing the right side cover
- Press the right side cover in the area A into rubber bushing 1
and press into rubber bushing B in area 2.
K01466-10
12.24
Removing the shock absorber
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the right side cover. ( p. 54)
Main work
- Pull brake line 1 out of the holder.
- Remove screw 2 and lower the link fork carefully.
- Remove screw 3, push splash protector 4 to the side, and
remove the shock absorber.
K01493-10
12.25
Installing the shock absorber
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic.
- Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the
new handling characteristic.
55
12
SERVICE WORK ON THE CHASSIS
Main work
- Push splash protector 1 to the side.
- Position the shock absorber with screw 2, depending on the
desired seating height.
- Raise the link fork, mount and tighten the shock absorber with
screw 3.
Guideline
Screw, bottom
M10
45 Nm (33.2 lbf ft)
K01493-11
shock absorber
Loctite®243™
– Tighten screw 2.
Guideline
Screw, top shock
M10
45 Nm (33.2 lbf ft)
absorber
Loctite®243™
– Attach brake line 4 to the holder.
Finishing work
- Install the right side cover. ( p. 55)
- Remove the motorcycle from the lift stand. ( p. 41)
12.26
Removing the seat
- Open quick release 1 and raise the rear of the seat.
- Pull back the seat and remove it.
F02987-10
12.27
Mounting the seat
- Hook seat onto screw 1 and lower the seat at the rear and push it
forward.
Holding lug 2 hooks into the fuel tank.
F02988-10
56
SERVICE WORK ON THE CHASSIS
12
– Close quick release 3.
F02987-11
12.28
Removing the frame protector
- Remove the cable ties.
- Remove screws 1 with the bushings.
- Take off the left frame protector.
- Push the right frame protector to the front and take off at the bot-
tom.
K01491-10
12.29
Installing the frame protector
- Position the left frame protector.
- Insert the right frame protector from below and push it to the rear.
- Mount screws 1 with the bushings and tighten.
Guideline
Remaining screws,
M5
5 Nm (3.7 lbf ft)
chassis
- Secure the frame protector with cable ties.
K01491-10
12.30
Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
- Only operate the vehicle if it is equipped with an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Preparatory work
- Remove the seat. ( p. 56)
57
12
SERVICE WORK ON THE CHASSIS
Main work
- Detach retaining tab 1. Remove the air filter to the front.
K01467-10
12.31
Installing the air filter
Main work
- Insert a clean air filter in area A.
- Secure air filter with retaining pin 1.
Info
If the air filter is not mounted correctly, dust and dirt may
enter the engine and result in damage.
K01467-11
Finishing work
- Mount the seat. ( p. 56)
12.32
Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
- Remove the seat. ( p. 56)
- Remove the air filter.
(
p. 57)
58
SERVICE WORK ON THE CHASSIS
12
Main work
- Wash the air filter thoroughly in special cleaning liquid and allow it
to dry properly.
Air filter cleaner ( p. 124)
Info
Only press the air filter to dry it, never wring it out.
- Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 124)
- Clean the air filter box.
- Check intake flange for damage and looseness.
I00672-10
Finishing work
- Install the air filter.
(
p. 58)
– Mount the seat. ( p. 56)
12.33
Removing the main silencer
Warning
Danger of burns The exhaust system gets hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
Preparatory work
- Remove the right side cover. ( p. 54)
Main work
- Remove screw 1.
- Pull off the main silencer from the manifold at sleeve 2.
K01468-10
59
12
SERVICE WORK ON THE CHASSIS
12.34
Installing the main silencer
- Position the main silencer.
- Mount the main silencer with sleeve 1.
Guideline
High seat position
A
Low seat position
B
– Mount and tighten screw 2.
Guideline
K01468-11
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
12.35
Changing the rock wool on the main silencer
Warning
Danger of burns The exhaust system gets hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the rock wool fibers disappear, and the main silencer “burns out”.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
- Remove the right side cover. ( p. 54)
- Remove main silencer. ( p. 59)
Main work
- Remove screws with toothed washers 1 from the silencer cap 2.
- Remove end cap and outer tube 3.
- Remove rock wool 4 from the inner tube.
- Clean the parts that need to be reinstalled and check for damage.
- Fit new rock wool on the inner tube.
- Slide outer tube over the rock wool.
- Insert the silencer cap into the outer tube.
F02992-10
- Mount and tighten the screws with the toothed washers.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
Finishing work
- Install the main silencer. ( p. 60)
60
SERVICE WORK ON THE CHASSIS
12
12.36
Removing the engine sprocket cover
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
Main work
- Remove screws 1.
- Remove screw 2.
- Take off the engine sprocket cover.
K01469-10
12.37
Installing the engine sprocket cover
Main work
- Position the engine sprocket cover. Mount screws 1, but do not
tighten yet.
- Mount and tighten screw 2.
Guideline
Screw, rear engine
M6x12
8 Nm (5.9 lbf ft)
sprocket cover
- Tighten screws 1.
K01469-10
Guideline
Screw, front engine
M6x35
8 Nm (5.9 lbf ft)
sprocket cover
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
12.38
Checking the chain for dirt
- Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
- Clean the chain. ( p. 62)
400678-01
61
12
SERVICE WORK ON THE CHASSIS
12.39
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. 41)
Main work
- Rinse off loose dirt with a soft jet of water.
- Remove old grease residue with chain cleaner.
Chain cleaner ( p. 124)
- After drying, apply chain spray.
Off-road chain spray ( p. 124)
400725-01
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
12.40
Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear-
ings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel
locks or the engine will be damaged.
- Check the chain tension regularly.
- Set the chain tension in accordance with the specification.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
62
SERVICE WORK ON THE CHASSIS
12
Main work
- Press the chain upward at the end of the chain sliding piece and
determine chain tension A.
Info
The top part of chain 1 must be taut.
Chain wear is not always even, so you should repeat this
measurement at different chain positions.
F02994-10
Chain tension
5 … 8 mm (0.2 … 0.31 in)
» If the chain tension does not meet the specification:
- Adjust the chain tension. ( p. 63)
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
12.41
Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear-
ings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel
locks or the engine will be damaged.
- Check the chain tension regularly.
- Set the chain tension in accordance with the specification.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Check the chain tension. ( p. 62)
Main work
- Loosen nut 1.
- Loosen nuts 2.
- Adjust the chain tension by turning adjusting screws 3 left and
right.
Guideline
Chain tension
5 … 8 mm (0.2 … 0.31 in)
Turn the adjusting screws 3 on the left and right so that the
F02198-10
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.
- Tighten nuts 2.
- Make sure that chain adjusters 4 are fitted correctly on adjusting
screws 3.
- Tighten nut 1.
Guideline
Nut, rear wheel spindle
M12x1
40 Nm (29.5 lbf ft)
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
63
12
SERVICE WORK ON THE CHASSIS
12.42
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the engine sprocket cover. ( p. 61)
Main work
-
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.
When fitting the chain joint, always make sure that
400227-01
the closed side of the joint faces forward (direction
of travel).
-
Check the engine sprocket cover for wear.
» If the engine sprocket cover is worn through in the marked
area A:
- Change the engine sprocket cover.
-
Check the engine sprocket cover for tightness.
» If the engine sprocket cover is loose:
- Tighten the engine sprocket cover.
Guideline
I00708-10
Screw, front engine
M6x35
8 Nm (5.9 lbf ft)
sprocket cover
-
Check the chain sliding guard for wear.
» If the lower edge of the chain pins is in line with, or below, the
chain sliding guard:
- Change the chain sliding guard.
-
Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
- Tighten the chain sliding guard.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
F02199-10
64
SERVICE WORK ON THE CHASSIS
12
– 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 the chain sliding piece.
Guideline
Screw, chain sliding
M8
15 Nm (11.1 lbf ft)
piece
F02200-10
- Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:
- Change the chain guide.
400985-01
- Check that the chain guide is firmly seated.
» If the chain guide is loose:
- Tighten the chain guide.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
F02201-01
Finishing work
- Install the engine sprocket cover. ( p. 61)
- Remove the motorcycle from the lift stand. ( p. 41)
65
12
SERVICE WORK ON THE CHASSIS
12.43
Adjusting the chain guide
Info
The size of the chain wheel varies with the number of teeth. The chain guide can be adjusted on small sprockets.
- Remove screw 1.
- Position the chain guide.
- Mount and tighten screw 1.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
F02201-10
12.44
Checking the frame
- Check the frame for damage, cracks, and deformation.
» If the frame shows signs of damage, cracks, or deformation:
- Change the frame.
Guideline
Repairs on the frame are not permitted.
R06661-10
12.45
Checking the link fork
- Check the link fork for damage, cracks, and deformation.
» If the link fork shows signs of damage, cracks, or deformation:
- Change the link fork.
Guideline
Repairs on the link fork are not permitted.
R06662-10
12.46
Checking the throttle cable routing
Warning
Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed correctly.
If the throttle cable is kinked, trapped or blocked, the speed can no longer be controlled.
- Make sure that the throttle cable routing and the play in throttle cable complies with the specification.
Preparatory work
- Remove the seat. ( p. 56)
- Turn the knurled screw on the fuel tap all the way clockwise.
- Remove the fuel tank.
(
p. 49)
66
SERVICE WORK ON THE CHASSIS
12
Main work
- Check the throttle cable routing.
The throttle cable must be routed to the carburetor at the rear of
the handlebar, above the fuel tank bracket. It must not be hooked
into the handlebar cushion.
» If the throttle cable routing is not as specified:
- Correct the throttle cable routing.
I00663-10
Finishing work
- Install the fuel tank.
(
p. 50)
– Mount the seat. ( p. 56)
12.47
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.
D07902-10
67
13
BRAKE SYSTEM
13.1
Adjusting the basic position of the hand brake lever
- Remove screw 1. Take off cover 2.
F02996-11
- Adjust the basic position of the hand brake lever with adjusting
screw 3 to the rider's hand size.
Info
Turn the adjusting screw clockwise to increase the distance
between the hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the
distance between the hand brake lever and the handlebar.
The range of adjustment is limited.
F02997-10
- Position cover 2. Mount and tighten screw 1.
F02996-11
13.2
Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
- Make sure that worn-out brake discs are replaced immediately. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
- Check the front and rear brake disc thickness at multiple points for
the dimension A.
Info
Wear reduces the thickness of the brake disc around the
contact surface of the brake linings.
Brake discs - wear limits
front
2.2 mm (0.087 in)
400257-10
rear
2.2 mm (0.087 in)
» If the brake disc thickness is less than the specified value:
- Change the front brake disc.
- Change the rear brake disc.
68
BRAKE SYSTEM
13
– Check the front and rear brake discs for damage, cracking, and
deformation.
» If the brake disc exhibits damage, cracking, or deformation:
- Change the front brake disc.
- Change the rear brake disc.
13.3
Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
- Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
- Remove screws 1.
- Take off cover 2 with membrane 3.
- Check the brake fluid level.
Brake fluid level below reser-
5 mm (0.2 in)
voir rim
» If the brake fluid level does not meet specifications:
F02998-10
- Add front brake fluid.
(
p. 70)
69
13
BRAKE SYSTEM
- Position the cover with the membrane. Mount and tighten the
screws.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
13.4
Adding front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Check that the brake linings of the front brake are secured.
(
p. 71)
70
BRAKE SYSTEM
13
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.
- Correct the brake fluid level.
Guideline
Brake fluid level below reser-
5 mm (0.2 in)
F02998-10
voir rim
Brake fluid DOT 4 / DOT 5.1 ( p. 122)
- Position the cover with the membrane. Mount and tighten the
screws.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
13.5
Checking that the brake linings of the front brake are secured
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
- Check the brake linings for lining thickness A.
≥ 1 mm (≥ 0.04 in)
Minimum thickness A
» If it is less than the minimum thickness:
- Change the brake linings of the front brake.
(
p. 71)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the brake linings of the front brake.
(
p. 71)
F02999-10
- Check that the brake linings are secured.
» If the brake linings are not secured correctly:
- Secure brake linings, replace with new parts if necessary.
13.6
Changing the front 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.)
71
13
BRAKE SYSTEM
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the
brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is
not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer
warranty shall be void.
- Only use brake linings approved and recommended by GASGAS Motorcycles.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
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.
F02998-10
72
BRAKE SYSTEM
13
–
Remove screw 4 and screw 5.
–
Press back the brake linings by slightly tilting the brake caliper later-
ally on the brake disc. Carefully pull the brake caliper backward from
the brake disc.
-
Press the brake piston back into the basic position and ensure that
brake fluid does not flow out of the brake fluid reservoir; extract
some if necessary.
F03000-11
-
Remove lock ring 6.
–
Remove screw 7.
–
Remove the brake linings.
–
Clean the brake caliper and the brake caliper bracket.
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.
F03001-10
-
Position the new brake linings.
Info
Always change the brake linings in pairs.
Ensure that the brake linings are correctly positioned in the
holding spring.
-
Mount and tighten screw 7.
Guideline
Screw, brake linings
M5
8 Nm (5.9 lbf ft)
–
Mount lock ring 6.
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.
-
Check the brake discs. ( p. 68)
73
13
BRAKE SYSTEM
-
Position the brake caliper.
–
Mount screw 4, but do not tighten it yet.
Guideline
Screw, front
M8x60
20 Nm (14.8 lbf ft)
brake caliper
Loctite®243™
–
Mount screw 5, but do not tighten it yet.
Guideline
Screw, front
M8x40
20 Nm (14.8 lbf ft)
F03000-11
brake caliper
Loctite®243™
–
Operate the hand brake lever repeatedly until the brake linings are
in contact with the brake disc and there is a pressure point. Secure
the hand brake lever in the activated position.
The brake caliper straightens.
-
Tighten screw 4.
Guideline
Screw, front
M8x60
20 Nm (14.8 lbf ft)
brake caliper
Loctite®243™
–
Tighten screw 5.
Guideline
Screw, front
M8x40
20 Nm (14.8 lbf ft)
brake caliper
Loctite®243™
–
Remove the locking piece of the hand brake lever.
–
Correct the brake fluid level.
Guideline
Brake fluid level below reser-
5 mm (0.2 in)
voir rim
Brake fluid DOT 4 / DOT 5.1 ( p. 122)
-
Position cover 2 with membrane 3.
–
Mount and tighten screws 1.
F02998-10
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
13.7
Checking the free travel of the foot brake lever
Warning
Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
- Ensure that the adjustment steps are performed properly. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
74
BRAKE SYSTEM
13
– Detach spring 1.
- Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check free
travel A.
Guideline
Free travel of foot brake lever
3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not match the specification:
- Adjust the free travel of the hand brake lever.
(
p. 75)
I00624-10
- Attach spring 1.
13.8
Adjusting the free travel of the foot brake lever
Warning
Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
- Ensure that the adjustment steps are performed properly. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
- Detach the foot brake lever spring.
- Loosen nut 1.
- Turn push rod 2 accordingly until you have free travel A.
Guideline
Free travel of foot brake lever
3 … 5 mm (0.12 … 0.2 in)
– Hold push rod 2 and tighten nut 1.
Guideline
K01492-10
Nut, push rod, foot
M6
6 Nm (4.4 lbf ft)
brake lever
- Attach the foot brake lever spring.
- Check whether the basic position of the foot brake lever is suitable
for the rider.
» When the basic position of the foot brake lever needs to be
adjusted:
- Adjust the basic position of the foot brake lever.
(
p. 75)
13.9
Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
- Ensure that the adjustment steps are performed properly. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
75
13
BRAKE SYSTEM
- Detach spring 1.
- Loosen nut 2 and, with push rod 3, turn it back until you have
maximum free travel.
- To adjust the basic position of the foot brake lever to individual
requirements, loosen nut 4 and turn screw 5 accordingly.
Info
The range of adjustment is limited.
- Turn push rod 3 accordingly until you have free travel A. If nec-
essary, adjust the basic position of the foot brake lever.
Guideline
Free travel of foot brake lever
3 … 5 mm (0.12 … 0.2 in)
– Hold screw 5 and tighten nut 4.
Guideline
Bushing, foot brake
M8
20 Nm (14.8 lbf ft)
lever stop
I00713-10
- Hold push rod 3 and tighten nut 2.
Guideline
Nut, push rod, foot
M6
6 Nm (4.4 lbf ft)
brake lever
- Attach spring 1.
13.10
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 specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
- Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
- Stand the vehicle upright.
- Check the brake fluid level in level viewer 1.
» If an air bubble is visible in viewer 1:
- Add rear brake fluid.
(
p. 77)
H01654-11
76
BRAKE SYSTEM
13
13.11
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 specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
- Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Check that the brake linings of the rear brake are secured. ( p. 78)
Main work
- Remove screws 1.
- Take off cover 2 with washer 3 and membrane 4.
F03004-10
77
13
BRAKE SYSTEM
- Add brake fluid up to level A.
Guideline
10 mm (0.39 in)
Level A (brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 122)
- Position cover with washer and membrane.
- Mount and tighten the screws.
H01654-10
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
13.12
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.)
- Check the brake linings for minimum thickness A.
≥ 1 mm (≥ 0.04 in)
Minimum thickness A
» If the minimum thickness is less than specified:
- Change the rear brake linings.
(
p. 78)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
- Change the rear brake linings.
(
p. 78)
M02047-10
- Check that the brake linings are secured.
» If the brake linings are not secured correctly:
- Secure brake linings, replace with new parts if necessary.
13.13
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.)
78
BRAKE SYSTEM
13
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the
brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is
not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer
warranty shall be void.
- Only use brake linings approved and recommended by GASGAS Motorcycles.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
Main work
- Remove lock ring 1.
- Remove screw 2.
- Remove screw 3 and screw 4.
F02205-10
79
13
BRAKE SYSTEM
- Take off the brake caliper.
Info
Do not kink or damage the brake line.
- Remove the brake linings.
- Clean the brake caliper and the brake caliper bracket.
- Allow the brake caliper and the brake line to hang loosely to the
side.
F02207-10
- Check the brake discs. ( p. 68)
- Remove screws 5.
- Take off cover 6 with washer 7 and membrane 8.
- Press the brake piston back to its basic position and make sure that
no brake fluid overflows from the brake fluid reservoir, extract brake
fluid if necessary.
F03004-11
- Position the new brake linings.
Info
Always change the brake linings in pairs.
Ensure that the brake linings are correctly positioned in the
holding spring.
- Position the brake caliper on the brake disc.
The brake linings are correctly positioned.
F02207-11
- Mount and tighten screw 3.
Guideline
Screw, rear brake
M6x16
10 Nm (7.4 lbf ft)
caliper
Loctite®243™
– Mount and tighten screw 4.
Guideline
Screw, rear brake
M6x40
10 Nm (7.4 lbf ft)
caliper
Loctite®243™
F02206-10
- Mount and tighten screw 2.
Guideline
Screw, brake linings
M5
8 Nm (5.9 lbf ft)
– Mount lock ring 1.
- Check the brake discs. ( p. 68)
- Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
80
BRAKE SYSTEM
13
– Add brake fluid up to level A.
Guideline
10 mm (0.39 in)
Level A (brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 122)
- Position cover with washer and membrane.
- Mount and tighten the screws.
H01654-10
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
81
14
WHEELS, TIRES
14.1
Removing the front wheel
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
Main work
- 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.
F03005-11
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
- Always lay the wheel down in such a way that the brake
disc is not damaged.
- Hold front wheel and remove wheel spindle. Take the front wheel
out of the fork.
F03006-10
Info
Do not actuate the hand brake lever when the front wheel is
removed.
- Remove spacers 3.
F03044-10
14.2
Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
82
WHEELS, TIRES
14
– 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. 124)
- Insert the spacers.
F03045-10
Info
Insert the wide spacer on the left in the direction of travel.
- Clean and grease the wheel spindle.
Long-life grease ( p. 124)
- Position the front wheel.
The brake linings are correctly positioned.
- Insert the wheel spindle.
- Mount and tighten screw 2.
Guideline
F03005-10
Screw, front
M10
40 Nm (29.5 lbf ft)
wheel spindle
Loctite®243™
– 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. 41)
- Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
- Tighten screws 3.
Guideline
Screw, fork stub
M6
10 Nm (7.4 lbf ft)
14.3
Removing the rear wheel
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
Main work
- Remove nut 1.
- Take off chain adjuster 2.
F02209-10
83
14
WHEELS, TIRES
- Pull out wheel spindle 3 far enough to allow the rear wheel to be
pushed forward.
- Push the rear wheel forward as far as possible. Remove the chain
from the rear sprocket.
Info
Cover the components to protect them against damage.
F02210-10
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 rear wheel and remove the wheel spindle. Take the rear
wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel is
removed.
- Remove spacers 4.
F03046-10
14.4
Installing the rear wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
Main work
- Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
- Change the rear wheel bearing.
- Clean and grease shaft seal rings 1 and contact surfaces A of the
spacers.
Long-life grease ( p. 124)
- Insert the spacers.
F03047-10
Info
Insert the wide spacer on the left in the direction of travel.
84
WHEELS, TIRES
14
– Clean and grease the wheel spindle.
Long-life grease ( p. 124)
- Position rear wheel and mount the chain.
The brake linings are correctly positioned.
- Insert wheel spindle 2.
F02210-11
- Position chain adjuster 3. Mount nut 4, but do not tighten it yet.
- Make sure that chain adjusters 3 are fitted correctly on adjusting
screws 5.
- Make sure that the markings on the left and right chain
adjusters 3 are in the same position relative to reference
marks B. The rear wheel is then correctly aligned.
Info
The wide adjustment range of the chain adjusters enables
F02198-11
different secondary ratios with the same chain length.
Chain adjusters 3 can be turned by 180°.
- Check the chain tension. ( p. 62)
- Tighten nut 4.
Guideline
Nut, rear wheel spindle
M12x1
40 Nm (29.5 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 41)
14.5
Checking the tire condition
Info
Only mount tires approved and/or recommended by GASGAS Motorcycles.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcy-
cle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
- Check the front and rear tires for cuts, embedded objects, and other
damage.
» If the tires have cuts, run-in objects, or other damage:
- Change the tires.
400602-10
85
14
WHEELS, TIRES
- Check the tire age.
Info
The tire date of manufacture is usually contained in the tire
label and is indicated by the last four digits of the DOT num-
ber. The first two digits indicate the week of manufacture
and the last two digits the year of manufacture.
GASGAS Motorcycles recommends that the tires be changed
after five years at the latest, regardless of the actual wear.
H01144-10
» If the tires are more than five years old:
- Change the tires.
14.6
Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
- Remove protection cap.
- Check tire pressure when the tires are cold.
Offroad tire pressure
front
1.0 bar (15 psi)
rear
1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
- Correct tire pressure.
- Mount the protection cap.
400695-01
14.7
Checking the spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam-
age.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low,
then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
- Check spoke tension regularly, and in particular on a new vehicle. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
- 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.
- Check the spoke torque.
86
WHEELS, TIRES
14
Guideline
Spoke nipple
M3.5
3 Nm (2.2 lbf ft)
Torque wrench kit (58429094000)
87
15
COOLING SYSTEM
15.1
Cooling system
The water pump 1 in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regu-
lated by a valve in the radiator cap 2. This ensures that operating the
vehicle at the specified coolant temperature will not result in a risk of
malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also
reduce the cooling effect.
K01470-10
15.2
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
- Stand the motorcycle upright on a horizontal surface.
- Take off radiator cap 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.
K01471-10
- Check the coolant level in the radiator.
10 mm (0.39 in)
Coolant level A above the
radiator fins
» If the coolant level does not match the specified value:
- Correct the coolant level.
Coolant ( p. 122)
- Mount the radiator cap.
400243-10
88
COOLING SYSTEM
15
15.3
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
- Stand the motorcycle upright on a horizontal surface.
- Remove the radiator cap.
- Check the coolant level in the radiator.
10 mm (0.39 in)
Coolant level A above the
radiator fins
» If the coolant level does not match the specified value:
- Correct the coolant level.
400243-10
Coolant ( p. 122)
- Mount the radiator cap.
15.4
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
89
15
COOLING SYSTEM
Condition
The engine is cold.
- Position the motorcycle upright.
- Place an appropriate container under the water pump cover.
- Remove screw 1. Take off the radiator cap.
- Completely drain the coolant.
- Mount and tighten screw 1 with a new seal ring.
Guideline
Drain plug, water
M6
6 Nm (4.4 lbf ft)
pump cover
K01472-10
15.5
Refilling with coolant
Warning
Danger of poisoning Coolant is harmful to health.
-
Keep coolant out of the reach of children.
–
Do not allow coolant to come into contact with the skin, the eyes and clothing.
–
Consult a doctor immediately if coolant is swallowed.
–
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–
Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
–
Change clothing if coolant spills onto your clothing.
Main work
- Make sure that screw 1 is tightened.
- Position the motorcycle upright.
- Add coolant to level A.
Guideline
10 mm (0.39 in)
Distance A above the radia-
tor fins
K01473-10
Coolant
0.7 l (0.7 qt.)
Coolant ( p. 122)
– Move the vehicle into the position shown and prevent it from rolling
away. Height difference B must be reached.
Guideline
50 cm (19.7 in)
Height difference B
Info
For all of the air to be able to escape from the cooling sys-
tem, the vehicle must be raised at the front. If the cool-
ing system is poorly de-aerated, its cooling power will be
400677-11
reduced and the engine may overheat.
- Return the vehicle to the horizontal position.
- Add coolant to level A.
- Mount the radiator cap.
Finishing work
- Go for a short test ride.
- Check the cooling system for leaks.
- Check the coolant level. ( p. 89)
90
COOLING SYSTEM
15
15.6
Changing the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
- Position the motorcycle upright.
- Place an appropriate container under the water pump cover.
- Remove screw 1. Take off the radiator cap.
- Completely drain the coolant.
- Mount and tighten screw 1 with a new seal ring.
Guideline
Drain plug, water
M6
6 Nm (4.4 lbf ft)
pump cover
K01472-10
- Add coolant to level A.
Guideline
10 mm (0.39 in)
Distance A above the radia-
tor fins
Coolant
0.7 l (0.7 qt.)
Coolant ( p. 122)
K01473-10
91
15
COOLING SYSTEM
- Move the vehicle into the position shown and secure it against
rolling away. Height difference B must be reached.
Guideline
50 cm (19.7 in)
Height difference B
Info
For all of the air to be able to escape from the cooling sys-
tem, the vehicle must be raised at the front. If the cool-
ing system is poorly de-aerated, its cooling power will be
400677-11
reduced and the engine may overheat.
- Return the vehicle to the horizontal position.
- Add coolant to level A.
- Mount the radiator cap.
Finishing work
- Go for a short test ride.
- Check the cooling system for leaks.
- Check the coolant level. ( p. 89)
92
TUNING THE ENGINE
16
16.1
Checking the play in the throttle cable
- Check the throttle grip for smooth operation.
- Move the handlebar to the straight-ahead position. Turn the throt-
tle grip back and forth slightly and determine the play in throttle
cable A.
Play in throttle cable
3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
- Adjust the play in the throttle cable.
(
p. 93)
400192-11
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and let it run at idle speed. Move the handlebar to
and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
- Adjust the play in the throttle cable.
(
p. 93)
16.2
Adjusting the play in the throttle cable
Preparatory work
- Remove the seat. ( p. 56)
- Turn the knurled screw on the fuel tap all the way clockwise.
- Remove the fuel tank.
(
p. 49)
– Check the throttle cable routing. ( p. 66)
Main work
- Move the handlebar to the straight-ahead position.
- Push back sleeve 1.
- Ensure that the throttle cable sleeve is pushed all the way into bar-
rel adjuster 2.
- Loosen nut 3.
F02895-10
- Turn barrel adjuster 2 so that there is play A in the throttle
cable at the throttle grip.
Guideline
Play in throttle cable
3 … 5 mm (0.12 … 0.2 in)
– Tighten nut 3.
- Slide on sleeve 1.
400192-11
93
16
TUNING THE ENGINE
Finishing work
- Install the fuel tank.
(
p. 50)
– Mount the seat. ( p. 56)
- Check the play in the throttle cable. ( p. 93)
16.3
Carburettor - idle speed
The idle setting of the carburetor has a big influence on the starting
behavior, stable idle speed, and the response to throttle opening. This
means that an engine with a correctly set idle speed will be easier to
start than one with an incorrectly set idle speed.
Info
The carburetor and its components are subject to increased
wear caused by engine vibration. Wear can result in malfunc-
tioning.
I00630-10
The idle speed is adjusted using the idle speed adjusting screw 1.
The idle mixture is adjusted using the idle air adjusting screw 2.
16.4
Carburetor - adjusting the idle speed
- Screw in idle air adjusting screw 2 all the way and turn it to the
specified basic setting.
Guideline
Idle air adjusting screw
Open
3 turns
– Run the engine until warm.
Guideline
Warming-up phase
≥ 5 min
I00630-10
- Connect the special tool.
Service hour counter with revolution counter (A54012920100)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Adjust the idle speed using idle speed adjusting screw 1.
Guideline
Choke function deactivated - The choke lever is pushed in to the
stop. ( p. 16)
Idle speed
1,400 … 1,500 rpm
– Turn idle air adjusting screw 2 slowly in a clockwise direction until
the idle speed begins to fall.
- Note the position and turn the idle air adjusting screw slowly coun-
terclockwise until the idle speed again begins to fall.
94
TUNING THE ENGINE
16
– Adjust to the point between these two positions with the highest
idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a
normal level and repeat the above steps.
If the procedure described here does not lead to satisfactory
results, the cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end with-
out any change of engine speed, mount a smaller idling jet.
After changing the idling jet, start from the beginning with
the adjusting steps.
Following extreme air temperature or altitude changes,
adjust the idle speed again.
16.5
Checking the clutch setting
- Connect special tool 1.
Service hour counter with revolution counter (A54012920100)
F03010-10
- Let the front wheel of the vehicle make contact with a fixed object.
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.
401521-01
- Start the motorcycle.
- Only ride full throttle to the point where the maximum engine speed
is reached.
Guideline
Operation at full throttle
≤3s
– Read the speed.
Slip speed
9,800 … 10,400 rpm
» If the specified value is not reached:
- Adjust the clutch.
(
p. 96)
95
16
TUNING THE ENGINE
16.6
Removing the clutch cover
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Info
Fuel can emerge via the carburetor.
Capture emerging fuel using a suitable container.
- Turn the knurled screw on the fuel tap all the way clockwise.
- Lay the vehicle down on its left side.
- Remove screws 1.
- Remove clutch cover 2 with the seal ring.
K01487-10
16.7
Adjusting the clutch
Preparatory work
Condition
Clutch cover remains fitted
- Raise the motorcycle with a lift stand. ( p. 41)
Condition
Clutch cover is removed
- Remove the clutch cover.
(
p. 96)
Condition
Clutch cover remains fitted
- Remove plug 1 and the seal ring.
K01488-10
96
TUNING THE ENGINE
16
– Turn the clutch basket until adjusting screws 2 become acces-
sible.
Info
The clutch basket is turned with the kick starter lever.
Adjusting screws 2 are turned with the rear wheel.
K01489-10
Condition
If there is no reference point:
- Turn adjusting screws 2 counterclockwise to the last
detectable click.
- Turn adjusting screws 2 clockwise by 8 clicks to the basic
setting.
Guideline
Basic setting of slip speed
9,800 … 10,400 rpm
K01490-10
Info
The springs may not be pretensioned by more than
14 clicks from the stop using the adjusting screws.
If 15 clicks or more are preloaded, the clutch can
become tense and can no longer be reset. The
clutch must be dismantled.
Condition
If the slip speed is too low:
- Turn adjusting screws 2 clockwise.
Guideline
1 click increases the slip
200 … 300 rpm
speed by
Info
The springs may not be pretensioned by more than
14 clicks from the stop using the adjusting screws.
Condition
If the slip speed is too high:
- Turn adjusting screws 2 counterclockwise.
Guideline
1 click decreases the slip
200 … 300 rpm
speed by
97
16
TUNING THE ENGINE
- Mount and tighten plug 1 with a new seal ring.
Guideline
Screw, gear oil level
M14x1.25
10 Nm (7.4 lbf ft)
monitoring
K01488-10
Condition
Clutch cover is removed
- Turn clutch basket 1 until adjusting screws 2 become acces-
sible.
Info
Clutch basket 1 is turned with the kick starter lever.
Adjusting screws 2 are turned with the rear wheel.
I00644-10
Condition
If there is no reference point:
- Turn adjusting screws 2 counterclockwise to the last
detectable click.
- Turn adjusting screws 2 clockwise by 8 clicks to the basic
setting.
Guideline
Basic setting of slip speed
9,800 … 10,400 rpm
I00644-11
Info
The springs may not be pretensioned by more than
14 clicks from the stop using the adjusting screws.
If 15 clicks or more are preloaded, the clutch can
become tense and can no longer be reset. The
clutch must be dismantled.
Condition
If the slip speed is too low:
- Turn adjusting screws 2 clockwise.
Guideline
1 click increases the slip
200 … 300 rpm
speed by
Info
The springs may not be pretensioned by more than
14 clicks from the stop using the adjusting screws.
Condition
If the slip speed is too high:
- Turn adjusting screws 2 counterclockwise.
Guideline
1 click decreases the slip
200 … 300 rpm
speed by
98
TUNING THE ENGINE
16
Finishing work
Condition
Clutch cover remains fitted
- Remove the motorcycle from the lift stand. ( p. 41)
Condition
Clutch cover is removed
- Install the clutch cover.
(
p. 99)
– Check the gear oil level. ( p. 100)
- Check the clutch setting.
(
p. 95)
16.8
Installing the clutch cover
Main work
- Position the clutch cover 1 with the seal ring.
- Mount and tighten screws 2.
Guideline
Screw, outer clutch
M6
10 Nm (7.4 lbf ft)
cover
K01487-11
Finishing work
- Check the gear oil level. ( p. 100)
99
17
SERVICE WORK ON THE ENGINE
17.1
Checking the gear oil level
Condition
The engine is cold.
Preparatory work
- Stand the motorcycle upright on a horizontal surface.
Main work
- Remove screw 1.
- Check the gear oil level.
Gear oil must not run out of the hole.
The gear oil level is at the lower edge of the hole.
» If the gear oil level is below the hole:
- Add the gear oil.
(
p. 101)
K01474-10
» If gear oil runs out:
- Correct the gear oil level.
- Mount and tighten screw 1.
Guideline
Screw, gear oil level
M14x1.25
10 Nm (7.4 lbf ft)
monitoring
17.2
Changing the gear oil
Warning
Danger of scalding Engine and gear oil get hot when the motorcycle is operated.
- Wear suitable protective clothing and safety gloves.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Drain gear oil with engine at operating temperature.
Preparatory work
- Stand the motorcycle on the plug-in stand on a horizontal surface.
Main work
- Position an appropriate container under the engine.
- Remove oil drain plug 1 with the magnet.
- Let the gear oil drain fully.
- Thoroughly clean the oil drain plug with magnet.
- Clean the sealing surface on the engine.
- Mount and tighten the oil drain plug with the magnet and new seal
ring.
K01475-10
Guideline
Oil drain plug with
M12x1.5
20 Nm (14.8 lbf ft)
magnet
100
SERVICE WORK ON THE ENGINE
17
– Remove filler plug 2 with the O-ring, and fill up with gear oil.
Gear oil
0.20 l (0.21 qt.)
Gear oil
(ATF Dexron 3)
(
p. 123)
Info
Too little gear oil or poor-quality gear oil results in prema-
ture wear to the transmission.
401955-11
- Mount and tighten filler plug 2 together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and check it for leaks.
Finishing work
- Check the gear oil level. ( p. 100)
17.3
Adding the gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Preparatory work
- Stand the motorcycle upright on a horizontal surface.
Main work
- Remove screw 1.
K01474-10
- Remove filler plug 2 with the O-ring.
- Add gear oil until it flows out of the hole of the gear oil level plug.
Gear oil (ATF Dexron 3) ( p. 123)
- Mount and tighten screw 1.
Guideline
Screw, gear oil level
M14x1.25
10 Nm (7.4 lbf ft)
monitoring
401955-11
- Mount and tighten filler plug 2 together with the O-ring.
101
17
SERVICE WORK ON THE ENGINE
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.
102
CARBURETOR
18
18.1
Removing the carburetor
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 41)
- Remove the seat. ( p. 56)
- Turn the knurled screw on the fuel tap all the way clockwise.
- Remove the fuel tank.
(
p. 49)
– Remove the right side cover. ( p. 54)
- Remove main silencer. ( p. 59)
- Remove the frame protector. ( p. 57)
- Remove the left side cover. ( p. 53)
Main work
- Loosen hose clips 1 and 2.
R06704-10
103
18
CARBURETOR
- Pull off vent hose 3.
R06705-10
- Remove screws 4.
- Repeat the operation on the opposite side.
- Remove subframe with the fender.
Info
Watch out for the intake flange.
R06706-10
- Take fuel line 5 out of the guide.
R06707-10
- Pull the carburetor back toward the rear.
R06708-10
- Open throttle slide cover 6.
- Pull the throttle slide out of the carburetor.
- Drain the remaining fuel.
R06709-10
104
CARBURETOR
18
– Pull throttle slide spring back.
- Push spring retainer 7 back.
R06710-10
- Detach throttle cable wire 8.
- Take off the throttle slide.
R06711-10
18.2
Installing the carburetor
Main work
- Attach throttle cable wire 1.
R06711-11
- Position spring retainer 2 and the throttle slide spring.
R06710-11
- Position the throttle slide and the throttle slide cover.
- Tighten throttle slide cover 3 hand-tight.
- Measure the distance between the carburetor housing and the
throttle slide cover.
» Distance: ≤ 3 mm (≤ 0.12 in)
If the specified value is not reached:
- Screw on the throttle slide cover correctly.
R06709-11
105
18
CARBURETOR
- Mount the carburetor.
R06708-11
- Position fuel hose 4 in the guide.
R06707-11
- Position the subframe.
Info
Watch out for the intake flange.
- Mount and tighten screws 5.
Guideline
Remaining screws,
M8
25 Nm (18.4 lbf ft)
chassis
R06706-11
- Repeat the operation on the opposite side.
- Mount vent hose 6.
R06705-11
106
CARBURETOR
18
– Position and tighten hose clips 7 and 8.
Guideline
Hose clip, carburetor
-
2.8 Nm (2.07 lbf ft)
R06704-11
Finishing work
- Check the play in the throttle cable. ( p. 93)
- Install the main silencer. ( p. 60)
- Install the left side cover. ( p. 54)
- Carburetor - adjust the idle speed.
(
p. 94)
– Install the frame protector. ( p. 57)
- Install the fuel tank.
(
p. 50)
– Mount the seat. ( p. 56)
- Remove the motorcycle from the lift stand. ( p. 41)
107
19
CLEANING, CARE
19.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
- Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
- Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance
60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Clean the motorcycle regularly to maintain its value and appearance over a long period.
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. 124)
Info
Use warm water containing normal motorcycle cleaner and
401061-01
a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always
rinse the vehicle with water first.
-
After rinsing the motorcycle with a gentle spray of water, allow it to
dry thoroughly.
-
Remove the closure of the exhaust system.
–
Empty the carburetor float chamber.
Warning
Danger of accidents Moisture and dirt impair the brake
system.
- Explain to your child that he or she must brake carefully
several times to dry out and remove dirt from the brake
linings and the brake discs.
-
After cleaning, your child should ride the vehicle a short distance
until the engine warms up and until the brakes system has dried
through careful application of the brakes.
Info
The heat produced causes water at inaccessible locations in
the engine and on the brake system to evaporate.
-
Push back the protection caps on the handlebar controls to allow
water to evaporate.
108
CLEANING, CARE
19
– After the motorcycle has cooled down, lubricate all moving parts
and pivot points.
- Clean the chain. ( p. 62)
- Treat bare metal (except for brake discs and the exhaust system)
with a corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 124)
- 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. 124)
109
20
STORAGE
20.1
Storage
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If the motorcycle is not being used for an extended length of time, additional measures are recommended.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are neces-
sary, you should do this during the storage period (less workshop overload). This allows you to avoid long waiting
periods when the next season starts.
- When refueling for the last time before taking the motorcycle out of
service, add fuel additive.
Fuel additive ( p. 124)
- Refuel. ( p. 23)
Tip
Fill the fuel tank completely as specified, using fuel with the
lowest possible ethanol content.
401058-01
- Clean the motorcycle. ( p. 108)
- Change the gear oil.
(
p. 100)
– Check the antifreeze and coolant level. ( p. 88)
- Empty the carburetor float chamber.
- Check tire pressure. ( p. 86)
- 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. 41)
- 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. Because the
engine will not warm up sufficiently, the water vapor pro-
duced during combustion will condense, causing engine
parts and the exhaust system to rust.
110
STORAGE
20
20.2
Preparing for use after storage
- Remove the motorcycle from the lift stand. ( p. 41)
- Perform checks and maintenance measures when preparing for use.
(
p. 20)
– Take a test ride.
401059-01
111
21
TROUBLESHOOTING
Faults
Possible cause
Action
Engine turns but does not start
Operating error
-
Carry out start procedure. ( p. 20)
Motorcycle was out of use for a
-
Empty the carburetor float chamber.
long time and there is old fuel in
the float chamber
Fuel supply interrupted
-
Check the fuel tank breather.
–
Clean the fuel tap.
–
Check/set the carburetor components.
Spark plug sooty or wet
-
Clean and dry the spark plug and spark
plug connector, or change if necessary.
Plug gap of spark plug too wide
-
Adjust plug gap.
Guideline
Spark plug electrode gap
0.70 mm (0.0276 in)
Fault in ignition system
-
Check the ignition system.
Short-circuit cable in wiring har-
-
Check the stop button.
ness frayed, stop button faulty
The connector or ignition coil is
-
Clean the plug-in connection and treat it
loose or oxidized
with contact spray.
Water in carburetor or jets
-
Check/set the carburetor components.
blocked
Engine has no idle speed
Idling jet blocked
-
Check/set the carburetor components.
Adjusting screws on the carbu-
-
Carburetor - adjust the idle speed.
retor are in turned to the wrong
(
p. 94)
position
Spark plug defective
-
Change spark plug.
Ignition system defective
-
Check the ignition coil.
–
Check the spark plug connector.
Engine does not speed up
The carburetor is flowing over
-
Check/set the carburetor components.
because the float needle is dirty or
worn
Loose carburetor jets
-
Check/set the carburetor components.
Fault in ignition system
-
Check the ignition system.
Engine has too little power
Fuel supply interrupted
-
Check the fuel tank breather.
–
Clean the fuel tap.
–
Check/set the carburetor components.
Air filter very dirty
-
Clean the air filter and air filter box.
(
p. 58)
Exhaust system leaky, deformed
-
Check exhaust system for damage.
or too little glass fiber yarn filling
–
Change the rock wool on the main
in main silencer
silencer.
(
p. 60)
Ignition system defective
-
Check the ignition coil.
–
Check the spark plug connector.
Diaphragm or reed valve housing
-
Check the diaphragm and reed valve hous-
damaged
ing.
Noticeable wear
-
Overhaul the engine.
Clutch engagement speed too low
-
Check the clutch setting.
(
p. 95)
or too high
Engine stalls or is popping into the
Lack of fuel
-
Turn the knurled screw on the fuel tap all
carburetor
the way counterclockwise.
-
Refuel. ( p. 23)
112
TROUBLESHOOTING
21
Faults
Possible cause
Action
Engine stalls or is popping into the
Engine takes in bad air
- Check the intake flange and carburetor for
carburetor
tightness.
The connector or ignition coil is
- Clean the plug-in connection and treat it
loose or oxidized
with contact spray.
Engine overheats
Too little coolant in cooling system
- Check the cooling system for leakage.
- Check the coolant level. ( p. 89)
Too little air stream
- Switch off engine when standing.
Radiator fins very dirty
- Clean radiator fins.
Foam formation in cooling system
- Drain the coolant.
(
p. 89)
– Refill with coolant.
(
p. 90)
Damaged cylinder head or cylin-
- Check the cylinder head or cylinder head
der head gasket
gasket.
Bent radiator hose
- Change the radiator hose.
White smoke emission (steam in
Damaged cylinder head or cylin-
- Check the cylinder head or cylinder head
exhaust gas)
der head gasket
gasket.
Gear oil exits at the vent hose
Too much gear oil added
- Check the gear oil level. ( p. 100)
Water in the gear oil
Damaged radial shaft seal ring or
- Check the radial shaft seal ring and the
water pump
water pump.
113
22
TECHNICAL SPECIFICATIONS
22.1
Engine
Design
1-cylinder 2-stroke engine, water-cooled, with reed intake
Displacement
49.9 cm³ (3.045 cu in)
Stroke
40.7 mm (1.602 in)
Bore
39.5 mm (1.555 in)
Crankshaft bearing
2 grooved ball bearings
Conrod bearing
Needle bearing
Piston pin bearing
Needle bearing
Pistons
Aluminum cast
Piston rings
1 rectangular ring
Engine lubrication
Mixed lubrication
Primary transmission
33:61 straight cut spur gear drive
Clutch
Multi-disc centrifugal force clutch
Gearbox
Rigid 1-stage reduction gear
Transmission ratio
14:31
Ignition
Selettra Digital
Spark plug
BRISK AR10C (Standard), BRISK AR10IR (recommended for
competition use)
Spark plug electrode gap
0.70 mm (0.0276 in)
Cooling
Water-cooled
Starting aid
Kick starter system
22.2
Engine tightening torques
Nut, water pump impeller
M5
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, bearing retainer
M5
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, kick starter lever
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, stator bracket
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Air release screw for coolant
M6
8 Nm (5.9 lbf ft)
Drain plug, water pump cover
M6
6 Nm (4.4 lbf ft)
Screw, alternator cover
M6
6 Nm (4.4 lbf ft)
Screw, cylinder head
M6x25
10 Nm (7.4 lbf ft)
Screw, engine case
M6
10 Nm (7.4 lbf ft)
Screw, engine sprocket
M6
10 Nm (7.4 lbf ft)
Loctite®2701™
Screw, exhaust flange
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, fitting pin
M6
10 Nm (7.4 lbf ft)
Loctite®2701™
Screw, front engine sprocket cover
M6x35
8 Nm (5.9 lbf ft)
Screw, ground wire
M6
10 Nm (7.4 lbf ft)
Screw, ignition coil
M6
8 Nm (5.9 lbf ft)
Loctite®243™
Screw, inner clutch cover
M6
10 Nm (7.4 lbf ft)
114
TECHNICAL SPECIFICATIONS
22
Screw, intake flange
M6
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, outer clutch cover
M6
10 Nm (7.4 lbf ft)
Screw, pressure plate
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
Vacuum connection (housing
M6
4 Nm (3 lbf ft)
breather)
Loctite®243™
Nuts, cylinder base
M8
20 Nm (14.8 lbf ft)
Screw, clutch basket
M8
35 Nm (25.8 lbf ft)
Loctite®243™
Screw, cylinder base
M8x41
7 Nm (5.2 lbf ft)
Spark plug
M10x1
13 Nm (9.6 lbf ft)
Nut, primary gear wheel
M10x1.25
40 Nm (29.5 lbf ft)
Loctite®243™
Nut, rotor
M10x1.25
15 Nm (11.1 lbf ft)
Loctite®243™
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
Screw, gear oil level monitoring
M14x1.25
10 Nm (7.4 lbf ft)
22.3
Carburetor with carburetor tuning
Carburetor type
Dell`Orto PHBG 19BS
Needle position
2nd position from top
Idle air adjusting screw
Open
3 turns
Main jet
88 (85, 90, 92)
Jet needle
W7
Idling jet
50
Needle jet
262AU
Throttle slide
40
Choke nozzle
65
22.3.1
Carburetor tuning (Option: Low seat position)
DellOrto PHBG19 BS
37 … 49 °C
-20 … -7 °C
-6 … 5 °C
6 … 15 °C (43
16 … 24 °C
25 … 36 °C
ASL
TEMP
(99 …
(-4 … 19 °F)
(21 … 41 °F)
… 59 °F)
(61 … 75 °F)
(77 … 97 °F)
120 °F)
ASO
3
3
3
3
3
2,301 …
IJ
50
48
45
48
48
3,000 m
NDL
W7
W7
W7
W7
W7
(7,549 …
POS
2
2
2
1
1
9,843 ft)
MJ
82
82
82
85
85
ASO
3
3
3
3
3
3
1,501 …
IJ
50
50
48
48
48
48
2,300 m
NDL
W7
W7
W7
W7
W7
W7
(4,925 …
POS
2
2
2
2
2
2
7,546 ft)
MJ
82
82
82
82
85
88
115
22
TECHNICAL SPECIFICATIONS
37 … 49 °C
-20 … -7 °C
-6 … 5 °C
6 … 15 °C (43
16 … 24 °C
25 … 36 °C
ASL
TEMP
(99 …
(-4 … 19 °F)
(21 … 41 °F)
… 59 °F)
(61 … 75 °F)
(77 … 97 °F)
120 °F)
ASO
3
3
3
3
3
3
751 …
IJ
52
50
50
50
50
50
1,500 m
NDL
W7
W7
W7
W7
W7
W7
(2,464 …
POS
2
2
2
2
2
2
4,921 ft)
MJ
88
85
85
85
88
90
ASO
3
3
3
3
3
3
301 …
IJ
55
52
50
50
50
50
750 m (988
NDL
W7
W7
W7
W7
W7
W7
… 2,461 ft)
POS
2
2
2
2
2
2
MJ
88
88
88
88
90
92
ASO
3
3
3
3
3
3
IJ
55
52
50
50
50
50
0 … 300 m
NDL
W7
W7
W7
W7
W7
W7
(0 … 984 ft)
POS
2
2
2
2
2
2
MJ
90
90
90
90
92
95
M/FT ASL
Above sea level
TEMP
Temperature
ASO
Open (rotations) idle air adjusting screw
IJ
Idling jet
NDL
Jet needle
POS
Needle position from top
MJ
Main jet
The carburetor tuning depends on the defined ambient and operating conditions.
22.3.2
Carburetor tuning (Option: High seat position)
DellOrto PHBG19 BS
37 … 49 °C
-20 … -7 °C
-6 … 5 °C
6 … 15 °C (43
16 … 24 °C
25 … 36 °C
ASL
TEMP
(99 …
(-4 … 19 °F)
(21 … 41 °F)
… 59 °F)
(61 … 75 °F)
(77 … 97 °F)
120 °F)
ASO
3
3
3
3
3
2,301 …
IJ
50
48
45
48
48
3,000 m
NDL
W7
W7
W7
W7
W7
(7,549 …
POS
2
2
2
1
1
9,843 ft)
MJ
85
85
85
88
88
ASO
3
3
3
3
3
3
1,501 …
IJ
50
50
48
48
48
48
2,300 m
NDL
W7
W7
W7
W7
W7
W7
(4,925 …
POS
2
2
2
2
2
2
7,546 ft)
MJ
85
85
85
85
88
90
ASO
3
3
3
3
3
3
751 …
IJ
52
50
50
50
50
50
1,500 m
NDL
W7
W7
W7
W7
W7
W7
(2,464 …
POS
2
2
2
2
2
2
4,921 ft)
MJ
90
88
88
88
90
92
ASO
3
3
3
3
3
3
301 …
IJ
55
52
50
50
50
50
750 m (988
NDL
W7
W7
W7
W7
W7
W7
… 2,461 ft)
POS
2
2
2
2
2
2
MJ
90
90
90
90
92
95
116
TECHNICAL SPECIFICATIONS
22
37 … 49 °C
-20 … -7 °C
-6 … 5 °C
6 … 15 °C (43
16 … 24 °C
25 … 36 °C
ASL
TEMP
(99 …
(-4 … 19 °F)
(21 … 41 °F)
… 59 °F)
(61 … 75 °F)
(77 … 97 °F)
120 °F)
ASO
3
3
3
3
3
3
IJ
55
52
50
50
50
50
0 … 300 m
NDL
W7
W7
W7
W7
W7
W7
(0 … 984 ft)
POS
2
2
2
2
2
2
MJ
92
92
92
92
95
98
M/FT ASL
Above sea level
TEMP
Temperature
ASO
Open (rotations) idle air adjusting screw
IJ
Idling jet
NDL
Jet needle
POS
Needle position from top
MJ
Main jet
The carburetor tuning depends on the defined ambient and operating conditions.
22.4
Capacities
22.4.1
Gear oil
Gear oil
0.20 l (0.21 qt.)
Gear oil (ATF Dexron 3) ( p. 123)
22.4.2
Coolant
Coolant
0.7 l (0.7 qt.)
Coolant ( p. 122)
22.4.3
Fuel
Fuel tank capacity, approx.
2.3 l (2.4 qt.)
Super unleaded (95 octane) mixed with
2-stroke engine oil (1:60) ( p. 123)
22.5
Chassis
Frame
Central tube frame of chrome molybdenum steel tubing,
powder-coated
Fork
WP XACT
Shock absorber
WP XACT Mono Shock
Suspension travel
Front
200.6 mm (7.898 in)
Rear
190.5 mm (7.5 in)
Fork offset
22 mm (0.87 in)
Brake system
front
Disc brake with 4-piston brake caliper
rear
Disc brake with 2-piston brake caliper
Brake disc diameters
front
160 mm (6.3 in)
rear
160 mm (6.3 in)
Brake discs - wear limits
front
2.2 mm (0.087 in)
rear
2.2 mm (0.087 in)
117
22
TECHNICAL SPECIFICATIONS
Offroad tire pressure
front
1.0 bar (15 psi)
rear
1.0 bar (15 psi)
Secondary drive ratio
11:40
Chain
1/2 x 3/16”
Rear sprockets available
38, 39, 40, 41, 42
Steering head angle
66°
Wheelbase
1,023.5 … 1,035.6 mm (40.295 … 40.772 in)
Seat height unloaded
634 … 683 mm (24.96 … 26.89 in)
Ground clearance unloaded
210 … 227.3 mm (8.27 … 8.949 in)
Weight without fuel approx.
42.4 kg (93.5 lb.)
Maximum rider weight
45 kg (99 lb.)
22.6
Tires
Front tire
Rear tire
60/100 - 12 36J TT
2.75 - 10 38J TT
MAXXIS MAXXCROSS MX-ST+
MAXXIS MAXXCROSS MX-ST+
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:
22.7
Fork
Fork article number
07.18.6U.02
Fork
WP XACT
Rebound damping
Comfort
15 clicks
Standard
12 clicks
Sport
10 clicks
Air pressure
2 bar (29 psi)
Fork length
685 mm (26.97 in)
Spring length with preload spacer(s)
337.5 mm (13.287 in)
Oil capacity external mechanism left
25 ± 5 ml (0.85 ± 0.17 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 122)
Oil capacity, right cartridge
225 ml (7.61 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 122)
Grease capacity, left cartridge
6 g (0.21 oz)
Special grease (00062010053)
(
p. 125)
118
TECHNICAL SPECIFICATIONS
22
22.8
Shock absorber
Shock absorber article number
A400C402X113000
Shock absorber
WP XACT Mono Shock
Low-speed compression damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
High-speed compression damping
Comfort
2.5 turns
Standard
2 turns
Sport
1.5 turns
Rebound damping
Comfort
18 clicks
Standard
15 clicks
Sport
12 clicks
Spring preload
5 mm (0.2 in)
Spring rate
Weight of rider: 15 … 25 kg (33 … 55 lb.)
25 N/mm (143 lb/in)
Weight of rider (standard): 25 … 35 kg (55 … 77 lb.)
30 N/mm (171 lb/in)
Weight of rider: 35 … 45 kg (77 … 99 lb.)
35 N/mm (200 lb/in)
Spring length
130 mm (5.12 in)
Gas pressure
10 bar (145 psi)
Static sag
12 mm (0.47 in)
Rider sag
80 mm (3.15 in)
Fitted length
275 mm (10.83 in)
Shock absorber oil
Shock absorber fluid (SAE 2.5)
(50180751S1) ( p. 123)
22.9
Chassis tightening torques
Hose clip, carburetor
-
2.8 Nm (2.07 lbf ft)
Remaining EJOT PT screws
EJOT PT K60x20
2 Nm (1.5 lbf ft)
Screw, brake hose bracket
EJOT PT K60x20-Z
2 Nm (1.5 lbf ft)
Stop button screw
M3
0.4 Nm (0.3 lbf ft)
Screw, seat thrust bearing quick
EJOT PT 35x16 M3.5
0.75 Nm (0.553 lbf ft)
release
Spoke nipple
M3.5
3 Nm (2.2 lbf ft)
Screw, fixed grip
M4
5 Nm (3.7 lbf ft)
Loctite®243™
Remaining nuts, chassis
M5
5 Nm (3.7 lbf ft)
Remaining screws, chassis
M5
5 Nm (3.7 lbf ft)
Screw, brake assembly
M5
5 Nm (3.7 lbf ft)
Screw, brake linings
M5
8 Nm (5.9 lbf ft)
Brake cylinder screw on the rear
M6
10 Nm (7.4 lbf ft)
brake system
Loctite®243™
Nut, push rod ball joint on the brake
M6
10 Nm (7.4 lbf ft)
cylinder of the rear brake system
119
22
TECHNICAL SPECIFICATIONS
Nut, push rod, foot brake lever
M6
6 Nm (4.4 lbf ft)
Remaining nuts, chassis
M6
10 Nm (7.4 lbf ft)
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Screw, fender
M6
6 Nm (4.4 lbf ft)
Screw, fork stub
M6
10 Nm (7.4 lbf ft)
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, main silencer silent block
M6
6 Nm (4.4 lbf ft)
Screw, radiator on frame
M6
10 Nm (7.4 lbf ft)
Screw, rear brake caliper
M6x16
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, rear brake caliper
M6x40
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, rear engine sprocket cover
M6x12
8 Nm (5.9 lbf ft)
Screw, rear mounting
M6
4 Nm (3 lbf ft)
Screw, splash protector
M6
7 Nm (5.2 lbf ft)
Screw, start number plate
M6
4 Nm (3 lbf ft)
Screw, throttle grip
M6
4.5 Nm (3.32 lbf ft)
Bushing, foot brake lever stop
M8
20 Nm (14.8 lbf ft)
Nut, foot brake lever
M8
22 Nm (16.2 lbf ft)
Nut, rim lock
M8
10 Nm (7.4 lbf ft)
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
15 Nm (11.1 lbf ft)
Screw, chain sliding piece
M8
15 Nm (11.1 lbf ft)
Screw, engine bracket
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, front brake caliper
M8x60
20 Nm (14.8 lbf ft)
Loctite®243™
Screw, front brake caliper
M8x40
20 Nm (14.8 lbf ft)
Loctite®243™
Screw, handlebar clamp
M8
20 Nm (14.8 lbf ft)
Screw, rear sprocket
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, steering stem
M8
20 Nm (14.8 lbf ft)
Screw, tail assembly
M8
30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
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, front wheel spindle
M10
40 Nm (29.5 lbf ft)
Loctite®243™
Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Loctite®243™
120
TECHNICAL SPECIFICATIONS
22
Screw, top shock absorber
M10
45 Nm (33.2 lbf ft)
Loctite®243™
Nut, rear wheel spindle
M12x1
40 Nm (29.5 lbf ft)
Swingarm pivot bushing
M12x1
40 Nm (29.5 lbf ft)
Nut, steering head
M20x1.5
10 Nm (7.4 lbf ft)
121
23
SUBSTANCES
Brake fluid DOT 4 / DOT 5.1
Standard/classification
- DOT
Guideline
- Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the
corresponding properties.
Recommended supplier
Castrol
- REACT PERFORMANCE DOT 4
MOTOREX®
- Brake Fluid DOT 5.1
Coolant
Guideline
- Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuit-
able antifreeze causes corrosion, deposits and frothing.
- Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and
lubrication properties.
- Only use coolant that complies with the requirements stated (see specifications on the container) and that has the rele-
vant properties.
Antifreeze protection to at least
-25 °C (-13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be
diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other
coolants.
Recommended supplier
MOTOREX®
- COOLANT M3.0
Engine oil, 2-stroke
Standard/classification
- JASO FD ( p. 126)
Guideline
- Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
Recommended supplier
MOTOREX®
- Cross Power 2T
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.
122
SUBSTANCES
23
Gear oil (ATF Dexron 3)
Standard/classification
- Dexron III (ATF Dexron 3)
Guideline
- Use only ATF gear oils that comply with the specified standards (see specifications on the container) and that possess
the necessary properties.
Recommended supplier
MOTOREX®
- ATF Dexron 3
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).
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
Standard/classification
- DIN EN 228
- JASO FD ( p. 126) (1:60)
Mixture ratio
1:60
Engine oil, 2-stroke ( p. 122)
Super unleaded (ROZ 95) ( p. 123)
Recommended supplier
MOTOREX®
- Cross Power 2T
123
24
AUXILIARY SUBSTANCES
Air filter cleaner
Recommended supplier
MOTOREX®
- Racing Bio Dirt Remover
Chain cleaner
Recommended supplier
MOTOREX®
- Chain Clean
Fuel additive
Recommended supplier
MOTOREX®
- Fuel Stabilizer
High viscosity grease
Recommended supplier
SKF®
- LGHB 2
Long-life grease
Recommended supplier
MOTOREX®
- Bike Grease 2000
Motorcycle cleaner
Recommended supplier
MOTOREX®
- Moto Clean
Off-road chain spray
Recommended supplier
MOTOREX®
- Chainlube Offroad
Oil for foam air filter
Recommended supplier
MOTOREX®
- Racing Bio Liquid Power
Preserving materials for paints, metal and rubber
Recommended supplier
MOTOREX®
- Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX®
- Quick Cleaner
124
AUXILIARY SUBSTANCES
24
Special grease (00062010053)
Recommended supplier
Klüber Lubrication®
- Klüberfood NH1 34-401
Universal oil spray
Recommended supplier
MOTOREX®
- Joker 440 Synthetic
125
25
STANDARDS
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing.
Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme
operating conditions.
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
LIST OF ABBREVIATIONS
26
Art. no.
Article number
ca.
circa
cf.
compare
e.g.
for example
etc.
et cetera
i.a.
inter alia
no.
number
poss.
possibly
127
INDEX
INDEX
checking
62
A
Choke
16
Accessories
9
Cleaning
108-109
Air filter
Clutch
cleaning
58
adjusting
96
installation
58
setting, checking
95
removal
57
Clutch cover
Air filter box
clutch cover, removing
96
cleaning
58
installing the clutch cover
99
Air suspension XACT 5235
26
Coolant
Antifreeze
changing
91
checking
88
draining
89
refilling
90
Article number
fork
12
Coolant level
checking
88-89
Auxiliary substances
9
Cooling system
88
B
Customer service
9
Basic chassis setting
E
rider's weight, checking with
26
Engine
Brake discs
running in
18
checking
68
Engine number
12
Brake fluid
adding front brake
70
Engine sprocket
adding to rear brake
77
checking
64
Brake fluid level
Engine sprocket cover
of the front brake, checking
69
installation
61
rear brake, checking
76
removing
61
Brake lining retainers
Environment
8
checking the rear brake
78
F
of front brake, checking
71
Figures
9
Brake linings
Foot brake lever
16
checking the rear brake
78
adjusting the basic position
75
of front brake, checking
71
free travel, adjusting
75
of the front brake, changing
71
free travel, checking
74
of the rear brake, changing
78
Fork
C
article number
12
Capacity
Fork article number
12
coolant
90-91,
117
Fork legs
fuel
23,
117
air pressure, adjusting
32
gear oil
101,
117
bleeding
41
Carburetor
checking basic setting
32
adjusting the idle speed
94
dust boots, cleaning
42
Idle speed
94
installing
44
installation
105
removing
44
removal
103
Fork protector
Chain
installing
43
checking
64
removing
43
cleaning
62
Frame
Chain guide
checking
66
adjusting
66
Frame label
12
checking
64
Frame protector
Chain tension
installation
57
adjusting
63
128
INDEX
removal
57
Misuse
6
Front fender
Motorcycle
installing
53
cleaning
108
removing
52
from lift stand, removing
41
raising with lift stand
41
Front wheel
installing
82
O
removing
82
Owner's Manual
8
Fuel tank
P
installation
50
removal
49
Play in throttle cable
adjusting
93
Fuel tank filler cap
checking
93
closing
15
opening
14
Plug-in stand
16
Fuel tap
15
Preparing for use
Fuel, oils, etc
9
advice on preparing for first use
17
after storage
111
G
checks and maintenance measures when preparing
Gear oil
for use
20
adding
101
Protective clothing
7
changing
100
R
Gear oil level
Rear sprocket
checking
100
checking
64
H
Rear wheel
Hand brake lever
14
installing
84
basic position, adjusting
68
removing
83
Handlebar position
34
Rebound damping
adjusting
34
adjusting the shock absorber
28
High-speed compression damping
fork, adjusting
34
adjusting the shock absorber
27
Refueling
I
fuel
23
Implied warranty
9
Rider sag
Intended use
6
setting
31
Right side cover
K
installation
55
Kick starter lever
16
removal
54
L
Rubber grip
Left side cover
checking
67
installation
54
S
removal
53
Safe operation
7
Link fork
Seat
checking
66
mounting
56
Lower triple clamp
removing
56
installing
46
Seat height
removing
45
adjusting on the fork
37
Low-speed compression damping
adjusting on the frame
38
adjusting the shock absorber
27
adjusting on the shock absorber
36
M
adjustment options
36
Main silencer
Service
9
changing rock wool
60
Service schedule
24-25
installation
60
Shock absorber
removal
59
adjusting the spring preload
30
Manufacturer warranty
9
checking riding sag
30
129
INDEX
installation
55
removal
55
static sag, checking
29
Shock absorber article number
13
Spare parts
9
Spoke tension
checking
86
Start number plate
installation
52
removal
52
Starting
20
Steering head bearing
lubricating
49
Steering head bearing play
adjusting
48
checking
48
Stop button
14
Storage
110
T
Technical specifications
capacities
117
carburetor
115
chassis
117
chassis tightening torques
119
engine
114
engine tightening torques
114
fork
118
shock absorber
119
tires
118
Throttle cable routing
checking
66
Throttle grip
14
Tire condition
checking
85
Tire pressure
checking
86
Transporting
22
Troubleshooting
112-113
U
Use definition
6
V
Vehicle identification number
12
View of vehicle
left side
10
right
11
W
Work rules
8
130