GASGAS MC 65. OWNER'S MANUAL (2024)

TABLE OF CONTENTS

MEANS OF REPRESENTATION

RIDING INSTRUCTIONS

1.1

Symbols used

8.1

Checks and maintenance measures

1.2

Formats used

when preparing for use

8.2

Starting the vehicle

SAFETY ADVICE

8.3

Starting off

2.1

Use definition - intended use

8.4

Shifting, riding

2.2

Misuse

8.5

Applying the brakes

2.3

Safety advice

8.6

Stopping, parking

2.4

Degrees of risk and symbols

8.7

Transporting

2.5

Tampering warning

8.8

Refueling

2.6

Safe operation

SERVICE SCHEDULE

2.7

Protective clothing

2.8

Work rules

9.1

Additional information

2.9

Environment

9.2

Service schedule

2.10

Owner's Manual

TUNING THE CHASSIS

IMPORTANT NOTES

10.1

Checking the basic chassis setting with

3.1

Manufacturer warranty, implied

rider's weight

warranty

10.2

Air suspension

3.2

Fuel, auxiliary substances

10.3

Compression damping of the shock

3.3

Spare parts, accessories

absorber

10.4

Adjusting the low-speed compression

3.4

Service

damping of the shock absorber

3.5

Figures

10.5

Adjusting the high-speed compression

3.6

Customer service

damping of the shock absorber

VIEW OF VEHICLE

10.6

Adjusting the rebound damping of the

shock absorber

4.1

View of vehicle, front left (example)

10.7

Measuring the dimension of the rear

4.2

View of vehicle, rear right (example)

wheel unloaded

SERIAL NUMBERS

10.8

Checking the static sag of the shock

absorber

5.1

Vehicle identification number

10.9

Checking the rider sag of the shock

5.2

Frame label

absorber

5.3

Engine number

10.10

Adjusting the spring preload of the

5.4

Fork article number

shock absorber

5.5

Shock absorber article number

10.11

Adjusting the riding sag

CONTROLS

10.12

Checking the basic setting of the fork

10.13

Adjusting the fork air pressure

6.1

Clutch lever

10.14

Adjusting the rebound damping of the

6.2

Hand brake lever

fork

6.3

Throttle grip

10.15

Handlebar position

6.4

Stop button

10.16

Adjusting the handlebar position

6.5

Opening the fuel tank filler cap

6.6

Closing the fuel tank filler cap

SEAT HEIGHT

6.7

Fuel tap

11.1

Seat height adjustment options

6.8

Choke

11.2

Adjusting the seat height on the shock

6.9

Shift lever

absorber

6.10

Kick starter lever

11.3

Adjusting the seat height on the fork

6.11

Foot brake lever

11.4

Adjusting the seat height on the

6.12

Plug-in stand

frame

6.13

Service hour counter

SERVICE WORK ON THE CHASSIS

PREPARING FOR USE

12.1

Raising the motorcycle with a lift stand

7.1

Advice on preparing for first use

12.2

Removing the motorcycle from the lift

7.2

Running in the engine

stand

12.3

Bleeding the fork legs

12.4

Cleaning the dust boots of the fork legs

12.5

Removing the fork protector

TABLE OF CONTENTS

12.6

Installing the fork protector

13.3

Checking the brake discs

12.7

Removing the fork legs

13.4

Checking the front brake fluid level

12.8

Installing the fork legs

13.5

Adding front brake fluid

12.9

Removing the lower triple clamp

13.6

Checking that the brake linings of the

12.10

Installing the lower triple clamp

front brake are secured

12.11

Checking the steering head bearing play ... 50

13.7

Changing the front brake linings

12.12

Adjusting the steering head bearing

13.8

Checking the free travel of the foot

play

brake lever

12.13

Lubricating the steering head bearing

13.9

Adjusting the free travel of the foot

12.14

Removing the start number plate

brake lever

12.15

Installing the start number plate

13.10

Adjusting the basic position of the foot

12.16

Removing the front fender

brake lever

12.17

Installing front fender

13.11

Checking the rear brake fluid level

12.18

Removing the rear fender

13.12

Adding rear brake fluid

12.19

Installing the rear fender

13.13

Checking that the brake linings of the

rear brake are secured

12.20

Removing the right side cover

13.14

Changing the rear brake linings

12.21

Installing the right side cover

12.22

Removing the left side cover

WHEELS, TIRES

12.23

Installing the left side cover

14.1

Removing the front wheel

12.24

Removing the frame protector

14.2

Installing the front wheel

12.25

Installing the frame protector

14.3

Removing the rear wheel

12.26

Removing the shock absorber

14.4

Installing the rear wheel

12.27

Installing the shock absorber

14.5

Checking the tire condition

12.28

Removing the seat

14.6

Checking tire pressure

12.29

Mounting the seat

14.7

Checking the spoke tension

12.30

Removing the air filter

12.31

Installing the air filter

COOLING SYSTEM

12.32

Cleaning the air filter and air filter

15.1

Cooling system

box

12.33

Removing the main silencer

15.2

Checking the antifreeze and coolant

level

12.34

Installing the main silencer

15.3

Checking the coolant level

12.35

Changing the rock wool on the main

silencer

15.4

Draining the coolant

15.5

Refilling with coolant

12.36

Removing the fuel tank

12.37

Installing the fuel tank

15.6

Changing the coolant

12.38

Checking the chain for dirt

TUNING THE ENGINE

12.39

Cleaning the chain

16.1

Checking the play in the throttle cable

12.40

Checking the chain tension

16.2

Adjusting the play in the throttle

12.41

Adjusting the chain tension

cable

12.42

Checking the chain, rear sprocket,

engine sprocket, and chain guide

16.3

Plug-in connector of ignition timing map

adjustment

12.43

Checking the frame

16.4

Changing the ignition timing map

12.44

Checking the link fork

16.5

Carburettor - idle speed

12.45

Checking the throttle cable routing

16.6

Carburetor - adjusting the idle speed

12.46

Checking the rubber grip

16.7

Emptying the carburetor float

12.47

Adjusting the basic position of the clutch

chamber

lever

12.48

Checking the fluid level of the hydraulic

SERVICE WORK ON THE ENGINE

100

clutch

17.1

Checking the gear oil level

100

12.49

Correcting the fluid level of the hydraulic

clutch

17.2

Changing the gear oil

100

12.50

Changing the hydraulic clutch fluid

17.3

Adding the gear oil

101

BRAKE SYSTEM

CLEANING, CARE

103

13.1

Checking the free travel of the hand

18.1

Cleaning the motorcycle

103

brake lever

STORAGE

105

13.2

Adjusting the basic position of the hand

brake lever

19.1

Storage

105

MEANS OF REPRESENTATION

1.1

Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g., of a work step or a function).

Indicates an unexpected reaction (e.g., of a work step or a function).

Indicates work that requires expert knowledge and technical understanding. In the interest of 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.

1.2

Formats used

The typographical formats used in this document are explained below.

Proprietary name

Indicates a proprietary name.

Name^®

Indicates a protected name.

Brand™

Indicates a brand available on the open market.

Underlined terms

Refer to technical details of the vehicle or indicate technical terms, which are

explained in the glossary.

SAFETY ADVICE

2.1

Use definition - intended use

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:

SAFETY ADVICE

The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of

any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or

delivery to the ultimate purchaser or while it is in use, or

the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

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

gases.

Removal or puncturing of parts of the intake system.

Lack of proper maintenance.

Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those

specified by the manufacturer.

2.6

Safe operation

Danger

Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.

- Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.

- Do not operate the vehicle if you are physically or mentally impaired.

Danger

Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

- Always make sure there is sufficient ventilation when running the engine.

- Use effective exhaust extraction when starting or running the engine in an enclosed space.

Warning

Danger of burns Some vehicle components become hot when the vehicle is operated.

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

cle parts have cooled down.

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

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and

environmentally compatible manner.

The vehicle should only be used by trained persons.

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 recommends that you only operate the vehicle while wearing suitable protective

clothing.

SAFETY ADVICE

2.8

Work rules

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

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

Special tools are necessary for certain tasks. If these special tools are not included in the scope of supply of the vehicle, the

special tools can be ordered using the specified article number. 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 screw connections, a thread locker (e.g., Loctite^®) is required. Observe the manufacturer's instruc-

tions.

If a 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.

Ensure that the work area is clean and clean components before disassembly if necessary. Penetrating dirt can lead to

increased wear and consequential damage.

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.

IntInternational GASGAS website: http://www.gasgas.com

IMPORTANT NOTES

3.1

Manufacturer warranty, implied warranty

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

confirmed in the electronic proof of service, as otherwise no warranty claims will be recognized. 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 and have them installed by an authorized GASGAS Motorcycles workshop. GASGAS accepts no liability for other prod-

ucts 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.

IntInternational GASGAS 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.

A list of authorized GASGAS Motorcycles dealers can be found on the GASGAS Motorcycles website.

IntInternational GASGAS website: http://www.gasgas.com

CONTROLS

6.1

Clutch lever

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

The clutch is hydraulically operated and self-adjusting.

V02820-10

6.2

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.

V02821-10

6.3

Throttle grip

Throttle grip 1 is fitted on the right side of the handlebar.

V02821-11

6.4

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.

V02820-11

CONTROLS

6.5

Opening the fuel tank filler cap

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

- Switch off the engine for refueling.

- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

- If any fuel is spilled, wipe it off immediately.

- Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is harmful to health.

- Avoid skin, eye and clothing contact with fuel.

- Immediately consult a doctor if you swallow fuel.

- Do not inhale fuel vapors.

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

- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

- Change your clothing if fuel spills on them.

- Keep fuels correctly in a suitable canister, and out of the reach of children.

Note

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

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

- Turn fuel tank filler cap 1 counterclockwise and lift it off.

S05995-10

6.6

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.

S05995-11

CONTROLS

6.7

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.

S05996-10

6.8

Choke

Choke lever 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

S05997-10

• Choke function activated - The choke lever is pushed down all the

way to the stop.

• Choke function deactivated - The choke lever is pushed up all the

way to the stop.

6.9

Shift lever

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

401950-10

The gear positions can be seen in the figure.

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

401950-11

CONTROLS

6.10

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.

401954-10

6.11

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

6.12

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

6.13

Service hour counter

The service hour counter 1 is fitted in front of the handlebar.

It shows the total number of service hours for the engine.

The service hour counter begins counting when the engine is started and

stops when the engine is switched off.

Info

The value indicated by the service hour counter cannot be

cleared or adjusted.

S06000-10

PREPARING FOR USE

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.

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 the basic position of the clutch lever. ( p. 70)

–

Adjust the basic position of the hand brake lever. ( p. 74)

–

Adjust the basic position of the foot brake lever.

(

p. 81)

–

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

50 kg (110 lb.)

–

Check the spoke tension. ( p. 90)

Info

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

Run the engine in. ( p. 19)

7.2

Running in the engine

– During the running-in 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.

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. 75)

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

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

(

p. 77)

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

- Check that the brake system is functioning properly.

- Check the coolant level. ( p. 92)

H02217-01

- Check the chain for dirt. ( p. 64)

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

(

p. 66)

– Check the chain tension. ( p. 65)

- Check the tire condition. ( p. 89)

- Check tire pressure. ( p. 90)

- Check the spoke tension. ( p. 90)

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. 44)

- Bleed the fork legs. ( p. 43)

- Check the air filter.

- Check the settings of all controls and ensure that they can be oper-

ated smoothly.

- Check all screws, nuts, and hose clamps regularly for tightness.

- Check the fuel level.

8.2

Starting 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.

RIDING INSTRUCTIONS

The motorcycle has been out of use for more than 1 week

- Empty the carburetor float chamber.

(

p. 99)

– Turn the knurled screw on the fuel tap all the way counterclockwise.

Fuel can flow from the fuel tank to the carburetor.

- Remove the motorcycle from the stand.

- Shift the transmission into neutral.

The engine is cold

- Push down the choke lever all the way to the stop.

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

Info

Do not open the throttle.

8.3

Starting off

Info

The plug-in stand must be removed prior to riding.

- Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

8.4

Shifting, riding

Warning

Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.

- Make it clear to your child that he or she must not change into a low gear at high engine speed.

Info

If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized

GASGAS Motorcycles workshop.

First-gear is used for starting off and for steep inclines.

- When conditions allow (incline, road situation, etc.), your child can shift into a higher gear. To do so, release the throttle

while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.

- If the choke function has been activated, deactivate it after the engine has warmed up.

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

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

- Your child should always open the throttle only as much as the engine can handle - abruptly opening the throttle

increases fuel consumption.

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

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

again.

- Your child should switch off the engine if prolonged operation at idle speed or while stationary is imminent.

Guideline

≥ 2 min

- Your child should avoid frequent or extended slipping of the clutch. This heats the engine oil, the engine, and the cool-

ing system.

- Insist that your child ride with a low speed instead of with a high speed and a slipping clutch.

RIDING INSTRUCTIONS

8.5

Applying the brakes

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.)

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 the rear brake.

- Always finish braking before you go into a bend. Your child should change down to a lower gear appropriate to the road

speed.

- Insist that your child take advantage of the braking action of the engine when riding on long downhills. To do so, shift

back one or two gears, but do not overrev the engine. Your child will need to apply the brakes far less often and the

brake system will not overheat.

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.

- Shift the transmission into neutral.

- 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.

RIDING INSTRUCTIONS

- 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.

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.

SERVICE SCHEDULE

9.1

Additional information

Any further work that results from the service work must be ordered separately and invoiced separately.

Different service intervals may apply in your country, depending on the local operating conditions.

Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service

schedule is available for authorized GASGAS Motorcycles dealers for the electronic proof of service. Your authorized GAS-

GAS 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. 77)

○

●

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

○

●

Check the brake discs. ( p. 74)

○

●

Check the brake lines for damage and tightness.

○

●

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

○

●

Change the front brake fluid.

●

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

○

●

Change the rear brake fluid.

●

Check the fluid level of the hydraulic clutch. ( p. 70)

○

●

Change the hydraulic clutch fluid.

(

p. 72)

●

Check the free travel of the hand brake lever. ( p. 74)

○

●

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

○

●

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. 69)

●

Check the link fork.

(

p. 69)

●

Check the fork bearing for play.

●

Check the shock absorber heim joint for play.

●

Check the tire condition. ( p. 89)

○

●

Check tire pressure. ( p. 90)

○

●

Check the wheel bearing for play.

●

Check the wheel hubs.

●

Check the rim run-out.

○

●

Check the spoke tension. ( p. 90)

○

●

Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 66)

○

●

Check the chain tension. ( p. 65)

○

●

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. 59)

○

●

SERVICE SCHEDULE

every 24 months

Every 90 operating hours

Every 45 operating hours

Every 15 operating hours

After 1 operating hour

Change the rock wool on the main silencer.

(

p. 61)

●

Service the fork.

●

Perform the shock absorber service.

●

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

○

●

Check the clutch.

●

Check the antifreeze and coolant level. ( p. 91)

○

●

Change the coolant.

(

p. 94)

●

Check the steering head bearing play. ( p. 50)

○

●

Lubricate the steering head bearing.

(

p. 51)

●

Check/set the carburetor components.

●

Check the cylinder and piston.

●

Check the inlet membrane.

●

Check the exhaust control for function and smooth operation.

●

Perform minor engine service. (Replace exhaust control spring, replace piston. Change the nee-

●

dle jet.)

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

●

necting rod, conrod bearing, and crank pin. Change the crankshaft bearing. Check the transmis-

sion and the shift mechanism. Change the intake flange. Change all engine bearings.)

Final check: check the operating safety of the vehicle and take for a test ride.

○

●

Enter electronic proof of service in the dealer portal.

○

●

○ One-time interval

● Periodic interval

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.

- In the delivered condition, this vehicle is adjusted for an average

rider's weight (with full protective clothing).

Guideline

Standard rider weight

35 … 45 kg (77 … 99 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

Air suspension is used in this fork.

In this system, the 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.

TUNING THE CHASSIS

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

F02172-10

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.

TUNING THE CHASSIS

- Turn adjusting screw 1 all the way clockwise with a socket wrench.

Info

Do not loosen fitting 2!

- Turn counterclockwise by the number of turns corresponding to the

shock absorber type.

Guideline

High-speed compression damping

F02172-11

Comfort

2 turns

Standard

1.5 turns

Sport

1 turn

Info

Turn clockwise to increase damping; turn counterclockwise

to reduce damping.

10.6

Adjusting the rebound damping of the shock absorber

Caution

Risk of 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

F02173-10

Info

Turn clockwise to increase the damping; turn counterclock-

wise to reduce damping when the shock absorber rebounds.

10.7

Measuring the dimension of the rear wheel unloaded

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

TUNING THE CHASSIS

Main work

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

marking SAG on the rear fender.

Sag gage (00029090200)

- Note the value as dimension A.

402415-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

10.8

Checking the static sag of the shock absorber

- Measure dimension A of rear wheel unloaded. ( p. 30)

- Hold the motorcycle upright with aid of an assistant.

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

on the rear fender using the sag gage.

- Note the value as dimension B.

Info

The static sag is the difference between measurements A

and B.

- Check the static sag.

Static sag

30 mm (1.18 in)

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

- Adjust the spring preload of the shock absorber.

(

p. 32)

402416-10

TUNING THE CHASSIS

10.9

Checking the rider sag of the shock absorber

- Measure dimension A of rear wheel unloaded. ( p. 30)

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

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

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

The rear wheel suspension levels out.

- Another person again measures the distance between the rear axle

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

- Note the value as dimension C.

Info

The rider sag is the difference between measurements A

and C.

- Check the rider sag.

Guideline

Rider sag

80 mm (3.15 in)

» If the rider sag differs from the specified measurement:

- Adjust the rider sag.

(

p. 33)

402417-10

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. 43)

- Remove the right side cover. ( p. 54)

- Remove main silencer. ( p. 60)

- Remove the shock absorber.

(

p. 57)

– After removing the shock absorber, clean it thoroughly.

TUNING THE CHASSIS

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.

Combination wrench (50329080000)

Hook wrench (T106S)

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)

F02171-10

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. 57)

– Install the main silencer. ( p. 60)

- Install the right side cover. ( p. 55)

- Remove the motorcycle from the lift stand. ( p. 43)

10.11

Adjusting the riding sag

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

- Remove the right side cover. ( p. 54)

- Remove main silencer. ( p. 60)

- Remove the shock absorber.

(

p. 57)

– After removing the shock absorber, clean it thoroughly.

Main work

- Select and mount a suitable spring.

Guideline

Spring rate

Weight of rider: 32 kg

40 N/mm (228 lb/in)

(71 lb.)

Weight of rider: 37 kg

45 N/mm (257 lb/in)

(82 lb.)

Weight of rider: 42 kg

50 N/mm (286 lb/in)

B00292-10

(93 lb.)

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. 57)

– Install the main silencer. ( p. 60)

- Install the right side cover. ( p. 55)

- Remove the motorcycle from the lift stand. ( p. 43)

- Check the static sag of the shock absorber. ( p. 31)

- Check the rider sag of the shock absorber. ( p. 32)

- Adjust the rebound damping of the shock absorber. ( p. 30)

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. 43)

TUNING THE CHASSIS

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.

S05998-10

- 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

3 bar (44 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. 43)

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 to the stop.

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

S05999-10

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.

16 mm (0.63 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.

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.

Info

If the seat height is adjusted on the shock absorber, the seat height should also be adjusted on the fork.

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

- 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

Low seat position

– Mount and tighten screw 1.

S06001-10

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. 43)

SEAT HEIGHT

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. 43)

- Remove the front wheel.

(

p. 86)

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.

S06002-10

– Tighten screw 2.

Guideline

Screw, bottom triple

15 Nm (11.1 lbf ft)

clamp

- Tighten screw 1.

Guideline

Screw, top triple clamp

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. 86)

SEAT HEIGHT

– Remove screws 4 and separate the subframe.

- Place air filter box in the desired position.

Guideline

High seat position

Drill holes A

Low seat position

Drill holes B

– Assemble the subframe, mount and tighten the screws.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

- Position the decorative trim with the screw and tighten.

S05984-10

- Position the subframe at the desired seat height and position and

tighten screws 2 on the right and left side.

Guideline

Screw, subframe

35 Nm (25.8 lbf ft)

Loctite^®2701™

High seat position

Position C

Low seat position

Position D

S06032-10

- Position the intake flange on the carburetor and tighten hose clip

Guideline

Hose clip, carburetor

2.8 Nm (2.07 lbf ft)

– Attach the throttle cable wire to the top tube with a cable tie.

S05987-10

SERVICE WORK ON THE CHASSIS

12.1

Raising the motorcycle with a lift stand

Note

Material damage The vehicle may be damaged by incorrect procedure when parking.

Significant damage may be caused if the vehicle rolls away or falls over.

The components for parking the vehicle are designed only for the weight of the vehicle.

- Park the vehicle on a firm and level surface.

- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

- Raise the motorcycle at the frame underneath the engine.

Neither wheel is in contact with the ground.

- Secure the motorcycle against falling over.

401942-01

12.2

Removing the motorcycle from the lift stand

Note

Material damage The vehicle may be damaged by incorrect procedure when parking.

Significant damage may be caused if the vehicle rolls away or falls over.

The components for parking the vehicle are designed only for the weight of the vehicle.

- Park the vehicle on a firm and level surface.

- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

- Remove the motorcycle from the lift stand.

- Remove the lift stand.

- To park the motorcycle, 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. 43)

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.

S05940-10

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

12.4

Cleaning the dust boots of the fork legs

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

- Remove the fork protector. ( p. 45)

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. 119)

- Press the dust boots back into the installation position.

- Remove the excess oil.

Finishing work

- Install the fork protector. ( p. 45)

- Remove the motorcycle from the lift stand. ( p. 43)

SERVICE WORK ON THE CHASSIS

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.

F03100-10

- Remove screws 3 on the right fork leg. Take off the fork protector.

F03099-10

12.6

Installing the fork protector

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

screws 1.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

F03099-11

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

screws 2.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

- Position the brake line and the clamp. Mount and tighten

screws 3.

Guideline

F03100-11

Screw, brake hose

EJOT

1.7 Nm (1.25 lbf ft)

bracket

Clamp the brake line only via the metal bushing.

Make sure that the upper edge of the bushing is as flush as possi-

ble with the bracket.

SERVICE WORK ON THE CHASSIS

12.7

Removing the fork legs

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

- Remove the front wheel.

(

p. 86)

Main work

- Remove screws 1 and take off the clamp.

- Remove screws 2 and take off the brake caliper.

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

Info

Do not kink the brake line.

S05943-10

- Loosen screws 3. Remove the left fork leg.

- Loosen screws 4. Remove the right fork leg.

S06003-11

12.8

Installing the fork legs

Main work

- Position the fork legs.

Bleeder screws 1 are positioned toward the front and left.

Info

The second milled groove in the fork leg must be flush with

the upper edge of the upper triple clamp.

S05940-10

- Tighten screws 2.

Guideline

Screw, top triple clamp

20 Nm (14.8 lbf ft)

– Tighten screws 3.

Guideline

Screw, bottom triple

15 Nm (11.1 lbf ft)

clamp

S06003-10

SERVICE WORK ON THE CHASSIS

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

Guideline

Screw, front

20 Nm (14.8 lbf ft)

brake caliper

Loctite^®243™

– Position the brake line and the clamp. Mount and tighten

screws 5.

Guideline

Screw, brake hose

EJOT

1.7 Nm (1.25 lbf ft)

S05943-11

bracket

Clamp the brake line only via the metal bushing.

Make sure that the upper edge of the bushing is as flush as possi-

ble with the bracket.

Finishing work

- Install the front wheel.

(

p. 86)

12.9

Removing the lower triple clamp

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

- Remove the front wheel.

(

p. 86)

– Remove the fork legs.

(

p. 46)

– Remove the start number plate. ( p. 51)

- Remove the 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.

S06004-10

- Remove protective ring 4.

- Remove the lower triple clamp with the steering stem.

- Remove the upper steering head bearing.

S05946-10

SERVICE WORK ON THE CHASSIS

– Tighten screws 5.

Guideline

Screw, bottom triple

15 Nm (11.1 lbf ft)

clamp

S06005-10

- 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.

S06006-10

- Tighten bolt 7.

Guideline

Screw, steering stem

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

20 Nm (14.8 lbf ft)

S06006-11

- Position the brake caliper, and mount and tighten screws 9.

Guideline

Screw, front

20 Nm (14.8 lbf ft)

brake caliper

Loctite^®243™

– Position the brake line and the clamp. Mount and tighten

screws bk.

Guideline

Screw, brake hose

EJOT

1.7 Nm (1.25 lbf ft)

S05943-12

bracket

Clamp the brake line only via the metal bushing.

Make sure that the upper edge of the bushing is as flush as possi-

ble with the bracket.

Finishing work

- Check that the wiring harness, throttle cable, and brake and clutch

lines can move freely and are routed correctly.

- Install front fender. ( p. 52)

- Install the start number plate. ( p. 51)

- Install the front wheel.

(

p. 86)

– Check the steering head bearing play. ( p. 50)

- Remove the motorcycle from the lift stand. ( p. 43)

SERVICE WORK ON THE CHASSIS

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. 43)

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. 50)

– 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. 50)

– Check the steering head bearing and replace if required.

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

12.12

Adjusting the steering head bearing play

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

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)

S06007-10

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

avoid stresses.

- Tighten screw 3.

Guideline

Screw, steering stem

20 Nm (14.8 lbf ft)

– Tighten screws 2.

SERVICE WORK ON THE CHASSIS

Guideline

Screw, top triple clamp

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. 50)

- Remove the motorcycle from the lift stand. ( p. 43)

12.13

Lubricating the steering head bearing

- Remove the lower triple clamp.

(

p. 47)

– Install the lower triple clamp.

(

p. 48)

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 start number plate

- Remove the service hour counter and hang it to one side.

- Remove screw 1.

- Take off the start number plate.

S06035-10

12.15

Installing the start number plate

- Position the start number plate.

Holding lugs 1 engage in the fender.

S06036-10

SERVICE WORK ON THE CHASSIS

12.23

Installing the left side cover

- Hook in side cover with holding lugs 1 in area A and holding

lugs 2 in area B.

- Press the side cover into the rubber bushings.

S06020-10

12.24

Removing the frame protector

Preparatory work

- Remove the right side cover. ( p. 54)

- Remove the left side cover. ( p. 55)

Main work

- Remove the cable ties.

- Remove screws 1 with the bushings.

- Take off the left frame protector.

- Take off the right frame protector.

S06037-10

12.25

Installing the frame protector

Main work

- Position the left frame protector.

- Position the right frame protector.

- Mount screws 1 with the bushings and tighten.

Guideline

Screw, frame protector

3 Nm (2.2 lbf ft)

– Secure the frame protector with cable ties.

S06037-10

Finishing work

- Install the left side cover. ( p. 56)

- Install the right side cover. ( p. 55)

SERVICE WORK ON THE CHASSIS

12.26

Removing the shock absorber

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

- Remove the right side cover. ( p. 54)

- Remove main silencer. ( p. 60)

Main work

- Remove screws 1 with bushings and splash protector 2.

S06023-10

- Take the brake line 3 out of the holders.

- Remove screw 4 and lower the rear wheel with the link fork as far

as possible without blocking the rear wheel. Secure the rear wheel

in this position.

- Remove screw 5 and shock absorber.

S06076-11

12.27

Installing the shock absorber

Main work

- Position the shock absorber and mount and tighten screw 1.

Guideline

Screw, top shock

M10

45 Nm (33.2 lbf ft)

absorber

Loctite^®243™

– Mount and tighten screw 2.

Guideline

Screw, bottom

M10

45 Nm (33.2 lbf ft)

S06076-10

shock absorber

Loctite^®243™

– Secure brake line 3 in the holder.

- Position splash protector 4, mount screws 5 with bushings, and

tighten.

Guideline

Screw, splash protector

EJOT PT^®

2 Nm (1.5 lbf ft)

K60x25-Z

S06023-11

Finishing work

- Install the main silencer. ( p. 60)

- Install the right side cover. ( p. 55)

SERVICE WORK ON THE CHASSIS

- Remove the motorcycle from the lift stand. ( p. 43)

12.28

Removing the seat

- Open quick release 1 and raise the rear of the seat.

- Pull back the seat and remove it.

S06021-10

12.29

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.

S06022-10

- Close quick release 3.

S06021-11

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. 58)

SERVICE WORK ON THE CHASSIS

Main work

- Detach retaining tab 1.

- Remove air filter with air filter support.

- Remove air filter from air filter support.

S06025-10

12.31

Installing the air filter

Main work

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

- Grease the air filter in area A.

Long-life grease ( p. 118)

S06016-10

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

The air filter is correctly positioned.

- Insert retaining tab 2.

Retaining pin 3 is secured by retaining tab 2.

Info

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

enter the engine and result in damage.

S06026-10

Finishing work

- Mount the seat. ( p. 58)

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. 58)

- Remove the air filter.

(

p. 58)

SERVICE WORK ON THE CHASSIS

Main work

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

to dry properly.

Air filter cleaner ( p. 118)

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.

S05968-10

Oil for foam air filter ( p. 118)

- Clean the air filter box.

- Check intake flange for damage and looseness.

Finishing work

- Install the air filter.

(

p. 59)

– Mount the seat. ( p. 58)

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 exhaust sleeve 2.

S06027-10

12.34

Installing the main silencer

Main work

- Mount the main silencer with intake sleeve 1.

- Mount and tighten screws 2 with bushing.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

S06027-11

Finishing work

- Install the right side cover. ( p. 55)

SERVICE WORK ON THE 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. 60)

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.

S05970-10

- Mount and tighten the screws with the toothed washers.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

Finishing work

- Install the main silencer. ( p. 60)

- Install the right side cover. ( p. 55)

12.36

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.

SERVICE WORK ON THE CHASSIS

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. 58)

- Turn the knurled screw on the fuel tap all the way clockwise.

Main work

- Remove screw 1.

S06039-10

- Remove screws 2.

S06040-10

- Pull off fuel hose 3.

Info

Remaining fuel may flow out of the fuel hose.

- Pull fuel tank breather out of the steering stem.

- Pull both spoilers off laterally from the radiator bracket and lift off

the fuel tank.

S06041-10

SERVICE WORK ON THE CHASSIS

12.37

Installing the fuel tank

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

- Switch off the engine for refueling.

- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

- If any fuel is spilled, wipe it off immediately.

- Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is harmful to health.

- Avoid skin, eye and clothing contact with fuel.

- Immediately consult a doctor if you swallow fuel.

- Do not inhale fuel vapors.

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

- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

- Change your clothing if fuel spills on them.

- Keep fuels correctly in a suitable canister, and out of the reach of children.

Main work

- Check the throttle cable routing. ( p. 69)

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

ator mount.

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

- Mount fuel hose 1.

S06041-11

- Mount and tighten screws 2.

Guideline

Screw, fuel tank spoiler

6 Nm (4.4 lbf ft)

on radiator

S06040-10

SERVICE WORK ON THE CHASSIS

- Mount and tighten screw 3.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

- Position the fuel tank breather in the steering stem.

S06039-11

Finishing work

- Turn the knurled screw on the fuel tap all the way counterclockwise.

- Mount the seat. ( p. 58)

12.38

Checking the chain for dirt

- Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

- Clean the chain. ( p. 64)

400678-01

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. 43)

SERVICE WORK ON THE CHASSIS

Main work

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

- Remove old grease residue with chain cleaner.

Chain cleaner ( p. 118)

- After drying, apply chain spray.

Off-road chain spray ( p. 118)

400725-01

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

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. 43)

Main work

- Press the chain upward at the end of the chain sliding piece and

determine chain tension A.

Info

Top chain section 1 must be taut.

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

measurement at different chain positions.

V00235-10

Chain tension

5 … 8 mm (0.2 … 0.31 in)

» If the chain tension does not meet the specification:

- Adjust the chain tension. ( p. 66)

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

SERVICE WORK ON THE CHASSIS

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. 43)

- Check the chain tension. ( p. 65)

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

V02827-10

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

M14x1.5

40 Nm (29.5 lbf ft)

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

12.42

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

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

Main work

- Shift the transmission into neutral.

- Check the chain, rear sprocket and engine sprocket for wear.

» If the chain, rear sprocket or engine sprocket is worn:

- Change the drivetrain kit.

400227-01

SERVICE WORK ON THE CHASSIS

Info

The engine sprocket, rear sprocket and chain should

always be replaced together.

When fitting the chain joint, always make sure that

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

S06042-10

Screw, engine

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,

10 Nm (7.4 lbf ft)

chassis

S06043-10

SERVICE WORK ON THE CHASSIS

- Check the chain sliding piece for wear.

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

chain sliding piece:

- Change the chain sliding piece.

- Check that the chain sliding piece is firmly seated.

» If the chain sliding piece is loose:

- Tighten the chain sliding piece.

Guideline

Screw, chain sliding

15 Nm (11.1 lbf ft)

piece

S06044-10

- 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,

10 Nm (7.4 lbf ft)

chassis

H00131-01

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

SERVICE WORK ON THE CHASSIS

12.43

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.

R06624-10

12.44

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.

V00216-01

12.45

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. 58)

- Turn the knurled screw on the fuel tap all the way clockwise.

- Remove the fuel tank.

(

p. 61)

Main work

- Check the throttle cable routing.

The throttle cable must be routed behind the handlebar, behind

the coolant hose and on the left of the frame.

» If the throttle cable is not routed as specified:

- Correct the throttle cable routing.

S06038-01

Finishing work

- Install the fuel tank.

(

p. 63)

– Turn the knurled screw on the fuel tap all the way counterclockwise.

- Mount the seat. ( p. 58)

SERVICE WORK ON THE CHASSIS

12.46

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

5 Nm (3.7 lbf ft)

Loctite^®243™

Diamond A must be located at the top.

D07902-10

12.47

Adjusting the basic position of the clutch lever

- Adjust the basic position of the clutch lever to the size of the rider's

hand using adjusting screw 1.

Info

Turn the adjusting screw clockwise to increase the distance

between the clutch lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the

distance between the clutch lever and the handlebar.

The range of adjustment is limited.

V02820-12

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

force.

Do not make any adjustments while riding.

12.48

Checking the fluid level of the hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch facing discs.

- Move the hydraulic clutch fluid reservoir mounted on the handlebar

into a horizontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

- Check the fluid level.

Guideline

4 mm (0.16 in)

Level A (fluid level below

container rim)

V02828-10

SERVICE WORK ON THE CHASSIS

» If the fluid level does not meet specifications:

- Correct the fluid level of the hydraulic clutch. ( p. 71)

- 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.

12.49

Correcting the fluid level of the hydraulic clutch

Warning

Skin irritation Brake fluid is a harmful substance.

- Keep brake fluid out of the reach of children.

- Wear suitable protective clothing and safety glasses.

- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

- Consult a doctor immediately if brake fluid has been swallowed.

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

- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the

eyes.

- If brake fluid spills on to your clothing, change the clothing.

Info

The fluid level rises with increasing wear of the clutch facing discs.

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

- Move the hydraulic clutch fluid reservoir mounted on the handlebar

into a horizontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

- Correct the fluid up to level A.

Guideline

4 mm (0.16 in)

Level A (fluid level below

container rim)

V02828-10

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

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

screws.

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

SERVICE WORK ON THE CHASSIS

12.50

Changing the hydraulic clutch fluid

Warning

Skin irritation Brake fluid is a harmful substance.

- Keep brake fluid out of the reach of children.

- Wear suitable protective clothing and safety glasses.

- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

- Consult a doctor immediately if brake fluid has been swallowed.

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

- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the

eyes.

- If brake fluid spills on to your clothing, change the clothing.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-

cable regulations.

Info

The fluid level rises with increasing wear of the clutch facing discs.

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

- Move the hydraulic clutch fluid reservoir mounted on the handlebar

into a horizontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

V02828-11

- Fill bleeding syringe 4 with the appropriate hydraulic fluid.

Syringe (50329050000)

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

- On the slave cylinder, remove bleeder screw and mount bleeding

syringe 4.

S06045-10

- Now press the fluid into the system until it emerges from hole A

of the master cylinder without bubbles.

- Occasionally extract the fluid from the master cylinder reservoir to

prevent overflowing.

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

- Correct the fluid level of the hydraulic clutch.

Guideline

Fluid level below container rim

4 mm (0.16 in)

V02829-10

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

screws.

BRAKE SYSTEM

13.1

Checking the free travel of the hand brake lever

Warning

Danger of accidents The brake system fails in the event of overheating.

If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.

- Set the free travel on the hand brake lever in accordance with the specification.

- Push the hand brake lever forward and check free travel A.

Free travel of hand brake lever

≥ 3 mm (≥ 0.12 in)

» If the free travel does not match the specification:

- Adjust the basic position of the hand brake lever. ( p. 74)

V02821-13

13.2

Adjusting the basic position of the hand brake lever

- Check the free travel of the hand brake lever. ( p. 74)

- Adjust the basic position of the hand brake lever using adjusting

screw 1.

Info

Turn the adjusting screw clockwise to increase the distance

between the hand brake lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the

distance between the hand brake lever and the handlebar.

V02821-12

The range of adjustment is limited.

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

force.

Do not make any adjustments while riding.

13.3

Checking the brake discs

Warning

Danger of accidents Worn-out brake discs reduce the braking effect.

- Make sure that worn-out brake discs are replaced immediately. (Your authorized GASGAS Motorcycles work-

shop will be glad to help.)

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

the dimension A.

Info

Wear reduces the thickness of the brake disc around the

contact surface of the brake linings.

Brake discs - wear limits

front

2.5 mm (0.098 in)

400257-10

rear

2.5 mm (0.098 in)

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

BRAKE SYSTEM

– Change the front brake disc.

- Change the rear brake disc.

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

deformation.

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

- Change the front brake disc.

- Change the rear brake disc.

13.4

Checking the front brake fluid level

Warning

Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the

brake linings are worn down.

- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-

GAS Motorcycles workshop will be glad to help.)

Warning

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

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.

(Your authorized GASGAS Motorcycles workshop will be glad to help.)

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

GAS Motorcycles workshop will be glad to help.)

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

zontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

- Check the brake fluid level.

Guideline

4 mm (0.16 in)

Level A (fluid level below

container rim)

V02822-10

» If the brake fluid level does not meet specifications:

- Add front brake fluid.

(

p. 76)

– 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.

BRAKE SYSTEM

13.5

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. 77)

Main work

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

zontal position.

- Remove screws 1.

- Take off cover 2 with membrane 3.

V02822-11

BRAKE SYSTEM

– Add brake fluid up to level A.

Guideline

4 mm (0.16 in)

Level A (brake fluid level

below reservoir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

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

screws.

309386-11

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

13.6

Checking that the brake linings of the front brake are secured

Warning

Danger of accidents Worn-out brake linings reduce the braking effect.

- Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop

will be glad to help.)

- 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. 77)

– Check the brake linings for damage and cracking.

» If there is damage or cracking:

- Change the brake linings of the front brake.

(

p. 77)

V02823-10

- Check that the brake linings are secured.

» If the brake linings are not secured correctly:

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

13.7

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.)

Warning

Skin irritation Brake fluid is a harmful substance.

- Keep brake fluid out of the reach of children.

- Wear suitable protective clothing and safety glasses.

- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

- Consult a doctor immediately if brake fluid has been swallowed.

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

- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the

eyes.

- If brake fluid spills on to your clothing, change the clothing.

BRAKE SYSTEM

Warning

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

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.

(Your authorized GASGAS Motorcycles workshop will be glad to help.)

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

GAS Motorcycles workshop will be glad to help.)

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.

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.

V02822-11

- Remove screws 4.

- 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.

V02824-10

BRAKE SYSTEM

–

Remove cotter pins 5.

–

Remove pin 6.

–

Remove the brake linings.

–

Clean the brake caliper.

–

Position the new brake linings.

Info

Always change the brake linings in pairs.

V02825-10

Ensure that the brake linings are correctly positioned in the

holding spring.

Position pins 6.

–

Mount cotter pins 5.

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. 74)

–

Position the brake caliper.

–

Mount screws 4, but do not tighten yet.

–

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 screws 4.

Guideline

V02824-10

Screw, front

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-

4 mm (0.16 in)

voir rim

Brake fluid DOT 4 / DOT 5.1 ( p. 116)

Position cover 2 with membrane 3.

–

Mount and tighten screws 1.

V02822-11

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

BRAKE SYSTEM

13.8

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.)

- 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. 80)

402026-10

- Attach spring 1.

13.9

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.

- Attach the foot brake lever spring.

S06046-10

- 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. 81)

BRAKE SYSTEM

13.10

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.)

- 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

Brake lever stop nut

20 Nm (14.8 lbf ft)

– Hold push rod 3 and tighten nut 2.

S06047-10

Guideline

Remaining nuts, chas-

10 Nm (7.4 lbf ft)

sis

- Attach spring 1.

13.11

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.)

BRAKE SYSTEM

- Position 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. 82)

H01654-11

13.12

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. 43)

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

BRAKE SYSTEM

Main work

- Remove screws 1.

- Take off cover 2 with membrane.

R06657-10

- 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. 116)

- Position the cover and the 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. 43)

13.13

Checking that the brake linings of the rear brake are secured

Warning

Danger of accidents Worn-out brake linings reduce the braking effect.

- Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop

will be glad to help.)

- Check the brake linings for lining thickness A.

≥ 1 mm (≥ 0.04 in)

Minimum thickness A

» If it is less than the minimum thickness:

- Change the rear brake linings.

(

p. 84)

– Check the brake linings for damage and cracking.

» If there is damage or cracking:

- Change the rear brake linings.

(

p. 84)

V02830-10

- Check that the brake linings are secured.

» If the brake linings are not secured correctly:

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

BRAKE SYSTEM

13.14

Changing the rear brake linings

Warning

Danger of accidents Incorrect servicing will cause the brake system to fail.

- Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy-

cles workshop will be glad to help.)

Warning

Skin irritation Brake fluid is a harmful substance.

- Keep brake fluid out of the reach of children.

- Wear suitable protective clothing and safety glasses.

- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

- Consult a doctor immediately if brake fluid has been swallowed.

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

- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the

eyes.

- If brake fluid spills on to your clothing, change the clothing.

Warning

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

- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.

(Your authorized GASGAS Motorcycles workshop will be glad to help.)

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

GAS Motorcycles workshop will be glad to help.)

Warning

Danger of accidents Oil or grease on the brake discs reduces the braking effect.

- Always keep the brake discs free of oil and grease.

- Clean the brake discs with brake cleaner when necessary.

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.

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-

cable regulations.

Info

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

BRAKE SYSTEM

–

Stand the vehicle upright.

–

Remove screws 1.

–

Take off cover 2 with membrane.

–

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.

R06657-10

Remove cotter pins 3.

–

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

ally on the brake disc.

Remove pin 4.

–

Remove the brake linings and the retainer spring.

–

Clean the brake caliper.

–

Position the retainer spring.

–

Position the new brake linings.

S06075-10

Info

Always change the brake linings in pairs.

Mount pin 4.

Info

To make it easier to mount the pin, push the brake linings

upwards against the retainer spring.

Make sure the brake linings and retainer spring are seated

correctly.

Mount cotter pins 3.

–

Check the brake discs. ( p. 74)

–

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

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

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. 116)

Mount the cover and membrane.

–

Mount and tighten the screws.

H01654-10

Info

Use water to immediately clean up any brake fluid that has

overflowed or spilled.

WHEELS, TIRES

14.1

Removing the front wheel

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

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.

F03113-10

Warning

Danger of accidents Damaged brake discs reduce the

braking effect.

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

disc is not damaged.

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

out of the fork.

F03114-10

Info

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

removed.

- Remove spacers 3.

F03040-10

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.

WHEELS, TIRES

– 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. 118)

- Insert the spacers.

F03041-10

- Clean and grease the wheel spindle.

Long-life grease ( p. 118)

- Position the front wheel.

The brake linings are correctly positioned.

- Insert the wheel spindle.

- Mount and tighten screw 2.

Guideline

F03113-11

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. 43)

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

The fork legs straighten.

- Tighten screws 3.

Guideline

Screw, fork stub

10 Nm (7.4 lbf ft)

14.3

Removing the rear wheel

Preparatory work

- Raise the motorcycle with a lift stand. ( p. 43)

Main work

- Remove nut 1.

- Take off chain adjuster 2.

V02834-10

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.

H00117-10

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.

F03042-10

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. 118)

- Insert the spacers.

F03043-10

Info

Insert the wide spacer on the left in the direction of travel.

WHEELS, TIRES

– Clean and grease wheel spindle 2.

Long-life grease ( p. 118)

- Position the rear wheel and insert wheel spindle.

The brake linings are correctly positioned.

- Mount the chain.

- Position chain adjuster 3 on both sides and push the wheel spin-

dle in all the way.

H00117-12

- Mount nut 4, but do not tighten yet.

- Make sure that the chain adjusters are fitted correctly on the adjust-

ing screws.

- Check the chain tension. ( p. 65)

- Tighten nut 4.

Guideline

Nut, rear wheel spindle

M14x1.5

40 Nm (29.5 lbf ft)

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

V02834-11

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

Finishing work

- Remove the motorcycle from the lift stand. ( p. 43)

14.5

Checking the tire condition

Info

Only mount tires approved and/or recommended by GASGAS.

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 characteristics of the motor-

cycle.

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

- 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 recommends that the tires be changed after 5 years

at the latest, regardless of the actual state of wear.

H01144-10

» If the tires are older than five years:

WHEELS, TIRES

- 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.

Guideline

Spoke nipple

M3.5

3 Nm (2.2 lbf ft)

Torque wrench kit (58429094000)

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.

S06048-10

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.

S06049-10

- 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. 116)

- Mount the radiator cap.

400243-10

COOLING SYSTEM

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. 116)

- 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.

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

8 Nm (5.9 lbf ft)

pump cover

S06050-10

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

S06051-10

Coolant

0.55 l (0.58 qt.)

Coolant ( p. 116)

– 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. 92)

COOLING SYSTEM

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

8 Nm (5.9 lbf ft)

pump cover

S06050-10

- Add coolant to level A.

Guideline

10 mm (0.39 in)

Distance A above the radia-

tor fins

Coolant

0.55 l (0.58 qt.)

Coolant ( p. 116)

S06051-10

TUNING THE ENGINE

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. 96)

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. 96)

16.2

Adjusting the play in the throttle cable

Preparatory work

- Remove the seat. ( p. 58)

- Turn the knurled screw on the fuel tap all the way clockwise.

- Remove the fuel tank.

(

p. 61)

– Check the throttle cable routing. ( p. 69)

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.

V02835-10

- 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

TUNING THE ENGINE

Finishing work

- Install the fuel tank.

(

p. 63)

– Turn the knurled screw on the fuel tap all the way counterclockwise.

- Mount the seat. ( p. 58)

- Check the play in the throttle cable. ( p. 96)

16.3

Plug-in connector of ignition timing map adjustment

Plug-in connector 1 of the ignition timing map adjustment is located

on the frame under the fuel tank.

Possible states

• Soft - The plug-in connector of the ignition timing map adjustment

is disconnected to achieve better rideability.

• Performance - The plug-in connector of the ignition timing map

adjustment is joined to achieve higher performance.

S05989-10

16.4

Changing the ignition timing map

Switching the ignition timing map from Performance to Soft

- Disconnect plug-in connector 1 of the ignition timing map adjustment. (Figure S05989-10

p. 97)

Soft - Better rideability

Switching the ignition timing map from Soft to Performance

- Join plug-in connector 1 of the ignition timing map adjustment. (Figure S05989-10

p. 97)

Performance - Higher performance

16.5

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.

S06052-10

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

The idle speed is adjusted using idle speed adjusting screw 2.

16.6

Carburetor - adjusting the idle speed

Preparatory work

- Remove the right side cover. ( p. 54)

TUNING THE ENGINE

Main work

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

specified basic setting.

Guideline

Idle air adjusting screw

Open

3.5 turns

–

Run the engine until warm.

Guideline

S06052-10

Warming-up phase

≥ 5 min

Danger

Danger of poisoning Exhaust gases are toxic and inhaling

them may result in unconsciousness and death.

- Always make sure there is sufficient ventilation when

running the engine.

- Use effective exhaust extraction when starting or run-

ning the engine in an enclosed space.

Adjust the idle speed using idle speed adjusting screw 2.

Guideline

Choke function deactivated - The choke lever is pushed up all the

way to the stop. ( p. 16)

Idle speed

1,500 … 2,000 rpm

–

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

the idle speed begins to fall.

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

terclockwise until the idle speed again begins to fall.

Adjust to the point between these two positions with the highest

idle speed.

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.

TUNING THE ENGINE

16.7

Emptying the carburetor float chamber

Danger

Fire hazard Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

- Switch off the engine for refueling.

- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

- If any fuel is spilled, wipe it off immediately.

- Observe the specifications for refueling.

Warning

Danger of poisoning Fuel is harmful to health.

- Avoid skin, eye and clothing contact with fuel.

- Immediately consult a doctor if you swallow fuel.

- Do not inhale fuel vapors.

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

- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

- Change your clothing if fuel spills on them.

- Keep fuels correctly in a suitable canister, and out of the reach of children.

Note

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

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

Info

Carry out work with a cold engine.

Water in the float chamber results in malfunctioning.

- Turn the knurled screw on the fuel tap all the way clockwise.

No more fuel flows from the tank to the carburetor.

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

- Remove screw plug 1.

- Fully drain the fuel.

- Mount and tighten the screw plug.

S06053-10

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.

A small quantity of gear oil must run out of the drilled hole.

» If no gear oil runs out:

- Add the gear oil.

(

p. 101)

– Mount and tighten screw 1.

S06054-10

Guideline

Screw, gear oil level

7 Nm (5.2 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.

S06055-10

Guideline

Oil drain plug with

M12x1.5

20 Nm (14.8 lbf ft)

magnet

100

SERVICE WORK ON THE ENGINE

– Remove filler plug 2 with the O-ring, and fill up with gear oil.

Gear oil

0.50 l (0.53 qt.)

Engine oil (15W/50)

(

p. 116)

Info

Too little gear oil or poor-quality gear oil results in prema-

ture wear to the transmission.

together with the O-ring.

- Mount and tighten filler plug 2

401955-11

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 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.

S06054-10

- Remove filler plug 2 with the O-ring.

- Add gear oil until it flows out of the hole of the gear oil level plug.

Engine oil (15W/50) ( p. 116)

- Mount and tighten screw 1.

Guideline

Screw, gear oil level

7 Nm (5.2 lbf ft)

monitoring

401955-11

- Mount and tighten filler plug 2 together with the O-ring.

101

CLEANING, CARE

18.1

Cleaning the motorcycle

Note

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

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

Pressure which is too high causes malfunctions and destroys components.

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

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

Minimum clearance

60 cm (23.6 in)

Note

Environmental hazard Hazardous substances cause environmental damage.

- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-

cable regulations.

Info

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. 118)

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.

(

p. 99)

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.

103

STORAGE

19.1

Storage

Warning

Danger of poisoning Fuel is harmful to health.

- Avoid skin, eye and clothing contact with fuel.

- Immediately consult a doctor if you swallow fuel.

- Do not inhale fuel vapors.

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

- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

- Change your clothing if fuel spills on them.

- Keep fuels correctly in a suitable canister, and out of the reach of children.

Info

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

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

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

periods when the next season starts.

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

service, add fuel additive.

Fuel additive ( p. 118)

- Refuel. ( p. 24)

Tip

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

lowest possible ethanol content.

401058-01

- Clean the motorcycle. ( p. 103)

- Change the gear oil.

(

p. 100)

– Check the antifreeze and coolant level. ( p. 91)

- Empty the carburetor float chamber.

(

p. 99)

– Check tire pressure. ( p. 90)

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

tions in temperature.

Info

GASGAS recommends jacking up the motorcycle.

- Raise the motorcycle with a lift stand. ( p. 43)

- 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.

105

TROUBLESHOOTING

Faults

Possible cause

Action

Engine turns but does not start

Operating error

Carry out start procedure. ( p. 21)

Motorcycle was out of use for a

Empty the carburetor float chamber.

long time and there is old fuel in

(

p. 99)

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.

–

Adjust the ignition.

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 carburetor

Carburetor - adjust the idle speed.

distorted

(

p. 97)

Spark plug defective

Change spark plug.

Ignition system defective

Check the ignition coil.

–

Check the spark plug connector.

Engine does not speed up

Carburetor running over because

Check/set the carburetor components.

float needle dirty or worn

Loose carburetor jets

Check/set the carburetor components.

Fault in ignition system

Check the ignition system.

–

Adjust the ignition.

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. 59)

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. 61)

Fault in ignition system

Check the ignition system.

–

Adjust the ignition.

Diaphragm or reed valve housing

Check the diaphragm and reed valve hous-

damaged

ing.

Noticeable wear

Overhaul the engine.

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. 24)

Engine takes in bad air

Check the intake flange and carburetor for

tightness.

107

TROUBLESHOOTING

Faults

Possible cause

Action

Engine stalls or is popping into the

The connector or ignition coil is

- Clean the plug-in connection and treat it

carburetor

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. 92)

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. 92)

– Refill with coolant.

(

p. 93)

Damaged cylinder head or cylin-

- Check the cylinder head or cylinder head

der head gasket

gasket.

Bent radiator hose

- Change the radiator hose.

Incorrect ignition point due to

- Adjust the ignition.

loose stator

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.

108

TECHNICAL SPECIFICATIONS

21.1

Engine

Design

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

membrane inlet

Displacement

64.90 cm³ (3.9605 cu in)

Stroke

40.8 mm (1.606 in)

Bore

45 mm (1.77 in)

Idle speed

1,500 … 2,000 rpm

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

23:75 straight cut spur gear wheel drive

Clutch

Multi-disc clutch in oil bath

Gearbox

6-gear transmission, claw shifted

Transmission ratio

1st gear