GASGAS MC 250 / EX 250 / EX 300. OWNER'S MANUAL (2024)
TABLE OF CONTENTS
TABLE OF CONTENTS
1
MEANS OF REPRESENTATION
5
7.2
Running in the engine
21
7.3
Starting power of lithium-ion batteries
1.1
Symbols used
5
at low temperatures
21
1.2
Formats used
5
7.4
Preparing the vehicle for difficult
2
SAFETY ADVICE
6
operating conditions
22
7.5
Preparing the vehicle for rides on dry
2.1
Use definition - intended use
6
sand
22
2.2
Misuse
6
7.6
Preparing the vehicle for rides on wet
2.3
Safety advice
6
sand
23
2.4
Degrees of risk and symbols
6
7.7
Preparing the vehicle for rides on wet
2.5
Tampering warning
6
and muddy circuits
23
2.6
Safe operation
7
7.8
Preparing vehicle for high temperatures
2.7
Protective clothing
7
or slow riding
24
2.8
Work rules
7
7.9
Preparing the vehicle for low
2.9
Environment
8
temperatures or snow
24
2.10
Owner's Manual
8
8
RIDING INSTRUCTIONS
25
3
IMPORTANT NOTES
9
8.1
Checks and maintenance measures
3.1
Manufacturer warranty, implied
when preparing for use
25
warranty
9
8.2
Starting
25
3.2
Fuel, auxiliary substances
9
8.3
Starting off
26
3.3
Spare parts, accessories
9
8.4
Shifting, riding
27
3.4
Service
9
8.5
Braking
27
3.5
Figures
9
8.6
Stopping, parking
28
3.6
Customer service
9
8.7
Transporting
28
8.8
Refueling
29
4
VIEW OF VEHICLE
10
9
SERVICE SCHEDULE
30
4.1
View of vehicle, front left (example)
10
4.2
View of vehicle, rear right (example)
11
9.1
Additional information
30
9.2
Service schedule
30
5
SERIAL NUMBERS
12
10
TUNING THE CHASSIS
32
5.1
Vehicle identification number
12
5.2
Steering head label
12
10.1
Checking the basic chassis setting with
5.3
Engine number
12
the rider's weight
32
5.4
Fork part number
12
10.2
Compression damping of the shock
5.5
Shock absorber article number
13
absorber
32
10.3
Adjusting the low-speed compression
6
CONTROLS
14
damping of the shock absorber
32
6.1
Clutch lever
14
10.4
Adjusting the high-speed compression
6.2
Hand brake lever
14
damping of the shock absorber
33
10.5
Adjusting the rebound damping of the
6.3
Throttle grip
14
shock absorber
34
6.4
Stop button
14
10.6
Measuring the dimension of the rear
6.5
Start button
15
wheel unloaded
34
6.6
Overview of indicator lamps (MC 250)
15
10.7
Checking the static sag of the shock
6.7
Overview of indicator lamps (All EX
absorber
35
models)
15
10.8
Checking the riding sag of the shock
6.8
Combination instrument
15
absorber
35
6.9
Opening the fuel tank filler cap
16
10.9
Adjusting the spring preload of the
6.10
Closing the fuel tank filler cap
17
shock absorber
36
6.11
Cold start button
17
10.10
Adjusting the riding sag
37
6.12
Idle speed adjusting screw
18
10.11
Air suspension XACT
38
6.13
Shift lever
18
10.12
Checking the basic setting of the fork
38
6.14
Foot brake lever
19
10.13
Adjusting the fork air pressure
6.15
Plug-in stand (MC 250)
19
(MC 250)
38
6.16
Side stand (All EX models)
19
10.14
Adjusting the compression damping of
7
PREPARING FOR USE
20
the fork
40
10.15
Adjusting the rebound damping of the
7.1
Advice on preparing for first use
20
fork
41
2
TABLE OF CONTENTS
10.16
Handlebar position
42
11.48
Changing the hydraulic clutch fluid
74
10.17
Adjusting the handlebar position
42
12
BRAKE SYSTEM
76
11
SERVICE WORK ON THE CHASSIS
45
12.1
Checking the free travel of the hand
11.1
Raising the motorcycle with a lift stand
45
brake lever
76
11.2
Removing the motorcycle from the lift
12.2
Adjusting the basic position of the hand
stand
45
brake lever
76
11.3
Bleeding the fork legs
46
12.3
Checking the brake discs
76
11.4
Cleaning the dust boots of the fork legs
46
12.4
Checking the front brake fluid level
77
11.5
Removing the fork protector
47
12.5
Adding front brake fluid
77
11.6
Installing the fork protector
47
12.6
Checking that the brake linings of the
11.7
Removing the fork legs
47
front brake are secured
79
11.8
Installing the fork legs
48
12.7
Changing the brake linings of the front
11.9
Removing the lower triple clamp
48
brake
79
12.8
Checking the free travel of foot brake
11.10
Installing the lower triple clamp
49
lever
81
11.11
Checking the steering head bearing play ... 51
12.9
Adjusting the basic position of the foot
11.12
Adjusting steering head bearing play
52
brake lever
82
11.13
Lubricating the steering head bearing
52
12.10
Checking the rear brake fluid level
83
11.14
Removing the start number plate
52
12.11
Adding rear brake fluid
83
11.15
Installing the start number plate
53
12.12
Checking that the brake linings of the
11.16
Removing front fender
53
rear brake are secured
84
11.17
Installing front fender
53
12.13
Changing the rear brake linings
85
11.18
Removing the shock absorber
53
11.19
Installing the shock absorber
55
13
WHEELS, TIRES
87
11.20
Removing the seat
56
13.1
Removing the front wheel
87
11.21
Mounting the seat
56
13.2
Installing the front wheel
88
11.22
Removing the frame protector
57
13.3
Removing the rear wheel
88
11.23
Installing the frame protector
57
13.4
Installing the rear wheel
89
11.24
Removing the right side panel
57
13.5
Checking the tire condition
91
11.25
Installing the right side panel
58
13.6
Checking tire pressure
91
11.26
Removing the air filter box cover
58
13.7
Checking spoke tension
92
11.27
Installing the air filter box cover
58
11.28
Removing the air filter
59
14
ELECTRICAL SYSTEM
93
11.29
Cleaning the air filter and air filter
14.1
Removing the 12-V battery
93
box
60
14.2
Installing the 12-V battery
94
11.30
Installing the air filter
60
14.3
Charging the 12-V battery
95
11.31
Preparing air filter box cover for
14.4
Changing the main fuse
96
securing
61
14.5
Changing the fuse of the fuel pump
97
11.32
Removing the main silencer
61
14.6
Diagnostics connector
98
11.33
Installing the main silencer
61
11.34
Changing the glass fiber yarn filling of
15
EXHAUST CONTROL
99
the main silencer
62
15.1
Programming the end positions of the
11.35
Removing the fuel tank
63
exhaust control
99
11.36
Installing the fuel tank
64
11.37
Checking the chain for dirt
66
16
COOLING SYSTEM
101
11.38
Cleaning the chain
66
16.1
Cooling system
101
11.39
Checking the chain tension
67
16.2
Checking the antifreeze and coolant
11.40
Adjusting the chain tension
67
level
101
11.41
Checking the chain, rear sprocket,
16.3
Checking the coolant level
102
engine sprocket, and chain guide
68
16.4
Draining the coolant
102
11.42
Checking the frame
71
16.5
Refilling with coolant
103
11.43
Checking the link fork
71
16.6
Changing the coolant
104
11.44
Checking the throttle cable routing
71
11.45
Checking the rubber grip
72
17
TUNING THE ENGINE
106
11.46
Adjusting the basic position of the clutch
17.1
Changing the mapping
106
lever
73
11.47
Checking/correcting the fluid level of
17.2
Checking the play in the throttle cable....
106
hydraulic clutch
73
3
TABLE OF CONTENTS
17.3
Adjusting the play in the throttle
cable
107
17.4
Adjusting the idle speed
108
17.5
Checking the basic position of the shift
lever
108
17.6
Adjusting the basic position of the shift
lever
109
18
SERVICE WORK ON THE ENGINE
110
18.1
Changing the fuel screen
110
18.2
Checking the gear oil level
111
18.3
Changing the gear oil
111
18.4
Adding the gear oil
112
19
CLEANING, CARE
114
19.1
Cleaning the motorcycle
114
20
STORAGE
116
20.1
Storage
116
20.2
Preparing for use after storage
117
21
TROUBLESHOOTING
118
22
BLINK CODE
120
23
TECHNICAL SPECIFICATIONS
122
23.1
Engine
122
23.2
Engine tightening torques
123
23.3
Capacities
124
23.3.1
Gear oil
124
23.3.2
Coolant
124
23.3.3
Fuel
124
23.4
Chassis
124
23.5
Electrical system
125
23.6
Tires
125
23.7
Fork
125
23.7.1
MC 250
125
23.7.2
All EX models
126
23.8
Shock absorber
126
23.8.1
MC 250
126
23.8.2
All EX models
127
23.9
Chassis tightening torques
128
24
SUBSTANCES
130
25
AUXILIARY SUBSTANCES
132
26
STANDARDS
134
27
INDEX OF SPECIAL TERMS
135
28
LIST OF ABBREVIATIONS
136
29
LIST OF SYMBOLS
137
29.1
Yellow and orange symbols
137
INDEX
138
4
MEANS OF REPRESENTATION
1
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g., of a work step or a function).
Indicates an unexpected reaction (e.g., of a work step or a function).
Indicates work that requires expert knowledge and technical understanding. In the interest of your own
safety, have this work performed by an authorized GASGAS Motorcycles workshop. Your motorcycle will
be cared for there to the highest degree by specially trained experts using the special tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential reworking.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name
Indicates a proprietary name.
Name®
Indicates a protected name.
Brand™
Indicates a brand available on the open market.
Underlined terms
Refer to technical details of the vehicle or indicate technical terms, which are
explained in the glossary.
5
2
SAFETY ADVICE
2.1
Use definition - intended use
2.2
Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respec-
tive use.
2.3
Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction
and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the
relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do not
remove any information or warning labels. If they are missing, you or others may not recognize dangers and may
therefore be injured.
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:
1
The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of
any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
2
the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
6
SAFETY ADVICE
2
1
Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust
gases.
2
Removal or puncturing of parts of the intake system.
3
Lack of proper maintenance.
4
Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those
specified by the manufacturer.
2.6
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
- Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
- Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when running the engine.
- Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become hot when the vehicle is operated.
- Do not touch any parts such as the exhaust system, radiator, engine, damper, or brake system before the vehi-
cle parts have cooled down.
- Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and
environmentally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety immediately eliminated by an authorized GASGAS Motorcycles workshop.
Adhere to the information and warning labels on the vehicle.
2.7
Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
- Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with pro-
tectors on all rides.
- Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, GASGAS Motorcycles recommends that you only operate the vehicle while wearing pro-
tective clothing.
2.8
Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with transpon-
der key) or the motor must be at a standstill (models without ignition lock or transponder key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the
number in parentheses. Example: bearing puller (15112017000)
Unless otherwise noted, normal conditions apply to all tasks and descriptions.
Ambient temperature
20 °C (68 °F)
Ambient air pressure
1,013 mbar (14.69 psi)
Relative air humidity
60 ± 5 %
7
2
SAFETY ADVICE
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion
screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instructions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn
parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of
the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of
others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regula-
tions of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regu-
lations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles dealer will be glad to
advise you.
2.10
Owner's Manual
Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful infor-
mation and many tips on how to operate, handle, and service your motorcycle. This is the only way to find out how best to
customize the vehicle for your own use and how you can protect yourself from injury.
Tip
Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need to.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized
GASGAS Motorcycles dealer.
The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be down-
loaded again by the new owner.
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate.
The Owner's Manual is also available for download from your authorized GASGAS Motorcycles dealer and on the GAS-
GAS Motorcycles website. A printed copy can also be ordered from your authorized GASGAS Motorcycles dealer.
International GASGAS Motorcycles website: http://www.gasgas.com
8
IMPORTANT NOTES
3
3.1
Manufacturer warranty, implied warranty
The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and
confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary dam-
age caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2
Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by
GASGAS Motorcycles and have them installed by an authorized GASGAS Motorcycles workshop. GASGAS Motorcycles
accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized
GASGAS Motorcycles dealer will be glad to advise you.
The latest news GASGAS Technical Accessories on your vehicle can be found on the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the
engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to
damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces, can result in significantly
increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it
may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always neces-
sary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized GASGAS Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle
and GASGAS Motorcycles.
A list of authorized GASGAS Motorcycles dealers can be found on the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
9
4
VIEW OF VEHICLE
4.1
View of vehicle, front left (example)
S05871-10
1 Hand brake lever ( p. 14)
2 Clutch lever ( p. 14)
3 Fuel tank filler cap
4 Air filter box cover
5 Shift lever ( p. 18)
6 Engine number ( p. 12)
10
VIEW OF VEHICLE
4
4.2
View of vehicle, rear right (example)
S05872-10
1 Shock absorber compression
2 Fork air pressure adjuster
3 Fork compression adjuster
4 Start button ( p. 15)
4 Stop button ( p. 14)
5 Throttle grip ( p. 14)
6 Vehicle identification number
7 Fork rebound adjustment
8 Idle speed adjusting screw ( p. 18)
9 Foot brake lever ( p. 19)
bk Cold start button ( p. 17)
bl Shock absorber rebound adjuster
11
5
SERIAL NUMBERS
5.1
Vehicle identification number
The vehicle identification number 1 is stamped on the right side of the
steering head.
401945-10
5.2
Steering head label
The steering head label 1 is attached to the front of the steering head.
401946-10
5.3
Engine number
The engine number 1 is embossed on the left side of the engine above
the engine sprocket.
H01047-10
5.4
Fork part number
The fork part number 1 is stamped on the inside of the axle clamp.
401947-10
12
SERIAL NUMBERS
5
5.5
Shock absorber article number
Shock absorber article number 1 is stamped on the top of the shock
absorber above the adjusting ring towards the engine side.
401948-10
13
6
CONTROLS
6.1
Clutch lever
Clutch lever 1 is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
J00075-10
6.2
Hand brake lever
Hand brake lever 1 is located on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
J00077-10
6.3
Throttle grip
The throttle grip 1 is fitted on the right side of the handlebar.
J00076-10
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.
W00019-10
14
CONTROLS
6
6.5
Start button
Start button 1 is fitted on the right side of the handlebar.
Possible states
• The start button is in the basic position
• The start button is pressed - In this position, the starter motor is
actuated.
W00020-10
6.6
Overview of indicator lamps (MC 250)
Possible states
Malfunction indicator lamp lights up/flashes orange - The
OBD has detected a malfunction in the vehicle electronics.
S05873-01
6.7
Overview of indicator lamps (All EX models)
Possible states
Malfunction indicator lamp lights up/flashes orange - The
OBD has detected a malfunction in the vehicle electronics.
FUEL is displayed - The fuel level has reached the reserve
mark.
S05874-01
6.8
Combination instrument
The combination instrument 1 is attached in front of the handlebar.
The combination instrument shows the total number of operating hours
of the engine.
The operating hour counter begins counting when the engine is started
and stops when the engine is switched off.
Info
Nothing can be cleared or adjusted on the combination instru-
ment.
S05827-10
As soon as the diagnostics tool is connected, the service hour
counter starts running.
Before longer diagnostic sessions, unplug the service hour
counter behind the start number plate.
15
6
CONTROLS
6.9
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.
(MC 250)
- Turn fuel tank filler cap 1 counterclockwise and lift it off.
S05828-10
(All EX models)
- Press release button 1, turn the fuel tank filler cap counter-
clockwise, and lift it off.
S05875-10
16
CONTROLS
6
6.10
Closing the fuel tank filler cap
(MC 250)
- 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.
S05828-11
(All EX models)
- 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.
S05875-11
6.11
Cold start button
The cold start button 1 is fitted to the bottom of the throttle valve
body.
The electronic fuel injection system extends the injection time if the
engine is cold and the ambient temperature is low. To help the engine
burn the increased fuel quantity, it must be supplied with additional
oxygen by pushing the cold start button.
After briefly opening up the throttle and then releasing the throttle grip
again, or turning the throttle grip towards the front, the cold start but-
ton returns to its original position.
Info
Check whether the cold start button has returned to its basic
position.
Possible states
• The cold start button is activated - The cold start button is pushed
in all the way.
• The cold start button is deactivated - The cold start button is in its
basic position.
S05876-10
17
6
CONTROLS
6.12
Idle speed adjusting screw
The idle setting of the throttle valve body substantially influences
the vehicle’s starting behavior, a stable idle speed, and the vehicle’s
response when the throttle is opened.
An engine with a correctly set idle speed is easier to start than an engine
with the idle speed set incorrectly.
The idle speed is adjusted using the idle speed adjusting screw 1.
Increase the idle speed by turning the idle speed adjusting screw clock-
wise.
Decrease the idle speed by turning the idle speed adjusting screw coun-
terclockwise.
S05830-10
6.13
Shift lever
Shift lever 1 is mounted on the left of the engine.
401950-10
(MC 250)
The gear positions can be seen in the figure.
The neutral or idle position is between the first and second gears.
401950-13
(All EX models)
The gear positions can be seen in the figure.
The neutral or idle position is between the first and second gears.
401950-11
18
CONTROLS
6
6.14
Foot brake lever
Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
401956-10
6.15
Plug-in stand (MC 250)
The holder for the plug-in stand 1 is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.
The plug-in stand is used as a fork locker when transporting the motor-
cycle.
Info
Remove the plug-in stand before riding.
H02629-10
6.16
Side stand (All EX models)
The side stand 1 is located on the left of the vehicle.
401943-10
The side stand is used for parking the motorcycle.
Info
When you are riding, side stand 1 must be folded up and
secured with rubber strap 2.
401944-10
19
7
PREPARING FOR USE
7.1
Advice on preparing for first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
- Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
- Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
- Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with pro-
tectors on all rides.
- Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
- Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
- Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
- Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
- Take your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
- Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of injury People who act without authorization may not be familiar with the vehicle.
- Do not leave the vehicle unattended if the engine is running.
- Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
-
Make sure that the pre-sales inspection work has been carried out by an authorized GASGAS Motorcycles workshop.
You will receive a delivery certificate when the vehicle is handed over.
-
Before riding for the first time, read the entire Owner's Manual carefully.
–
Get to know the controls.
–
Adjust basic position of the clutch lever. ( p. 73)
–
Adjust the basic position of the hand brake lever. ( p. 76)
–
Adjust the basic position of the foot brake lever.
(
p. 82)
–
Adjust the basic position of the shift lever.
(
p. 109)
20
PREPARING FOR USE
7
– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging
trips.
Info
Your motorcycle is not approved for use on public roads.
When offroad, it is recommended that you are accompanied by another person on another vehicle so that you
can help each other.
- Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
- Do not make any off-road trips that exceed your ability and experience.
- Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
- Do not take luggage along.
- Do not exceed the maximum permissible weight and the maximum permissible axle loads.
Guideline
Maximum permissible overall weight
335 kg (739 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
– Check the spoke tension. ( p. 92)
Info
The spoke tension must be checked after half an hour of operation.
- Run the engine in. ( p. 21)
7.2
Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
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.
- Avoid fully opening the throttle.
7.3
Starting power of lithium-ion batteries at low temperatures
Lithium-ion batteries are far lighter than lead batteries, have a low
self-discharge rate, and have more starting power at temperatures over
15 °C (60 °F). At low temperatures, however, the starting power of
lithium-ion batteries drops to below that of lead batteries.
Multiple starting attempts may be needed. Press the start button for
5 seconds, and wait 30 seconds between attempts. The pauses are nec-
essary so that the heat created can be distributed through the lithium-
ion battery without damaging the lithium-ion battery.
If the charged lithium-ion battery is unable to actuate the starter motor
or does so only weakly when temperatures are below 15 °C (60 °F), the
402555-01
battery is not faulty but needs to be warmed up internally to increase its
starting power (current output).
The starting power increases as the battery warms up.
21
7
PREPARING FOR USE
7.4
Preparing the vehicle for difficult operating conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in signifi-
cantly increased wear of components, such as the drive train, brake system, or suspension components. For this
reason, it may be necessary to inspect or replace parts before the next scheduled service.
- Prepare air filter box cover for securing.
(
p. 61)
– Clean the air filter and air filter box.
(
p. 60)
Info
Check the air filter approx. every 30 minutes.
- Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
- Clean and dry the connector, or change it if necessary.
Difficult operating conditions are:
- Rides on dry sand. ( p. 22)
- Rides on wet sand. ( p. 23)
- Rides on wet and muddy circuits. ( p. 23)
- Rides at high temperatures or slow riding. ( p. 24)
- Riding at low temperatures and in snow. ( p. 24)
7.5
Preparing the vehicle for rides on dry sand
- Mount the air filter dust cover.
Air filter dust cover (A46006920000)
Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.
F03669-01
- Mount the air filter sand cover.
Air filter sand cover (A46006922000)
Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.
F03670-01
22
PREPARING FOR USE
7
– Clean the chain.
Chain cleaner ( p. 132)
- Mount the steel sprocket.
- Grease the chain.
Universal oil spray ( p. 133)
- Clean the radiator fins.
- Straighten the bent radiator fins carefully.
600868-01
Condition
Regular use in sand
- Change the piston every 10 operating hours.
7.6
Preparing the vehicle for rides on wet sand
- Mount the air filter rain cover.
Air filter rain cover (A46006921000)
Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.
F03668-01
- Clean the chain.
Chain cleaner ( p. 132)
- Mount the steel sprocket.
- Grease the chain.
Universal oil spray ( p. 133)
- Clean the radiator fins.
- Straighten the bent radiator fins carefully.
600868-01
Condition
Regular use in sand
- Change the piston every 10 operating hours.
7.7
Preparing the vehicle for rides on wet and muddy circuits
- Mount the air filter rain cover.
Air filter rain cover (A46006921000)
Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.
F03668-01
23
7
PREPARING FOR USE
- Mount the steel sprocket.
- Clean the motorcycle. ( p. 114)
- Straighten the bent radiator fins carefully.
600868-01
7.8
Preparing vehicle for high temperatures or slow riding
- Adjust the secondary drive to the road conditions.
Info
The engine oil heats up quickly when the clutch is operated
frequently due to an excessively high secondary ratio.
- Clean the chain.
Chain cleaner ( p. 132)
- Clean the radiator fins.
600868-01
- Straighten the bent radiator fins carefully.
- Check the coolant level. ( p. 102)
7.9
Preparing the vehicle for low temperatures or snow
- Mount the air filter rain cover.
Air filter rain cover (A46006921000)
Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.
F03668-01
24
RIDING INSTRUCTIONS
8
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. 111)
- Check the front brake fluid level. ( p. 77)
- Check the rear brake fluid level. ( p. 83)
- Check that the brake linings of the front brake are secured.
(
p. 79)
– Check that the brake linings of the rear brake are secured. ( p. 84)
- Check that the brake system is functioning properly.
- Check the coolant level. ( p. 102)
H02217-01
- Check the chain for dirt. ( p. 66)
- Check the chain, rear sprocket, engine sprocket, and chain guide.
(
p. 68)
– Check the chain tension. ( p. 67)
- Check the tire condition. ( p. 91)
- Check tire pressure. ( p. 91)
- Check the spoke tension. ( p. 92)
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. 46)
- Bleed the fork legs. ( p. 46)
- 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
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when running the engine.
- Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
- Always run the engine warm at a low speed.
25
8
RIDING INSTRUCTIONS
(MC 250)
- Take the motorcycle off side stand 1 and secure the side
stand with rubber strap 2.
H02629-10
(All EX models)
- Take the motorcycle off side stand 1 and secure the side
stand with rubber strap 2.
- Shift the transmission to neutral position.
401944-10
Condition
Ambient temperature: < 20 °C (< 68 °F)
- Push the cold start button in all the way.
- Press the start button.
Info
Press the start button for a maximum of 5 seconds. Wait
for 15 seconds before a further attempt at starting.
At low temperatures, wait for 30 seconds.
400733-01
At temperatures below 6 °C (43 °F), several attempts at
starting may be necessary to warm-up the lithium-ion
battery and thereby increase the starting power.
After 6 unsuccessful starting attempts, do not try again,
and check the vehicle for other malfunctions instead.
During the starting process, the malfunction indicator
lamp lights up.
8.3
Starting off
Info
The plug-in stand must be removed before riding.
When you are riding, the side stand must be folded up and secured with the rubber strap.
- Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.
26
RIDING INSTRUCTIONS
8
8.4
Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
- Do not change into a low gear at high engine speed.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized GAS-
GAS Motorcycles workshop.
First-gear is used for starting off and for steep inclines.
- Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
- If the choke function has been activated, deactivate it after the engine has warmed up.
- After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely
reduce the speed, but fuel consumption will be considerably lower.
- Always open the throttle only as much as the engine can handle - abrupt throttle opening increases fuel consumption.
- To shift down, apply the brakes and close the throttle at the same time.
- Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift
again.
- Switch off the engine if running at idle speed or stationary for a long time.
Guideline
≥ 2 min
- Avoid frequent or lengthy slipping of the clutch. This causes the gear oil, engine and cooling system to heat up.
- Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
8.5
Braking
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
- Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
- Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
- On sandy, wet, or slippery surfaces, use mostly the rear brake.
- Always finish braking before the going into a bend. Shift down to a lower gear appropriate to your speed.
- Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not overrev the
engine when doing so. This means that significantly less braking is required and the brake system does not overheat.
27
8
RIDING INSTRUCTIONS
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
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
- Do not park the vehicle near to materials which are highly flammable or explosive.
- Allow the vehicle to cool down before covering it.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
- Park the vehicle on a firm and level surface.
- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
- Apply the brakes on the motorcycle.
- Shift the transmission to neutral position.
- Press and hold the stop button while the engine is idling until the engine stops.
- Park the motorcycle on firm ground.
8.7
Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
- Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
- Do not park the vehicle near to materials which are highly flammable or explosive.
- Allow the vehicle to cool down before covering it.
(MC 250)
- Switch off the engine.
- Mount plug-in stand on the fork legs.
Plug-in stand (79029094000)
Info
The plug-in stand is included.
Make sure the brake line runs in front of the plug-in
stand and does not become wedged.
H02628-01
28
RIDING INSTRUCTIONS
8
– Use tension belts or other suitable devices to secure the motor-
cycle against falling over or rolling away.
Info
Only tighten the tension belts to the point that the plug-
in stand is in contact with the fender and tires.
Pay attention to the alignment of the plug-in stand to
the fender.
(All EX models)
401475-01
- Switch off the engine.
- Use tension belts or other suitable devices to secure the motor-
cycle against falling over or rolling away.
8.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
- Switch off the engine.
- Open the fuel tank filler cap. ( p. 16)
- Fill the fuel tank with fuel up to a maximum of level A.
Guideline
35 mm (1.38 in)
Dimension A
Total fuel tank capac-
7.9 l
Super unleaded (95
ity, approx. (MC 250)
(2.09 US gal)
octane) mixed with
2-stroke engine oil
(1:60) ( p. 131)
Total fuel tank capac-
9.0 l
Super unleaded (95
400382-10
ity, approx. (All EX
(2.38 US gal)
octane) mixed with
models)
2-stroke engine oil
(1:60) ( p. 131)
- Close the fuel tank filler cap. ( p. 17)
29
9
SERVICE SCHEDULE
9.1
Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and
invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service
schedule can always be found on GASGAS Motorcycles Dealer.net. Your authorized GASGAS Motorcycles dealer will be glad
to advise you.
The use of a service hour counter is recommended in order to be able to check the mileage at any time.
Service hour counter (A54012920000)
9.2
Service schedule
every 24 months
Every 90 operating hours
Every 45 operating hours
After 15 operating hours / Every 15 operating hours
After 1 operating hour
Read out the fault memory using the GASGAS Motorcycles diagnostics tool.
○
●
●
●
●
Check that the electrical system is functioning properly.
○
●
●
●
Check and charge the 12-V battery.
○
●
●
●
●
Check that the brake linings of the front brake are secured. ( p. 79)
○
●
●
●
●
Check that the brake linings of the rear brake are secured. ( p. 84)
○
●
●
●
●
Check the brake discs. ( p. 76)
○
●
●
●
●
Check the brake lines for damage and tightness.
○
●
●
●
●
Check the front brake fluid level. ( p. 77)
○
●
●
Change the front brake fluid.
●
●
Check the rear brake fluid level. ( p. 83)
○
●
●
Change the rear brake fluid.
●
●
Check/correct the fluid level of hydraulic clutch. ( p. 73)
●
Change the hydraulic clutch fluid.
(
p. 74)
●
●
Check the free travel of the hand brake lever. ( p. 76)
○
●
●
●
●
Check the free travel of the foot brake lever. ( p. 81)
○
●
●
●
●
Check the idle speed.
○
●
●
●
●
Change the gear oil.
(
p. 111)
○
●
●
●
●
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. 71)
●
●
●
Check the link fork.
(
p. 71)
●
●
●
Check the fork bearing for play.
●
●
Check the shock absorber heim joint for play.
●
●
Check the shock absorber linkage.
●
●
●
Check the tire condition. ( p. 91)
●
●
●
●
Check tire pressure. ( p. 91)
○
●
●
●
●
Check the wheel bearing for play.
●
●
●
Check the wheel hubs.
●
●
●
Check the rim run-out.
○
●
●
●
Check the spoke tension. ( p. 92)
○
●
●
●
30
SERVICE SCHEDULE
9
every 24 months
Every 90 operating hours
Every 45 operating hours
After 15 operating hours / Every 15 operating hours
After 1 operating hour
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 68)
○
●
●
●
Check the chain tension. ( p. 67)
○
●
●
●
●
Grease all moving parts (e.g., hand lever, chain, etc.) and check for smooth operation.
○
●
●
●
●
Check the basic throttle valve position sensor setting.
○
●
●
●
Change the spark plug and spark plug connector.
●
●
●
Change the fuel filter.
●
●
Check the clutch.
●
●
●
Clean the air filter and air filter box.
(
p. 60)
●
●
●
●
Change the glass fiber yarn filling of the main silencer.
(
p. 62)
●
●
Service the fork.
●
●
Perform the shock absorber service.
●
●
Check all screws, nuts, and hose clips for a tight fit.
○
●
●
●
●
Change the fuel screen.
(
p. 110)
○
●
●
●
●
Check the fuel pressure.
○
●
●
●
Check the antifreeze and coolant level. ( p. 101)
●
●
Check the coolant level. ( p. 102)
○
●
Change the coolant.
(
p. 104)
●
Check the steering head bearing for play. ( p. 51)
○
●
Lubricate the steering head bearing.
(
p. 52)
●
●
●
Check the electric starter drive.
●
●
●
Check the reed valve housing, reed valve and intake flange.
●
●
●
Perform minor engine service. (Change the piston. Check the cylinder head. Change the O-rings
●
●
●
of the manifold and the cylinder head. Check the cylinder and Z dimension. Clean the exhaust
control. Check the exhaust control for function and smooth operation. Program the exhaust con-
trol end positions. Check and clean the pressure sensor flange.)
Perform major engine service including removing and installing the engine. (Change the con-
●
●
necting rod, conrod bearing, and crank pin. Check the transmission and the shift mechanism.
Change all the engine bearings, the radial shaft seal rings and the seals.)
Final check: check vehicle for operating safety.
○
●
●
●
●
Read out the fault memory after the test ride using the GASGAS Motorcycles diagnostics tool.
○
●
●
●
●
Make a service entry in GASGAS Motorcycles Dealer.net.
○
●
●
●
●
○ One-time interval
● Periodic interval
31
10
TUNING THE CHASSIS
10.1
Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
- For optimal motorcycle riding characteristics and to avoid damage
to forks, shock absorbers, link fork and frame, the basic settings of
the suspension components must match the rider's weight.
- As delivered, GASGAS offroad motorcycles are adjusted for an aver-
age rider's weight (with full protective clothing).
Guideline
Standard rider weight
75 … 85 kg (165 … 187 lb.)
– If the rider's weight is above or below this range, the basic setting of
the suspension components must be adjusted accordingly.
- Small weight differences can be compensated by adjusting the
spring preload, but in the case of large weight differences, the
springs must be replaced.
401030-01
10.2
Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension
compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel sus-
pension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus,
modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.
10.3
Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.
32
TUNING THE CHASSIS
10
– Turn adjuster 1 clockwise up to the last perceptible click.
- Turn counterclockwise by the number of clicks corresponding to the
shock absorber type.
Guideline
Lowspeed compression damping (MC 250)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
F03639-11
Lowspeed compression damping (All EX models)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
10.4
Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber.
- Turn adjuster 1 clockwise all the way to the stop.
- Turn counterclockwise by the number of turns corresponding to the
shock absorber type.
Guideline
Highspeed compression damping (MC 250)
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
F03639-10
Highspeed compression damping (All EX models)
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
33
10
TUNING THE CHASSIS
10.5
Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Turn adjusting screw 1 clockwise up to the last perceptible click.
- Turn counterclockwise by the number of clicks corresponding to the
shock absorber type.
Guideline
Rebound damping (MC 250)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
F03640-10
Rebound damping (All EX models)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info
Turn clockwise to increase the damping; turn counterclock-
wise to reduce damping when the shock absorber rebounds.
10.6
Measuring the dimension of the rear wheel unloaded
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
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
34
TUNING THE CHASSIS
10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
10.7
Checking the static sag of the shock absorber
- Measure dimension A of rear wheel unloaded. ( p. 34)
- 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 (MC 250)
35 mm (1.38 in)
Static sag (All EX models)
35 mm (1.38 in)
» If the static sag is less or more than the specified value:
- Adjust the spring preload of the shock absorber.
(
p. 36)
402416-10
10.8
Checking the riding sag of the shock absorber
- Measure dimension A of rear wheel unloaded. ( p. 34)
- 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 riding sag is the difference between measurements A
and C.
- Check riding sag.
Guideline
Riding sag (MC 250)
105 mm (4.13 in)
Riding sag (EX 250 US)
105 mm (4.13 in)
Riding sag (EX 300 US)
100 mm (3.94 in)
402417-10
» If the riding sag differs from the specified measurement:
- Adjust the riding sag.
(
p. 37)
35
10
TUNING THE CHASSIS
10.9
Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.
Preparatory work
- Remove the frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove main silencer. ( p. 61)
- Raise the motorcycle with a lift stand. ( p. 45)
- Remove the shock absorber.
(
p. 53)
– After removing the shock absorber, clean it thoroughly.
Main work
- Loosen screw 1.
- Turn adjusting ring 2 until the spring is no longer under tension.
Hook wrench (90129051000)
Info
If the spring cannot be fully released, the spring must be
removed to accurately measure the spring length.
- Measure the total spring length while the spring is not under ten-
sion.
- Tension the spring by turning adjusting ring 2 to specified dimen-
sion A.
Guideline
Spring preload (MC 250)
8 mm (0.31 in)
Spring preload (All EX models)
8 mm (0.31 in)
Info
F03627-10
Depending on the static sag and/or the riding sag, it may be
necessary to increase or decrease the spring preload.
- Tighten bolt 1.
Guideline
Screw, shock absorber
M5
5 Nm (3.7 lbf ft)
adjusting ring
Make sure that the adjusting ring does not touch any other com-
ponents when installed.
Finishing work
- Install the shock absorber.
(
p. 55)
– Install the main silencer. ( p. 61)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
- Check the free travel of the foot brake lever. ( p. 81)
36
TUNING THE CHASSIS
10
– Remove the motorcycle from the lift stand. ( p. 45)
10.10
Adjusting the riding sag
Preparatory work
- Remove the frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove main silencer. ( p. 61)
- Raise the motorcycle with a lift stand. ( p. 45)
- Remove the shock absorber.
(
p. 53)
– After removing the shock absorber, clean it thoroughly.
Main work
- Select and mount a suitable spring.
Guideline
Spring rate (MC 250)
Weight of rider: 65 … 75 kg
42 N/mm (240 lb/in)
(143 … 165 lb.)
Weight of rider: 75 … 85 kg
45 N/mm (257 lb/in)
(165 … 187 lb.)
Weight of rider: 85 … 95 kg
48 N/mm (274 lb/in)
B00292-10
(187 … 209 lb.)
Spring rate (All EX models)
Weight of rider: 65 … 75 kg
42 N/mm (240 lb/in)
(143 … 165 lb.)
Weight of rider: 75 … 85 kg
45 N/mm (257 lb/in)
(165 … 187 lb.)
Weight of rider: 85 … 95 kg
48 N/mm (274 lb/in)
(187 … 209 lb.)
Info
The spring rate is shown on the outside of the spring.
Finishing work
- Install the shock absorber.
(
p. 55)
– Install the main silencer. ( p. 61)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
- Check the free travel of the foot brake lever. ( p. 81)
- Remove the motorcycle from the lift stand. ( p. 45)
- Check the static sag of the shock absorber. ( p. 35)
- Check the riding sag of the shock absorber. ( p. 35)
- Adjust the rebound damping of the shock absorber. ( p. 34)
37
10
TUNING THE CHASSIS
10.11
Air suspension XACT
Air suspension WP Suspension XACT is used in the 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.
F03628-01
As with a conventional fork, the damping can be adjusted in rebound
and compression stages.
The rebound adjuster is located at the lower end of the right fork leg.
The compression adjuster is located at the upper end of the right fork
leg.
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.
- If the fork feels unusually hard after extended periods of operation,
the fork legs need to be bled.
401000-01
10.13
Adjusting the fork air pressure (MC 250)
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.
- Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
38
TUNING THE CHASSIS
10
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 pressure and rebound damping is located in the right fork leg.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
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.
A01166-10
- 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.
Read the accompanying GASGAS Technical Accessories
instructions.
- Adjust the air pressure as specified.
Guideline
Air pressure
10.5 bar (152 psi)
Gradual changing of the air
0.2 bar (3 psi)
pressure in steps of
Minimum air pressure
7 bar (102 psi)
Maximum air pressure
12 bar (174 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. 45)
39
10
TUNING THE CHASSIS
10.14
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
(MC 250)
- 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.
A01167-10
Guideline
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping during compression.
(All EX models)
- Turn white adjuster 1 clockwise as far as it will go.
Info
Adjusters 1 are located at the top end of the fork legs.
- Turn counterclockwise by the number of clicks corresponding to
the fork type.
Guideline
W00297-10
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping during compression.
40
TUNING THE CHASSIS
10
10.15
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
(MC 250)
- Turn adjuster 1 clockwise all the way to the stop.
Info
Adjuster 1 is located at the lower end of the right fork
leg.
- Turn counterclockwise by the number of clicks corresponding to
the fork type.
Z01370-10
Guideline
Rebound damping
Comfort
23 clicks
Standard
18 clicks
Sport
13 clicks
Info
Turn clockwise to increase the damping; turn counter-
clockwise to reduce damping when the shock absorber
rebounds.
(All EX models)
- Turn red adjuster 1 clockwise as far as it will go.
Info
Adjuster 1 is located at the bottom end of the fork
legs.
- Turn counterclockwise by the number of clicks corresponding to
the fork type.
W00298-10
Guideline
Rebound damping
Comfort
23 clicks
Standard
18 clicks
Sport
13 clicks
Info
Turn clockwise to increase the damping; turn counter-
clockwise to reduce damping when the shock absorber
rebounds.
41
10
TUNING THE CHASSIS
10.16
Handlebar position
The holes on the handlebar support 1 are placed at a distance of A
from the center.
Hole distance A
3.5 mm (0.138 in)
The handlebar can be mounted in 2 different positions. This allows the
handlebar to be mounted in the most comfortable position for the rider.
Info
In addition, the handlebar can be mounted rigidly or on a rubber
bearing.
A01168-10
10.17
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.
Info
The handlebar can be mounted rigidly or on a rubber bearing.
Preparatory work
- Take off the handlebar cushion.
42
TUNING THE CHASSIS
10
Main work
- Remove screws 1. Take off handlebar clamp 2. Take off the han-
dlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables or lines.
- Remove screws 7 and bushing 6. Take off handlebar
support 3.
Adjusting the handlebar position with the handlebar clamp in the
rubber bearing
- Position the rubber bushings 4 and 5.
- Place the handlebar support in the required position.
Info
The handlebar support is longer and higher on one side.
- Mount and tighten the screws 7 with bushing 6.
A01169-10
Guideline
Screw, handle-
M10
40 Nm (29.5 lbf ft)
bar support
Loctite®243™
– Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
- Position handlebar clamp 2.
- Mount screws 1, but do not tighten yet.
- First bolt the handlebar clamp with screws 1 onto the longer,
higher side of the handlebar supports so that both parts touch.
- Tighten screws 1 evenly.
Guideline
Screw, handlebar
M8
20 Nm (14.8 lbf ft)
clamp
43
10
TUNING THE CHASSIS
Adjusting the handlebar position with the handlebar clamp
- Place the handlebar support in the required position.
Info
The handlebar support is longer and higher on one side.
- Mount and tighten the screws 7 with the bushings 8.
Guideline
Screw, handle-
M10
40 Nm (29.5 lbf ft)
bar support
Loctite®243™
Rigid handlebar support bushing (A46001038010)
The conical side of bushing faces downwards.
- Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
A01170-10
- Position handlebar clamp 2.
- Mount screws 1, but do not tighten yet.
- First bolt the handlebar clamp with screws 1 onto the longer,
higher side of the handlebar supports so that both parts touch.
- Tighten screws 1 evenly.
Guideline
Screw, handlebar
M8
20 Nm (14.8 lbf ft)
clamp
Finishing work
- Mount the handlebar cushion.
44
SERVICE WORK ON THE CHASSIS
11
11.1
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.
Lift stand (A54029955100)
Neither wheel is in contact with the ground.
- Secure the motorcycle against falling over.
401942-01
11.2
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.
(MC 250)
- Remove the motorcycle from the lift stand.
- Remove the lift stand.
- To park the motorcycle, insert plug-in stand 1 into the left
side of the wheel spindle.
Info
Remove the plug-in stand before riding.
H02629-10
(All EX models)
- Remove the motorcycle from the lift stand.
- Remove the lift stand.
- To park the motorcycle, press side stand 1 to the ground with
your foot and lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up
and secured with rubber strap.
401943-10
45
11
SERVICE WORK ON THE CHASSIS
11.3
Bleeding the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
Main work
- Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
A01215-10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
11.4
Cleaning the dust boots of the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
- Remove the fork protector. ( p. 47)
Main work
- Push dust boots 1 of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from
the inside fork tubes. Over time, dirt can accumulate behind
the dust boots. If this dirt is not removed, the oil seals
behind can start to leak.
M01134-10
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when neces-
sary.
- Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray ( p. 133)
- Press the dust boots back into their normal position.
- Remove excess oil.
Finishing work
- Install the fork protector. ( p. 47)
- Remove the motorcycle from the lift stand. ( p. 45)
46
SERVICE WORK ON THE CHASSIS
11
11.5
Removing the fork protector
- Remove screws 1. Remove the clamp.
- Remove screws 2. Take off the left fork protector.
- Remove screws 3. Take off the right fork protector.
E01988-10
11.6
Installing the fork protector
- Position the fork protection on the left fork leg. Mount and tighten
screws 1.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Position the brake line and clamp. Mount and tighten screws 2.
- Position the fork protector on the right fork leg. Mount and tighten
screws 3.
E01988-11
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
11.7
Removing the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
- Remove the front wheel.
(
p. 87)
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 actuate the hand brake lever when the front wheel is
removed.
I01079-10
- Loosen screws 3. Remove the left fork leg.
- Loosen screws 4. Remove the right fork leg.
S05831-10
47
11
SERVICE WORK ON THE CHASSIS
11.8
Installing the fork legs
Main work
- Position the fork legs.
Air bleeder screw 1 of the right fork leg is positioned to the
front.
Valve A of the left fork leg faces the front.
Info
Grooves are milled into the side of the upper end of the fork
legs. The second milled groove (from the top) must be flush
W00091-10
with the upper edge of the upper triple clamp.
The air suspension is located in the left fork leg. The pres-
sure and rebound damping is located in the right fork leg.
- Tighten screws 2.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom triple
M8
15 Nm (11.1 lbf ft)
clamp
S05832-10
- Position the brake caliper. Mount and tighten screws 4.
Guideline
Screw, front
M8
25 Nm (18.4 lbf ft)
brake caliper
Loctite®243™
– Position the brake line and the clamp. Mount and tighten
screws 5.
I01081-10
Finishing work
- Install the front wheel.
(
p. 88)
11.9
Removing the lower triple clamp
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
- Remove the front wheel.
(
p. 87)
– Remove the fork legs.
(
p. 47)
– Remove the start number plate. ( p. 52)
- Remove front fender. ( p. 53)
- Take off the handlebar cushion.
48
SERVICE WORK ON THE CHASSIS
11
Main work
- Remove screw 1. Detach the wiring harness.
- Remove screw 2.
- Remove screw 3.
- Take off the upper triple clamp with the handlebar and hang them
to the side.
Info
I00184-10
Cover the components to protect them against damage.
Do not kink the cables or lines.
- Remove steering head seal 4.
- Take off the lower triple clamp with the steering stem.
- Remove the upper steering head bearing.
W00031-10
11.10
Installing the lower triple clamp
Main work
- Clean the bearing and sealing elements, check for damage, and
grease.
High viscosity grease ( p. 132)
- Insert the lower triple clamp with the steering stem. Mount upper
steering head bearing.
- Push on steering head seal 1.
A01192-10
- Position the upper triple clamp and handlebar.
- Mount screw 2, but do not tighten it yet.
Guideline
Screw, top steering
M20x1.5
12 Nm (8.9 lbf ft)
head
A01190-11
49
11
SERVICE WORK ON THE CHASSIS
- Position the fork legs.
Air bleeder screw 3 of the right fork leg is positioned to the
front.
Valve A of the left fork leg faces the front.
Info
Grooves are milled into the side of the upper end of the fork
legs. The second milled groove (from the top) must be flush
with the upper edge of the upper triple clamp.
F03764-10
The air suspension is located in the left fork leg. The pres-
sure and rebound damping is located in the right fork leg.
- Tighten screws 4.
Guideline
Screw, bottom triple
M8
15 Nm (11.1 lbf ft)
clamp
A01198-10
- Tighten screw 2.
Guideline
Screw, top steering
M20x1.5
12 Nm (8.9 lbf ft)
head
A01190-11
- Mount and tighten screw 5.
Guideline
Screw, top steer-
M8
20 Nm (14.8 lbf ft)
ing stem
Loctite®243™
A01191-10
- Using a plastic hammer, tap lightly on the upper triple clamp to
avoid stresses.
- Tighten screws 6.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
– Secure the wiring harness with cable holder on the left. Mount and
tighten screw 7.
A01198-11
50
SERVICE WORK ON THE CHASSIS
11
– Position the brake caliper. Mount and tighten screws 8.
Guideline
Screw, front
M8
25 Nm (18.4 lbf ft)
brake caliper
Loctite®243™
– Position the brake line and the clamp. Mount and tighten
screws 9.
I01080-10
Finishing work
- Install front fender. ( p. 53)
- Mount the handlebar cushion.
- Install the start number plate. ( p. 53)
- Install the front wheel.
(
p. 88)
– Check the wiring harness, cables, and brake and clutch lines for free-
dom of movement and correct routing.
- Check the steering head bearing for play. ( p. 51)
- Remove the motorcycle from the lift stand. ( p. 45)
11.11
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. 45)
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 steering head bearing play.
(
p. 52)
– 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 steering head bearing play.
(
p. 52)
– Check the steering head bearing and change if necessary.
- Check the steering stop bolts for correct adjustment and locking.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
51
11
SERVICE WORK ON THE CHASSIS
11.12
Adjusting steering head bearing play
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
- Remove the handlebar cushion.
Main work
- Loosen screws 1.
- Remove screw 2.
- Loosen and retighten screw 3.
Guideline
Screw, top steering
M20x1.5
12 Nm (8.9 lbf ft)
head
- Using a plastic hammer, tap lightly on the upper triple clamp to
A10214-10
avoid stresses.
- Tighten screws 1.
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
– Mount and tighten screw 2.
Guideline
Screw, top steer-
M8
20 Nm (14.8 lbf ft)
ing stem
Loctite®243™
Finishing work
- Check the steering head bearing for play. ( p. 51)
- Remove the motorcycle from the lift stand. ( p. 45)
- Mount the handlebar cushion.
11.13
Lubricating the steering head bearing
- Remove the lower triple clamp.
(
p. 48)
– Install the lower triple clamp.
(
p. 49)
Info
The steering head bearing is cleaned and lubricated in the
course of removal and installation.
H02387-01
11.14
Removing the start number plate
- Remove screw 1.
- Disconnect the brake line at the start number plate. Take off the
start number plate.
S05833-10
52
SERVICE WORK ON THE CHASSIS
11
11.15
Installing the start number plate
- Connect the brake line at the start number plate.
- Position the start number plate.
The holding lugs engage in the fender.
- Mount and tighten screw 1.
Guideline
Remaining screws on
EJOT PT K60x25
2 Nm (1.5 lbf ft)
chassis
S05834-10
11.16
Removing front fender
Preparatory work
- Remove the start number plate. ( p. 52)
Main work
- Remove screws 1 and 2. Remove front fender.
S05835-10
11.17
Installing front fender
Main work
- Position front fender. Mount and tighten screws 1 and 2.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
S05835-10
Finishing work
- Install the start number plate. ( p. 53)
11.18
Removing the shock absorber
Preparatory work
- Remove the frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove main silencer. ( p. 61)
- Raise the motorcycle with a lift stand. ( p. 45)
53
11
SERVICE WORK ON THE CHASSIS
Main work
- Remove screw 1.
- Remove fitting 2.
Info
Raise the swingarm slightly to be able to remove the screws
more easily.
W00036-10
- Remove screws 3.
- Pull off foot brake cylinder from the push rod.
W00051-10
- Remove connecting link A of the chain.
- Take off the chain.
Info
Cover the components to protect them against damage.
S05826-10
- Remove nut 4 and the swingarm pivot.
- Push the link fork back and secure it against falling over.
W00053-10
- Hold the shock absorber and remove screw 5.
- Remove the shock absorber carefully at the bottom.
S05836-10
54
SERVICE WORK ON THE CHASSIS
11
11.19
Installing the shock absorber
Main work
- Carefully position the shock absorber into the vehicle from the bot-
tom.
- Mount and tighten screw 1.
Guideline
Screw, top shock
M10
60 Nm (44.3 lbf ft)
absorber
Loctite®2701™
S05836-11
- Position the link fork and mount the swingarm pivot.
Info
Pay attention to flat area A.
- Mount and tighten nut 2.
Guideline
Nut, fork pivot
M16x1.5
100 Nm (73.8 lbf ft)
W00054-10
- Mount the chain.
- Connect the chain with connecting link 3.
Guideline
The closed side of the chain joint lock must face in the direction
of travel.
S05826-11
- Position the foot brake cylinder.
Push rod 4 engages in the foot brake cylinder.
Info
Ensure that the dust boot is correctly seated.
- Mount and tighten screws 5.
Guideline
W00052-10
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Position the angle lever and linkage lever.
- Mount and tighten fitting 6.
Guideline
Nut, pull rod on trian-
M16x1.5
80 Nm (59 lbf ft)
gular lever
Info
Pay attention to flat area B.
F03704-10
- Mount and tighten screw 7.
55
11
SERVICE WORK ON THE CHASSIS
Guideline
Screw, bottom
M10
60 Nm (44.3 lbf ft)
shock absorber
Loctite®2701™
Info
Raise the link fork slightly to be able to mount the screw
more easily.
Finishing work
- Install the main silencer. ( p. 61)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
- Check the free travel of the foot brake lever. ( p. 81)
- Remove the motorcycle from the lift stand. ( p. 45)
11.20
Removing the seat
Preparatory work
- Remove the air filter box cover. ( p. 58)
Main work
- Remove screw 1 with the wedge lock washers.
S05837-10
- Raise the rear of the seat, pull the seat back and lift it off.
H02218-10
11.21
Mounting the seat
Main work
- Mount the front of the seat on the collar bushing of the fuel tank,
lower the seat at the rear, and push the seat forward.
- Make sure the seat is latched in place correctly.
H02218-11
56
SERVICE WORK ON THE CHASSIS
11
– Mount and tighten screw 1 with the wedge lock washers.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
S05837-10
Finishing work
- Install the air filter box cover. ( p. 58)
11.22
Removing the frame protector
- Remove the cable ties.
- Remove screws 1 with the bushings.
- Take off the left frame protector.
- Push the right frame protector to the front and take off at the bot-
tom.
S05838-10
11.23
Installing the frame protector
- Position the left frame protector.
- Insert the right frame protector from below and push it to the rear.
- Mount screws 1 with the bushings and tighten.
Guideline
Screw, frame protector
M5
3 Nm (2.2 lbf ft)
– Secure the frame protector with cable ties.
S05838-10
11.24
Removing the right side panel
Preparatory work
- Remove the frame protector. ( p. 57)
Main work
- Pull the right side panel off sideways in area A and remove toward
the rear.
S05844-10
57
11
SERVICE WORK ON THE CHASSIS
11.25
Installing the right side panel
Main work
- Slide right side panel forward and hook into area A.
- Engage the side panel in area B.
Guideline
Ensure that the side panel is correctly hooked in to areas A
and B.
S05844-11
Finishing work
- Install the frame protector. ( p. 57)
11.26
Removing the air filter box cover
Condition
The air filter box cover is secured.
- Remove screw 1.
S05877-11
- Pull the air filter box cover off sideways in area A and remove
toward the rear.
Condition
The air filter box cover is not secured.
- Pull the air filter box cover off sideways in area A and remove
toward the rear.
S05877-10
11.27
Installing the air filter box cover
Condition
The air filter box cover is secured.
- Slide the air filter box cover forward and hook into area A.
- Engage the air filter box cover in area B.
Guideline
Ensure that the air filter box cover is correctly hooked in to
areas A and B.
S05877-12
58
SERVICE WORK ON THE CHASSIS
11
– Mount and tighten screw 1.
Guideline
Screw, air filter box
EJOT PT®
3 Nm (2.2 lbf ft)
cover
K60x20-Z
S05877-11
Condition
The air filter box cover is not secured.
- Slide the air filter box cover forward and hook into area A.
- Engage in areas B.
S05877-12
11.28
Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
- Only operate the vehicle if it is equipped with an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Preparatory work
- Remove the air filter box cover. ( p. 58)
Main work
- Detach retaining tab 1. Remove air filter with air filter support.
- Take off air filter from air filter support.
S05841-10
59
11
SERVICE WORK ON THE CHASSIS
11.29
Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
- Remove the air filter box cover. ( p. 58)
- Remove the air filter.
(
p. 59)
Main work
- Wash the air filter thoroughly in special cleaning liquid and allow it
to dry properly.
Air filter cleaner ( p. 132)
Info
Only press the air filter to dry it, never wring it out.
- Oil the dry air filter with a high-grade air filter oil.
F03685-01
Oil for foam air filter ( p. 132)
- Clean the air filter box.
- Clean the intake flange and check it for damage and tightness.
Finishing work
- Install the air filter.
(
p. 60)
– Install the air filter box cover. ( p. 58)
11.30
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. 132)
F03686-10
- Insert the air filter and position the top retaining pin 1 in bush-
ing B.
The air filter is correctly positioned.
- Secure the bottom retaining pin with holding tab 2.
Info
If the air filter is not mounted correctly, dust and dirt may
enter the engine and result in damage.
S05842-10
60
SERVICE WORK ON THE CHASSIS
11
Finishing work
- Install the air filter box cover. ( p. 58)
11.31
Preparing air filter box cover for securing
Preparatory work
- Remove the air filter box cover. ( p. 58)
Main work
- Drill a hole at marking A.
Guideline
Diameter
4 mm (0.16 in)
S05878-10
Finishing work
- Install the air filter box cover. ( p. 58)
11.32
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 frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
Main work
- Remove screws 1 with the washers.
- Pull off the main silencer from the manifold at exhaust sleeve 2.
S05845-10
11.33
Installing the main silencer
Main work
- Position the main silencer in exhaust sleeve 1.
- Mount and tighten screws 2 with washers.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
S05846-10
61
11
SERVICE WORK ON THE CHASSIS
Finishing work
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
11.34
Changing the glass fiber yarn filling of the main silencer
Warning
Danger of burns The exhaust system gets hot when the vehicle is driven.
- Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the rock wool escape into the air, and the main silencer “burns out”.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
- Remove the frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove main silencer. ( p. 61)
Main work
- Remove screws 1. Pull out inner tube 2 with O-ring 3.
- Pull glass fiber yarn filling 4 from the inner tube.
- Clean the parts that need to be reinstalled and check for damage.
- Mount new glass fiber yarn filling 4 on the inner tube.
- Push outer tube 5 over the inner tube with the new glass fiber
yarn filling and the O-ring.
- Mount and tighten all screws 1.
Guideline
Screws on main
M5
7 Nm (5.2 lbf ft)
silencer
V01636-10
Finishing work
- Install the main silencer. ( p. 61)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
62
SERVICE WORK ON THE CHASSIS
11
11.35
Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
- Remove the frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
Main work
- Unplug fuel pump connector 1.
- Clean quick release coupling 2 thoroughly with compressed air.
Info
Under no circumstances should dirt enter into the fuel line.
Dirt in the fuel line clogs the injection valve!
- Disconnect the quick release coupling.
S05847-10
Info
Remaining fuel may flow out of the fuel hose.
- Mount the wash cap set.
Wash cap set (81212016100)
- Pull the fuel tank breather hose off the fuel tank lid.
63
11
SERVICE WORK ON THE CHASSIS
(MC 250)
- Remove screw 3 with the rubber bushing.
S05848-10
- Remove screws 4 with the collar bushings.
- Pull both spoilers laterally off the radiator and lift off the fuel tank.
S05849-10
11.36
Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
Main work
- Check the throttle cable routing. ( p. 71)
64
SERVICE WORK ON THE CHASSIS
11
– Position the fuel tank and fit the two spoilers laterally to the radia-
tor.
- Make sure that no cables or throttle cables are trapped or damaged.
- Attach the fuel tank breather hose to the fuel tank lid.
- Mount and tighten screws 1 with the collar bushings.
Guideline
Screw, fuel tank spoiler
M6
6 Nm (4.4 lbf ft)
on radiator
S05849-11
(MC 250)
- Mount and tighten screw 2 with the rubber bushing.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
S05848-11
- Plug in fuel pump connector 3.
- Remove the wash cap set and thoroughly clean the quick release
coupling using compressed air.
Info
Under no circumstances should dirt enter into the fuel line.
Dirt in the fuel line clogs the injection valve!
- Spray silicone spray onto a lint-free cleaning cloth and lightly lubri-
S05847-11
cate the O-ring of the quick-release coupling.
Silicone spray ( p. 132)
- Join the quick-release coupling 4 of the fuel line.
Info
Route the cable and fuel line at a safe distance from the
exhaust system.
Finishing work
- Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
65
11
SERVICE WORK ON THE CHASSIS
11.37
Checking the chain for dirt
- Check the chain for heavy soiling.
» If the chain is very dirty:
- Clean the chain. ( p. 66)
400678-01
11.38
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. 45)
Main work
- Rinse off loose dirt with a soft jet of water.
- Remove old grease residue with chain cleaner.
Chain cleaner ( p. 132)
- After drying, apply chain spray.
Off-road chain spray ( p. 132)
400725-01
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
66
SERVICE WORK ON THE CHASSIS
11
11.39
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. 45)
Main work
- Pull the chain at the end of the chain sliding piece upward to mea-
sure chain tension A.
Guideline
Lower chain section 1 must be taut.
Info
Chain wear is not always even, so you should repeat this
measurement at different chain positions.
F00251-10
Chain tension
55 … 58 mm (2.17 … 2.28 in)
» If the chain tension does not meet the specification:
- Adjust the chain tension. ( p. 67)
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
11.40
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. 45)
- Check the chain tension. ( p. 67)
67
11
SERVICE WORK ON THE CHASSIS
Main work
- Loosen nut 1.
- Loosen nuts 2.
- Adjust the chain tension by turning adjusting screws 3 left and
right.
Guideline
Chain tension
55 … 58 mm (2.17 … 2.28 in)
Turn adjusting screws 3 on the left and right so that the mark-
ings on the left and right chain adjusters are in the same position
relative to reference marks A. The rear wheel is then correctly
aligned.
- Tighten nuts 2.
- Make sure that chain adjusters 4 are fitted correctly on adjusting
screws 3.
- Tighten nut 1.
Guideline
I01018-10
Info
The wide adjustment range of the chain adjusters (32 mm
(1.26 in)) enables different secondary ratios with the same
chain length.
Chain adjusters 4 can be turned by 180°.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
11.41
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
Main work
- Shift the transmission into neutral.
- Check the chain, rear sprocket and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
- Change the drivetrain kit.
Info
The engine sprocket, rear sprocket and chain should
always be replaced together.
400227-01
68
SERVICE WORK ON THE CHASSIS
11
–
Pull on the top section of the chain with the specified weight A.
Guideline
Weight, chain wear measure-
10 … 15 kg (22 … 33 lb.)
ment
-
Measure distance B of 18 chain rollers in the lower chain section.
Info
Chain wear is not always even, so you should repeat this
measurement at different chain positions.
272 mm (10.71 in)
Maximum distance B from
18 chain rollers at the longest
chain section
» If distance B is greater than the specified measurement:
- Change the drivetrain kit.
Info
When a new chain is mounted, the rear sprocket
400987-10
and the engine sprocket should also be changed.
New chains wear out faster on an old, worn rear
sprocket or engine sprocket.
-
Check the chain sliding guard for wear.
» If the lower edge of the chain pins is in line with, or below, the
chain sliding guard:
- Change the chain sliding guard.
-
Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
- Tighten screws on the chain sliding guard.
Guideline
Screw, chain
M6
6 Nm (4.4 lbf ft)
sliding guard
Loctite®243™
S05516-10
69
11
SERVICE WORK ON THE CHASSIS
- Check the chain sliding piece for wear.
» If the lower edge of the chain pins is in line with or below the
chain sliding piece:
- Change the chain sliding piece.
- Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
- Tighten screw on the chain sliding piece.
Guideline
Screw, chain sliding
M8
15 Nm (11.1 lbf ft)
piece
S05517-10
- Check the chain guide with a slide gage for dimension C.
6 mm (0.24 in)
Minimum thickness C of the
chain guide
» If the measured value is less than the specified value:
- Change the chain guide.
F03687-10
- Check that the chain guide is firmly seated.
» If the chain guide is loose:
- Tighten the screws on the chain guide.
Guideline
Screw, chain guide
M6x16
10 Nm (7.4 lbf ft)
on link fork at the
rear
Screw, chain guide
M6x45
10 Nm (7.4 lbf ft)
on link fork at the
F03682-01
front
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
70
SERVICE WORK ON THE CHASSIS
11
11.42
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.
F03645-01
11.43
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.
S02305-01
11.44
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 frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
- Remove the fuel tank.
(
p. 63)
71
11
SERVICE WORK ON THE CHASSIS
Main work
- Check the throttle cable routing.
Both throttle cables must be routed, side by side, on the back of
the handlebars, above the fuel tank bracket on the right of the
frame to the throttle valve body. Both throttle cables must be
secured behind the rubber strap of the fuel tank support.
» If the throttle cable is not routed as specified:
- Correct the throttle cable routing.
S05850-01
Finishing work
- Install the fuel tank.
(
p. 64)
– Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
11.45
Checking the rubber grip
- Check the rubber grips on the handlebar for damage, wear, and
looseness.
Info
The rubber grips are vulcanized onto a sleeve on the left and
onto the handle tube of the throttle grip on the right. The
left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or the
throttle tube.
401197-01
» If a rubber grip is damaged or worn:
- Change the rubber grip.
- Check that screw 1 is firmly seated.
Guideline
Screw, fixed grip
M4
5 Nm (3.7 lbf ft)
Loctite®243™
Diamond A must be positioned visibly as shown in the figure.
S05879-10
72
SERVICE WORK ON THE CHASSIS
11
11.46
Adjusting the basic position of the clutch lever
- Adjust the basic position of the clutch lever to your hand size by
turning adjusting screw 1.
Info
Turn the adjusting screw counterclockwise to decrease the
distance between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to increase the distance
between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any
J00081-10
force.
Do not make any adjustments while riding.
11.47
Checking/correcting the fluid level of hydraulic clutch
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
- Move the hydraulic clutch fluid reservoir mounted on the handlebar
into a horizontal position.
- Remove screws 1.
- Take off cover 2 with membrane 3.
- Check the fluid level.
Fluid level below container rim
4 mm (0.16 in)
» If the fluid level does not meet specifications:
H04933-10
- Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 130)
- 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.
73
11
SERVICE WORK ON THE CHASSIS
11.48
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
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.
H04933-10
- Fill bleeding syringe 4 with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 130)
- On the clutch slave cylinder, remove bleeder screw 5 and mount
bleeding syringe 4.
H04934-10
- Now press the fluid into the system until it emerges from hole 6
of the master cylinder without bubbles.
- Occasionally extract the fluid from the master cylinder reservoir to
prevent overflowing.
- Remove the bleeding syringe. Mount and tighten the bleeder screw.
- Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim
4 mm (0.16 in)
H04932-10
- Position the cover with the membrane. Mount and tighten the
screws.
74
SERVICE WORK ON THE CHASSIS
11
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
75
12
BRAKE SYSTEM
12.1
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:
- Inspect the brake system for damage and dirt.
S05880-10
12.2
Adjusting the basic position of the hand brake lever
- Check the free travel of the hand brake lever. ( p. 76)
- Adjust the basic position of the hand brake lever to your hand size
by turning adjusting screw 1.
Info
Turn the adjusting screw clockwise to increase the distance
between the hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the
distance between the hand brake lever and the handlebar.
S05881-10
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
12.3
Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
- Make sure that worn-out brake discs are replaced immediately. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
- Check the front and rear brake disc thickness at multiple points for
the dimension A.
Info
Wear reduces the thickness of the brake disc around the
contact surface of the brake linings.
Brake discs - wear limit
front
2.5 mm (0.098 in)
H00938-10
rear
3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
76
BRAKE SYSTEM
12
– 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.
12.4
Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
- Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents 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.)
Preparatory work
- Check that the brake linings of the front brake are secured.
(
p. 79)
Main work
- Move the brake reservoir mounted on the handlebar to a horizontal
position.
- Check the brake fluid level in level viewer 1.
» If the brake fluid level has dropped below the marking A:
- Add front brake fluid.
(
p. 77)
S05882-10
12.5
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.)
77
12
BRAKE SYSTEM
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Check that the brake linings of the front brake are secured.
(
p. 79)
Main work
- Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
- Remove screws 1.
- Take off cover 2 with membrane 3.
- Add brake fluid to level A.
Guideline
5 mm (0.2 in)
Level A (brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 130)
- Position cover 2 with membrane 3. Mount and tighten
screws 1.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
E02029-10
78
BRAKE SYSTEM
12
12.6
Checking that the brake linings of the front brake are secured
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
- 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. 79)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the brake linings of the front brake.
(
p. 79)
I01025-10
- Check that the brake linings are secured.
» If the brake linings are not secured correctly:
- Secure brake linings, replace with new parts if necessary.
12.7
Changing the brake linings of the front brake
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
- Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy-
cles workshop will be glad to help.)
Warning
Skin irritation Brake fluid 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.
79
12
BRAKE SYSTEM
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the
brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is
not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer
warranty shall be void.
- Only use brake linings approved and recommended by GASGAS Motorcycles.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
- Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
- Remove screws 1.
- Take off cover 2 with membrane 3.
- Manually press the brake caliper toward the brake disc to push back
the brake pistons. Ensure that brake fluid does not flow out of the
brake fluid reservoir, extract some if necessary.
Info
E02031-10
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake pistons.
- Remove cotter pins 4, pull out pin 5, and remove the brake lin-
ings.
- Clean the brake caliper and the brake caliper bracket.
S05112-10
- Check that spring plate 6 in the brake caliper and brake pad slid-
ing plate 7 in the brake caliper bracket are seated correctly.
S04465-10
80
BRAKE SYSTEM
12
– Insert the new brake linings.
- Insert pins 5 and mount cotter pins 4.
Guideline
Mount the outer cotter pins from the front to the rear.
Mount the inner cotter pins from the rear to the front.
Info
Always change the brake linings in pairs.
- Operate the hand brake lever repeatedly until the brake linings are
in contact with the brake disc and there is a pressure point.
S05113-10
- Correct the brake fluid level to level A.
Guideline
5 mm (0.2 in)
Level A (brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 130)
- Position cover 2 with membrane 3. Mount and tighten
screws 1.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
E02029-10
12.8
Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
- Ensure that the adjustment steps are performed properly. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
81
12
BRAKE SYSTEM
- Disconnect spring 1.
- Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check free
travel A.
Guideline
Free travel at foot brake lever
3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not meet specifications:
- Adjust the basic position of the foot brake lever.
402026-10
(
p. 82)
– Reconnect spring 1.
12.9
Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
- Set the free travel on the foot brake lever in accordance with the specification.
- Ensure that the adjustment steps are performed properly. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
- 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 at foot brake lever
3 … 5 mm (0.12 … 0.2 in)
– Hold push rod 3 and tighten nut 2.
Guideline
Remaining nuts, chas-
M6
10 Nm (7.4 lbf ft)
sis
J00118-10
- Hold screw 5 and tighten nut 4.
Guideline
Rear brake lever stop
M8
20 Nm (14.8 lbf ft)
nut
- Attach spring 1.
82
BRAKE SYSTEM
12
12.10
Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the 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.)
Preparatory work
- Check that the brake linings of the rear brake are secured. ( p. 84)
Main work
- Stand the vehicle upright.
- Check the brake fluid level in level viewer 1.
» If the brake fluid has dropped below marking A:
- Add rear brake fluid.
(
p. 83)
S05851-10
12.11
Adding rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the 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.
83
12
BRAKE SYSTEM
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Remove the frame protector. ( p. 57)
- Check that the brake linings of the rear brake are secured. ( p. 84)
Main work
- Stand the vehicle upright.
- Remove screw cap 1 with membrane 2 and the O-ring.
- Add brake fluid up to the marking A.
Brake fluid DOT 4 / DOT 5.1 ( p. 130)
- Mount the screw cap with the membrane and the O-ring.
Info
S05852-10
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
12.12
Checking that the brake linings of the rear brake are secured
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
- Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
- 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. 85)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the rear brake linings.
(
p. 85)
J00083-10
- Check that the brake linings are secured.
» If the brake linings are not secured correctly:
- Secure brake linings, replace with new parts if necessary.
84
BRAKE SYSTEM
12
12.13
Changing the rear brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
- Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy-
cles workshop will be glad to help.)
Warning
Skin irritation Brake fluid 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
- Remove the frame protector. ( p. 57)
Main work
- Stand the vehicle upright.
- Remove screw cap 1 with membrane 2 and the O-ring.
S05853-10
85
12
BRAKE SYSTEM
- Manually press the brake caliper toward the brake disc to push back
the brake piston. Ensure that brake fluid does not flow out of the
brake fluid reservoir; extract some if necessary.
Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake piston.
- Remove cotter pins 3, pull out pin 4, and remove the brake lin-
ings.
J00084-10
- Clean the brake caliper and the brake caliper bracket.
- Check that spring plate 5 in the brake caliper and brake pad slid-
ing plate 6 in the brake caliper bracket are seated correctly.
Info
The arrow on the spring plate points in the direction of rota-
tion of the brake disc.
J00085-10
- Insert the new brake linings, insert pin 4, and mount cotter
pins 3.
Info
Always change the brake linings in pairs.
Make sure that decoupling plate 7 is mounted on the pis-
ton side brake lining.
- Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
J00088-10
- Correct brake fluid level to marking A.
Brake fluid DOT 4 / DOT 5.1 ( p. 130)
- Mount and tighten screw cap 1 with membrane 2 and the O-
ring.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
S05852-10
Finishing work
- Install the frame protector. ( p. 57)
86
WHEELS, TIRES
13
13.1
Removing the front wheel
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
Main work
- Manually press the brake caliper toward the brake disc to push back
the brake pistons.
Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake pistons.
J00082-10
- Loosen screw 1 by several rotations.
- Loosen screws 2.
- Press on screw 1 to push the wheel spindle out of the axle clamp.
- Remove screw 1.
A00839-10
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.
A00840-10
Info
Do not actuate the hand brake lever when the front wheel is
removed.
- Remove spacers 3.
H00934-10
87
13
WHEELS, TIRES
13.2
Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
- Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
- Change front wheel bearing.
- Clean and grease shaft seal rings 1 and contact surfaces A of the
spacers.
Long-life grease ( p. 132)
- Insert the spacers.
- Clean and grease the wheel spindle.
H00935-10
Long-life grease ( p. 132)
- Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
- Mount and tighten screw 2.
Guideline
Screw, front wheel
M20x1.5
35 Nm (25.8 lbf ft)
spindle
- Operate the hand brake lever several times until the brake linings
are seated correctly against the brake disc.
A00839-11
- Remove the motorcycle from the lift stand. ( p. 45)
- Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
- Tighten screws 3.
Guideline
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
13.3
Removing the rear wheel
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 45)
88
WHEELS, TIRES
13
Main work
- Manually press the brake caliper toward the brake disc to push back
the brake piston.
Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake piston.
- Remove nut 1.
- Take off chain adjuster 2. Pull out wheel spindle 3 far enough to
allow the rear wheel to be pushed forward.
- Push the rear wheel forward as far as possible. Remove the chain
from the rear sprocket.
Info
Cover the components to protect them against damage.
Warning
Danger of accidents Damaged brake discs reduce the
I01016-10
braking effect.
- Always lay the wheel down in such a way that the brake
disc is not damaged.
- Hold the rear wheel and remove the wheel spindle. Take the rear
wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel is
removed.
- Remove spacers 4.
H03002-10
13.4
Installing the rear wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
89
13
WHEELS, TIRES
Main work
- Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
- Change the rear wheel bearing.
- Clean and grease shaft seal rings 1 and contact surfaces A of the
spacers.
Long-life grease ( p. 132)
- Insert the spacers.
H03001-10
- Clean and grease the wheel spindle.
Long-life grease ( p. 132)
- Position rear wheel and insert wheel spindle 2.
The brake linings are correctly positioned.
- Mount the chain.
V01716-10
- Position chain adjuster 3. Mount nut 4, but do not tighten it yet.
- Make sure that chain adjusters 3 are fitted correctly on adjusting
screws 5.
- Check the chain tension. ( p. 67)
- Tighten nut 4.
Guideline
Info
The wide adjustment range of the chain adjusters (32 mm
(1.26 in)) enables different secondary ratios with the same
chain length.
Chain adjusters 3 can be turned by 180°.
- Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
I01017-10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 45)
90
WHEELS, TIRES
13
13.5
Checking the tire condition
Info
Only mount tires approved and/or recommended by GASGAS Motorcycles.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcy-
cle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
- Check the front and rear tires for cuts, embedded objects, and other
damage.
» If the tires have cuts, run-in objects, or other damage:
- Change the tires.
400602-10
- Check the tire age.
Info
The tire date of manufacture is usually contained in the tire
label and is indicated by the last four digits of the DOT num-
ber. The first two digits indicate the week of manufacture
and the last two digits the year of manufacture.
GASGAS Motorcycles recommends that the tires be changed
after five years at the latest, regardless of the actual wear.
H01144-01
» If the tires are more than five years old:
- Change the tires.
13.6
Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
- Remove the protection cap.
- Check the 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 the tire pressure.
- Mount the protection cap.
400695-01
91
13
WHEELS, TIRES
13.7
Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam-
age.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low,
then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
- Check spoke tension regularly, and in particular on a new vehicle. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
- Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length
and spoke diameter.
If you hear different tone frequencies from different spokes
of equal length and diameter, this is an indication of differ-
ent spoke tensions.
You should hear a high note.
400694-01
» If the spoke tension differs:
- Correct the spoke tension.
- Check the spoke torque.
Guideline
Spoke nipple, front
M4.5
6 Nm (4.4 lbf ft)
wheel
Spoke nipple, rear
M4.5
6 Nm (4.4 lbf ft)
wheel
Torque wrench kit (58429094000)
92
ELECTRICAL SYSTEM
14
14.1
Removing the 12-V battery
Warning
Risk of injury
12 V batteries contain harmful substances.
– Keep 12 V batteries out of the reach of children.
- Keep sparks and open flames away from 12 V batteries.
- Only charge 12 V batteries in well-ventilated rooms.
- Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance
1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge
9V
– Dispose of 12 V batteries correctly if they have less than the minimum voltage.
Preparatory work
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
Main work
- Disconnect negative cable 1 from the 12-V battery.
- Pull back positive terminal cover 2 and disconnect positive
cable 3 from the 12-V battery.
S05858-10
- Remove screw 4.
- Remove relay 5 from the holder and hang it to the side.
- Slide the battery holding bracket to the side out of the attachment.
S05859-10
- Pull up battery holding bracket 6 and remove the 12-V battery to
the rear.
Info
Pay attention to the wiring harness.
S05860-10
93
14
ELECTRICAL SYSTEM
14.2
Installing the 12-V battery
Main work
- Pull up battery holding bracket 1, insert the 12-V battery into the
battery compartment with the terminals facing upward and secure
with battery holding bracket 1.
12-V battery (HJTZ5S-FP-C) ( p. 125)
S05860-11
- Mount and tighten screw 2.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Attach relay 3 in the holder.
S05859-11
- Connect positive cable 4 to the 12-V battery.
Guideline
Screw, battery terminal
M5
2.5 Nm (1.84 lbf ft)
– Connect negative cable 5 to the 12 V battery.
Guideline
Screw, battery terminal
M5
2.5 Nm (1.84 lbf ft)
Contact disks A must be mounted under screws 6 and cable
sockets 7 with the claws toward the battery terminal.
- Slide positive terminal cover 8 over the positive terminal.
S05861-10
Finishing work
- Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
94
ELECTRICAL SYSTEM
14
14.3
Charging the 12-V battery
Warning
Risk of injury
12 V batteries contain harmful substances.
– Keep 12 V batteries out of the reach of children.
- Keep sparks and open flames away from 12 V batteries.
- Only charge 12 V batteries in well-ventilated rooms.
- Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance
1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge
9V
– Dispose of 12 V batteries correctly if they have less than the minimum voltage.
Note
Environmental hazard
12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
- Dispose of 12 V batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, the 12-V battery will be destroyed.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and suffer a
loss of capacity, destroying the battery.
The 12-V battery is maintenance-free.
Preparatory work
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
- Remove the 12-V battery.
(
p. 93)
Main work
- Check the battery voltage.
» Battery voltage: < 9 V
- Do not charge the 12-V battery.
- Replace the 12-V battery and dispose of the old 12-V bat-
tery properly.
» If the specifications have been met:
Battery voltage: ≥ 9 V
- Charge the 12-V battery.
S00863-10
95
14
ELECTRICAL SYSTEM
Guideline
The charging current, charging voltage, and charging time
must not be exceeded.
Maximum charging voltage
14.4 V
Maximum charging current
3.0 A
Maximum charging time
24 h
Recharge the 12-V battery
6 months
regularly when the motor-
cycle is not being used
Battery charger (A54029974000)
This battery charger tests whether the 12-V battery retains
its voltage. It is also impossible to overcharge the 12-V bat-
tery with this battery charger. The charging time may be
longer at low temperatures.
This battery charger is only suitable for lithium iron phos-
phate batteries. Read the accompanying GASGAS Techni-
cal Accessories instructions.
Info
Never remove cover 1.
- Switch off the battery charger after charging and disconnect from
the 12-V battery.
Finishing work
- Install the 12-V battery.
(
p. 94)
– Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
14.4
Changing the main fuse
Warning
Fire hazard Incorrect fuses overload the electrical system.
- Only use fuses with the required ampere value.
- Do not bypass or repair fuses.
Info
The main fuse protects all electrical power consumers of the vehicle. It is located in the starter relay housing under
the seat.
Preparatory work
- Remove the frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
- Remove the fuel tank.
(
p. 63)
96
ELECTRICAL SYSTEM
14
Main work
- Remove the protection caps.
- Remove faulty main fuse 1.
Info
A faulty fuse has a burned-out fuse wire A.
A spare fuse 2 is located in the starter relay.
- Insert a new main fuse.
S05863-10
Fuse (58011109110) ( p. 125)
- Check that the electrical system is functioning properly.
Tip
Insert a spare fuse so that it is available if needed.
- Mount the protection caps.
Finishing work
- Install the fuel tank.
(
p. 64)
– Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
14.5
Changing the fuse of the fuel pump
Warning
Fire hazard Incorrect fuses overload the electrical system.
- Only use fuses with the required ampere value.
- Do not bypass or repair fuses.
Caution
Danger of burns The voltage regulator gets very hot when the vehicle is operated.
- Allow the voltage regulator to cool down before performing any work.
Info
The fuel pump is protected by the fuel pump fuse. This is located under the seat.
Preparatory work
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
97
14
ELECTRICAL SYSTEM
Main work
- Take off protection cap 1.
- Remove the faulty fuse 2.
Info
A faulty fuse has a burned-out fuse wire A.
- Insert the new fuse for the fuel pump.
Fuse (58011109105) ( p. 125)
- Check that the electrical system is functioning properly.
- Attach protection cap 1.
W00073-10
Finishing work
- Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
14.6
Diagnostics connector
Diagnostics connector 1 is located under the seat below the engine
control unit.
Info
As soon as the diagnostics tool is connected, the service hour
counter starts running.
Before longer diagnostic sessions, unplug the service hour
counter behind the start number plate.
F03736-10
98
EXHAUST CONTROL
15
15.1
Programming the end positions of the exhaust control
Info
If work has been carried out on the exhaust control, the end positions must be reprogrammed.
Condition
The engine is off.
Preparatory work
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
Main work
- Pull engine control unit 1 upward and off the bracket and hang to
the side.
- Pull diagnostics connector 2 off the holder.
R06533-10
- Move throttle grip 3 to where it is half open and hold in position.
G05894-10
- Plug wake-up connector A into diagnostics connector 1.
- Wait for at least five seconds.
The end positions of the exhaust control are read. The proce-
dure is clearly audible.
The combination instrument lighting is activated, the combina-
tion switch lights up green.
- Release the fixing from the throttle grip.
The end positions of the exhaust control are programmed.
D08202-10
- Wait until you can no longer hear the exhaust control engine operat-
ing.
- Disconnect wake-up connector A from diagnostics connector 1.
99
15
EXHAUST CONTROL
- Mount diagnostics connector 2 on the holder.
- Attach the engine control unit 1 to the holder.
R06533-11
Finishing work
- Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
100
COOLING SYSTEM
16
16.1
Cooling system
Water pump 1 in the engine ensures forced circulation of the coolant.
The pressure resulting from the warming of the cooling system is reg-
ulated by a valve in radiator cap 2. This ensures that operating the
vehicle at the specified coolant temperature will not result in a risk of
malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also
reduce the cooling effect.
S05886-10
16.2
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
- Stand the motorcycle upright on a horizontal surface.
- Remove the radiator cap.
- Check the coolant antifreeze.
-25 … -45 °C (-13 … -49 °F)
» If the antifreeze in the coolant does not match the specified
value:
- Correct the coolant antifreeze.
- Check the coolant level in the radiator.
400243-10
10 mm (0.39 in)
Coolant level A above the
radiator fins
» If the coolant level does not match the specified value:
- Correct the coolant level.
Coolant ( p. 130)
- Mount the radiator cap.
101
16
COOLING SYSTEM
16.3
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
- Stand the motorcycle upright on a horizontal surface.
- Remove the radiator cap.
- Check the coolant level in the radiator.
10 mm (0.39 in)
Coolant level A above the
radiator fins
» If the coolant level does not match the specified value:
- Correct the coolant level.
400243-10
Coolant ( p. 130)
- Mount the radiator cap.
16.4
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
102
COOLING SYSTEM
16
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
- Position the motorcycle upright.
- Place an appropriate container under the water pump cover.
- Remove screw 1. Take off radiator cap 2.
- Completely drain the coolant.
- Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump
M6x40
10 Nm (7.4 lbf ft)
cover, short
S05886-11
16.5
Refilling with coolant
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
- Make sure that screw 1 is tightened.
- Position the motorcycle upright.
- Completely fill the radiator with coolant.
Coolant ( p. 130)
S05887-10
103
16
COOLING SYSTEM
- Loosen screw 2 until coolant escapes without bubbles.
- Mount and tighten screw 2.
Guideline
Bleeder screw, cylinder
M6
10.5 Nm (7.74 lbf ft)
head
- Completely fill the radiator with coolant.
Coolant ( p. 130)
S05888-10
- Mount radiator cap 3.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
S05857-10
- Allow the engine to warm up and cool down again.
- Check the coolant level. ( p. 102)
16.6
Changing the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
104
COOLING SYSTEM
16
–
Remove screw 1. Take off radiator cap 2.
–
Place an appropriate container under the water pump cover.
–
Completely drain the coolant.
–
Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump
M6x40
10 Nm (7.4 lbf ft)
cover, short
-
Position the motorcycle upright.
S05886-11
-
Completely fill the radiator with coolant.
Coolant ( p. 130)
-
Loosen screw 3 until coolant escapes without bubbles.
–
Mount and tighten screw 3.
Guideline
Bleeder screw, cylinder
M6
10.5 Nm (7.74 lbf ft)
head
-
Completely fill the radiator with coolant.
Coolant ( p. 130)
S05888-11
-
Mount radiator cap 2.
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.
S05857-11
-
Allow the engine to warm up and cool down again.
–
Check the cooling system for leaks.
–
Check the coolant level. ( p. 102)
105
17
TUNING THE ENGINE
17.1
Changing the mapping
Info
The desired engine characteristic can be altered using the combination switch.
Changing the mapping also affects the response of the exhaust control.
The setting most recently selected is activated again when restarting.
The mapping can also be changed during the ride.
Activating lean mapping:
- Press button 1.
Guideline
Engine speed
< 4,000 rpm
The indicator lamp A lights up.
Lean - Recommended for firm/hard surfaces
W00077-10
Activating rich mapping:
- Press button 2.
Guideline
Engine speed
< 4,000 rpm
The indicator lamp B lights up.
Rich - Recommended for sandy/loose surfaces
W00077-11
17.2
Checking the play in the throttle cable
- Check the throttle grip for smooth operation.
- Move the handlebar to the straight-ahead position. Turn the throt-
tle grip back and forth slightly and determine the play in throttle
cable A.
Play in throttle cable
2 … 3 mm (0.08 … 0.12 in)
» If the throttle cable play does not meet the specified value:
- Adjust the play in the throttle cable.
(
p. 107)
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. 107)
106
TUNING THE ENGINE
17
17.3
Adjusting the play in the throttle cable
Info
If the correct routing of the throttle cable has already been secured, the fuel tank does not need to be removed.
Preparatory work
- Remove the frame protector. ( p. 57)
- Remove the right side panel. ( p. 57)
- Remove the air filter box cover. ( p. 58)
- Remove the seat. ( p. 56)
- Remove the fuel tank.
(
p. 63)
– Check the throttle cable routing. ( p. 71)
Main work
- Move the handlebar to the straight-ahead position.
- Push back sleeve 1.
- Loosen nut 2.
- Turn adjusting screw 3 in as far as possible.
- Loosen nut 4.
- Push cold start button 6 all the way to the stop.
- Turn adjusting screw 5 so that the cold start button moves to the
basic position when the throttle grip is turned to the front.
- Tighten nut 4.
- Turn adjusting screw 3 so that there is play in the throttle cable at
the throttle grip.
Guideline
Play in throttle cable
2 … 3 mm (0.08 … 0.12 in)
S05883-10
Finishing work
- Check the throttle grip for smooth operation.
- Install the fuel tank.
(
p. 64)
– Mount the seat. ( p. 56)
- Install the air filter box cover. ( p. 58)
- Install the right side panel. ( p. 58)
- Install the frame protector. ( p. 57)
- Check the play in the throttle cable. ( p. 106)
107
17
TUNING THE ENGINE
17.4
Adjusting the idle speed
Warning
Danger of accidents The engine may go out spontaneously if the idle speed is set too low.
- Set the idle speed to the specified value. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Run the engine until warm.
The cold start button is deactivated - The cold start button is in
its basic position. ( p. 17)
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.
S05830-10
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Adjust the idle speed by turning idle speed adjusting screw 1 using
a suitable tachometer.
Guideline
Idle speed
1,400 … 1,500 rpm
Info
Turning counterclockwise lowers the idle speed.
Turning clockwise raises the idle speed.
Make the setting in small steps.
An incorrect idle speed can have a negative impact on over-
all engine running.
17.5
Checking the basic position of the shift lever
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
- Sit on the vehicle in the riding position and determine distance A
between the upper edge of your boot and the shift lever.
Distance between shift lever
10 … 20 mm (0.39 … 0.79 in)
and upper edge of boot
» If the distance does not meet specifications:
- Adjust the basic position of the shift lever.
(
p. 109)
400692-10
108
TUNING THE ENGINE
17
17.6
Adjusting the basic position of the shift lever
- Remove screw 1 with the washers and take off shift lever 2.
401950-12
- Clean gear teeth A of the shift lever and shift shaft.
- Mount the shift lever on the shift shaft in the required position and
engage gearing.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other
vehicle components during the shift procedure.
401951-10
- Mount and tighten screw 1 with washers.
Guideline
Screw, shift lever
M6
14 Nm (10.3 lbf ft)
Loctite®243™
109
18
SERVICE WORK ON THE ENGINE
18.1
Changing the fuel screen
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
- Clean quick release coupling 1 thoroughly with compressed air.
Info
Under no circumstances should dirt enter into the fuel line.
Dirt in the fuel line clogs the injection valve!
- Disconnect the quick release coupling.
Info
Remaining fuel may flow out of the fuel hose.
- Pull fuel screen 2 out of the connecting piece.
- Insert the new fuel screen all the way into the connecting piece.
- Spray silicone spray onto a lint-free cleaning cloth and lightly lubri-
cate the O-ring of the quick-release coupling.
Silicone spray ( p. 132)
- Join the quick release coupling.
Danger
S05865-10
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and check the response.
110
SERVICE WORK ON THE ENGINE
18
18.2
Checking the gear oil level
Info
The gear oil level must be checked when the engine is cold.
Preparatory work
- Stand the motorcycle upright on a horizontal surface.
Main work
- Remove gear oil level monitoring 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. 112)
– Mount and tighten the gear oil level monitoring screw.
Guideline
S05884-10
Screw, gear oil level
M6
8 Nm (5.9 lbf ft)
monitoring
18.3
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 the gear oil while the engine is at operating temperature.
Preparatory work
- Park the motorcycle on a level surface.
- Position an appropriate container under the engine.
Main work
- Remove gear oil drain plug 1 with magnet.
- Let the gear oil drain fully.
- Thoroughly clean the gear oil drain plug with magnet.
- Clean the sealing surface on the engine.
- Mount and tighten gear oil drain plug 1 with the magnet and a
new seal ring.
Guideline
S05885-10
Gear oil drain plug with
M12x1.5
20 Nm (14.8 lbf ft)
magnet
111
18
SERVICE WORK ON THE ENGINE
- Remove filler plug 2 with the O-ring, and fill up with gear oil.
Gear oil
0.80 l (0.85 qt.)
Engine oil (15W/50)
(
p. 130)
– Mount and tighten the filler plug together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
401955-11
- 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. 111)
18.4
Adding the gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Gear oil must only be topped up when the engine is cold.
Preparatory work
- Park the motorcycle on a level surface.
Main work
- Remove gear oil level monitoring screw 1.
S05884-10
- Remove filler plug 2 with the O-ring.
- Add gear oil until it emerges from the drill hole of the gear oil level
monitoring screw.
Engine oil (15W/50) ( p. 130)
- Mount and tighten the gear oil level monitoring screw.
Guideline
Screw, gear oil level
M6
8 Nm (5.9 lbf ft)
monitoring
401955-11
- Mount and tighten filler plug 2 with the O-ring.
112
SERVICE WORK ON THE ENGINE
18
Finishing work
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.
113
19
CLEANING, CARE
19.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
- Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
- Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance
60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
-
Close off exhaust system to keep water from entering.
–
Remove the coarse dirt particles with a gentle water jet.
–
Spray the heavily soiled parts with a normal commercial motorcycle
cleaner and clean using a brush.
Motorcycle cleaner ( p. 132)
Info
Use warm water containing normal motorcycle cleaner and
401061-01
a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always
rinse the vehicle with water first.
-
After rinsing the motorcycle with a gentle spray of water, allow it to
dry thoroughly.
-
Remove the closure of the exhaust system.
Warning
Danger of accidents Moisture and dirt impair the brake
system.
- Brake carefully several times to dry out and remove dirt
from the brake linings and the brake discs.
-
After cleaning, ride the vehicle a short distance until the engine
warms up.
Info
The heat produced causes water at inaccessible locations in
the engine and on the brake system to evaporate.
-
After the motorcycle has cooled down, lubricate all moving parts
and pivot points.
-
Clean the chain. ( p. 66)
–
Treat bare metal (except for brake discs and the exhaust system)
with a corrosion inhibitor.
114
CLEANING, CARE
19
Preserving materials for paints, metal and rubber ( p. 132)
- Treat all plastic parts and powder-coated parts with a mild cleaning
and care product.
Special cleaner for glossy and matte paint finishes, metal and
plastic surfaces ( p. 133)
115
20
STORAGE
20.1
Storage
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are neces-
sary, you should do this during the storage period (less workshop overload). In this way, you can avoid long work-
shop waiting times at the start of the new season.
- When refueling for the last time before taking the motorcycle out of
service, add fuel additive.
Fuel additive ( p. 132)
- Refuel. ( p. 29)
Tip
Fill the fuel tank completely as specified, using fuel with the
lowest possible ethanol content.
401058-01
- Clean the motorcycle. ( p. 114)
- Change the gear oil.
(
p. 111)
– Check the antifreeze and coolant level. ( p. 101)
- Check tire pressure. ( p. 91)
- Remove the 12-V battery.
(
p. 93)
– Charge the 12-V battery.
(
p. 95)
Guideline
Storage temperature of the
0 … 35 °C (32 … 95 °F)
12-V battery without direct
sunlight
- Store the vehicle in a dry location that is not subject to large fluctua-
tions in temperature.
Info
GASGAS Motorcycles recommends jacking up the motorcy-
cle.
- Raise the motorcycle with a lift stand. ( p. 45)
- Cover the vehicle with a tarp or a similar cover that is permeable to
air.
116
STORAGE
20
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.
20.2
Preparing for use after storage
- Install the 12-V battery.
(
p. 94)
– Remove the motorcycle from the lift stand. ( p. 45)
- Perform checks and maintenance measures when preparing for use.
(
p. 25)
– Make a test ride.
401059-01
117
21
TROUBLESHOOTING
Faults
Possible cause
Action
The engine does not turn over
Operating error
-
Carry out start procedure. ( p. 25)
when the start button is actuated
12-V battery discharged
-
Charge the 12-V battery.
(
p. 95)
–
Check the charging voltage.
–
Check the open-circuit current.
–
Check the stator winding of the alterna-
tor.
Main fuse blown
-
Change the main fuse. ( p. 96)
Starter relay faulty
-
Check the starter relay.
Starter motor faulty
-
Check the starter motor.
The engine turns but does not
Operating error
-
Carry out start procedure. ( p. 25)
start
Quick release coupling not joined
-
Join quick release coupling.
Idle speed is not set correctly
-
Adjust the idle speed.
(
p. 108)
Fuel supply interrupted
-
Check the fuel tank breather.
Fuel screen in the quick release
-
Change the fuel screen.
(
p. 110)
coupling is clogged
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
0.60 mm (0.0236 in)
Fault in ignition system
-
Check the ignition system.
Short-circuit cable in wiring har-
-
Check the stop button.
ness frayed, stop button faulty
The connector or ignition coil is
-
Clean the connector and treat it with con-
loose or oxidized
tact spray.
Malfunction in the electronic fuel
-
Read out the fault memory using the GAS-
injection
GAS Motorcycles diagnostics tool.
Engine does not speed up
Malfunction in the electronic fuel
-
Read out the fault memory using the GAS-
injection
GAS Motorcycles diagnostics tool.
Engine has too little power
Air filter very dirty
-
Clean the air filter and air filter box.
(
p. 60)
Fuel filter is very dirty
-
Change the fuel filter.
Fuel screen is very dirty
-
Change the fuel screen.
(
p. 110)
Malfunction in the electronic fuel
-
Read out the fault memory using the GAS-
injection
GAS Motorcycles diagnostics tool.
Fuel supply interrupted
-
Check the fuel tank breather.
Exhaust system leaky, deformed
-
Check exhaust system for damage.
or too little glass fiber yarn filling
–
Change the glass fiber yarn filling of the
in main silencer
main silencer.
(
p. 62)
Diaphragm or reed valve housing
-
Check the diaphragm and reed valve hous-
damaged
ing.
The engine dies during the trip
Lack of fuel
-
Refuel. ( p. 29)
The engine takes in false air
-
Check that the intake flange is firmly
seated.
The connector or ignition coil is
-
Clean the connector and treat it with con-
loose or oxidized
tact spray.
Engine overheats
Too little coolant in cooling system
-
Check the cooling system for leakage.
–
Check the coolant level. ( p. 102)
118
TROUBLESHOOTING
21
Faults
Possible cause
Action
Engine overheats
Too little air stream
- Switch off engine when stationary.
Radiator fins very dirty
- Clean the radiator fins.
Foam formation in cooling system
- Drain the coolant.
(
p. 102)
– Refill with coolant.
(
p. 103)
Damaged cylinder head or cylin-
- Check the cylinder head and cylinder head
der head gasket
gasket.
Bent radiator hose
- Change the radiator hose.
Thermostat defective
- Check the thermostat.
Guideline
Opening temperature: 70 °C (158 °F)
Malfunction indicator lamp lights
Malfunction in the electronic fuel
- Check the wiring for damage and the elec-
up or flashes
injection
trical plug-in connections for corrosion
and damage.
- Read out the fault memory using the GAS-
GAS Motorcycles diagnostics tool.
White smoke emission (steam in
Damaged cylinder head or cylin-
- Check the cylinder head and 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. 111)
Water in the gear oil
Damaged radial shaft seal ring or
- Check the radial shaft seal ring and the
water pump
water pump.
12-V battery discharged
12 V battery is not charging
- Check the charging voltage.
- Check the stator winding of the alterna-
tor.
Unwanted electrical power con-
- Check the open-circuit current.
sumer
119
22
BLINK CODE
Blink code for malfunction
indicator lamp
14 Malfunction indicator lamp flashes 1x long, 4x short
Error level condition
Crankcase pressure sensor - difference too high between sensor and engine control unit
Blink code for malfunction
indicator lamp
09 Malfunction indicator lamp flashes 9x short
Error level condition
Crankcase pressure sensor - short circuit to ground
Crankcase pressure sensor - open/short circuit to plus
Ambient air pressure sensor - short circuit to ground
Ambient air pressure sensor - open/short circuit to plus
Blink code for malfunction
indicator lamp
13 Malfunction indicator lamp flashes 1x long, 3x short
Error level condition
Intake air temperature sensor - input signal too low
Intake air temperature sensor - input signal too high
Blink code for malfunction
indicator lamp
12 Malfunction indicator lamp flashes 1x long, 2x short
Error level condition
Coolant temperature sensor - input signal too low
Coolant temperature sensor - input signal too high
Blink code for malfunction
indicator lamp
06 Malfunction indicator lamp flashes 6x short
Error level condition
Throttle valve position sensor circuit A - input signal too low
Throttle valve position sensor circuit A - input signal too high
Blink code for malfunction
indicator lamp
41 Malfunction indicator lamp flashes 4x long, 1x short
Error level condition
Fuel pump - short circuit to ground/open circuit
Fuel pump - short circuit to plus
Blink code for malfunction
indicator lamp
33 Malfunction indicator lamp flashes 3x long, 3x short
Error level condition
Injection valve 1, cylinder 1 - input signal too low
Injection valve 1, cylinder 1 - input signal too high
Blink code for malfunction
indicator lamp
34 Malfunction indicator lamp flashes 3x long, 4x short
Error level condition
Injection valve 2, cylinder 1 - input signal too low
Injection valve 2, cylinder 1 - input signal too high
120
BLINK CODE
22
Blink code for malfunction
indicator lamp
37 Malfunction indicator lamp flashes 3x long, 7x short
Error level condition
Ignition coil - circuit fault
Blink code for malfunction
indicator lamp
02 Malfunction indicator lamp flashes 2x short
Error level condition
Crankshaft speed sensor - synchronization faulty
Crankshaft speed sensor - signal implausible
Blink code for malfunction
indicator lamp
50 Malfunction indicator lamp flashes 5x long
Error level condition
Exhaust control actuator - no signal
Exhaust control actuator - temperature too high
Exhaust control actuator - incorrect setting
Exhaust control actuator - setpoint value signal faulty
Exhaust control actuator - input signal too low
Exhaust control actuator - input signal too high
Exhaust control actuator - mechanical error in the lower position
Exhaust control actuator - mechanical error in the upper position
Exhaust control actuator - mechanical error
Blink code for malfunction
indicator lamp
21 Malfunction indicator lamp flashes 2x long, 1x short
Error level condition
Battery voltage - input voltage too low
Battery voltage - input voltage too high
Blink code for malfunction
indicator lamp
53 Malfunction indicator lamp flashes 5x long, 3x short
Error level condition
Sensor voltage 1 - open circuit/short circuit to ground
Sensor voltage 1 - short circuit to plus
Blink code for malfunction
indicator lamp
54 Malfunction indicator lamp flashes 5x long, 4x short
Error level condition
Sensor voltage 2 - open circuit/short circuit to ground
Sensor voltage 2 - short circuit to plus
Blink code for malfunction
indicator lamp
Malfunction indicator lamp lights up
Error level condition
Tilt sensor - input signal too low
Tilt sensor - input signal too high
121
23
TECHNICAL SPECIFICATIONS
23.1
Engine
Design
1-cylinder 2-stroke engine, water-cooled, with reed intake
and exhaust control
Displacement (MC 250, EX 250 US)
249 cm³ (15.19 cu in)
Displacement (EX 300 US)
293.15 cm³ (17.8892 cu in)
Stroke
72 mm (2.83 in)
Hole (MC 250, EX 250 US)
66.4 mm (2.614 in)
Hole (EX 300 US)
72 mm (2.83 in)
Crankshaft bearing
1 grooved ball bearing/1 roller bearing
Conrod bearing
Needle bearing
Piston pin bearing
Needle bearing
Piston
Cast aluminum
Piston rings (MC 250, EX 250 US)
2 half keystone rings
Piston rings (EX 300 US)
2 rectangular rings
X-distance (upper edge of piston to special tool)
0 … 0.10 mm (0 … 0.0039 in)
Z distance (height of control flap) (MC 250, EX 250 US)
48.0 mm (1.89 in)
Z distance (height of control flap) (EX 300 US)
48.0 mm (1.89 in)
Primary transmission
26:72
Clutch
Multidisc clutch in oil bath/hydraulically activated
Transmission (MC 250)
5-gear transmission, claw shifted
Transmission (All EX models)
6-gear transmission, claw shifted
Transmission ratio (MC 250)
first-gear
14:28
second-gear
16:26
third-gear
18:24
fourth-gear
21:24
fifth-gear
22:21
Transmission ratio (All EX models)
first-gear
13:33
second-gear
16:30
third-gear
18:26
fourth-gear
22:26
fifth-gear
23:23
sixth-gear
26:22
Ignition system
Electronic ignition
Spark plug
NGK BR 8 ES
Spark plug electrode gap
0.60 mm (0.0236 in)
Starting aid
Electric starter system
122
TECHNICAL SPECIFICATIONS
23
23.2
Engine tightening torques
Screw, inner reed paddles
EJOT DELTA PT® 3.5x25
1 Nm (0.7 lbf ft)
Screw, membrane support plate
EJOT DELTA PT® 3x12
1 Nm (0.7 lbf ft)
Screw, outer reed paddles
EJOT DELTA PT® 3x6
1 Nm (0.7 lbf ft)
Nut, axle for control flap
M5
5 Nm (3.7 lbf ft)
Screw, actuator, exhaust control
M5
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, bearing retainer
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, clutch spring retainer
M5
6 Nm (4.4 lbf ft)
Screw, control flap, exhaust control
M5
8 Nm (5.9 lbf ft)
Loctite®243™
Screw, cover, actuator, exhaust con-
M5
5 Nm (3.7 lbf ft)
trol
Loctite®243™
Screw, crankshaft speed sensor
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, exhaust control cover
M5
6 Nm (4.4 lbf ft)
Screw, idler shaft, exhaust control
M5
8 Nm (5.9 lbf ft)
Loctite®243™
Screw, locking lever
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, retaining bracket of exhaust
M5
6 Nm (4.4 lbf ft)
control
Loctite®2701™
Screw, stator
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Bleeder screw, cylinder head
M6
10.5 Nm (7.74 lbf ft)
Nut, water pump impeller
M6
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, alternator cover
M6
8 Nm (5.9 lbf ft)
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6x25
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6x60
10 Nm (7.4 lbf ft)
Screw, cover, starter motor
M6
8 Nm (5.9 lbf ft)
Screw, engine case
M6x45
10 Nm (7.4 lbf ft)
Screw, engine case
M6x60
10 Nm (7.4 lbf ft)
Screw, gear oil level monitoring
M6
8 Nm (5.9 lbf ft)
Screw, intake flange/reed valve hous-
M6
6 Nm (4.4 lbf ft)
ing
Screw, intermediate flange
M6
8 Nm (5.9 lbf ft)
Screw, outer clutch cover
M6
8 Nm (5.9 lbf ft)
Screw, shift drum locating
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift lever
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter motor
M6
10 Nm (7.4 lbf ft)
Screw, water pump cover, long
M6x60
10 Nm (7.4 lbf ft)
Screw, water pump cover, short
M6x40
10 Nm (7.4 lbf ft)
Screw, balancer shaft
M8
30 Nm (22.1 lbf ft)
Loctite®243™
123
23
TECHNICAL SPECIFICATIONS
Screw, cylinder head
M8
27 Nm (19.9 lbf ft)
Nut, cylinder base
M10
38 Nm (28 lbf ft)
Screw, drive chain engine sprocket
M10
60 Nm (44.3 lbf ft)
Loctite®2701™
Stud, cylinder base
M10
12 Nm (8.9 lbf ft)
Nut, rotor
M12x1
60 Nm (44.3 lbf ft)
Gear oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
Spark plug
M14x1.25
25 Nm (18.4 lbf ft)
Nut, inner clutch hub
M18x1.5
100 Nm (73.8 lbf ft)
Nut, primary gear wheel
M18LHx1.5
150 Nm (110.6 lbf ft)
Loctite®243™
23.3
Capacities
23.3.1
Gear oil
Gear oil
0.80 l (0.85 qt.)
Engine oil (15W/50) ( p. 130)
23.3.2
Coolant
Coolant
1.2 l (1.3 qt.)
Coolant ( p. 130)
23.3.3
Fuel
Total fuel tank capacity, approx.
7.9 l (2.09 US gal)
Super unleaded (95 octane) mixed with
(MC 250)
2-stroke engine oil (1:60) ( p. 131)
Total fuel tank capacity, approx. (All
9.0 l (2.38 US gal)
Super unleaded (95 octane) mixed with
EX models)
2-stroke engine oil (1:60) ( p. 131)
23.4
Chassis
Frame
Central tube frame made of chrome molybdenum steel
tubing
Fork (MC 250)
WP AER
Fork (All EX models)
WP Closed Cartridge
Shock absorber (MC 250)
WP XACT LDS
Shock absorber (All EX models)
WP XACT LDS
Suspension travel (MC 250)
Front
310 mm (12.2 in)
Rear
300 mm (11.81 in)
Suspension travel (All EX models)
Front
300 mm (11.81 in)
Rear
300 mm (11.81 in)
Fork offset
22 mm (0.87 in)
Brake system
Disc brakes, floating brake calipers
Brake discs - diameter
front
260 mm (10.24 in)
rear
220 mm (8.66 in)
Brake discs - wear limit
front
2.5 mm (0.098 in)
rear
3.5 mm (0.138 in)
124
TECHNICAL SPECIFICATIONS
23
Offroad tire pressure
front
1.0 bar (15 psi)
rear
1.0 bar (15 psi)
Secondary ratio
14:49
Chain
5/8 x 1/4"
Rear sprockets available
48, 50, 51, 52
Steering head angle
63.9°
Wheelbase
1,493 ± 10 mm (58.78 ± 0.39 in)
Seat height unloaded
956 mm (37.64 in)
Ground clearance unloaded (MC 250)
354 mm (13.94 in)
Ground clearance unloaded (All EX models)
355 mm (13.98 in)
Weight without fuel, approx. (MC 250)
100.1 kg (220.7 lb.)
Weight without fuel, approx. (All EX models)
102.6 kg (226.2 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
Maximum permissible overall weight
335 kg (739 lb.)
23.5
Electrical system
12-V battery
HJTZ5S-FP-C
Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
Fuse
58011109105
5A
Fuse
58011109110
10 A
23.6
Tires
Validity
Front tire
Rear tire
(MC 250)
80/100 - 21 M/C 51M TT
110/90 - 19 M/C 62M TT
MAXXIS MAXXCROSS MX-ST
MAXXIS MAXXCROSS MX-ST
(All EX models)
80/100 - 21 51M TT
110/100 - 18 64M TT
Dunlop GEOMAX MX 33 F
Dunlop GEOMAX AT 81
The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an
authorized dealer or qualified tire dealership. If local road approval regulations apply, these and the respective technical
specifications must be observed. Additional information is available in the Service section under:
23.7
Fork
23.7.1
MC 250
Fork article number
A460C103X406000
Fork
WP AER
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Rebound damping
Comfort
23 clicks
125
23
TECHNICAL SPECIFICATIONS
Standard
18 clicks
Sport
13 clicks
Air pressure
10.5 bar (152 psi)
Fork length
950 mm (37.4 in)
Oil capacity external mechanism left
240+10-50 ml (8.11+0.34-1.69 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 131)
Oil capacity external mechanism right
240+10-50 ml (8.11+0.34-1.69 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 131)
Grease capacity, left cartridge
5 g (0.18 oz)
Special grease (00062010053)
(
p. 133)
Oil capacity, right cartridge
380 ml (12.85 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 131)
23.7.2
All EX models
Fork article number
A590C173X402000
Fork
WP Closed Cartridge
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Rebound damping
Comfort
23 clicks
Standard
18 clicks
Sport
13 clicks
Spring length with preload spacer(s)
478 mm (18.82 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
4.4 N/mm (25.1 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
4.6 N/mm (26.3 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
4.8 N/mm (27.4 lb/in)
Fork length
940 mm (37.01 in)
Oil capacity, cartridge
175 ml (5.92 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 131)
Oil capacity, external mechanism
385 … 395 ml (13.02 … 13.35 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 131)
23.8
Shock absorber
23.8.1
MC 250
Shock absorber article number
A460C403X408000
Shock absorber
WP XACT LDS
Lowspeed compression damping
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Highspeed compression damping
Comfort
2 turns
Standard
1.5 turns
126
TECHNICAL SPECIFICATIONS
23
Sport
1 turn
Rebound damping
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Spring preload
8 mm (0.31 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
42 N/mm (240 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
45 N/mm (257 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
48 N/mm (274 lb/in)
Spring length
240 mm (9.45 in)
Gas pressure
10 bar (145 psi)
Static sag
35 mm (1.38 in)
Riding sag
105 mm (4.13 in)
Fitted length
456.3 mm (17.965 in)
Shock absorber fluid ( p. 131)
SAE 2.5
23.8.2
All EX models
Shock absorber article number
A460C473X408000
Shock absorber
WP XACT LDS
Lowspeed compression damping
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Highspeed compression damping
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Rebound damping
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Spring preload
8 mm (0.31 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
42 N/mm (240 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
45 N/mm (257 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
48 N/mm (274 lb/in)
Spring length
240 mm (9.45 in)
Gas pressure
10 bar (145 psi)
Static sag
35 mm (1.38 in)
Riding sag (EX 250 US)
105 mm (4.13 in)
Riding sag (EX 300 US)
100 mm (3.94 in)
Fitted length
456.3 mm (17.965 in)
Shock absorber fluid ( p. 131)
SAE 2.5
127
23
TECHNICAL SPECIFICATIONS
23.9
Chassis tightening torques
Screw, fuel pump
EJOT
2.5 Nm (1.84 lbf ft)
Screw, intake air temperature sensor
EJOTPT® K50x18-T20
0.7 Nm (0.52 lbf ft)
Screw, seat fixing
EJOT EJOFORM PT® K60x23/18
2.5 Nm (1.84 lbf ft)
Screw, start/stop button
EJOT PT® K50x18 T20
2 Nm (1.5 lbf ft)
Screw, fixed grip
M4
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, hose clip, throttle valve body
M4
5 Nm (3.7 lbf ft)
Screw, hose clip, throttle valve body
M4
2.8 Nm (2.07 lbf ft)
Screw, service hour counter
M4
0.8 Nm (0.59 lbf ft)
Spoke nipple, front wheel
M4.5
6 Nm (4.4 lbf ft)
Spoke nipple, rear wheel
M4.5
6 Nm (4.4 lbf ft)
Remaining nuts, chassis
M5
5 Nm (3.7 lbf ft)
Remaining screws, chassis
M5
5 Nm (3.7 lbf ft)
Screw, battery terminal
M5
2.5 Nm (1.84 lbf ft)
Screw, shock absorber adjusting ring
M5
5 Nm (3.7 lbf ft)
Screw, throttle valve body cover
M5
2.6 Nm (1.92 lbf ft)
Screws on main silencer
M5
7 Nm (5.2 lbf ft)
Nut, cable on starter motor
M6
4 Nm (3 lbf ft)
Remaining nuts, chassis
M6
10 Nm (7.4 lbf ft)
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Screw, ball joint of push rod on brake
M6
10 Nm (7.4 lbf ft)
cylinder
Loctite®243™
Screw, battery holding bracket
M6
6 Nm (4.4 lbf ft)
Screw, chain guide on link fork at the
M6x45
10 Nm (7.4 lbf ft)
front
Screw, chain guide on link fork at the
M6x16
10 Nm (7.4 lbf ft)
rear
Screw, chain sliding guard
M6
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, fuel tank spoiler on radiator
M6
6 Nm (4.4 lbf ft)
Screw, hand lever
M6
5 Nm (3.7 lbf ft)
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter cable to starter relay
M6x8
6 Nm (4.4 lbf ft)
Screw, throttle grip
M6
5 Nm (3.7 lbf ft)
Nut, rear sprocket screw
M8
35 Nm (25.8 lbf ft)
Loctite®2701™
Nut, rim lock
M8
12 Nm (8.9 lbf ft)
Rear brake lever stop nut
M8
20 Nm (14.8 lbf ft)
Remaining nuts, chassis
M8
25 Nm (18.4 lbf ft)
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
Screw, bottom triple clamp
M8
15 Nm (11.1 lbf ft)
Screw, chain sliding piece
M8
15 Nm (11.1 lbf ft)
Screw, engine sprocket cover
M8
15 Nm (11.1 lbf ft)
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
128
TECHNICAL SPECIFICATIONS
23
Screw, front brake caliper
M8
25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handlebar clamp
M8
20 Nm (14.8 lbf ft)
Screw, manifold
M8
15 Nm (11.1 lbf ft)
Screw, side stand (All EX models)
M8
33 Nm (24.3 lbf ft)
Loctite®2701™
Screw, subframe, bottom
M8x18
35 Nm (25.8 lbf ft)
Loctite®243™
Screw, top steering stem
M8
20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
Top subframe screw
M8x20
40 Nm (29.5 lbf ft)
Loctite®2701™
Engine bracket screw
M10
60 Nm (44.3 lbf ft)
Remaining nuts, chassis
M10
45 Nm (33.2 lbf ft)
Remaining screws, chassis
M10
45 Nm (33.2 lbf ft)
Screw, bottom shock absorber
M10
60 Nm (44.3 lbf ft)
Loctite®2701™
Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Loctite®243™
Screw, top shock absorber
M10
60 Nm (44.3 lbf ft)
Loctite®2701™
Nut for frame on pull rod
M16x1.5
80 Nm (59 lbf ft)
Nut, fork pivot
M16x1.5
100 Nm (73.8 lbf ft)
Nut, pull rod on triangular lever
M16x1.5
80 Nm (59 lbf ft)
Nut, triangular lever on link fork
M16x1.5
80 Nm (59 lbf ft)
Screw, front wheel spindle
M20x1.5
35 Nm (25.8 lbf ft)
Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
Screw-in fitting, cooling system
M24x1.5
7.5 Nm (5.53 lbf ft)
129
24
SUBSTANCES
Brake fluid DOT 4 / DOT 5.1
Standard/classification
- DOT
Guideline
- Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the
corresponding properties.
Recommended supplier
Castrol
- REACT PERFORMANCE DOT 4
MOTOREX®
- Brake Fluid DOT 5.1
Coolant
Guideline
- Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuit-
able antifreeze causes corrosion, deposits and frothing.
- Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and
lubrication properties.
- Only use coolant that complies with the requirements stated (see specifications on the container) and that has the rele-
vant properties.
Antifreeze protection to at least
-25 °C (-13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be
diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other
coolants.
Recommended supplier
MOTOREX®
- COOLANT M3.0
Engine oil (15W/50)
Standard/classification
- JASO T903 MA2 ( p. 134)
- SAE ( p. 134) (15W/50)
Guideline
- Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the
corresponding properties.
Recommended supplier
MOTOREX®
- Top Speed 4T
Engine oil, 2-stroke
Standard/classification
- JASO FD ( p. 134)
Guideline
- Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
Recommended supplier
MOTOREX®
- Cross Power 2T
130
SUBSTANCES
24
Fork oil (SAE 4) (48601166S1)
Standard/classification
- SAE ( p. 134) (SAE 4)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre-
sponding properties.
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
- SAE ( p. 134) (SAE 2.5)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre-
sponding properties.
Super unleaded (ROZ 95)
Standard/classification
- DIN EN 228 (ROZ 95)
Guideline
- Only use super unleaded fuel that matches or is equivalent to the specified standard.
- Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15, E25, E85,
E100).
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
Standard/classification
- DIN EN 228
- JASO FD ( p. 134) (1:60)
Mixture ratio
1:60
Engine oil, 2-stroke ( p. 130)
Super unleaded (ROZ 95) ( p. 131)
Recommended supplier
MOTOREX®
- Cross Power 2T
131
25
AUXILIARY SUBSTANCES
Air filter cleaner
Recommended supplier
MOTOREX®
- Racing Bio Dirt Remover
Chain cleaner
Recommended supplier
MOTOREX®
- Chain Clean
Fuel additive
Recommended supplier
MOTOREX®
- Fuel Stabilizer
High viscosity grease
Recommended supplier
SKF®
- LGHB 2
Long-life grease
Recommended supplier
MOTOREX®
- Bike Grease 2000
Motorcycle cleaner
Recommended supplier
MOTOREX®
- Moto Clean
Off-road chain spray
Recommended supplier
MOTOREX®
- Chainlube Offroad
Oil for foam air filter
Recommended supplier
MOTOREX®
- Racing Bio Liquid Power
Preserving materials for paints, metal and rubber
Recommended supplier
MOTOREX®
- Moto Protect
Silicone spray
Recommended supplier
MOTOREX®
- Silicone Spray
132
AUXILIARY SUBSTANCES
25
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX®
- Quick Cleaner
Special grease (00062010053)
Recommended supplier
Klüber Lubrication®
- Klüberfood NH1 34-401
Universal oil spray
Recommended supplier
MOTOREX®
- Joker 440 Synthetic
133
26
STANDARDS
JASO T903 MA2
Different technical development directions required a separate specification for motorcycles - the JASO T903 MA2 stan-
dard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle
specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high perfor-
mance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to
their viscosity. The viscosity describes only one property of oil and says nothing about quality.
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing.
Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme
operating conditions.
134
INDEX OF SPECIAL TERMS
27
OBD
On-board diagnosis
Vehicle system, which monitors the specified parameters
of the vehicle electronics
135
28
LIST OF ABBREVIATIONS
Art. no.
Article number
ca.
circa
cf.
compare
e.g.
for example
etc.
et cetera
i.a.
inter alia
no.
number
poss.
possibly
136
LIST OF SYMBOLS
29
29.1
Yellow and orange symbols
Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also repre-
sented by yellow or orange symbols.
Malfunction indicator lamp lights up/flashes orange - The OBD has detected a malfunction in the vehi-
cle electronics.
Malfunction indicator lamp lights up/flashes orange - The OBD has detected a malfunction in the vehi-
cle electronics.
137
INDEX
INDEX
Chain guide
1
checking
68
12-V battery
Chain tension
charging
95
adjusting
67
starting power
21
checking
67
12-V battery
Clutch
installing
94
fluid level, checking/correcting
73
removing
93
fluid, changing
74
A
Clutch lever
14
basic position, adjusting
73
Accessories
9
Cold start button
17
Air filter
Combination instrument
15
cleaning
60
installing
60
Compression damping
removing
59
adjusting the fork
40
Air filter box
Coolant
cleaning
60
changing
104
draining
102
Air filter box cover
refilling
103
installing
58
preparing for securing
61
Coolant level
removing
58
checking
101-102
Air suspension XACT
38
Cooling system
101
Customer service
9
Antifreeze
checking
101
D
Auxiliary substances
9
Diagnostics connector
98
B
Difficult operating conditions
22
dry sand
22
Basic chassis setting
high temperature
24
rider's weight, checking with
32
low temperature
24
Blink code
120-121
muddy surfaces
23
Brake discs
slow speed
24
checking
76
snow
24
wet sand
23
Brake fluid
wet surfaces
23
adding to rear brake
83
front brake, adding
77
E
Brake fluid level
Engine
front brake, checking
77
running in
21
rear brake, checking
83
Engine number
12
Brake lining retainers
Engine sprocket
of front brake, checking
79
checking
68
of rear brake, checking
84
Environment
8
Brake linings
Exhaust control
changing on the rear brake
85
end positions, programming
99
of front brake, changing
79
of front brake, checking
79
F
of rear brake, checking
84
Figures
9
C
Foot brake lever
19
basic position, adjusting
82
Capacity
free travel, checking
81
coolant
124
gear oil
112, 124
Fork
air pressure, adjusting
38
Chain
article number
12
checking
68
basic setting, checking
38
cleaning
66
138
INDEX
Fork legs
Indicator lamps
bleeding
46
overview
15
dust boots, cleaning
46
Intended use
6
installing
48
L
removing
47
Fork protector
Link fork
checking
71
installing
47
removing
47
Lower triple clamp
Frame
installing
49
removing
48
checking
71
Frame protector
Low-speed compression damping
adjusting the shock absorber
32
installing
57
removing
57
M
Front fender
Main fuse
installing
53
changing
96
removing
53
Main silencer
Front wheel
glass fiber yarn filling, changing
62
installing
88
installing
61
removing
87
removing
61
Fuel screen
Manufacturer warranty
9
changing
110
Mapping
Fuel tank
changing
106
installing
64
Misuse
6
removing
63
Motorcycle
Fuel tank filler cap
cleaning
114
closing
17
lift stand, removing from
45
opening
16
raising with lift stand
45
Fuel, oils, etc
9
O
Fuse
Overview of indicator lamps
15
main fuse, changing
96
Owner's Manual
8
of the fuel pump, changing
97
P
G
Play in throttle cable
Gear oil
adjusting
107
adding
112
checking
106
changing
111
Plug-in stand
19
Gear oil level
checking
111
Preparing for use
advice on preparing for first use
20
H
after storage
117
Hand brake lever
14
checks and maintenance measures when preparing
basic position, adjusting
76
for use
25
free travel, checking
76
Protective clothing
7
Handlebar position
42
R
adjusting
42
Rear sprocket
High-speed compression damping
checking
68
adjusting the shock absorber
33
Rear wheel
I
installing
89
Idle speed
removing
88
adjusting
108
Rebound damping
Idle speed adjusting screw
18
adjusting the fork
41
Implied warranty
9
adjusting the shock absorber
34
139
INDEX
Refueling
engine tightening torques
123
fuel
29
fork
125
shock absorber
126
Riding sag
tires
125
adjusting
37
Throttle cable routing
Right side panel
checking
71
installing
58
removing
57
Throttle grip
14
Rubber grip
Tire condition
checking
72
checking
91
S
Tire pressure
checking
91
Safe operation
7
Transporting
28
Seat
Troubleshooting
118-119
mounting
56
removing
56
U
Service
9
Use definition
6
Shift lever
18
V
adjusting the basic position
109
Vehicle identification number
12
basic position, checking
108
View of vehicle
Shock absorber
front left
10
adjusting the spring preload
36
rear right
11
article number
13
W
checking static sag
35
compression damping, general
32
Work rules
7
installing
55
removing
53
riding sag, checking
35
Side stand
19
Spare parts
9
Spoke tension
checking
92
Start button
15
Start number plate
installing
53
removing
52
Starting
25
Starting power of lithium-ion batteries
at
low
temperatures
21
Steering head bearing
lubricating
52
Steering head bearing play
adjusting
52
checking
51
Steering head label
12
Stop button
14
Storage
116
T
Technical specifications
capacities
124
chassis
124
chassis tightening torques
128
electrical system
125
engine
122
140