GASGAS MC 450F / EX 450F. OWNER'S MANUAL (2024)
TABLE OF CONTENTS
TABLE OF CONTENTS
1
MEANS OF REPRESENTATION
5
6.18
Factory Start (FACTORY EDITION)
20
1.1
Symbols used
5
7
PREPARING FOR USE
21
1.2
Formats used
5
7.1
Advice on preparing for first use
21
2
SAFETY ADVICE
6
7.2
Running in the engine
22
7.3
Starting power of lithium-ion batteries
2.1
Use definition - intended use
6
at low temperatures
22
2.2
Misuse
6
7.4
Preparing the vehicle for difficult
2.3
Safety advice
6
operating conditions
23
2.4
Degrees of risk and symbols
6
7.5
Preparing the vehicle for rides on dry
2.5
Tampering warning
7
sand
23
2.6
Safe operation
7
7.6
Preparing the vehicle for rides on wet
2.7
Protective clothing
7
sand
24
2.8
Work rules
8
7.7
Preparing the vehicle for rides on wet
2.9
Environment
8
and muddy circuits
24
2.10
Owner's Manual
8
7.8
Preparing vehicle for high temperatures
or slow riding
25
3
IMPORTANT NOTES
9
7.9
Preparing the vehicle for low
3.1
Manufacturer warranty, implied
temperatures or snow
25
warranty
9
8
RIDING INSTRUCTIONS
26
3.2
Fuel, auxiliary substances
9
3.3
Spare parts, technical accessories
9
8.1
Checks and maintenance measures
3.4
Service
9
when preparing for use
26
3.5
Figures
9
8.2
Starting the vehicle
26
3.6
Customer service
9
8.3
Activating launch control
(FACTORY EDITION)
27
4
VIEW OF VEHICLE
10
8.4
Activating traction control
4.1
View of vehicle, front left (example)
10
(FACTORY EDITION)
28
4.2
View of vehicle, rear right (example)
11
8.5
Activating the Factory Start
(FACTORY EDITION)
28
5
SERIAL NUMBERS
12
8.6
Starting off
29
5.1
Vehicle identification number
12
8.7
Quickshifter (FACTORY EDITION)
29
5.2
Steering head label
12
8.8
Activating the quickshifter
(FACTORY EDITION)
29
5.3
Engine number
12
8.9
Shifting, riding
30
5.4
Fork article number
12
8.10
Applying the brakes
31
5.5
Shock absorber article number
13
8.11
Stopping, parking
31
6
CONTROLS
14
8.12
Transporting
32
8.13
Refueling
32
6.1
Clutch lever
14
6.2
Hand brake lever
14
9
SERVICE SCHEDULE
34
6.3
Throttle grip
14
6.4
Stop button
14
9.1
Additional information
34
9.2
Service schedule
34
6.5
Start button
15
6.6
Combination switch
10
TUNING THE CHASSIS
36
(FACTORY EDITION)
15
10.1
Checking the basic chassis setting with
6.7
Overview of indicator lamps (MC-F /
EX-F)
15
the rider's weight
36
6.8
Overview of indicator lamps
10.2
Air suspension XACT (All MC-F models)
36
(FACTORY EDITION)
16
10.3
Compression damping of the shock
6.9
Combination instrument
16
absorber
37
10.4
Adjusting the low-speed compression
6.10
Opening the fuel tank filler cap
16
damping of the shock absorber
37
6.11
Closing the fuel tank filler cap
17
10.5
Adjusting the high-speed compression
6.12
Cold start button
18
damping of the shock absorber
38
6.13
Idle speed adjusting screw
18
10.6
Adjusting the rebound damping of the
6.14
Shift lever
19
shock absorber
38
6.15
Foot brake lever
19
10.7
Measuring the dimension of the rear
6.16
Plug-in stand (All MC-F models)
19
wheel unloaded
39
6.17
Side stand (EX-F)
20
2
TABLE OF CONTENTS
10.8
Checking the static sag of the shock
11.36
Changing the glass fiber yarn filling of
absorber
40
the main silencer
72
10.9
Checking the rider sag of the shock
11.37
Removing the fuel tank
74
absorber
40
11.38
Installing the fuel tank
75
10.10
Adjusting the spring preload of the
11.39
Checking for chain dirt accumulation
77
shock absorber
41
11.40
Cleaning the chain
77
10.11
Adjusting the riding sag
42
11.41
Checking the chain tension
78
10.12
Checking the basic setting of the fork
43
11.42
Adjusting the chain tension
78
10.13
Adjusting the fork air pressure
43
11.43
Checking the chain, rear sprocket,
10.14
Adjusting the compression damping of
engine sprocket, and chain guide
79
the fork
45
11.44
Checking the frame
82
10.15
Adjusting the rebound damping of the
11.45
Checking the link fork
82
fork
46
11.46
Checking the throttle cable routing
82
10.16
Handlebar position
47
11.47
Checking the rubber grips
83
10.17
Adjusting the handlebar position
47
11.48
Programming the quickshifter
84
11.49
Adjusting the basic position of the clutch
11
SERVICE WORK ON THE CHASSIS
50
lever
84
11.1
Raising the motorcycle with a lift stand
50
11.50
Checking/correcting the fluid level of
11.2
Removing the motorcycle from the lift
hydraulic clutch
84
stand
50
11.51
Changing the hydraulic clutch fluid
85
11.3
Bleeding the fork legs
51
12
BRAKE SYSTEM
87
11.4
Cleaning the dust boots of the fork legs
52
11.5
Removing the fork protector
52
12.1
Checking the free travel of the hand
11.6
Installing the fork protector
53
brake lever
87
11.7
Removing the engine guard
12.2
Adjusting the basic position of the hand
(FACTORY EDITION)
53
brake lever
87
11.8
Installing the engine guard
12.3
Checking the brake discs
87
(FACTORY EDITION)
53
12.4
Checking the front brake fluid level
88
11.9
Removing the frame protector
54
12.5
Adding front brake fluid
88
11.10
Installing the frame protector
54
12.6
Checking that the brake linings of the
11.11
Removing the fork legs
54
front brake are secured
90
11.12
Installing the fork legs
55
12.7
Changing the brake linings of the front
11.13
Removing the lower triple clamp
57
brake
90
11.14
Installing the lower triple clamp
57
12.8
Checking the free travel of foot brake
11.15
Checking the steering head bearing play ... 60
lever
92
11.16
Adjusting the steering head bearing
12.9
Adjusting the basic position of the foot
play
60
brake lever
93
11.17
Lubricating the steering head bearing
61
12.10
Checking the rear brake fluid level
94
11.18
Removing the start number plate
61
12.11
Adding rear brake fluid
94
11.19
Installing the start number plate
61
12.12
Checking that the brake linings of the
11.20
Removing the front fender
62
rear brake are secured
95
11.21
Installing the front fender
63
12.13
Changing the rear brake linings
96
11.22
Removing the shock absorber
63
13
WHEELS, TIRES
98
11.23
Installing the shock absorber
64
11.24
Removing the seat
66
13.1
Removing the front wheel
98
11.25
Mounting the seat
66
13.2
Installing the front wheel
100
11.26
Removing the right side panel
67
13.3
Removing the rear wheel
101
11.27
Installing the right side panel
67
13.4
Installing the rear wheel
102
11.28
Removing the air filter box cover
68
13.5
Checking the tire condition
104
11.29
Installing the air filter box cover
68
13.6
Checking tire pressure
104
11.30
Preparing air filter box cover for
13.7
Checking the spoke tension
105
securing
69
14
ELECTRICAL SYSTEM
106
11.31
Removing the air filter
70
11.32
Cleaning the air filter and air filter
14.1
Removing the 12-V battery
106
box
70
14.2
Installing the 12-V battery
107
11.33
Installing the air filter
71
14.3
Charging the 12-V battery
108
11.34
Removing the main silencer
71
14.4
Changing the main fuse
109
11.35
Installing the main silencer
72
14.5
Changing the fuse of the fuel pump
110
3
TABLE OF CONTENTS
14.6
Diagnostics connector
110
23.8
Shock absorber
144
14.7
Connectivity Unit Offroad (CUO)
111
23.8.1
MC-F
144
23.8.2
EX-F
144
15
COOLING SYSTEM
113
23.8.3
FACTORY EDITION
145
15.1
Cooling system
113
23.9
Chassis tightening torques
146
15.2
Checking the antifreeze and coolant
24
DECLARATIONS OF CONFORMITY CUO
level
113
(FACTORY EDITION)
148
15.3
Checking the coolant level
114
15.4
Draining the coolant
114
24.1
Country-specific declarations of
15.5
Refilling with coolant
115
conformity - Connectivity Unit Offroad ...
148
15.6
Changing the coolant
116
25
FCC STATEMENTS CUO (FACTORY EDITION)
149
16
TUNING THE ENGINE
118
25.1
FCC statements - Connectivity Unit
16.1
Checking the play in the throttle cable....
118
Offroad
149
16.2
Adjusting the play in the throttle
26
SUBSTANCES
150
cable
118
16.3
Adjusting the characteristic map of the
27
AUXILIARY SUBSTANCES
152
throttle response
119
28
STANDARDS
154
16.4
Adjusting the idle speed
121
16.5
Programming the throttle valve
29
INDEX OF SPECIAL TERMS
155
position
121
30
LIST OF ABBREVIATIONS
156
16.6
Checking the basic position of the shift
lever
122
31
LIST OF SYMBOLS
157
16.7
Adjusting the basic position of the shift
31.1
Yellow and orange symbols
157
lever
122
31.2
Green and blue symbols
157
17
SERVICE WORK ON THE ENGINE
124
31.3
White symbols
157
17.1
Changing the fuel screen
124
INDEX
160
17.2
Checking the engine oil level
125
17.3
Changing the engine oil and oil filter,
cleaning the oil screens
125
17.4
Adding engine oil
128
18
CLEANING, CARE
129
18.1
Cleaning the motorcycle
129
19
STORAGE
131
19.1
Storage
131
19.2
Putting into operation after storage
132
20
TROUBLESHOOTING
133
21
BLINK CODE
135
22
TROUBLESHOOTING CUO (FACTORY EDITION)
137
23
TECHNICAL SPECIFICATIONS
138
23.1
Engine
138
23.2
Engine tightening torques
138
23.3
Capacities
140
23.3.1
Engine oil
140
23.3.2
Coolant
140
23.3.3
Fuel
140
23.4
Chassis
141
23.5
Electrical system
142
23.6
Tires
142
23.7
Fork
142
23.7.1
MC-F
142
23.7.2
EX-F
142
23.7.3
FACTORY EDITION
143
4
MEANS OF REPRESENTATION
1
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g., of a work step or a function).
Indicates an unexpected reaction (e.g., of a work step or a function).
Indicates work that requires expert knowledge and technical understanding. In the interest of your own
safety, have this work performed by an authorized GASGAS Motorcycles workshop. Your motorcycle will
be cared for there to the highest degree by specially trained experts using the special tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates the end of an activity, including potential reworking.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name
Indicates a proprietary name.
Name®
Indicates a protected name.
Brand™
Indicates a brand available on the open market.
Underlined terms
Refer to technical details of the vehicle or indicate technical terms, which are
explained in the glossary.
5
2
SAFETY ADVICE
2.1
Use definition - intended use
(All MC-F models)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies
with the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
(EX-F)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies
with the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.
2.2
Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respec-
tive use.
2.3
Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction
and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the
relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do not
remove any information or warning labels. If they are missing, you or others may not recognize dangers and may
therefore be injured.
2.4
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate
measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
6
SAFETY ADVICE
2
2.5
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1
The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of
any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
2
the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1
Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust
gases.
2
Removal or puncturing of parts of the intake system.
3
Lack of proper maintenance.
4
Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those
specified by the manufacturer.
2.6
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
- Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
- Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when running the engine.
- Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become 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.
7
2
SAFETY ADVICE
2.8
Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with transpon-
der key) or the motor must be at a standstill (models without ignition lock or transponder key).
Special tools are necessary for certain tasks. If these special tools are not included in the scope of supply of the vehicle, the
special tools can be ordered using the specified article number. Example: bearing puller (15112017000)
Unless otherwise noted, normal conditions apply to all tasks and descriptions.
Ambient temperature
20 °C (68 °F)
Ambient air pressure
1,013 mbar (14.69 psi)
Relative air humidity
60 ± 5 %
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion
screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screw connections, a thread locker (e.g., Loctite®) is required. Observe the manufacturer's instruc-
tions.
If a thread locker (e.g. Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn
parts.
Ensure that the work area is clean and clean components before disassembly if necessary. Penetrating dirt can lead to
increased wear and consequential damage.
After completing a repair or service work, check the operating safety of the vehicle.
2.9
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of
the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of
others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and guidelines
of the country in which you are disposing of them.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regu-
lations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles dealer will be glad to
advise you.
2.10
Owner's Manual
Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful infor-
mation and many tips on how to operate, handle, and service your motorcycle. This is the only way to find out how best to
customize the vehicle for your own use and how you can protect yourself from injury.
Tip
Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need to.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized
GASGAS Motorcycles dealer.
The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be down-
loaded again by the new owner.
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate.
The Owner's Manual is also available for download from your authorized GASGAS Motorcycles dealer and on the GAS-
GAS Motorcycles website. A printed copy can also be ordered from your authorized GASGAS Motorcycles dealer.
International GASGAS Motorcycles website: http://www.gasgas.com
8
IMPORTANT NOTES
3
3.1
Manufacturer warranty, implied warranty
The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and
confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary dam-
age caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2
Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3
Spare parts, technical accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by
GASGAS Motorcycles and have them mounted by an authorized GASGAS Motorcycles workshop. GASGAS 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)
W00427-10
1 Hand brake lever ( p. 14)
2 Clutch lever ( p. 14)
3 Fuel tank filler cap
4 Air filter box cover
5 Cold start button ( p. 18)
6 Engine number ( p. 12)
7 Shift lever ( p. 19)
10
VIEW OF VEHICLE
4
4.2
View of vehicle, rear right (example)
W00428-10
1 Shock absorber compression adjuster
2 Stop button ( p. 14)
2 Start button ( p. 15)
3 Throttle grip ( p. 14)
4 Vehicle identification number ( p. 12)
4 Steering head label ( p. 12)
5 Fork article number ( p. 12)
6 Idle speed adjusting screw ( p. 18)
7 Foot brake lever ( p. 19)
8 Engine oil level viewer
9 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
Engine number 1 is located on the left side of the engine over the
engine sprocket.
H01047-10
5.4
Fork article number
The fork article number 1 is stamped on the inside of the axle clamp.
401947-10
12
SERIAL NUMBERS
5
5.5
Shock absorber article number
The shock absorber article number 1 is stamped on the top of the
shock absorber.
F03756-10
13
6
CONTROLS
6.1
Clutch lever
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
F03647-10
6.2
Hand brake lever
Hand brake lever 1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
F03648-10
6.3
Throttle grip
The throttle grip 1 is fitted on the right side of the handlebar.
F03648-11
6.4
Stop button
The stop button 1 is located on the right side of the handlebar.
Possible states
• The stop button is in the basic position - In this position, the
ignition circuit is closed and the engine can be started.
• Stop button pressed - In this position, the ignition circuit is inter-
rupted, a running engine stops, and a non-running engine will not
start.
F03650-11
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.
F03650-10
6.6
Combination switch (FACTORY EDITION)
The combination switch is fitted on the left side of the handlebar.
Possible states
1
STANDARD - STANDARD mapping is activated when the
indicator lamp A lights up.
1 TC
STANDARD with TC - STANDARD mapping with traction
control is activated when the indicator lamp A and the
TC indicator lamp light up.
2
ADVANCED - ADVANCED mapping is activated when the
indicator lamp B lights up.
2 TC
ADVANCED with TC - ADVANCED mapping with traction
control is activated when the indicator lamp B and the
TC indicator lamp light up.
The engine characteristic can be changed using button 1 and but-
ton 2 on the combination switch.
Traction control can be activated using the TC button 3 on the combi-
nation switch.
Launch control and the quickshifter can also be activated using the com-
bination switch.
F03761-10
6.7
Overview of indicator lamps (MC-F / EX-F)
Possible states
Malfunction indicator lamp lights up/flashes orange - The
OBD has detected a malfunction in the vehicle electronics.
The malfunction indicator lamp also lights up if traction
control is activated and the speed limiter intervenes.
W00429-10
15
6
CONTROLS
6.8
Overview of indicator lamps (FACTORY EDITION)
Possible states
Malfunction indicator lamp lights up/flashes orange - The
OBD has detected a malfunction in the vehicle electronics.
The malfunction indicator lamp also lights up if traction
control is activated and the speed limiter intervenes.
TC indicator lamp lights up orange - TC is enabled or is
currently intervening. The TC indicator lamp flashes if
launch control is activated.
QS indicator lamp lights up blue - The quickshifter is acti-
F03758-10
vated. The QS indicator lamp flashes when the quickshifter
is being programmed.
Indicator lamp A lights up white - STANDARD mapping is
activated.
Indicator lamp B lights up green - ADVANCED mapping is
activated.
6.9
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.
W00429-11
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.
6.10
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.
16
CONTROLS
6
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
- Turn fuel tank filler cap 1 counterclockwise and lift it off.
W00205-10
6.11
Closing the fuel tank filler cap
- Mount fuel tank filler cap 1 and turn it clockwise until the fuel
tank is tightly closed.
Info
Route fuel tank breather hose 2 without kinks.
W00206-10
17
6
CONTROLS
6.12
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.
W00244-10
6.13
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.
W00243-10
18
CONTROLS
6
6.14
Shift lever
Shift lever 1 is mounted on the left side of the engine.
401950-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
401950-13
6.15
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
6.16
Plug-in stand (All MC-F models)
The support for 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.
The tool can be attached to the plug-in stand holders.
H02629-10
19
6
CONTROLS
6.17
Side stand (EX-F)
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
6.18
Factory Start (FACTORY EDITION)
The Factory Start 1 is mounted on the right fork protector.
Possible states
• A Factory Start is deactivated - The fork is in the normal operat-
ing mode.
• B Factory Start is activated - The fork is compressed and the
front of the motorcycle is lowered.
Activating the Factory Start lowers the front of the motorcycle, which
then causes the front wheel to lift off the ground when accelerating.
When the fork compresses for the first time, the Factory Start lock but-
ton is released automatically. From this point on, the fork operates as if
the Factory Start were deactivated or not installed.
H04998-10
20
PREPARING FOR USE
7
7.1
Advice on preparing for first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
- Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
- Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
- Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with pro-
tectors on all rides.
- Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
- Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents 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 the motorcycle, remember that others may be disturbed by excessive noise.
-
Ensure that the pre-sale inspection work has been carried out by an authorized GASGAS Motorcycles workshop.
You will receive a delivery certificate when the vehicle is handed over.
-
Read the entire Owner's Manual before riding for the first time.
–
Get to know the controls.
–
Adjust the basic position of the clutch lever. ( p. 84)
–
Adjust the basic position of the hand brake lever. ( p. 87)
–
Adjust the basic position of the foot brake lever.
(
p. 93)
–
Adjust the basic position of the shift lever.
(
p. 122)
21
7
PREPARING FOR USE
- Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more challenging
ride.
Info
This vehicle 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.
- Also, ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
- Do not undertake 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.
(FACTORY EDITION)
- Do not carry the luggage.
- Do not exceed the maximum permissible weight and maximum permissible axle loads.
Guideline
Maximum permissible overall weight
335 kg (739 lb.)
Maximum permissible front axle load
145 kg (320 lb.)
Maximum permissible rear axle load
190 kg (419 lb.)
– Run the engine in. ( p. 22)
7.2
Running in the engine
– Do not exceed the specified engine speed and load during the running-in time.
Guideline
Maximum engine speed
During the first operating hour
7,000 rpm
Maximum engine performance
During the first 3 operating hours
≤ 75 %
– Avoid fully opening the throttle.
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 6 °C
(43 °F).
Several attempts to start may be required. Press the start button for
5 seconds, and wait 15 seconds between attempts. At low tempera-
tures, wait for 30 seconds. The pauses are necessary so that the heat
created can distribute through the lithium-ion battery and the lithium-
ion battery is not damaged.
The starting power increases as the battery warms up.
Always make sure the lithium-ion battery is charged to that there is
402555-01
enough power to spare for starting at low temperatures.
After 6 unsuccessful starting attempts, do not try again, and check the
vehicle for other malfunctions instead.
22
PREPARING FOR USE
7
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.
- Clean the air filter and air filter box.
(
p. 70)
Info
Check the air filter approx. every 30 minutes.
- Prepare air filter box cover for securing.
(
p. 69)
– 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. 23)
- Rides on wet sand. ( p. 24)
- Rides on wet and muddy circuits. ( p. 24)
- Rides at high temperatures or slow riding. ( p. 25)
- Riding at low temperatures and in snow. ( p. 25)
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
23
7
PREPARING FOR USE
- Clean the chain.
Chain cleaner ( p. 152)
- Mount the steel sprocket.
- Grease the chain.
Universal oil spray ( p. 153)
- Clean the radiator fins.
- Straighten the bent radiator fins carefully.
600868-01
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. 152)
- Mount the steel sprocket.
- Grease the chain.
Universal oil spray ( p. 153)
- Clean the radiator fins.
- Straighten the bent radiator fins carefully.
600868-01
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
- Mount the steel sprocket.
- Clean the motorcycle. ( p. 129)
- Straighten the bent radiator fins carefully.
600868-01
24
PREPARING FOR USE
7
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. 152)
- Clean the radiator fins.
600868-01
- Straighten bent radiator fins carefully.
- Check the coolant level. ( p. 114)
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
25
8
RIDING INSTRUCTIONS
8.1
Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
-
Check that the electrical system is functioning properly.
–
Check the engine oil level. ( p. 125)
–
Check the front brake fluid level. ( p. 88)
–
Check the rear brake fluid level. ( p. 94)
–
Check that the brake linings of the front brake are secured.
(
p. 90)
–
Check that the brake linings of the rear brake are secured. ( p. 95)
–
Check the function, condition, and free travel of the brake system.
H02217-01
-
Check the coolant level. ( p. 114)
–
Check for chain dirt accumulation. ( p. 77)
–
Check the chain, rear sprocket, engine sprocket, and chain guide.
(
p. 79)
–
Check the chain tension. ( p. 78)
–
Check the tire condition. ( p. 104)
–
Check the tire pressure. ( p. 104)
–
Check the spoke tension. ( p. 105)
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. 52)
–
Bleed the fork legs. ( p. 51)
–
Check the air filter and clean if necessary.
–
Check the settings of all controls and ensure that they can be oper-
ated smoothly.
-
Check all screws, nuts, and hose clips regularly for tightness.
–
Check the fuel level.
8.2
Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when running the engine.
- Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
- Always run the engine warm at a low speed.
26
RIDING INSTRUCTIONS
8
(All MC-F models)
- Remove plug-in stand 1.
H02629-10
(EX-F)
- Take the motorcycle off side stand 1 and secure the side
stand with rubber strap 2.
- Shift the transmission into neutral.
Condition
Ambient temperature: < 20 °C (< 68 °F)
- Push the cold start button in all the way.
401944-10
- Press start button
Info
Press the start button for a maximum of 5 seconds. Wait for
15 seconds before a further attempt at starting.
At low temperatures, wait for 30 seconds.
At temperatures below 6 °C (43 °F), several attempts at
starting may be necessary to warm-up the lithium-ion bat-
tery and thereby increase the starting power.
After 6 unsuccessful starting attempts, do not try again, and
400733-01
check the vehicle for other malfunctions instead.
During the starting process, the malfunction indicator lamp
lights up.
8.3
Activating launch control (FACTORY EDITION)
Info
The launch control helps the rider to generate optimum motorcycle acceleration at the beginning of a race. The
maximum speed of the engine with the throttle valve fully opened (full throttle) is reduced. After the start, it is
gradually increased up to the maximum engine speed. The clutch must be operated exactly as it would be without
launch control activated.
Condition
The motorcycle is stationary.
The engine is running at idle speed.
The transmission is in neutral.
27
8
RIDING INSTRUCTIONS
- Press and hold the TC button 1 and the QS button 2 simultane-
ously.
The TC indicator lamp and the QS indicator lamp flash when
launch control is activated.
Info
The launch control is deactivated automatically for a few
seconds after the vehicle has started.
Launch control is also deactivated in the following cases: if
F03760-13
the throttle valve is closed more than 1/3 of the way after
full throttle, and/or if there is no start within 3 minutes.
For safety reasons, the engine must be switched off for at
least 10 seconds before the launch control can be activated
again, regardless of whether the vehicle has been started or
not.
If the engine has already been running for some time, the
engine must first be restarted before the launch control can
be activated.
8.4
Activating traction control (FACTORY EDITION)
Info
The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion, particularly in
wet conditions.
When traction control is switched off, the rear wheel may spin more during high acceleration and on surfaces with
low grip.
Traction control can be switched on or off during the ride.
The setting most recently selected is activated again when restarting.
- Press the TC button 1 to switch traction control on or off.
Guideline
Engine speed
≤ 4,000 rpm
The TC indicator lamp lights up when traction control is acti-
vated.
F03760-11
8.5
Activating the Factory Start (FACTORY EDITION)
Warning
Danger of accidents The Factory Start actuator may freeze up in cold weather.
If the actuator freezes while Factory Start is activated, the fork will not decompress fully.
The greatly reduced suspension travel impairs the handling characteristic.
- Check that the actuator moves easily before activating the Factory Start.
- Activate the Factory Start shortly before starting.
28
RIDING INSTRUCTIONS
8
– Check lock button 1 to ensure it can move easily.
- Bend over the handlebars while sitting on the motorcycle. Grip the
rim and compress the fork. Press lock button 1 and decompress
slowly until the lock button engages in lock ring 2.
When the fork compresses for the first time, the lock button is
released automatically.
H04999-10
8.6
Starting off
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
8.7
Quickshifter (FACTORY EDITION)
When the quickshifter is activated, you can shift up without actuating
the clutch.
Info
The quickshifter is not activated when shifting up from first to
second gear, and the clutch lever must be used when shifting up
instead.
Even if the quickshifter is activated, you need to use the clutch
lever to shift down.
Because there is no need to close the throttle grip, uninterrupted gear
shifts are possible.
The quickshifter uses the shifter shaft position to check whether or not a
shift should be initiated, and sends a corresponding signal to the engine
control.
If the quickshifter is deactivated, the clutch needs to be actuated in the
normal way for each shift.
F03643-10
8.8
Activating the quickshifter (FACTORY EDITION)
- Press the QS button 1 to switch the quickshifter on or off.
The QS indicator lamp lights up when the quickshifter is acti-
vated.
Info
The quickshifter is not activated when shifting up from first
to second gear, and the clutch lever must be used when
shifting up instead.
Even if the quickshifter is activated, you need to use the
F03760-12
clutch lever to shift down.
29
8
RIDING INSTRUCTIONS
8.9
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 unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized
GASGAS Motorcycles workshop.
First-gear is used for starting off and for steep inclines.
- Shift into a higher gear when conditions allow (incline, road situa-
tion, etc.). To do so, release the throttle while simultaneously pulling
the clutch lever, shift into the next gear, release the clutch lever and
open the throttle.
- If the cold start button was pushed while starting, open the throttle
briefly and release the throttle grip or turn the throttle grip forward.
The cold start button goes to the basic position.
- 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.
- Only open the throttle as much as the engine can handle - abrupt
throttle grip 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 you are likely to be running at idle speed or
stationary for a long time.
Guideline
≥ 1 min
- Avoid frequent or lengthy slipping of the clutch. This causes the
engine oil, engine and cooling system to heat up.
- Ride at a low engine speed instead of at a high engine speed with a
slipping clutch.
Condition
Quickshifter activated.
- If the quickshifter is activated, you can shift up in the engine
speed range shown without pulling the clutch lever.
Info
The quickshifter is not activated when shifting up from
first to second gear, and the clutch lever must be used
when shifting up instead.
F03642-10
The minimum engine speed before shifting up is shown
in the figure in revolutions per minute.
Pull the shift lever to the stop quickly without changing
the throttle twist grip position.
Even if the quickshifter is activated, you need to use the
clutch lever to shift down.
If the shifting performance of the quickshifter starts to
decrease, it must be reprogrammed.
30
RIDING INSTRUCTIONS
8
8.10
Applying the brakes
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 you go 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.
8.11
Stopping, parking
Warning
Risk of injury People who act without authorization may not be familiar with the vehicle.
- Do not leave the vehicle unattended if the engine is running.
- Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become hot when the vehicle is operated.
- Do not touch any parts such as the exhaust system, radiator, engine, damper, or brake system before the vehi-
cle parts have cooled down.
- Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
- Park the vehicle on a firm and level surface.
- Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
- Do not park the vehicle near to materials which are highly flammable or explosive.
- Allow the vehicle to cool down before covering it.
- Apply the brakes on the motorcycle.
- Shift the transmission to the neutral position.
- Press and hold the stop button while the engine is idling until the engine stops.
- Park the motorcycle on firm ground.
31
8
RIDING INSTRUCTIONS
8.12
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.
(All MC-F models)
- Switch off the engine.
- Mount plug-in stand on the fork legs.
Plug-in stand (A46029094000)
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
- 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 firmly in contact with the fender and the tires.
Pay attention to the alignment of the plug-in stand to
the fender.
(EX-F)
401475-01
- Switch off the engine.
- Use tension belts or other suitable devices to secure the motor-
cycle against falling over or rolling away.
8.13
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.
32
RIDING INSTRUCTIONS
8
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
Note
Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged.
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems
with the fuel system.
- Refuel only with clean fuel that meets the specified standards. (Your authorized GASGAS Motorcycles workshop will be
glad to help.)
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
- Do not allow fuel to enter the groundwater, the soil, or the sewage system.
- Switch off the engine.
- Open the fuel tank filler cap. ( p. 16)
- Fill the fuel tank with fuel up to level A.
Guideline
35 mm (1.38 in)
Dimension A
Total fuel tank capacity, approx. (MC-F)
Super unleaded (ROZ 95) ( p. 151)
7.9 l (2.09 US gal)
Total fuel tank capacity, approx. (EX-F)
Super unleaded (ROZ 95) ( p. 151)
9 l (2.4 US gal)
401522-10
Total fuel tank capacity, approx. (FACTORY EDITION)
Super unleaded (ROZ 95) ( p. 151)
7.2 l (1.9 US gal)
– Close the fuel tank filler cap. ( p. 17)
33
9
SERVICE SCHEDULE
9.1
Additional information
Any further work that results from the service work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
If the vehicle is used in particularly harsh conditions such as heavy rain, mud, sand, snow, extreme temperatures, frequent
full load etc., shorter service intervals than those in the table may be necessary.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service
schedule can always be found on GASGAS Motorcycles Dealer.net. Your authorized GASGAS Motorcycles dealer will be glad
to advise you.
9.2
Service schedule
every 24 months
Every 90 operating hours
Every 45 operating hours
Every 15 operating hours
After 1 operating hour
Read out the fault memory using the GASGAS Motorcycles diagnostics tool.
○
●
●
●
●
Program the gear position sensor.
●
●
●
Check that the electrical system is functioning properly.
○
●
●
●
Check and charge the 12-V battery.
○
●
●
●
●
Check that the brake linings of the front brake are secured. ( p. 90)
○
●
●
●
●
Check that the brake linings of the rear brake are secured. ( p. 95)
○
●
●
●
●
Check the brake discs. ( p. 87)
○
●
●
●
●
Check the brake lines for damage and tightness.
○
●
●
●
●
Check the front brake fluid level. ( p. 88)
○
●
●
Change the front brake fluid.
●
●
Check the rear brake fluid level. ( p. 94)
○
●
●
Change the rear brake fluid.
●
●
Check/correct the fluid level of hydraulic clutch. ( p. 84)
●
Change the hydraulic clutch fluid.
(
p. 85)
●
●
Check the free travel of the hand brake lever. ( p. 87)
○
●
●
●
●
Check the free travel of the foot brake lever. ( p. 92)
○
●
●
●
●
Check the idle speed.
○
●
●
●
●
Change the engine oil and the oil filter, clean the oil screens.
(
p. 125)
○
●
●
●
●
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 for routing without kinks.
●
●
●
●
Check that the throttle cables are undamaged, routed without kinks, and set correctly.
●
●
●
●
Check the frame.
(
p. 82)
●
●
●
Check the link fork.
(
p. 82)
●
●
●
Check the fork bearing for play.
●
●
Check the shock absorber heim joint for play.
●
●
Check the shock absorber linkage.
●
●
●
Check the tire condition. ( p. 104)
●
●
●
●
Check the tire pressure. ( p. 104)
●
●
●
●
Check the wheel bearing for play.
●
●
●
Check the wheel hubs.
●
●
●
Check the rim run-out.
○
●
●
●
Check the spoke tension. ( p. 105)
○
●
●
●
34
SERVICE SCHEDULE
9
every 24 months
Every 90 operating hours
Every 45 operating hours
Every 15 operating hours
After 1 operating hour
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 79)
○
●
●
●
Check the chain tension. ( p. 78)
○
●
●
●
●
Grease all moving parts (e.g., hand lever, chain,...) and check for smooth operation.
○
●
●
●
●
Change the spark plug and spark plug connector.
●
●
Check the valve clearance.
○
●
●
Change the fuel filter.
●
●
Check the clutch.
●
●
●
Clean the air filter and air filter box.
(
p. 70)
●
●
●
●
Check the funnel in the inlet sleeve in the air filter box.
●
●
●
●
Change the glass fiber yarn filling of the main silencer.
(
p. 72)
●
●
Service the fork. (All MC-F models)
●
●
Service the fork. (EX-F)
●
●
Perform the shock absorber service.
●
●
Check all screws, nuts, and hose clips for a tight fit.
○
●
●
●
●
Change the fuel screen.
(
p. 124)
○
●
●
●
●
Check the fuel pressure.
○
●
●
●
Check the antifreeze and coolant level. ( p. 113)
●
●
Check the coolant level. ( p. 114)
○
●
Change the coolant. ( p. 116)
●
Check the steering head bearing play. ( p. 60)
○
●
Lubricate the steering head bearing.
(
p. 61)
●
●
●
Perform minor engine service including removing and installing the engine. (Change the piston,
●
●
check/measure the cylinder. Check the cylinder head. Check the camshafts and valve train sys-
tem components. Check the timing assembly. Change the radial shaft seal rings of the water
pump. Change the crankshaft seal ring. Change the intake flange. Change inlet sleeve.
Perform major engine service, engine is removed. (Change valves, valve springs, valve spring
●
seats, and valve spring retainer. Change the connecting rod, conrod bearing and crank pin.
Check the transmission and the shift mechanism. Check the oil pressure control valve. Change
the suction pump. Check the force pump and lubrication system. Change the timing chain.
Change all engine bearings and all gaskets. Change the freewheel.)
Final check: check vehicle for operating safety.
○
●
●
●
●
Take a test ride.
○
●
●
●
●
Read out the fault memory after the test ride using the GASGAS Motorcycles diagnostics tool.
○
●
●
●
●
Make a service entry in GASGAS Motorcycles Dealer.net.
○
●
●
●
●
○ One-time interval
● Periodic interval
35
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 pretension of the shock absorber, but in the case of large
weight differences, the springs must be replaced.
401030-01
10.2
Air suspension XACT (All MC-F models)
Air suspension WP 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.
F03629-01
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.
36
TUNING THE CHASSIS
10
10.3
Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension
compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel sus-
pension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus,
modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.
10.4
Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.
- Turn adjuster 1 clockwise all the way to the stop.
- Turn counterclockwise by the number of clicks corresponding to the
shock absorber type.
Guideline
Lowspeed compression damping (MC-F)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
F03639-11
Lowspeed compression damping (EX-F)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Lowspeed compression damping (FACTORY EDITION)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
37
10
TUNING THE CHASSIS
10.5
Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the high speed compression adjuster can be seen in the fast compression of the shock absorber.
- 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-F)
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
F03639-10
Highspeed compression damping (EX-F)
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Highspeed compression damping (FACTORY EDITION)
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
10.6
Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
38
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
Rebound damping (MC-F)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
F03640-10
Rebound damping (EX-F)
Comfort
17 clicks
Standard
15 clicks
Sport
13 clicks
Rebound damping (FACTORY EDITION)
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.
10.7
Measuring the dimension of the rear wheel unloaded
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
- Position the sag gage in the rear axle and measure the distance to
marking SAG on the rear fender.
Sag gauge (00029090200)
- Note the value as dimension A.
F03630-10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 50)
39
10
TUNING THE CHASSIS
10.8
Checking the static sag of the shock absorber
- Measure dimension A of rear wheel unloaded. ( p. 39)
- 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-F)
35 mm (1.38 in)
Static sag (EX-F)
35 mm (1.38 in)
Static sag (FACTORY EDITION)
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. 41)
402416-10
10.9
Checking the rider sag of the shock absorber
- Measure dimension A of rear wheel unloaded. ( p. 39)
- With another person holding the motorcycle, the rider, wearing full
protective clothing, sits on the seat in a normal sitting position (feet
on footrests) and bounces up and down a few times.
The rear wheel suspension levels out.
- Another person again measures the distance between the rear axle
and marking SAG on the rear fender using the sag gage.
- Note the value as dimension C.
Info
The rider sag is the difference between measurements A
and C.
- Check the rider sag.
Riding sag (MC-F)
105 mm (4.13 in)
Riding sag (EX-F)
105 mm (4.13 in)
Riding sag (FACTORY EDITION)
105 mm (4.13 in)
402417-10
» If the rider sag differs from the specified measurement:
- Adjust the rider sag.
(
p. 42)
40
TUNING THE CHASSIS
10
10.10
Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
- Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
Note the current adjustment before changing the spring preload - e.g. measure the spring length.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
- Remove main silencer. ( p. 71)
- Remove the shock absorber.
(
p. 63)
– 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-F)
8 mm (0.31 in)
Spring preload (EX-F)
8 mm (0.31 in)
Spring preload (FACTORY EDI-
8 mm (0.31 in)
TION)
F03627-10
Info
Depending on the static sag and/or the rider sag, it may be
necessary to increase or decrease the spring preload.
- Tighten screw 1.
Guideline
Screw, shock absorber
M5
5 Nm (3.7 lbf ft)
adjusting ring
Finishing work
- Install the shock absorber.
(
p. 64)
– Check the free travel of the foot brake lever. ( p. 92)
- Install the main silencer. ( p. 72)
- Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
41
10
TUNING THE CHASSIS
- Remove the motorcycle from the lift stand. ( p. 50)
10.11
Adjusting the riding sag
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
- Remove main silencer. ( p. 71)
- Remove the shock absorber.
(
p. 63)
– After removing the shock absorber, clean it thoroughly.
Main work
- Select and mount a suitable spring.
Guideline
Spring rate (MC-F)
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 (EX-F)
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.)
Spring rate (FACTORY EDITION)
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. 64)
– Check the free travel of the foot brake lever. ( p. 92)
- Install the main silencer. ( p. 72)
- Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
- Check the static sag of the shock absorber. ( p. 40)
- Check the rider sag of the shock absorber. ( p. 40)
- Adjust the rebound damping of the shock absorber. ( p. 38)
- Remove the motorcycle from the lift stand. ( p. 50)
42
TUNING THE CHASSIS
10
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
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.
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. 50)
Main work
(MC-F)
- 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
S05322-10
accessory pack.
- 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.
43
10
TUNING THE CHASSIS
Guideline
Air pressure
10.4 bar (151 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.
(FACTORY EDITION)
- 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.
W00638-10
- 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.
44
TUNING THE CHASSIS
10
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. 50)
10.14
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
(All MC-F models)
- 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.
W00250-12
Guideline
Compression damping (MC-F)
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Compression damping (FACTORY EDITION)
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Info
Turn clockwise to increase damping; turn counterclock-
wise to reduce damping during compression.
(EX-F)
- Turn adjusters 1 clockwise all the way to the stop.
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.
W00250-10
45
10
TUNING THE CHASSIS
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.
10.15
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
(All MC-F models)
- 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.
F03633-10
Guideline
Rebound damping (MC-F)
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Rebound damping (FACTORY EDITION)
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.
(EX-F)
- Turn adjusters 1 clockwise all the way to the stop.
Info
Adjusters 1 are located at the bottom end of the fork
legs.
- Turn counterclockwise by the number of clicks corresponding to
the fork type.
W00249-10
46
TUNING THE CHASSIS
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.
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.
47
10
TUNING THE CHASSIS
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 and lines.
- Remove the screws 7 and bushing 6. Take off handlebar sup-
port 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
48
TUNING THE CHASSIS
10
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.
49
11
SERVICE WORK ON THE CHASSIS
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.
(MC-F)
- Remove the plug-in stand and lift up the motorcycle by the
frame underneath the engine.
Lift stand (A54029955100)
Neither wheel is in contact with the ground.
(FACTORY EDITION)
- Remove the plug-in stand and lift up the motorcycle by the
motor guard underneath the engine.
401942-01
Lift stand (A54029955100)
Neither wheel is in contact with the ground.
(EX-F)
- Fold in the side stand and 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.
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.
(All MC-F models)
- 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.
Plug-in stand (A46029094000)
Info
H02629-10
The plug-in stand is included.
Remove the plug-in stand before riding.
50
SERVICE WORK ON THE CHASSIS
11
(EX-F)
- 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 the rubber strap.
401943-10
11.3
Bleeding the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
(MC-F)
- Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
F03665-10
(FACTORY EDITION)
- Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
W00636-12
(EX-F)
- Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
- Tighten the bleeder screws.
W00250-11
Finishing work
- Remove the motorcycle from the lift stand. ( p. 50)
51
11
SERVICE WORK ON THE CHASSIS
11.4
Cleaning the dust boots of the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Remove the fork protector. ( p. 52)
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.
F03666-10
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. 153)
- Press the dust boots back into their installation position.
- Remove excess oil.
Finishing work
- Install the fork protector. ( p. 53)
- Remove the motorcycle from the lift stand. ( p. 50)
11.5
Removing the fork protector
- Remove screws 1 and take off the clamp.
- Remove screws 2 and take off the left fork protector.
- Remove screws 3 and take off the right fork protector.
W00204-10
52
SERVICE WORK ON THE CHASSIS
11
11.6
Installing the fork protector
- Position the fork protector on left fork leg. Mount and tighten
screws 1.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Position the brake line and the clamp. Mount and tighten
screws 2.
- Position the fork protector on the right fork leg. Mount and tighten
W00204-11
screws 3.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
11.7
Removing the engine guard (FACTORY EDITION)
- Remove screws 1 with the bushings.
- Remove screws 2. Take off the engine guard.
W00431-10
11.8
Installing the engine guard (FACTORY EDITION)
- Position the engine guard on the frame.
- Mount screws 1, but do not tighten yet.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Mount screws 2 with bushings, but do not tighten yet.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
W00431-10
chassis
The engine guard is directed evenly toward the front.
- Tighten all the screws of the engine guard.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
53
11
SERVICE WORK ON THE CHASSIS
11.9
Removing the frame protector
- Remove the cable ties.
- Remove screws 1 with the bushings.
- Take off the left frame protector.
- Push the right frame protector to the front and take off at the bot-
tom.
W00430-10
11.10
Installing the frame protector
- Position the left frame protector.
- Insert the right frame protector from below and push it to the rear.
- Mount screws 1 with the bushings and tighten.
Guideline
Screw, frame protector
M5
3 Nm (2.2 lbf ft)
– Secure the frame protector with cable ties.
W00430-11
11.11
Removing the fork legs
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Remove the front wheel.
(
p. 98)
Main work
- Remove screws 1 and take off the clamp.
- Remove screws 2 and take off the brake caliper.
- Allow the brake caliper and the brake line to hang loosely to the
side.
Info
Do not actuate the hand brake lever when the front wheel is
removed.
S05330-10
(FACTORY EDITION)
- Detach rubber strap A and the Connectivity Unit from the
right fork leg and hang to the side.
W00590-11
54
SERVICE WORK ON THE CHASSIS
11
– Loosen screws 3. Remove the left fork leg.
- Loosen screws 4. Remove the right fork leg.
W00432-10
11.12
Installing the fork legs
Main work
(MC-F)
- 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
F03665-11
fork legs. The second milled groove (from the top) must
be flush with the upper edge of the upper triple clamp.
The air suspension is located in the left fork leg. The
pressure and rebound damping is located in the right
fork leg.
(FACTORY EDITION)
- 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
W00636-10
be flush with the upper edge of the upper triple clamp.
The air suspension is located in the left fork leg. The
pressure and rebound damping is located in the right
fork leg.
(EX-F)
- Position the fork legs.
Air bleeder screw 1 of the fork leg is positioned to 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.
W00250-11
The pressure and rebound damping is located in the left
and right fork leg.
55
11
SERVICE WORK ON THE CHASSIS
(MC-F / EX-F)
- Tighten screws 2.
Guideline
Screw, top triple
M8
20 Nm (14.8 lbf ft)
clamp
- Tighten screws 3.
Guideline
Screw, bottom triple
M8
15 Nm (11.1 lbf ft)
W00432-11
clamp
(FACTORY EDITION)
- Tighten screws 2.
Guideline
Screw, top triple
M8
17 Nm (12.5 lbf ft)
clamp
- Tighten screws 3.
Guideline
Screw, bottom triple
M8
12 Nm (8.9 lbf ft)
clamp
(FACTORY EDITION)
- Fit rubber strap B with the Connectivity Unit to the right fork
leg.
Guideline
Distance to the upper triple
19 mm (0.75 in)
clamp
W00590-10
- 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.
S05330-11
Finishing work
- Install the front wheel.
(
p. 100)
56
SERVICE WORK ON THE CHASSIS
11
11.13
Removing the lower triple clamp
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Remove the front wheel.
(
p. 98)
– Remove the fork legs.
(
p. 54)
– Remove the start number plate. ( p. 61)
- Remove the front fender. ( p. 62)
- Take off the handlebar cushion.
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 place to one
side.
Info
W00434-10
Cover the components to protect them against damage.
Do not kink the cables or lines.
- Remove steering head seal 4.
- Remove the lower triple clamp with steering stem.
- Remove the upper steering head bearing.
S05333-10
11.14
Installing the lower triple clamp
Main work
- Clean the bearing and sealing elements, check for damage, and
grease.
High viscosity grease ( p. 152)
- Insert the lower triple clamp with the steering stem. Mount upper
steering head bearing.
- Push on steering head seal 1.
F03661-10
57
11
SERVICE WORK ON THE CHASSIS
- 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
W00435-10
- 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
(MC-F / EX-F)
Screw, bottom triple
M8
15 Nm (11.1 lbf ft)
clamp
(FACTORY EDITION)
Screw, bottom triple
M8
12 Nm (8.9 lbf ft)
clamp
W00433-11
- Tighten screw 2.
Guideline
Screw, top steering
M20x1.5
12 Nm (8.9 lbf ft)
head
W00436-10
- Mount and tighten screw 5.
Guideline
Screw, top steer-
M8
20 Nm (14.8 lbf ft)
ing stem
Loctite®243™
W00437-10
58
SERVICE WORK ON THE CHASSIS
11
– Using a plastic hammer, tap lightly on the upper triple clamp to
avoid stresses.
- Tighten screws 6.
Guideline
(MC-F / EX-F)
Screw, top triple
M8
20 Nm (14.8 lbf ft)
clamp
(FACTORY EDITION)
W00433-10
Screw, top triple
M8
17 Nm (12.5 lbf ft)
clamp
- Mount and tighten screw 7.
(FACTORY EDITION)
- Fit rubber strap B with the Connectivity Unit to the right fork
leg.
Guideline
Distance to the upper triple
19 mm (0.75 in)
clamp
W00590-10
- 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.
S05330-12
Finishing work
- Install the front fender. ( p. 63)
- Mount the handlebar cushion.
- Install the start number plate. ( p. 61)
- Install the front wheel.
(
p. 100)
– Check the wiring harness, cables, and brake and clutch lines for free-
dom of movement and correct routing.
- Check the steering head bearing play. ( p. 60)
- Remove the motorcycle from the lift stand. ( p. 50)
59
11
SERVICE WORK ON THE CHASSIS
11.15
Checking the steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages com-
ponents.
- Correct incorrect steering head bearing play immediately. (Your authorized GASGAS Motorcycles workshop will
be glad to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing
seats in the frame can become damaged over time.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
- Move the handlebar to the straight-ahead position. Move the fork
legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
- Adjust the steering head bearing play.
(
p. 60)
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire
H01167-01
steering range. There should be no detectable detent positions.
» If detent positions are detected:
- Adjust the steering head bearing play.
(
p. 60)
– Check the steering head bearing and adjust if necessary.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 50)
11.16
Adjusting the steering head bearing play
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Take off 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
W00438-10
avoid stresses.
- Mount and tighten screw 2.
Guideline
Screw, top steer-
M8
20 Nm (14.8 lbf ft)
ing stem
Loctite®243™
– Tighten screws 1.
60
SERVICE WORK ON THE CHASSIS
11
Guideline
(MC-F / EX-F)
Screw, top triple
M8
20 Nm (14.8 lbf ft)
clamp
(FACTORY EDITION)
Screw, top triple
M8
17 Nm (12.5 lbf ft)
clamp
- Check the steering head bearing play. ( p. 60)
Finishing work
- Mount the handlebar cushion.
- Remove the motorcycle from the lift stand. ( p. 50)
11.17
Lubricating the steering head bearing
- Remove the lower triple clamp.
(
p. 57)
– Install the lower triple clamp.
(
p. 57)
Info
The steering head bearing is cleaned and lubricated in the
course of removal and installation of the lower triple clamp.
H02387-01
11.18
Removing the start number plate
- Remove screw 1.
- Unhook the start number plate from the brake line and remove it.
W00195-10
11.19
Installing the start number plate
- Position the brake line in the holder A on the start number plate.
- Position the start number plate. Mount and tighten screw 1.
The holding lugs engage in the fender.
W00196-10
61
11
SERVICE WORK ON THE CHASSIS
11.20
Removing the front fender
Preparatory work
- Remove the start number plate. ( p. 61)
Main work
(FACTORY EDITION)
- Disconnect plug-in connector A (antenna of the Connectivity
Unit).
W00589-10
- Remove screws 1 and 2. Take off the front fender.
F03675-10
62
SERVICE WORK ON THE CHASSIS
11
11.21
Installing the front fender
Main work
- Position the front fender. Mount and tighten screws 1 and 2.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
F03675-10
(FACTORY EDITION)
- Join plug-in connector A (antenna of the Connectivity Unit).
W00589-10
Finishing work
- Install the start number plate. ( p. 61)
11.22
Removing the shock absorber
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
- Remove main silencer. ( p. 71)
Main work
- Remove screw 1.
- Remove fitting 2.
Info
Raise the swingarm slightly to be able to remove the screws
more easily.
W00186-10
63
11
SERVICE WORK ON THE CHASSIS
- Remove screws 3.
- Pull off brake cylinder from the push rod.
W00187-10
- Remove the connecting link of the chain.
- Take off the chain.
Info
Cover the components to protect them against damage.
F03702-01
- Remove nut 4 and the swingarm pivot.
- Push the link fork back and secure it against falling over.
W00188-10
- Hold the shock absorber and remove screw 5.
- Remove the shock absorber carefully at the bottom.
W00218-10
11.23
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™
W00219-10
64
SERVICE WORK ON THE CHASSIS
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)
F03705-10
- Mount the chain.
- Connect the chain with connecting link 3.
Guideline
The closed side of the chain joint lock must face in the direction
of travel.
F03702-12
- Position the brake cylinder.
Push rod 4 engages in the brake cylinder.
Info
Ensure that the dust boot is correctly seated.
- Mount and tighten screws 5.
Guideline
F03706-10
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
- Position the angle lever and linkage lever.
- Mount and tighten fitting 6.
Guideline
Nut, linkage lever on
M16x1.5
80 Nm (59 lbf ft)
angle lever
Info
Pay attention to flat area B.
F03704-10
- Mount and tighten screw 7.
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
- Check the free travel of the foot brake lever. ( p. 92)
- Install the main silencer. ( p. 72)
- Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
65
11
SERVICE WORK ON THE CHASSIS
- Remove the motorcycle from the lift stand. ( p. 50)
11.24
Removing the seat
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.
Preparatory work
- Remove the air filter box cover. ( p. 68)
Main work
- Remove screw 1.
W00439-10
- Slide the seat toward the rear and lift it off.
W00439-11
11.25
Mounting the seat
Main work
- Attach the seat to the collar bushings and simultaneously slide it
forward.
The holding lugs engage in the recesses.
- Make sure the seat is latched in place correctly.
W00440-10
66
SERVICE WORK ON THE CHASSIS
11
– Mount and tighten screw and lock washer 1.
Guideline
Screw, seat fixing
M6
8 Nm (5.9 lbf ft)
W00439-10
Finishing work
- Install the air filter box cover. ( p. 68)
11.26
Removing the right side panel
Preparatory work
- Remove the frame protector. ( p. 54)
Main work
- Detach right side panel 1 in area A and slide it in area B to the
rear.
- Take the right side panel off.
W00441-10
11.27
Installing the right side panel
Main work
- Position right side panel 1.
- Position side panel in area B and slide it forward.
- Press the side panel in area A into the rubber bushings.
Guideline
Ensure that the side panel is correctly hooked in to areas A
and B.
W00442-10
Finishing work
- Install the frame protector. ( p. 54)
67
11
SERVICE WORK ON THE CHASSIS
11.28
Removing the air filter box cover
Condition
The air filter box cover is secured.
- Remove screw 1.
W00443-11
- Detach the air filter box cover in area A and slide it in area B
to the rear.
- Take off the air filter box cover.
W00443-10
Condition
The air filter box cover is not secured.
- Detach the air filter box cover in area A and slide it in area B
to the rear.
- Take off the air filter box cover.
W00443-10
11.29
Installing the air filter box cover
Condition
The air filter box cover is secured.
- Position the air filter box cover in area B and slide it forward.
- Press the air filter box cover in area A into the rubber bush-
ings.
W00444-10
68
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
W00443-11
Condition
The air filter box cover is not secured.
- Position the air filter box cover in area B and slide it forward.
- Press the air filter box cover in area A into the rubber bush-
ings.
W00444-10
11.30
Preparing air filter box cover for securing
Preparatory work
- Remove the air filter box cover. ( p. 68)
Main work
- Drill a hole at marking A.
Guideline
Diameter
6 mm (0.24 in)
W00211-10
Finishing work
- Install the air filter box cover. ( p. 68)
69
11
SERVICE WORK ON THE CHASSIS
11.31
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. 68)
Main work
- Detach retaining tab 1.
- Remove air filter with air filter support.
- Remove air filter from air filter support.
W00216-10
11.32
Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
- Remove the air filter box cover. ( p. 68)
- Remove the air filter.
(
p. 70)
Main work
- Wash the air filter thoroughly in special cleaning liquid and allow it
to dry properly.
Air filter cleaner ( p. 152)
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. 152)
- Clean the air filter box.
- Clean the intake flange and check it for damage and tightness.
70
SERVICE WORK ON THE CHASSIS
11
Finishing work
- Install the air filter.
(
p. 71)
– Install the air filter box cover. ( p. 68)
11.33
Installing the air filter
Main work
- Mount the clean air filter on the air filter support.
Info
The marking on the air filter support must face upwards.
- Grease the air filter in area A.
Long-life grease ( p. 152)
F03779-10
- Insert air filter and position retaining pin 1 in bushing B.
The air filter is correctly positioned.
Info
The marking on the air filter must face upwards.
- Insert retaining tab 2.
Retaining pin 3 is secured by retaining tab 2.
W00217-10
Info
If the air filter is not mounted correctly, dust and dirt may
enter the engine and result in damage.
Finishing work
- Install the air filter box cover. ( p. 68)
11.34
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. 54)
- Remove the right side panel. ( p. 67)
71
11
SERVICE WORK ON THE CHASSIS
Main work
- Detach spring 1.
Spring hook (50305017000C1)
- Remove screws 2 with the washers and take off the main silencer.
W00445-10
11.35
Installing the main silencer
Main work
- Position the main silencer.
- Mount screws 1 with washers, but do not tighten yet.
- Attach spring 2.
Spring hook (50305017000C1)
- Tighten screws 1.
Guideline
W00445-11
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
Finishing work
- Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
11.36
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 glass fiber yarn filling escape and the damper "burns" out.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
- Remove main silencer. ( p. 71)
72
SERVICE WORK ON THE CHASSIS
11
Main work
(MC-F / EX-F)
- Remove the screws 1 on the main silencer.
- Take off silencer cap 2 and O-ring 3.
- Pull glass fiber yarn filling 4 out of the silencer cap.
- Pull glass fiber yarn filling 5 from the inner tube.
- Clean the parts that need to be reinstalled and check for dam-
age.
- Mount new glass fiber yarn filling 5 on the inner tube.
- Position new glass fiber yarn filling 4 in the silencer cap.
- Insert O-ring and silencer cap into outer tube 6.
- Mount and tighten screws 1.
Guideline
Screws on main
M5
7 Nm (5.2 lbf ft)
silencer
F03637-10
(FACTORY EDITION)
- Drill out all rivets on the main silencer and remove silencer
cap 1 with O-ring 2.
- Remove glass fiber yarn filling 3 from the silencer cap.
- Pull glass fiber yarn filling 4 out of outer tube 5.
- Clean the parts that need to be reinstalled and check for dam-
age.
- Mount new glass fiber yarn filling 4 on the inner tube.
- Position new glass fiber yarn filling 3 in silencer cap 1.
- Insert silencer cap with O-ring 2 into the outer tube.
- Rivet according to manufacturer specifications.
F02581-10
Finishing work
- Install the main silencer. ( p. 72)
- Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
73
11
SERVICE WORK ON THE CHASSIS
11.37
Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
- Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
- Switch off the engine for refueling.
- Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
- If any fuel is spilled, wipe it off immediately.
- Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is harmful to health.
-
Avoid skin, eye and clothing contact with fuel.
–
Immediately consult a doctor if you swallow fuel.
–
Do not inhale fuel vapors.
–
Rinse the affected area immediately with plenty of water in the event of contact with the skin.
–
Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–
Change your clothing if fuel spills on them.
–
Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
- Remove the air filter box cover. ( p. 68)
- Remove the seat. ( p. 66)
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
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!
H05043-10
- Disconnect the quick release coupling.
Info
Remaining fuel may flow out of the fuel hose.
- Mount wash cap set 3.
Wash cap set (81212016100)
- Pull the fuel tank breather hose off the fuel tank lid.
H05044-10
74
SERVICE WORK ON THE CHASSIS
11
– Remove screw 4 with the rubber bushing.
W00213-10
- Remove screws 5 with the collar bushings.
W00446-10
- Pull both spoilers laterally off the radiator and lift off the fuel tank.
W00446-12
11.38
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.
75
11
SERVICE WORK ON THE CHASSIS
Main work
- Check the throttle cable routing. ( p. 82)
- 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
W00446-11
- Mount and tighten screw 2 with the rubber bushing.
Guideline
Remaining screws,
M6
10 Nm (7.4 lbf ft)
chassis
W00213-11
- Plug in fuel pump connector 3.
- Remove the wash cap set. Clean the quick release coupling thor-
oughly with compressed air.
Info
Under no circumstances should dirt enter into the fuel line.
Dirt in the fuel line clogs the injection valve!
- Spray silicone spray onto a lint-free cleaning cloth and lightly lubri-
cate the O-ring of the quick-release coupling.
H05043-11
Silicone spray ( p. 152)
- Join quick release coupling 4.
Info
Route the cable and fuel line at a safe distance from the
exhaust system.
Finishing work
- Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
- Mount the seat. ( p. 66)
- Install the air filter box cover. ( p. 68)
76
SERVICE WORK ON THE CHASSIS
11
11.39
Checking for chain dirt accumulation
- Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
- Clean the chain. ( p. 77)
400678-01
11.40
Cleaning the chain
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
- Remove lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
- Always keep the brake discs free of oil and grease.
- Clean the brake discs with brake cleaner when necessary.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
- Rinse off loose dirt with a soft jet of water.
- Remove old grease residue with chain cleaner.
Chain cleaner ( p. 152)
- After drying, apply chain spray.
Off-road chain spray ( p. 152)
400725-01
Finishing work
- Remove the motorcycle from the lift stand. ( p. 50)
77
11
SERVICE WORK ON THE CHASSIS
11.41
Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear-
ings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel
locks or the engine will be damaged.
- Check the chain tension regularly.
- Set the chain tension in accordance with the specification.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
- Pull the chain at the end of the chain sliding piece upward to mea-
sure chain tension A.
Info
Lower chain section 1 must be taut.
Chain wear is not always even, so you should repeat this
measurement at different chain positions.
F03680-10
Chain tension
58 … 61 mm (2.28 … 2.4 in)
» If the chain tension does not meet the specification:
- Adjust the chain tension. ( p. 78)
Finishing work
- Remove the motorcycle from the lift stand. ( p. 50)
11.42
Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear-
ings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel
locks or the engine will be damaged.
- Check the chain tension regularly.
- Set the chain tension in accordance with the specification.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
- Check the chain tension. ( p. 78)
78
SERVICE WORK ON THE CHASSIS
11
Main work
- Loosen nut 1.
- Loosen nuts 2.
- Adjust the chain tension by turning adjusting screws 3 left and
right.
Guideline
Chain tension
58 … 61 mm (2.28 … 2.4 in)
Turn adjusting screws 3 on the left and right so that the mark-
ings on the left and right chain adjusters are in the same position
relative to reference marks A. The rear wheel is then correctly
aligned.
- Tighten nuts 2.
- Make sure that chain adjusters 4 are fitted correctly on adjusting
screws 3.
- Tighten nut 1.
Guideline
Nut, rear wheel spindle
M22x1.5
80 Nm (59 lbf ft)
F03681-10
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. 50)
11.43
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
- Shift the transmission into neutral.
- Check the chain, rear sprocket and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
- Change the drivetrain kit.
Info
The engine sprocket, rear sprocket and chain should
always be replaced together.
400227-01
79
11
SERVICE WORK ON THE CHASSIS
-
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 sliding
M6
6 Nm (4.4 lbf ft)
guard on link fork
W00221-10
80
SERVICE WORK ON THE CHASSIS
11
– 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
F03714-10
- 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. 50)
81
11
SERVICE WORK ON THE CHASSIS
11.44
Checking the frame
- Check the frame for damage, cracks, and deformation.
» If the frame shows signs of damage, cracks, or deformation:
- Change the frame.
Guideline
Repairs on the frame are not permitted.
F03645-01
11.45
Checking the link fork
- Check the link fork for damage, cracks, and deformation.
» If the link fork shows signs of damage, cracks, or deformation:
- Change the link fork.
Guideline
Repairs on the link fork are not permitted.
F03646-01
11.46
Checking the throttle cable routing
Warning
Danger of accidents The throttle cable can become kinked, trapped or blocked if it is not routed correctly.
If the throttle cable is kinked, trapped or blocked, the speed can no longer be controlled.
- Make sure that the throttle cable routing and the play in throttle cable complies with the specification.
Preparatory work
- Remove the air filter box cover. ( p. 68)
- Remove the seat. ( p. 66)
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
- Remove the fuel tank.
(
p. 74)
82
SERVICE WORK ON THE CHASSIS
11
Main work
- Check the throttle cable routing.
Both throttle cables must be routed, side by side, on the back of
the handlebars and above the fuel tank bracket, to the throttle
valve body. Both throttle cables must be secured behind the rub-
ber strap of the fuel tank support.
» If the throttle cable is not routed as specified:
- Correct the throttle cable routing.
W00246-10
Finishing work
- Install the fuel tank.
(
p. 75)
– Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
- Mount the seat. ( p. 66)
- Install the air filter box cover. ( p. 68)
11.47
Checking the rubber grips
- 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.
F03684-10
83
11
SERVICE WORK ON THE CHASSIS
11.48
Programming the quickshifter
Info
If the shifting performance of the quickshifter starts to decrease, it must be reprogrammed.
- Carry out start procedure. ( p. 26)
- Press and hold the QS button 1 for at least 10 seconds.
The QS indicator lamp flashes.
- Pull the clutch lever, engage first-gear and hold the shift lever all the
way down.
- Briefly press the QS button 1.
The QS indicator lamp lights up blue, the teaching procedure
was successful.
F03760-12
Info
If the quickshifter cannot be activated, the teaching proce-
dure was unsuccessful and must be repeated.
11.49
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.
F03647-11
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
11.50
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.
84
SERVICE WORK ON THE CHASSIS
11
– 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. 150)
- 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.
11.51
Changing the hydraulic clutch fluid
Warning
Skin irritation Brake fluid is a harmful substance.
- Keep brake fluid out of the reach of children.
- Wear suitable protective clothing and safety glasses.
- Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
- Consult a doctor immediately if brake fluid has been swallowed.
- Rinse the affected area with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
- If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
- Move the hydraulic clutch fluid reservoir mounted on the handlebar
into a horizontal position.
- Remove screws 1.
- Take off cover 2 with membrane 3.
H04933-10
85
11
SERVICE WORK ON THE CHASSIS
- Fill bleeding syringe 4 with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 150)
- On the clutch slave cylinder, remove the protection cap and mount
bleeding syringe 4 with an appropriate hose piece on bleeder
screw 5.
- Only loosen bleeder screw 5 on the clutch slave cylinder until fill-
ing is possible.
H04934-10
Info
Avoid contact between brake fluid and painted parts. Brake
fluid corrodes paint.
- 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.
- Tighten the bleeder screw and remove the bleeding syringe with the
hose. Mount the protection cap.
- 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.
86
BRAKE SYSTEM
12
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:
- Adjust the basic position of the hand brake lever. ( p. 87)
F03649-10
12.2
Adjusting the basic position of the hand brake lever
Preparatory work
- Check the free travel of the hand brake lever. ( p. 87)
Main work
- 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.
F03648-12
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
3.0 mm (0.118 in)
F03688-10
rear
4.3 mm (0.169 in)
87
12
BRAKE SYSTEM
» If the brake disc thickness is less than the specification:
- 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. 90)
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. 88)
F03689-10
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.)
88
BRAKE SYSTEM
12
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. 90)
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. 150)
- 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.
F03694-10
89
12
BRAKE SYSTEM
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. 90)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the brake linings of the front brake.
(
p. 90)
F03691-10
- 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.
90
BRAKE SYSTEM
12
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
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.
F03690-10
- Remove screws 4.
- Press back the brake linings by slightly tilting the brake caliper later-
ally on the brake disc. Carefully pull the brake caliper up and off the
brake disc.
- Press the brake piston back into the basic position and ensure that
brake fluid does not flow out of the brake fluid reservoir; extract
some if necessary.
Info
F03695-10
Do not operate the hand brake lever if the brake caliper has
been removed.
- Remove cotter pins 5, pull out pin 6, and remove the brake lin-
ings.
- Clean the brake caliper and the brake caliper bracket.
F03696-10
- Check that spring plate 7 in the brake caliper and brake pad slid-
ing plate 8 in the brake caliper bracket are seated correctly.
F03692-10
91
12
BRAKE SYSTEM
-
Insert the new brake linings, insert pin 6, and mount cotter
pins 5.
Info
Always change the brake linings in pairs.
To make it easier to mount the pin, push the brake linings
against the retainer spring.
Make sure the brake linings and retainer spring are seated
correctly.
F03696-10
-
Position the brake caliper.
–
Mount and tighten screws 4.
Guideline
Screw, front
M8
25 Nm (18.4 lbf ft)
brake caliper
Loctite®243™
–
Operate the hand brake lever repeatedly until the brake linings are
in contact with the brake disc and there is a pressure point.
F03695-10
-
Add brake fluid up 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. 150)
-
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.
F03693-10
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.)
92
BRAKE SYSTEM
12
– 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. 93)
– 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 4 and, with push rod 5, turn it back until you have
maximum free travel.
- To adjust the basic position of the foot brake lever to individual
requirements, loosen nut 2 and turn screw 3 accordingly.
Info
The range of adjustment is limited.
- Turn push rod 5 accordingly until you have free travel A. If nec-
essary, adjust the basic position of the foot brake lever.
Guideline
Free travel at foot brake lever
3 … 5 mm (0.12 … 0.2 in)
– Hold push rod 5 and tighten nut 4.
Guideline
Remaining nuts, chas-
M6
10 Nm (7.4 lbf ft)
sis
F03715-10
- Hold screw 3 and tighten nut 2.
Guideline
Brake lever stop nut
M8
20 Nm (14.8 lbf ft)
– Attach spring 1.
93
12
BRAKE SYSTEM
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. 95)
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. 94)
F03716-10
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.
94
BRAKE SYSTEM
12
Warning
Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system.
- Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
- Make sure that only clean, approved brake fluid from a tightly sealed container is used. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Check that the brake linings of the rear brake are secured. ( p. 95)
- Remove the frame protector. ( p. 54)
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. 150)
- Mount and tighten the screw cap with the membrane and O-ring.
Info
W00190-10
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
Finishing work
- Install the frame protector. ( p. 54)
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. 96)
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
- Change the rear brake linings.
(
p. 96)
F03719-10
- Check that the brake linings are secured.
» If the brake linings are not secured correctly:
- Secure brake linings, replace with new parts if necessary.
95
12
BRAKE SYSTEM
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.)
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
Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint.
Preparatory work
- Remove the frame protector. ( p. 54)
Main work
- Stand the vehicle upright.
- Remove screw cap 1 with membrane 2 and the O-ring.
W00191-10
96
BRAKE SYSTEM
12
– 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.
W00192-10
- 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.
W00193-10
- 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
W00194-10
contact with the brake disc and there is a pressure point.
- Correct brake fluid level to marking A.
Brake fluid DOT 4 / DOT 5.1 ( p. 150)
- 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.
W00190-10
Finishing work
- Install the frame protector. ( p. 54)
97
13
WHEELS, TIRES
13.1
Removing the front wheel
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
(MC-F / EX-F)
- 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.
S05368-10
- 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.
S05369-10
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.
S05370-10
Info
Do not actuate the hand brake lever when the front
wheel is removed.
- Remove spacers 3.
H00934-10
98
WHEELS, TIRES
13
(FACTORY EDITION)
- 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.
H04986-10
- 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.
W00222-11
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
- Always lay the wheel down in such a way that the
brake disc is not damaged.
- Hold front wheel and remove wheel spindle. Take the front
wheel out of the fork.
W00223-10
Info
Do not actuate the hand brake lever when the front
wheel is removed.
- Remove spacer 3 and brake disc guard 4.
F03725-10
99
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.
(MC-F / EX-F)
- 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. 152)
- Insert the spacers.
H00935-10
- Clean and lightly grease the wheel spindle.
Long-life grease ( p. 152)
- 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
Tip
Temporarily tighten one of the axle clamp screws so that the
axle does not rotate with it.
Loosen the axle clamp screw again before compression to
S05369-11
allow the fork legs to align.
- Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
- Remove the motorcycle from the lift stand. ( p. 50)
- Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
- Tighten screws 3.
Guideline
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
(FACTORY EDITION)
- 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. 152)
- Insert the spacer and brake disc guard.
F03726-10
- Clean and lightly grease the wheel spindle.
100
WHEELS, TIRES
13
Long-life grease ( p. 152)
- Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
- Position the brake disc guard.
F03724-01
- Mount and tighten screw 2.
Guideline
Screw, front wheel
M20x1.5
35 Nm (25.8 lbf ft)
spindle
Tip
Temporarily tighten one of the axle clamp screws so that the
axle does not rotate with it.
Loosen the axle clamp screw again before compression to
W00222-10
allow the fork legs to align.
- Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
- Remove the motorcycle from the lift stand. ( p. 50)
- Operate the front brake and compress the fork a few times
firmly.
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. 50)
101
13
WHEELS, TIRES
Main work
- Manually press the brake caliper toward the brake disc to push back
the brake piston.
Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake piston.
- Remove nut 1.
- Take off chain adjuster 2. Pull out wheel spindle 3 far enough to
allow the rear wheel to be pushed forward.
- Push the rear wheel forward as far as possible. Remove the chain
from the rear sprocket.
Info
Cover the components to protect them against damage.
Warning
Danger of accidents Damaged brake discs reduce the
H04989-10
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.
F03727-10
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.
102
WHEELS, TIRES
13
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. 152)
- Insert the spacers.
F03728-10
- Clean and grease the wheel spindle.
Long-life grease ( p. 152)
- Position rear wheel and insert wheel spindle 2.
The brake linings are correctly positioned.
- Mount the chain.
F03757-10
- 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. 78)
- Tighten nut 4.
Guideline
Nut, rear wheel spindle
M22x1.5
80 Nm (59 lbf ft)
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.
H04990-10
Finishing work
- Remove the motorcycle from the lift stand. ( p. 50)
103
13
WHEELS, TIRES
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.
Preparatory work
- Raise the motorcycle with a lift stand. ( p. 50)
Main work
- 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.
Finishing work
- Remove the motorcycle from the lift stand. ( p. 50)
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 tire pressure when the tires are cold.
Offroad tire pressure
front
1.0 bar (15 psi)
rear
1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
- Correct tire pressure.
- Mount the protection cap.
400695-01
104
WHEELS, TIRES
13
13.7
Checking the spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam-
age.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low,
then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
- Check spoke tension regularly, and in particular on a new vehicle. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
- Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length
and spoke diameter.
If spokes of the same length and diameter vibrate with a
different tone, this is an indication that the spoke tensions
differ.
You should hear a high note.
400694-01
» If the spoke tension differs:
- Correct the spoke tension.
- Check the spoke torque.
Guideline
Spoke nipple, 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)
105
14
ELECTRICAL SYSTEM
14.1
Removing the 12-V battery
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.
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.
Preparatory work
- Remove the air filter box cover. ( p. 68)
- Remove the seat. ( p. 66)
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.
W00225-10
- 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.
W00226-10
- Pull up battery holding bracket 6 and remove the 12-V battery to
the rear.
Info
Pay attention to the wiring harness.
W00224-10
106
ELECTRICAL SYSTEM
14
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.
Info
Ensure that the cable is routed correctly.
W00224-11
- Slide the battery holding bracket into the attachment.
- Mount and tighten screw 2.
Guideline
Screw, battery support
M6
6 Nm (4.4 lbf ft)
bracket
- Attach relay 3 in the holder.
W00226-11
- 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.
W00227-10
Finishing work
- Mount the seat. ( p. 66)
- Install the air filter box cover. ( p. 68)
107
14
ELECTRICAL SYSTEM
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.
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 discharged by repeated starting, charge the 12-V battery immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and suffer a
loss of capacity, destroying the battery.
The 12-V battery is maintenance-free.
Preparatory work
- Remove the air filter box cover. ( p. 68)
- Remove the seat. ( p. 66)
- Remove the 12-V battery.
(
p. 106)
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
- Connect a battery charger to the 12-V battery. Switch on
102223-10
the battery charger.
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
108
ELECTRICAL SYSTEM
14
(US) battery charger (A54029974500)
Alternative 1
(EU) battery charger (A54029974000)
These battery chargers test whether the 12-V battery
retains its voltage. It is also impossible to overcharge the
12-V battery with these battery chargers. The charging time
may be longer at low temperatures.
These battery chargers are only suitable for lithium
iron phosphate batteries. Read the accompanying
GASGAS Technical 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. 107)
– Mount the seat. ( p. 66)
- Install the air filter box cover. ( p. 68)
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.
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 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 air filter box cover. ( p. 68)
- Remove the seat. ( p. 66)
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
- Remove the fuel tank.
(
p. 74)
Finishing work
- Install the fuel tank.
(
p. 75)
– Install the right side panel. ( p. 67)
- Install the frame protector. ( p. 54)
- Mount the seat. ( p. 66)
- Install the air filter box cover. ( p. 68)
109
14
ELECTRICAL SYSTEM
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. 68)
- Remove the seat. ( p. 66)
Finishing work
- Mount the seat. ( p. 66)
- Install the air filter box cover. ( p. 68)
14.6
Diagnostics connector
Diagnostics connector 1 is located under the seat.
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
110
ELECTRICAL SYSTEM
14
14.7
Connectivity Unit Offroad (CUO)
M02091-10
Connectivity Unit Offroad 1 is attached on the right fork leg.
GPS unit 2 is mounted on the fender.
The app provided by the manufacturer guides you through the operation of the Connectivity Unit Offroad.
Possible states
• Button 3 is pressed briefly (<1.5 s) - A recording is started or stopped.
• Button 3 is pressed and held (1.5 s... 6 s) - The pairing process is started.
• Button 3 is pressed and held (6 s... 12 s) - The Connectivity Unit Offroad is prepared for reset to factory settings.
• Button 3 is pressed and held (12 s... 18 s) - The Connectivity Unit Offroad is reset to factory settings.
• Button 3 is pressed and held (>18 s) - All processes are aborted, the Connectivity Unit Offroad condition is not
changed, all indicator lamps go out.
• Indicator lamp A does not light up - The Connectivity Unit Offroad is switched off.
• Indicator lamp A lights up blue - The Connectivity Unit is ready for operation.
• Indicator lamp A flashes blue - A recording is downloaded.
• Indicator lamp A flashes green - A recording is active.
• Indicator lamp A flashes yellow - A recording was started before the position was captured via GPS.
• Indicator lamp B does not light up - The Bluetooth® module is switched off.
• Indicator lamp B lights up blue - Bluetooth® is active and no end device is stored.
• Indicator lamp B flashes blue - The pairing procedure via Bluetooth® has been started.
• Indicator lamp B lights up green - The Connectivity Unit Offroad is connected to an end device via Bluetooth®.
• Indicator lamp C does not light up - The WiFi module is switched off.
• Indicator lamp C lights up blue - The WiFi module is active but not connected.
• Indicator lamp C lights up green - The WiFi module is active and connected.
• Indicator lamp D does not light up - The GPS module is switched off.
111
14
ELECTRICAL SYSTEM
• Indicator lamp D lights up blue - The GPS module is active but the position is not detected.
• Indicator lamp D lights up green - The GPS module is active and the position is detected.
• All indicator lamps flash blue - The Connectivity Unit Offroad is prepared for reset to factory settings.
• All indicator lamps light up green - The Connectivity Unit Offroad is reset to factory settings.
Info
Possible trouble codes of indicator lamp A are described in the Troubleshooting section.
112
COOLING SYSTEM
15
15.1
Cooling system
Water pump 1 in the engine circulates 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.
A01230-10
15.2
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
- Stand the motorcycle upright on a horizontal surface.
- Remove the radiator cap.
- Check the antifreeze in the coolant.
-25 … -45 °C (-13 … -49 °F)
» If the antifreeze in the coolant does not match the specified
value:
- Correct the antifreeze in the coolant.
- Check the coolant level in the radiator.
400243-10
10 mm (0.39 in)
Coolant level A above the
radiator fins
» If the coolant level does not match the specified value:
- Correct the coolant level.
Coolant ( p. 150)
- Mount the radiator cap.
113
15
COOLING SYSTEM
15.3
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
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. 150)
- Mount the radiator cap.
15.4
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
114
COOLING SYSTEM
15
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
Preparatory work
(FACTORY EDITION)
- Remove the engine guard. ( p. 53)
Main work
- Position the motorcycle upright.
- Place an appropriate container under the water pump cover.
- Remove screw 1. Take off radiator cap 2.
- Completely drain the coolant.
- Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump
M6
10 Nm (7.4 lbf ft)
A01231-10
cover
15.5
Refilling with coolant
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Main work
- Make sure that screw 1 is tightened.
- Position the motorcycle upright.
- Pour coolant in up to measurement A above the radiator fins.
Guideline
10 mm (0.39 in)
Distance A above the radia-
tor fins
A01232-10
Coolant
0.95 l (1 qt.)
Coolant ( p. 150)
– Mount the radiator cap.
- Go for a short test ride.
- Check the coolant level. ( p. 114)
115
15
COOLING SYSTEM
Finishing work
(FACTORY EDITION)
- Install the engine guard. ( p. 53)
15.6
Changing the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.
- Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
- Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is harmful to health.
- Keep coolant out of the reach of children.
- Do not allow coolant to come into contact with the skin, the eyes and clothing.
- Consult a doctor immediately if coolant is swallowed.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
- Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
Preparatory work
(FACTORY EDITION)
- Remove the engine guard. ( p. 53)
Main work
- Position the motorcycle upright.
- Place an appropriate container under the water pump cover.
- Remove screw 1. Take off radiator cap 2.
- Completely drain the coolant.
A01231-10
- Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump
M6
10 Nm (7.4 lbf ft)
cover
- Pour coolant in up to level A above the radiator fins.
Guideline
10 mm (0.39 in)
Distance A above the radia-
tor fins
A01232-10
Coolant
0.95 l (1 qt.)
Coolant ( p. 150)
– Mount the radiator cap.
- Go for a short test ride.
- Check the coolant level. ( p. 114)
116
COOLING SYSTEM
15
Finishing work
(FACTORY EDITION)
- Install the engine guard. ( p. 53)
117
16
TUNING THE ENGINE
16.1
Checking the play in the throttle cable
- Check the throttle grip for smooth operation.
- Move the handlebar to the straight-ahead position. Turn the throt-
tle grip back and forth slightly and determine the play in throttle
cable A.
Play in throttle cable
3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
- Adjust the play in the throttle cable.
(
p. 118)
– Push the cold start button in all the way.
400192-11
When the throttle grip is turned forward, the cold start button
returns to its original position.
» If the cold start button does not return to its original position:
- Adjust the play in the throttle cable.
(
p. 118)
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. 118)
16.2
Adjusting the play in the throttle cable
Info
If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be removed.
Preparatory work
- Remove the air filter box cover. ( p. 68)
- Remove the seat. ( p. 66)
- Remove the frame protector. ( p. 54)
- Remove the right side panel. ( p. 67)
- Remove the fuel tank.
(
p. 74)
– Check the throttle cable routing. ( p. 82)
118
TUNING THE ENGINE
16
Main work
- Move the handlebar to the straight-ahead position.
- Push back sleeve 1.
- Loosen nut 2.
- Turn adjusting screw 3 in as far as possible.
- Loosen nut 4.
- Push cold start button 6 all the way to the stop.
- Turn adjusting screw 5 so that the cold start button moves to the
basic position when the throttle grip is turned to the front.
- Tighten nut 4.
- Turn adjusting screw 3 so that there is play in the throttle cable at
the throttle grip.
Guideline
Play in throttle cable
3 … 5 mm (0.12 … 0.2 in)
– Tighten nut 2.
- Slide on sleeve 1.
W00245-10
- Check the throttle grip for smooth operation.
Finishing work
- Check the play in the throttle cable. ( p. 118)
16.3
Adjusting the characteristic map of the throttle response
Info
On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate.
A guide plate with a different characteristic map is supplied.
Main work
- Push back sleeve 1.
- Remove screws 2 and half-shells 3.
- Detach the throttle cables and take off the grip tube.
F03743-10
119
16
TUNING THE ENGINE
- Remove guide plate 4 from handle tube 5.
- Position the required guide plate on the grip tube.
Guideline
The label OUTSIDE must be visible. Marking A must be posi-
tioned at marking B.
Gray guide plate (A48002014000)
Alternative 1
Black guide plate (A46002014000)
Info
The gray guide plate opens the throttle valve more slowly.
The black guide plate opens the throttle valve more quickly.
The gray guide plate is mounted upon delivery.
F03780-10
- Clean the outside of the handlebar and the inside of the grip tube.
Mount the grip tube on the handlebar.
- Attach the throttle cables to the guide plate and route correctly.
- Position half-shells 3, mount and tighten screws 2.
Guideline
Screw, throttle grip
M6
5 Nm (3.7 lbf ft)
– Slide on sleeve 1 and check the throttle grip for ease of move-
ment.
F03744-10
Finishing work
- Check the play in the throttle cable. ( p. 118)
120
TUNING THE ENGINE
16
16.4
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. 18)
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Adjust the idle speed by turning idle speed adjusting screw 1 using
a suitable tachometer.
Guideline
Idle speed
2,200 … 2,300 rpm
Info
Turning counterclockwise lowers the idle speed.
W00243-10
Turning clockwise raises the idle speed.
16.5
Programming the throttle valve position
Info
If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed, then the mal-
function indicator lamp flashes 2x per second.
121
16
TUNING THE ENGINE
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Allow the vehicle to run at idle speed.
The malfunction indicator lamp stops flashing once program-
ming is completed.
Info
If the engine becomes too warm, perform a cool-down ride
at medium speed.
After this, do not switch off the engine, but leave it running
at idle speed until the programming is finished.
H02263-10
16.6
Checking the basic position of the shift lever
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
If the shift lever is permanently touching the boot, the transmission will be subject to excessive load; this can cause
a malfunction of the quickshifter.
- 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. 122)
400692-10
16.7
Adjusting the basic position of the shift lever
- Remove screw 1 with the washers and take off shift lever 2.
401950-12
122
TUNING THE ENGINE
16
– 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
M6x16
14 Nm (10.3 lbf ft)
Loctite®243™
123
17
SERVICE WORK ON THE ENGINE
17.1
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 hose 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. 152)
- Join quick release coupling 1.
F03792-10
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and check the response.
124
SERVICE WORK ON THE ENGINE
17
17.2
Checking the engine oil level
Info
The engine oil level can be checked when the engine is cold or warm.
Preparatory work
- Stand the motorcycle upright on a horizontal surface.
Condition
The engine is cold.
- Check the engine oil level.
The engine oil reaches the middle of level viewer A.
» If the engine oil does not reach the middle of the level
viewer:
- Add engine oil. ( p. 128)
Condition
W00235-10
The engine is at operating temperature.
- Check the engine oil level.
Info
After switching off the engine, wait one minute before
checking the level.
The engine oil level is between the middle of the level
viewer A and the upper edge of the level viewer B.
» If the engine oil does not reach the middle of level
viewer A:
- Add engine oil. ( p. 128)
17.3
Changing the engine oil and oil filter, cleaning the oil screens
Warning
Danger of scalding Engine and gear oil get hot when the motorcycle is operated.
- Wear suitable protective clothing and safety gloves.
- In the event of scalding, rinse the area affected immediately with lukewarm water.
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Drain the engine oil while the engine is at operating temperature.
Preparatory work
- Park the motorcycle on a level surface.
(FACTORY EDITION)
- Remove the engine guard. ( p. 53)
125
17
SERVICE WORK ON THE ENGINE
Main work
- Position an appropriate container under the engine.
- Remove oil drain plug 1 with the magnet and seal ring.
F03774-10
- Remove screw plug 2 with the O-ring.
Info
Do not remove screw A.
F03775-10
- Remove screw plug 3 with long oil screen 4 and the O-rings.
- Allow the engine oil to drain completely.
- Thoroughly clean the parts and the sealing surfaces.
H05063-10
- Mount and tighten screw plug 2 with new O-ring.
Guideline
Screw plug, crankcase
M16x1.5
15 Nm (11.1 lbf ft)
F03775-11
- Position long oil screen 4 with the O-rings on a pin wrench.
- Position the pin wrench through the drill hole of the screw plug in
the opposite section of the engine case.
- Push the oil screen all the way into the engine case.
F03776-10
126
SERVICE WORK ON THE ENGINE
17
– Mount and tighten screw plug 3 with the O-ring.
Guideline
Screw plug, oil screen
M20x1.5
15 Nm (11.1 lbf ft)
– Mount and tighten oil drain plug 1 with the magnet and a new
seal ring.
Guideline
Oil drain plug with
M12x1.5
20 Nm (14.8 lbf ft)
magnet
H05065-10
- Remove screws 5. Take off the oil filter cover with the O-ring.
H05066-10
- Pull oil filter 6 out of the oil filter housing.
Lock ring plier (51012011000)
- Allow the engine oil to drain completely.
- Thoroughly clean the parts and the sealing surfaces.
H05067-10
- Lay the motorcycle on its side and fill the oil filter housing to about
⅓ full with engine oil.
- Place the oil filter into the oil filter housing.
- Lubricate the O-ring of the oil filter cover and mount it with oil filter
cover 7.
- Mount and tighten the screws.
Guideline
Screw, oil filter cover
M6x16
10 Nm (7.4 lbf ft)
H05068-10
- Stand the motorcycle upright.
- Remove filler plug 8 with the O-ring, and fill up with engine oil.
Engine oil
1.2 l (1.3 qt.)
Engine oil (SAE
10W/50) ( p. 150)
Info
Too little engine oil or poor-quality engine oil will result in
premature wear of the engine.
- Mount and tighten the filler plug together with the O-ring.
W00547-10
127
17
SERVICE WORK ON THE ENGINE
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and check it for leaks.
Finishing work
(FACTORY EDITION)
- Install the engine guard. ( p. 53)
- Check the engine oil level. ( p. 125)
17.4
Adding engine oil
Info
Too little engine oil or poor-quality engine oil will result in premature wear of the engine.
- Remove filler plug 1 with the O-ring.
- Add the same engine oil used when the last oil change was carried
out.
Engine oil (SAE 10W/50) ( p. 150)
Info
In order to achieve optimal engine oil performance, it is not
advisable to mix different engine oils.
401955-10
GASGAS Motorcycles recommends changing the engine oil,
if necessary.
- Mount and tighten the filler plug together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
- Always make sure there is sufficient ventilation when
running the engine.
- Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
- Start the engine and check it for leaks.
128
CLEANING, CARE
18
18.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
- Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
- Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance
60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
- Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
-
Close off exhaust system to keep water from entering.
–
Remove loose dirt first with a soft jet of water.
–
Spray the heavily soiled parts with a normal commercial motorcycle
cleaner and clean using a brush.
Motorcycle cleaner ( p. 152)
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.
-
Push back the protection caps of the handlebar controls to allow any
water that has penetrated to evaporate.
-
After the motorcycle has cooled down, lubricate all moving parts
and pivot points.
-
Clean the chain. ( p. 77)
129
18
CLEANING, CARE
- Treat bare metal (except for brake discs and the exhaust system)
with a corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 152)
- 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. 153)
130
STORAGE
19
19.1
Storage
Warning
Danger of poisoning Fuel is harmful to health.
- Avoid skin, eye and clothing contact with fuel.
- Immediately consult a doctor if you swallow fuel.
- Do not inhale fuel vapors.
- Rinse the affected area immediately with plenty of water in the event of contact with the skin.
- Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
- Change your clothing if fuel spills on them.
- Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If 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. 152)
- Refuel. ( p. 32)
Tip
Fill the fuel tank completely as specified, using fuel with the
lowest possible ethanol content.
401058-01
- Clean the motorcycle. ( p. 129)
- Change the engine oil and the oil filter, clean the oil screens.
(
p. 125)
– Check the antifreeze and coolant level. ( p. 113)
- Check the tire pressure. ( p. 104)
- Remove the 12-V battery.
(
p. 106)
– Charge the 12-V battery.
(
p. 108)
Guideline
Ideal charging and storage tem-
10 … 20 °C (50 … 68 °F)
perature of the lithium-ion bat-
tery
- Store the vehicle in a dry location that is not subject to large fluctua-
tions in temperature.
Info
GASGAS Motorcycles recommends jacking up the motorcy-
cle.
- Raise the motorcycle with a lift stand. ( p. 50)
- Cover the vehicle with a tarp or a similar cover that is permeable to
air.
131
19
STORAGE
Info
Do not use non-porous materials since they prevent humid-
ity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since the
engine cannot warm up properly, the water vapor produced
during combustion condenses and causes valves and the
exhaust system to rust.
19.2
Putting into operation after storage
- Install the 12-V battery.
(
p. 107)
– Remove the motorcycle from the lift stand. ( p. 50)
- Perform checks and maintenance measures when preparing for use.
(
p. 26)
– Take a test ride.
401059-01
132
TROUBLESHOOTING
20
Faults
Possible cause
Action
The engine does not turn when
Operating error
-
Carry out start procedure. ( p. 26)
the start button is pressed
12-V battery discharged
-
Charge the 12-V battery.
(
p. 108)
–
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. 109)
Faulty starter relay
-
Check the starter relay.
Faulty starter motor
-
Check the starter motor.
Engine turns but does not start
Quick release coupling not joined
-
Join quick release coupling.
Fuel screen in the quick release
-
Change the fuel screen.
(
p. 124)
coupling is clogged
Idle speed is not set correctly
-
Adjust the idle speed.
(
p. 121)
Spark plug sooty or wet
-
Clean and dry the spark plug and spark
plug connector, or change if necessary.
Plug gap of spark plug too wide
-
Adjust plug gap.
Guideline
Spark plug electrode gap
1.0 mm (0.039 in)
Short-circuit cable in wiring har-
-
Check the wiring harness. (visual check)
ness frayed, stop button faulty
-
Check the electrical system.
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 is very dirty
-
Clean the air filter and air filter box.
(
p. 70)
Fuel filter is very dirty
-
Change the fuel filter.
Malfunction in the electronic fuel
-
Read out the fault memory using the GAS-
injection
GAS Motorcycles diagnostics tool.
Exhaust system leaks, 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. 72)
Valve clearance too little
-
Adjust the valve clearance.
Engine dies during the trip
Lack of fuel
-
Refuel. ( p. 32)
Engine overheats
Too little coolant in cooling system
-
Check the cooling system for leakage.
–
Check the coolant level. ( p. 114)
Too little air stream
-
Switch off the engine when standing.
Radiator fins very dirty
-
Clean the radiator fins.
Foam formation in cooling system
-
Drain the coolant.
(
p. 114)
–
Refill with coolant.
(
p. 115)
Bent radiator hose
-
Change the radiator hose.
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.
High oil consumption
Engine vent hose bent
-
Route the vent hose without bends or
change it if necessary.
133
20
TROUBLESHOOTING
Faults
Possible cause
Action
High oil consumption
Engine oil level too high
- Check the engine oil level. ( p. 125)
Engine oil too thin (low viscosity)
- Change the engine oil and the oil filter,
clean the oil screens.
(
p. 125)
Piston or cylinder worn
- Measure the piston/cylinder mounting
clearance.
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
134
BLINK CODE
21
Error level condition
Combination switch, left side - buttons pressed longer than 20 seconds
Blink code for malfunction
indicator lamp
Malfunction indicator lamp flashes continuously
Error level condition
THREF - internal malfunction of the engine control unit
Blink code for malfunction
indicator lamp
02 Malfunction indicator lamp flashes 2x short
Error level condition
Crankshaft speed sensor - circuit fault
Blink code for malfunction
indicator lamp
06 Malfunction indicator lamp flashes 6x short
Error level condition
Throttle valve position sensor circuit A - input signal too low
Throttle valve position sensor circuit A - input signal too high
Blink code for malfunction
indicator lamp
09 Malfunction indicator lamp flashes 9x short
Error level condition
Induction manifold pressure sensor - input signal too high
Induction manifold pressure sensor - input signal too low
Blink code for malfunction
indicator lamp
12 Malfunction indicator lamp flashes 1x long, 2x short
Error level condition
Coolant temperature sensor - input signal too high
Coolant temperature sensor - input signal too low
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 high
Intake air temperature sensor - input signal too low
Blink code for malfunction
indicator lamp
15 Malfunction indicator lamp flashes 1x long, 5x short
Error level condition
Tilt sensor - input signal too low
Tilt sensor - open / input signal too high
Blink code for malfunction
indicator lamp
21 Malfunction indicator lamp flashes 2x long, 1x short
Error level condition
Battery voltage - input voltage too high
Blink code for malfunction
indicator lamp
22 Malfunction indicator lamp flashes 2x long, 2x short
Error level condition
Gear position sensor - input signal too low
Gear position sensor - input signal too high
Gear position sensor - malfunction
135
21
BLINK CODE
Blink code for malfunction
indicator lamp
33 Malfunction indicator lamp flashes 3x long, 3x short
Error level condition
Injection valve cylinder 1 - circuit fault
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
41 Malfunction indicator lamp flashes 4x long, 1x short
Error level condition
Fuel pump controller - short circuit to ground/open circuit
Fuel pump controller - short circuit to plus
Blink code for malfunction
indicator lamp
65 Malfunction indicator lamp flashes 6x long, 5x short
Error level condition
EEPROM - malfunction
Blink code for malfunction
indicator lamp
91 Malfunction indicator lamp flashes 9x long, 1x short
Error level condition
CAN bus communication - faulty
136
TROUBLESHOOTING CUO (FACTORY EDITION)
22
Malfunctions are indicated by indicator lamp 1 flashing red.
Info
The individual flashes are 0.5 seconds long (0.25 seconds on,
0.25 seconds off).
The pause until the blink code repeats is 2 seconds.
M02092-10
Faults
Possible cause
Action
Blink code 2
No CAN communication
- Check connections on the Connectivity
Unit Offroad.
Blink code 3
WiFi connection failed
- Repeat connection attempt.
Blink code 4
Bluetooth® connection failed
- Repeat connection attempt.
Blink code 5
Malfunction in the analog sensor
- Check connections on the Connectivity
Unit Offroad.
Blink code 6
Stored VIN differs from the vehicle
- Press and hold button 3 (6 s... 12 s).
(Figure M02091-10
p. 111)
Blink code 7
Recording memory full
- Delete recordings.
Continuously lights up red
Several malfunctions are present
- Press and hold button 3 (6 s... 12 s).
(Figure M02091-10
p. 111)
137
23
TECHNICAL SPECIFICATIONS
23.1
Engine
Design
1-cylinder 4-stroke engine, water-cooled
Displacement
449.9 cm³ (27.455 cu in)
Stroke
63.4 mm (2.496 in)
Bore
95 mm (3.74 in)
Compression ratio
13.6:1
Idle speed
2,200 … 2,300 rpm
Control
OHC, 4 valves controlled via rocker arm
Valve diameter, intake
40 mm (1.57 in)
Valve diameter, exhaust
33 mm (1.3 in)
Valve clearance
Intake at: 20 °C (68 °F)
0.10 … 0.15 mm (0.0039 … 0.0059 in)
Exhaust at: 20 °C (68 °F)
0.12 … 0.17 mm (0.0047 … 0.0067 in)
Crankshaft bearing
2 cylinder roller bearing
Conrod bearing
Slide bearing
Piston pin bearing
Bearing bush
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
Pressure circulation lubrication with 2 trochoidal pumps
Primary transmission
29:72
Clutch
Multidisc clutch in oil bath, hydraulically activated
Gearbox
5-gear transmission, claw shifted
Transmission ratio
first-gear
14:28
second-gear
16:26
third-gear
18:24
fourth-gear
21:24
fifth-gear
22:21
Alternator
14 V, 70 W
Ignition
Contactless controlled fully electronic ignition with digital
ignition adjustment
Spark plug
NGK LMAR9AI-10
Spark plug electrode gap
1.0 mm (0.039 in)
Cooling
Water cooling, permanent circulation of coolant by water
pump
Starting aid
Starter motor
23.2
Engine tightening torques
Oil nozzle for the clutch lubrication
M4
0.8 Nm (0.59 lbf ft)
(alternator cover sealing surface)
Screw, oil nozzle bent for piston cool-
M4
2 Nm (1.5 lbf ft)
ing
Loctite®243™
Crankshaft speed sensor screw and
M5
6 Nm (4.4 lbf ft)
cable retainer
Loctite®243™
Oil nozzle for piston cooling
M5
2 Nm (1.5 lbf ft)
Loctite®243™
138
TECHNICAL SPECIFICATIONS
23
Oil nozzle for timing chain lubrication
M5
2 Nm (1.5 lbf ft)
Loctite®243™
Screw, bearing retainer
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, clutch adjusting ring
M5x16
6 Nm (4.4 lbf ft)
Screw, clutch spring retainer
M5
8 Nm (5.9 lbf ft)
Screw, gear position sensor
M5x14
5 Nm (3.7 lbf ft)
Loctite®243™
Screw, lock washer, oil pump idler
M5x10
6 Nm (4.4 lbf ft)
gear
Loctite®243™
Screw, locking lever
M5
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, pressure pump cover
M5x16
6 Nm (4.4 lbf ft)
Loctite®243™
Screw, stator
M5
6 Nm (4.4 lbf ft)
Loctite®2701™
Screw, suction pump cover
M5x16
6 Nm (4.4 lbf ft)
Loctite®243™
Screws, main bearing lock washer,
M5x12
6 Nm (4.4 lbf ft)
transmission bearings
Nut, water pump impeller
M6
6 Nm (4.4 lbf ft)
Loctite®243™
Remaining screws on water pump
M6
10 Nm (7.4 lbf ft)
cover
Loctite® 222™
Remaining screws, alternator cover
M6
10 Nm (7.4 lbf ft)
Remaining screws, clutch cover
M6
10 Nm (7.4 lbf ft)
Screw, alternator cover
M6x25
10 Nm (7.4 lbf ft)
Screw, balancer shaft fastening to
M6
10 Nm (7.4 lbf ft)
water pump cover
Loctite® 222™
Screw, clutch cover
M6x25
10 Nm (7.4 lbf ft)
Screw, clutch cover
M6x55
10 Nm (7.4 lbf ft)
Screw, clutch slave cylinder
M6
10 Nm (7.4 lbf ft)
Screw, cylinder head
M6x75
10 Nm (7.4 lbf ft)
Screw, engine case
M6x65
10 Nm (7.4 lbf ft)
Screw, engine case
M6x80
10 Nm (7.4 lbf ft)
Screw, exhaust flange
M6x16
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, oil filter cover
M6x16
10 Nm (7.4 lbf ft)
Screw, shift drum locating unit
M6x30
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift lever
M6x16
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, starter motor
M6x25
10 Nm (7.4 lbf ft)
Screw, tensioning rail
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, timing chain clip
M6
10 Nm (7.4 lbf ft)
Loctite®243™
Screw, timing chain tensioner
M6
10 Nm (7.4 lbf ft)
Screw, torque governor
M6
10 Nm (7.4 lbf ft)
Loctite®243™
139
23
TECHNICAL SPECIFICATIONS
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
Screw, water pump cover
M6x20
10 Nm (7.4 lbf ft)
Screw, water pump cover
M6x25
10 Nm (7.4 lbf ft)
Loctite®243™
Screws, section of the engine case
M6
10 Nm (7.4 lbf ft)
Plug, oil channel
M7
9 Nm (6.6 lbf ft)
Loctite®243™
Screw, camshaft retaining bracket
M7x1
15 Nm (11.1 lbf ft)
Screw, rocker arm bearing
M7x1
15 Nm (11.1 lbf ft)
Crankshaft clamp screw plug
M8
10 Nm (7.4 lbf ft)
Crankshaft locking bolt
M8
10 Nm (7.4 lbf ft)
Plug, timing chain tensioner
M8
8 Nm (5.9 lbf ft)
Plug, oil channel
M10
15 Nm (11.1 lbf ft)
Loctite®243™
Screw, engine sprocket
M10
60 Nm (44.3 lbf ft)
Loctite®2701™
Screw, rotor
M10x1
70 Nm (51.6 lbf ft)
Spark plug
M10x1
10 … 12 Nm (7.4 … 8.9 lbf ft)
Engine coolant temperature sensor
M10x1.25
12 Nm (8.9 lbf ft)
Screw, cylinder head
M10x1.25
1st stage
10 Nm (7.4 lbf ft)
2nd stage
30 Nm (22.1 lbf ft)
3rd stage
50 Nm (36.9 lbf ft)
Collar and thread oiled
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
Screw plug, oil pressure control valve
M12x1.5
20 Nm (14.8 lbf ft)
Screw plug, crankcase
M16x1.5
15 Nm (11.1 lbf ft)
Nut, inner clutch hub
M18x1.5
100 Nm (73.8 lbf ft)
Nut, primary gear wheel
M18LHx1.5
120 Nm (88.5 lbf ft)
Screw plug, oil screen
M20x1.5
15 Nm (11.1 lbf ft)
Screw plug, alternator cover
M24x1.5
18 Nm (13.3 lbf ft)
23.3
Capacities
23.3.1
Engine oil
Engine oil
1.2 l (1.3 qt.)
Engine oil (SAE 10W/50) ( p. 150)
23.3.2
Coolant
Coolant
0.95 l (1 qt.)
Coolant ( p. 150)
23.3.3
Fuel
Total fuel tank capacity, approx. (MC-F)
Super unleaded (ROZ 95) ( p. 151)
7.9 l (2.09 US gal)
Total fuel tank capacity, approx. (EX-F)
Super unleaded (ROZ 95) ( p. 151)
9 l (2.4 US gal)
Total fuel tank capacity, approx. (FACTORY EDITION)
140
TECHNICAL SPECIFICATIONS
23
Super unleaded (ROZ 95) ( p. 151)
7.2 l (1.9 US gal)
23.4
Chassis
Frame
Central tube frame made of chrome molybdenum steel
tubing
Fork (MC-F)
WP XACT AER
Fork (EX-F)
WP XPLOR CC
Fork (FACTORY EDITION)
WP XACT AER
Suspension travel (All MC-F models)
Front
310 mm (12.2 in)
Rear
300 mm (11.81 in)
Suspension travel (EX-F)
Front
300 mm (11.81 in)
Rear
300 mm (11.81 in)
Fork offset
22 mm (0.87 in)
Shock absorber (MC-F)
WP XACT LDS
Shock absorber (EX-F)
WP XACT LDS
Shock absorber (FACTORY EDITION)
WP XACT LDS
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
3.0 mm (0.118 in)
rear
4.3 mm (0.169 in)
Offroad tire pressure
front
1.0 bar (15 psi)
rear
1.0 bar (15 psi)
Secondary ratio (All MC-F models)
13:51
Secondary ratio (EX-F)
13:52
Chain
5/8 x 1/4"
Available rear sprockets
47, 48, 49, 50, 51, 52
Steering head angle
63.9°
Wheelbase (All MC-F models)
1,493 ± 10 mm (58.78 ± 0.39 in)
Wheelbase (EX-F)
1,489 ± 10 mm (58.62 ± 0.39 in)
Seat height, unloaded (All MC-F models)
956 mm (37.64 in)
Seat height, unloaded (EX-F)
957 mm (37.68 in)
Ground clearance, unloaded (All MC-F models)
343 mm (13.5 in)
Ground clearance, unloaded (EX-F)
344 mm (13.54 in)
Weight without fuel, approx. (All MC-F models)
103.4 kg (228 lb.)
Weight without fuel, approx. (EX-F)
105.8 kg (233.2 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.)
141
23
TECHNICAL SPECIFICATIONS
23.5
Electrical system
Fuse
58011109110
10 A
Fuse
58011109105
5A
Combination instrument lighting and indicator lamps
LED
23.6
Tires
Validity
Front tire
Rear tire
(MC-F)
80/100 - 21 M/C 51M TT
110/90 - 19 M/C 62M TT
MAXXIS MAXXCROSS MX-ST+
MAXXIS MAXXCROSS MX-ST
(EX-F)
80/100 - 21 51M TT
110/100 - 18 64M TT
Dunlop GEOMAX MX33F
Dunlop GEOMAX AT81
(FACTORY EDITION)
80/100 - 21 51M TT
120/80 - 19 62M TT
Dunlop GEOMAX MX34F
Dunlop GEOMAX MX34
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-F
Fork article number
A460C109X406000
Fork
WP XACT AER
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Rebound damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Air pressure
10.4 bar (151 psi)
Fork length
950 mm (37.4 in)
Oil capacity external mechanism right
240+10-50 ml (8.11+0.34-1.69 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
Oil capacity external mechanism left
240+10-50 ml (8.11+0.34-1.69 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
Oil capacity, right cartridge
380 ml (12.85 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
Grease capacity, left cartridge
5 g (0.18 oz)
Special grease (00062010053)
(
p. 153)
23.7.2
EX-F
Fork article number
A590C179X402000
Fork
WP XPLOR CC
Compression damping
Comfort
17 clicks
142
TECHNICAL SPECIFICATIONS
23
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.)
4.6 N/mm (26.3 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
4.8 N/mm (27.4 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
5.0 N/mm (28.6 lb/in)
Fork length
940 mm (37.01 in)
Oil capacity, external mechanism
390 ± 5 ml (13.19 ± 0.17 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
Oil capacity, cartridge
175 ml (5.92 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
23.7.3
FACTORY EDITION
Fork article number
A460C159Y406000
Fork
WP XACT AER
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Rebound damping
Comfort
23 clicks
Standard
18 clicks
Sport
13 clicks
Air pressure
10.5 bar (152 psi)
Fork length
950 mm (37.4 in)
Oil capacity external mechanism right
240+10-50 ml (8.11+0.34-1.69 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
Oil capacity external mechanism left
240+10-50 ml (8.11+0.34-1.69 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
Oil capacity, right cartridge
380 ml (12.85 fl. oz.)
Fork oil (SAE 4) (48601166S1)
(
p. 150)
Grease capacity, left cartridge
5 g (0.18 oz)
Special grease (00062010053)
(
p. 153)
143
23
TECHNICAL SPECIFICATIONS
23.8
Shock absorber
23.8.1
MC-F
Shock absorber article number
A460C409X408000
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
105 mm (4.13 in)
Fitted length
456.3 mm (17.965 in)
Shock absorber oil
Shock absorber fluid (SAE 2.5)
(50180751S1) ( p. 151)
23.8.2
EX-F
Shock absorber article number
A460C479X408000
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)
144
TECHNICAL SPECIFICATIONS
23
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 oil
Shock absorber fluid (SAE 2.5)
(50180751S1) ( p. 151)
23.8.3
FACTORY EDITION
Shock absorber article number
A460C459Y408000
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
105 mm (4.13 in)
Fitted length
456.3 mm (17.965 in)
Shock absorber oil
Shock absorber fluid (SAE 2.5)
(50180751S1) ( p. 151)
145
23
TECHNICAL SPECIFICATIONS
23.9
Chassis tightening torques
Remaining screws, chassis
EJOT PT® K60x25-Z
2 Nm (1.5 lbf ft)
Screw, air filter box cover
EJOT PT® K60x20-Z
3 Nm (2.2 lbf ft)
Screw, air filter box, on subframe
EJOT PT® K60x20AL
5 Nm (3.7 lbf ft)
Screw, combination switch
EJOT PT® K50x18 T20
2 Nm (1.5 lbf ft)
Screw, fuel pump on fuel tank
EJOT PT® K60x30-Z
2.5 Nm (1.84 lbf ft)
Screw, intake air temperature sensor
EJOT PT® K50x18 T20
0.7 Nm (0.52 lbf ft)
Screw, radiator hoses clip
2.4 Nm (1.77 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, throttle valve body hose clamp
M4
5 Nm (3.7 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, frame protector
M5
3 Nm (2.2 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, starter cable on starter motor
M6
4 Nm (3 lbf ft)
Nut, throttle cable on throttle valve
M6
3 Nm (2.2 lbf ft)
body
Remaining nuts, chassis
M6
10 Nm (7.4 lbf ft)
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Screw, battery support bracket
M6
6 Nm (4.4 lbf ft)
Screw, brake line guide on link fork
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 on link fork
M6
6 Nm (4.4 lbf ft)
Screw, connector board with combi-
M6
5 Nm (3.7 lbf ft)
nation instrument
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, ground wire on frame
M6
10 Nm (7.4 lbf ft)
Screw, hand lever
M6
5 Nm (3.7 lbf ft)
Screw, push rod ball joint on the rear
M6
10 Nm (7.4 lbf ft)
brake cylinder
Loctite®243™
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
Loctite®243™
Screw, seat fixing
M6
8 Nm (5.9 lbf ft)
Screw, starter cable to starter relay
M6
6 Nm (4.4 lbf ft)
Screw, throttle grip
M6
5 Nm (3.7 lbf ft)
146
TECHNICAL SPECIFICATIONS
23
Brake lever stop nut
M8
20 Nm (14.8 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)
Remaining nuts, chassis
M8
25 Nm (18.4 lbf ft)
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
Screw, bottom triple clamp
M8
12 Nm (8.9 lbf ft)
(FACTORY EDITION)
Screw, bottom triple clamp (MC-F /
M8
15 Nm (11.1 lbf ft)
EX-F)
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)
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 on cylinder head
M8
15 Nm (11.1 lbf ft)
brace
Screw, side stand attachment (EX-F)
M8
33 Nm (24.3 lbf ft)
Loctite®2701™
Screw, subframe, bottom
M8
35 Nm (25.8 lbf ft)
Loctite®243™
Screw, subframe, top
M8
40 Nm (29.5 lbf ft)
Loctite®2701™
Screw, top steering stem
M8
20 Nm (14.8 lbf ft)
(FACTORY EDITION)
Loctite®243™
Screw, top steering stem
M8
20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp (FACTORY EDI-
M8
17 Nm (12.5 lbf ft)
TION)
Screw, top triple clamp (MC-F / EX-F)
M8
20 Nm (14.8 lbf ft)
Engine carrying 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, angle lever to link fork
M16x1.5
80 Nm (59 lbf ft)
Nut, fork pivot
M16x1.5
100 Nm (73.8 lbf ft)
Nut, frame on linkage lever
M16x1.5
80 Nm (59 lbf ft)
Nut, linkage lever on angle lever
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)
Nut, rear wheel spindle
M22x1.5
80 Nm (59 lbf ft)
Screw-in fitting, cooling system
M24x1.5
7.5 Nm (5.53 lbf ft)
147
24
DECLARATIONS OF CONFORMITY CUO (FACTORY EDITION)
24.1
Country-specific declarations of conformity - Connectivity Unit Offroad
W00603-10
148
FCC STATEMENTS CUO (FACTORY EDITION)
25
25.1
FCC statements - Connectivity Unit Offroad
Declaration regarding modifications
Alterations and modifications not expressly approved by the relevant authority may result in the user being prohibited from
operating the equipment.
Declaration regarding interference
This device complies with article 15 of the FCC regulations.
Operation is subject to the following two conditions:
1
This device must not cause interference.
2
This device must be able to absorb any interference, including interference that potentially causes undesirable opera-
tion of the device.
149
26
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 (SAE 10W/50)
Standard/classification
- JASO T903 MA2 ( p. 154)
- SAE ( p. 154) (SAE 10W/50)
Guideline
- Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the
corresponding properties.
Fully synthetic engine oil
Recommended supplier
MOTOREX®
- Cross Power 4T
Fork oil (SAE 4) (48601166S1)
Standard/classification
- SAE ( p. 154) (SAE 4)
Guideline
- Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre-
sponding properties.
150
SUBSTANCES
26
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
- SAE ( p. 154) (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).
151
27
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
152
AUXILIARY SUBSTANCES
27
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
153
28
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.
154
INDEX OF SPECIAL TERMS
29
-
Launch control
Vehicles electronics functions for achieving the best possi-
ble acceleration from a standing position
OBD
On-board diagnosis
Vehicle system, which monitors the specified parameters
of the vehicle electronics
-
Quickshifter
Function of the engine electronics for shifting up without
clutch actuation
TC
Traction Control
Auxiliary function of the motor control that reduces engine
torque with spinning rear wheel
155
30
LIST OF ABBREVIATIONS
Art. no.
Article number
ca.
circa
cf.
compare
e.g.
for example
etc.
et cetera
i.a.
inter alia
no fig.
no figure
no.
number
poss.
possibly
s.
see
156
LIST OF SYMBOLS
31
31.1
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. The malfunction indicator lamp also lights up if traction control is activated and the
speed limiter intervenes.
TC indicator lamp lights up orange - TC is enabled or is currently intervening. The TC indicator lamp
flashes if launch control is activated.
31.2
Green and blue symbols
Green and blue symbols reflect information.
QS indicator lamp lights up blue - The quickshifter is activated. The QS indicator lamp flashes when the
quickshifter is being programmed.
Indicator lamp B lights up green - ADVANCED mapping is activated.
31.3
White symbols
White symbols convey information.
Indicator lamp A lights up white - STANDARD mapping is activated.
157