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OWNER'S MANUAL 2021
MC 125
Art. no. 3215008en
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DEAR GASGAS CUSTOMER
DEARGASGAS CUSTOMER
Congratulations on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports
vehicle which, with appropriate care, will bring you pleasure for a long time to come.
We wish you good and safe riding at all times!
Enter the serial numbers of your vehicle below.
Vehicle identification number ( p. 12)
Engine number ( p. 12)
The Owner's Manual contained the latest information for this model series at the time of publication. However, minor differences due to further developments in design cannot be ruled out completely.
All specifications contained herein are non-binding. GASGAS Motorcycles GmbH specifically reserves the right to modify or
delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and
without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without
prior notice. GASGAS Motorcycles accepts no liability for delivery options, deviations from illustrations and descriptions,
as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
Dealer's stamp
© 2020 GASGAS Motorcycles GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
GASGAS Motorcycles applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
GASGAS Motorcycles GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
MC 125 (F0101U0)
*3215008en*
3215008en
10/2020
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TABLE OF CONTENTS
TABLEOF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used................................................. 5
1.2 Formats used................................................. 5
2 SAFETY ADVICE ............................................................ 6
2.1 Use definition – intended use ....................... 6
2.2 Misuse............................................................ 6
2.3 Safety advice.................................................. 6
2.4 Degrees of risk and symbols ......................... 6
2.5 Tampering warning ....................................... 7
2.6 Safe operation ............................................... 7
2.7 Protective clothing ........................................ 7
2.8 Work rules ..................................................... 8
2.9 Environment.................................................. 8
2.10 Owner's Manual ............................................ 8
3 IMPORTANT NOTES ..................................................... 9
3.1 Manufacturer warranty, implied
warranty ........................................................ 9
3.2 Fuel, auxiliary substances.............................. 9
3.3 Spare parts, accessories................................ 9
3.4 Service ........................................................... 9
3.5 Figures ........................................................... 9
3.6 Customer service........................................... 9
4 VIEW OF VEHICLE ...................................................... 10
4.1 View of vehicle, front left (example) .......... 10
4.2 View of vehicle, rear right (example).......... 11
5 SERIAL NUMBERS....................................................... 12
5.1 Vehicle identification number..................... 12
5.2 Type label .................................................... 12
5.3 Engine number ............................................ 12
5.4 Fork part number ........................................ 12
5.5 Shock absorber article number................... 13
6 CONTROLS.................................................................. 14
6.1 Clutch lever.................................................. 14
6.2 Hand brake lever ......................................... 14
6.3 Throttle grip................................................. 14
6.4 Stop button.................................................. 14
6.5 Opening the fuel tank filler cap................... 15
6.6 Closing the fuel tank filler cap..................... 15
6.7 Fuel tap........................................................ 16
6.8 Choke........................................................... 16
6.9 Shift lever..................................................... 16
6.10 Kick starter lever.......................................... 17
6.11 Foot brake lever .......................................... 17
6.12 Plug-in stand................................................ 17
7 PREPARING FOR USE ................................................. 18
7.1 Advice on preparing for first use ................ 18
7.2 Running in the engine ................................. 19
7.3 Preparing the vehicle for difficult
operating conditions ................................... 19
7.4 Preparing the vehicle for rides on dry
sand ............................................................. 20
7.5 Preparing the vehicle for rides on wet
sand ............................................................. 21
7.6 Preparing the vehicle for rides on wet
and muddy circuits ...................................... 22
7.7 Preparing vehicle for high temperatures
or slow riding ............................................... 23
7.8 Preparing the vehicle for low
temperatures or snow ................................ 24
8 RIDING INSTRUCTIONS .............................................. 25
8.1 Checks and maintenance measures
when preparing for use............................... 25
8.2 Starting ........................................................ 25
8.3 Starting off................................................... 26
8.4 Shifting, riding ............................................. 26
8.5 Applying the brakes..................................... 27
8.6 Stopping, parking......................................... 27
8.7 Transporting ................................................ 28
8.8 Refueling...................................................... 28
9 SERVICE SCHEDULE.................................................... 30
9.1 Additional information................................ 30
9.2 Required work ............................................. 30
9.3 Recommended work ................................... 31
10 TUNING THE CHASSIS ................................................ 32
10.1 Checking the basic chassis setting with
the rider's weight ........................................ 32
10.2 Air suspension XACT 5448........................... 32
10.3 Compression damping of the shock
absorber ...................................................... 33
10.4 Adjusting the low-speed compression
damping of the shock absorber .................. 33
10.5 Adjusting the high-speed compression
damping of the shock absorber .................. 33
10.6 Adjusting the rebound damping of the
shock absorber ............................................ 34
10.7 Measuring the rear wheel dimension
unloaded...................................................... 34
10.8 Checking the static sag of the shock
absorber ...................................................... 35
10.9 Checking the riding sag of the shock
absorber ...................................................... 36
10.10 Adjusting the spring preload of the
shock absorber ........................................ 36
10.11 Adjusting the riding sag ........................... 37
10.12 Checking the basic setting of the fork ........ 38
10.13 Adjusting the fork air pressure.................... 38
10.14 Adjusting the compression damping of
the fork ........................................................ 39
10.15 Adjusting the rebound damping of the
fork............................................................... 40
10.16 Handlebar position...................................... 40
10.17 Adjusting the handlebar position ........... 40
11 SERVICE WORK ON THE CHASSIS .............................. 42
11.1 Raising the motorcycle with a lift stand ..... 42
11.2 Removing the motorcycle from the lift
stand ............................................................ 42
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TABLE OF CONTENTS
11.3 Bleeding the fork legs.................................. 42
11.4 Cleaning the dust boots of the fork legs..... 43
11.5 Removing the fork legs ........................... 43
11.6 Installing the fork legs ............................. 44
11.7 Removing the fork protector ...................... 45
11.8 Installing the fork protector ........................ 45
11.9 Removing the lower triple clamp ............ 45
11.10 Installing the lower triple clamp ............. 46
11.11 Checking steering head bearing play .......... 48
11.12 Adjusting steering head bearing play ..... 48
11.13 Lubricating the steering head bearing .... 49
11.14 Removing the start number plate............... 49
11.15 Installing the start number plate ................ 49
11.16 Removing front fender................................ 50
11.17 Installing front fender ................................. 50
11.18 Removing the shock absorber ................ 50
11.19 Installing the shock absorber .................. 52
11.20 Removing the seat....................................... 53
11.21 Mounting the seat....................................... 54
11.22 Removing the air filter box cover................ 54
11.23 Installing the air filter box cover ................. 55
11.24 Removing the air filter ............................ 56
11.25 Cleaning the air filter and air filter
box ........................................................... 56
11.26 Installing the air filter .............................. 57
11.27 Preparing air filter box cover for
securing ................................................... 57
11.28 Removing the main silencer........................ 58
11.29 Installing the main silencer ......................... 58
11.30 Changing the glass fiber yarn filling in
the main silencer ..................................... 58
11.31 Removing the fuel tank ........................... 59
11.32 Installing the fuel tank ............................. 60
11.33 Checking the chain for dirt .......................... 61
11.34 Cleaning the chain....................................... 62
11.35 Checking the chain tension ......................... 62
11.36 Adjusting the chain tension ........................ 63
11.37 Checking the chain, rear sprocket,
engine sprocket, and chain guide ............... 64
11.38 Checking the frame ................................. 66
11.39 Checking the link fork .............................. 66
11.40 Checking throttle cable routing .................. 66
11.41 Checking the rubber grip ............................ 67
11.42 Adjusting the basic position of the clutch
lever............................................................. 68
11.43 Checking/correcting the fluid level of the
hydraulic clutch ........................................... 68
11.44 Changing the hydraulic clutch fluid ........ 69
12 BRAKE SYSTEM........................................................... 71
12.1 Checking the free travel of the hand
brake lever................................................... 71
12.2 Adjusting the basic position of the hand
brake lever................................................... 71
12.3 Checking the brake discs............................. 71
12.4 Checking the front brake fluid level ............ 72
12.5 Adding front brake fluid .......................... 72
12.6 Checking the front brake linings ................. 74
12.7 Changing the brake linings of the front
brake ........................................................ 74
12.8 Checking the free travel of foot brake
lever............................................................. 76
12.9 Adjusting the basic position of the foot
brake lever ............................................... 77
12.10 Checking the rear brake fluid level ............. 77
12.11 Adding rear brake fluid ........................... 78
12.12 Checking the brake linings of the rear
brake............................................................ 79
12.13 Changing the rear brake linings .............. 79
13 WHEELS, TIRES........................................................... 82
13.1 Removing the front wheel ...................... 82
13.2 Installing the front wheel ........................ 83
13.3 Removing the rear wheel ........................ 83
13.4 Installing the rear wheel ......................... 84
13.5 Checking the tire condition......................... 86
13.6 Checking tire pressure................................. 86
13.7 Checking spoke tension............................... 87
14 COOLING SYSTEM...................................................... 88
14.1 Cooling system ............................................ 88
14.2 Radiator cover ............................................. 88
14.3 Installing the radiator cover ........................ 88
14.4 Removing the radiator cover ...................... 89
14.5 Checking the antifreeze and coolant
level.............................................................. 89
14.6 Checking the coolant level .......................... 90
14.7 Draining the coolant ................................ 91
14.8 Refilling with coolant ............................... 92
14.9 Changing the coolant .............................. 93
15 TUNING THE ENGINE................................................. 95
15.1 Checking the play in the throttle cable....... 95
15.2 Adjusting throttle cable play ................... 95
15.3 Carburetor tuning........................................ 96
15.4 Carburetor – idle setting ............................. 98
15.5 Carburetor - adjusting the idle speed ..... 99
15.6 Plug-in connector of ignition timing
map adjustment ....................................... 100
15.7 Changing the ignition timing map............ 100
15.8 Checking the basic position of the shift
lever.......................................................... 100
15.9 Adjusting the basic position of the shift
lever ...................................................... 100
16 SERVICE WORK ON THE ENGINE ............................ 102
16.1 Emptying the carburetor float
chamber ............................................... 102
16.2 Checking the gear oil level ....................... 103
16.3 Changing the gear oil ........................... 103
16.4 Adding the gear oil ............................... 104
17 CLEANING, CARE..................................................... 106
17.1 Cleaning the motorcycle .......................... 106
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18 STORAGE................................................................. 108
18.1 Storage...................................................... 108
18.2 Preparing for use after storage................ 109
19 TROUBLESHOOTING ............................................... 110
20 TECHNICAL DATA.................................................... 112
20.1 Engine ....................................................... 112
20.2 Engine tightening torques........................ 112
20.3 Carburetor ................................................ 114
20.3.1 Carburetor tuning ............................... 114
20.3.2 Carburetor - basic setting for sandy
20.4 Capacities.................................................. 115
20.4.1 Gear oil ................................................ 115
20.4.2 Coolant ................................................ 115
20.4.3 Fuel ...................................................... 115
20.5 Chassis ...................................................... 115
20.6 Tires .......................................................... 116
20.7 Fork........................................................... 116
20.8 Shock absorber......................................... 117
20.9 Chassis tightening torques ....................... 117
surfaces ............................................... 115
21 SUBSTANCES........................................................... 120
22 AUXILIARY SUBSTANCES......................................... 122
23 STANDARDS ............................................................ 124
24 LIST OF ABBREVIATIONS......................................... 125
INDEX ............................................................................... 126
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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).
All work marked with this symbol requires specialist 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.
MEANS OF REPRESENTATION 1
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential reworking.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
®
Name
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are
Indicates a protected name.
explained in the glossary.
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2 SAFETY ADVICE
2.1 Use definition – intended use
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with
the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respec-
tive use.
2.3 Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction
and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the
relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do not
remove any information or warning labels. If they are missing, you or others may not recognize dangers and may
therefore be injured.
2.4 Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate
measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
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SAFETY ADVICE 2
2.5 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of
any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust
gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those
specified by the manufacturer.
2.6 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before
the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and
environmentally compatible manner.
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 protective clothing.
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2 SAFETY ADVICE
2.8 Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote
key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the
number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion
screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instructions.
If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn
parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of
the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of
others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations 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 information 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 downloaded 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 available for download from your authorized GASGAS Motorcycles dealer and on the
GASGAS Motorcycles website. A printed copy can also be ordered from your authorized GASGAS Motorcycles dealer.
International GASGAS Motorcycles website: http://www.gasgas.com
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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 damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2 Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by
GASGAS Motorcycles and have them installed by an authorized GASGAS Motorcycles workshop. GASGAS Motorcycles
accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized
GASGAS Motorcycles dealer will be glad to advise you.
The latest news GASGAS Technical Accessories on your vehicle can be found on the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the
engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to
damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly
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.
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
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4 VIEW OF VEHICLE
4.1 View of vehicle, front left (example)
Hand brake lever ( p. 14)
1
Clutch lever ( p. 14)
2
Air filter box cover
3
Shift lever ( p. 16)
4
Choke ( p. 16)
5
Fuel tap
6
S04515-10
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4.2 View of vehicle, rear right (example)
VIEW OF VEHICLE 4
Seat
1
Fuel tank filler cap
2
Stop button ( p. 14)
3
Throttle grip ( p. 14)
4
Kick starter lever ( p. 17)
5
Foot brake lever ( p. 17)
6
Shock absorber compression adjustment
7
Shock absorber rebound adjustment
8
Level viewer for brake fluid, rear
9
S04516-10
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5 SERIAL NUMBERS
5.1 Vehicle identification number
5.2 Type label
The vehicle identification number1is stamped on the right side of the
steering head.
401945-10
The type label1is fixed to the front of the steering head.
5.3 Engine number
5.4 Fork part number
401946-10
The engine number1is stamped on the left side of the engine under
the engine sprocket.
401949-10
The fork part number1is stamped on the inside of the axle clamp.
12
401947-10
Page 15
5.5 Shock absorber article number
401948-10
SERIAL NUMBERS 5
Shock absorber article number1is stamped on the top of the shock
absorber above the adjusting ring towards the engine side.
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6 CONTROLS
6.1 Clutch lever
6.2 Hand brake lever
Clutch lever1is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
S04517-10
Hand brake lever1is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3 Throttle grip
6.4 Stop button
S04518-10
Throttle grip1is fitted on the right side of the handlebar.
S04518-11
The stop button1is fitted on the left side of the handlebar.
Possible states
• The stop button is in the basic position – In this position, the
ignition circuit is closed and the engine can be started.
• Stop button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not
start.
14
S04519-10
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6.5 Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
CONTROLS 6
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 cap1counterclockwise and lift it off.
S04520-10
6.6 Closing the fuel tank filler cap
–
Mount fuel tank filler cap1and turn it clockwise until the fuel
tank is tightly closed.
Info
Route fuel tank breather hose2without kinks.
S04520-11
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6 CONTROLS
6.7 Fuel tap
6.8 Choke
S04521-10
The fuel tap is on the left side of the fuel tank.
Open or close the fuel supply to the carburetor using knurled screw
on the fuel tap.
Possible states
• Fuel tap is closed – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel tap is open – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.
Choke1is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through
which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.
1
Info
If the engine is warm, the choke function must be deactivated.
6.9 Shift lever
K01129-10
401950-10
Possible states
• Choke function activated – The choke lever is pulled out to the
stop.
• Choke function deactivated – The choke lever is pushed in to the
stop.
Shift lever1is mounted on the left of the engine.
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
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401950-11
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6.10 Kick starter lever
6.11 Foot brake lever
CONTROLS 6
Kick starter lever1is fitted on the right side of the engine.
The kick starter lever can be swiveled.
Info
Before riding, swing the kick starter lever inwards towards the
engine.
401954-10
Foot brake lever1is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
6.12 Plug-in stand
401956-10
The holder for the plug-in stand1is 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 motorcycle.
Info
Remove the plug-in stand before riding.
H02629-10
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7 PREPARING FOR USE
7.1 Advice on preparing for first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with pro-
tectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-sales inspection work has been carried out by an authorized GASGAS Motorcycles workshop.
You will receive a delivery certificate when the vehicle is handed over.
– Before riding for the first time, read the entire Owner's Manual carefully.
– Get to know the controls.
–
Adjust the basic position of the clutch lever. ( p. 68)
–
Adjust the basic position of the hand brake lever. ( p. 71)
–
Adjust the basic position of the foot brake lever. ( p. 77)
–
Adjust the basic position of the shift lever. ( p. 100)
18
Page 21
PREPARING FOR USE 7
– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging
trips.
Info
Your motorcycle is not approved for use on public roads.
When offroad, it is recommended that you are accompanied by another person on another vehicle so that you
can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
– Do not make any off-road trips that exceed your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Do not take luggage along.
– Do not exceed the maximum permissible weight and the maximum permissible axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
–
Check the spoke tension. ( p. 87)
Info
The spoke tension must be checked after half an hour of operation.
–
Run the engine in. ( p. 19)
7.2 Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %
Info
The use of a service hour counter is recommended in order to be able to check the mileage at any time.
– Avoid fully opening the throttle.
7.3 Preparing the vehicle for difficult operating conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy circuits/surfaces, can lead to
considerably more rapid wear of components such as the drive train, brake system, or suspension components. For
this reason, it may be necessary to inspect or replace parts before the next scheduled service.
–
Prepare air filter box cover for securing. ( p. 57)
–
Clean the air filter and air filter box. ( p. 56)
Info
Check the air filter approx. every 30 minutes.
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
19
Page 22
7 PREPARING FOR USE
» If humidity, corrosion, or damage is found:
– Clean and dry the connector, or change it if necessary.
– Make sure that no radiator covers are installed.
Difficult operating conditions are:
–
Rides on dry sand. ( p. 20)
–
Rides on wet sand. ( p. 21)
–
Rides on wet and muddy circuits. ( p. 22)
–
Riding at high temperatures or slow riding. ( p. 23)
–
Riding at low temperatures and in snow. ( p. 24)
7.4 Preparing the vehicle for rides on dry sand
M01129-01
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
Warning
Danger of scalding During motorcycle operation,
the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or
other cooling system components if the engine
or the cooling system are at operating temperature.
– Allow the cooling system and the engine to
cool down before you open the radiator, the
radiator hoses or other components of the
cooling system.
– In the event of scalding, rinse the area affected
immediately with lukewarm water.
M01104-01
M01105-01
– Change the radiator cap.
– Mount the air filter dust cover.
Air filter dust cover (79006920000)
Info
Observe the fitting instructions for GASGAS Technical Accessories.
– Mount the air filter sand cover.
Air filter sand cover (79006922000)
Info
Observe the fitting instructions for GASGAS Technical Accessories.
20
Page 23
M01107-01
600868-01
PREPARING FOR USE 7
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.
– Clean the chain.
Chain cleaner ( p. 122)
– Mount the steel sprocket.
– Grease the chain.
Universal oil spray ( p. 123)
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
7.5 Preparing the vehicle for rides on wet sand
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
M01129-01
– Change the radiator cap.
Warning
Danger of scalding During motorcycle operation,
the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or
other cooling system components if the engine
or the cooling system are at operating temperature.
– Allow the cooling system and the engine to
cool down before you open the radiator, the
radiator hoses or other components of the
cooling system.
– In the event of scalding, rinse the area affected
immediately with lukewarm water.
21
Page 24
7 PREPARING FOR USE
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for GASGAS Technical Accessories.
M01106-01
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.
M01107-01
– Clean the chain.
Chain cleaner ( p. 122)
– Mount the steel sprocket.
–
Grease the chain.
Universal oil spray ( p. 123)
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
600868-01
Condition
Regular use in sand
– Change the piston every 10 operating hours.
7.6 Preparing the vehicle for rides on wet and muddy circuits
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for GASGAS Technical Accessories.
22
M01106-01
Page 25
M01107-01
600868-01
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.
– Mount the steel sprocket.
–
Clean the motorcycle. ( p. 106)
– Straighten the bent radiator fins carefully.
PREPARING FOR USE 7
7.7 Preparing vehicle for high temperatures or slow riding
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
Warning
Danger of scalding During motorcycle operation,
the coolant gets very hot and is under pressure.
M01129-01
– Change the radiator cap.
– Adjust the secondary drive to the road conditions.
– 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.
600868-01
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. 122)
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
–
Check the coolant level. ( p. 90)
23
Page 26
7 PREPARING FOR USE
7.8 Preparing the vehicle for low temperatures or snow
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for GASGAS Technical Accessories.
M01106-01
– Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.
M01107-01
24
Page 27
8.1 Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
–
Check the gear oil level. ( p. 103)
–
Check the front brake fluid level. ( p. 72)
–
Check the rear brake fluid level. ( p. 77)
–
Check the front brake linings. ( p. 74)
–
Check the brake linings of the rear brake. ( p. 79)
– Check that the brake system is functioning properly.
–
Check the coolant level. ( p. 90)
–
Check the chain for dirt. ( p. 61)
H02217-01
– Check the chain, rear sprocket, engine sprocket, and chain guide.
( p. 64)
–
Check the chain tension. ( p. 62)
–
Check the tire condition. ( p. 86)
–
Check tire pressure. ( p. 86)
–
Check the spoke tension. ( p. 87)
RIDING INSTRUCTIONS 8
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. 43)
–
Bleed the fork legs. ( p. 42)
– Check the air filter.
– Check the settings of all controls and ensure that they can be oper-
ated smoothly.
– Check all screws, nuts, and hose clamps regularly for tightness.
– Check the fuel level.
8.2 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the
fuel evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
25
Page 28
8 RIDING INSTRUCTIONS
8.3 Starting off
Info
The plug-in stand must be removed before riding.
When you are riding, the side stand must be folded up and secured with the rubber strap.
H02629-10
The motorcycle has been out of use for more than 1 week
–
Empty the carburetor float chamber. ( p. 102)
– Turn the knurled screw on the fuel tap all the way counterclockwise.
Fuel can flow from the fuel tank to the carburetor.
–
Remove plug-in stand1.
– Shift the transmission into neutral.
Condition
The engine is cold
– Pull the choke lever out as far as possible.
– Press the kick starter robustly through its full range.
Info
Do not open the throttle.
– Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.
8.4 Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
– Do not change into a low gear at high engine speed.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized GASGAS Motorcycles workshop.
First-gear is used for starting off and for steep inclines.
– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
– If the choke function has been activated, deactivate it after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely
reduce the speed, but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, apply the brakes and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift
again.
– Switch off the engine if running at idle speed or stationary for a long time.
Guideline
≥ 2 min
– Avoid frequent or lengthy slipping of the clutch. This causes the gear oil, engine and cooling system to heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
26
Page 29
RIDING INSTRUCTIONS 8
8.5 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 the rear brake mostly if possible.
– Always finish braking before you go into a bend. Change down to a lower gear appropriate to your road speed.
– Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the
engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.
8.6 Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before
the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
–
Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
– Apply the brakes on the motorcycle.
– Shift the transmission to neutral position.
– Press and hold the stop button while the engine is idling until the engine stops.
– Turn the knurled screw on the fuel tap all the way clockwise.
– Rest the vehicle on the plug-in stand.
27
Page 30
8 RIDING INSTRUCTIONS
8.7 Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Switch off the engine.
– Mount plug-in stand on the fork legs.
Plug-in stand (79029094000)
Info
The plug-in stand is included.
Make sure the brake line runs in front of the plug-in stand
and does not become wedged.
H02628-01
– Use tension belts or other suitable devices to secure the motorcycle
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.
401475-01
8.8 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
28
Page 31
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. 15)
–
Fill the fuel tank with fuel up to measurementA.
Guideline
Measurement of
A
RIDING INSTRUCTIONS 8
35 mm (1.38 in)
400382-10
Total fuel tank capacity, approx.
Engine oil, 2-stroke ( p. 120)
–
Close the fuel tank filler cap. ( p. 15)
7.5 l
(1.98 US gal)
Super unleaded (98
octane) mixed with
2-stroke engine oil
(1:40) ( p. 121)
29
Page 32
9 SERVICE SCHEDULE
9.1 Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and
invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service
schedule can always be found on GASGAS Motorcycles Dealer.net. Your authorized GASGAS Motorcycles dealer will be glad
to advise you.
The use of a service hour counter is recommended in order to be able to check the mileage at any time.
Service hour counter (A54012920000)
9.2 Required work
Change the gear oil. ( p. 103)
Check the front brake linings. ( p. 74)
Check the brake linings of the rear brake. ( p. 79)
Check the brake discs. ( p. 71)
Check the brake lines for damage and leakage. ● ● ● ●
Check the rear brake fluid level. ( p. 77)
Check the free travel of the foot brake lever. ( p. 76)
Check the frame. ( p. 66)
Check the link fork. ( p. 66)
Checking the link fork bearing for play. ● ●
Checking the shock absorber heim joint for play. ● ● ● ●
Check the shock absorber linkage. ● ● ● ●
Check the tire condition. ( p. 86)
Check tire pressure. ( p. 86)
Check the wheel bearing for play. ● ● ● ●
Check the wheel hubs. ● ● ● ●
Check the rim run-out. ○ ● ● ● ●
Check the spoke tension. ( p. 87)
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 64)
Check the chain tension. ( p. 62)
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. ● ● ● ●
Check/correct the fluid level of the hydraulic clutch. ( p. 68)
Check the front brake fluid level. ( p. 72)
Check the free travel of the hand brake lever. ( p. 71)
Check steering head bearing play. ( p. 48)
Change the spark plug and spark plug connector. ● ● ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and
incorrect routing.
Check the antifreeze and coolant level. ( p. 89)
Check the cables for damage and for routing without kinks. ● ● ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly. ○ ● ● ● ●
Clean the air filter and air filter box. ( p. 56)
after every race
Every 40 operating hours
Every 20 operating hours
Every 10 operating hours
After 1 operating hour
● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
● ● ● ●
○ ● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
● ● ● ●
30
Page 33
SERVICE SCHEDULE 9
after every race
Every 40 operating hours
Every 20 operating hours
Every 10 operating hours
After 1 operating hour
Change the glass fiber yarn filling in the main silencer. ( p. 58)
Service the fork. ●
Perform the shock absorber service. ●
Check the tightness of the easily accessible, safety-relevant screws and nuts. ○ ● ● ● ●
Check the idle speed. ○ ● ● ● ●
Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ●
Make a service entry in GASGAS Motorcycles Dealer.net. ○ ● ● ● ●
○ One-time interval
● Periodic interval
9.3 Recommended work
every 12 months
after every race
Every 40 operating hours
After 20 operating hours / Every 20 operating hours
After 10 operating hours / Every 10 operating hours
Change the front brake fluid. ● ●
Change the rear brake fluid. ● ●
Change the hydraulic clutch fluid. ( p. 69)
Lubricate the steering head bearing. ( p. 49)
Service the fork. ○
Perform the shock absorber service. ○
Check/adjust the carburetor components. ● ● ●
Change the needle jet. ● ● ●
Change the coolant. ( p. 93)
Perform minor engine service. (Check the inlet membrane. Check the clutch. Under difficult
operating conditions: Change the piston and check the cylinder and Z dimension.)
Perform the intermediate engine service. (Change the piston and check the cylinder and Z
dimension. Check the exhaust control for functioning and smooth operation.)
Perform major engine service including removing and installing the engine. (Change the
connecting rod, conrod bearing, and crank pin. Check the transmission and shift mechanism. Change all engine bearings.)
○ One-time interval
● Periodic interval
● ● ● ●
● ●
● ●
every 48 months
● ●
● ●
●
●
31
Page 34
10 TUNING THE CHASSIS
10.1 Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage
to forks, shock absorbers, link fork and frame, the basic settings of
the suspension components must match the rider's weight.
– As delivered, GASGAS offroad motorcycles are adjusted for an aver-
age rider's weight (with full protective clothing).
Guideline
Standard rider weight 75 … 85 kg (165 … 187 lb.)
– If the rider's weight is above or below this range, the basic setting of
the suspension components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the
spring preload, but in the case of large weight differences, the
springs must be replaced.
401030-01
10.2 Air suspension XACT 5448
M01110-01
Air suspension WP Suspension XACT 5448 is used in the fork.
In this system, suspension is located in the left fork leg and damping in
the right fork leg.
As fork springs are no longer required, a significant weight advantage is
achieved when compared to conventional forks. The response on slightly
uneven surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air
cushion. A steel spring is located in the left fork leg as an end stop.
Info
If the fork is frequently overloaded, then the air pressure in the
fork must be increased to avoid damage to the fork and frame.
The air pressure in the fork can be quickly adjusted to the rider's weight,
surface conditions and the rider's preference using a fork airpump. The
fork does not have to be dismantled. The time consuming mounting of
harder or softer fork springs is not required.
If the air chamber loses air due to a damaged seal, the fork will still not
sag. In this case the air is retained in the fork. The suspension travel is
maintained as far as possible. The damping becomes harder and the
riding comfort reduces.
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.
32
Page 35
TUNING THE CHASSIS 10
10.3 Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension
compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel sus-
pension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus,
modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.
10.4 Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.
–
Turn adjusting screw1clockwise with a screwdriver as far as the
last perceptible click.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of clicks corresponding to the
shock absorber type.
S04522-10
Guideline
Lowspeed compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
10.5 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.
33
Page 36
10 TUNING THE CHASSIS
10.6 Adjusting the rebound damping of the shock absorber
S04523-10
–
Turn adjusting screw1all the way clockwise with a socket wrench.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of turns corresponding to the
shock absorber type.
Guideline
Highspeed compression damping
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
–
Turn adjusting screw1clockwise up to the last perceptible click.
– Turn counterclockwise by the number of clicks corresponding to the
shock absorber type.
Guideline
Rebound damping
Comfort 17 clicks
Standard 15 clicks
S04524-10
Sport 13 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.7 Measuring the rear wheel dimension unloaded
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
34
Page 37
402415-10
TUNING THE CHASSIS 10
Main work
– Position the sag gage in the rear axle and measure the distance to
marking SAG on the rear fender.
Sag gauge (00029090000)
Sag gage pin (00029990010)
–
Note down the value as dimensionA.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
10.8 Checking the static sag of the shock absorber
–
Measure dimensionAof rear wheel unloaded. ( p. 34)
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance again between the rear axle and marking SAG
on the rear fender using the sag gage.
–
Note the value as dimensionB.
Info
The static sag is the difference between measurements
andB.
– Check the static sag.
Static sag 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
( p. 36)
A
402416-10
35
Page 38
10 TUNING THE CHASSIS
10.9 Checking the riding sag of the shock absorber
402417-10
–
Measure dimensionAof rear wheel unloaded. ( p. 34)
– With another person holding the motorcycle, the rider, wearing full
protective clothing, sits on the seat in a normal sitting position (feet
on footrests) and bounces up and down a few times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear axle
and marking SAG on the rear fender using the sag gage.
–
Note the value as dimensionC.
Info
The riding sag is the difference between measurements
andC.
– Check riding sag.
Guideline
Riding sag 105 mm (4.13 in)
» If the riding sag differs from the specified measurement:
–
Adjust the riding sag. ( p. 37)
A
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
Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
–
Remove the shock absorber. ( p. 50)
– After removing the shock absorber, clean it thoroughly.
36
Page 39
402659-10
TUNING THE CHASSIS 10
Main work
–
Loosen screw1.
–
Turn adjusting ring2until 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 ring2to specified dimensionA.
Guideline
Spring preload 7 mm (0.28 in)
Info
Depending on the static sag and/or the riding sag, it may be
necessary to increase or decrease the spring preload.
10.11 Adjusting the riding sag
B00292-10
–
Tighten screw1.
Guideline
Screw, shock absorber
adjusting ring
Finishing work
–
Install the shock absorber. ( p. 52)
–
Remove the motorcycle from the lift stand. ( p. 42)
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
–
Remove the shock absorber. ( p. 50)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65 … 75 kg
(143 … 165 lb.)
Weight of rider: 75 … 85 kg
(165 … 187 lb.)
Weight of rider: 85 … 95 kg
(187 … 209 lb.)
M5 5 Nm (3.7 lbf ft)
36 N/mm (206 lb/in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
Info
The spring rate is shown on the outside of the spring.
Finishing work
–
Install the shock absorber. ( p. 52)
–
Remove the motorcycle from the lift stand. ( p. 42)
37
Page 40
10 TUNING THE CHASSIS
10.12 Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
401000-01
–
Check the static sag of the shock absorber. ( p. 35)
–
Check the riding sag of the shock absorber. ( p. 36)
–
Adjust the rebound damping of the shock absorber. ( p. 34)
– 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 specified 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.
10.13 Adjusting the fork air pressure
Warning
Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic.
Extreme modifications 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. 42)
Main work
–
Remove protection cap1.
–
Push together fork airpump2fully.
Fork airpump (79412966100)
Info
The fork airpump is included as part of the motorcycle's
S04525-10
– Connect the fork airpump to the left fork leg.
accessory pack.
The fork airpump indicator switches on automatically.
A little air escapes from the fork leg when connecting.
38
Page 41
TUNING THE CHASSIS 10
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 8.3 bar (120 psi)
Gradual changing of the air
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.
0.2 bar (3 psi)
Info
Only mount the protection cap by hand.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
10.14 Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
–
Turn adjusting screw1clockwise all the way.
Info
Adjusting screw1is located at the upper end of the right
fork leg.
– Turn counterclockwise by the number of clicks corresponding to the
fork type.
S04526-10
Guideline
Compression damping
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks
39
Page 42
10 TUNING THE CHASSIS
10.15 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
Z01370-10
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping during compression.
–
Turn adjusting screw1clockwise all the way.
Info
Adjusting screw1is located at the lower end of the right
fork leg.
– Turn counterclockwise by the number of clicks corresponding to the
fork type.
Guideline
Rebound damping
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.16 Handlebar position
The holes on the handlebar supports are placed at a distance of
from the center.
Hole distance A 3.5 mm (0.138 in)
The handlebar can be mounted in 2 different positions. In this way, the
handlebar can be mounted in the most comfortable position for the
rider.
H01188-10
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.
A
40
Preparatory work
– Remove the handlebar cushion.
Page 43
H01189-10
TUNING THE CHASSIS 10
Main work
–
Remove screws1. Remove the handlebar clamp. Remove the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove screws2. Take off handlebar supports3.
–
Position rubber bushings4and push through nuts5from
below.
– Place the handlebar supports in the required position.
Info
The handlebar supports are longer and higher on one side.
Position the left and right handlebar supports evenly.
–
Mount and tighten screws2.
Guideline
Screw, handlebar
support
– Position the handlebar.
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
Make sure the cables and wiring are positioned correctly.
– Position the handlebar clamp.
–
Mount screws1but do not tighten yet.
–
First bolt the handlebar clamp with screws1onto the longer,
higher side of the handlebar supports so that both parts touch.
Guideline
Screw, handlebar
clamp
–
Tighten screws1evenly.
Guideline
Screw, handlebar
clamp
Finishing work
–
Mount the handlebar cushion.
M8 20 Nm (14.8 lbf ft)
M8 20 Nm (14.8 lbf ft)
41
Page 44
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.
401942-01
– 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.
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
–
To park the motorcycle, insert plug-in stand1into the left side of
the wheel spindle.
Info
Remove the plug-in stand before riding.
H02629-10
11.3 Bleeding the fork legs
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
Main work
–
Release bleeder screws1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
42
H01182-12
Page 45
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
11.4 Cleaning the dust boots of the fork legs
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
–
Remove the fork protector. ( p. 45)
Main work
–
Push dust boots1of both fork legs downward.
M01134-10
SERVICE WORK ON THE CHASSIS 11
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.
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.
11.5 Removing the fork legs
S04527-10
– Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray ( p. 123)
– Press the dust boots back into their normal position.
– Remove excess oil.
Finishing work
–
Install the fork protector. ( p. 45)
–
Remove the motorcycle from the lift stand. ( p. 42)
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
–
Remove the front wheel. ( p. 82)
Main work
–
Remove screws1and take off the clamp.
–
Remove screws2and take off the brake caliper.
– Allow the brake caliper and brake line to hang loosely to the side.
Info
Do not actuate the hand brake lever when the front wheel is
removed.
43
Page 46
11 SERVICE WORK ON THE CHASSIS
S04528-10
11.6 Installing the fork legs
H01182-10
–
Loosen screws3. Remove the left fork leg.
–
Loosen screws4. Remove the right fork leg.
Main work
– Position the fork legs.
Air bleeder screw1of the right fork leg is positioned to the
front.
ValveAof 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.
The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
S04528-11
S04527-11
–
Tighten screws2.
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
–
Tighten screws3.
Guideline
Screw, bottom triple
clamp
–
Position the brake caliper. Mount and tighten screws4.
Guideline
Screw, front
brake caliper
– Position the brake line and the clamp. Mount and tighten
screws5.
Finishing work
–
Install the front wheel. ( p. 83)
M8 15 Nm (11.1 lbf ft)
M8 25 Nm (18.4 lbf ft)
Loctite®243™
44
Page 47
11.7 Removing the fork protector
F00024-10
11.8 Installing the fork protector
F00024-11
SERVICE WORK ON THE CHASSIS 11
–
Remove screws1. Remove the clamp.
–
Remove screws2. Take off the left fork protector.
–
Remove screws3. Take off the right fork protector.
– Position the fork protection on the left fork leg. Mount and tighten
screws1.
Guideline
Remaining screws,
chassis
–
Position the brake line and clamp. Mount and tighten screws2.
– Position the fork protector on the right fork leg. Mount and tighten
screws3.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
11.9 Removing the lower triple clamp
Preparatory work
–
–
–
–
–
– Remove the handlebar cushion.
Main work
–
–
– Take off the upper triple clamp with the handlebar and hang them
S04530-10
Raise the motorcycle with a lift stand. ( p. 42)
Remove the front wheel. ( p. 82)
Remove the fork legs. ( p. 43)
Remove the start number plate. ( p. 49)
Remove front fender. ( p. 50)
Remove screw1.
Remove screw2.
to the side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
45
Page 48
11 SERVICE WORK ON THE CHASSIS
M01117-10
11.10 Installing the lower triple clamp
–
Remove O-ring3. Remove protective ring4.
– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
Main work
– Clean the bearing and sealing elements, check for damage, and
grease.
High viscosity grease ( p. 122)
– Insert the lower triple clamp with the steering stem. Mount upper
steering head bearing.
–
Check whether upper steering head seal1is correctly positioned.
–
Slide on protective ring2and O-ring3.
102146-10
S04531-10
H01182-11
– Position the upper triple clamp with the handlebar.
–
Mount screw4, but do not tighten yet.
– Position the fork legs.
Air bleeder screw5of the right fork leg is positioned to the
front.
ValveAof the left fork leg faces the front.
Info
The air suspension AER valve is located in the left fork leg.
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.
46
Page 49
S04532-10
S04533-10
–
Tighten screws6.
Guideline
Screw, bottom triple
clamp
–
Tighten screw4.
Guideline
Screw, top steering
head
SERVICE WORK ON THE CHASSIS 11
M8 15 Nm (11.1 lbf ft)
M20x1.5 12 Nm (8.9 lbf ft)
S04533-11
S04532-11
–
Mount and tighten screw7.
Guideline
Screw, top steering stem
–
Tighten screws8.
M8 20 Nm (14.8 lbf ft)
Loctite®243™
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
–
Position the brake caliper. Mount and tighten screws9.
Guideline
Screw, front
brake caliper
M8 25 Nm (18.4 lbf ft)
Loctite®243™
– Position the brake line and the clamp. Mount and tighten
screwsbk.
S04527-12
Finishing work
– Check that the wiring harness, throttle cables, and brake and clutch
lines can move freely and are routed correctly.
–
Install front fender. ( p. 50)
–
Install the front wheel. ( p. 83)
47
Page 50
11 SERVICE WORK ON THE CHASSIS
11.11 Checking 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.
H01167-01
–
Check steering head bearing play. ( p. 48)
–
Remove the motorcycle from the lift stand. ( p. 42)
–
Install the start number plate. ( p. 49)
– Mount the handlebar cushion.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Move the handlebar to the straight-ahead position. Move the fork
legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
–
Adjust steering head bearing play. ( p. 48)
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire
steering range. There should be no detectable detent positions.
» If detent positions are detected:
–
Adjust steering head bearing play. ( p. 48)
– Check the steering head bearing and change if necessary.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
11.12 Adjusting steering head bearing play
Preparatory work
–
– Remove the handlebar cushion.
Main work
–
–
–
S04534-10
48
Raise the motorcycle with a lift stand. ( p. 42)
Loosen screws1.
Remove screw2.
Loosen and retighten screw3.
Guideline
Screw, top steering
head
M20x1.5 12 Nm (8.9 lbf ft)
Page 51
– Using a plastic hammer, tap lightly on the upper triple clamp to
avoid stresses.
–
Tighten screws1.
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
–
Mount and tighten screw2.
Guideline
Screw, top steering stem
Finishing work
–
Check steering head bearing play. ( p. 48)
–
Remove the motorcycle from the lift stand. ( p. 42)
– Mount the handlebar cushion.
11.13 Lubricating the steering head bearing
–
Remove the lower triple clamp. ( p. 45)
–
Install the lower triple clamp. ( p. 46)
SERVICE WORK ON THE CHASSIS 11
M8 20 Nm (14.8 lbf ft)
Loctite®243™
H02387-01
11.14 Removing the start number plate
–
– Disconnect the brake line at the start number plate. Take off the
S04535-10
11.15 Installing the start number plate
– Connect the brake line at the start number plate.
– Position the start number plate.
–
Info
The steering head bearing is cleaned and lubricated in the
course of removal and installation.
Remove screw1.
start number plate.
The holding lugs engage in the fender.
Mount and tighten screw1.
S04536-10
49
Page 52
11 SERVICE WORK ON THE CHASSIS
11.16 Removing front fender
S04537-10
11.17 Installing front fender
Preparatory work
–
Remove the start number plate. ( p. 49)
Main work
–
Remove screws1and2. Remove front fender.
Main work
–
Position front fender. Mount and tighten screws1and2.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
S04537-10
11.18 Removing the shock absorber
S04538-10
Finishing work
–
Install the start number plate. ( p. 49)
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Remove the cable ties.
–
Remove screws1along with the washers.
– Take off the left frame protector.
– Push the right frame protector to the front and take off at the bot-
tom.
–
Remove screw2.
–
Remove fitting3.
Info
Raise the wheel slightly to be able to remove the screws
more easily.
50
S04569-10
Page 53
S04570-10
S04540-10
SERVICE WORK ON THE CHASSIS 11
–
Press angle lever4toward the rear.
–
Press linkage lever5downward.
–
Remove screws6and pull foot brake cylinder off the push rod.
M01149-01
S04571-10
– Remove the connecting link of the chain.
– Take off the chain.
Info
Cover the components to protect them against damage.
–
Remove nut7and pull out the swingarm pivot.
– Push the link fork back and secure it against falling over.
–
Hold the shock absorber and remove screw8.
S04541-10
51
Page 54
11 SERVICE WORK ON THE CHASSIS
S04542-01
11.19 Installing the shock absorber
– Remove the shock absorber carefully at the bottom.
Main work
– Carefully position the shock absorber into the vehicle from the bot-
tom.
S04543-01
S04541-11
V01527-10
–
Mount and tighten screw1.
Guideline
Screw, top shock
M10 60 Nm (44.3 lbf ft)
absorber
– Position the link fork and mount the swingarm pivot.
Info
Pay attention to flat areaA.
–
Mount and tighten nut2.
Guideline
Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft)
– Mount the chain.
– Connect the chain with the connecting link.
Guideline
The closed side of the chain joint lock must face in the direction
of travel.
Loctite®2701™
52
M01149-01
Page 55
K01148-10
K00864-10
SERVICE WORK ON THE CHASSIS 11
– Position the foot brake cylinder.
Push rod3engages in the foot brake cylinder.
The dust boot is correctly positioned.
–
Mount and tighten screws4.
Guideline
Remaining screws,
chassis
– Position the angle lever and linkage lever.
–
Mount and tighten fitting5.
Guideline
Nut, linkage lever on
angle lever
Info
Pay attention to flat areaB.
–
Mount and tighten screw6.
Guideline
Screw, bottom
shock absorber
M6 10 Nm (7.4 lbf ft)
M14x1.5 60 Nm (44.3 lbf ft)
M10 60 Nm (44.3 lbf ft)
Loctite®2701™
11.20 Removing the seat
S04538-11
Info
Raise the wheel slightly to be able to mount the screw more
easily.
– Position the left frame protector.
– Insert the right frame protector from below and push it to the rear.
–
Mount and tighten screws7with the washers.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
– Mount the new cable ties.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
–
Remove screw1.
S04544-10
53
Page 56
11 SERVICE WORK ON THE CHASSIS
H02218-10
11.21 Mounting the seat
– Raise the rear of the seat, pull the seat back, and lift it off.
– Mount the front of the seat on the collar bushing of the fuel tank,
lower the seat at the rear, and push the seat forward.
– Make sure that the seat is locked in correctly.
H02218-11
–
S04544-10
11.22 Removing the air filter box cover
Condition
Mount and tighten screw1.
Guideline
Remaining screws,
chassis
The air filter box cover is secured.
–
Remove the seat. ( p. 53)
–
Remove screw1.
M6 10 Nm (7.4 lbf ft)
54
S04545-10
Page 57
S04546-10
S04547-10
SERVICE WORK ON THE CHASSIS 11
–
Pull off the air filter box cover in areaAsideways and take off
toward the front.
Condition
The air filter box cover is not secured.
–
Pull off the air filter box cover in areaAsideways and take off
toward the front.
11.23 Installing the air filter box cover
S04546-11
S04546-12
Condition
The air filter box cover is secured.
–
Insert the air filter box cover in areaAand clip it into areaB.
–
Mount and tighten screw1.
Guideline
Screw, air filter box
cover
–
Mount the seat. ( p. 54)
EJOT PT
K60x20-Z
®
3 Nm (2.2 lbf ft)
Condition
The air filter box cover is not secured.
–
Insert the air filter box cover in areaAand clip it into areaB.
S04547-11
55
Page 58
11 SERVICE WORK ON THE CHASSIS
11.24 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. 54)
Main work
–
Detach retaining tab1. Remove air filter with air filter support.
– Take off air filter from air filter support.
S04548-10
11.25 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. 54)
–
Remove the air filter. ( p. 56)
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it
to dry properly.
Air filter cleaner ( p. 122)
Info
Only press the air filter to dry it, never wring it out.
56
K00518-01
– Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 122)
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
Page 59
11.26 Installing the air filter
102178-10
SERVICE WORK ON THE CHASSIS 11
Finishing work
–
Install the air filter. ( p. 57)
–
Install the air filter box cover. ( p. 55)
Main work
– Mount the clean air filter on the air filter support.
–
Grease the air filter in areaA.
Long-life grease ( p. 122)
–
Insert the air filter and position the top retaining pin1in bushingB.
The air filter is correctly positioned.
–
Secure the bottom retaining pin with holding tab2.
S04549-10
Finishing work
–
Install the air filter box cover. ( p. 55)
11.27 Preparing air filter box cover for securing
Preparatory work
–
Remove the air filter box cover. ( p. 54)
Main work
–
Drill a hole at markingA.
Guideline
Diameter 6 mm (0.24 in)
S02308-10
Finishing work
–
Install the air filter box cover. ( p. 55)
Info
If the air filter is not mounted correctly, dust and dirt may
enter the engine and result in damage.
57
Page 60
11 SERVICE WORK ON THE CHASSIS
11.28 Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
S04550-10
11.29 Installing the main silencer
–
Remove screws1with the washers.
–
Pull off the main silencer from the manifold at exhaust sleeve2.
–
Position the main silencer in exhaust sleeve1.
–
Mount and tighten screws2with the washers.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
S04551-10
11.30 Changing the glass fiber yarn filling in the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the rock wool escape into the air, and the main silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.
Preparatory work
–
Remove the main silencer. ( p. 58)
58
Page 61
H01759-10
SERVICE WORK ON THE CHASSIS 11
Main work
–
Remove screws1. Pull out inner tube2.
–
Remove the glass fiber yarn filling3from the inner tube.
– Clean the parts that need to be reinstalled and check for damage.
–
Fit the new glass fiber yarn filling3into the inner tube.
–
Slide outer tube4over the inner tube with the new glass fiber
yarn filling.
–
Mount and tighten all screws1.
Guideline
Screws on main
silencer
M5 7 Nm (5.2 lbf ft)
Finishing work
–
Install the main silencer. ( p. 58)
11.31 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 poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
–
Remove the seat. ( p. 53)
– Turn the knurled screw on the fuel tap all the way clockwise.
59
Page 62
11 SERVICE WORK ON THE CHASSIS
S04552-10
S04553-10
Main work
– Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
–
Remove screws1.
–
Remove screw2with the rubber bushing.
– Pull the fuel tank breather hose off the fuel tank lid.
– Pull both spoilers laterally off the radiator and take off the fuel tank
upwards.
S04554-10
11.32 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 poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
60
Page 63
S04554-11
SERVICE WORK ON THE CHASSIS 11
Main work
–
Check throttle cable routing. ( p. 66)
– 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.
–
Mount and tighten screw1with the rubber bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
S04553-11
S04552-11
11.33 Checking the chain for dirt
–
Mount and tighten screws2.
Guideline
Remaining screws,
M6 10 Nm (7.4 lbf ft)
chassis
– Connect the fuel hose.
Finishing work
–
Mount the seat. ( p. 54)
– Check the chain for heavy soiling.
» If the chain is very dirty:
–
Clean the chain. ( p. 62)
400678-01
61
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11 SERVICE WORK ON THE CHASSIS
11.34 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. 42)
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 122)
– After drying, apply chain spray.
Off-road chain spray ( p. 122)
400725-01
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
11.35 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 bearings 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.
62
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
Page 65
K01197-10
11.36 Adjusting the chain tension
SERVICE WORK ON THE CHASSIS 11
Main work
– Pull the chain at the end of the chain sliding piece upward to mea-
sure chain tensionA.
Guideline
Lower chain section1must be taut.
Info
Chain wear is not always even, so you should repeat this
measurement at different chain positions.
Chain tension 55 … 58 mm (2.17 … 2.28 in)
» If the chain tension does not meet the specification:
–
Adjust the chain tension. ( p. 63)
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
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 bearings 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. 42)
–
Check the chain tension. ( p. 62)
Main work
–
Loosen nut1.
–
Loosen nuts2.
–
Adjust the chain tension by turning adjusting screws3left and
right.
Guideline
Chain tension 55 … 58 mm (2.17 … 2.28 in)
Turn adjusting screws3on the left and right so that the markings on the left and right chain adjusters are in the same position
relative to reference marksA. The rear wheel is then correctly
aligned.
–
Tighten nuts2.
–
Make sure that chain adjusters4are fitted correctly on adjusting
screws3.
–
Tighten nut1.
Guideline
H00016-10
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)
63
Page 66
11 SERVICE WORK ON THE CHASSIS
11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide
Info
The wide adjustment range of the chain adjusters (32 mm
(1.26 in)) enables different secondary ratios with the same
chain length.
Chain adjusters4can be turned by 180°.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Shift the transmission into neutral.
– Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
– Change the drivetrain kit.
400227-01
400987-10
Info
The engine sprocket, rear sprocket, and chain
should always be replaced together.
–
Pull on the top section of the chain with the specified weightA.
Guideline
Weight, chain wear measurement
–
Measure distanceBof 18 chain rollers in the lower chain section.
10 … 15 kg (22 … 33 lb.)
Info
Chain wear is not always even, so you should repeat this
measurement at different chain positions.
Maximum distanceBfrom
18 chain rollers at the longest
chain section
»
If distanceBis greater than the specified measurement:
– Change the drivetrain kit.
272 mm (10.71 in)
Info
When a new chain is mounted, the rear sprocket
and engine sprocket should also be changed.
New chains wear out faster on an old, worn rear
sprocket or engine sprocket.
64
Page 67
V01528-10
SERVICE WORK ON THE CHASSIS 11
– 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 guard
M6 6 Nm (4.4 lbf ft)
Loctite®243™
K01199-10
– 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
piece
–
Check the chain guide with a slide gage for dimensionC.
Minimum thicknessCof the
chain guide
» If the measured value is less than the specification:
– Change the chain guide.
M8 15 Nm (11.1 lbf ft)
6 mm (0.24 in)
402421-10
65
Page 68
11 SERVICE WORK ON THE CHASSIS
102192-01
11.38 Checking the frame
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws,
chassis
Remaining nuts,
chassis
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
– 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.
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
S02306-01
11.39 Checking the link fork
– Check the link fork for damage, cracks, and deformation.
» If the link fork shows signs of damage, cracks, or deformation:
– Change the link fork.
Guideline
Repairs on the link fork are not permitted.
S02305-01
11.40 Checking throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specification.
Preparatory work
–
Remove the seat. ( p. 53)
– Turn the knurled screw on the fuel tap all the way clockwise.
–
Remove the fuel tank. ( p. 59)
66
Page 69
S04555-10
SERVICE WORK ON THE CHASSIS 11
Main work
– Check throttle cable routing.
The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and
to the carburetor. The throttle cable must be secured on the fuel
tank bracket with a rubber strap.
» If the throttle cable routing is not as specified:
– Correct the throttle cable routing.
11.41 Checking the rubber grip
401197-01
Finishing work
–
Install the fuel tank. ( p. 60)
–
Mount the seat. ( p. 54)
– 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.
» If a rubber grip is damaged or worn:
– Change the rubber grip.
–
Check that screw1is firmly seated.
Guideline
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™
DiamondAmust be located at the top.
102245-10
67
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11 SERVICE WORK ON THE CHASSIS
11.42 Adjusting the basic position of the clutch lever
F00009-11
11.43 Checking/correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.
– Adjust the basic position of the clutch lever to your hand size by
turning adjusting screw1.
Info
Turn the adjusting screw counterclockwise to decrease the
distance between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to increase the distance
between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any
force.
Do not make any adjustments while riding.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the clutch fluid reservoir mounted on the handlebar to a hori-
zontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
– Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the fluid level does not meet specifications:
H01330-10
– Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– Position the cover with the membrane. Mount and tighten the
screws.
68
Page 71
SERVICE WORK ON THE CHASSIS 11
Info
Clean up overflowed or spilled brake fluid immediately with
water.
11.44 Changing the hydraulic clutch fluid
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the clutch fluid reservoir mounted on the handlebar to a hori-
zontal position.
–
Remove screws1.
–
Remove cover2with membrane3.
H01330-10
–
Fill bleeding syringe4with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
–
On the clutch slave cylinder, remove bleeder screw5and mount
bleeding syringe4.
S04556-10
69
Page 72
11 SERVICE WORK ON THE CHASSIS
L01223-10
– Now inject the liquid into the system until it emerges from the drill
hole6of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir to
prevent overflow.
– Remove the bleeding syringe. Mount and tighten screws bleeder
screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim 4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the
screws.
Info
Clean up overflowed or spilled brake fluid immediately with
water.
70
Page 73
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 travelA.
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. 71)
S04557-10
12.2 Adjusting the basic position of the hand brake lever
BRAKE SYSTEM 12
–
Check the free travel of the hand brake lever. ( p. 71)
– Adjust the basic position of the hand brake lever to your hand size
by turning adjusting screw1.
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
S04557-11
distance between the hand brake lever and the handlebar.
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 dimensionA.
H00938-10
Info
Wear reduces the thickness of the brake disc around the
contact surface of the brake linings.
Brake discs - wear limit
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
71
Page 74
12 BRAKE SYSTEM
12.4 Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
– 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.
Preparatory work
–
Check the front brake linings. ( p. 74)
Main work
– Move the brake reservoir mounted on the handlebar to a horizontal
position.
–
Check the brake fluid level in level viewer1.
»
If the brake fluid level has dropped below the markingA:
–
Add front brake fluid. ( p. 72)
S04558-10
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.)
72
Page 75
BRAKE SYSTEM 12
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
–
Check the front brake linings. ( p. 74)
Main work
– Move the brake reservoir mounted on the handlebar to a horizontal
position.
–
Remove screws1.
–
Take off cover2with membrane3.
–
Add brake fluid to levelA.
Guideline
LevelA(brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– Position the cover with the membrane. Mount and tighten the
screws.
5 mm (0.2 in)
Info
Clean up overflowed or spilled brake fluid immediately with
water.
K00470-10
73
Page 76
12 BRAKE SYSTEM
12.6 Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
–
Check the brake linings for minimum thicknessA.
≥ 1 mm (≥ 0.04 in)
H01333-10
Minimum thickness
» If the minimum thickness is less than specified:
–
Change the brake linings of the front brake. ( p. 74)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
–
Change the brake linings of the front brake. ( p. 74)
A
12.7 Changing the brake linings of the front brake
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy-
cles workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
74
Page 77
BRAKE SYSTEM 12
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the
brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not
guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be
void.
– Only use brake linings approved and recommended by GASGAS Motorcycles.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
K00469-10
101737-10
– Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
–
Remove screws1.
–
Take off cover2with membrane3.
– Manually press the brake caliper toward the brake disc to push back
the brake pistons. Ensure that brake fluid does not flow out of the
brake fluid reservoir, extract some if necessary.
Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake pistons.
–
Remove cotter pins4, pull out pin5, and remove the brake linings.
– Clean the brake caliper and the brake caliper bracket.
–
Check that spring plate6in the brake caliper and sliding plate
in the brake caliper bracket are seated correctly.
7
100397-01
75
Page 78
12 BRAKE SYSTEM
101738-01
K00521-10
– Insert the new brake linings, insert pin, and mount cotter pins.
Info
Always change the brake linings in pairs.
– Operate the hand brake lever repeatedly until the brake linings are
in contact with the brake disc and there is a pressure point.
–
Correct the brake fluid level to levelA.
Guideline
LevelA(brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– Position the cover with the membrane. Mount and tighten the
screws.
5 mm (0.2 in)
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
12.8 Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
–
Disconnect spring1.
– Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check free
travelA.
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not meet specifications:
402026-10
– Adjust the basic position of the foot brake lever.
( p. 77)
–
Reconnect spring1.
76
Page 79
12.9 Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
–
Detach spring1.
–
Loosen nut2and, with push rod3, turn it back until you have
maximum free travel.
– To adjust the basic position of the foot brake lever to individual
requirements, loosen nut4and turn screw5accordingly.
Info
The range of adjustment is limited.
–
Turn push rod3accordingly until you have free travelA. If necessary, 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 screw5and tighten nut4.
Guideline
K00523-10
Nut, foot brake lever
stop
–
Hold push rod3and tighten nut2.
Guideline
Remaining nuts, chassis
–
Attach spring1.
M8 20 Nm (14.8 lbf ft)
M6 10 Nm (7.4 lbf ft)
BRAKE SYSTEM 12
12.10 Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Preparatory work
–
Check the brake linings of the rear brake. ( p. 79)
77
Page 80
12 BRAKE SYSTEM
12.11 Adding rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the 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.)
S04559-10
Main work
– Stand the vehicle upright.
–
Check the brake fluid level in level viewer1.
»
If the brake fluid has dropped below markingA:
–
Add rear brake fluid. ( p. 78)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
78
Preparatory work
–
Check the brake linings of the rear brake. ( p. 79)
Page 81
BRAKE SYSTEM 12
Main work
– Stand the vehicle upright.
–
Remove screw cap1with membrane2and the O-ring.
–
Add brake fluid to levelA.
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– Mount the screw cap with the membrane and the O-ring.
S04561-10
Info
Clean up overflowed or spilled brake fluid immediately with
water.
12.12 Checking the brake linings of the rear brake
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)
–
Check the brake linings for minimum thicknessA.
≥ 1 mm (≥ 0.04 in)
M01180-10
Minimum thickness
» If the minimum thickness is less than specified:
–
Change the rear brake linings. ( p. 79)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
–
Change the rear brake linings. ( p. 79)
A
12.13 Changing the rear brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy-
cles workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.
79
Page 82
12 BRAKE SYSTEM
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Position the vehicle upright.
–
Remove screw cap1with membrane2and the O-ring.
S04560-10
101740-10
101741-10
– 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 pins3, pull out pin4, and remove the brake linings.
– Clean the brake caliper and the brake caliper bracket.
–
Check that spring plate5in the brake caliper and sliding plate
in the brake caliper bracket are seated properly.
6
Info
The arrow on the spring plate points in the direction of rotation of the brake disc.
80
Page 83
M01181-10
K01185-10
BRAKE SYSTEM 12
–
Insert the new brake linings, insert pin4, and mount cotter
pins3.
Info
Always change the brake linings in pairs.
Make sure that decoupling plate7is mounted on the piston side brake lining.
– Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
–
Add brake fluid to levelA.
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
–
Mount and tighten screw cap1with membrane2and the Oring.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
81
Page 84
13 WHEELS, TIRES
13.1 Removing the front wheel
H01337-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Manually press the brake caliper toward the brake disc to push back
the brake pistons.
Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake pistons.
–
Loosen screw1by several rotations.
–
Loosen screws2.
–
Press on screw1to push the wheel spindle out of the axle clamp.
–
Remove screw1.
K00454-10
H01340-10
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the brake
disc is not damaged.
– Hold the front wheel and remove the wheel spindle. Take the front
wheel out of the fork.
Info
Do not actuate the hand brake lever when the front wheel is
removed.
–
Remove spacers3.
82
H00934-10
Page 85
13.2 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change front wheel bearing.
–
Clean and grease shaft seal rings1and contact surfacesAof the
spacers.
Long-life grease ( p. 122)
– Insert the spacers.
H00935-10
K00454-11
– Clean and grease the wheel spindle.
Long-life grease ( p. 122)
– Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
–
Mount and tighten screw2.
Guideline
Screw, front wheel
spindle
– Operate the hand brake lever several times until the brake linings
are seated correctly against the brake disc.
–
Remove the motorcycle from the lift stand. ( p. 42)
– Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
–
Tighten screws3.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
WHEELS, TIRES 13
M20x1.5 35 Nm (25.8 lbf ft)
13.3 Removing the rear wheel
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 42)
83
Page 86
13 WHEELS, TIRES
H00027-10
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 nut1.
–
Take off chain adjuster2. Pull out wheel spindle3far 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
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 spacers4.
H03002-10
13.4 Installing the rear wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
84
Page 87
H03001-10
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 rings1and contact surfacesAof the
spacers.
Long-life grease ( p. 122)
– Insert the spacers.
– Clean and grease the wheel spindle.
Long-life grease ( p. 122)
–
Position rear wheel and insert wheel spindle2.
The brake linings are correctly positioned.
– Mount the chain.
H00006-10
H00007-10
–
Position chain adjuster3. Mount nut4, but do not tighten it yet.
–
Make sure that chain adjusters3are fitted correctly on adjusting
screws5.
–
Check the chain tension. ( p. 62)
–
Tighten nut4.
Guideline
Nut, rear wheel spindle M25x1.5 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 adjusters3can 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.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 42)
85
Page 88
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.
400602-10
–
Check the front and rear tires for cuts, embedded objects, and other
damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
– Check 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 number. The first two digits indicate the week of manufacture
and the last two digits the year of manufacture.
GASGAS Motorcycles recommends that the tires be changed
after five years at the latest, regardless of the actual wear.
H01144-01
» If the tires are more than five years old:
–
Change the tires.
13.6 Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
– Remove the protection cap.
– Check the tire pressure when the tires are cold.
Offroad tire pressure
front 1.0 bar (15 psi)
rear 1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
400695-01
– Mount the protection cap.
86
Page 89
13.7 Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam-
age.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low,
then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
–
Check spoke tension regularly, and in particular on a new vehicle. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length
and spoke diameter.
If you hear different tone frequencies from different spokes
of equal length and diameter, this is an indication of different spoke tensions.
WHEELS, TIRES 13
400694-01
You should hear a high note.
» If the spoke tension differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple, front
wheel
Spoke nipple, rear
wheel
Torque wrench kit (58429094000)
M4.5 6 Nm (4.4 lbf ft)
M4.5 6 Nm (4.4 lbf ft)
87
Page 90
14 COOLING SYSTEM
14.1 Cooling system
14.2 Radiator cover
S04562-10
Water pump1in the engine ensures forced circulation of the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap2. 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.
Info
Do not use radiator covers in difficult operating conditions.
The radiator cover is mounted in front of the left radiator between the
radiator shield and radiator.
The radiator cover keeps the coolant temperature in the correct range.
Coolant temperature 65 … 70 °C (149 … 158 °F)
K00459-01
M01121-10
14.3 Installing the radiator cover
K00460-10
The radiator cover is installed in front of the left radiator, depending on
the ambient temperature.
Full radiator cover
Half radiator cover
No radiator cover > 16 °C (> 61 °F)
< 7 °C (< 45 °F)
1
7 … 16 °C (45 … 61 °F)
2
Info
Do not use both radiator covers at the same time.
–
Remove screws1.
–
Remove screws2.
–
Take off radiator shield3.
88
Page 91
H01341-10
K00460-10
–
Position the matching radiator cover ( p. 88).
The larger holding lug is located at the top left.
Info
Do not use both radiator covers at the same time.
–
Position radiator shield3.
–
Mount and tighten screws2.
Guideline
Remaining screws,
chassis
–
Mount and tighten screws1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
COOLING SYSTEM 14
14.4 Removing the radiator cover
–
Remove screws1.
–
Remove screws2.
–
Take off radiator shield3.
– Remove the radiator cover.
–
Position radiator shield3.
–
Mount and tighten screws2.
Guideline
K00460-10
Remaining screws,
chassis
–
Mount and tighten screws1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
14.5 Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
89
Page 92
14 COOLING SYSTEM
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– 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.
400243-10
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant antifreeze.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the specified
value:
– Correct the coolant antifreeze.
– Check the coolant level in the radiator.
Coolant levelAabove the
radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 120)
– Mount the radiator cap.
10 mm (0.39 in)
14.6 Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– 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.
90
Page 93
COOLING SYSTEM 14
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant levelAabove the
radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
400243-10
– Mount the radiator cap.
Coolant ( p. 120)
14.7 Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
10 mm (0.39 in)
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
–
Remove screw1. Take off radiator cap2.
– Completely drain the coolant.
–
Mount and tighten screw1with a new seal ring.
Guideline
Drain plug, water
pump cover
S04562-11
M6 10 Nm (7.4 lbf ft)
91
Page 94
14 COOLING SYSTEM
14.8 Refilling with coolant
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
–
Make sure that screw1is tightened.
– Position the motorcycle upright.
– Completely fill the radiator with coolant.
Coolant ( p. 120)
S04563-10
S04564-10
K01179-10
–
Loosen screw2until coolant escapes without bubbles.
–
Mount and tighten screw2.
Guideline
Bleeder screw, cylinder
head
– Completely fill the radiator with coolant.
Coolant ( p. 120)
–
Mount radiator cap3.
M6 8 Nm (5.9 lbf ft)
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 engine to warm up and cool down again.
–
Check the coolant level. ( p. 90)
92
Page 95
COOLING SYSTEM 14
14.9 Changing the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– 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.
S04562-11
S04564-11
Condition
The engine is cold.
–
Remove screw1. Take off radiator cap2.
– Place an appropriate container under the water pump cover.
– Completely drain the coolant.
–
Mount and tighten screw1with a new seal ring.
Guideline
Screw, water pump
cover
– Position the motorcycle upright.
– Completely fill the radiator with coolant.
Coolant ( p. 120)
–
Loosen screw3until coolant escapes without bubbles.
–
Mount and tighten screw3.
Guideline
Bleeder screw, cylinder
head
– Completely fill the radiator with coolant.
Coolant ( p. 120)
M6 10 Nm (7.4 lbf ft)
M6 8 Nm (5.9 lbf ft)
93
Page 96
14 COOLING SYSTEM
S04253-10
–
Mount radiator cap2.
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 engine to warm up and cool down again.
– Check the cooling system for leaks.
–
Check the coolant level. ( p. 90)
94
Page 97
15.1 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
cableA.
Play in throttle cable 2 … 3 mm (0.08 … 0.12 in)
» If the throttle cable play does not meet the specified value:
–
Adjust throttle cable play. ( p. 95)
TUNING THE ENGINE 15
400192-11
– Start the engine and let it run at idle speed. Move the handlebar to
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.
and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
–
Adjust throttle cable play. ( p. 95)
15.2 Adjusting throttle cable play
Info
If the correct routing of the throttle cable has already been secured, the fuel tank does not need to be removed.
Preparatory work
–
Remove the seat. ( p. 53)
– Turn the knurled screw on the fuel tap all the way clockwise.
–
Remove the fuel tank. ( p. 59)
–
Check throttle cable routing. ( p. 66)
Main work
– Move the handlebar to the straight-ahead position.
–
Push back sleeve1.
– Ensure that the throttle cable sleeve is pushed all the way into bar-
rel adjuster2.
–
Loosen nut3.
S04565-10
95
Page 98
15 TUNING THE ENGINE
15.3 Carburetor tuning
Effects of carburetor tuning
400192-11
–
Turn barrel adjuster2so that there is playAin the throttle
cable at the throttle grip.
Guideline
Play in throttle cable 2 … 3 mm (0.08 … 0.12 in)
–
Tighten nut3.
–
Slide on sleeve1.
Finishing work
– Check the throttle grip for smooth operation.
–
Install the fuel tank. ( p. 60)
–
Mount the seat. ( p. 54)
–
Check the play in the throttle cable. ( p. 95)
H01400-01
The different carburetor components must be tuned both to one another and for the use intended.
Main jet MJ
The main jet MJ has the greatest influence with the throttle slide open (full throttle).
If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger
main jet needs to be used. If the insulator is dark brown or sooty, a smaller main jet needs to be used.
Needle position POS
The needle position has the greatest influence in the mid throttle slide range.
If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine
knocks when accelerating at the full power rpm range, the jet needle must be raised.
Cylindrical part of the needle CYL
The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.
96
Page 99
TUNING THE ENGINE 15
Idling jet IJ
The idling jet has the greatest influence in the low to mid throttle slide range.
If the engine stutters at idle speed or when accelerating with a partially open throttle slide, a smaller idling jet must be
used. If the engine knocks in this power range, then a larger idling jet must be used.
Idle air adjusting screw open ASO
The idle air adjusting screw has the greatest influence at idle speed.
Influence of throttle slide adjustment
K00495-01
The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip
position have only minimal influence.
When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influence.
K00496-01
When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first
cylindrical part of the needle is less.
When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and
the idling jet is only minimal.
K00497-01
When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only
minimal influence.
When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only
minimal influence.
Needle overview
The jet needles available are shown in the following table.
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Page 100
15 TUNING THE ENGINE
Column 2 corresponds to a needle in the standard position.
Column 1 corresponds to a needle which is half a clip leaner.
Column 3 corresponds to a needle which is half a clip richer.
Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical
part of the needle, the richer the mixture preparation. The larger the diameter of the first cylindrical part of the needle, the
leaner the mixture preparation. The first cylindrical part of the needle has the greatest influence in the lowest load range.
Info
The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1
corresponds to the leanest. The optimal carburetor tuning is shown under the respective model.
402674-01
Clip position
1... 5 Clip position from above
The five possible clip positions are shown here.
The carburetor tuning depends on the defined ambient and operating
conditions.
B00075-10
15.4 Carburetor – idle setting
402799-10
The idle setting of the carburetor significantly influences the vehicle’s
starting behavior, the stability of the idle speed, and the vehicle’s
response when accelerating. This means that an engine with a correctly
set idle speed will be easier to start than one with an incorrectly set idle
speed.
Info
The carburetor and its components are subject to increased
wear caused by engine vibration. Wear can result in malfunctioning.
The factory setting for the carburetor is set for the following values.
Height above sea level 301 … 750 m (988 … 2,461 ft)
Ambient temperature 16 … 24 °C (61 … 75 °F)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
( p. 121)
The idle speed is adjusted with adjusting screw1.
The idle mixture is adjusted using the idle air adjusting screw2.
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