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OWNER'S MANUAL 2021
MC 50
Art. no. 3215005en
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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 that will continue to give you and your child pleasure for a long time if you maintain it properly.
We hope your child has many safe and enjoyable rides!
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 going to print. 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 50 (F0001U4)
*3215005en*
3215005en
08/2020
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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 Hand brake lever ......................................... 14
6.2 Throttle grip................................................. 14
6.3 Stop button.................................................. 14
6.4 Opening the fuel tank filler cap................... 14
6.5 Closing the fuel tank filler cap..................... 15
6.6 Fuel tap........................................................ 15
6.7 Choke........................................................... 16
6.8 Kick starter lever.......................................... 16
6.9 Foot brake lever .......................................... 16
6.10 Plug-in stand................................................ 16
7 PREPARING FOR USE ................................................. 17
7.1 Advice on preparing for first use ................ 17
7.2 Running in the engine ................................. 19
8 RIDING INSTRUCTIONS .............................................. 20
8.1 Checks and maintenance measures
when preparing for use............................... 20
8.2 Starting the vehicle ..................................... 20
8.3 Starting off................................................... 21
8.4 Riding........................................................... 21
8.5 Applying the brakes..................................... 21
8.6 Stopping, parking......................................... 22
8.7 Transporting ................................................ 22
8.8 Refueling...................................................... 23
9 SERVICE SCHEDULE.................................................... 24
9.1 Additional information................................ 24
9.2 Required work ............................................. 24
9.3 Recommended work ................................... 25
10 TUNING THE CHASSIS ................................................ 26
10.1 Checking the basic chassis setting with
rider's weight............................................... 26
10.2 Air suspension XACT 5235........................... 26
10.3 Compression damping of the shock
absorber ...................................................... 27
10.4 Adjusting the low-speed compression
damping of the shock absorber .................. 27
10.5 Adjusting the high-speed compression
damping of the shock absorber .................. 27
10.6 Adjusting the rebound damping of the
shock absorber ............................................ 28
10.7 Measuring the dimension of the rear
wheel unloaded........................................... 29
10.8 Checking the static sag of the shock
absorber ...................................................... 29
10.9 Checking the riding sag of the shock
absorber ...................................................... 30
10.10 Adjusting the spring preload of the
shock absorber ........................................ 30
10.11 Adjusting the riding sag ........................... 31
10.12 Checking the basic setting of the fork ........ 32
10.13 Adjusting the fork air pressure.................... 32
10.14 Adjusting the rebound damping of the
fork............................................................... 34
10.15 Handlebar position...................................... 34
10.16 Adjusting the handlebar position ........... 34
10.17 Adjusting the seat height ........................ 35
11 SERVICE WORK ON THE CHASSIS .............................. 37
11.1 Raising the motorcycle with a lift stand ..... 37
11.2 Removing the motorcycle from the lift
stand ............................................................ 37
11.3 Bleeding the fork legs.................................. 37
11.4 Cleaning the dust boots of the fork legs..... 38
11.5 Removing the fork protector ...................... 38
11.6 Installing the fork protector ........................ 39
11.7 Removing the fork legs ........................... 39
11.8 Installing the fork legs ............................. 40
11.9 Removing the lower triple clamp ............ 41
11.10 Installing the lower triple clamp ............. 42
11.11 Checking the steering head bearing play ... 44
11.12 Adjusting the steering head bearing
play .......................................................... 44
11.13 Lubricating the steering head bearing .... 45
11.14 Removing the fuel tank ........................... 45
11.15 Installing the fuel tank ............................. 46
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TABLE OF CONTENTS
11.16 Removing the start number plate............... 47
11.17 Installing the start number plate ................ 47
11.18 Removing front fender................................ 48
11.19 Installing the front fender ........................... 48
11.20 Removing the shock absorber ................ 49
11.21 Installing the shock absorber .................. 49
11.22 Removing the seat....................................... 50
11.23 Mounting the seat....................................... 50
11.24 Removing the air filter ............................ 50
11.25 Installing the air filter .............................. 51
11.26 Cleaning the air filter and air filter
box ........................................................... 51
11.27 Removing the main silencer........................ 52
11.28 Installing the main silencer ......................... 52
11.29 Changing the glass fiber yarn filling of
the main silencer ..................................... 52
11.30 Removing the engine sprocket cover ......... 53
11.31 Installing the engine sprocket cover ........... 53
11.32 Checking the chain for dirt .......................... 54
11.33 Cleaning the chain....................................... 54
11.34 Checking the chain tension ......................... 55
11.35 Adjusting the chain tension ........................ 55
11.36 Checking the chain, rear sprocket,
engine sprocket, and chain guide ............... 56
11.37 Adjusting the chain guide ....................... 58
11.38 Checking the frame ................................. 58
11.39 Checking the link fork .............................. 59
11.40 Checking the throttle cable routing ............ 59
11.41 Checking the rubber grip ............................ 59
11.42 Additionally securing the rubber grip ......... 60
12 BRAKE SYSTEM........................................................... 61
12.1 Checking play of handbrake lever............... 61
12.2 Adjusting the play of the hand brake
lever............................................................. 61
12.3 Adjusting the basic position of the hand
brake lever................................................... 61
12.4 Checking the brake discs............................. 62
12.5 Checking the front brake fluid level ............ 62
12.6 Adding the front brake fluid ................... 64
12.7 Checking the front brake linings ................. 65
12.8 Changing the brake linings of the front
brake ........................................................ 65
12.9 Checking the free travel of the foot
brake lever................................................... 68
12.10 Adjusting the free travel of the foot
brake lever ............................................... 69
12.11 Adjusting the basic position of the foot
brake lever ............................................... 69
12.12 Checking the rear brake fluid level ............. 70
12.13 Adding rear brake fluid ........................... 70
12.14 Checking the brake linings of the rear
brake............................................................ 71
12.15 Changing the rear brake linings .............. 72
13 WHEELS, TIRES........................................................... 75
13.1 Removing the front wheel ...................... 75
13.2 Installing the front wheel ........................ 75
13.3 Removing the rear wheel ........................ 76
13.4 Installing the rear wheel ......................... 77
13.5 Checking the tire condition......................... 78
13.6 Checking tire pressure................................. 79
13.7 Checking spoke tension............................... 79
14 COOLING SYSTEM...................................................... 81
14.1 Cooling system ............................................ 81
14.2 Checking the antifreeze and coolant
level.............................................................. 81
14.3 Checking the coolant level .......................... 82
14.4 Draining the coolant ................................ 82
14.5 Refilling with coolant ............................... 83
14.6 Changing the coolant .............................. 84
15 TUNING THE ENGINE................................................. 86
15.1 Checking the play in the throttle cable....... 86
15.2 Adjusting the play in the throttle
cable ........................................................ 86
15.3 Carburettor – idle speed ............................. 87
15.4 Carburetor – adjusting the idle speed .... 87
15.5 Checking the clutch setting ..................... 88
15.6 Removing the clutch cover ..................... 89
15.7 Adjusting the clutch ................................ 89
15.8 Installing the clutch cover ....................... 90
16 SERVICE WORK ON THE ENGINE ............................... 91
16.1 Checking the gear oil level .......................... 91
16.2 Changing the gear oil .............................. 91
16.3 Adding the gear oil .................................. 92
17 CARBURETOR............................................................. 94
17.1 Removing the carburetor ........................ 94
17.2 Installing the carburetor ......................... 95
18 CLEANING, CARE........................................................ 97
18.1 Cleaning the motorcycle ............................. 97
19 STORAGE.................................................................... 99
19.1 Storage......................................................... 99
19.2 Preparing for use after storage................ 100
20 TROUBLESHOOTING ............................................... 101
21 TECHNICAL DATA.................................................... 103
21.1 Engine ....................................................... 103
21.2 Engine tightening torques........................ 103
21.3 Carburetor with carburetor tuning.......... 104
21.4 Capacities.................................................. 104
21.4.1 Gear oil ................................................ 104
21.4.2 Coolant ................................................ 104
21.4.3 Fuel ...................................................... 104
21.5 Chassis ...................................................... 104
21.6 Tires .......................................................... 105
21.7 Fork........................................................... 105
21.8 Shock absorber......................................... 106
21.9 Chassis tightening torques ....................... 106
22 SUBSTANCES........................................................... 108
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23 AUXILIARY SUBSTANCES......................................... 110
24 STANDARDS ............................................................ 112
25 LIST OF ABBREVIATIONS......................................... 113
INDEX ............................................................................... 114
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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 the safety of your child, have these jobs performed in 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 the end of an activity, including potential reworking.
Indicates a voltage measurement.
Indicates a current measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
®
Name
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.
– Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as trousers and a
jacket with protectors on all rides.
– Alway use protective clothing for your child that is in good condition and meets the legal requirements.
– When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
In the interest of your own safety, GASGAS Motorcycles recommends that you only operate the vehicle while wearing 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
It is important that you read this Owner's Manual carefully and completely before your child makes his or her first trip. The
Owner's Manual contains useful information and many tips for you and your child on how to operate, handle, and service
your motorcycle. This is the only way for you to find out how to ideally tune the vehicle and how to protect your child from
injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
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 and must be handed over to the new owner if the vehicle is
sold.
The Owner's Manual is also available for download from your authorized GASGAS Motorcycles dealer and on the GASGAS Motorcycles website.
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 the safety of your child, 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)
Fuel tank filler cap
1
Quick release of seat
2
Chain guide
3
Plug-in stand ( p. 16)
4
Choke
5
Fuel tap ( p. 15)
6
F02964-10
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4.2 View of vehicle, rear right (example)
VIEW OF VEHICLE 4
Stop button ( p. 14)
1
Throttle grip ( p. 14)
2
Hand brake lever ( p. 14)
3
Vehicle identification number ( p. 12)
4
Kick starter lever ( p. 16)
5
Foot brake lever ( p. 16)
6
Level viewer for brake fluid, rear
7
F02965-10
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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 located on the front frame tube.
5.3 Engine number
5.4 Fork part number
402154-10
The engine number1is located on the left side of the engine under
the engine sprocket.
401949-11
The fork part number1is stamped on the outside of the axle clamp.
12
401947-10
Page 15
5.5 Shock absorber article number
H01186-10
SERIAL NUMBERS 5
The shock absorber article number1is stamped on the bottom of the
shock absorber toward the right-hand side.
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6 CONTROLS
6.1 Hand brake lever
6.2 Throttle grip
Hand brake lever1is fitted on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
F02966-10
Throttle grip1is fitted on the right side of the handlebar.
F02966-11
6.3 Stop button
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.
F02967-10
6.4 Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–
If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
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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.
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.
CONTROLS 6
F02968-10
6.5 Closing the fuel tank filler cap
F02968-11
6.6 Fuel tap
–
Mount fuel tank filler cap1and turn it clockwise until the fuel
tank is tightly closed.
Info
Route fuel tank breather hose2without kinks.
Fuel tap1is on the left of the fuel tank.
Possible states
• Fuel tap is closed – The knurled screw is turned all the way clockwise. Fuel cannot flow out of the fuel tank.
• Fuel tap is open – The knurled screw is turned all the way counterclockwise. Fuel can flow out of the fuel tank.
F02969-10
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6 CONTROLS
6.7 Choke
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.
Info
If the engine is warm, the choke function must be deactivated.
6.8 Kick starter lever
6.9 Foot brake lever
F02970-10
H01184-10
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.
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.
Foot brake lever1is located in front of the right footrest.
The rear brake is engaged with the foot brake lever.
6.10 Plug-in stand
16
401956-10
The fixture for plug-in stand1is located on the frame on the left side
of the vehicle.
The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before riding.
402581-10
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PREPARING FOR USE 7
7.1 Advice on preparing for first use
Warning
Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk.
Children often underestimate or fail to recognize dangerous situations.
– Your child must already be able to ride a bicycle.
– Your child must be able to put the vehicle upright independently after a fall.
– Your child must understand that regulations and instructions from you or from other guardians must be fol-
lowed.
– Make it clear to your child that he or she should not, under any circumstances, operate the vehicle without
supervision.
–
Make it clear to your child that he or she may only drive at speeds commensurate with the child's riding abilities and the road conditions.
– Do not ask too much of your child.
Do not consider participation in competitive activities until your child's stamina, riding techniques and motivation are at the necessary levels.
– Only let your child ride on the vehicle if he or she is physically and mentally ready.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as trousers and a
jacket with protectors on all rides.
– Alway use protective clothing for your child that is in good condition and meets the legal requirements.
– When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style constitutes a major risk.
– Ensure that your child adapts the riding speed to the road conditions and to his or her riding abilities.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Make it clear to your child that he or she must not carry a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Ensure that your child raises his or her foot from the foot brake lever if he or she does not want to brake.
Warning
Danger of accidents The suspension components will become damaged or destroyed if overloaded.
– Do not exceed the maximum permissible weight of the rider.
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7 PREPARING FOR USE
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 the motorcycle, remember that others may be disturbed by excessive noise.
– Ensure that the pre-sale inspection work has been carried out by an authorized GASGAS Motorcycles workshop.
You will receive a delivery certificate when the vehicle is handed over.
– Read through the entire Owner's Manual together with your child before riding for the first time.
Info
Pay special attention to the safety instructions and to the risk of injury.
Explain to your child the techniques of riding and falling, e.g., how shifting weight can influence handling charac-
teristics.
– Familiarize your child with the controls.
–
Adjust the basic position of the hand brake lever. ( p. 61)
–
Adjust the basic position of the foot brake lever. ( p. 69)
– Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the weight of
your child.
– Allow your child to become accustomed to the handling of the motorcycle on suitable terrain, preferably on a large,
open meadow.
Info
To give your child a feeling for the brake system, you should push your child at first. Do not start the engine
until your child is able to apply the necessary front brake pressure.
Initially, let your child ride to another person who can help your child stop and turn.
– Erect obstacles for your child to navigate around so that your child becomes accustomed to handling the vehicle.
– Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for the motorcy-
cle.
– Your child should not ride on terrain that exceeds your child's capabilities and experience.
– Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding.
– Make sure the maximum permissible weight of the rider is not exceeded.
Guideline
Maximum rider weight 45 kg (99 lb.)
Maximum rider size < 130 cm (< 51.2 in)
–
Check the spoke tension. ( p. 79)
Info
The spoke tension must be checked after half an hour of operation.
–
Run the engine in. ( p. 19)
18
Page 21
7.2 Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %
Info
The use of a service hour counter is recommended in order to be able to check the mileage at any time.
– Avoid fully opening the throttle.
PREPARING FOR USE 7
19
Page 22
8 RIDING INSTRUCTIONS
8.1 Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
H02217-01
–
Check the gear oil level. ( p. 91)
–
Check the front brake fluid level. ( p. 62)
–
Check the rear brake fluid level. ( p. 70)
–
Check the front brake linings. ( p. 65)
–
Check the brake linings of the rear brake. ( p. 71)
– Check that the brake system is functioning properly.
–
Check the coolant level. ( p. 82)
–
Check the chain for dirt. ( p. 54)
– Check the chain, rear sprocket, engine sprocket, and chain guide.
( p. 56)
–
Check the chain tension. ( p. 55)
–
Check the tire condition. ( p. 78)
–
Check tire pressure. ( p. 79)
–
Check the spoke tension. ( p. 79)
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. 38)
–
Bleed the fork legs. ( p. 37)
– Check the air filter.
– Check the settings of all controls and ensure that they can be oper-
ated smoothly.
– Check all screws, nuts, and hose clips regularly for tightness.
– Check the fuel level.
8.2 Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine failure High rpm with a cold engine negatively impacts the lifespan of the engine.
– Ensure that the engine is always warmed up at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the
fuel evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
20
Page 23
Preliminary work
–
Raise the motorcycle with a lift stand. ( p. 37)
The motorcycle has been out of use for more than 1 week
– Empty the carburetor float chamber.
– Turn the knurled screw on the fuel tap all the way counterclockwise.
Fuel can flow from the fuel tank to the carburetor.
The engine is cold
– Pull the choke knob up all the way to the stop and turn it by a max. ¼ turn.
– Press the kick starter lever robustly through its full range.
Info
Do not open the throttle.
Final steps
–
Remove the motorcycle from the lift stand. ( p. 37)
8.3 Starting off
Info
The plug-in stand must be removed before riding.
RIDING INSTRUCTIONS 8
– Open the throttle carefully.
8.4 Riding
Info
If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized
GASGAS Motorcycles workshop.
– If the choke function has been activated, deactivate it after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely
reduce the speed, but fuel consumption will be considerably lower.
– Your child should always open the throttle only as much as the engine can handle – abruptly opening the throttle
increases fuel consumption.
– Your child should switch off the engine if prolonged operation at idle speed or while stationary is imminent.
Guideline
≥ 2 min
8.5 Applying the brakes
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Explain to your child that he or she must adapt the braking to the traffic situation and the road conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not allow your child to continue riding until the problem is eliminated. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
21
Page 24
8 RIDING INSTRUCTIONS
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Explain to your child that he or she must brake carefully several times to dry out and remove dirt from the
brake linings and the brake discs.
– On sandy, wet, or slippery surfaces, use the rear brake.
– Always finish braking before you go into a bend.
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
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Apply the brakes on the motorcycle.
– Press and hold the stop button while the engine is idling until the engine stops.
– Turn the knurled screw on the fuel tap all the way clockwise.
– Park the motorcycle on firm ground.
8.7 Transporting
Note
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.
22
Page 25
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle
against falling over or rolling away.
401475-01
8.8 Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
RIDING INSTRUCTIONS 8
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.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
– Switch off the engine.
–
Open the fuel tank filler cap. ( p. 14)
–
Fill the fuel tank with fuel up to a maximum of levelA.
Guideline
35 mm (1.38 in)
2.3 l (2.4 qt.) Super unleaded (95
octane) mixed with
2-stroke engine oil
(1:60) ( p. 109)
400214-10
Dimension
Fuel tank capacity,
approx.
–
Close the fuel tank filler cap. ( p. 15)
A
23
Page 26
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
Check the front brake linings. ( p. 65)
Check the brake linings of the rear brake. ( p. 71)
Check the brake discs. ( p. 62)
Check the brake lines for damage and leakage. ○ ● ● ●
Change the foot brake cylinder sealing cup. ● ● ●
Check the rear brake fluid level. ( p. 70)
Check the free travel of the foot brake lever. ( p. 68)
Check the frame. ( p. 58)
Check the link fork. ( p. 59)
Check the fork bearing for play. ● ● ●
Check the shock absorber heim joint for play. ● ● ●
Check the tire condition. ( p. 78)
Check tire pressure. ( p. 79)
Check the wheel bearing for play. ● ● ●
Check the wheel hubs. ● ● ●
Check the rim run-out. ○ ● ● ●
Check the spoke tension. ( p. 79)
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 56)
Check the chain tension. ( p. 55)
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. ○ ● ● ●
Check the front brake fluid level. ( p. 62)
Check the play of the handbrake lever. ( p. 61)
Check the steering head bearing play. ( p. 44)
Change the spark plug and spark plug connector. ● ● ●
Change the gear oil. ( p. 91)
Check the gear oil level. ( p. 91)
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incor-
rect routing.
Check the antifreeze and coolant level. ( p. 81)
Check the cables for damage and routing without sharp bends. ○ ● ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly. ○ ● ● ●
Clean the air filter and air filter box. ( p. 51)
Change the glass fiber yarn filling of the main silencer. ( p. 52)
Every 80 operating hours
Every 40 operating hours
Every 20 operating hours
After 10 operating hours
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
● ● ●
● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ●
●
○ ● ● ●
○ ● ● ●
○ ● ● ●
● ● ●
24
Page 27
SERVICE SCHEDULE 9
Every 80 operating hours
Every 40 operating hours
Every 20 operating hours
After 10 operating hours
Service the fork. ● ●
Perform the shock absorber service. ●
Check the tightness of the easily accessible, safety-relevant screws and nuts. ○ ● ● ●
Check the idle speed. ○ ● ● ●
Check the clutch setting. ( p. 88)
Final check: Check the vehicle for safe operation 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
Every 80 operating hours
After 20 operating hours / Every 20 operating hours
After 10 operating hours
Change the front brake fluid. ● ●
Change the rear brake fluid. ● ●
Service the fork. ○
Perform the shock absorber service. ○
Lubricate the steering head bearing. ( p. 45)
Check/adjust the carburetor components. ● ●
Change the coolant. ( p. 84)
Perform minor engine service. Check the cylinder and piston. Check the inlet membrane.) ● ●
Perform major engine service including removing and installing engine. (Check the clutch.
Change the piston. Change the connecting rod, conrod bearing, and crank pin. Check the
transmission. Change the crankshaft bearing. Change all engine bearings.)
○ One-time interval
● Periodic interval
● ● ●
every 48 months
● ●
●
●
25
Page 28
10 TUNING THE CHASSIS
10.1 Checking the basic chassis setting with rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage
to forks, shock absorbers, link fork and frame, the basic settings of
the suspension components must match the rider's weight.
– This vehicle is delivered pre-set for a standard rider's weight (with
full protective clothing).
Guideline
Standard rider weight 25 … 35 kg (55 … 77 lb.)
– If the rider's weight is above or below this range, the basic setting of
the suspension components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the
spring preload, but in the case of large weight differences, the
springs must be replaced.
401030-01
10.2 Air suspension XACT 5235
Air suspension WP XACT 5235 is used in the fork.
In this system, suspension is located in the left fork leg and damping in the right fork leg.
As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks. The
response on slightly uneven surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air cushion. A steel spring is located in the left fork leg as
an end stop.
Info
If the fork is frequently overloaded, then the air pressure in the fork must be increased to avoid damage to the fork
and frame.
The air pressure in the fork can be quickly adjusted to the rider's weight, surface conditions and the rider's preference using
a fork airpump. The fork does not have to be dismantled. The time consuming mounting of harder or softer fork springs is
not required.
If the air chamber loses air due to a damaged seal, the fork will still not sag. In this case the air is retained in the fork. The
suspension travel is maintained as far as possible. The damping becomes harder and the riding comfort reduces.
The rebound damping can be adjusted.
The rebound adjustment is located at the upper end of the right fork leg.
26
Page 29
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.
F02184-10
Guideline
Low-speed compression damping
Comfort 18 clicks
Standard 15 clicks
Sport 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
10.5 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info
The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.
27
Page 30
10 TUNING THE CHASSIS
F02184-11
– Push the splash protector to the side.
–
Using an open end wrench, turn adjusting screw1clockwise all
the way.
Info
Do not loosen fitting2!
– Turn counterclockwise by the number of turns corresponding to the
shock absorber type.
Guideline
High-speed compression damping
Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise
to reduce damping.
– Position the splash protector.
10.6 Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
–
Turn adjusting 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
F02185-10
Sport 13 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
28
Page 31
10.7 Measuring the dimension of the rear wheel unloaded
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
– Measure the vertical distance between the rear axle and a fixed
point, such as a marking on the side cover.
–
Note the value as dimensionA.
400988-10
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
10.8 Checking the static sag of the shock absorber
–
Measure dimensionAof rear wheel unloaded. ( p. 29)
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance between rear axle and fixed point again.
–
Note the value as dimensionB.
TUNING THE CHASSIS 10
400989-10
Info
The static sag is the difference between measurements
andB.
– Check the static sag.
Static sag 12 mm (0.47 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
( p. 30)
A
29
Page 32
10 TUNING THE CHASSIS
10.9 Checking the riding sag of the shock absorber
–
Measure dimensionAof rear wheel unloaded. ( p. 29)
– With another person holding the motorcycle, the rider, wearing full
protective clothing, sits on the seat in a normal sitting position (feet
on footrests) and bounces up and down a few times.
The rear wheel suspension levels out.
– Another person now measures the distance between the rear axle
and the fixed point.
–
Note the value as dimensionC.
Info
The riding sag is the difference between measurements
andC.
– Check riding sag.
Riding sag 80 mm (3.15 in)
» If the riding sag differs from the specified measurement:
–
Adjust the riding sag. ( p. 31)
A
400990-10
10.10 Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
–
Remove the shock absorber. ( p. 49)
– After removing the shock absorber, clean it thoroughly.
30
Page 33
F03048-10
TUNING THE CHASSIS 10
Main work
– Measure the full spring length while it is under tension and note
down the value.
–
Loosen retaining ring1.
–
Turn adjusting ring2until the spring is no longer under tension.
Hook wrench (T304)
Hook wrench (T1533)
Info
If the spring cannot be fully released, the spring must be
removed to accurately measure the spring length.
– Measure the total spring length while the spring is not under ten-
sion.
–
Tension the spring by turning adjusting ring2to specified dimensionA.
Guideline
Spring preload 3 mm (0.12 in)
10.11 Adjusting the riding sag
B00292-10
Info
The spring preload is the difference between the relaxed
spring length and the tensioned spring length.
Depending on the static sag and/or the riding sag, it may be
necessary to increase or decrease the spring preload.
–
Tighten retaining ring1.
Finishing work
–
Install the shock absorber. ( p. 49)
–
Remove the motorcycle from the lift stand. ( p. 37)
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
–
Remove the shock absorber. ( p. 49)
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 15 … 25 kg
(33 … 55 lb.)
Weight of rider (standard):
25 … 35 kg (55 … 77 lb.)
Weight of rider: 35 … 45 kg
(77 … 99 lb.)
25 N/mm (143 lb/in)
30 N/mm (171 lb/in)
35 N/mm (200 lb/in)
31
Page 34
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.
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing
the spring preload.
Finishing work
–
Install the shock absorber. ( p. 49)
–
Remove the motorcycle from the lift stand. ( p. 37)
–
Check the static sag of the shock absorber. ( p. 29)
–
Check the riding sag of the shock absorber. ( p. 30)
–
Adjust the rebound damping of the shock absorber. ( p. 28)
– 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.
401000-01
10.13 Adjusting the fork air pressure
Warning
Danger of accidents 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.
– Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the
new handling characteristic.
Info
Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine.
The air suspension is located in the left fork leg. The rebound damping is located in the right fork leg.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
32
Page 35
F02971-10
TUNING THE CHASSIS 10
Main work
–
Remove protection cap1.
–
Push together fork airpump2fully.
Fork airpump (79412966100)
Info
The fork airpump is included as part of the motorcycle's
accessory pack.
– Connect the fork airpump to the left fork leg.
The fork airpump indicator switches on automatically.
A little air escapes from the fork leg when connecting.
Info
This is due to the volume of the hose and not due to a
defect in the fork airpump or the fork.
Observe the accompanying instructions for GASGAS technical accessories.
– Adjust the air pressure as specified.
Guideline
Air pressure 2 bar (29 psi)
Gradual changing of the air
pressure in steps of
Minimum air pressure 1.4 bar (20 psi)
Maximum air pressure 4 bar (58 psi)
0.2 bar (3 psi)
Info
Never adjust the air pressure to a value outside the stated
range.
– Disconnect the fork airpump from the left fork leg.
When disconnecting, excess pressure will escape from the hose
– the fork leg itself does not lose any air.
The fork airpump indicator switches off automatically after
80 seconds.
– Mount the protection cap.
Info
Only mount the protection cap by hand.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
33
Page 36
10 TUNING THE CHASSIS
10.14 Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
F02972-10
–
Turn adjuster1clockwise all the way.
Info
Adjuster1is located at the upper end of the right fork leg.
– Turn counterclockwise by the number of clicks corresponding to the
fork type.
Guideline
Rebound damping
Comfort 15 clicks
Standard 12 clicks
Sport 10 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.15 Handlebar position
On the upper triple clamp, there are 2 holes at a distance ofAto each
other.
15 mm (0.59 in)
3.5 mm (0.138 in)
C00248-10
Hole distance
The holes on the handlebar supports are placed at a distance of
from the center.
Hole distance
The handlebar supports can be mounted in four different positions. This
allows the handlebar to be mounted in the most comfortable position
for the rider.
A
B
10.16 Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.
– Change the handlebar if the handlebar is damaged or bent.
B
34
Page 37
C00249-10
TUNING THE CHASSIS 10
–
Remove screws1. Take off the handlebar clamps. Remove the
handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–
Remove screws2. Take off handlebar supports.
– Place handlebar supports in required position. Mount and tighten
screws2.
Guideline
Screw, handlebar
support
– Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–
Position the handlebar clamps. Mount screws1and tighten
evenly.
Guideline
Screw, handlebar
clamp
M10 40 Nm (29.5 lbf ft)
Loctite®243™
M8 20 Nm (14.8 lbf ft)
Info
Make sure the installed gaps are even.
10.17 Adjusting the seat height
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic.
– Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the
new handling characteristic.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Remove nut1.
F02973-10
35
Page 38
10 TUNING THE CHASSIS
F02974-10
F02973-10
–
Hold the rear wheel with the link fork and remove screw2.
– Position the shock absorber according to the required seat height.
Guideline
Low seat position (standard)
High seat position
–
Position screw2.
–
Mount nut1and tighten the fitting.
Guideline
Screw, top shock
absorber
M10 45 Nm (33.2 lbf ft)
A
B
Loctite®243™
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
36
Page 39
SERVICE WORK ON THE CHASSIS 11
11.1 Raising the motorcycle with a lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
– Raise the motorcycle at the frame underneath the engine.
Neither wheel is in contact with the ground.
– Secure the motorcycle against falling over.
401942-01
11.2 Removing the motorcycle from the lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
–
To park the motorcycle, insert plug-in stand1into the plug-in
stand bracket on the left side of the vehicle.
Info
Remove the plug-in stand before riding.
402581-10
11.3 Bleeding the fork legs
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Release bleeder screws1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
F02179-10
37
Page 40
11 SERVICE WORK ON THE CHASSIS
11.4 Cleaning the dust boots of the fork legs
F02975-10
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
–
Remove the fork protector. ( p. 38)
Main work
–
Push dust boots1of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from
the inside fork tubes. Over time, dirt can accumulate behind
the dust boots. If this dirt is not removed, the seals rings
behind can start to leak.
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 protector
F02976-10
– Clean and oil the dust boots and inside fork tubes of both fork legs.
Universal oil spray ( p. 111)
– Press the dust boots back into the installation position.
– Remove the excess oil.
Finishing work
–
Install the fork protector. ( p. 39)
–
Remove the motorcycle from the lift stand. ( p. 37)
–
Remove screws1and take off the clamp.
–
Remove screws2on the left fork leg. Take off the fork protector.
38
Page 41
F02977-10
11.6 Installing the fork protector
SERVICE WORK ON THE CHASSIS 11
–
Remove screws3on the right fork leg. Take off the fork protector.
– Position fork protector on the right fork leg. Mount and tighten
screws1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
11.7 Removing the fork legs
F02977-11
F02976-11
– Position fork protector on left fork leg. Mount and tighten
screws2.
Guideline
Remaining screws,
chassis
– Position the brake line and the clamp. Mount and tighten
screws3.
Guideline
Screw, brake line
bracket
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
–
Remove the front wheel. ( p. 75)
Main work
–
Remove screws1and take off the clamp.
–
Remove screws2and take off the brake caliper.
– Allow the brake caliper and the brake line to hang loosely to the
side.
M6 10 Nm (7.4 lbf ft)
EJOT 1.7 Nm (1.25 lbf ft)
F03020-10
Info
Do not kink the brake line.
39
Page 42
11 SERVICE WORK ON THE CHASSIS
F03022-10
11.8 Installing the fork legs
–
Loosen screws3. Remove the left fork leg.
–
Loosen screws4. Remove the right fork leg.
Main work
– Position the fork legs.
Bleeder screws1are positioned toward the rear.
Info
The second milled groove in the fork leg must be flush with
the upper edge of the upper triple clamp.
F02179-10
F03022-11
F03021-10
–
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 screw4, and tighten.
Guideline
Screw, front
brake caliper
–
Mount and tighten screw5.
Guideline
Screw, front
brake caliper
– Position the brake line and the clamp. Mount and tighten
screws6.
Guideline
Screw, brake line
bracket
M8 15 Nm (11.1 lbf ft)
M8x60 20 Nm (14.8 lbf ft)
Loctite®243™
M8x40 20 Nm (14.8 lbf ft)
Loctite®243™
EJOT 1.7 Nm (1.25 lbf ft)
40
Finishing work
–
Install the front wheel. ( p. 75)
Page 43
11.9 Removing the lower triple clamp
Preparatory work
–
–
–
–
–
Main work
–
–
–
F03025-10
–
– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
SERVICE WORK ON THE CHASSIS 11
Raise the motorcycle with a lift stand. ( p. 37)
Remove the front wheel. ( p. 75)
Remove the fork legs. ( p. 39)
Remove the start number plate. ( p. 47)
Remove front fender. ( p. 48)
Pull fuel tank breather1out of the steering stem.
Remove nut2.
Release screw3, take off the upper triple clamp with the handlebar and set aside.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
Remove protective ring4.
F03026-10
41
Page 44
11 SERVICE WORK ON THE CHASSIS
11.10 Installing the lower triple clamp
Main work
– Clean the bearing and sealing elements, check for damage, and
grease.
High viscosity grease ( p. 110)
– Insert the lower triple clamp with the steering stem. Mount upper
steering head bearing1.
–
Check whether upper steering head seal2is correctly positioned.
–
Push on protective ring3.
F02885-10
F03023-10
F02179-11
– Position the upper triple clamp with the handlebar.
–
Mount nut4, but do not tighten yet.
– Position the fork legs.
Bleeder screws5are positioned toward the rear.
Info
The upper milled groove in the fork leg must be flush with
the upper edge of the upper triple clamp.
42
Page 45
F03024-10
F03027-10
SERVICE WORK ON THE CHASSIS 11
–
Tighten screws6.
Guideline
Screw, bottom triple
clamp
–
Tighten nut4.
Guideline
Nut, steering head M20x1.5 10 Nm (7.4 lbf ft)
–
Position the fuel tank breather7in the steering stem.
M8 15 Nm (11.1 lbf ft)
F03028-10
F03021-11
–
Tighten screw8.
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to
avoid stresses.
–
Tighten screws9.
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
–
Position the brake caliper, mount screwbk, and tighten.
Guideline
Screw, front
brake caliper
–
Mount and tighten screwbl.
M8x60 20 Nm (14.8 lbf ft)
Loctite®243™
Guideline
Screw, front
brake caliper
M8x40 20 Nm (14.8 lbf ft)
Loctite®243™
– Position the brake line and the clamp. Mount and tighten
screwsbm.
Guideline
Screw, brake line
EJOT 1.7 Nm (1.25 lbf ft)
bracket
Finishing work
– Check that the wiring harness, throttle cables, brake line have the
necessary freedom of movement and are correctly routed.
–
Install the front fender. ( p. 48)
–
Install the start number plate. ( p. 47)
–
Install the front wheel. ( p. 75)
–
Check the steering head bearing play. ( p. 44)
–
Remove the motorcycle from the lift stand. ( p. 37)
43
Page 46
11 SERVICE WORK ON THE CHASSIS
11.11 Checking the steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages com-
ponents.
– Correct incorrect steering head bearing play immediately. (Your authorized GASGAS Motorcycles workshop will
be glad to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing
seats in the frame can become damaged over time.
H01167-01
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
– Move the handlebar to the straight-ahead position. Move the fork
legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
–
Adjust the steering head bearing play. ( p. 44)
– 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 the steering head bearing play. ( p. 44)
– Check the steering head bearing and replace if required.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
11.12 Adjusting the steering head bearing play
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Pull fuel tank breather1out of the steering stem.
–
Loosen screws2.
–
Loosen screw3.
–
Loosen and retighten nut4.
Guideline
Nut, steering head M20x1.5 10 Nm (7.4 lbf ft)
F03028-11
– Using a plastic hammer, tap lightly on the upper triple clamp to
avoid stresses.
–
Tighten screw3.
Guideline
Screw, steering stem M8 20 Nm (14.8 lbf ft)
–
Tighten screws2.
44
Page 47
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
–
Position the fuel tank breather1in the steering stem.
Finishing work
–
Check the steering head bearing play. ( p. 44)
–
Remove the motorcycle from the lift stand. ( p. 37)
11.13 Lubricating the steering head bearing
–
Remove the lower triple clamp. ( p. 41)
–
Install the lower triple clamp. ( p. 42)
H02387-01
SERVICE WORK ON THE CHASSIS 11
Info
The steering head bearing is cleaned and lubricated in the
course of removal and installation of the lower triple clamp.
11.14 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is 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. 50)
– Turn the knurled screw on the fuel tap all the way clockwise.
45
Page 48
11 SERVICE WORK ON THE CHASSIS
F02978-10
F02979-10
Main work
–
Remove screw1.
– Raise the fuel tank.
–
Pull off fuel hose2.
Info
Remaining fuel may flow out of the fuel hose.
– Pull fuel tank breather out of the steering stem.
– Take off the fuel tank.
11.15 Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
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.
Main work
–
Check the throttle cable routing. ( p. 59)
46
Page 49
F02979-11
F02978-11
SERVICE WORK ON THE CHASSIS 11
–
Mount fuel hose1.
– Position the fuel tank.
– Make sure that no cables or throttle cables are trapped or damaged.
–
Mount and tighten screw2.
Guideline
Remaining screws,
chassis
– Position the fuel tank breather in the steering stem.
M6 10 Nm (7.4 lbf ft)
Finishing work
–
11.16 Removing the start number plate
–
– Unhook the start number plate from the brake line and remove it.
F02980-10
11.17 Installing the start number plate
– Attach the start number plate to the brake line.
– Position the start number plate.
Mount the seat. ( p. 50)
Remove screw1.
Holding lugs1engage in the fender.
F02981-10
47
Page 50
11 SERVICE WORK ON THE CHASSIS
F02982-10
11.18 Removing front fender
–
Mount and tighten screw2.
Guideline
Screw, start number
plate
–
Remove screws1. Take off the front fender.
M6 4 Nm (3 lbf ft)
F02983-10
11.19 Installing the front fender
F02984-10
F02983-11
– Position start number plate on the fender.
The holding lugs of the start number plate engage in drill
holes1of the fender.
– Position fender on the lower triple clamp, mount and tighten
screws2.
Guideline
Screw, fender M6 6 Nm (4.4 lbf ft)
48
Page 51
11.20 Removing the shock absorber
F02985-10
SERVICE WORK ON THE CHASSIS 11
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Pull brake line1out of the holder.
–
Remove nut2.
–
Remove screw3and lower the link fork carefully.
–
Remove screw4, push splash protector5to the side, and
remove the shock absorber.
F02986-10
11.21 Installing the shock absorber
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic.
– Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
Main work
–
Push splash protector1to the side.
–
Position the shock absorber with screw2, depending on the
desired seating height.
F02986-11
– Raise the link fork, mount and tighten the shock absorber with
screw3.
Guideline
F02985-11
Screw, bottom
shock absorber
–
Mount nut4and tighten the fitting.
Guideline
Screw, top shock
absorber
–
Attach brake line5to the holder.
M10 45 Nm (33.2 lbf ft)
M10 45 Nm (33.2 lbf ft)
Loctite®243™
Loctite®243™
49
Page 52
11 SERVICE WORK ON THE CHASSIS
11.22 Removing the seat
F02987-10
11.23 Mounting the seat
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
–
Open quick release1and raise the rear of the seat.
– Pull back the seat and remove it.
–
Hook seat onto screw1and lower the seat at the rear and push it
forward.
Holding lug2hooks into the fuel tank.
F02988-10
–
Close quick release3.
F02987-11
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.
50
Preparatory work
–
Remove the seat. ( p. 50)
Page 53
11.25 Installing the air filter
F02989-10
SERVICE WORK ON THE CHASSIS 11
Main work
–
Press rear holding lug1together slightly and swing the air filter
box cover upward.
– Pull out the front holding lug and take off the air filter box cover.
– Take off the air filter.
Main work
– Position the clean air filter.
– Position the rear holding lug. Lower the air filter box cover and allow
the front holding lug1to snap in.
Info
If the air filter is not mounted correctly, dust and dirt may
enter the engine and result in damage.
F03029-10
Finishing work
–
Mount the seat. ( p. 50)
11.26 Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Preparatory work
–
Remove the seat. ( p. 50)
–
Remove the air filter. ( p. 50)
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it
to dry properly.
Air filter cleaner ( p. 110)
F02990-01
Info
Only press the air filter to dry it, never wring it out.
– Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 110)
– Clean the air filter box.
– Check intake flange for damage and looseness.
51
Page 54
11 SERVICE WORK ON THE CHASSIS
11.27 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.
Finishing work
–
Install the air filter. ( p. 51)
–
Mount the seat. ( p. 50)
–
Remove screw1.
–
Remove screw2.
–
Pull off the main silencer from the manifold at sleeve3.
F02991-10
11.28 Installing the main silencer
– Position the main silencer.
–
Mount the main silencer with sleeve1.
–
Mount the silent block with screw2.
Guideline
Remaining screws,
chassis
– Position the collar bushings.
–
F02991-11
Mount and tighten screw3.
Guideline
Remaining screws,
chassis
11.29 Changing the glass fiber yarn filling of 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.
M6 10 Nm (7.4 lbf ft)
M6 10 Nm (7.4 lbf ft)
Info
Over time, the fibers of the glass fiber yarn escape and the damper “burns” out.
Not only is the noise level higher, but the performance characteristics change.
Preparatory work
–
Remove main silencer. ( p. 52)
52
Page 55
Main work
–
Remove screws with toothed washers1from the silencer cap2.
–
Remove end cap and outer tube3.
–
Remove glass fiber yarn filling4from the inner tube.
– Clean the parts that need to be reinstalled and check for damage.
– Mount the new glass fiber yarn filling on the inner tube.
– Slide the outer tube over the glass fiber yarn filling.
F02992-10
– Insert the end cap into the outer tube.
– Mount and tighten the screws with the toothed washers.
Guideline
Finishing work
–
Install the main silencer. ( p. 52)
11.30 Removing the engine sprocket cover
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Remove screws1.
–
Remove screw2.
– Take off the engine sprocket cover.
SERVICE WORK ON THE CHASSIS 11
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
F02993-10
11.31 Installing the engine sprocket cover
Main work
–
–
–
F02993-10
Finishing work
–
Position the engine sprocket cover. Mount screws1, but do not
tighten yet.
Mount and tighten screw2.
Guideline
Screw, engine sprocket
cover
Tighten screws1.
Guideline
Screw, engine sprocket
cover
Remove the motorcycle from the lift stand. ( p. 37)
M8 15 Nm (11.1 lbf ft)
M6 10 Nm (7.4 lbf ft)
53
Page 56
11 SERVICE WORK ON THE CHASSIS
11.32 Checking the chain for dirt
400678-01
11.33 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.
– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
–
Clean the chain. ( p. 54)
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. 37)
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 110)
– After drying, apply chain spray.
Off-road chain spray ( p. 110)
400725-01
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
54
Page 57
SERVICE WORK ON THE CHASSIS 11
11.34 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.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
– Press the chain upward at the end of the chain sliding piece and
determine chain tensionA.
Info
The top part of chain1must be taut.
Chain wear is not always even, so you should repeat this
measurement at different chain positions.
F02994-10
Chain tension 5 … 8 mm (0.2 … 0.31 in)
» If the chain tension does not meet the specification:
–
Adjust the chain tension. ( p. 55)
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
11.35 Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel 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. 37)
–
Check the chain tension. ( p. 55)
55
Page 58
11 SERVICE WORK ON THE CHASSIS
F02198-10
Main work
–
Loosen nut1.
–
Loosen nuts2.
–
Adjust the chain tension by turning adjusting screws3left and
right.
Guideline
Chain tension 5 … 8 mm (0.2 … 0.31 in)
Turn the adjusting screws3on the left and right so that the
markings on the left and right chain adjusters4are in the same
position relative to the reference marksA. The rear wheel is
then correctly aligned.
–
Tighten nuts2.
–
Make sure that chain adjusters4are fitted correctly on adjusting
screws3.
–
Tighten nut1.
Guideline
Nut, rear wheel spindle M12x1 40 Nm (29.5 lbf ft)
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
11.36 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
–
Remove the engine sprocket cover. ( p. 53)
Main work
– Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or motor sprocket is worn:
– Change the drivetrain kit.
Info
The engine sprocket, the rear sprocket, and the
chain should always be replaced together.
400227-01
– Check the engine sprocket cover for wear.
» If the engine sprocket cover is worn through in the marked
areaA:
– Change the engine sprocket cover.
– Check the engine sprocket cover for tightness.
» If the engine sprocket cover is loose:
– Tighten the engine sprocket cover.
100896-10
When fitting the chain joint, always make sure that
the closed side of the joint faces forward (riding
direction).
Guideline
Screw, engine
sprocket cover
M6 10 Nm (7.4 lbf ft)
56
Page 59
F02199-10
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 the chain sliding guard.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
F02200-10
– 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 the chain sliding piece.
Guideline
Screw, chain sliding
piece
– Check the chain guide for wear.
M8 15 Nm (11.1 lbf ft)
Info
Wear can be seen on the front of the chain guide.
400985-01
» If the light part of the chain guide is worn:
– Change the chain guide.
57
Page 60
11 SERVICE WORK ON THE CHASSIS
F02201-01
11.37 Adjusting the chain guide
Info
The size of the chain wheel varies with the number of teeth. The chain guide can be adjusted on small sprockets.
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the chain guide.
Guideline
Remaining screws,
chassis
Finishing work
–
Install the engine sprocket cover. ( p. 53)
–
Remove the motorcycle from the lift stand. ( p. 37)
M6 10 Nm (7.4 lbf ft)
11.38 Checking the frame
F02201-10
S00876-01
–
Loosen screw1.
– Position the chain guide.
– Tighten the screw.
Guideline
Remaining screws,
chassis
– Check the frame for cracks and deformation.
» If the frame exhibits cracks or deformation due to a mechanical
impact:
– Change the frame.
M6 10 Nm (7.4 lbf ft)
Info
Always replace a frame that has been damaged due
to a mechanical impact. Repair of the frame is not
authorized by GASGAS Motorcycles.
58
Page 61
SERVICE WORK ON THE CHASSIS 11
11.39 Checking the link fork
– Check the link fork for damage, cracking, and deformation.
» If the link fork shows signs of damage, cracking, or deformation:
– Change the link fork.
Info
Always replace a damaged link fork. GASGAS Motorcycles does not permit repairing link forks.
F02202-01
11.40 Checking the 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.
F02995-01
11.41 Checking the rubber grip
Preparatory work
–
Remove the seat. ( p. 50)
– Turn the knurled screw on the fuel tap all the way clockwise.
–
Remove the fuel tank. ( p. 45)
Main work
– Check the throttle cable routing.
The throttle cable must be routed to the carburetor behind the
handlebars and above the fuel tank bracket.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
Finishing work
–
Install the fuel tank. ( p. 46)
–
Mount the seat. ( p. 50)
– Check the rubber grips on the handlebar for damage, wear, and
looseness.
» If a rubber grip is damaged, worn, or loose:
– Change the rubber grip.
Rubber grip adhesive (00062030051) ( p. 110)
–
Additionally secure the rubber grip. ( p. 60)
401197-01
59
Page 62
11 SERVICE WORK ON THE CHASSIS
11.42 Additionally securing the rubber grip
401198-01
Preparatory work
–
Check the rubber grip. ( p. 59)
Main work
– Secure the rubber grip at two locations with the retaining wire.
Securing wire (54812016000)
Wire twister forceps (U6907854)
The twisted wire ends face away from the palms and are bent
in toward the rubber grip.
60
Page 63
12.1 Checking play of handbrake 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 handbrake lever forwards and check playA.
Play of hand brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the play does not meet specifications:
–
Adjust the play of the hand brake lever. ( p. 61)
F02966-12
12.2 Adjusting the play of the hand brake lever
BRAKE SYSTEM 12
–
Check the play of the handbrake lever. ( p. 61)
–
Adjust the play of the hand brake lever using adjusting screw1.
Guideline
Play of hand brake lever 3 … 5 mm (0.12 … 0.2 in)
F02996-10
12.3 Adjusting the basic position of the hand brake lever
–
Remove screw1. Take off cover2.
F02996-11
–
Check the play of the handbrake lever. ( p. 61)
– Adjust the basic position of the hand brake lever with adjusting
screw3to the rider's hand size.
F02997-10
Info
Turn the adjusting screw clockwise to increase the distance
between the hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the
distance between the hand brake lever and the handlebar.
The range of adjustment is limited.
61
Page 64
12 BRAKE SYSTEM
12.4 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.)
F02996-11
–
Position cover2. Mount and tighten screw1.
– Check the front and rear brake disc thickness at multiple points for
the dimensionA.
Info
Wear reduces the thickness of the brake disc around the
contact surface of the brake linings.
Brake discs - wear limits
400257-10
– Check the front and rear brake discs for damage, cracking, and
front 2.2 mm (0.087 in)
rear 2.2 mm (0.087 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc.
– Change the rear brake disc.
deformation.
» If the brake disc exhibits damage, cracking, or deformation:
–
Change the front brake disc.
– Change the rear brake disc.
12.5 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.)
62
Page 65
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.
– Move the brake fluid reservoir mounted on the handlebar into a
horizontal position.
–
Remove screws1.
–
Take off cover2with membrane3.
– Check the brake fluid level.
F02998-10
Brake fluid level under top level
of container
» If the brake fluid level does not meet specifications:
–
Add the front brake fluid. ( p. 64)
– Position the cover with the membrane. Mount and tighten the
screws.
5 mm (0.2 in)
Info
Clean up the overflowed or spilled brake fluid immediately
with water.
63
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12 BRAKE SYSTEM
12.6 Adding the front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid 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. 65)
Main work
– Move the brake fluid reservoir mounted on the handlebar into a
horizontal position.
–
Remove screws1.
–
Take off cover2with membrane3.
– Correct the brake fluid level.
Guideline
F02998-10
Brake fluid level under top level
of container
5 mm (0.2 in)
64
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Position the cover with the membrane. Mount and tighten the
screws.
Page 67
Info
Clean up the overflowed or spilled brake fluid immediately
with water.
12.7 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.
BRAKE SYSTEM 12
≥ 1 mm (≥ 0.04 in)
F02999-10
Minimum thickness
» If the minimum thickness is less than specified:
–
Change the brake linings of the front brake. ( p. 65)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
–
Change the brake linings of the front brake. ( p. 65)
A
12.8 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.)
65
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12 BRAKE SYSTEM
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the
brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is
not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer
warranty shall be void.
– Only use brake linings approved and recommended by GASGAS Motorcycles.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
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.
F02998-10
F03000-11
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
–
Remove screws1.
–
Take off cover2with membrane3.
–
Remove screw4and screw5.
– Press back the brake linings by slightly tilting the brake caliper later-
ally on the brake disc. Carefully pull the brake caliper backward from
the brake disc.
– Press the brake piston back into the basic position and ensure that
brake fluid does not flow out of the brake fluid reservoir, extracting
some if necessary.
66
Page 69
F03001-10
–
Remove lock ring6.
–
Remove screw7.
– Remove the brake linings.
– Clean the brake caliper and the brake caliper bracket.
Warning
Danger of accidents Brake linings which have not been
approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS
motorcycles. The structure and friction coefficient of the
brake linings, and thus their brake power, may vary greatly
from that of original brake linings.
If brake linings are used that differ from the original
equipment, compliance with the original homologation
is not guaranteed. In this case, the vehicle no longer
corresponds to its condition at delivery and the
manufacturer warranty shall be void.
– Only use brake linings approved and recommended by
GASGAS Motorcycles.
BRAKE SYSTEM 12
F03000-11
– Position the new brake linings.
Info
Always change the brake linings in pairs.
Ensure that the brake linings are correctly positioned in the
holding spring.
–
Mount and tighten screw7.
Guideline
Screw, brake linings M5 8 Nm (5.9 lbf ft)
–
Mount lock ring6.
Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when neces-
sary.
–
Check the brake discs. ( p. 62)
– Position the brake caliper.
–
Mount screw4, but do not tighten yet.
Guideline
Screw, front
brake caliper
–
Mount screw5, but do not tighten yet.
Guideline
Screw, front
brake caliper
M8x60 20 Nm (14.8 lbf ft)
M8x40 20 Nm (14.8 lbf ft)
Loctite®243™
Loctite®243™
67
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12 BRAKE SYSTEM
– Operate the hand brake lever repeatedly until the brake linings are
in contact with the brake disc and there is a pressure point. Secure
the hand brake lever in the activated position.
The brake caliper straightens.
–
Tighten screw4.
Guideline
Screw, front
brake caliper
–
Tighten screw5.
Guideline
Screw, front
brake caliper
– Remove the locking piece of the hand brake lever.
– Correct the brake fluid level.
Guideline
Brake fluid level below reservoir rim
M8x60 20 Nm (14.8 lbf ft)
Loctite®243™
M8x40 20 Nm (14.8 lbf ft)
Loctite®243™
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
–
Position cover2with membrane3.
–
Mount and tighten screws1.
F02998-10
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
12.9 Checking the free travel 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.
–
Disconnect spring1.
– Move the foot brake lever back and forth between the end stop and
the foot brake cylinder piston bracket and check free travelA.
Guideline
Free travel of foot brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not meet specifications:
–
Adjust the free travel of the hand brake lever. ( p. 69)
–
F03002-10
Attach spring1.
68
Page 71
12.10 Adjusting the free travel 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 the foot brake lever spring.
–
Loosen nut1.
–
Turn push rod2accordingly until you have free travelA.
Guideline
Free travel of foot brake lever 3 … 5 mm (0.12 … 0.2 in)
–
Hold push rod2and tighten nut1.
– Attach the foot brake lever spring.
F03003-10
– Check whether the basic position of the foot brake lever is suitable
for the rider.
» When the basic position of the foot brake lever needs to be
adjusted:
– Adjust the basic position of the foot brake lever.
( p. 69)
BRAKE SYSTEM 12
12.11 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 the foot brake lever spring.
–
Loosen nut1.
–
Turn back push rod2until free travel is at a maximum.
– For an individual adjustment of the basic position of the foot brake
lever, loosen the screw3and turn the eccentric brake lever
stop4accordingly.
–
Tighten screw3.
F03003-11
Guideline
Remaining screws,
chassis
–
Turn push rod2accordingly until you have free travelA.
Guideline
Free travel of foot brake lever 3 … 5 mm (0.12 … 0.2 in)
–
Hold push rod2and tighten nut1.
– Attach the foot brake lever spring.
– Check whether the basic position of the foot brake lever is suitable
for the rider.
M6 10 Nm (7.4 lbf ft)
69
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12 BRAKE SYSTEM
12.12 Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
– Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidents 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.)
– Stand the vehicle upright.
–
Check the brake fluid level in level viewer1.
»
If an air bubble is visible in viewer1:
–
Add rear brake fluid. ( p. 70)
H01654-11
12.13 Adding rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the
brake linings are worn down.
– Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated. (Your
authorized GASGAS Motorcycles workshop will be glad to help.)
Warning
Skin irritation Brake fluid 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.)
70
Page 73
BRAKE SYSTEM 12
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
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
–
Raise the motorcycle with a lift stand. ( p. 37)
–
Check the brake linings of the rear brake. ( p. 71)
Main work
–
Remove screws1.
–
Take off cover2with washer3and membrane4.
F03004-10
–
Add brake fluid up to levelA.
Guideline
LevelA(brake fluid level
below reservoir rim)
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Position the cover with the washer and membrane.
– Mount and tighten the screws.
H01654-10
10 mm (0.39 in)
Info
Clean up overflowed or spilled brake fluid immediately with
water.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
12.14 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.)
71
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12 BRAKE SYSTEM
–
Check the brake linings for minimum thicknessA.
≥ 1 mm (≥ 0.04 in)
F02204-10
Minimum thickness
» If the minimum thickness is less than specified:
–
Change the rear brake linings. ( p. 72)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
–
Change the rear brake linings. ( p. 72)
A
12.15 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.
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.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the
brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is
not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer
warranty shall be void.
– Only use brake linings approved and recommended by GASGAS Motorcycles.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
72
Page 75
BRAKE SYSTEM 12
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
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Remove lock ring1.
–
Remove screw2.
–
Remove screw3and screw4.
F02205-10
– Take off the brake caliper.
F02207-10
F03004-11
Info
Do not kink or damage the brake line.
– Remove the brake linings.
– Clean the brake caliper and the brake caliper bracket.
– Allow the brake caliper and the brake line to hang loosely to the
side.
–
Check the brake discs. ( p. 62)
–
Remove screws5.
–
Take off cover6with washer7and membrane8.
– Press the brake piston back to its basic position and make sure that
no brake fluid overflows from the brake fluid reservoir, extract brake
fluid if necessary.
– Position the new brake linings.
Info
Always change the brake linings in pairs.
Ensure that the brake linings are correctly positioned in the
holding spring.
F02207-11
– Position the brake caliper on the brake disc.
The brake linings are correctly positioned.
73
Page 76
12 BRAKE SYSTEM
F02206-10
–
Mount and tighten screw3.
Guideline
Screw, rear brake
caliper
–
Mount and tighten screw4.
Guideline
Screw, rear brake
caliper
–
Mount and tighten screw2.
Guideline
Screw, brake linings M5 8 Nm (5.9 lbf ft)
–
Mount lock ring1.
–
Check the brake discs. ( p. 62)
– Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
–
Add brake fluid up to levelA.
Guideline
LevelA(brake fluid level
below reservoir rim)
M6x16 10 Nm (7.4 lbf ft)
Loctite®243™
M6x40 10 Nm (7.4 lbf ft)
Loctite®243™
10 mm (0.39 in)
H01654-10
Brake fluid DOT 4 / DOT 5.1 ( p. 108)
– Position cover with washer and membrane.
– Mount and tighten the screws.
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
74
Page 77
13.1 Removing the front wheel
F03005-11
WHEELS, TIRES 13
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Loosen screw1by several rotations.
–
Loosen screws2.
–
Press on screw1to push the wheel spindle out of the axle clamp.
–
Remove screw1.
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the brake
disc is not damaged.
– Hold front wheel and remove wheel spindle. Take the front wheel
F03006-10
out of the fork.
Info
Do not actuate the hand brake lever when the front wheel is
removed.
–
Remove spacers3.
F03044-10
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.
75
Page 78
13 WHEELS, TIRES
F03045-10
F03005-10
– 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. 110)
– Insert the spacers.
Info
Insert the wide spacer on the left in the direction of travel.
– Clean and grease the wheel spindle.
Long-life grease ( p. 110)
– Position the front wheel.
The brake linings are correctly positioned.
– Insert the wheel spindle.
–
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. 37)
– Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
–
Tighten screws3.
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
M10 40 Nm (29.5 lbf ft)
Loctite®243™
13.3 Removing the rear wheel
F02209-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 37)
Main work
–
Remove nut1.
–
Take off chain adjuster2.
76
Page 79
WHEELS, TIRES 13
–
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.
F02210-10
F03046-10
Warning
Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the brake
disc is not damaged.
– Hold the rear wheel and remove the wheel spindle. Take the rear
wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel is
removed.
–
Remove spacers4.
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.
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. 110)
F03047-10
– Insert the spacers.
Info
Insert the wide spacer on the left in the direction of travel.
77
Page 80
13 WHEELS, TIRES
F02210-11
F02198-11
– Clean and grease the wheel spindle.
Long-life grease ( p. 110)
– Position rear wheel and mount the chain.
The brake linings are correctly positioned.
–
Insert wheel spindle2.
–
Position chain adjuster3. Mount nut4, but do not tighten it yet.
–
Make sure that chain adjusters3are fitted correctly on adjusting
screws5.
– Make sure that the markings on the left and right chain
adjusters3are in the same position relative to reference
marksB. The rear wheel is then correctly aligned.
Info
The wide adjustment range of the chain adjusters enables
different secondary ratios with the same chain length.
Chain adjusters3can be turned by 180°.
–
Check the chain tension. ( p. 55)
–
Tighten nut4.
Guideline
Nut, rear wheel spindle M12x1 40 Nm (29.5 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings are in
contact with the brake disc and there is a pressure point.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 37)
13.5 Checking the tire condition
Info
Only mount tires approved and/or recommended by GASGAS Motorcycles.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcy-
cle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
– Check the front and rear tires for cuts, embedded objects, and other
damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
78
400602-10
Page 81
– 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.
H01144-10
» 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 protection cap.
– Check tire pressure when the tires are cold.
Offroad tire pressure
front 1.0 bar (15 psi)
rear 1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct tire pressure.
400695-01
– Mount the protection cap.
WHEELS, TIRES 13
13.7 Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam-
age.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low,
then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length
and spoke diameter.
If you hear different tone frequencies from different spokes
of equal length and diameter, this is an indication of different spoke tensions.
400694-01
You should hear a high note.
» If the spoke tension differs:
– Correct the spoke tension.
79
Page 82
13 WHEELS, TIRES
– Check the spoke torque.
Guideline
Spoke nipple M3.5 3 Nm (2.2 lbf ft)
Torque wrench kit (58429094000)
80
Page 83
COOLING SYSTEM 14
14.1 Cooling system
The water pump1in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve in the 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
F03030-10
14.2 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.
reduce the cooling effect.
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.
– Stand the motorcycle upright on a horizontal surface.
–
Take off radiator cap1.
– Check the antifreeze in the coolant.
−25 … −45 °C (−13 … −49 °F)
» If the antifreeze in the coolant does not match the specified
value:
– Correct the antifreeze in the coolant.
F03031-10
– 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. 108)
– Mount the radiator cap.
400243-10
10 mm (0.39 in)
81
Page 84
14 COOLING SYSTEM
14.3 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.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.
10 mm (0.39 in)
400243-10
Coolant levelAabove the
radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 108)
– Mount the radiator cap.
14.4 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.
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.
82
Page 85
Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
–
Remove screw1. Take off the radiator cap.
– Completely drain the coolant.
–
Mount and tighten screw1with a new seal ring.
Guideline
F03007-10
Drain plug, water
pump cover
M6 6 Nm (4.4 lbf ft)
14.5 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.
COOLING SYSTEM 14
F03008-10
400677-11
Main work
–
Make sure that screw1is tightened.
– Position the motorcycle upright.
–
Add coolant to levelA.
Guideline
DistanceAabove the radiator fins
Coolant 0.7 l (0.7 qt.)
– Move the vehicle into the position shown and prevent it from rolling
away. Height differenceBmust be reached.
Guideline
Height difference
B
10 mm (0.39 in)
Coolant ( p. 108)
50 cm (19.7 in)
Info
For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front. If the cooling system is poorly de-aerated, its cooling power will be
reduced and the engine may overheat.
– Return the vehicle to the horizontal position.
–
Add coolant to levelA.
– Mount the radiator cap.
Finishing work
–
Go for a short test ride.
– Check the cooling system for leaks.
83
Page 86
14 COOLING SYSTEM
14.6 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.
–
Check the coolant level. ( p. 82)
F03007-10
F03008-10
Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
–
Remove screw1. Take off the radiator cap.
– Completely drain the coolant.
–
Mount and tighten screw1with a new seal ring.
Guideline
Drain plug, water
pump cover
–
Make sure that screw1is tightened.
–
Add coolant to levelA.
Guideline
DistanceAabove the radiator fins
Coolant 0.7 l (0.7 qt.)
M6 6 Nm (4.4 lbf ft)
10 mm (0.39 in)
Coolant ( p. 108)
84
Page 87
400677-11
COOLING SYSTEM 14
– Move the vehicle into the position shown and secure it against
rolling away. Height differenceBmust be reached.
Guideline
Height difference
B
Info
For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front. If the cooling system is poorly de-aerated, its cooling power will be
reduced and the engine may overheat.
– Return the vehicle to the horizontal position.
–
Add coolant to levelA.
– Mount the radiator cap.
Finishing work
– Go for a short test ride.
– Check the cooling system for leaks.
–
Check the coolant level. ( p. 82)
50 cm (19.7 in)
85
Page 88
15 TUNING THE ENGINE
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 3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
–
Adjust the play in the throttle cable. ( p. 86)
400192-11
– Start the engine and let it run at idle speed. Move the handlebar to
and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
15.2 Adjusting the play in the throttle cable
Preparatory work
–
Remove the seat. ( p. 50)
– Turn the knurled screw on the fuel tap all the way clockwise.
–
Remove the fuel tank. ( p. 45)
–
Check the throttle cable routing. ( p. 59)
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.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
–
Adjust the play in the throttle cable. ( p. 86)
86
F02895-10
400192-11
–
Turn barrel adjuster2so that there is playAin the throttle
cable at the throttle grip.
Guideline
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
–
Tighten nut3.
–
Slide on sleeve1.
Page 89
15.3 Carburettor – idle speed
F03009-10
TUNING THE ENGINE 15
Finishing work
–
Install the fuel tank. ( p. 46)
–
Mount the seat. ( p. 50)
–
Check the play in the throttle cable. ( p. 86)
The idle setting of the carburetor has a big influence on the starting
behavior, stable idle speed, and the response to throttle opening. This
means that an engine with a correctly set idle speed will be easier to
start than one with an incorrectly set idle speed.
Info
The carburetor and its components are subject to increased
wear caused by engine vibration. Wear can result in malfunctioning.
The idle speed is adjusted using the idle speed adjusting screw1.
The idle mixture is adjusted using the idle air adjusting screw2.
15.4 Carburetor – adjusting the idle speed
–
Screw in idle air adjusting screw2all the way and turn it to the
specified basic setting.
Guideline
Idle air adjusting screw
– Run the engine until warm.
Guideline
F03009-10
Warming-up phase ≥ 5 min
– Connect the special tool.
Tachometer (45129075000)
–
Adjust the idle speed using idle speed adjusting screw1.
Guideline
Choke function deactivated – The choke lever is pushed in to the
stop. ( p. 16)
Idle speed 1,400 … 1,500 rpm
–
Turn idle air adjusting screw2slowly in a clockwise direction until
the idle speed begins to fall.
– Note the position and turn the idle air adjusting screw slowly coun-
terclockwise until the idle speed again begins to fall.
Open 3 turns
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.
87
Page 90
15 TUNING THE ENGINE
15.5 Checking the clutch setting
– Adjust to the point between these two positions with the highest
idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a
normal level and repeat the above steps.
If the procedure described here does not lead to satisfactory
results, the cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end without any change of engine speed, mount a smaller idling jet.
After changing the idling jet, start from the beginning with
the adjusting steps.
Following extreme air temperature or altitude changes,
adjust the idle speed again.
–
Connect special tool1.
Tachometer (45129075000)
F03010-10
401521-01
– Let the front wheel of the vehicle make contact with a fixed object.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
– Start the motorcycle.
– Only ride full throttle to the point where the maximum engine speed
is reached.
Guideline
Operation at full throttle ≤ 3 s
– Read the speed.
Slip speed 8,700 … 9,300 rpm
» If the specified value is not reached:
–
Adjust the clutch. ( p. 89)
88
Page 91
15.6 Removing the clutch cover
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Info
Fuel can emerge via the carburetor.
Capture emerging fuel using a suitable container.
– Turn the knurled screw on the fuel tap all the way clockwise.
– Lay the vehicle down on its left side.
–
Remove screws1.
–
Remove clutch cover2with the seal ring.
TUNING THE ENGINE 15
15.7 Adjusting the clutch
F03032-10
F03033-10
F03033-11
Preparatory work
–
Remove the clutch cover. ( p. 89)
Main work
–
Turn clutch basket1until adjusting screws2become accessible.
Condition
If there is no reference point:
–
Turn adjusting screws2counterclockwise to the last
detectable click.
–
Turn adjusting screws2clockwise by 9 clicks to the basic setting.
Guideline
Basic setting of slip speed 8,700 … 9,300 rpm
Info
The springs may not be pretensioned by more than 17
clicks from the stop using the adjusting screws.
Condition
If the slip speed is too low:
89
Page 92
15 TUNING THE ENGINE
–
Turn adjusting screws2clockwise.
Guideline
1 click increases the slip
speed by
Info
The springs may not be pretensioned by more than 17
clicks from the stop using the adjusting screws.
Condition
If the slip speed is too high:
–
Turn adjusting screws2counterclockwise.
Guideline
1 click decreases the slip
speed by
Finishing work
–
Install the clutch cover. ( p. 90)
–
Check the gear oil level. ( p. 91)
–
Check the clutch setting. ( p. 88)
250 … 350 rpm
250 … 350 rpm
15.8 Installing the clutch cover
F03032-11
Main work
–
Position the clutch cover1with the seal ring.
–
Mount and tighten screws2.
Guideline
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
Finishing work
–
Check the gear oil level. ( p. 91)
90
Page 93
16.1 Checking the gear oil level
F03034-10
SERVICE WORK ON THE ENGINE 16
Condition
The engine is cold.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
–
Remove screw1.
– Check the gear oil level.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
–
Add the gear oil. ( p. 92)
–
Mount and tighten screw1.
Guideline
Screw, gear oil level
monitoring
M6 6 Nm (4.4 lbf ft)
16.2 Changing the gear oil
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Drain gear oil with engine at operating temperature.
Preparatory work
– Stand the motorcycle on the plug-in stand on a horizontal surface.
Main work
– Position an appropriate container under the engine.
–
Remove oil drain plug1with the magnet.
– Let the gear oil drain fully.
– Thoroughly clean the oil drain plug with magnet.
– Clean the sealing surface on the engine.
– Mount and tighten the oil drain plug with the magnet and new seal
ring.
F03034-11
Guideline
Oil drain plug with
magnet
M12x1.5 20 Nm (14.8 lbf ft)
91
Page 94
16 SERVICE WORK ON THE ENGINE
401955-11
–
Remove filler plug2with the O-ring, and fill up with gear oil.
Gear oil 0.20 l (0.21 qt.) Gear oil
(ATF Dexron 3)
( p. 109)
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
–
Mount and tighten filler plug2with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
– Start the engine and check for leaks.
Finishing work
–
Check the gear oil level. ( p. 91)
16.3 Adding the gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
–
Remove screw1.
F03034-10
–
Remove filler plug2with the O-ring.
– Add gear oil until it flows out of the hole of the gear oil level plug.
Gear oil (ATF Dexron 3) ( p. 109)
–
Mount and tighten screw1.
Guideline
Screw, gear oil level
monitoring
401955-11
–
Mount and tighten filler plug2with the O-ring.
M6 6 Nm (4.4 lbf ft)
92
Page 95
SERVICE WORK ON THE ENGINE 16
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.
– Start the engine and check for leaks.
93
Page 96
17 CARBURETOR
17.1 Removing the carburetor
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is 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.
F02979-11
F03011-10
Preparatory work
– Turn the knurled screw on the fuel tap all the way clockwise.
Main work
–
Pull off fuel hose1.
Info
Remaining fuel may flow out of the fuel hose.
–
Loosen hose clip2.
–
Loosen hose clip3.
94
Page 97
F03012-10
F03013-10
–
Push back hose clamp4and pull off the vent hose.
– Pull the carburetor out of the intake flange.
– Pull the carburetor forward out of the inlet sleeve.
–
Remove throttle slide cover5.
– Pull the throttle slide out of the carburetor.
– Drain the remaining fuel.
CARBURETOR 17
F03016-11
17.2 Installing the carburetor
F03016-10
– Pull back the spring retainer and throttle slide spring.
–
Detach throttle cable wire6.
– Take off the throttle slide.
Main work
–
Attach throttle cable wire1.
– Position the spring retainer and throttle slide spring.
95
Page 98
17 CARBURETOR
F03015-10
– Position the throttle slide and throttle slide cover.
–
Tighten throttle slide cover2hand-tight.
– Measure the distance between the carburetor housing and the
throttle slide cover.
»
DistanceA: ≤ 3 mm (≤ 0.12 in)
If the specified value is not reached:
– Screw on the throttle slide cover correctly.
F03012-12
F03011-11
– Mount the carburetor.
–
Mount the engine breather hose and position clamp3.
– Mount the inlet sleeve.
–
Position and tighten hose clip4.
Guideline
Hose clip, carburetor - 2.8 Nm (2.07 lbf ft)
–
Position and tighten hose clip5.
Guideline
Hose clip, carburetor - 2.8 Nm (2.07 lbf ft)
–
Mount fuel hose6.
96
F02979-12
Finishing work
–
Check the play in the throttle cable. ( p. 86)
–
Carburetor – adjust the idle speed. ( p. 87)
Page 99
CLEANING, CARE 18
18.1 Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.
Info
Clean the motorcycle regularly to maintain its value and appearance over a long period.
Avoid direct sunshine when cleaning the motorcycle.
401061-01
– Close off exhaust system to keep water from entering.
– Remove loose dirt first with a soft jet of water.
– Spray the heavily soiled parts with a normal commercial motorcycle
cleaner and clean using a brush.
Motorcycle cleaner ( p. 110)
Info
Use warm water containing normal motorcycle cleaner and
a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always
rinse the vehicle with water first.
– After rinsing the motorcycle with a gentle spray of water, allow it to
dry thoroughly.
– Remove the closure of the exhaust system.
– Empty the carburetor float chamber.
Warning
Danger of accidents Moisture and dirt impair the brake
system.
– Explain to your child that he or she must brake carefully
several times to dry out and remove dirt from the brake
linings and the brake discs.
– After cleaning, your child should ride the vehicle a short distance
until the engine warms up and until the brakes system has dried
through careful application of the brakes.
Info
The heat produced causes water at inaccessible locations in
the engine and on the brake system to evaporate.
97
Page 100
18 CLEANING, CARE
– Push back the protection caps on the handlebar controls to allow
water to evaporate.
– After the motorcycle has cooled down, lubricate all moving parts
and pivot points.
–
Clean the chain. ( p. 54)
– Treat bare metal (except for brake discs and the exhaust system)
with a corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 110)
– Treat all plastic parts and powder-coated parts with a mild cleaning
and care product.
Special cleaner for glossy and matte paint finishes, metal and
plastic surfaces ( p. 111)
98
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