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GAS GAS EC 250 2021, Owner'S Manual

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GAS GAS EC 250 2021 Owner'S Manual Download Page 62

12 SERVICE WORK ON THE CHASSIS

60

12.13

Lubricating the steering head bearing

H02387-01

–

Remove the lower triple clamp.

(

p. 55)

–

Install the lower triple clamp.

(

p. 56)

12.14

Removing front fender

Preparatory work

–

Remove the headlight mask with the headlight. (

p. 106)

S04424-10

Main work

–

Remove screws

1

.

S04425-10

–

Remove screws

2

. Take off front fender.

12.15

Installing front fender

S04425-11

Main work

–

Position front fender. Mount and tighten screws

1

.

Guideline

Remaining screws,
chassis

M6

10 Nm (7.4 lbf ft)

Summary of Contents for EC 250 2021

Page 1: ...OWNER S MANUAL 2021 EC 250 EC 300 Art no 3215011en ...

Page 2: ......

Page 3: ...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...

Page 4: ... 6 17 Closing 2 stroke oil tank cap 18 6 18 Cold start button 19 6 19 Idle speed adjusting screw 19 6 20 Shift lever 20 6 21 Foot brake lever 20 6 22 Side stand 20 6 23 Steering lock All EU models 21 6 24 Locking the steering All EU models 21 6 25 Unlocking the steering All EU models 21 7 COMBINATION INSTRUMENT 22 7 1 Combination instrument overview 22 7 2 Activation 22 7 3 Messages on the combina...

Page 5: ... air filter 66 12 23 Installing the air filter 67 12 24 Cleaning the air filter and air filter box 67 12 25 Preparing air filter box cover for securing 68 12 26 Removing the main silencer 68 12 27 Installing the main silencer 69 12 28 Changing the glass fiber yarn filling of the main silencer 69 12 29 Removing the fuel tank 70 12 30 Installing the fuel tank 71 12 31 Checking the chain for dirt 73 ...

Page 6: ... ignition timing map 121 17 8 Checking the basic position of the shift lever 121 17 9 Adjusting the basic position of the shift lever 122 18 SERVICE WORK ON THE ENGINE 123 18 1 Changing the fuel screen 123 18 2 Checking 2 stroke oil level 124 18 3 Priming oil pump 124 18 4 Cleaning the oil screen in the oil tank 126 18 5 Checking the gear oil level 128 18 6 Changing the gear oil 129 18 7 Adding th...

Page 7: ...pecially trained experts using the spe cial tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates the end of an activity including potential reworking 1 2 Formats used The typographical formats used i...

Page 8: ...ety 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 a...

Page 9: ...ger 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 sy...

Page 10: ...of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regula tions of the respective country Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles there are no legal regu lations that pertain to the disposal of an end of life motorcycle Your authorized GASGAS Motorcycles dealer will be glad...

Page 11: ...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 mu...

Page 12: ... brake lever p 14 2 Clutch lever p 14 3 Light switch p 15 All EU models 3 Stop button p 14 All EU models 3 Turn signal switch p 16 All EU models 3 Horn button p 15 All EU models 4 Ignition curve plug in connector p 120 5 Side stand p 20 6 Air filter box cover 7 Shift lever p 20 ...

Page 13: ... OF VEHICLE 4 11 4 2 View of vehicle rear right example S04404 10 1 Fuel tank filler cap 2 Throttle grip p 14 3 Vehicle identification number p 12 4 Foot brake lever p 20 5 Level viewer for brake fluid rear ...

Page 14: ...e of the steering head 5 2 Type label 401946 10 Type label 1is fixed to the front of the steering head 5 3 Key number All EU models H02475 10 The key number 1for the steering lock is stamped onto the key con nector 5 4 Engine number H01047 10 The engine number 1is located on the left side of the engine over the engine sprocket ...

Page 15: ...401947 10 The fork part number 1is stamped on the inside of the axle clamp 5 6 Shock absorber article number 401948 10 Shock absorber article number 1is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 16: ...using the hand brake lever 6 3 Throttle grip S04406 11 Throttle grip 1is fitted on the right side of the handlebar 6 4 Stop button All EU models S04407 10 The stop button 1is 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...

Page 17: ...n The horn button is pressed The horn is operated in this position 6 7 Light switch All EU models S04407 11 Light switch 1is fitted on the left side of the handlebar Possible states Low beam on Light switch is in the central position In this position the low beam and tail light are switched on High beam on Light switch is turned to the left In this position the high beam and the tail light are swi...

Page 18: ...rt Ignition on In this position the ignition circuit is closed and the engine can be started 6 11 Start button S04412 10 Start button 1is fitted on the right side of the handlebar Possible states The start button is in the basic position The start button is pressed In this position the starter motor is actuated 6 12 Overview of indicator lamps All EU models S04409 01 Possible states The high beam ...

Page 19: ... 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 Wa...

Page 20: ...er cap and turn it clockwise until release but ton 1engages Info Route fuel tank breather hose 2without kinks 6 16 Opening 2 stroke oil tank cap S04415 10 Fold loop 1upward Turn the 2 stroke oil tank cap counterclockwise and pull it up 6 17 Closing 2 stroke oil tank cap S04416 10 Put the 2 stroke oil tank cap on and turn it clockwise Fold loop 1down The 2 stroke oil tank cap engages ...

Page 21: ...urther turn returns the cold start button back to the basic position 6 19 Idle speed adjusting screw S03529 11 The idle setting of the throttle valve body substantially influences the vehicle s starting behavior a stable idle speed and the vehicle s response when the throttle is opened An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly T...

Page 22: ... can be seen in the photograph The neutral or idle position is between the first and second gears 6 21 Foot brake lever 401956 10 Foot brake lever 1is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 22 Side stand 401943 10 The side stand 1is located on the left of the vehicle ...

Page 23: ...the vehicle on a firm and level surface 400732 01 Park the vehicle Turn handlebar as far as possible to the right Insert the key for the steering lock into the steering lock turn it to the left press it in and turn it to the right Pull out the key for the steering lock Steering is no longer possible Info Never leave the key for the steering lock in the steering lock 6 25 Unlocking the steering All...

Page 24: ...on the combination instrument 401901 01 Possible states Battery voltage of the combination instrument The bat tery voltage of the combination instrument is too low Change combination instrument battery Service A service is due Contact an authorized GAS GAS Motorcycles workshop 7 4 Setting the combination instrument Condition The motorcycle is stationary 401909 01 Press both buttons for 3 5 seconds...

Page 25: ...e time Press the right button The value increases 401913 01 Wait for 5 seconds The combination instrument changes to the next menu item The symbol flashes Set the service Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left butt...

Page 26: ... the 24h or 12h display of the clock 401912 01 Wait for 5 seconds The combination instrument changes to the next menu item The symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press both buttons for 3 5 seconds The Setup menu is d...

Page 27: ...3 5 seconds DST can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 seconds DST is reset to 0 0 7 9 Speed time and DST2 distance 2 401902 01 Press one of the buttons until DST2 appears on the combination instrument KM H or M H shows the speed shows the time DST2 shows the distance 2 since the last ...

Page 28: ... the combination instrument AVG shows the average speed since the last reset ART shows the operating hours ODO shows the total distance covered Press the left button briefly Next display mode Press the left button for 3 5 seconds The OPEN END WRENCH SYMBOL shows the remaining operating hours until the next service is due Press the right button briefly Next display mode Press the right button for 3...

Page 29: ... speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever if you do not want to brake Warning Danger of ...

Page 30: ...he center of the vehicle and ensure even weight distribution between the front and rear wheels Info Motorcycles react sensitively to any changes of weight distribution The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear...

Page 31: ...ms up 8 4 Preparing the vehicle for difficult riding conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can lead to consid erably more rapid wear of components such as the drive train brake system or suspension components For this reason it may be necessary to inspect or replace parts before the next scheduled service Seal the air filter box ...

Page 32: ...scalding rinse the area affected immediately with lukewarm water Change the radiator cap M01104 01 Mount the air filter dust cover Air filter dust cover 79006920000 Info Observe the GASGAS Technical Accessories fitting instruc tions M01105 01 Mount the air filter sand cover Air filter sand cover 79006922000 Info Observe the GASGAS Technical Accessories fitting instruc tions 600868 01 Clean the cha...

Page 33: ... ature 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 Change the radiator cap M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the GASGAS Technical Accessories fitting instruc tions 6...

Page 34: ...ning 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 temper ature 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...

Page 35: ...or fins carefully Check the coolant level p 112 8 9 Preparing the vehicle for low temperatures or snow M01106 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the GASGAS Technical Accessories fitting instruc tions ...

Page 36: ...e condition p 97 Check tire pressure p 97 Check the spoke tension p 98 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 53 Bleed the fork legs p 52 Check the air filter Check the settings of all controls and ensure that they can be oper ated smoothly Check all screws nuts and hose clamps regularly...

Page 37: ...tand must be folded up and secured with the rubber strap Pull the clutch lever shift into first gear release the clutch lever slowly and at the same time open the throttle carefully 9 4 Shifting riding Warning Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Warning Engine failure The engine wi...

Page 38: ...ely forceful application of the brakes blocks the wheels Adjust application of the brakes to the respective riding situation and riding surface conditions Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency Check the brake system and do not continue riding until the problem is eliminated Your authorized GAS GAS Motorcycles workshop will be glad...

Page 39: ...s idling until the engine stops Park the motorcycle on firm ground 9 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 cover...

Page 40: ...elp 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 Open the fuel tank filler cap p 17 400382 10 Fill the fuel tank with fuel up to level A Guideline Level A 35 mm 1 38 in Total fuel tank capac ity approx 8 5 l 2 25 US gal Super unleaded ROZ 95 p 150 Info Do not refuel using pre mixed fuel C...

Page 41: ...e 2 stroke oil tank up to the lower edge Aof the filler neck Guideline Only use 2 stroke oil which is appropriate for separate lubrication 2 stroke oil tank con tent approx 0 6 l 0 6 qt Engine oil 2 stroke p 149 Close 2 stroke oil tank cap p 18 ...

Page 42: ...gs of the rear brake p 90 Check the brake discs p 82 Check the brake lines for damage and leakage Check the rear brake fluid level p 88 Check the free travel of the foot brake lever p 87 Check the frame p 78 Check the link fork p 78 Checking the fork bearing for play Checking the shock absorber heim joint for play Check the shock absorber linkage Check the tire condition p 97 Check tire pressure p...

Page 43: ...operating safety and take a test ride Read out the fault memory after the test ride using the GASGAS Motorcycles diagnostics tool Make a service entry in GASGAS Motorcycles Dealer net One time interval Periodic interval 10 3 Recommended work Every 40 operating hours when used for motorsports Every 10 operating hours when used for motorsports every 48 months every 12 months Every 80 operating hours...

Page 44: ...g hours After 10 operating hours Perform minor engine service Check the exhaust control for functioning and smooth operation Check the clutch Perform major engine service including removing and installing the engine Change the connecting rod conrod bearing and crank pin Clean the hose connections of the pressure sensor Check the transmission and shift mechanism Change all engine bearings One time ...

Page 45: ...ided 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 w...

Page 46: ...e 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 S04419 10 Using an open end wrench turn adjust...

Page 47: ...erclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counterclock wise to reduce damping when the shock absorber rebounds 11 6 Measuring the dimension of the rear wheel unloaded Preparatory work Raise the motorcycle with a lift stand p 52 402415 10...

Page 48: ... preload of the shock absorber p 47 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension Aof rear wheel unloaded p 45 With another person holding the motorcycle the rider wearing full protective clothing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person again measures the...

Page 49: ...After removing the shock absorber clean it thoroughly 402405 10 Main work Loosen screw 1 Turn adjusting ring 2until the spring is no longer under tension Hook wrench 90129051000 Info If the spring cannot be fully released the spring must be removed to accurately measure the spring length Measure the total spring length while the spring is not under ten sion Tension the spring by turning adjusting ...

Page 50: ...ork Install the shock absorber p 63 Remove the motorcycle from the lift stand p 52 Check the static sag of the shock absorber p 46 Check the riding sag of the shock absorber p 46 Adjust the rebound damping of the shock absorber p 45 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determined for the fork 401000 01 As with the shock absorber smaller d...

Page 51: ...t 12 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping during compression 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior S04313 11 Turn red adjuster 1clockwise as far as it will go Info Adjuster 1is located at the upper end of the right fork leg The rebound damping is located in right f...

Page 52: ...oses 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 M00993 11 Remove screws 1 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 screws 2 Take off th...

Page 53: ...TUNING THE CHASSIS 11 51 Position the handlebar clamps Mount screws 1and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the gap widths are even ...

Page 54: ...ge The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with the rubber strap 12 3 Bleeding the fork legs Preparatory ...

Page 55: ...rning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when neces sary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 152 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork pro...

Page 56: ...leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Raise the motorcycle with a lift stand p 52 Remove the front wheel p 93 Remove the headlight mask with the headlight p 106 S04422 10 Main work Remove screws 1and take off the clamp Remove the cable tie Remove screws 2and take off the brake caliper Hang the brake calipe...

Page 57: ... M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S04422 11 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable ties Position the brake line the wiring harness and the clamp Mount and tighten screws 5 Finishing work Install the front wheel p 94 Install the headli...

Page 58: ...nk the cables and lines E00922 10 Remove O ring 4 Remove protective ring 5 Take off the lower triple clamp with the steering stem Remove the upper steering head bearing 12 10 Installing the lower triple clamp V00359 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 151 Insert the lower triple clamp with the steering stem Mount upper steering he...

Page 59: ... the fork legs Bleeder screws 6are positioned toward the front Info The rebound damping is located in right fork leg REB red adjuster The compression damping is located in left fork leg COMP white adjuster Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp S03525 11 Tighten screws 7 Gu...

Page 60: ...Mount the handlebar cushion Install front fender p 60 Install the front wheel p 94 Install the headlight mask with the headlight p 106 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check steering head bearing play p 58 Remove the motorcycle from the lift stand p 52 Check the headlight setting p 108 12 11 Checking steering head bea...

Page 61: ...y over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play p 59 Check the steering head bearing and change if necessary Finishing work Remove the motorcycle from the lift stand p 52 12 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 52 S04450 10 Main wor...

Page 62: ...le clamp p 56 12 14 Removing front fender Preparatory work Remove the headlight mask with the headlight p 106 S04424 10 Main work Remove screws 1 S04425 10 Remove screws 2 Take off front fender 12 15 Installing front fender S04425 11 Main work Position front fender Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 63: ...k the headlight setting p 108 12 16 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 52 S04430 10 Main work Remove the cable tie Remove screws 1and the frame protector S04427 10 Remove screw 2 Remove fitting 3 Info Raise the link fork slightly to be able to remove the screws more easily S04428 10 Press angle lever 4toward the rear Press linkage lever 5downward ...

Page 64: ...inder from the push rod H03696 10 Remove the connecting link of the chain Info Cover the components to protect them against damage Take off the chain S04431 10 Remove nut 8and pull out the swingarm pivot Push the link fork back and secure it against falling over S04432 10 Hold the shock absorber and remove screw 9 Remove the shock absorber carefully at the bottom ...

Page 65: ...ntion to flat area A Mount and tighten nut 2 Guideline Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft F02306 10 Mount the chain Connect the chain with the connecting link Guideline The closed side of the chain joint lock must face in the direction of travel S04426 11 All EU models Join plug in connector 3of the brake light switch S04435 10 Position the foot brake cylinder Push rod 4engages in the foot ...

Page 66: ...bsorber M10 60 Nm 44 3 lbf ft Loctite 2701 Info Raise the link fork slightly to be able to mount the screw more easily S04430 11 Position the frame protector Mount and tighten screws 8with the washers Guideline Screw frame protector M5 3 Nm 2 2 lbf ft Mount the new cable ties Finishing work Remove the motorcycle from the lift stand p 52 12 18 Removing the seat S04437 10 Remove screw 1on the left s...

Page 67: ...rd Make sure the seat is locked in correctly S04437 10 Mount and tighten screw 1on the left side Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 20 Removing the air filter box cover Preparatory work Remove the seat p 64 S04438 10 Condition The air filter box cover is secured Remove screw 1 S04438 11 Pull off the air filter box cover in area Alaterally and take it off at the front ...

Page 68: ...filtered 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 P...

Page 69: ...e seat p 65 12 24 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 64 Rem...

Page 70: ...at p 64 Remove the air filter box cover p 65 S04440 10 Main work Drill a hole at marking A Guideline Diameter 6 mm 0 24 in Finishing work Install the air filter box cover p 66 Mount the seat p 65 12 26 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 S04441 ...

Page 71: ...er time the fibers of the glass fiber yarn filling escape and the damper burns out Not only is the noise level higher but the performance characteristics change Preparatory work Remove main silencer p 68 V01636 10 Main work Remove screws 1 Pull out inner tube 2with O ring 3 Pull glass fiber yarn filling 4from the inner tube Clean the parts that need to be reinstalled and check for damage Mount new...

Page 72: ...r 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 64 S04445 10 Main work ...

Page 73: ... 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...

Page 74: ...Mount and tighten screws 2with the collar bushings Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S04451 10 Remove the wash cap set Clean the quick release coupling thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Spray silicone spray onto a lint free cleaning cloth and lightly lubri cate the O r...

Page 75: ... discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle wit...

Page 76: ... it must be possible to pull up the chain at least to the point where it makes contact with chain guard B Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet the specification Adjust the chain tension p 74 Finishing work Remove the motorcycle from the lift stand p 52 12 34 Adjusting ...

Page 77: ... 1 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 4can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 52 12 35 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle w...

Page 78: ...n 272 mm 10 71 in If distance Bis greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets E00886 10 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...

Page 79: ...n screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide E00333 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screw...

Page 80: ...nk fork Guideline Repairs on the link fork are not permitted 12 38 Checking the throttle cable routing Preparatory work Remove the seat p 64 Remove the fuel tank p 70 S04453 01 Main work Check the throttle cable routing Both throttle cables must be routed side by side on the back of the handlebars above the fuel tank bracket on the right of the frame to the throttle valve body Both throttle cables...

Page 81: ... the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 41 Checking correcting the fluid level of the h...

Page 82: ...cations Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 149 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 12 42 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clo...

Page 83: ...opriate hydraulic fluid Syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 149 On the clutch slave cylinder remove bleeder protection cap release the bleeder screw 5and mount bleeding syringe 4 S04456 10 Now press the fluid into the system until it emerges from the hole 6of the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Remove the...

Page 84: ... hand brake lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not ma...

Page 85: ...orkshop 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 S03517 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal position Check the brake fluid level in level...

Page 86: ...cycles 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...

Page 87: ...op 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 ...

Page 88: ...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 S04459 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal po...

Page 89: ...clean up any brake fluid that has overflowed or spilled 13 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect sprin...

Page 90: ...s limited Turn push rod 3accordingly until you have free travel A If nec essary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 5and tighten nut 4 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod 3and tighten nut 2 Guideline Remaining nuts chas sis M6 10 Nm 7 4 lbf ft Attach spring 1 13 10 Checking the ...

Page 91: ...itable 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 flui...

Page 92: ...ange the rear brake linings p 90 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 90 13 13 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized GASGAS Motorcy cles workshop will be glad to he...

Page 93: ...nly 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 b...

Page 94: ... and mount the cotter pins Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point S04468 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 149 Mount screw cap 1with membrane 2and O ring Info Use water to immediately clean up any brake fluid that has overflowed or spilled ...

Page 95: ...ck the brake pistons S04474 10 Loosen screw 1by several rotations Loosen screws 2 Press on screw 1to push the wheel spindle out of the axle clamp Remove screw 1 S04475 01 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of th...

Page 96: ...s Clean and grease the wheel spindle Long life grease p 151 Jack up the front wheel into the fork position it and insert the wheel spindle The brake linings are correctly positioned S04474 11 Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove th...

Page 97: ... sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the rear wheel and remove the wheel spindle Take the rear wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed H03002 10 Remove space...

Page 98: ...rectly positioned S04478 10 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3are fitted correctly on adjusting screws 5 Check the chain tension p 74 Tighten nut 4 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Cha...

Page 99: ...e minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT num ber The first two digits indicate the week of manufacture and the last two digits the year of manufacture GASGAS Motorcycles recommends that the tires be changed after five years at the latest regardless...

Page 100: ...nd in particular on a new vehicle Your authorized GASGAS Motorcycles work shop will be glad to help 400694 01 Strike each spoke briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indication of differ ent spoke tensions You should hear a ...

Page 101: ...12 V batteries contain harmful substances Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V batteries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when charging 12 V batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already below the minimum vo...

Page 102: ...ttery compartment to the front Lift out the 12 V battery 15 2 Installing the 12 V battery S04483 10 Main work Insert the 12 V battery into the battery compartment with the ter minals facing forward and secure with holding bracket 1 12 V battery HJTZ5S FP C p 145 Mount and tighten screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 103: ...tive cable 7to the 12 V battery Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Info Contact disk Amust be mounted under screw 8and cable lug 9with the claws toward the battery terminal Slide positive terminal cover bkover the positive terminal Connect negative cable blto the 12 V battery Guideline Screw battery terminal M5 2 5 Nm 1 84 lbf ft Finishing work Mount the seat p 65 ...

Page 104: ... oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Even when there is no load on the 12 V battery it discharges steadily each day The charging level and the method of charging are very important for the service life of the 12 V battery Rapid recharging with a high charging current shortens the service life of the battery If t...

Page 105: ...low temperatures This battery charger is only suitable for lithium iron phos phate batteries Read the accompanying GASGAS Techni cal Accessories instructions Info Never remove cover 1 Switch off the battery charger after charging and disconnect from the 12 V battery Finishing work Install the 12 V battery p 100 Mount the seat p 65 15 4 Changing main fuse Warning Fire hazard Incorrect fuses overloa...

Page 106: ... spare fuse 6is located in the starter relay Insert a new main fuse Fuse 58011109120 p 145 Check that the electrical system is functioning properly Tip Insert a spare fuse so that it is available if needed Attach the protection caps 4 Mount starter relay 3onto the holder and route the cable S04485 10 Mount the EFI control unit 1on the rubber lugs 2 Finishing work Mount the seat p 65 ...

Page 107: ... tail light license plate lamp Fuse 4 5 A fuel pump EC 300 US Fuse 1 10 A EFI control unit oil pump combination instru ment electronic fuel injection diagnostics connector Fuse 2 10 A radiator fan optional Fuse 3 10 A low beam position light tail light Fuse 4 5 A fuel pump Fuses res 10 A spare fuse Info A faulty fuse has a burned out fuse wire A Warning Fire hazard Incorrect fuses overload the ele...

Page 108: ...sk up and swing it forward S04490 10 All EU models Detach plug in connectors 2and take off the headlight mask with the headlight S04491 10 EC 300 US Disconnect plug in connector 2and take off the headlight mask together with the headlight 15 7 Installing the headlight mask with the headlight S04490 11 Main work All EU models Join plug in connectors 1 S04491 11 EC 300 US Join plug in connector 1 ...

Page 109: ...lbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 106 S04492 10 Main work Turn protection cap 1together with the underlying bulb socket counterclockwise all the way and remove it Pull bulb socket 2of the position light out of the reflector F03250 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight S2 socket BA20d p 145 Insert the protection c...

Page 110: ...ocket and turn it clockwise until it stops Turn signal R10W socket BA15s p 145 Mount the orange cap Position the turn signal glass Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk Tighten the screw lightly Finishing work Check that the turn signal system is functioning properly 15 10 Checking the headlight setting 400726 10 Park the vehicle on a hor...

Page 111: ...the mark Checking the headlight setting Info If you have a payload you may have to correct the headlight range Install the headlight mask with the headlight p 106 Check the headlight setting p 108 15 12 Changing the combination instrument battery Preparatory work Remove the headlight mask with the headlight p 106 S04494 10 Main work Remove screws 1 Pull the combination instrument upward out of the...

Page 112: ...ed Position the combination instrument in the holder Mount and tighten the screws with washers Finishing work Install the headlight mask with the headlight p 106 Check the headlight setting p 108 Set the kilometers or miles Adjust combination instrument function Set the clock 15 13 Diagnostics connector H00933 12 Diagnostics connector 1is located under the seat below the EFI control unit ...

Page 113: ...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 immediate...

Page 114: ...ater in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level Aabove the radiator fins 10 mm 0 39 in...

Page 115: ...nder the water pump cover S04497 10 Remove screw 1 Take off radiator cap 2 Completely drain the coolant Mount and tighten screw 1with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 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 ey...

Page 116: ...ine Screw cylinder head temperature sensor M10x1 25 12 Nm 8 9 lbf ft Plug in connector 3 Position protection cap 2 400243 10 Pour coolant in up to measurement Aabove the radiator fins Guideline 10 mm 0 39 in Coolant p 149 S04498 10 Mount radiator cap 5 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient v...

Page 117: ...d 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 ...

Page 118: ...ug in connector 4 Mount protection cap 3 S04498 11 Mount radiator cap 2 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or run ning the engine in an enclosed space Allow the engine to warm up and cool down again Check t...

Page 119: ... the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 117 17 2 Adjusting the play in the throttle cable Info If the correct routing of the throttle cables has already been secured the fuel tank does not need to be removed Preparatory work Remove the seat p 64 Remove the fuel tank p 70 Check the thro...

Page 120: ...ap is supplied S04500 10 Main work Push back sleeve 1 Remove screws 2and half shells 3 Detach the throttle cables and take off the grip tube 102246 10 Remove guide plate 4from handle tube 5 Position the required guide plate on the grip tube Guideline The label OUTSIDE must be visible Marking Amust be posi tioned at marking B Grey guide plate 79002014000 Alternative 1 Black guide plate 79002014100 ...

Page 121: ...o out spontaneously if the idle speed is set too low Set the idle speed to the specified value Your authorized GASGAS Motorcycles workshop will be glad to help S03529 11 Run the engine until warm The cold start button is deactivated A further turn returns the cold start button back to the basic position p 19 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsc...

Page 122: ... on an ongoing basis If the vehicle is transported over great differences in height the ambient pressure must be reprogrammed H02349 01 Start the vehicle at the new height above sea level and switch off the engine again Wait for at least five seconds Start the vehicle again and check the response of the vehicle If the response has not improved Repeat the procedure 17 6 Ignition curve plug in conne...

Page 123: ...or 1of the ignition timing map adjust ment Performance better performance Finishing work Install the fuel tank p 71 Mount the seat p 65 17 8 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to an excessive load 400692 10 Sit on the...

Page 124: ...eth Aof the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten screw 1with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 125: ... 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 E00911 10 Clean quick release coupling 1thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the quick release coupling I...

Page 126: ...nk Info For a full tank of fuel the 2 stroke oil tank must be filled up to at least the upper abutting edge A The 2 stroke oil tank must be completely filled if possible If the 2 stroke oil level is too low Add 2 stroke oil p 38 18 3 Priming oil pump Warning Engine failure The engine will not be lubricated unless there is 2 stroke oil in the oil tank If the oil level warning light lights up the 2 ...

Page 127: ...re S04504 10 Plug in wake up connector 4for priming the oil pump to the diag nostics connector 5 The combination instrument lighting is activated Wait for at least five seconds Release the fixing means from the throttle grip The oil pump is timed Info The oil pump is actuated at various speeds The procedure is clearly audible Wait until you can no longer hear the oil pump operating Disconnect the ...

Page 128: ...g work Mount the seat p 65 18 4 Cleaning the oil screen in the oil tank Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Preparatory work Raise the motorcycle with a lift stand p 52 Remove main silencer p 68 Remove the seat p 64 Remove the fuel t...

Page 129: ...e valve body 6towards the rear out of the intake flange and hang it to the side S04508 10 Open hose clamp 7using a screwdriver Pull off the angle piece and collect the 2 stroke oil in a suitable con tainer S04509 10 Remove oil screen 8and clean it Check the oil screen for damage If the oil screen is damaged Change the oil screen S03506 10 Insert the oil screen and mount the angle piece with a new ...

Page 130: ...crews 1 Guideline Screw subframe bottom M8 30 Nm 22 1 lbf ft Loctite 2701 Remove screws 2 Mount and tighten screws 2 Guideline Screw subframe top M8 35 Nm 25 8 lbf ft Loctite 2701 Finishing work Install the air filter box cover p 66 Install the fuel tank p 71 Add 2 stroke oil p 38 Prime the oil pump p 124 Mount the seat p 65 Install the main silencer p 69 Remove the motorcycle from the lift stand ...

Page 131: ...In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Drain the gear oil while the engine is at operating temperature Preparatory work Park the motorcycle on a level...

Page 132: ...ishing work Check the gear oil level p 128 18 7 Adding the gear oil Info Too little gear oil or poor quality gear oil results in premature wear to the transmission Gear oil must only be topped up when the engine is cold Preparatory work Park the motorcycle on a level surface S04511 10 Main work Detach the foot brake lever spring Remove gear oil level monitoring screw 1 401955 11 Remove filler plug...

Page 133: ...ing 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 128 ...

Page 134: ...larly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove the coarse dirt particles with a gentle water jet Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Motorcycle cleaner p 151 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle c...

Page 135: ...tions against aggressive road salt If the vehicle has been used on salted roads use cold water for cleaning after riding Warm water enhances the cor rosive effects of salt 401060 01 Clean the motorcycle p 132 Clean the brakes Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down and without removing them with cold water and dry them...

Page 136: ... repairs or replacements are neces sary you should do this during the storage period less workshop overload In this way you can avoid long work shop waiting times at the start of the new season 401058 01 Clean the motorcycle p 132 Change the gear oil p 129 Check the antifreeze and coolant level p 111 When refueling for the last time before taking the motorcycle out of service add fuel additive Fue...

Page 137: ...ecause the engine will not warm up sufficiently the water vapor pro duced during combustion will condense causing engine parts and the exhaust system to rust 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 52 Install the 12 V battery p 100 Perform checks and maintenance measures when preparing for use p 34 Make a test ride ...

Page 138: ... Faulty ignition Ignition coil check the primary wind ing Check the spark plug connector Check the stator winding of the alterna tor Short circuit cable in wiring har ness frayed stop button or emer gency OFF switch faulty Check wiring harness visual check Check the electrical system The connector or ignition coil is loose or oxidized Clean the connector and treat it with con tact spray Error in t...

Page 139: ...ition Ignition coil check the primary wind ing Check the spark plug connector Check the stator winding of the alterna tor Diaphragm or reed valve housing damaged Check the diaphragm and reed valve hous ing Ambient pressure is incorrectly stored Program ambient air pressure p 120 The engine dies during the trip Lack of fuel Refuel p 37 The engine takes in false air Check that the intake flange is f...

Page 140: ...n indicator lamp lights up or flashes Error in the electronic fuel injec tion Check wiring for damage and electrical plug in connectors for corrosion and dam age Read out the fault memory using the GAS GAS Motorcycles diagnostics tool 12 V battery discharged The 12 V battery is not being charged by the alternator Check the charging voltage Check the stator winding of the alterna tor Unwanted elect...

Page 141: ... too low Intake air temperature sensor input signal too high Blink code for malfunction indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor input signal too low Coolant temperature sensor input signal too high Blink code for malfunction indicator lamp 06 Malfunction indicator lamp flashes 6x short Error level condition Throttle val...

Page 142: ...shaft speed sensor synchronization faulty Crankshaft speed sensor signal implausible Crankshaft speed sensor signal irregular Crankshaft speed sensor no signal Blink code for malfunction indicator lamp 42 Malfunction indicator lamp flashes 4x long 2x short Error level condition Oil pump input signal too low Oil pump input signal too high Blink code for malfunction indicator lamp 21 Malfunction ind...

Page 143: ...lutch Multidisc clutch in oil bath hydraulically activated Transmission 6 gear transmission claw shifted Transmission ratio first gear 14 32 second gear 16 26 third gear 20 25 fourth gear 22 23 fifth gear 25 22 sixth gear 26 20 Alternator 12 V 196 W Ignition system Contactless controlled fully electronic ignition with digital ignition adjustment Spark plug NGK BR 7 ES Spark plug electrode gap 0 6 ...

Page 144: ...er cooling permanent circulation of coolant by water pump Starting aid Electric starter system 23 2 Motor tightening torques Screw inner membrane sheets EJOTDELTA PT 35x25 1 Nm 0 7 lbf ft Screw membrane support plate EJOTDELTA PT 30x12 1 Nm 0 7 lbf ft Screw outer membrane sheets EJOTDELTA PT 30x6 1 Nm 0 7 lbf ft Screw angle lever exhaust control M5 6 Nm 4 4 lbf ft Loctite 243 Screw bearing retaine...

Page 145: ...t drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 lbf ft Screw starter motor bearing bush M6 10 Nm 7 4 lbf ft Loctite 243 Screw starter motor protection cap M6 8 Nm 5 9 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Vacuum connection cylinder M6 4 Nm 3 lbf ft Loctite 2701 Screw balancer shaft M8 30 Nm 22 1 lbf ft ...

Page 146: ... mm 0 87 in Brake system Disc brakes floating brake calipers Brake discs diameter front 260 mm 10 24 in rear 220 mm 8 66 in Brake discs wear limit front 2 5 mm 0 098 in rear 3 5 mm 0 138 in Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi Secondary ratio EC 250 EU 14 52 13 52 Secondary ratio All 300 models 14 50 13 50 Chain 5 8 x 1 4 Rear sprockets available 45 48 49 50 51 52 Steerin...

Page 147: ... Maxx EnduPro 140 80 18 M C 70R M S TT MAXXIS Maxx EnduPro EC 300 US 80 100 21 M C 51M TT Dunlop GEOMAX AT81F 110 100 18 M C 64M TT Dunlop GEOMAX AT81 The tires specified represent one of the possible series production tires Additional information is available in the Service section under http www gasgas com 23 7 Fork Fork article number A540C163U401000 Fork WP XPLOR Compression damping Comfort 18...

Page 148: ...bar 145 psi Static sag 37 mm 1 46 in Riding sag 110 mm 4 33 in Fitted length 477 mm 18 78 in Shock absorber fluid p 150 SAE 2 5 23 9 Chassis tightening torques Remaining screws chassis EJOT PT K60x25 Z 2 Nm 1 5 lbf ft Screw intake air temperature sensor EJOTDELTA PT 45x12 Z 0 7 Nm 0 52 lbf ft Screw oil fill level sensor G 3 4 7 Nm 5 2 lbf ft Screw oil pump holder on oil tank EJOTDELTA PT 45x12 Z 0...

Page 149: ... Screw oil pump M6 7 Nm 5 2 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw seat fixing M6 10 Nm 7 4 lbf ft Screw silent block on frame M6 6 Nm 4 4 lbf ft Screw throttle grip M6 5 Nm 3 7 lbf ft Fuel connection on fuel pump M8 15 Nm 11 1 lbf ft Nut foot brake lever M8 20 Nm 14 8 lbf ft Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Nut fuel pump M8 15 Nm 11 1 lbf ft Nut rear spr...

Page 150: ...bf ft Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Screw front wheel spindle M20x1 ...

Page 151: ...ns on the container and that has the rele vant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other co...

Page 152: ...on SAE p 153 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corre sponding properties Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do...

Page 153: ...mended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Silicone spray ...

Page 154: ...IARY SUBSTANCES 152 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 155: ...t motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classificati...

Page 156: ... transfer ducts Trans fer Port Injection Electronic fuel injection in which two injection valves in the transfer ducts of the cylinders are used OBD On board diagnosis Vehicle system which monitors the specified parameters of the vehicle electronics ...

Page 157: ...LIST OF ABBREVIATIONS 28 155 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 158: ...ition that requires prompt intervention Active driving aids are also repre sented by yellow or orange symbols Malfunction indicator lamp lights up flashes yellow The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized GASGAS Motorcycles workshop The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 29 3 Green and b...

Page 159: ...ecking 90 C Capacity coolant 114 144 fuel 38 144 Gear oil 130 144 Chain checking 75 cleaning 73 Chain guide checking 75 Chain tension adjusting 74 checking 74 Characteristic map of the throttle response adjusting 118 Cleaning care 132 133 Clutch fluid level checking correcting 79 fluid changing 80 Clutch lever 14 basic position adjusting 79 Cold start button 19 Combination instrument adjusting 22 ...

Page 160: ...r oil level checking 128 H Hand brake lever 14 basic position adjusting 82 free travel checking 82 Handlebar position 50 adjusting 50 Headlight range adjusting 109 Headlight bulb changing 107 Headlight mask with headlight installing 106 removing 106 Headlight setting checking 108 High speed compression damping shock absorber adjusting 44 Horn button 15 I Idle speed adjusting 119 Idle speed adjusti...

Page 161: ...lling 63 removing 61 riding sag checking 46 spring preload adjusting 47 static sag checking 46 Side stand 20 Spare parts 9 Spoke tension checking 98 Start button 16 Starting 34 Starting power of lithium ion batteries at low temperatures 29 Steering locking 21 unlocking 21 Steering head bearing lubricating 60 Steering head bearing play adjusting 59 checking 58 Stop button 14 15 Storage 134 T Techni...

Page 162: ... 3215011en 3215011en 10 2020 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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