GAS GAS EX 250 2023 Owner'S Manual Download

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21 BLINK CODE

122

Blink code for malfunction

indicator lamp

14 Malfunction indicator lamp flashes 1x long, 4x short

Error level condition

Crankcase pressure sensor

–

difference too high between sensor and engine control unit

Blink code for malfunction

indicator lamp

09 Malfunction indicator lamp flashes 9x short

Error level condition

Crankcase pressure sensor - short circuit to ground
Crankcase pressure sensor - open/short circuit to plus
Ambient air pressure sensor

–

short circuit to ground

Ambient air pressure sensor

–

open/short circuit to plus

Blink code for malfunction

indicator lamp

13 Malfunction indicator lamp flashes 1x long, 3x short

Error level condition

Intake air temperature sensor

–

input signal too low

Intake air temperature sensor

–

input signal too high

Blink code for malfunction

indicator lamp

12 Malfunction indicator lamp flashes 1x long, 2x short

Error level condition

Coolant temperature sensor

–

input signal too low

Coolant temperature sensor

–

input signal too high

Blink code for malfunction

indicator lamp

06 Malfunction indicator lamp flashes 6x short

Error level condition

Throttle valve position sensor circuit A - adaption failed
Throttle valve position sensor circuit A

–

input signal too low

Throttle valve position sensor circuit A

–

input signal too high

Blink code for malfunction

indicator lamp

41 Malfunction indicator lamp flashes 4x long, 1x short

Error level condition

Fuel pump - short circuit to ground/open circuit
Fuel pump

–

open circuit/short circuit to plus

Blink code for malfunction

indicator lamp

33 Malfunction indicator lamp flashes 3x long, 3x short

Error level condition

Injection valve 0, cylinder 1

–

input signal too low

Injection valve 0, cylinder 1 - input signal too high

Blink code for malfunction

indicator lamp

34 Malfunction indicator lamp flashes 3x long, 4x short

Error level condition

Injection valve 1, cylinder 1

–

input signal too low

Injection valve 1, cylinder 1 - input signal too high

Summary of Contents for EX 250 2023

Page 1: ...OWNER S MANUAL 2023 EX 250 EX 300 Art no 3215096en...

Page 2: ......

Page 3: ...igns 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 ac...

Page 4: ...at low temperatures 20 7 4 Preparing the vehicle for difficult operating conditions 21 7 5 Preparing the vehicle for rides on dry sand 21 7 6 Preparing the vehicle for rides on wet sand 22 7 7 Prepari...

Page 5: ...hrottle cable routing 68 11 41 Checking the rubber grip 69 11 42 Adjusting the basic position of the clutch lever 70 11 43 Checking correcting the fluid level of hydraulic clutch 70 11 44 Changing the...

Page 6: ...LEANING CARE 116 18 1 Cleaning the motorcycle 116 19 STORAGE 118 19 1 Storage 118 19 2 Preparing for use after storage 119 20 TROUBLESHOOTING 120 21 BLINK CODE 122 22 TECHNICAL DATA 124 22 1 Engine 12...

Page 7: ...trained experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a...

Page 8: ...ate 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...

Page 9: ...sically 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...

Page 10: ...environmentally aware and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regula tions of the respective count...

Page 11: ...ttp 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 descr...

Page 12: ...VEHICLE 10 4 1 View of vehicle front left example E01984 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Fuel tank filler cap 4 Air filter box cover 5 Side stand p 18 6 Shift lever p 17 7 Engine num...

Page 13: ...VEHICLE 4 11 4 2 View of vehicle rear right example E01985 10 1 2 stroke oil tank cap 2 Stop button p 14 3 Start button p 15 4 Throttle grip p 14 5 Foot brake lever p 18 6 Level viewer for brake flui...

Page 14: ...side of the steering head 5 2 Type label 401946 10 The type label 1is fixed to the front of the steering head 5 3 Engine number H01047 10 The engine number 1is embossed on the left side of the engine...

Page 15: ...SERIAL NUMBERS 5 13 5 5 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: ...aged using the hand brake lever 6 3 Throttle grip J00076 10 The throttle grip 1is fitted on the right side of the handlebar 6 4 Stop button E01997 10 The stop button 1is fitted on the left side of the...

Page 17: ...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...

Page 18: ...d turn it clockwise until the release button engages Info Route fuel tank breather hose 2without kinks 6 9 Opening 2 stroke oil tank cap V01647 10 Fold loop 1upward Turn the 2 stroke oil tank cap coun...

Page 19: ...1992 10 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...

Page 20: ...ht footrest The foot brake lever is used to activate the rear brake 6 15 Side stand 401943 10 The side stand 1is located on the left of the vehicle 401944 10 The side stand is used for parking the mot...

Page 21: ...bility 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 fo...

Page 22: ...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 us...

Page 23: ...it if necessary Difficult operating conditions are Rides on dry sand p 21 Rides on wet sand p 22 Rides on wet and muddy circuits p 23 Riding at high temperatures or slow riding p 24 Riding at low tem...

Page 24: ...nd Change the piston every 10 operating hours 7 6 Preparing the vehicle for rides on wet sand M01129 01 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the indicated value does not...

Page 25: ...l spray p 134 Clean the radiator fins Straighten the bent radiator fins carefully Condition Regular use in sand Change the piston every 10 operating hours 7 7 Preparing the vehicle for rides on wet an...

Page 26: ...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...

Page 27: ...he tire condition p 88 Check tire pressure p 88 Check the spoke tension p 89 Info The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety Clean the du...

Page 28: ...engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Info If you hear unusual noises while riding stop immediately switch off the engine and conta...

Page 29: ...or two gears but do not overrev the engine when doing so This means that significantly less braking is required and the brake system does not overheat 8 6 Stopping parking Warning Risk of injury Peopl...

Page 30: ...le 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...

Page 31: ...ng light lights up the 2 stroke oil is sufficient for the remaining tank of fuel As soon as the oil level warning light lights up ride for no longer than until the remaining fuel in the tank is deplet...

Page 32: ...arge the 12 V battery Change the gear oil p 113 Check the front brake linings p 76 Check the brake linings of the rear brake p 81 Check the brake discs p 73 Check the brake lines for damage and leakag...

Page 33: ...test ride using the GASGAS Motorcycles diagnostics tool Make a service entry in GASGAS Motorcycles Dealer net One time interval Periodic interval 9 3 Recommended work every 48 months every 12 months E...

Page 34: ...ating hours Every 10 operating hours Perform major engine service including removing and installing the engine Change the piston and check the cylinder Change the connecting rod conrod bearing and cra...

Page 35: ...ht 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...

Page 36: ...etached 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...

Page 37: ...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 worksho...

Page 38: ...the shock absorber 402416 10 Measure dimension Aof rear wheel unloaded p 35 Hold the motorcycle upright with aid of an assistant Measure the distance again between the rear axle and marking SAG on th...

Page 39: ...measurements A and C Check riding sag Guideline Riding sag 105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag p 38 10 10 Adjusting the spring preload of the...

Page 40: ...Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 53 Remove the motorcycle from the lift stand p 43 10 11 Adjusting the riding sag Preparator...

Page 41: ...haracteristic Modifications which are not coordinated with others to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustmen...

Page 42: ...rom 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 Finish...

Page 43: ...ping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counterclock wise to reduce damping when the shock absorber rebounds 10 16 Handlebar position...

Page 44: ...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 handlebar supports Place handlebar supports in required position Moun...

Page 45: ...orcycle against falling over 11 2 Removing the motorcycle from the lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if th...

Page 46: ...oots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Dan...

Page 47: ...s 4 Remove the right fork leg 11 6 Installing the fork legs H01182 10 Main work Position the fork legs Air bleeder screw 1of the right fork leg is positioned to the front Valve Aof the left fork leg f...

Page 48: ...ight fork protector 11 8 Installing the fork protector E01988 11 Position the fork protection on the left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Pos...

Page 49: ...e ring 5 Remove the lower triple clamp with the steering stem Remove the upper steering head bearing 11 10 Installing the lower triple clamp V00359 10 Main work Clean the bearing and sealing elements...

Page 50: ...second milled groove from the top must be flush with the upper edge of the upper triple clamp E02043 10 Tighten screws 6 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft Secure the wiring harn...

Page 51: ...ately 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...

Page 52: ...clamp M8 20 Nm 14 8 lbf ft Mount and tighten screw 2 Guideline Screw top steer ing stem M8 20 Nm 14 8 lbf ft Loctite 243 Finishing work Check the steering head bearing for play p 49 Remove the motorc...

Page 53: ...moving front fender Preparatory work Remove the start number plate p 50 E02012 10 Main work Remove screws 1and 2 Remove front fender 11 17 Installing front fender E02012 10 Main work Position front fe...

Page 54: ...92 12 Remove screw 2 Remove fitting 3 Info Raise the swingarm slightly to be able to remove the screws more easily V01704 11 Press angle lever 4toward the rear Press linkage lever 5downward I01022 10...

Page 55: ...work Carefully position the shock absorber into the vehicle from the bot tom Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 E02015 10 Position the link...

Page 56: ...ngle lever M14x1 5 60 Nm 44 3 lbf ft Info Pay attention to flat area B Mount and tighten screw 6 Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Info Raise the link fork sligh...

Page 57: ...seat on the collar bushings of the fuel tank lower the seat at the rear and push the seat forward Make sure the seat is latched in place correctly E01989 10 Mount and tighten screw 1 Guideline Screw...

Page 58: ...take off toward the front 11 23 Installing the air filter box cover E02017 12 Condition The air filter box cover is secured Insert the air filter box cover in area Aand clip it into area B E02017 10...

Page 59: ...f air filter from air filter support 11 25 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel clea...

Page 60: ...the top retaining pin 1in bush ing B The air filter is correctly positioned Secure the bottom retaining pin with holding tab 2 Info If the air filter is not mounted correctly dust and dirt may enter...

Page 61: ...ion the main silencer in exhaust sleeve 1 Mount and tighten screws 2with the washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 30 Changing the glass fiber yarn filling of the main sile...

Page 62: ...scape 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...

Page 63: ...fuel line Dirt in the fuel line clogs the injection valve V01661 10 Disconnect the quick release coupling Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 812120161...

Page 64: ...lth Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors Rinse the affected area immediately with plenty of water in the event of co...

Page 65: ...f the quick release coupling Silicone spray p 133 Join quick release coupling 4 Info Route the cable and fuel line at a safe distance from the exhaust system Finishing work Mount the seat p 55 11 33 C...

Page 66: ...sion damages components and results in accidents If the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bear ings wear more quickly Some components may...

Page 67: ...Preparatory work Raise the motorcycle with a lift stand p 43 Check the chain tension p 64 I01018 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3left and...

Page 68: ...er 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear measure ment 10 15 kg 22 33 lb Measure distance Bof 18 chain rollers in the lower chain sectio...

Page 69: ...m 4 4 lbf ft Loctite 243 V01664 11 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that...

Page 70: ...on Change the frame Guideline Repairs on the frame are not permitted 11 39 Checking the link fork S02305 01 Check the link fork for damage cracks and deformation If the link fork shows signs of damage...

Page 71: ...work Install the fuel tank p 62 Mount the seat p 55 11 41 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized...

Page 72: ...wallowed 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...

Page 73: ...hing 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 regu...

Page 74: ...from the master cylinder reservoir to prevent overflowing Remove the bleeding syringe Mount and tighten the bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below c...

Page 75: ...sting 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...

Page 76: ...nts 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 wi...

Page 77: ...orcycles 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 co...

Page 78: ...p 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...

Page 79: ...e 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 brak...

Page 80: ...cotter pins from the rear to the front Info Always change the brake linings in pairs Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a...

Page 81: ...he 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...

Page 82: ...cidents 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...

Page 83: ...icle upright Remove screw cap 1with membrane 2and the O ring Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 131 Mount the screw cap with the membrane and the O ring Info Clean up overflowed or...

Page 84: ...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 t...

Page 85: ...slid ing plate 6in the brake caliper bracket are seated correctly Info The arrow on the spring plate points in the direction of rota tion of the brake disc J00088 10 Insert the new brake linings inser...

Page 86: ...back the brake pistons A00839 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 A00840 10 Warning Danger of accident...

Page 87: ...the spacers Clean and grease the wheel spindle Long life grease p 133 A00839 11 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned Mount and tighten scre...

Page 88: ...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...

Page 89: ...Mount the chain I01017 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 64 Tight...

Page 90: ...ire 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 t...

Page 91: ...rized 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...

Page 92: ...ve cable 1from the 12 V battery Pull back positive terminal cover 2and disconnect the positive cable from the 12 V battery Remove screw 3 Pull holding bracket 4forward and remove the 12 V battery upwa...

Page 93: ...s 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 T...

Page 94: ...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 f...

Page 95: ...relay 3onto the holder and route the cable Mount the EFI control unit 1on the rubber lugs 2 Finishing work Mount the seat p 55 14 5 Changing the fuses of individual electrical power consumers Info Th...

Page 96: ...e fuses with the required ampere value Do not bypass or repair fuses Insert the spare fuse with the correct rating Fuse 75011088010 p 127 Fuse 75011088005 p 127 Tip Put a spare fuse in the fuse box so...

Page 97: ...or hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is harmful to health Keep coolan...

Page 98: ...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...

Page 99: ...er the water pump cover E02034 11 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...

Page 100: ...r 4with the O ring Guideline 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 level Aabove the radiator fi...

Page 101: ...th 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...

Page 102: ...n connector 4 Position protection cap 3 400243 10 Pour coolant in up to level Aabove the radiator fins Guideline 10 mm 0 39 in Coolant p 131 E02035 10 Mount radiator cap 2 Danger Danger of poisoning E...

Page 103: ...e 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 101 16 2 Adjusting the play in the throttle c...

Page 104: ...ap is supplied E02037 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 t...

Page 105: ...ut 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 E01992 10 Run the engine until warm The col...

Page 106: ...e sea level the ambient pressure is pro grammed on an ongoing basis If the vehicle is transported over great height differences the ambient pressure must be reprogrammed H02349 01 Start the vehicle at...

Page 107: ...ter performance Finishing work Install the fuel tank p 62 Mount the seat p 55 16 8 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when...

Page 108: ...eeth 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...

Page 109: ...if fuel spills on them Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system V01687 10 Clean quick...

Page 110: ...il tank Info For one tank of fuel the 2 stroke oil tank must be filled up to at least the upper edge A The 2 stroke oil tank must be completely filled if possible If the 2 stroke oil level is too low...

Page 111: ...in wake up connector 5for priming the oil pump to the diag nostics connector 6 Info The connector is included as part of the motorcycle s sepa rate enclosure Wait for at least five seconds Release the...

Page 112: ...ork Mount the seat p 55 17 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...

Page 113: ...ut of the intake flange and hang it to the side V01725 11 Open hose clamp 6using a screwdriver Pull off the angle piece and collect the 2 stroke oil in a suitable con tainer V01724 11 Remove oil scree...

Page 114: ...bottom M8x18 30 Nm 22 1 lbf ft Loctite 2701 Remove screws 2 Mount and tighten screws 2 Guideline Screw subframe top M8x20 35 Nm 25 8 lbf ft Loctite 2701 Finishing work Remove the motorcycle from the...

Page 115: ...es 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...

Page 116: ...en the engine is cold Preparatory work Park the motorcycle on a level surface E01991 10 Main work Remove gear oil level monitoring screw 1 401955 11 Remove filler plug 2with the O ring Add gear oil un...

Page 117: ...SERVICE WORK ON THE ENGINE 17 115 Start the engine and check it for leaks...

Page 118: ...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 cl...

Page 119: ...eserving materials for paints metal and rubber p 133 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...

Page 120: ...work shop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 133 Refuel p 28 Clean t...

Page 121: ...19 19 2 Preparing for use after storage 401059 01 Install the 12 V battery p 90 Remove the motorcycle from the lift stand p 43 Perform checks and maintenance measures when preparing for use p 25 Make...

Page 122: ...ean the connector and treat it with con tact spray Malfunction in the electronic fuel injection Read out the fault memory using the GAS GAS Motorcycles diagnostics tool The engine has no idle speed Sp...

Page 123: ...he cooling system for leakage Check the coolant level p 96 Too little air stream Switch off engine when stationary Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Dra...

Page 124: ...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 6...

Page 125: ...gnal 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 Oi...

Page 126: ...X 250 US 49 0 mm 1 929 in Z distance height of control flap EX 300 US 49 5 mm 1 949 in Primary transmission 26 73 Clutch Multidisc clutch in oil bath hydraulically activated Transmission 6 gear transm...

Page 127: ...243 Screw exhaust flange M6 8 Nm 5 9 lbf ft Screw gear oil level monitoring M6 8 Nm 5 9 lbf ft Screw intake flange reed valve hous ing M6 6 Nm 4 4 lbf ft Screw kick starter intermediate gear steel pi...

Page 128: ...approx 8 5 l 2 25 US gal Super unleaded ROZ 95 p 132 Fuel reserve approx 1 5 l 1 6 qt 2 stroke oil tank content approx 0 6 l 0 6 qt Engine oil 2 stroke p 131 22 4 Chassis Frame Central tube frame mad...

Page 129: ...r alternative manufacturers if any contact an authorized dealer or qualified tire dealership If local road approval regulations apply these and the respective technical specifications must be observed...

Page 130: ...E 2 5 22 9 Chassis tightening torques Screw intake air temperature sensor EJOTPT K50x18 T20 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 EJOTD...

Page 131: ...il pump M6 6 Nm 4 4 lbf ft Screw oil tank on frame M6 5 Nm 3 7 lbf ft Screw rear brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw seat fixing M6 6 Nm 4 4 lbf ft Screw throttle grip M6 5 Nm 3 7 lbf ft...

Page 132: ...rew 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 fuel pump M12 15 Nm 11 1 lbf ft Nut angle lever to link fork M14x1 5 60 Nm 44 3...

Page 133: ...s 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 th...

Page 134: ...n SAE p 135 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 c...

Page 135: ...ended 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 Ch...

Page 136: ...and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Kl ber Lubrication Kl berfood NH1 34 401 Universal oil s...

Page 137: ...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 o...

Page 138: ...26 INDEX OF SPECIAL TERMS 136 OBD On board diagnosis Vehicle system which monitors the specified parameters of the vehicle electronics...

Page 139: ...LIST OF ABBREVIATIONS 27 137 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 140: ...refuel with 2 stroke oil 28 2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention Active driving aids are also repre sented by yellow or o...

Page 141: ...0 Brake linings of front brake changing 76 of front brake checking 76 of rear brake checking 81 of the rear brake changing 82 C Capacity coolant 98 126 gear oil 113 126 Chain checking 66 cleaning 63 C...

Page 142: ...lebar position 41 adjusting 42 High speed compression damping shock absorber adjusting 34 I Idle speed adjusting 103 Idle speed adjusting screw 17 Ignition timing map changing 105 plug in connector 10...

Page 143: ...ing 89 Start button 15 Start number plate installing 51 removing 50 Starting 25 Starting power of lithium ion batteries at low temperatures 20 Steering head bearing lubricating 50 Steering head bearin...

Page 144: ...3215096en 3215096en 31 08 2022 Stallhofnerstra e 3 5230 Mattighofen Austria http www gasgas com...

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