GAS GAS EX 450F 2021 Owner'S Manual Download

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17 SERVICE WORK ON THE ENGINE

106

17.1

Changing the fuel screen

Danger

Fire hazard

Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

–

Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

–

Switch off the engine for refueling.

–

Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

–

If any fuel is spilled, wipe it off immediately.

–

Observe the specifications for refueling.

Warning

Danger of poisoning

Fuel is poisonous and a health hazard.

–

Avoid skin, eye and clothing contact with fuel.

–

Immediately consult a doctor if you swallow fuel.

–

Do not inhale fuel vapors.

–

In case of skin contact, rinse the affected area with plenty of water.

–

Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

–

Change your clothing in case of fuel spills on them.

Note

Environmental hazard

Improper handling of fuel is a danger to the environment.

–

Do not allow fuel to enter the groundwater, the soil, or the sewage system.

A00898-10

(MC)

–

Clean 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!

–

Disconnect the quick release coupling.

Info

Remaining fuel may flow out of the fuel hose.

–

Pull fuel screen

out of the connecting piece.

–

Insert the new fuel screen all the way into the connecting piece.

–

Spray silicone spray onto a lint-free cleaning cloth and lightly
lubricate the O-ring of the quick-release coupling.

Silicone spray (

p. 131)

–

Join quick release coupling

Summary of Contents for EX 450F 2021

Page 1: ...OWNER S MANUAL 2021 MC 450F EX 450F Art no 3215010en ...

Page 2: ......

Page 3: ...s designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice GASGAS Motorcycles accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that does not be...

Page 4: ...ifficult operating conditions 22 7 5 Preparing the vehicle for rides on dry sand 22 7 6 Preparing the vehicle for rides on wet sand 23 7 7 Preparing the vehicle for rides on wet and muddy circuits 24 7 8 Preparing vehicle for high temperatures or slow riding 24 7 9 Preparing the vehicle for low temperatures or snow 24 8 RIDING INSTRUCTIONS 25 8 1 Checks and maintenance measures when preparing for ...

Page 5: ...41 Checking the rubber grips 72 11 42 Adjusting the basic position of the clutch lever 73 11 43 Checking correcting the fluid level of the hydraulic clutch 73 11 44 Changing the hydraulic clutch fluid 74 12 BRAKE SYSTEM 76 12 1 Checking the free travel of the hand brake lever 76 12 2 Adjusting the basic position of the hand brake lever 76 12 3 Checking the brake discs 76 12 4 Checking the front br...

Page 6: ...ROUBLESHOOTING 116 21 BLINK CODE 118 22 TECHNICAL DATA 120 22 1 Engine 120 22 2 Engine tightening torques 120 22 3 Capacities 122 22 3 1 Engine oil 122 22 3 2 Coolant 122 22 3 3 Fuel 122 22 4 Chassis 122 22 5 Electrical system 123 22 6 Tires 123 22 7 Fork 124 22 7 1 MC 124 22 7 2 EX 124 22 8 Shock absorber 125 22 8 1 MC 125 22 8 2 EX 125 22 9 Chassis tightening torques 126 23 SUBSTANCES 129 24 AUX...

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: ...ry fluids which do not meet the required specification for the respec tive use 2 3 Safety advice A number of safety instructions need to be followed to operate the product described safely Therefore read this instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warni...

Page 9: ...ysically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do no...

Page 10: ...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 workshop will be glad to advise you 2 10 Owner s Manual Read t...

Page 11: ...http www gasgas com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual An incorrect suspension setting can lead to damage and breakage of chassis components Use of the vehicle under difficult conditions such as on sand or on wet dusty and mudd...

Page 12: ...EHICLE 10 4 1 View of vehicle front left example A00873 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Fuel tank filler cap 4 Air filter box cover 5 Cold start button p 17 6 Engine number p 12 7 Shift lever p 18 ...

Page 13: ...ber compression adjuster 2 Stop button p 14 3 Start button p 15 4 Throttle grip p 14 5 Vehicle identification number p 12 6 Type label p 12 6 Fork article number p 12 7 Idle speed adjusting screw p 18 8 Foot brake lever p 19 9 Engine oil level viewer bk Shock absorber rebound adjuster ...

Page 14: ...n the right 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 H00940 10 The engine number 1is stamped on the left side of the engine 5 4 Fork article number 401947 10 The fork article number 1is stamped on the inside of the axle clamp ...

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: ...d using the hand brake lever 6 3 Throttle grip A00759 10 The throttle grip 1is fitted on the right side of the handlebar 6 4 Stop button A00796 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 circuit...

Page 17: ...icinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow ...

Page 18: ...r clockwise and lift it off 6 8 Closing the fuel tank filler cap A00771 10 MC Mount fuel tank filler cap 1and turn it clockwise until the fuel tank is tightly closed Info Route fuel tank breather hose 2without kinks A00770 10 EX Mount the fuel tank filler cap and turn it clockwise until release button 1engages Info Route fuel tank breather hose 2without kinks ...

Page 19: ... burn the increased fuel quantity it must be supplied with additional oxygen by pushing the cold start button After briefly opening up the throttle and then releasing the throttle grip again or turning the throttle grip towards the front the cold start but ton returns to its original position Info Check whether the cold start button has returned to its basic position Possible states The cold start...

Page 20: ...peed is adjusted using the idle speed adjusting screw 1 Increase the idle speed by turning the idle speed adjusting screw clock wise Decrease the idle speed by turning the idle speed adjusting screw coun terclockwise 6 11 Shift lever 401950 10 Shift lever 1is mounted on the left side of the engine 401950 13 MC The gear positions can be seen in the photograph The neutral or idle position is between...

Page 21: ...indle The plug in stand is used to park the motorcycle The plug in stand is used as a fork locker when transporting the motor cycle Info Remove the plug in stand before riding The tool can be attached to the plug in stand holders 6 14 Side stand EX 401943 10 The side stand 1is located on the left of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding si...

Page 22: ...ing ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever if you do not want to brake Warning Danger of accidents Total weight and axle loads infl...

Page 23: ...t is fixed firmly as close as possible to the 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 Do not exceed the maximum permissible weight and maximum permissible axle loads Guideline Maximum permissible overall weight 335 kg 739 lb Maximum permissible front axle load 145 kg 320 lb ...

Page 24: ... 4 Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can 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 Clean the air filter and air...

Page 25: ... fins carefully Condition Regular use in sand Change the piston every 20 operating hours 7 6 Preparing the vehicle for rides on wet sand 102137 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for GASGAS Techni cal Accessories 600868 01 Clean the chain Chain cleaner p 131 Mount the steel sprocket Grease the chain Universal oil spray p 132 C...

Page 26: ...vehicle for high temperatures or slow riding 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary ratio Clean the chain Chain cleaner p 131 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 98 7 9 Preparing the vehicle for low temperatures ...

Page 27: ...he tire condition p 91 Check tire pressure p 91 Check the spoke tension p 92 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 45 Bleed the fork legs p 45 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 reg...

Page 28: ... 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 8 4 Shifting riding Warning Danger of accidents If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Info If unusual noises occur while riding stop safely immediately switch off the engine and contact an authorized GAS GAS Motorcy...

Page 29: ...inated Your authorized GAS GAS Motorcycles workshop will be glad to help Warning Danger of accidents Moisture and dirt impair the brake system Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs On sandy wet or slippery surfaces use mostly the rear brake Always finish braking before you go into a bend Shift down to a lower gear appropriate to your sp...

Page 30: ...l surface Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it H02628 01 MC Switch off the engine Mount plug in stand on the fork legs Plug in stand 79029094000 Info The plug in stand is included Make sure the brake line runs in front of the p...

Page 31: ...case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Material damage Inadequate fuel quality causes the fuel filter to quickly become clogged In some countries and regions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your author...

Page 32: ...he front brake linings p 79 Check the brake linings of the rear brake p 84 Check the brake discs p 76 Check the brake lines for damage and leakage Check the rear brake fluid level p 82 Check the free travel of the foot brake lever p 81 Check the frame p 71 Check the link fork p 71 Check the fork bearing for play Check the shock absorber heim joint for play Check the shock absorber linkage Check th...

Page 33: ...3 Recommended work every 48 months every 12 months Every 100 operating hours Every 50 operating hours After 20 operating hours After 10 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 74 Lubricate the steering head bearing p 52 Service the fork Perform the shock absorber service Change the fuel filter Change the coolant p 100 Perform min...

Page 34: ...9 SERVICE SCHEDULE 32 One time interval Periodic interval ...

Page 35: ... in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork is frequently overloaded then the air...

Page 36: ... range and vice versa 10 4 Adjusting the low speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized GASGAS Motorcycles workshop will be glad to help Info The effect of the low s...

Page 37: ... the number of turns corresponding to the shock absorber type Guideline Highspeed compression damping MC Comfort 2 turns Standard 1 5 turns Sport 1 turn Highspeed compression damping EX Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 6 Adjusting the rebound damping of the shock absorber Caution Risk of injury Par...

Page 38: ...clock wise to reduce damping when the shock absorber rebounds 10 7 Measuring the dimension of the rear wheel unloaded Preparatory work Raise the motorcycle with a lift stand p 44 F03178 10 Main work Position the sag gage in the rear axle and measure the distance to the marking on the rear fender Sag gauge 00029090100 Pin sag scale 00029990010 Note the value as dimension A Finishing work Remove the...

Page 39: ...reload of the shock absorber p 38 10 9 Checking the riding sag of the shock absorber 402417 10 Measure dimension Aof rear wheel unloaded p 36 With another person holding the motorcycle the rider wearing full protective clothing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now remeasures the d...

Page 40: ...oughly 402659 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 ring 2to specified dimen sion A Guideline Sprin...

Page 41: ... rate is shown on the outside of the spring Finishing work Install the shock absorber p 55 Check the free travel of the foot brake lever p 81 Check the static sag of the shock absorber p 37 Check the riding sag of the shock absorber p 37 Adjust the rebound damping of the shock absorber p 35 Remove the motorcycle from the lift stand p 44 10 12 Checking the basic setting of the fork Info For various...

Page 42: ...A00775 10 Main work Remove protection cap 1 Push together fork airpump 2fully Fork airpump 79412966100 Info The fork airpump is included as part of the motorcycle s accessory pack Connect the fork airpump to the left fork leg The fork airpump indicator switches on automatically A little air escapes from the fork leg when connecting Info This is due to the volume of the hose and not due to a defect...

Page 43: ...rn adjuster 1clockwise all the way to the stop Info Adjuster 1is located at the upper end of the right fork leg Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping MC Comfort 17 clicks Standard 12 clicks Sport 7 clicks Compression damping EX Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping turn counte...

Page 44: ...Rebound damping EX 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 F03176 10 On the upper triple clamp there are 2 holes at a distance of Ato each other Hole distance A 15 mm 0 59 in The holes on the handlebar supports are placed at a distance of B fro...

Page 45: ...y 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 Mount and tighten screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Info Position the left and right handlebar supports evenly Position the handlebar Info Make sure the cables ...

Page 46: ... raise the motorcycle at the frame underneath the engine Lift stand A54029955100 Neither wheel is in contact with the ground Secure the motorcycle against falling over 11 2 Removing the motorcycle from the lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking...

Page 47: ...move the motorcycle from the lift stand p 44 11 4 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand p 44 Remove the fork protector p 46 H03152 10 Main work Push dust boots 1of both fork legs downward Info The dust boots remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is ...

Page 48: ...he right fork protector 11 6 Installing the fork protector A00777 11 Position the fork protector on left fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and the clamp Mount and tighten screws 2 Guideline Screw brake line bracket EJOT 1 7 Nm 1 25 lbf ft Position the fork protector on the right fork leg Mount and tighten screws 3 Gui...

Page 49: ...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 faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is located in the left fork leg The pres sure and r...

Page 50: ...ise the motorcycle with a lift stand p 44 Remove the front wheel p 87 Remove the fork legs p 46 Remove the start number plate p 52 Remove front fender p 53 Remove the handlebar cushion A00801 10 Main work Open cable holder 1on the left and detach the wiring harness Remove screw 2 Remove screw 3 Take off the upper triple clamp with the handlebar and set aside Info Cover the components to protect th...

Page 51: ...he upper triple clamp with the handlebar Mount screw 4 but do not tighten yet H01182 11 Position the fork legs Air bleeder screw 5of the right fork leg is positioned to the front Valve Aof the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air...

Page 52: ...le holder 9on the left A00885 12 Position the brake caliper Mount and tighten screws bk Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line and the clamp Mount and tighten screws bl Guideline Screw brake line bracket EJOT 1 7 Nm 1 25 lbf ft Finishing work Install front fender p 53 Mount the handlebar cushion Install the start number plate p 52 Install the f...

Page 53: ...eering head bearing If there is detectable play Adjust the steering head bearing play p 51 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play p 51 Check the steering head bearing and adjust if...

Page 54: ...mp p 48 Install the lower triple clamp p 49 Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp 11 14 Removing the start number plate A00778 10 Remove screw 1 Unhook the start number plate from the brake line and remove it 11 15 Installing the start number plate A00779 10 Position the brake line in holders Aon the start numbe...

Page 55: ...t number plate p 52 A00780 10 Main work Remove screws 1and 2 Take off the front fender 11 17 Installing front fender A00780 10 Main work Position front fender Mount and tighten screws 1and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start number plate p 52 ...

Page 56: ...rea Aand take it off F03191 10 Remove screw 2 Remove fitting 3 Info Raise the swingarm slightly to be able to remove the screws more easily A00810 10 Remove screws 4 Pull off foot brake cylinder from the push rod A00811 10 Remove the connecting link of the chain Take off the chain Info Cover the components to protect them against damage A00887 10 Remove nut 5and the swingarm pivot Push the link fo...

Page 57: ...te 2701 A00816 10 Position the link fork and mount the swingarm pivot Info Pay attention to flat area A Mount and tighten nut 2 Guideline Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft A00812 10 Mount the chain Connect the chain with connecting link 3 Guideline The closed side of the chain joint lock must face in the direction of travel A00817 10 Position the foot brake cylinder Push rod 4engages in th...

Page 58: ...ightly to be able to mount the screw more easily A00886 11 Attach the frame protector in area Cand position it 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 Check the free travel of the foot brake lever p 81 Remove the motorcycle from the lift stand p 44 11 20 Removing the seat Caution Danger of burns The volta...

Page 59: ... Mount the front of the seat on the collar bushing of the fuel tank lower the seat at the rear and push the seat forward A00781 10 Mount and tighten screw 1 Guideline Screw rear seat fixing M6 6 Nm 4 4 lbf ft 11 22 Removing the air filter box cover Condition The air filter box cover is secured Remove the seat p 56 A00782 10 Remove screw 1 ...

Page 60: ...d take off toward the front 11 23 Installing the air filter box cover A00782 12 Condition The air filter box cover is secured Insert the air filter box cover in area Aand clip it into area B A00782 10 Mount and tighten screw 1 Guideline Screw air filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft Mount the seat p 57 A00819 11 Condition The air filter box cover is not secured Insert the air filter b...

Page 61: ...e 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 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...

Page 62: ...ining pin 1in bushing B The air filter is correctly positioned Insert retaining tab 2 Retaining pin 3is secured by retaining tab 2 Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in damage Finishing work Install the air filter box cover p 58 11 27 Preparing air filter box cover for securing Preparatory work Remove the air filter box cover p 57 F03206 1...

Page 63: ...encer Mount screws 1with the washers but do not tighten yet Attach spring 2 Spring hook 50305017000C1 Tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 30 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehic...

Page 64: ...ble The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous a...

Page 65: ...unt wash cap set 3 Wash cap set 81212016100 Pull the fuel tank breather hose off the fuel tank lid A00786 10 Remove screw 4with the rubber bushing A00891 10 EX Unplug connector 1of the fuel pump Clean quick release coupling 2thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve A00820 10 Disconnect the quick ...

Page 66: ... lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel v...

Page 67: ...g Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft A00890 11 Plug in connector 3for the fuel pump Remove the wash cap set Clean the quick release coupling thor oughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Spray silicone spray onto a lint free cleaning cloth and lightly lubricate the O ring of the q...

Page 68: ...Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 66 11 34 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip Remove lubricants from the tires using a suitable cleaning agent Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always k...

Page 69: ...wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 44 A00791 10 Main work Pull the chain ...

Page 70: ...orcycle with a lift stand p 44 Check the chain tension p 67 A00821 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3left and right Guideline Chain tension 55 58 mm 2 17 2 28 in Turn adjusting screws 3on the left and right so that the mark ings on the left and right chain adjusters are in the same position relative to reference marks A The rear wheel is ...

Page 71: ...ether 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 section Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance Bfrom 18 chain rollers at the longest chain section 272 mm 10 71 in If dista...

Page 72: ... Nm 4 4 lbf ft Loctite 243 A00793 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 402421 10 Check th...

Page 73: ...amage cracks and deformation If the frame shows signs of damage cracks or deformation 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 cracks or deformation Change the link fork Info Always replace a damaged link fork GASGAS Motor cycles does not perm...

Page 74: ...all the fuel tank p 64 Mount the seat p 57 11 41 Checking the rubber grips 401197 01 Check the rubber grips on the handlebar for damage wear and looseness Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right The left sleeve is clamped onto the handlebar The rubber grip can only be replaced with the sleeve or the throttle tube If ...

Page 75: ...uid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Info The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone ...

Page 76: ...fo The fluid level rises with increasing wear of the clutch facing discs Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid corrodes paint Only use clean brake fluid from a sealed container A00825 10 Move the hydraulic clutch fluid reservoir mounted on...

Page 77: ...casionally extract the fluid from the master cylinder reservoir to prevent overflowing Tighten the bleeder screw and remove the bleeding syringe with the hose Mount the protection cap Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws ...

Page 78: ...c position of the hand brake lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Only turn the adjusting screw by hand and do not use forc...

Page 79: ... be glad to help Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized GASGAS Motorcycles workshop will be glad to help Preparatory work Check the front brake linings p 79 A00828 10 Main work Move the brake reservoir mounted on the handlebar to a horizontal po...

Page 80: ...anged in accordance with the service schedule Your authorized GASGAS Motorcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals an...

Page 81: ...ts Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized GASGAS Motorcy cles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with ...

Page 82: ...uid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container A00829 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal position Remove screws 1 Take off cover 2with membrane 3 A00830 11 Manually press the brake caliper toward the brake disc to push back the brake pistons Ensure that brake fluid does not flow out of the brake fluid rese...

Page 83: ...y brake fluid that has overflowed or spilled 12 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring 1 Move th...

Page 84: ... brake lever 3 5 mm 0 12 0 2 in Hold push rod 5and tighten nut 4 Guideline Remaining nuts chas sis M6 10 Nm 7 4 lbf ft Hold screw 3and tighten nut 2 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Attach spring 1 12 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below t...

Page 85: ...y if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the...

Page 86: ... Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 84 12 13 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized GASGAS Motorcy cles workshop will be glad to help Warning Skin irritation Brake...

Page 87: ...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 A00835 10 Position the vehicle upright Remove screw cap 1with membrane 2and the O ring A00836 10 Manually press the brake caliper toward the brake disc to push back the brake piston Ensure that bra...

Page 88: ...unted on the pis ton side brake lining Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point A00833 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 129 Mount and tighten screw cap 1with membrane 2and the O ring Info Use water to immediately clean up any brake fluid that has overflowed or spilled ...

Page 89: ...g 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 accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold front wheel and remove wheel spindle Take the front wheel out of the fo...

Page 90: ...t the spacers Clean and grease the wheel spindle Long life grease p 131 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned A00839 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 the motorcycle ...

Page 91: ... 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 92: ...d Mount the chain A00843 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 67 Tighten nut 4 Guideline Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Cha...

Page 93: ... Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT num ber The first two digits indicate the week of manufacture and the last two digits the year of manufacture GASGAS Motorcycles recommends that the tires be changed after five years at the latest regardless of the actual wear If the tires are more than f...

Page 94: ...egularly and 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 spokes of the same length and diameter vibrate with a different tone this is an indication that the spoke tensions differ You should hear a high n...

Page 95: ...cable from the 12 V battery Remove screw 3 Pull holding bracket 4forward and remove the 12 V battery upwards 14 2 Installing the 12 V battery H00386 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 123 Mount and tighten screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Conn...

Page 96: ...nt for the service life of the 12 V battery Rapid recharging with a high charging current shortens the service life of the battery If the charging current charging voltage or charging time is exceeded the 12 V battery will be destroyed If the 12 V battery is depleted by repeated starting the 12 V battery must be charged immediately If the 12 V battery is left in a discharged state for an extended ...

Page 97: ... the battery charger after charging and disconnect from the 12 V battery Finishing work Install the 12 V battery p 93 Mount the seat p 57 14 4 Changing main fuse Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven Allow th...

Page 98: ...r relay Insert a new main fuse Fuse 58011109110 p 123 Check that the electrical system is functioning properly Tip Insert a spare fuse so that it is available if needed Mount the protection caps Mount the starter relay onto the holder and route the cable Finishing work Mount the seat p 57 14 5 Diagnostics connector H00933 12 Diagnostics connector 1is located under the seat ...

Page 99: ...mponents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of...

Page 100: ...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 101: ...and tighten screw 1with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 15 5 Refilling with coolant Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with ...

Page 102: ...act with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold A00894 11 Position the motorcycle ...

Page 103: ...inal position Adjust the play in the throttle cable p 101 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or run ning the engine in an enclosed space Start the engine and let it run at idle speed Move the handlebar to a...

Page 104: ...ere is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work Check the play in the throttle cable p 101 16 3 Adjusting the characteristic map of the throttle response Info On the throttle grip the characteristic map of the throttle response is changed by changin...

Page 105: ...vehicle is delivered A00850 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route correctly Position half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm 3 7 lbf ft Slide on sleeve 1and check the throttle grip for ease of move ment Finishing work Check the play in ...

Page 106: ...aises the idle speed 16 5 Programming the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed then the mal function indicator lamp flashes 2x per second H02263 10 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation wh...

Page 107: ...ge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 105 16 7 Adjusting the basic position of the shift lever 401950 12 Remove screw 1with the washers and take off shift lever 2 401951 10 Clean gear teeth Aof the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage gearing In...

Page 108: ...ed area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system A00898 10 MC Clean quick release coupling 1thoroughly with compress...

Page 109: ...y flow out of the fuel hose Pull fuel screen 2out of the connecting piece Insert the new fuel screen all the way into the connecting piece Spray silicone spray onto a lint free cleaning cloth and lightly lubricate the O ring of the quick release coupling Silicone spray p 131 Join quick release coupling 1 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconscious...

Page 110: ... engine oil p 111 17 3 Changing the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils ...

Page 111: ...reen and the O rings Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft S02291 10 Position long oil screen 4with the O rings on a pin wrench Position the pin wrench through the drill hole of the screw plug in the opposite section of the engine case Push the oil screen all the way into the engine case S02292 10 Mount and tighten screw plug 3with the O ring Guideline Screw plug oil screen M20...

Page 112: ... the screws Guideline Screw oil filter cover M6 10 Nm 7 4 lbf ft Stand the motorcycle upright 401955 12 Remove filler plug 8with the O ring and fill up with engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 129 Info Too little engine oil or poor quality engine oil will result in premature wear of the engine Mount and tighten the filler plug together with the O ring Danger Danger of poison...

Page 113: ...ieve optimal engine oil performance it is not advisable to mix different engine oils GASGAS Motorcycles recommends changing the engine oil if necessary Mount and tighten the filler plug together with the O ring Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use eff...

Page 114: ...rcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Motorcycle cleaner p 131 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the vehicle with wate...

Page 115: ...e exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 131 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 132 ...

Page 116: ...r 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 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 131 Refuel p 29 Clean the motorcycle p 112 Change the engine oil and the oil filter clean the o...

Page 117: ...only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and the exhaust system to rust 19 2 Putting into operation after storage 401059 01 Install the 12 V battery p 93 Remove the motorcycle from the lift stand p 44 Perform checks and maintenance measures when preparing for use p 25 Take a test ride ...

Page 118: ...nostics tool Engine does not speed up Malfunction in the electronic fuel injection Read out the fault memory using the GAS GAS Motorcycles diagnostics tool Engine has too little power Air filter is very dirty Clean the air filter and air filter box p 59 Fuel filter is very dirty Change the fuel filter Malfunction in the electronic fuel injection Read out the fault memory using the GAS GAS Motorcyc...

Page 119: ...he engine oil level p 107 Engine oil too thin low viscosity Change the engine oil and the oil filter clean the oil screens p 108 Piston or cylinder worn Measure the piston cylinder mounting clearance 12 V battery discharged 12 V battery is not charging Check the charging voltage Check the stator winding of the alterna tor Unwanted electrical power con sumer Check the open circuit current ...

Page 120: ...e for malfunction indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor circuit fault Coolant temperature sensor input signal too low Blink code for malfunction indicator lamp 13 Malfunction indicator lamp flashes 1x long 3x short Error level condition Intake air temperature sensor circuit fault Intake air temperature sensor input si...

Page 121: ...ircuit fault Blink code for malfunction indicator lamp 41 Malfunction indicator lamp flashes 4x long 1x short Error level condition Fuel pump controller short circuit to ground open circuit Fuel pump controller open circuit short circuit to plus Blink code for malfunction indicator lamp 65 Malfunction indicator lamp flashes 6x long 5x short Error level condition EEPROM malfunction Blink code for m...

Page 122: ...ication with 2 trochoidal pumps Primary transmission 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox Transmission ratio Alternator 12 V 70 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Spark plug NGK LMAR9AI 8 Spark plug electrode gap 0 8 mm 0 031 in Cooling Water cooling permanent circulation of coolant by water pump Startin...

Page 123: ...rum 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 tensioning rail M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain failure protection M6 10 Nm 7 4 lbf ft Loctite 243 Screw timing chain tensioner M6 10 Nm 7 4 lbf ft Screw torque governor M6 10 Nm 7 4 lbf ft Loctite 243 Screw valve cover M6 10 Nm 7 4 lbf ft...

Page 124: ...acities 22 3 1 Engine oil Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 129 22 3 2 Coolant Coolant 0 95 l 1 qt Coolant p 129 22 3 3 Fuel Total fuel tank capacity approx MC Super unleaded ROZ 95 p 130 7 l 1 8 US gal Total fuel tank capacity approx EX Super unleaded ROZ 95 p 130 8 5 l 2 25 US gal Fuel reserve approx EX 1 5 l 1 6 qt 22 4 Chassis Frame Central tube frame made of chrome molybdenum st...

Page 125: ...t 335 kg 739 lb 22 5 Electrical system 12 V battery HJTZ5S FP C Lithium ion battery Battery voltage 12 V Nominal capacity 2 0 Ah Maintenance free Fuse 58011109110 10 A Malfunction indicator lamp LED 22 6 Tires Validity Front tire Rear tire MC 80 100 21 51M TT MAXXIS MAXXCROSS MX ST 100 90 19 57M TT MAXXIS MAXXCROSS MX ST The tires specified represent one of the possible series production tires Add...

Page 126: ...85 fl oz Fork oil SAE 4 48601166S1 p 129 Grease capacity left cartridge 5 g 0 18 oz Special grease 00062010053 p 132 22 7 2 EX Fork article number A540C179U406000 Fork WP XACT AER Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Air pressure 10 0 bar 145 psi Fork length 950 mm 37 4 in Oil capacity external ...

Page 127: ...ight of rider 75 85 kg 165 187 lb 42 N mm 240 lb in Weight of rider 85 95 kg 187 209 lb 45 N mm 257 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 477 mm 18 78 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 130 22 8 2 EX Shock absorber article number 18 18 7U 79 Shock absorber WP XACT 5750 Lowspeed c...

Page 128: ... ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Screw service hour counter M4 0 8 Nm 0 59 lbf ft Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw battery terminal M5 2 5 Nm 1 84 lbf ft Screw brake line guide on link fork M5 5 Nm 3 7 lbf ft Screw frame protector ...

Page 129: ...sprocket cover M8 15 Nm 11 1 lbf ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw manifold on cylinder head brace M8 15 Nm 11 1 lbf ft Screw side stand attachment EX M8 33 Nm 24 3 lbf ft Loctite 2701 Screw subframe bottom M8 30 Nm 22 1 lbf ft Loctite 2701 Screw subframe top M8 35 Nm 25 8 lbf ft Locti...

Page 130: ...x1 5 100 Nm 73 8 lbf ft Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Screw in fitting cooling system M24x1 5 18 Nm 13 3 lbf ft Loctite 243 Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft ...

Page 131: ...as the rele vant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other coolants Recommended supplier MO...

Page 132: ... the container and that exhibit the corre sponding properties Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 133: ...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 134: ...y and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Klüber Lubrication KLÜBERFOOD NH1 34 401 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 135: ...ice intervals are demanded for automobile engines the focus for motorcycle engines is on high perfor mance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils accordi...

Page 136: ...26 INDEX OF SPECIAL TERMS 134 OBD On board diagnosis Vehicle system which monitors the specified parameters of the vehicle electronics ...

Page 137: ...LIST OF ABBREVIATIONS 27 135 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 138: ...on that requires prompt intervention Active driving aids are also repre sented by yellow or orange symbols Malfunction indicator lamp lights up flashes orange The OBD has detected a malfunction in the vehi cle electronics Fuel level warning lamp lights up orange The fuel level has reached the reserve mark ...

Page 139: ...10 122 fuel 29 122 Chain checking 69 cleaning 66 Chain guide checking 69 Chain tension adjusting 68 checking 67 Characteristic map of the throttle response adjusting 102 Clutch fluid level checking correcting 73 fluid changing 74 Clutch lever 14 basic position adjusting 73 Cold start button 17 Compression damping fork adjusting 41 Coolant antifreeze and coolant level checking 97 draining 98 level ...

Page 140: ...g screw 18 Implied warranty 9 Indicator lamps overview 15 Intended use 6 L Link fork checking 71 Lower triple clamp installing 49 removing 48 Low speed compression damping shock absorber adjusting 34 M Main fuse changing 95 Main silencer glass fiber yarn filling changing 61 installing 61 removing 61 Manufacturer warranty 9 Misuse 6 Motorcycle cleaning 112 from lift stand removing 44 with lift stan...

Page 141: ...cking 92 Start button 15 Start number plate installing 52 removing 52 Starting 25 Starting power of lithium ion batteries at low temperatures 22 Steering head bearing lubricating 52 Steering head bearing play adjusting 51 checking 51 Stop button 14 Storage 114 T Technical data capacities 122 chassis 122 chassis tightening torques 126 electrical system 123 engine 120 engine tightening torques 120 f...

Page 142: ... 3215010en 3215010en 10 2020 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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GAS GAS EX 450F 2021, Owner'S Manual

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