GAS GAS MC 125 2021 Owner'S Manual Download Page 55

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SERVICE WORK ON THE CHASSIS 11

K01148-10

–

Position the foot brake cylinder.

Push rod

engages in the foot brake cylinder.

The dust boot is correctly positioned.

–

Mount and tighten screws

Guideline

Remaining screws,
chassis

10 Nm (7.4 lbf ft)

K00864-10

–

Position the angle lever and linkage lever.

–

Mount and tighten fitting

Guideline

Nut, linkage lever on
angle lever

M14x1.5

60 Nm (44.3 lbf ft)

Info

Pay attention to flat area

–

Mount and tighten screw

Guideline

Screw, bottom
shock absorber

M10

60 Nm (44.3 lbf ft)

Loctite

2701™

Info

Raise the wheel slightly to be able to mount the screw more
easily.

S04538-11

–

Position the left frame protector.

–

Insert the right frame protector from below and push it to the rear.

–

Mount and tighten screws

with the washers.

Guideline

Screw, frame protector M5

3 Nm (2.2 lbf ft)

–

Mount the new cable ties.

Finishing work

–

Remove the motorcycle from the lift stand. (

p. 42)

11.20

Removing the seat

S04544-10

–

Remove screw

Summary of Contents for MC 125 2021

Page 1: ...OWNER S MANUAL 2021 MC 125 Art no 3215008en ...

Page 2: ......

Page 3: ...ls 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 d...

Page 4: ... 6 Preparing the vehicle for rides on wet and muddy circuits 22 7 7 Preparing vehicle for high temperatures or slow riding 23 7 8 Preparing the vehicle for low temperatures or snow 24 8 RIDING INSTRUCTIONS 25 8 1 Checks and maintenance measures when preparing for use 25 8 2 Starting 25 8 3 Starting off 26 8 4 Shifting riding 26 8 5 Applying the brakes 27 8 6 Stopping parking 27 8 7 Transporting 28...

Page 5: ...nging the hydraulic clutch fluid 69 12 BRAKE SYSTEM 71 12 1 Checking the free travel of the hand brake lever 71 12 2 Adjusting the basic position of the hand brake lever 71 12 3 Checking the brake discs 71 12 4 Checking the front brake fluid level 72 12 5 Adding front brake fluid 72 12 6 Checking the front brake linings 74 12 7 Changing the brake linings of the front brake 74 12 8 Checking the fre...

Page 6: ...2 20 3 Carburetor 114 20 3 1 Carburetor tuning 114 20 3 2 Carburetor basic setting for sandy surfaces 115 20 4 Capacities 115 20 4 1 Gear oil 115 20 4 2 Coolant 115 20 4 3 Fuel 115 20 5 Chassis 115 20 6 Tires 116 20 7 Fork 116 20 8 Shock absorber 117 20 9 Chassis tightening torques 117 21 SUBSTANCES 120 22 AUXILIARY SUBSTANCES 122 23 STANDARDS 124 24 LIST OF ABBREVIATIONS 125 INDEX 126 ...

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: ...s instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are missing you or others may not recognize dangers and may therefore be injured...

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: ...her 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 to advise you 2 10 Owner s Manual Read...

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: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example S04515 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Air filter box cover 4 Shift lever p 16 5 Choke p 16 6 Fuel tap ...

Page 13: ...t example S04516 10 1 Seat 2 Fuel tank filler cap 3 Stop button p 14 4 Throttle grip p 14 5 Kick starter lever p 17 6 Foot brake lever p 17 7 Shock absorber compression adjustment 8 Shock absorber rebound adjustment 9 Level viewer for brake fluid rear ...

Page 14: ...t 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 401949 10 The engine number 1is stamped on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 The fork part 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: ...ngaged using the hand brake lever 6 3 Throttle grip S04518 11 Throttle grip 1is fitted on the right side of the handlebar 6 4 Stop button S04519 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 circui...

Page 17: ... consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handlin...

Page 18: ... the carburetor Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mix ture which is needed for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is p...

Page 19: ...ine 6 11 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 12 Plug in stand H02629 10 The holder for the plug in stand 1is the left side of the wheel spindle The plug in stand is used to park the motorcycle The plug in stand is used as a fork locker when transporting the motor cycle Info Remove the plug ...

Page 20: ...ity Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever if you do not want to brake Warning Danger of accidents Total weight and axle loads influence th...

Page 21: ...oke tension p 87 Info The spoke tension must be checked after half an hour of operation Run the engine in p 19 7 2 Running in the engine During the running in phase do not exceed the specified engine performance Guideline Maximum engine performance During the first 3 operating hours 70 During the first 5 operating hours 100 Info The use of a service hour counter is recommended in order to be able ...

Page 22: ...r 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 of scaldi...

Page 23: ... 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 correspond to the setpoint value Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating tem...

Page 24: ...ed GASGAS Motorcycles workshop 600868 01 Clean the chain Chain cleaner p 122 Mount the steel sprocket Grease the chain Universal oil spray p 123 Clean the radiator fins Straighten the bent radiator fins carefully Condition Regular use in sand Change the piston every 10 operating hours 7 6 Preparing the vehicle for rides on wet and muddy circuits M01106 01 Mount the air filter rain cover Air filter...

Page 25: ...ant 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 of scalding rinse the area affected immediately with lukewa...

Page 26: ...Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for GASGAS Techni cal Accessories M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized GASGAS Motorcycles workshop ...

Page 27: ...arly as incorrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 43 Bleed the fork legs p 42 Check the air filter Check the settings of all controls and ensure that they can be oper ated smoothly Check all screws nuts and hose clamps regularly for tightness Check the fuel level 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling th...

Page 28: ...engine and contact an authorized GAS GAS Motorcycles workshop First gear is used for starting off and for steep inclines Shift into a higher gear when conditions allow incline road situation etc To do so release the throttle while simulta neously pulling the clutch lever shift into the next gear release the clutch lever and open the throttle If the choke function has been activated deactivate it a...

Page 29: ...People who act without authorization endanger themselves and others Do not leave the vehicle unattended if the engine is running Protect the vehicle against access by unauthorized persons Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator engine shock absorber or brake system before the vehicle par...

Page 30: ...hat the plug in stand is firmly in contact with the fender and the tires Pay attention to the alignment of the plug in stand to the fender 8 8 Refueling Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fue...

Page 31: ...l or the sewage system Switch off the engine Open the fuel tank filler cap p 15 400382 10 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Total fuel tank capac ity approx 7 5 l 1 98 US gal Super unleaded 98 octane mixed with 2 stroke engine oil 1 40 p 121 Engine oil 2 stroke p 120 Close the fuel tank filler cap p 15 ...

Page 32: ... leakage Check the rear brake fluid level p 77 Check the free travel of the foot brake lever p 76 Check the frame p 66 Check the link fork p 66 Checking the link fork bearing for play Checking the shock absorber heim joint for play Check the shock absorber linkage Check the tire condition p 86 Check tire pressure p 86 Check the wheel bearing for play Check the wheel hubs Check the rim run out Chec...

Page 33: ...ating hours Every 10 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 69 Lubricate the steering head bearing p 49 Service the fork Perform the shock absorber service Check adjust the carburetor components Change the needle jet Change the coolant p 93 Perform minor engine service Check the inlet membrane Check the clutch Under difficult op...

Page 34: ... 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 pressu...

Page 35: ...detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized GASGAS Motorcycles workshop will be glad to help Info The effect of the low speed compression adjuster can be seen in slow to normal compression of the shock absorber S04522 10 Turn adjusting screw 1clockwise with a screwdriver as far as the last perceptible clic...

Page 36: ...ll 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 S04524 10 Turn adjusting screw 1clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Re...

Page 37: ...he static sag of the shock absorber 402416 10 Measure dimension Aof rear wheel unloaded p 34 Hold the motorcycle upright with aid of an assistant Measure the distance again between the rear axle and marking SAG on the rear fender using the sag gage Note the value as dimension B Info The static sag is the difference between measurements A and B Check the static sag Static sag 35 mm 1 38 in If the s...

Page 38: ...n 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 37 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please f...

Page 39: ... preload Tighten screw 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 52 Remove the motorcycle from the lift stand p 42 10 11 Adjusting the riding sag Preparatory work Raise the motorcycle with a lift stand p 42 Remove the shock absorber p 50 After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a ...

Page 40: ...tting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components Only make adjustments within the recommended range Ride slowly to start with after making adjustments to get the feel of the new handling characteristic Info Check or adjust the air pressure under the same con...

Page 41: ... When disconnecting excess pressure will escape from the hose the fork leg itself does not lose any air The fork airpump indicator switches off automatically after 80 seconds Mount the protection cap Info Only mount the protection cap by hand Finishing work Remove the motorcycle from the lift stand p 42 10 14 Adjusting the compression damping of the fork Info The hydraulic compression damping dete...

Page 42: ...s Info Turn clockwise to increase the damping turn counterclock wise to reduce damping when the shock absorber rebounds 10 16 Handlebar position H01188 10 The holes on the handlebar supports are placed at a distance of A from the center Hole distance A 3 5 mm 0 138 in The handlebar can be mounted in 2 different positions In this way the handlebar can be mounted in the most comfortable position for...

Page 43: ...er and higher on one side Position the left and right handlebar supports evenly Mount and tighten screws 2 Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamp Mount screws 1but do not tighten yet First bolt the handlebar clamp with screws 1onto the longer higher side of...

Page 44: ...emoving the motorcycle from the lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on...

Page 45: ...iscs 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 123 Press the dust boots back into their normal position Remove excess oil Finishing work Install the fork protector p 45 Remove the motorcycle from the lift stand p 42 1...

Page 46: ...lled 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 rebound damping is located in the right fork leg S04528 11 Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft S04527 11 Position the brake caliper Mount...

Page 47: ...mp Mount and tighten screws 2 Position the fork protector on the right fork leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 9 Removing the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 42 Remove the front wheel p 82 Remove the fork legs p 43 Remove the start number plate p 49 Remove front fender p 50 Remove the handlebar cushi...

Page 48: ... steering head bearing Check whether upper steering head seal 1is correctly positioned Slide on protective ring 2and O ring 3 S04531 10 Position the 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 The air suspension AER val...

Page 49: ...4 8 lbf ft Loctite 243 S04532 11 Tighten screws 8 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft S04527 12 Position the brake caliper Mount and tighten screws 9 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 bk Finishing work Check that the wiring harness throttle cables and brake and clutch lines can move ...

Page 50: ... H01167 01 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steering head bearing If there is detectable play Adjust steering head bearing play p 48 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily over the entire steering range There...

Page 51: ...he handlebar cushion 11 13 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 45 Install the lower triple clamp p 46 Info The steering head bearing is cleaned and lubricated in the course of removal and installation 11 14 Removing the start number plate S04535 10 Remove screw 1 Disconnect the brake line at the start number plate Take off the start number plate 11 15 In...

Page 52: ...emaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the start number plate p 49 11 18 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 42 S04538 10 Main work Remove the cable ties Remove screws 1along with the washers Take off the left frame protector Push the right frame protector to the front and take off at the bot tom S04569 10 Remove screw 2...

Page 53: ...nd pull foot brake cylinder off the push rod M01149 01 Remove the connecting link of the chain Take off the chain Info Cover the components to protect them against damage S04571 10 Remove nut 7and pull out the swingarm pivot Push the link fork back and secure it against falling over S04541 10 Hold the shock absorber and remove screw 8 ...

Page 54: ...1 11 Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 V01527 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 M01149 01 Mount the chain Connect the chain with the connecting link Guideline The closed side of the chain joint lock must fac...

Page 55: ...4x1 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 wheel slightly to be able to mount the screw more easily S04538 11 Position the left frame protector Insert the right frame protector from below and push it to the rear Mount and tighten screws 7with the washers Guideline Screw ...

Page 56: ...eat on the collar bushing of the fuel tank lower the seat at the rear and push the seat forward Make sure that the seat is locked in correctly S04544 10 Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 22 Removing the air filter box cover Condition The air filter box cover is secured Remove the seat p 53 S04545 10 Remove screw 1 ...

Page 57: ...d take off toward the front 11 23 Installing the air filter box cover S04546 11 Condition The air filter box cover is secured Insert the air filter box cover in area Aand clip it into area B S04546 12 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 54 S04547 11 Condition The air filter box cover is not secured Insert the air filter b...

Page 58: ...ff 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 wor...

Page 59: ...n 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 the engine and result in damage Finishing work Install the air filter box cover p 55 11 27 Preparing air filter box cover for securing Preparatory work Remove the air filter box cover p 54 S02308 10 ...

Page 60: ...sition 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 in the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Info Over time the fibers of...

Page 61: ... 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 docto...

Page 62: ...led 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 Immediat...

Page 63: ...ged S04553 11 Attach the fuel tank breather hose Mount and tighten screw 1with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S04552 11 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Connect the fuel hose Finishing work Mount the seat p 54 11 33 Checking the chain for dirt 400678 01 Check the chain for heavy soiling If the chain is very...

Page 64: ...e motorcycle with a lift stand p 42 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 122 After drying apply chain spray Off road chain spray p 122 Finishing work Remove the motorcycle from the lift stand p 42 11 35 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and resul...

Page 65: ...ar more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 42 Check the chain tension p 62 H00016 1...

Page 66: ...et is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 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 diff...

Page 67: ... Nm 4 4 lbf ft Loctite 243 K01199 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 402421 10 Check the ch...

Page 68: ...me 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 Guideline Repairs on the link fork are not permitted 11 40 Checking throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly The throttle slide...

Page 69: ...work Install the fuel tank p 60 Mount the seat p 54 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 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 ...

Page 70: ...onsult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Info The fluid level rises with increasing wear of the clutch facing discs Neve...

Page 71: ...d spills on to your clothing change the clothing Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and clutch lines are not designed for DOT 5 brake fluid Avoid co...

Page 72: ...xtract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water ...

Page 73: ...y 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 force Do not make any adjustments while riding 12 3 Checki...

Page 74: ...ents 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 74 S04558 10 Main work Move the brake reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in le...

Page 75: ...ASGAS Motorcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid cont...

Page 76: ...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 77: ...liance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container K00469 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal position ...

Page 78: ...n up any brake fluid that has overflowed or spilled 12 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 10 Disconnect spring 1 ...

Page 79: ... 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 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 80: ...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 81: ...ck the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 79 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 flu...

Page 82: ...rake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container S04560 10 Position the vehicle upright Remove screw cap 1with membrane 2and the O ring 101740 10 Manually press the brake caliper toward the brake disc to push back the brake piston Ensure that brake fluid does not flow out of the brake fluid reservoir extract some if necessary Info Make sure ...

Page 83: ...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 K01185 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 120 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 84: ...ck the brake pistons K00454 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 H01340 10 Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of th...

Page 85: ...t the spacers Clean and grease the wheel spindle Long life grease p 122 K00454 11 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned 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 86: ... 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 87: ...d Mount the chain H00007 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 62 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 88: ...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 five years o...

Page 89: ...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 90: ...oling effect 14 2 Radiator cover Info Do not use radiator covers in difficult operating conditions K00459 01 The radiator cover is mounted in front of the left radiator between the radiator shield and radiator The radiator cover keeps the coolant temperature in the correct range Coolant temperature 65 70 C 149 158 F M01121 10 The radiator cover is installed in front of the left radiator depending ...

Page 91: ...Position radiator shield 3 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 14 5 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other coolin...

Page 92: ...he specified value Correct the coolant level Coolant p 120 Mount the radiator cap 14 6 Checking the coolant level Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine...

Page 93: ...her components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with ple...

Page 94: ...clothing S04563 10 Make sure that screw 1is tightened Position the motorcycle upright Completely fill the radiator with coolant Coolant p 120 S04564 10 Loosen screw 2until coolant escapes without bubbles Mount and tighten screw 2 Guideline Bleeder screw cylinder head M6 8 Nm 5 9 lbf ft Completely fill the radiator with coolant Coolant p 120 K01179 10 Mount radiator cap 3 Danger Danger of poisoning...

Page 95: ... 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 S04562 11 Remove screw 1 Take off radiator cap...

Page 96: ...hem may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or run ning the engine in an enclosed space Allow the engine to warm up and cool down again Check the cooling system for leaks Check the coolant level p 90 ...

Page 97: ... 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 and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust throttle cable play p 95 15 2 Adjusting throttle cable play Info If the correct routing of the throttle cable has already been secured th...

Page 98: ...has the greatest influence with the throttle slide open full throttle If the insulator of a new spark plug is very light or white after a brief ride at full throttle or if the engine knocks a larger main jet needs to be used If the insulator is dark brown or sooty a smaller main jet needs to be used Needle position POS The needle position has the greatest influence in the mid throttle slide range ...

Page 99: ... When the throttle slide is 1 8 open the first cylindrical part of the needle the idling jet and the clip position have the great est influence K00496 01 When the throttle slide is 1 4 open the idling jet and the clip position have the greatest influence The influence of the first cylindrical part of the needle is less When the throttle slide is 1 2 open the position of the needle has the greatest...

Page 100: ...ective model B00075 10 Clip position 1 5 Clip position from above The five possible clip positions are shown here The carburetor tuning depends on the defined ambient and operating conditions 15 4 Carburetor idle setting 402799 10 The idle setting of the carburetor significantly influences the vehicle s starting behavior the stability of the idle speed and the vehicle s response when accelerating ...

Page 101: ... is pushed in to the stop p 16 Idle speed 1 400 1 500 rpm Turn idle air adjusting screw 1slowly in a clockwise direction until the idle speed begins to fall Note the position and turn the idle air adjusting screw slowly coun terclockwise until the idle speed again begins to fall Adjust to the point between these two positions with the highest idle speed Info If there is a big engine speed rise red...

Page 102: ...y Switching the ignition timing map from Soft to Performance Join plug in connector 1of the ignition timing map adjustment Figure S04566 10 p 100 Performance better performance 15 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 ...

Page 103: ... 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 104: ...fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allo...

Page 105: ...r oil level monitoring M6 8 Nm 5 9 lbf ft 16 3 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fue...

Page 106: ... O ring and fill up with gear oil Gear oil 0 80 l 0 85 qt Engine oil 15W 50 p 120 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 effective exhaust extraction when starting or run ning the engine in an e...

Page 107: ...en the gear oil level monitoring screw Guideline Screw gear oil level monitoring M6 8 Nm 5 9 lbf ft Mount and tighten filler plug 2with the O ring Finishing work 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 ni...

Page 108: ...nshine 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 122 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehic...

Page 109: ...e exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 122 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 122 ...

Page 110: ...ss 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 122 Refuel p 28 Clean the motorcycle p 106 Change the gear oil p 103 Check the antifreeze and coolant level p 89 Empty the carburetor float chamber p 102 Check tire pressur...

Page 111: ...STORAGE 18 109 18 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 42 Perform checks and maintenance measures when preparing for use p 25 Take a test ride ...

Page 112: ...e idle speed p 99 Spark plug defective Change the spark plug Ignition system defective Check the ignition coil Check the spark plug connector Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor components Loose carburetor jets Check set the carburetor components Fault in ignition system Check the ignition system Engine has too little power F...

Page 113: ...coolant p 91 Refill with coolant p 92 Damaged cylinder head or cylin der head gasket Check the cylinder head and cylinder head gasket Bent radiator hose Change the radiator hose White smoke emission steam in exhaust gas Damaged cylinder head or cylin der head gasket Check the cylinder head and cylinder head gasket Gear oil exits at the vent hose Too much gear oil added Check the gear oil level p 1...

Page 114: ...urth gear 19 27 fifth gear 19 23 sixth gear 22 24 Ignition Contactless controlled fully electronic ignition with digital ignition adjustment Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter system 20 2 Engine 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 ...

Page 115: ... Nm 7 4 lbf ft Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6x20 8 Nm 5 9 lbf ft Screw outer clutch cover M6x50 8 Nm 5 9 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw stop plate of exhaust control M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Vacuum co...

Page 116: ... 480 1 5 30 42 71 2 480 1 501 2 300 m 4 925 7 546 ft ASO IJ NDL POS MJ 2 37 5 43 71 2 520 1 5 35 43 71 2 500 2 32 5 43 71 2 500 2 30 43 71 2 490 2 30 43 71 2 480 1 5 30 42 71 2 480 751 1 500 m 2 464 4 921 ft ASO IJ NDL POS MJ 1 5 35 42 71 3 520 2 37 5 43 71 2 520 1 5 35 43 71 2 500 2 32 5 43 71 2 500 2 30 43 71 2 490 2 30 43 71 2 480 301 750 m 988 2 461 ft ASO IJ NDL POS MJ 1 5 37 5 42 71 3 540 1 ...

Page 117: ... 2 l 1 3 qt Coolant p 120 20 4 3 Fuel Total fuel tank capacity approx 7 5 l 1 98 US gal Super unleaded 98 octane mixed with 2 stroke engine oil 1 40 p 121 20 5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XACT AER Shock absorber WP XACT 5750 Suspension travel front 310 mm 12 2 in rear 300 mm 11 81 in Fork offset 22 mm 0 87 in Brake system Disc brakes floating bra...

Page 118: ...esent one of the possible series production tires Additional information is available in the Service section under http www gasgas com 20 7 Fork Fork article number A540C101U406000 Fork WP XACT AER Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 8 3 bar 120 psi Fork length 950 mm 37 4 in Oil ca...

Page 119: ...75 85 kg 165 187 lb 260 mm 10 24 in Weight of rider 85 95 kg 187 209 lb 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 fluid p 121 SAE 2 5 20 9 Chassis tightening torques Screw switch off button M3 0 4 Nm 0 3 lbf ft Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ...

Page 120: ...er M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw manifold M8 15 Nm 11 1 lbf ft Screw subframe bottom M8x18 30 Nm 22 1 lbf ft Loctite 2701 Screw subframe top M8x20 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Screw top triple clamp M8 20 Nm 14 8 lbf ft Engine bracket screw M10 60 Nm 44 3 lbf ft Remaining nuts chassis M10...

Page 121: ...TECHNICAL DATA 20 119 Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft ...

Page 122: ...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 123: ... p 124 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 98 RON 98 PON 94 Standard classification DIN EN 228 ROZ 98 RON 98 PON 94 Super unleaded 98 octane mixed with 2 stroke engine oil 1 40 Standard classification DIN EN 228 JASO FD p 124 1 40 Mixture ratio 1 40 Engine oil ...

Page 124: ...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 Special cleaner for glossy and matte paint fini...

Page 125: ...AUXILIARY SUBSTANCES 22 123 Special grease 00062010053 Recommended supplier Klüber Lubrication KLÜBERFOOD NH1 34 401 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 126: ...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 127: ...LIST OF ABBREVIATIONS 24 125 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 128: ...or tuning 96 Chain checking 64 cleaning 62 Chain guide checking 64 Chain tension adjusting 63 checking 62 Choke 16 Clutch fluid level checking correcting 68 fluid changing 69 Clutch lever 14 basic position adjusting 68 Compression damping fork adjusting 39 Coolant changing 93 draining 91 refilling 92 Coolant level checking 89 90 Cooling system 88 Customer service 9 D Defined use 6 Difficult operat...

Page 129: ...encer glass fiber yarn filling changing 58 installing 58 removing 58 Manufacturer warranty 9 Misuse 6 Motorcycle cleaning 106 from lift stand removing 42 raising with lift stand 42 O Owner s Manual 8 P Play in throttle cable checking 95 Plug in stand 17 Preparing for use advice on preparing for first use 18 after storage 109 checks and maintenance measures when preparing for use 25 Protective clot...

Page 130: ...echnical data capacities 115 carburetor 114 chassis 115 chassis tightening torques 117 engine 112 engine tightening torques 112 fork 116 shock absorber 117 tires 116 Throttle cable play adjusting 95 Throttle cable routing checking 66 Throttle grip 14 Tire condition checking 86 Tire pressure checking 86 Transporting 28 Troubleshooting 110 111 Type label 12 V Vehicle identification number 12 View of...

Page 131: ... 3215008en 3215008en 10 2020 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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