GAS GAS MC 250F FACTORY EDITION 2023 Owner'S Manual Download Page 60

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11 SERVICE WORK ON THE CHASSIS

11.22

Removing the shock absorber

Preparatory work

–

Raise the motorcycle with a lift stand. (

p. 47)

–

Remove the frame protector. (

p. 50)

–

Remove the right side panel. (

p. 62)

–

Remove main silencer. (

p. 66)

W00186-10

Main work

–

Remove screw

–

Remove fitting

Info

Raise the swingarm slightly to be able to remove the screws

more easily.

W00187-10

–

Remove screws

–

Pull off foot brake cylinder from the push rod.

F03702-01

–

Remove the connecting link of the chain.

–

Take off the chain.

Info

Cover the components to protect them against damage.

W00188-10

–

Remove nut

and the swingarm pivot.

–

Push the link fork back and secure it against falling over.

Summary of Contents for MC 250F FACTORY EDITION 2023

Page 1: ...OWNER S MANUAL 2023 MC 250F FACTORY EDITION Art no 3215098en...

Page 2: ......

Page 3: ...vices 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 Motor...

Page 4: ...s at low temperatures 21 7 4 Preparing the vehicle for difficult 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 Prepa...

Page 5: ...9 Checking for chain dirt accumulation 71 11 40 Cleaning the chain 71 11 41 Checking the chain tension 72 11 42 Adjusting the chain tension 73 11 43 Checking the chain rear sprocket engine sprocket an...

Page 6: ...and oil filter cleaning the oil screen 115 17 4 Adding engine oil 118 18 CLEANING CARE 119 18 1 Cleaning the motorcycle 119 19 STORAGE 121 19 1 Storage 121 19 2 Putting into operation after storage 1...

Page 7: ...the highest degree by specially trained experts using the special tools required Indicates a page reference more information is provided on the specified page Indicates information with more details o...

Page 8: ...y 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...

Page 9: ...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 t...

Page 10: ...ally aware and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and guidelines of the country in which you are disp...

Page 11: ...p 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 describ...

Page 12: ...HICLE 10 4 1 View of vehicle front left example W00230 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 Shif...

Page 13: ...uster 2 Combination switch p 15 3 Stop button p 14 3 Start button p 15 4 Throttle grip p 14 5 Vehicle identification number p 12 5 Steering head label p 12 6 Fork article number p 12 7 Idle speed adju...

Page 14: ...e steering head 5 2 Steering head label 401946 10 The steering head label 1is attached to the front of the steering head 5 3 Engine number H01047 10 Engine number 1is located on the left side of the e...

Page 15: ...SERIAL NUMBERS 5 13 5 5 Shock absorber article number F03756 10 The shock absorber article number 1is stamped on the top of the shock absorber...

Page 16: ...using the hand brake lever 6 3 Throttle grip F03648 11 The throttle grip 1is fitted on the right side of the handlebar 6 4 Stop button F03650 11 The stop button 1is located on the right side of the ha...

Page 17: ...p light up The engine characteristic can be changed using button 1and but ton 2on the combination switch Traction control can be activated using the TC button 3on the combi nation switch Launch contro...

Page 18: ...nity 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...

Page 19: ...e ambient temperature is low To help the engine 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 t...

Page 20: ...art than an engine with the idle speed set incorrectly The idle speed is adjusted using the idle speed adjusting screw 1 Increase the idle speed by turning the idle speed adjusting screw clock wise De...

Page 21: ...e attached to the plug in stand holders 6 16 Factory Start H04998 10 The Factory Start 1is mounted on the right fork protector Possible states AFactory Start is deactivated The fork is in the normal o...

Page 22: ...ding 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...

Page 23: ...ing in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine pe...

Page 24: ...heck the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector or change it if necessary Difficult oper...

Page 25: ...ting instructions for GASGAS Techni cal Accessories 600868 01 Clean the chain Chain cleaner p 137 Mount the steel sprocket Grease the chain Universal oil spray p 138 Clean the radiator fins Straighten...

Page 26: ...operated frequently due to an excessively high secondary ratio Clean the chain Chain cleaner p 137 Clean the radiator fins Straighten bent radiator fins carefully Check the coolant level p 105 7 9 Pr...

Page 27: ...guide p 74 Check the chain tension p 72 Check the tire condition p 96 Check tire pressure p 96 Check the spoke tension p 97 Info The spoke tension must be checked regularly as incorrect spoke tension...

Page 28: ...hrottle valve fully opened full throttle is reduced After the start it is gradually increased up to the maximum engine speed The clutch must be operated exactly as it would be without launch control a...

Page 29: ...ry Start Warning Danger of accidents The Factory Start actuator may freeze up in cold weather If the actuator freezes while Factory Start is activated the fork will not decompress fully The greatly re...

Page 30: ...or lamp lights up when the quickshifter is acti vated Info The quickshifter is not activated when shifting up from first to second gear and the clutch lever must be used when shifting up instead Even...

Page 31: ...vated when shifting up from first to second gear and the clutch lever must be used when shifting up instead The minimum engine speed before shifting up is shown in the figure in revolutions per minute...

Page 32: ...ect 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 vehi...

Page 33: ...ot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is harmful to health Avoid skin eye and clothing contac...

Page 34: ...witch off the engine Open the fuel tank filler cap p 16 401522 10 Fill the fuel tank with fuel up to level A Guideline Dimension A 35 mm 1 38 in Super unleaded ROZ 95 p 136 7 9 l 2 09 US gal Close the...

Page 35: ...charge the 12 V battery Check that the brake linings of the front brake are secured p 84 Check that the brake linings of the rear brake are secured p 89 Check the brake discs p 81 Check the brake lin...

Page 36: ...Lubricate the steering head bearing p 56 Perform minor engine service including removing and installing the engine Change the piston check measure the cylinder Check the cylinder head Check the camsha...

Page 37: ...e 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 improve...

Page 38: ...round 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...

Page 39: ...hock 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 he...

Page 40: ...the shock absorber 402416 10 Measure dimension Aof rear wheel unloaded p 37 Hold the motorcycle upright with aid of an assistant Measure the distance again between the rear axle and marking SAG on th...

Page 41: ...sag Riding sag 105 mm 4 13 in If the riding sag differs from the specified measurement Adjust the riding sag p 40 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts...

Page 42: ...be necessary to increase or decrease the spring preload Tighten bolt 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 59 Check the free t...

Page 43: ...rious reasons no exact riding sag can be determined for the fork 401000 01 Smaller differences in the rider s weight can be compensated for by the fork air pressure However if the fork frequently bott...

Page 44: ...the fork leg when connecting Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork Read the accompanying GASGAS Technical Accessories instructions Adjust t...

Page 45: ...7 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping during compression 10 15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determin...

Page 46: ...ble position for the rider Info In addition the handlebar can be mounted rigidly or on a rubber bearing 10 17 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a...

Page 47: ...shings 4and 5 Place the handlebar support in the required position Info The handlebar support is longer and higher on one side Mount and tighten the screws 7with bushing 6 Guideline Screw handle bar s...

Page 48: ...5 lbf ft Loctite 243 Rigid handlebar support bushing A46001038010 The conical side of bushing faces downwards Position the handlebar Info Make sure the cables and wiring are positioned cor rectly Pos...

Page 49: ...ound 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...

Page 50: ...s remove dust and coarse dirt particles from the inside fork tubes Over time dirt can accumulate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger...

Page 51: ...or W00204 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 scre...

Page 52: ...the screws of the engine guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 9 Removing the frame protector W00203 10 Remove the cable ties Remove screws 1with the bushings Take off the l...

Page 53: ...rews 4 Remove the right fork leg 11 12 Installing the fork legs F03665 11 Main work Position the fork legs Air bleeder screw 1of the right fork leg is positioned to the front Valve Aof the left fork l...

Page 54: ...rk Raise the motorcycle with a lift stand p 47 Remove the front wheel p 92 Remove the fork legs p 51 Remove the start number plate p 56 Remove front fender p 57 Take off the handlebar cushion W00182 1...

Page 55: ...tighten it yet Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft F03764 10 Position the fork legs Air bleeder screw 3of the right fork leg is positioned to the front Valve Aof the left fork l...

Page 56: ...harness with cable holder on the left Mount and tighten screw 7 W00220 12 Position the brake caliper Mount and tighten screws 8 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Po...

Page 57: ...ad bearing If there is detectable play Adjust the steering head bearing play p 55 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily over the...

Page 58: ...p p 52 Install the lower triple clamp p 53 Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp 11 18 Removing the start number...

Page 59: ...number plate p 56 F03675 10 Main work Remove screws 1and 2 Take off the front fender 11 21 Installing front fender F03675 10 Main work Position front fender Mount and tighten screws 1and 2 Guideline...

Page 60: ...10 Main work Remove screw 1 Remove fitting 2 Info Raise the swingarm slightly to be able to remove the screws more easily W00187 10 Remove screws 3 Pull off foot brake cylinder from the push rod F037...

Page 61: ...e 2701 F03705 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 F03702 12 Mount the c...

Page 62: ...fork slightly to be able to mount the screw more easily Finishing work Check the free travel of the foot brake lever p 86 Install the main silencer p 67 Install the right side panel p 62 Install the...

Page 63: ...00200 10 Main work Attach the seat to the collar bushings and simultaneously slide it back The holding lugs engage in the recesses Make sure the seat is latched in place correctly W00197 10 Mount and...

Page 64: ...off 11 27 Installing the right side panel I00299 10 Main work Position right side panel 1 Position side panel in area Band slide it forward Press the side panel in area Ainto the rubber bushings Guid...

Page 65: ...filter box cover in area Aand slide it in area B to the rear Take off the air filter box cover 11 29 Installing the air filter box cover W00210 10 Condition The air filter box cover is secured Positio...

Page 66: ...ne Diameter 6 mm 0 24 in Finishing work Install the air filter box cover p 63 11 31 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the en...

Page 67: ...Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 62 Remove the air filter p 64 F03685 01 Main work Wash the...

Page 68: ...ed Info The marking on the air filter must face upwards 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...

Page 69: ...4 lbf ft Finishing work Install the right side panel p 62 Install the frame protector p 50 11 36 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system g...

Page 70: ...arm 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...

Page 71: ...he fuel line clogs the injection valve H04982 10 Disconnect the quick release coupling Info Remaining fuel may flow out of the fuel hose Mount wash cap set 3 Wash cap set 81212016100 Pull the fuel tan...

Page 72: ...a doctor if you swallow fuel Do not inhale fuel vapors Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse the eyes thoroughly with water and consult...

Page 73: ...ame protector p 50 Mount the seat p 61 Install the air filter box cover p 63 11 39 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirt...

Page 74: ...nsmission and rear wheel bear ings 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 r...

Page 75: ...rcycle with a lift stand p 47 Check the chain tension p 72 F03681 10 Main work Loosen nut 1 Loosen nuts 2 Adjust the chain tension by turning adjusting screws 3left and right Guideline Chain tension 5...

Page 76: ...er 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear measure ment 10 15 kg 22 33 lb Measure distance Bof 18 chain rollers in the lower chain sectio...

Page 77: ...k fork M6 6 Nm 4 4 lbf ft F03714 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 tha...

Page 78: ...t permitted 11 45 Checking the link fork F03646 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 Rep...

Page 79: ...62 Install the frame protector p 50 Mount the seat p 61 Install the air filter box cover p 63 11 47 Checking the rubber grips 401197 01 Check the rubber grips on the handlebar for damage wear and loos...

Page 80: ...o Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar Turn the adjusting screw clockwise to increase the distance between the clutch lever and...

Page 81: ...n 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 th...

Page 82: ...l ing is possible Info Use water to immediately clean up any brake fluid that has overflowed or spilled Avoid contact between the brake fluid and painted parts Brake fluid corrodes paint Only use clea...

Page 83: ...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 adjustin...

Page 84: ...anger 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 Motorcyc...

Page 85: ...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...

Page 86: ...d 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...

Page 87: ...bar to a hori zontal position Remove screws 1 Take off cover 2with membrane 3 F03695 10 Remove screws 4 Press back the brake linings by slightly tilting the brake caliper later ally on the brake disc...

Page 88: ...rake linings are in contact with the brake disc and there is a pressure point F03693 10 Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid DO...

Page 89: ...builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification F03715 10 Detach spring 1 Loosen nut 4and with push rod 5 turn it back...

Page 90: ...er of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or t...

Page 91: ...ing A Brake fluid DOT 4 DOT 5 1 p 135 Mount and tighten the screw cap with the membrane and O ring Info Use water to immediately clean up any brake fluid that has overflowed or spilled Finishing work...

Page 92: ...anger 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 Motorcyc...

Page 93: ...rake caliper bracket are seated correctly Info The arrow on the spring plate points in the direction of rota tion of the brake disc W00194 10 Insert the new brake linings insert pin 4 and mount cotter...

Page 94: ...brake pistons W00222 11 Loosen screw 1by several rotations Loosen screws 2 Press on screw 1to push the wheel spindle out of the axle clamp Remove screw 1 W00223 10 Warning Danger of accidents Damaged...

Page 95: ...brake disc guard Clean and lightly grease the wheel spindle Long life grease p 137 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned F03724 01 Position...

Page 96: ...Pull out wheel spindle 3far enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to prot...

Page 97: ...Long life grease p 137 Position rear wheel and insert wheel spindle 2 The brake linings are correctly positioned Mount the chain H04990 10 Position chain adjuster 3 Mount nut 4 but do not tighten it...

Page 98: ...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 manufa...

Page 99: ...gularly 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 sou...

Page 100: ...12 V batteries at a collection point for used batteries Preparatory work Remove the air filter box cover p 62 Remove the seat p 60 W00225 10 Main work Disconnect negative cable 1from the 12 V battery...

Page 101: ...attachment Mount and tighten screw 2 Guideline Screw battery support bracket M6 6 Nm 4 4 lbf ft Attach relay 3in the holder W00227 10 Connect positive cable 4to the 12 V battery Guideline Screw batte...

Page 102: ...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 b...

Page 103: ...the 12 V battery Finishing work Install the 12 V battery p 99 Mount the seat p 61 Install the air filter box cover p 63 14 4 Changing the main fuse Warning Fire hazard Incorrect fuses overload the ele...

Page 104: ...arter relay onto the holder and route the cable Finishing work Install the fuel tank p 70 Install the right side panel p 62 Install the frame protector p 50 Mount the seat p 61 Install the air filter...

Page 105: ...ump Fuse 58011109105 p 131 Check that the electrical system is functioning properly Attach protection cap 1 Finishing work Mount the seat p 61 Install the air filter box cover p 63 14 6 Diagnostics co...

Page 106: ...r components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is harmful to health Keep coolant out of the rea...

Page 107: ...in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The...

Page 108: ...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 harmful to health Keep coolant out of th...

Page 109: ...r 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 i...

Page 110: ...p 108 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 effectiv...

Page 111: ...re 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 Ch...

Page 112: ...slowly The black guide plate opens the throttle valve more quickly The black guide plate is already mounted when the vehicle is delivered F03744 10 Clean the outside of the handlebar and the inside of...

Page 113: ...000 rpm The indicator lamp Alights up STANDARD balanced response Info Traction control can be activated additionally using the TC button 3 F03763 10 Activating ADVANCED mapping Press button 2 Guidelin...

Page 114: ...e raises the idle speed 16 6 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 indi...

Page 115: ...een shift lever and upper edge 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 113 16 8 Adjusting the basic position of the sh...

Page 116: ...if fuel spills on them Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F03737 10 Clean quic...

Page 117: ...e middle of the level viewer Aand the upper edge of the level viewer B If the engine oil does not reach the middle of level viewer A Add engine oil p 118 17 3 Changing the engine oil and oil filter cl...

Page 118: ...04993 10 Position 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 w...

Page 119: ...ter 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 135 Info Too little...

Page 120: ...ve 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 th...

Page 121: ...cycle 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 cle...

Page 122: ...exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 137 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner...

Page 123: ...ing 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 137 Refuel p 31 Clean the motorcycle p...

Page 124: ...19 2 Putting into operation after storage 401059 01 Install the 12 V battery p 99 Remove the motorcycle from the lift stand p 47 Perform checks and maintenance measures when preparing for use p 25 Ta...

Page 125: ...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 65...

Page 126: ...thin low viscosity Change the engine oil and oil filter clean the oil screen p 115 Piston or cylinder worn Measure the piston cylinder mounting clearance 12 V battery discharged 12 V battery is not c...

Page 127: ...nal too low Blink code for malfunction indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor input signal too high Coolant temperature...

Page 128: ...uit 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 con...

Page 129: ...ngine lubrication Pressure circulation lubrication with 2 trochoidal pumps Primary transmission 24 72 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear transmission claw shift...

Page 130: ...4 4 lbf ft Loctite 243 Screw stator M5 6 Nm 4 4 lbf ft Loctite 2701 Nut cylinder head M6 10 Nm 7 4 lbf ft Nut water pump impeller M6 6 Nm 4 4 lbf ft Loctite 243 also in gap between shaft and water pum...

Page 131: ...M10x1 12 Nm 8 9 lbf ft Coolant temperature sensor M10x1 25 12 Nm 8 9 lbf ft Nut cylinder head M10x1 25 Tightening sequence Tighten diagonally 1st tightening stage 10 Nm 7 4 lbf ft 2nd tightening stage...

Page 132: ...isc brakes floating brake calipers Brake discs diameter front 260 mm 10 24 in rear 220 mm 8 66 in Brake discs wear limit front 2 5 mm 0 098 in rear 3 5 mm 0 138 in Offroad tire pressure front 1 0 bar...

Page 133: ...and the respective technical specifications must be observed Additional information is available in the Service section under http www gasgas com 22 7 Fork Fork article number A460C195W406000 Fork WP...

Page 134: ...E 2 5 50180751S1 p 136 22 9 Chassis tightening torques Remaining screws chassis EJOT PT K60x25 Z 2 Nm 1 5 lbf ft Screw air filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft Screw air filter box on sub...

Page 135: ...ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw fuel tank spoiler on radiator M6 6 Nm 4 4 lbf ft Screw ground wire on frame M6 10 Nm 7 4 lbf ft Screw hand lever M6 5 Nm 3 7 lbf ft Sc...

Page 136: ...handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Nut angle lever to link fork M16x1 5 60 Nm 44 3 lbf ft Nut fork pivot M16x1 5 100 Nm 73...

Page 137: ...s 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...

Page 138: ...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...

Page 139: ...ended supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Ch...

Page 140: ...and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Kl ber Lubrication Kl berfood NH1 34 401 Universal oil s...

Page 141: ...ce 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 wi...

Page 142: ...a standing position OBD On board diagnosis Vehicle system which monitors the specified parameters of the vehicle electronics Quickshifter Function of the engine electronics for shifting up without cl...

Page 143: ...LIST OF ABBREVIATIONS 27 141 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 144: ...ction control is activated and the speed limiter intervenes TC indicator lamp lights up orange TC is enabled or is currently intervening The TC indicator lamp flashes if launch control is activated 28...

Page 145: ...the rear brake changing 90 C Capacity coolant 106 107 130 engine oil 117 130 Chain checking 74 cleaning 71 Chain guide checking 74 Chain tension adjusting 73 checking 72 Characteristic map of the thro...

Page 146: ...ake lever 14 basic position adjusting 81 free travel checking 81 Handlebar position 44 adjusting 44 High speed compression damping shock absorber adjusting 36 I Idle speed adjusting 111 Idle speed adj...

Page 147: ...58 riding sag checking 39 spring preload adjusting 39 static sag checking 38 Shock absorber article number 13 Spare parts 9 Spoke tension checking 97 Start button 15 Start number plate installing 56...

Page 148: ...3215098en 3215098en 29 11 2022 Stallhofnerstra e 3 5230 Mattighofen Austria http www gasgas com...

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