GAS GAS MC 450F 2021 Owner'S Manual Download Page 126

Page: 126 / 142

22 TECHNICAL DATA

124

22.7

Fork

22.7.1

Fork article number

A540C109U406000

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

10.7 bar (155 psi)

Fork length

950 mm (37.4 in)

Oil capacity external mechanism right

230

+ 10

−

ml (7.78

+ 0.34

−

1.69

fl. oz.)

Fork oil (SAE 4) (48601166S1)
(

p. 129)

Oil capacity external mechanism left

230

+ 10

−

ml (7.78

+ 0.34

−

1.69

fl. oz.)

Fork oil (SAE 4) (48601166S1)
(

p. 129)

Oil capacity, right cartridge

380 ml (12.85 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

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 mechanism right

230

+ 10

−

ml (7.78

+ 0.34

−

1.69

fl. oz.)

Fork oil (SAE 4) (48601166S1)
(

p. 129)

Oil capacity external mechanism left

230

+ 10

−

ml (7.78

+ 0.34

−

1.69

fl. oz.)

Fork oil (SAE 4) (48601166S1)
(

p. 129)

Oil capacity, right cartridge

380 ml (12.85 fl. oz.)

Fork oil (SAE 4) (48601166S1)
(

p. 129)

Grease capacity, left cartridge

5 g (0.18 oz)

Special grease (00062010053)
(

p. 132)

Summary of Contents for MC 450F 2021

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

Page 2: ......

Page 3: ...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 Motorcycle...

Page 4: ...fficult 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...

Page 5: ...1 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...

Page 6: ...OUBLESHOOTING 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 1...

Page 7: ...ecially 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 re...

Page 8: ...y 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 re...

Page 9: ...sically or mentally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running...

Page 10: ...perating 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 us...

Page 11: ...ttp www gasgas com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the service care and tuning work on the engine and chassis is properly carried out as descr...

Page 12: ...HICLE 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 Shif...

Page 13: ...er 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...

Page 14: ...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 t...

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: ...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 han...

Page 17: ...cinity 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 immediatel...

Page 18: ...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...

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...

Page 20: ...eed 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 co...

Page 21: ...ndle 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...

Page 22: ...ng 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 th...

Page 23: ...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 dis...

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...

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...

Page 26: ...ehicle 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 excessivel...

Page 27: ...e 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 dus...

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 an...

Page 29: ...nated 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 f...

Page 30: ...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...

Page 31: ...ase 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 an...

Page 32: ...e 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 t...

Page 33: ...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 brak...

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 im...

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 incorr...

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 tur...

Page 38: ...lock 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 Po...

Page 39: ...eload 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 wearin...

Page 40: ...ughly 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...

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 r...

Page 42: ...00775 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 airp...

Page 43: ...n 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 Co...

Page 44: ...ebound 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 Handl...

Page 45: ...it to one side Info Cover the components to protect them against damage Do not kink the cables and lines Remove screws 2 Take off handlebar supports Place handlebar supports in required position Moun...

Page 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...

Page 47: ...ove 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 wor...

Page 48: ...e 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 Posit...

Page 49: ...egs 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...

Page 50: ...se 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 w...

Page 51: ...e 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 for...

Page 52: ...e 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...

Page 53: ...ering 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...

Page 54: ...p 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...

Page 55: ...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...

Page 56: ...ea 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 t...

Page 57: ...e 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 c...

Page 58: ...ghtly 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...

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...

Page 60: ...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...

Page 61: ...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 clean...

Page 62: ...ning 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 ente...

Page 63: ...ncer 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 fi...

Page 64: ...le The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that...

Page 65: ...nt 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...

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 specificati...

Page 67: ...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 Und...

Page 68: ...hecking 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 Lubrican...

Page 69: ...ear 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 b...

Page 70: ...rcycle 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 5...

Page 71: ...ther 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 sect...

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 tha...

Page 73: ...mage 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...

Page 74: ...ll 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 sl...

Page 75: ...id 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 con...

Page 76: ...o 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...

Page 77: ...asionally 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...

Page 78: ...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 th...

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 a...

Page 80: ...nged 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...

Page 81: ...s 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 Sk...

Page 82: ...id 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 scr...

Page 83: ...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...

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 lb...

Page 85: ...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 c...

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 servicin...

Page 87: ...n 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 containe...

Page 88: ...nted 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 leve...

Page 89: ...back the brake pistons A00839 10 Loosen screw 1by several rotations Loosen screws 2 Press on screw 1to push the wheel spindle out of the axle clamp Remove screw 1 A00840 10 Warning Danger of accident...

Page 90: ...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 scre...

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...

Page 92: ...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 Tight...

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 manufa...

Page 94: ...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 95: ...able 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 batter...

Page 96: ...t 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...

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 ove...

Page 98: ...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...

Page 99: ...ponents 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...

Page 100: ...ter 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...

Page 101: ...nd 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 ou...

Page 102: ...ct 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 th...

Page 103: ...nal 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 sufficie...

Page 104: ...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 105: ...ehicle 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...

Page 106: ...ises 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 indicato...

Page 107: ...e 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 sc...

Page 108: ...d 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 hazar...

Page 109: ...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 light...

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...

Page 111: ...een 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...

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 oi...

Page 113: ...eve 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 t...

Page 114: ...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 115: ...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...

Page 116: ...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 re...

Page 117: ...nly 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 I...

Page 118: ...ostics 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 ver...

Page 119: ...e 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 1...

Page 120: ...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 Bl...

Page 121: ...rcuit 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 c...

Page 122: ...cation 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 fu...

Page 123: ...um 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 timin...

Page 124: ...cities 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...

Page 125: ...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...

Page 126: ...5 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 C...

Page 127: ...ght 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 1...

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...

Page 129: ...procket 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...

Page 130: ...1 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 re...

Page 131: ...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 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...

Page 133: ...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 134: ...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 135: ...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 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: ...n 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...

Page 139: ...0 122 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 cor...

Page 140: ...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...

Page 141: ...king 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 beari...

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

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