GAS GAS MC 450F 2022 Owner'S Manual Download

Page: 68 / 157

11 SERVICE WORK ON THE CHASSIS

A00781-10

–

Mount and tighten screw

Guideline

Screw, rear seat fixing

6 Nm (4.4 lbf ft)

11.24

Removing the air filter box cover

Condition

The air filter box cover is secured.

–

Remove the seat. (

p. 65)

A00782-10

–

Remove screw

A00782-11

–

Pull off the air filter box cover in area

sideways and take off

toward the front.

A00819-10

Condition

The air filter box cover is not secured.

–

Pull off the air filter box cover in area

sideways and take off

toward the front.

Summary of Contents for MC 450F 2022

Page 1: ...OWNER S MANUAL 2022 MC 450F EX 450F MC 450F TROY LEE DESIGNS Art no 3215055en...

Page 2: ......

Page 3: ...pment 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...

Page 4: ...1 Advice on preparing for first use 22 7 2 Running in the engine 23 7 3 Starting power of lithium ion batteries at low temperatures 24 7 4 Preparing the vehicle for difficult operating conditions 24...

Page 5: ...ng of the main silencer 71 11 33 Removing the fuel tank 72 11 34 Installing the fuel tank 74 11 35 Checking for chain dirt accumulation 76 11 36 Cleaning the chain 76 11 37 Checking the chain tension...

Page 6: ...22 17 4 Adding engine oil 125 18 CLEANING CARE 126 18 1 Cleaning the motorcycle 126 19 STORAGE 128 19 1 Storage 128 19 2 Putting into operation after storage 129 20 TROUBLESHOOTING 130 21 BLINK CODE 1...

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

Page 8: ...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: ...nvironmentally aware and respect the rights of others When disposing of used oil other operating and auxiliary fluids and used components comply with the laws and regula tions of the respective countr...

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 18 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 19...

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: ...sting 6 2 Hand brake lever A00798 10 Hand brake lever 1is fitted on the right side of the handlebar The front brake is engaged using the hand brake lever 6 3 Throttle grip A00759 10 The throttle grip...

Page 17: ...n The start button is pressed In this position the starter motor is actuated 6 6 Combination switch MC 450F TROY LEE DESIGNS H02887 01 The combination switch is fitted on the left side of the handleba...

Page 18: ...ands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly...

Page 19: ...clockwise and lift it off 6 10 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 20: ...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 21: ...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 22: ...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 23: ...y Start is activated The fork is compressed and the front of the motorcycle is lowered Activating the Factory Start lowers the front of the motorcycle which then causes the front wheel to lift off the...

Page 24: ...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 25: ...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 26: ...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 result in signifi cantly increased wear of...

Page 27: ...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 28: ...hicle for high temperatures or slow riding 600868 01 Adjust the secondary drive to the road conditions Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively...

Page 29: ...n tension p 77 Check the tire condition p 102 Check tire pressure p 103 Check the spoke tension p 103 Info The spoke tension must be checked regularly as incorrect spoke tension will strongly impair r...

Page 30: ...y increase the starting power During the starting process the malfunction indicator lamp lights up 8 3 Activating launch control MC 450F TROY LEE DESIGNS Info The launch control helps the rider to gen...

Page 31: ...duces excessive slip on the rear wheel in favor of more control and propulsion particularly in wet conditions When traction control is switched off the rear wheel may spin more during high acceleratio...

Page 32: ...o 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 cold start button was pushed while starting o...

Page 33: ...of misappropriation 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...

Page 34: ...other suitable devices to secure the motor cycle against falling over or rolling away Info Only tighten the tension belts to the point that the plug in stand is firmly in contact with the fender and...

Page 35: ...egions the available fuel quality and cleanliness may not be sufficient This will result in problems with the fuel system Refuel only with clean fuel that meets the specified standards Your authorized...

Page 36: ...the front brake linings p 88 Check the brake linings of the rear brake p 95 Check the brake discs p 85 Check the brake lines for damage and leakage Check the rear brake fluid level p 93 Check the free...

Page 37: ...the easily accessible safety relevant screws and nuts Change the fuel screen p 120 Check the fuel pressure Check the idle speed Final check Check the vehicle for operating safety and take a test ride...

Page 38: ...and rocker arm shafts Check timing assembly Perform major engine service including removing and installing the engine Change valves valve springs valve spring seats and valve spring retainers Change...

Page 39: ...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 40: ...ssion damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compresse...

Page 41: ...2 Turn counterclockwise by the number of turns corresponding to the shock absorber type Guideline Highspeed compression damping MC 450F Comfort 2 turns Standard 1 5 turns Sport 1 turn Highspeed compr...

Page 42: ...s Rebound damping EX Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counterclock wise to reduce damping when the shock absorber rebounds 10 7 Mea...

Page 43: ...load of the shock absorber p 42 10 9 Checking the riding sag of the shock absorber 402417 10 Measure dimension Aof rear wheel unloaded p 40 With another person holding the motorcycle the rider wearing...

Page 44: ...sen screw 1 Turn adjusting ring 2until the spring is no longer under tension Hook wrench 90129051000 Info If the spring cannot be fully released the spring must be removed to accurately measure the sp...

Page 45: ...ght of rider 65 75 kg 143 165 lb 42 N mm 240 lb in Weight of rider 75 85 kg 165 187 lb 45 N mm 257 lb in Weight of rider 85 95 kg 187 209 lb 48 N mm 274 lb in Spring rate EX Weight of rider 65 75 kg 1...

Page 46: ...oad 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 pre...

Page 47: ...onnecting 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...

Page 48: ...e hydraulic rebound damping determines the fork suspension behavior Z01370 10 Turn adjusting screw 1clockwise all the way Info Adjusting screw 1is located at the lower end of the right fork leg Turn c...

Page 49: ...lebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent Preparatory work Remove the handlebar cushion F...

Page 50: ...cables and wiring are positioned correctly Position the handlebar clamps Mount screws 1and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the installed gaps are eve...

Page 51: ...ft stand A54029955100 Neither wheel is in contact with the ground EX Fold in the side stand and raise the motorcycle at the frame underneath the engine Lift stand A54029955100 Neither wheel is in cont...

Page 52: ...ove the motorcycle from the lift stand p 49 11 4 Cleaning the dust boots of the fork legs Preparatory work Raise the motorcycle with a lift stand p 49 Remove the fork protector p 51 H03152 10 Main wor...

Page 53: ...rews 3and take off the 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 1...

Page 54: ...lbf ft S05115 11 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 9 Removing the fork legs Preparatory work Raise the motorcycle with a lift stand p 49 Remove the f...

Page 55: ...1of the right fork leg is positioned to the front Valve Aof the left fork leg faces the front Info Grooves are milled into the side of the upper end of the fork legs The second milled groove from the...

Page 56: ...Screw brake line holder EJOT 1 7 Nm 1 25 lbf ft Finishing work Install the front wheel p 99 11 11 Removing the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 49 Remove th...

Page 57: ...tive ring 5 Remove the lower triple clamp and steering stem Remove the upper steering head bearing 11 12 Installing the lower triple clamp B01605 10 Main work Clean the bearing and sealing elements ch...

Page 58: ...d in the left fork leg The pressure and rebound damping is located in the right fork leg A00803 10 Tighten screws 6 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft A00804 10 Tighten screw 4 G...

Page 59: ...it yet H01182 11 Position the fork legs Air bleeder screw 5of the right fork leg is positioned to the front Valve Aof the left fork leg faces the front Info Grooves are milled into the side of the upp...

Page 60: ...lamp Mount and tighten screws bl Guideline Screw brake line holder EJOT 1 7 Nm 1 25 lbf ft Finishing work Install front fender p 62 Mount the handlebar cushion Install the start number plate p 61 Inst...

Page 61: ...andlebar easily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play p 59 Check the steering head bearin...

Page 62: ...Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Check the steering head bearing play p 58 Finishing work Mount the handlebar cushion Remove the motorcycle from the lift stand p 49 11 15 Lubrica...

Page 63: ...he brake line in holders Aon the start number plate Position the start number plate Mount and tighten screw 1 The holding lugs engage in the fender 11 18 Removing front fender Preparatory work Remove...

Page 64: ...nishing work Install the start number plate p 61 11 20 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 49 A00886 10 Main work Remove the cable ties Remove screws...

Page 65: ...A00887 10 Remove nut 5and the swingarm pivot Push the link fork back and secure it against falling over A00888 10 Hold the shock absorber and remove screw 6 Remove the shock absorber carefully at the...

Page 66: ...Position the foot brake cylinder Push rod 4engages in the foot brake cylinder Info Ensure that the dust boot is correctly seated Mount and tighten screws 5 Guideline Remaining screws chassis M6 10 Nm...

Page 67: ...2 Remove the motorcycle from the lift stand p 49 11 22 Removing the seat Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven Allow the voltage regulator to cool down...

Page 68: ...filter box cover Condition The air filter box cover is secured Remove the seat p 65 A00782 10 Remove screw 1 A00782 11 Pull off the air filter box cover in area Asideways and take off toward the fron...

Page 69: ...ecured Insert the air filter box cover in area Aand clip it into area B Info An air filter box cover with openings for greater airflow and a more direct response is included 11 26 Removing the air fil...

Page 70: ...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 66 Remove the air filter p 67 F01027 01 Main work Wash the...

Page 71: ...he 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 67 11 29 Preparing air filter box cover for securing Pr...

Page 72: ...main silencer 11 31 Installing the main silencer A00889 11 All standard models Position the main silencer Mount screws 1with washers but do not tighten yet Attach spring 2 Spring hook 50305017000C1 Ti...

Page 73: ...installed and check for dam age Mount new glass fiber yarn filling 4on the inner tube Position new glass fiber yarn filling 3in the silencer cap Insert O ring and silencer cap into outer tube 5 Mount...

Page 74: ...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...

Page 75: ...r no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve A00820 10 Disconnect the quick release coupling Info Remaining fuel may flow out of the fuel hos...

Page 76: ...poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse...

Page 77: ...the quick release coupling Silicone spray p 146 Join quick release coupling 4 Info Route the cable and fuel line at a safe distance from the exhaust system A00788 11 EX Mount and tighten screw 2with t...

Page 78: ...l or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous...

Page 79: ...to mea sure chain tension A Info Lower chain section 1must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in...

Page 80: ...1 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 Chain adjus...

Page 81: ...n If distance Bis greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out fas...

Page 82: ...e chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 402421 10 Check the chain guide with a slide gauge for dimension C Minimum thickness Cof the chain guide 6 mm 0 24 in If...

Page 83: ...Always replace a damaged link fork GASGAS Motor cycles does not permit repairing link forks 11 42 Checking the throttle cable routing Preparatory work Remove the seat p 65 Remove the fuel tank p 72 A0...

Page 84: ...urn 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 th...

Page 85: ...kin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with...

Page 86: ...ill ing is possible Info Use water to immediately clean up any brake fluid that has overflowed or spilled Avoid contact between brake fluid and painted parts Brake fluid corrodes paint Only use clean...

Page 87: ...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 88: ...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 89: ...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 90: ...e linings of the front brake p 88 Check the brake linings for damage and cracking If damage or wear is encountered Change the brake linings of the front brake p 88 S05118 10 MC 450F TROY LEE DESIGNS C...

Page 91: ...s free of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning...

Page 92: ...brake linings are in contact with the brake disc and there is a pressure point A00855 10 Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 5 mm 0 2 in Brake fluid D...

Page 93: ...kes when pushing back the brake pistons S05120 10 Remove screws 4and take off the brake caliper S05121 10 Remove cotter pins 5 pull out pin 6 and remove the brake linings Clean the brake caliper and t...

Page 94: ...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...

Page 95: ...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 96: ...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 97: ...Check the brake linings for damage and cracking If damage or wear is encountered Change the rear brake linings p 95 12 13 Changing the rear brake linings Warning Danger of accidents Incorrect servicin...

Page 98: ...Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid corrodes paint Only use clean brake fluid from a sealed container A008...

Page 99: ...n 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 Correct brake fluid level to...

Page 100: ...brake pistons A00839 10 Loosen screw 1by several rotations Loosen screws 2 Press on screw 1to push the wheel spindle out of the axle clamp Remove screw 1 A00840 10 Warning Danger of accidents Damaged...

Page 101: ...gs 1and contact surfaces A of the spacers Long life grease p 146 Insert the spacers Clean and lightly grease the wheel spindle Long life grease p 146 Position the front wheel and insert the wheel spin...

Page 102: ...t 13 3 Removing the rear wheel Preparatory work Raise the motorcycle with a lift stand p 49 A00841 10 Main work Manually press the brake caliper toward the brake disc to push back the brake piston Inf...

Page 103: ...Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary H03001 10 Main work Check the wheel bearing for damage and wear If the wheel bearing is damag...

Page 104: ...sure point Finishing work Remove the motorcycle from the lift stand p 49 13 5 Checking the tire condition Info Only mount tires approved and or recommended by GASGAS Motorcycles Other tires could have...

Page 105: ...ires are cold Offroad tire pressure front 1 0 bar 15 psi rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct tire pressure Mount the protection cap 13 7 Checking the spoke te...

Page 106: ...S 104 If the spoke tension differs Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench k...

Page 107: ...ble from the 12 V battery Remove screw 3 Pull holding bracket 4forward and remove the 12 V battery upwards 14 2 Installing the 12 V battery H00386 10 Main work Insert the 12 V battery into the battery...

Page 108: ...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 109: ...the battery charger after charging and disconnect from the 12 V battery Finishing work Install the 12 V battery p 105 Mount the seat p 65 14 4 Changing main fuse Warning Fire hazard Incorrect fuses o...

Page 110: ...relay Insert a new main fuse Fuse 58011109110 p 137 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 111: ...mponents of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the...

Page 112: ...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 113: ...pletely drain the coolant Mount and tighten screw 1with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 15 5 Refilling with coolant Warning Danger of poisoning Coolant is toxic an...

Page 114: ...ith 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 thorou...

Page 115: ...COOLING SYSTEM 15 113 Finishing work MC 450F TROY LEE DESIGNS Install the motor guard p 52...

Page 116: ...nal position Adjust the play in the throttle cable p 114 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficie...

Page 117: ...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 118: ...ube on the handlebar Attach the throttle cables to the guide plate and route correctly Position half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm 3 7 lbf ft Slide on sleev...

Page 119: ...osition p 18 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 e...

Page 120: ...e but leave it running at idle speed until the programming is finished 16 7 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when in the...

Page 121: ...r 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 p...

Page 122: ...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 123: ...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 124: ...nging the engine oil and oil filter cleaning the oil screens Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety glov...

Page 125: ...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 126: ...il 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 2 l 1 3 qt Engine oil SAE 10W 50 p 144 Info Too...

Page 127: ...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 128: ...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 129: ...exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 146 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner...

Page 130: ...od less workshop overload In this way you can avoid long work shop waiting times at the start of the new season 401058 01 When refueling for the last time before taking the motorcycle out of service a...

Page 131: ...19 2 Putting into operation after storage 401059 01 Install the 12 V battery p 105 Remove the motorcycle from the lift stand p 49 Perform checks and maintenance measures when preparing for use p 27 Ta...

Page 132: ...stics tool Engine does not speed up Malfunction in the electronic fuel injection Read out the fault memory using the GAS GAS Motorcycles diagnostics tool Engine has too little power Air filter is very...

Page 133: ...e engine oil level p 121 Engine oil too thin low viscosity Change the engine oil and the oil filter clean the oil screens p 122 Piston or cylinder worn Measure the piston cylinder mounting clearance 1...

Page 134: ...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 135: ...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 136: ...ressure circulation lubrication with 2 trochoidal pumps Primary transmission 31 76 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear transmission claw shifted Transmission rat...

Page 137: ...4 lbf ft Screw exhaust flange M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 lbf ft Screw pressure pump cover M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm 7...

Page 138: ...ut primary gear wheel M20LHx1 5 100 Nm 73 8 lbf ft Loctite 243 Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft 22 3 Capacities 22 3 1 Engine oil Engine oil 1 2 l 1 3 qt Engine oil SAE 10W 50 p 144 22...

Page 139: ...Maximum permissible overall weight 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...

Page 140: ...37 4 in Oil capacity external mechanism right 230 10 50 ml 7 78 0 34 1 69 fl oz Fork oil SAE 4 48601166S1 p 144 Oil capacity external mechanism left 230 10 50 ml 7 78 0 34 1 69 fl oz Fork oil SAE 4 48...

Page 141: ...37 4 in Oil capacity external mechanism right 230 10 50 ml 7 78 0 34 1 69 fl oz Fork oil SAE 4 48601166S1 p 144 Oil capacity external mechanism left 230 10 50 ml 7 78 0 34 1 69 fl oz Fork oil SAE 4 4...

Page 142: ...licks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring pr...

Page 143: ...ew intake air temperature sensor EJOT DELTA PT 45x12 Z 0 7 Nm 0 52 lbf ft Screw radiator hoses clip 2 4 Nm 1 77 lbf ft Fitting start button M3 0 4 Nm 0 3 lbf ft Fitting stop button M3 0 4 Nm 0 3 lbf f...

Page 144: ...8 lbf ft Nut rear sprocket screw M8 35 Nm 25 8 lbf ft Loctite 2701 Nut rim lock M8 12 Nm 8 9 lbf ft Remaining nuts chassis M8 25 Nm 18 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft Screw bot...

Page 145: ...el pump M12 15 Nm 11 1 lbf ft Nut angle lever to link fork M14x1 5 60 Nm 44 3 lbf ft Nut frame on linkage lever M14x1 5 60 Nm 44 3 lbf ft Nut linkage lever on angle lever M14x1 5 60 Nm 44 3 lbf ft Nut...

Page 146: ...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 147: ...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 148: ...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 149: ...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 150: ...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 151: ...149 Launch control Vehicles electronics functions for achieving the best possi ble acceleration from a standing position OBD On board diagnosis Vehicle system which monitors the specified parameters o...

Page 152: ...27 LIST OF ABBREVIATIONS 150 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly...

Page 153: ...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 154: ...fuel 33 136 Chain checking 78 cleaning 76 Chain guide checking 78 Chain tension adjusting 77 checking 77 Characteristic map of the throttle response adjusting 115 Clutch fluid level checking correcti...

Page 155: ...le speed adjusting screw 19 Implied warranty 9 Indicator lamps overview 16 Intended use 6 L Launch control activating 28 Link fork checking 81 Lower triple clamp installing 55 removing 54 Low speed co...

Page 156: ...Side stand 20 Spare parts 9 Spoke tension checking 103 Start button 15 Start number plate installing 61 removing 60 Starting 27 Starting power of lithium ion batteries at low temperatures 24 Steering...

Page 157: ...3215055en 3215055en 11 2021 Stallhofnerstra e 3 5230 Mattighofen Austria http www gasgas com...

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