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GAS GAS MC 50 2022, Owner'S Manual, Page: 93 / 119

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GAS GAS MC 50 2022 Owner'S Manual Download Page 93

SERVICE WORK ON THE ENGINE 16

91

16.1

Checking the gear oil level

Condition

The engine is cold.

Preparatory work

–

Stand the motorcycle upright on a horizontal surface.

F03034-10

Main work

–

Remove screw

1

.

–

Check the gear oil level.

A small quantity of gear oil must run out of the drilled hole.

» If no gear oil runs out:

–

Add the gear oil.

(

p. 92)

–

Mount and tighten screw

1

.

Guideline

Screw, gear oil level
monitoring

M6

6 Nm (4.4 lbf ft)

16.2

Changing the gear oil

Warning

Danger of scalding

 

Engine and gear oil get very hot when the motorcycle is ridden.

–

Wear suitable protective clothing and safety gloves.

–

In the event of scalding, rinse the area affected immediately with lukewarm water.

Note

Environmental hazard

 

Hazardous substances cause environmental damage.

–

Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Info

Drain gear oil with engine at operating temperature.

Preparatory work

–

Stand the motorcycle on the plug-in stand on a horizontal surface.

F03034-11

Main work

–

Position an appropriate container under the engine.

–

Remove oil drain plug

1

with the magnet.

–

Let the gear oil drain fully.

–

Thoroughly clean the oil drain plug with magnet.

–

Clean the sealing surface on the engine.

–

Mount and tighten the oil drain plug with the magnet and new seal
ring.
Guideline

Oil drain plug with
magnet

M12x1.5

20 Nm (14.8 lbf ft)

Summary of Contents for MC 50 2022

Page 1: ...OWNER S MANUAL 2022 MC 50 Art no 3215048en ...

Page 2: ......

Page 3: ...olors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice GASGAS Motorcycles accepts no liability for delivery options deviations from figures and descriptions as well as misprints and other errors The models portrayed partly contain special equ...

Page 4: ...1 Additional information 24 9 2 Required work 24 9 3 Recommended work 25 10 TUNING THE CHASSIS 26 10 1 Checking the basic chassis setting with rider s weight 26 10 2 Air suspension XACT 5235 26 10 3 Compression damping of the shock absorber 27 10 4 Adjusting the low speed compression damping of the shock absorber 27 10 5 Adjusting the high speed compression damping of the shock absorber 27 10 6 Ad...

Page 5: ...e free travel of the foot brake lever 69 12 11 Adjusting the basic position of the foot brake lever 69 12 12 Checking the rear brake fluid level 70 12 13 Adding rear brake fluid 70 12 14 Checking the brake linings of the rear brake 71 12 15 Changing the rear brake linings 72 13 WHEELS TIRES 75 13 1 Removing the front wheel 75 13 2 Installing the front wheel 75 13 3 Removing the rear wheel 76 13 4 ...

Page 6: ...TABLE OF CONTENTS 4 23 AUXILIARY SUBSTANCES 110 24 STANDARDS 112 25 LIST OF ABBREVIATIONS 113 INDEX 114 ...

Page 7: ...e 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 or tips Indicates the result of a testing step Indicates the end of an activity including potential reworking Indicates a voltage measurement Indicates a current measurement 1 2 Formats used The typographical formats u...

Page 8: ...s instruction and all further instructions included carefully The safety instructions are highlighted in the text and are referred to at the relevant passages Info Various information and warning labels are attached in prominent locations on the product described Do not remove any information or warning labels If they are missing you or others may not recognize dangers and may therefore be injured...

Page 9: ... gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or running the engine in an enclosed space Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust system radiator engine sho...

Page 10: ...fluids and used components comply with the laws and regula tions of the respective country Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles there are no legal regu lations that pertain to the disposal of an end of life motorcycle Your authorized GASGAS Motorcycles dealer will be glad to advise you 2 10 Owner s Manual It is important that you read th...

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

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example V02172 10 1 Fuel tank filler cap 2 Quick release of seat 3 Chain guide 4 Choke 5 Fuel tap p 15 ...

Page 13: ...ew of vehicle rear right example V02173 10 1 Stop button p 14 2 Throttle grip p 14 3 Hand brake lever p 14 4 Vehicle identification number p 12 5 Kick starter lever p 16 6 Foot brake lever p 16 7 Level viewer for brake fluid rear ...

Page 14: ...right side of the steering head 5 2 Type label 402154 10 The type label 1is located on the front frame tube 5 3 Engine number 401949 11 The engine number 1is located on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 The fork part number 1is stamped on the outside of the axle clamp ...

Page 15: ...SERIAL NUMBERS 5 13 5 5 Shock absorber article number H01186 10 The shock absorber article number 1is stamped on the bottom of the shock absorber toward the right hand side ...

Page 16: ...nition circuit is closed and the engine can be started Stop button pressed In this position the ignition circuit is inter rupted a running engine stops and a non running engine will not start 6 4 Opening the fuel tank filler cap Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames...

Page 17: ...nvironmental 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 F02968 10 Turn fuel tank filler cap 1counterclockwise and lift it off 6 5 Closing the fuel tank filler cap F02968 11 Mount fuel tank filler cap 1and turn it clockwise until the fuel tank is tightly closed Info Route fuel tank breather hose 2without k...

Page 18: ...oke function deactivated The choke lever is pushed in to the stop 6 8 Kick starter lever H01184 10 Kick starter lever 1is fitted on the right side of the engine The kick starter lever can be swiveled Info Before riding swing the kick starter lever inwards towards the engine 6 9 Foot brake lever 401956 10 Foot brake lever 1is located in front of the right footrest The rear brake is engaged with the...

Page 19: ...ing such as helmet boots gloves as well as trousers and a jacket with protectors on all rides Alway use protective clothing for your child that is in good condition and meets the legal requirements When you ride a motorcycle set an example for your child and wear suitable protective clothing Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling ch...

Page 20: ...ime ensure that the basic settings of the chassis are suitable for the weight of your child Allow your child to become accustomed to the handling of the motorcycle on suitable terrain preferably on a large open meadow Info To give your child a feeling for the brake system you should push your child at first Do not start the engine until your child is able to apply the necessary front brake pressur...

Page 21: ...ed the specified engine performance Guideline Maximum engine performance During the first 3 operating hours 70 During the first 5 operating hours 100 Info The use of a service hour counter is recommended in order to be able to check the mileage at any time Avoid fully opening the throttle ...

Page 22: ...rect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 38 Bleed the fork legs p 37 Check the air filter Check the settings of all controls and ensure that they can be oper ated smoothly Check all screws nuts and hose clips regularly for tightness Check the fuel level 8 2 Starting the vehicle Danger Danger of poisoning Exhaust gases are toxic and inhaling them...

Page 23: ...as been activated deactivate it after the engine has warmed up After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but fuel consumption will be considerably lower Your child should always open the throttle only as much as the engine can handle abruptly opening the throttle increases fuel consumption Your child shoul...

Page 24: ...e The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand Note Fire hazard Hot vehicle components pose a fire h...

Page 25: ...s and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Note Environmental hazard Improper handl...

Page 26: ...up Check the rear brake fluid level p 70 Check the free travel of the foot brake lever p 68 Check the frame p 58 Check the link fork p 59 Check the fork bearing for play Check the shock absorber heim joint for play Check the tire condition p 78 Check tire pressure p 79 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 79 Check the chain rear spro...

Page 27: ...onths every 12 months Every 80 operating hours After 20 operating hours Every 20 operating hours After 10 operating hours Change the front brake fluid Change the rear brake fluid Service the fork Perform the shock absorber service Lubricate the steering head bearing p 45 Check adjust the carburetor components Change the coolant p 84 Perform minor engine service Check the cylinder and piston Check ...

Page 28: ... in the left fork leg and damping in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork is f...

Page 29: ...etached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized GASGAS Motorcycles workshop will be glad to help Info The effect of the low speed compression adjuster can be seen in slow to normal compression of the shock absorber F02184 10 Turn adjusting screw 1clockwise with a screwdriver as far as the last perceptible click...

Page 30: ...e rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized GASGAS Motorcycles workshop will be glad to help F02185 10 Turn adjusting screw 1clockwise up to the last perceptible click Turn c...

Page 31: ...ve the motorcycle from the lift stand p 37 10 8 Checking the static sag of the shock absorber 400989 10 Measure dimension Aof rear wheel unloaded p 29 Hold the motorcycle upright with aid of an assistant Measure the distance between rear axle and fixed point again Note the value as dimension B Info The static sag is the difference between measurements A and B Check the static sag Static sag 12 mm ...

Page 32: ...fo The riding sag is the difference between measurements A and C Check riding sag Riding sag 80 mm 3 15 in If the riding sag differs from the specified measurement Adjust the riding sag p 31 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with high...

Page 33: ...e spring preload is the difference between the relaxed spring length and the tensioned spring length Depending on the static sag and or the riding sag it may be necessary to increase or decrease the spring preload Tighten retaining ring 1 Finishing work Install the shock absorber p 49 Remove the motorcycle from the lift stand p 37 10 11 Adjusting the riding sag Preparatory work Raise the motorcycl...

Page 34: ...com pression the fork air pressure must be increased within the speci fied values to avoid damage to the fork and frame 10 13 Adjusting the fork air pressure Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload ...

Page 35: ...ng instructions for GASGAS techni cal accessories Adjust the air pressure as specified Guideline Air pressure 2 bar 29 psi Gradual changing of the air pressure in steps of 0 2 bar 3 psi Minimum air pressure 1 4 bar 20 psi Maximum air pressure 4 bar 58 psi Info Never adjust the air pressure to a value outside the stated range Disconnect the fork airpump from the left fork leg When disconnecting exc...

Page 36: ...the shock absorber rebounds 10 15 Handlebar position C00248 10 On the upper triple clamp there are 2 holes at a distance of Ato each other Hole distance A 15 mm 0 59 in The holes on the handlebar supports are placed at a distance of B from the center Hole distance B 3 5 mm 0 138 in The handlebar supports can be mounted in four different positions This allows the handlebar to be mounted in the most...

Page 37: ... handlebar Info Make sure the 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 even 10 17 Adjusting the seat height Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic Make sure your child...

Page 38: ... shock absorber according to the required seat height Guideline Low seat position standard A High seat position B Position screw 2 F02973 10 Mount nut 1and tighten the fitting Guideline Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Finishing work Remove the motorcycle from the lift stand p 37 ...

Page 39: ...from the lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand 402581 10 Remo...

Page 40: ...removed the seals rings behind can start to leak Warning Danger of accidents Oil 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 neces sary Clean and oil the dust boots and inside fork tubes of both fork legs Universal oil spray p 111 Press the dust boots back into the installation position Rem...

Page 41: ...unt and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and the clamp Mount and tighten screws 3 Guideline Screw brake hose bracket EJOT PT K60x20 Z 2 Nm 1 5 lbf ft 11 7 Removing the fork legs Preparatory work Raise the motorcycle with a lift stand p 37 Remove the front wheel p 75 F03020 10 Main work Remove screws 1and take off the clamp Remove screw...

Page 42: ...2 11 Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F03021 10 Position the brake caliper mount screw 4 and tighten Guideline Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Mount and tighten screw 5 Guideline Screw front brake caliper M8x40 20 Nm 14 8 lbf ft Loctite 243 Position the brak...

Page 43: ...te p 47 Remove front fender p 48 F03025 10 Main work Pull fuel tank breather 1out of the steering stem Remove nut 2 Release screw 3 take off the upper triple clamp with the handle bar and set aside Info Cover the components to protect them against damage Do not kink the cables and lines F03026 10 Remove protective ring 4 Remove the lower triple clamp with the steering stem Remove the upper steerin...

Page 44: ... the steering stem Mount upper steering head bearing 1 Check whether upper steering head seal 2is correctly positioned Push on protective ring 3 F03023 10 Position the upper triple clamp with the handlebar Mount nut 4 but do not tighten yet F02179 11 Position the fork legs Bleeder screws 5are positioned toward the rear Info The upper milled groove in the fork leg must be flush with the upper edge ...

Page 45: ...21 11 Position the brake caliper mount screw bk and tighten Guideline Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Mount and tighten screw bl Guideline Screw front brake caliper M8x40 20 Nm 14 8 lbf ft Loctite 243 Position the brake line and the clamp Mount and tighten screws bm Guideline Screw brake hose bracket EJOT PT K60x20 Z 2 Nm 1 5 lbf ft Finishing work Check that the wirin...

Page 46: ...eering head bearing If there is detectable play Adjust the steering head bearing play p 44 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily over the entire steering range There should be no detectable detent positions If detent positions are detected Adjust the steering head bearing play p 44 Check the steering head bearing and replace i...

Page 47: ... fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consul...

Page 48: ...ng Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected ...

Page 49: ...rews chassis M6 10 Nm 7 4 lbf ft Position the fuel tank breather in the steering stem Finishing work Mount the seat p 50 11 16 Removing the start number plate F02980 10 Remove screw 1 Unhook the start number plate from the brake line and remove it 11 17 Installing the start number plate F02981 10 Attach the start number plate to the brake line Position the start number plate Holding lugs 1engage i...

Page 50: ...fender F02983 10 Remove screws 1 Take off the front fender 11 19 Installing the front fender F02984 10 Position start number plate on the fender The holding lugs of the start number plate engage in drill holes 1of the fender F02983 11 Position fender on the lower triple clamp mount and tighten screws 2 Guideline Screw fender M6 6 Nm 4 4 lbf ft ...

Page 51: ...ations to the suspension setting may seriously alter the handling characteristic Ride slowly to start with after making adjustments to get the feel of the new handling characteristic F02986 11 Main work Push splash protector 1to the side Position the shock absorber with screw 2 depending on the desired seating height F02985 11 Raise the link fork mount and tighten the shock absorber with screw 3 G...

Page 52: ...s into the fuel tank F02987 11 Close quick release 3 11 24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Only operate the vehicle if it is equipped with an air filter Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease fil...

Page 53: ...11 26 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the seat p 50 Remove the air ...

Page 54: ...he main silencer with sleeve 1 Mount the silent block with screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the collar bushings Mount and tighten screw 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust s...

Page 55: ...hed washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the main silencer p 52 11 30 Removing the engine sprocket cover Preparatory work Raise the motorcycle with a lift stand p 37 F02993 10 Main work Remove screws 1 Remove screw 2 Take off the engine sprocket cover 11 31 Installing the engine sprocket cover F02993 10 Main work Position the engine sprocket cover M...

Page 56: ...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 agents brake fluid etc correctly and in compliance with the appli cable regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with a lift sta...

Page 57: ... Info The top part of chain 1must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 5 8 mm 0 2 0 31 in If the chain tension does not meet the specification Adjust the chain tension p 55 Finishing work Remove the motorcycle from the lift stand p 37 11 35 Adjusting the chain tension Warning Danger of accidents Incorrect chain tensi...

Page 58: ...g the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with a lift stand p 37 Remove the engine sprocket cover p 53 400227 01 Main work Check the chain rear sprocket and engine sprocket for wear If the chain rear sprocket or engine sprocket is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 59: ... screws chassis M6 10 Nm 7 4 lbf ft F02200 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the ch...

Page 60: ...tand p 37 11 37 Adjusting the chain guide Info The size of the chain wheel varies with the number of teeth The chain guide can be adjusted on small sprockets F02201 10 Loosen screw 1 Position the chain guide Tighten the screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 38 Checking the frame S00876 01 Check the frame for damage cracks and deformation If the frame shows signs of damage...

Page 61: ... play in throttle cable complies with the specification Preparatory work Remove the seat p 50 Turn the knurled screw on the fuel tap all the way clockwise Remove the fuel tank p 45 F02995 01 Main work Check the throttle cable routing The throttle cable must be routed to the carburetor behind the handlebars and above the fuel tank bracket If the throttle cable is not routed as specified Correct the...

Page 62: ...grip Preparatory work Check the rubber grip p 59 401198 01 Main work Secure the rubber grip at two locations with the retaining wire Securing wire 54812016000 Wire twister forceps U6907854 The twisted wire ends face away from the palms and are bent in toward the rubber grip ...

Page 63: ...ing the play of the hand brake lever F02996 10 Check the play of the handbrake lever p 61 Adjust the play of the hand brake lever using adjusting screw 1 Guideline Play of hand brake lever 3 5 mm 0 12 0 2 in 12 3 Adjusting the basic position of the hand brake lever F02996 11 Remove screw 1 Take off cover 2 F02997 10 Check the play of the handbrake lever p 61 Adjust the basic position of the hand b...

Page 64: ...2 2 mm 0 087 in If the brake disc thickness is less than the specified value Change the front brake disc Change the rear brake disc Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deformation Change the front brake disc Change the rear brake disc 12 5 Checking the front brake fluid level Warning Danger of accidents An insuffici...

Page 65: ... GASGAS Motorcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid co...

Page 66: ...spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized GASGAS Motorcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel ...

Page 67: ...e the brake system to fail Ensure that service work and repairs are performed professionally Your authorized GASGAS Motorcy cles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Co...

Page 68: ...ase filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Raise...

Page 69: ...elivery and the manufacturer warranty shall be void Only use brake linings approved and recommended by GASGAS Motorcycles Position the new brake linings Info Always change the brake linings in pairs Ensure that the brake linings are correctly positioned in the holding spring Mount and tighten screw 7 Guideline Screw brake linings M5 8 Nm 5 9 lbf ft Mount lock ring 6 Warning Danger of accidents Oil...

Page 70: ...t and tighten screws 1 Info Use water to immediately clean up any brake fluid that has overflowed or spilled Finishing work Remove the motorcycle from the lift stand p 37 12 9 Checking the free travel of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the...

Page 71: ...sition of the foot brake lever p 69 12 11 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification F03003 11 Detach the foot brake lever...

Page 72: ...l 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 the brake linings are worn down Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated Your authorized GASGAS Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irrita...

Page 73: ...stand p 37 Check the brake linings of the rear brake p 71 F03004 10 Main work Remove screws 1 Take off cover 2with washer 3and membrane 4 H01654 10 Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 10 mm 0 39 in Brake fluid DOT 4 DOT 5 1 p 108 Position the cover with the washer and membrane Mount and tighten the screws Info Clean up overflowed or spilled brake f...

Page 74: ... clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized GASGAS Motorcycles workshop will be glad to help Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil...

Page 75: ... or damage the brake line Remove the brake linings Clean the brake caliper and the brake caliper bracket Allow the brake caliper and the brake line to hang loosely to the side Check the brake discs p 62 F03004 11 Remove screws 5 Take off cover 6with washer 7and membrane 8 Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir ex...

Page 76: ... Check the brake discs p 62 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point H01654 10 Add brake fluid up to level A Guideline Level A brake fluid level below reservoir rim 10 mm 0 39 in Brake fluid DOT 4 DOT 5 1 p 108 Position cover with washer and membrane Mount and tighten the screws Info Use water to immediately cl...

Page 77: ... discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold front wheel and remove wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake lever when the front wheel is removed F03044 10 Remove spacers 3 13 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking ...

Page 78: ...brake linings are correctly positioned Insert the wheel spindle Mount and tighten screw 2 Guideline Screw front wheel spindle M10 40 Nm 29 5 lbf ft Loctite 243 Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 37 Operate the front brake and compress the fork a few times firmly The fork legs str...

Page 79: ...wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed F03046 10 Remove spacers 4 13 4 Installing the rear wheel Warning Danger of accidents Oil 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 F03047 10 Main work Check the wheel bearing for ...

Page 80: ...on p 55 Tighten nut 4 Guideline Nut rear wheel spindle M12x1 40 Nm 29 5 lbf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point Finishing work Remove the motorcycle from the lift stand p 37 13 5 Checking the tire condition Info Only mount tires approved and or recommended by GASGAS Motorcycles Other tires could have a ...

Page 81: ...0 bar 15 psi If the tire pressure does not meet specifications Correct tire pressure Mount the protection cap 13 7 Checking spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam age The spokes break due to being overloaded if they are too tightly tensioned If the tension in the spokes is too low then lateral and radial...

Page 82: ...13 WHEELS TIRES 80 Check the spoke torque Guideline Spoke nipple M3 5 3 Nm 2 2 lbf ft Torque wrench kit 58429094000 ...

Page 83: ...oses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediatel...

Page 84: ...ght on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level Aabove the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value Correct the coolant level Coolant p 108 Mount the radiator cap 14 4 Draining the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not ...

Page 85: ...eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing F03008 10 Main work Make sure that screw 1is tightened Position the motorcycle upright Add coolant to level A Guideline Distance Aabove the radia tor fins 10 mm 0 39 in Coolant 0 7 l 0 7 qt Coolant p 108 400677 11 Move the vehicle into the position shown an...

Page 86: ... of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing...

Page 87: ... of the air to be able to escape from the cooling sys tem the vehicle must be raised at the front If the cool ing system is poorly de aerated its cooling power will be reduced and the engine may overheat Return the vehicle to the horizontal position Add coolant to level A Mount the radiator cap Finishing work Go for a short test ride Check the cooling system for leaks Check the coolant level p 82 ...

Page 88: ...arting or run ning the engine in an enclosed space Start the engine and let it run at idle speed Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 86 15 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 50 Turn the knurled screw on the fuel tap all the way clockwi...

Page 89: ...e speed F03009 10 Screw in idle air adjusting screw 2all the way and turn it to the specified basic setting Guideline Idle air adjusting screw Open 3 turns Run the engine until warm Guideline Warming up phase 5 min Connect the special tool Tachometer 45129075000 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is su...

Page 90: ...air temperature or altitude changes adjust the idle speed again 15 5 Checking the clutch setting F03010 10 Connect special tool 1 Tachometer 45129075000 401521 01 Let the front wheel of the vehicle make contact with a fixed object 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 runnin...

Page 91: ...3032 10 Remove screws 1 Remove clutch cover 2with the seal ring 15 7 Adjusting the clutch Preparatory work Remove the clutch cover p 89 F03033 10 Main work Turn clutch basket 1until adjusting screws 2become accessi ble F03033 11 Condition If there is no reference point Turn adjusting screws 2counterclockwise to the last detectable click Turn adjusting screws 2clockwise by 9 clicks to the basic set...

Page 92: ...p speed is too high Turn adjusting screws 2counterclockwise Guideline 1 click decreases the slip speed by 250 350 rpm Finishing work Install the clutch cover p 90 Check the gear oil level p 91 Check the clutch setting p 88 15 8 Installing the clutch cover F03032 11 Main work Position the clutch cover 1with the seal ring Mount and tighten screws 2 Guideline Screw clutch cover M6 10 Nm 7 4 lbf ft Fi...

Page 93: ...es In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Drain gear oil with engine at operating temperature Preparatory work Stand the motorcycle on the plug in sta...

Page 94: ...ine Use effective exhaust extraction when starting or run ning the engine in an enclosed space Start the engine and check for leaks Finishing work Check the gear oil level p 91 16 3 Adding the gear oil Info Too little gear oil or poor quality gear oil results in premature wear to the transmission Preparatory work Stand the motorcycle upright on a horizontal surface F03034 10 Main work Remove screw...

Page 95: ...ses are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or run ning the engine in an enclosed space Start the engine and check for leaks ...

Page 96: ...Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in ...

Page 97: ...ve F03013 10 Remove throttle slide cover 5 Pull the throttle slide out of the carburetor Drain the remaining fuel F03016 11 Pull back the spring retainer and throttle slide spring Detach throttle cable wire 6 Take off the throttle slide 17 2 Installing the carburetor F03016 10 Main work Attach throttle cable wire 1 Position the spring retainer and throttle slide spring ...

Page 98: ... reached Screw on the throttle slide cover correctly F03012 12 Mount the carburetor Mount the engine breather hose and position clamp 3 F03011 11 Mount the inlet sleeve Position and tighten hose clip 4 Guideline Hose clip carburetor 2 8 Nm 2 07 lbf ft Position and tighten hose clip 5 Guideline Hose clip carburetor 2 8 Nm 2 07 lbf ft F02979 12 Mount fuel hose 6 Finishing work Check the play in the ...

Page 99: ...aning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove loose dirt first with a soft jet of water Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Motorcycle cleaner p 110 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse the veh...

Page 100: ...g parts and pivot points Clean the chain p 54 Treat bare metal except for brake discs and the exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 110 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 111 ...

Page 101: ... period less workshop overload This allows you to avoid long waiting periods when the next season starts 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 110 Refuel p 23 Clean the motorcycle p 97 Change the gear oil p 91 Check the antifreeze and coolant level p 81 Empty the carburetor float chamber Check tire pressure p 79 Sto...

Page 102: ...19 STORAGE 100 19 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 37 Perform checks and maintenance measures when preparing for use p 20 Take a test ride ...

Page 103: ...uretor components Adjusting screws on the carbu retor are in turned to the wrong position Carburetor adjust the idle speed p 87 Spark plug defective Change spark plug Ignition system defective Check the ignition coil Check the spark plug connector Engine does not speed up The carburetor is flowing over because the float needle is dirty or worn Check set the carburetor components Loose carburetor j...

Page 104: ...he coolant level p 82 Too little air stream Switch off engine when standing Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant p 82 Refill with coolant p 83 Damaged cylinder head or cylin der head gasket Check the cylinder head or cylinder head gasket Bent radiator hose Change the radiator hose White smoke emission steam in exhaust gas Damaged cylinder ...

Page 105: ...id Kick starter system 21 2 Engine tightening torques Screw bearing retainer M5 5 Nm 3 7 lbf ft Screw kick starter lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator bracket M5 6 Nm 4 4 lbf ft Loctite 243 Screw water pump impeller M5 2 Nm 1 5 lbf ft Loctite 243 Bleeder flange of engine case M6 4 Nm 3 lbf ft Loctite 243 Drain plug water pump cover M6 6 Nm 4 4 lbf ft Screw alternator cover M6 6 Nm 4 ...

Page 106: ...uretor type Dell Orto PHBG 19BS Needle position 2nd position from top Idle air adjusting screw Open 3 turns Main jet 95 Jet needle W7 Idling jet 50 Needle jet 262AU Throttle slide 40 Choke nozzle 60 21 4 Capacities 21 4 1 Gear oil Gear oil 0 20 l 0 21 qt Gear oil ATF Dexron 3 p 109 21 4 2 Coolant Coolant 0 7 l 0 7 qt Coolant p 108 21 4 3 Fuel Fuel tank capacity approx 2 3 l 2 4 qt Super unleaded 9...

Page 107: ...rider weight 45 kg 99 lb 21 6 Tires Front tire Rear tire 60 100 12 36M TT MAXXIS MAXX CROSS SI 2 75 10 38J TT MAXXIS MAXX CROSS SI The tires specified represent one of the possible series production tires Additional information is available in the Service section under http www gasgas com 21 7 Fork Fork article number 07 18 6U 02 Fork WP XACT 5235 Rebound damping Comfort 15 clicks Standard 12 clic...

Page 108: ... 0 47 in Riding sag 80 mm 3 15 in Fitted length 275 mm 10 83 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 109 21 9 Chassis tightening torques Hose clip carburetor 2 8 Nm 2 07 lbf ft Screw brake hose bracket EJOT PT K60x20 Z 2 Nm 1 5 lbf ft Stop button screw M3 0 4 Nm 0 3 lbf ft Spoke nipple M3 5 3 Nm 2 2 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M...

Page 109: ...1 1 lbf ft Screw engine bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw engine sprocket cover M8 15 Nm 11 1 lbf ft Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Screw front brake caliper M8x40 20 Nm 14 8 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear sprocket M8 25 Nm 18 4 lbf ft Loctite 243 Screw steering stem M8 20 Nm 14 8 lbf ft Screw top triple clamp M8...

Page 110: ...rements stated see specifications on the container and that has the rele vant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibil...

Page 111: ...pecifications on the container and that exhibit the corre sponding properties Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 ...

Page 112: ... supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Rubber grip adhesive ...

Page 113: ...y and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Klüber Lubrication KLÜBERFOOD NH1 34 401 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 114: ... first rate synthetic esters and specially designed additives superb combustion is achieved even under extreme operating conditions SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality ...

Page 115: ...LIST OF ABBREVIATIONS 25 113 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 116: ... 54 Chain guide adjusting 58 checking 56 Chain tension adjusting 55 checking 55 Choke 16 Cleaning 97 98 Clutch adjusting 89 setting checking 88 Clutch cover clutch cover installing 90 clutch cover removing 89 Coolant changing 84 draining 82 refilling 83 Coolant level checking 81 82 Cooling system 81 Customer service 9 E Engine running in 19 Engine number 12 Engine sprocket checking 56 Engine sproc...

Page 117: ...tand 37 O Owner s Manual 8 P Play in throttle cable adjusting 86 checking 86 Plug in stand 16 Preparing for use advice on preparing for first use 17 after storage 100 checks and maintenance measures when preparing for use 20 Protective clothing 7 R Rear sprocket checking 56 Rear wheel installing 77 removing 76 Rebound damping fork adjusting 34 shock absorber adjusting 28 Refueling fuel 23 Riding s...

Page 118: ...engine tightening torques 103 fork 105 shock absorber 106 tires 105 Throttle cable routing checking 59 Throttle grip 14 Tire condition checking 78 Tire pressure checking 79 Transporting 22 Troubleshooting 101 102 Type label 12 U Use definition 6 V Vehicle identification number 12 View of vehicle front left 10 rear right 11 W Work rules 8 ...

Page 119: ... 3215048en 3215048en 04 2021 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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