GAS GAS MC 85 2021 Owner'S Manual Download Page 71

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BRAKE SYSTEM 12

12.1

Checking the free travel of the hand brake lever

Warning

Danger of accidents

The brake system fails in the event of overheating.

If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.

–

Set the free travel on the hand brake lever in accordance with the specification.

S04282-10

–

Push the hand brake lever forward and check free travel

Free travel of hand brake lever

≥

3 mm (

≥

0.12 in)

» If the free travel does not match the specification:

–

Adjust the free travel of the handbrake lever. (

p. 69)

12.2

Adjusting the free travel of the handbrake lever

S04283-10

–

Check the free travel of the hand brake lever. (

p. 69)

–

Adjust the free travel of the handbrake lever with adjustment
screw

Info

Turn the adjusting screw clockwise to reduce free travel. The
pressure point moves away from the handlebar.

Turn the adjusting screw counterclockwise to increase free
travel. The pressure point moves towards the handlebar.

The range of adjustment is limited.

Turn the adjusting screw by hand only, and do not apply any
force.

Do not make any adjustments while riding.

12.3

Checking the brake discs

Warning

Danger of accidents

Worn-out brake discs reduce the braking effect.

–

Make sure that worn-out brake discs are replaced immediately. (Your authorized GASGAS Motorcycles work-
shop will be glad to help.)

400257-10

–

Check the front and rear brake disc thickness at multiple points for
the dimension

Info

Wear reduces the thickness of the brake disc around the
contact surface of the brake linings.

Brake discs - wear limit

front

3.5 mm (0.138 in)

rear

3.7 mm (0.146 in)

Summary of Contents for MC 85 2021

Page 1: ...OWNER S MANUAL 2021 MC 85 Art no 3215007en ...

Page 2: ......

Page 3: ...s 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 illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special e...

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

Page 5: ...h 66 11 44 Changing the hydraulic clutch fluid 67 12 BRAKE SYSTEM 69 12 1 Checking the free travel of the hand brake lever 69 12 2 Adjusting the free travel of the handbrake lever 69 12 3 Checking the brake discs 69 12 4 Checking the front brake fluid level 70 12 5 Adding the front brake fluid 70 12 6 Checking the front brake linings 72 12 7 Changing the brake linings of the front brake 72 12 8 Ch...

Page 6: ...0 20 3 Carburetor 112 20 3 1 Carburetor tuning 112 20 3 2 Basic carburetor setting for sandy surfaces 113 20 4 Capacities 113 20 4 1 Gear oil 113 20 4 2 Coolant 113 20 4 3 Fuel 113 20 5 Chassis 113 20 6 Tires 114 20 7 Fork 114 20 8 Shock absorber 114 20 9 Chassis tightening torques 115 21 SUBSTANCES 117 22 AUXILIARY SUBSTANCES 119 23 STANDARDS 121 24 LIST OF ABBREVIATIONS 122 INDEX 123 ...

Page 7: ...pecially trained experts using the spe cial tools required Indicates a page reference more information is provided on the specified page Indicates information with more details or tips Indicates the result of a testing step Indicates a voltage measurement Indicates a current measurement Indicates the end of an activity including potential reworking 1 2 Formats used The typographical formats used i...

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

Page 9: ... 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: ...ot occur To protect the future of the motorcycle sport make sure that you use your motorcycle legally be environmentally 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 country Because motorcycles are not subject to the EU regulations governing the disposal of used veh...

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

Page 12: ...IEW OF VEHICLE 10 4 1 View of vehicle front left example S04315 10 1 Hand brake lever p 14 2 Clutch lever p 14 3 Fuel tank filler cap 4 Air filter box cover 5 Shift lever p 16 6 Choke p 16 7 Fuel tap p 16 ...

Page 13: ...CLE 4 11 4 2 View of vehicle rear right example S04316 10 1 Switch off button p 14 2 Throttle grip p 14 3 Fork part number p 12 4 Foot brake lever p 17 5 Kick starter lever p 17 6 Level viewer for brake fluid rear ...

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

Page 15: ...SERIAL NUMBERS 5 13 5 5 Shock absorber article number H02222 10 The shock absorber part number 1is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 16: ... hand brake lever 6 3 Throttle grip S04275 11 Throttle grip 1is fitted on the right side of the handlebar 6 4 Switch off button S04274 11 Switch off button 1is fitted on the left side of the handlebar Possible states The switch off button is in the basic position In this position the ignition circuit is closed and the engine can be started The switch off button is pressed In this position the igni...

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

Page 18: ... completely 6 8 Choke S04319 10 Choke 1is fitted on the left side of the carburetor Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mix ture which is needed for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pu...

Page 19: ...k starter lever can be swiveled Info Before riding swing the kick starter lever inwards towards the engine 6 11 Foot brake lever 401956 10 Foot brake lever 1is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 12 Plug in stand 402001 10 The support for plug in stand 1is the left side of the wheel spindle The plug in stand is used to park the motorcycl...

Page 20: ...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 21: ...ake lever p 75 Before using the vehicle for the first time 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 start by pushing your child Do not start the engine until your child is ...

Page 22: ...n components For this reason it may be necessary to inspect or replace parts before the next scheduled service Clean the air filter and air filter box p 55 Info Check the air filter approx every 30 minutes Check the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Clean and dry the connector or change it if necessary Difficu...

Page 23: ...water Change the radiator cap M01104 01 Mount the air filter dust cover Air filter dust cover 47206920000 Info Observe the GASGAS Technical Accessories fitting instruc tions M01105 01 Mount the air filter sand cover Air filter sand cover 79006922000 Info Observe the GASGAS Technical Accessories fitting instruc tions M01107 01 Adjust the carburetor jetting and setting Info The recommended carbureto...

Page 24: ...ooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Change the radiator cap M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized GASGAS Motorcycles workshop Clean the ...

Page 25: ...torcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temper ature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affec...

Page 26: ...R USE 24 7 8 Preparing the vehicle for low temperatures or snow M01107 01 Adjust the carburetor jetting and setting Info The recommended carburetor tuning is available from your authorized GASGAS Motorcycles workshop ...

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

Page 28: ...ing off and for steep inclines When conditions allow incline road situation etc your child can shift into a higher gear To do so release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch lever and open the throttle If the choke function has been activated deactivate it after the engine has warmed up After reaching maximum speed by fully opening ...

Page 29: ...em will not overheat 8 6 Stopping parking Warning Risk 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 persons Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch any parts such as the exhaust s...

Page 30: ... 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 consult a d...

Page 31: ... tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 in Fuel tank capacity approx 5 2 l 1 37 US gal Super unleaded 98 octane mixed with 2 stroke engine oil 1 40 p 118 Engine oil 2 stroke p 117 Close the fuel tank filler cap p 15 ...

Page 32: ... rear brake fluid level p 75 Check the free travel of the foot brake lever p 74 Check the frame p 64 Check the link fork p 64 Check the fork bearing for play Check the shock absorber heim joint for play Check the tire condition p 83 Check tire pressure p 84 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 84 Check the chain rear sprocket engine ...

Page 33: ...ery 10 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 67 Grease the steering head bearing p 51 Service the fork Perform the shock absorber service Check adjust the carburetor components Change the coolant p 91 Perform minor engine service Check the inlet membrane Check the clutch Under difficult operating conditions Change the piston an...

Page 34: ... fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly uneven surfaces is significantly improved In normal driving mode suspension is provided exclusively by an air cushion A steel spring is located in the left fork leg as an end stop Info If the fork is frequently overloaded then the air pressure in the fork mus...

Page 35: ...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 S04321 10 Turn adjusting screw 1clockwise with a screwdriver as far as the last perceptible click...

Page 36: ...nd 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 S04323 10 Turn adjusting screw 1clockwise up to the last perceptible click Turn counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound dampin...

Page 37: ...e static sag of the shock absorber 400989 10 Measure dimension Aof rear wheel unloaded p 34 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 30 mm 1 18 in If the static sag is less or more than the specifie...

Page 38: ...fo The riding sag is the difference between measurements A and C Check riding sag Riding sag 120 mm 4 72 in If the riding sag differs from the specified measurement Adjust the riding sag p 37 10 10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with hig...

Page 39: ...erence 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 screw 1 Guideline Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Finishing work Install the shock absorber p 53 Remove the motorcycle from the lift stand p 42 10 11 Adjusting the riding sag Preparat...

Page 40: ...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 41: ...ying GASGAS Technical Accessories instructions Adjust the air pressure as specified Guideline Air pressure 5 bar 73 psi Gradual changing of the air pressure in steps of 0 2 bar 3 psi Minimum air pressure 4 bar 58 psi Maximum air pressure 8 bar 116 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 excess ...

Page 42: ...ase damping turn counterclockwise to reduce damping during compression Mount protection cap 1 10 15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior S04325 10 Turn red adjusting screw 1clockwise as far as it will go Info Adjusting screw 1is located at the upper end of the right fork leg The rebound damping is located in right fork...

Page 43: ... bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent C00249 10 Remove screws 1 Take off the handlebar clamps Remove the handlebar and lay 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 the handlebar support Place the handleba...

Page 44: ...Note Danger of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402001 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand 1into the left side of the wheel spindle Info Remove the plug in stand before riding 11 3 Bleeding the fork legs Preparatory work Raise the motorcycle with a lift stand ...

Page 45: ...s keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when neces sary Clean and oil the dust boots and inner fork tubes of both fork legs Universal oil spray p 120 Press the dust boots back into their installation position Remove excess oil Finishing work Install the fork protector p 45 Remove the motorcycle from the lift stand p 42 11 5 Removing the fork legs Prep...

Page 46: ...e pres sure and rebound damping is located in the right fork leg S04327 11 Tighten screws 2 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft H00935 15 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 4and contact surfaces Bof...

Page 47: ...k stub M8 15 Nm 11 1 lbf ft 11 7 Removing the fork protector S04330 10 Remove screws 1and take off the clamp Remove screws 2on the left fork leg Take off the fork protector Remove screws 3on the right fork leg Take off the fork protector 11 8 Installing the fork protector S04331 10 Position the fork protector on the right fork leg Mount and tighten screws 1 Guideline Remaining screws chassis M6 10...

Page 48: ... handlebar cushion V00874 10 Main work Pull fuel tank breather 1out of the steering stem Loosen screw 2 Remove nut 3 pull off the upper triple clamp with the handlebar in an upward direction and hang it to the side Info Cover the components to protect them against damage Do not kink the cables and lines V00875 10 Remove protective ring 4 Take off the lower triple clamp with the steering stem in a ...

Page 49: ...g 2 Position protective ring 3 S03451 10 Position the upper triple clamp with the handlebar Mount nut 4 but do not tighten yet S03452 10 Position the fork legs Air bleeder screw 5of the right fork leg is positioned to the front Valve Aof the left fork leg faces the front Info The second milled groove from the top must be flush with the upper edge of the upper triple clamp The air suspension is loc...

Page 50: ...ten screw 7 Guideline Steering stem clamp screw M8 20 Nm 14 8 lbf ft S04327 13 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 8 Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft S03455 10 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease shaft seal rings 9and contact sur...

Page 51: ...g work Install front fender p 52 Install the start number plate p 51 Check that the wiring harness throttle cables and brake and clutch lines can move freely and are routed correctly Check the steering head bearing play p 49 Remove the motorcycle from the lift stand p 42 Position the handlebar cushion and secure with a cable tie 11 11 Checking the steering head bearing play Warning Danger of accid...

Page 52: ...ing head bearing and replace if required Finishing work Remove the motorcycle from the lift stand p 42 11 12 Adjusting the steering head bearing play Preparatory work Raise the motorcycle with a lift stand p 42 S03421 10 Main work Pull fuel tank breather 1out of the steering stem Loosen screws 2 Loosen screw 3 Loosen and retighten nut 4 Guideline Nut steering stem M20x1 5 10 Nm 7 4 lbf ft Using a ...

Page 53: ...ing the start number plate S04332 10 Remove screw 1 Unhook the start number plate from the brake line and remove it 11 15 Installing the start number plate S04333 10 Attach the start number plate to the brake line Position the start number plate Holding lugs 1engage in the fender S04334 10 Mount and tighten screw 2 Guideline Start number plate screw M6 4 Nm 3 lbf ft ...

Page 54: ... 4 4 lbf ft Mount and tighten screws 2 Guideline Screw front fender M6 6 Nm 4 4 lbf ft Finishing work Install the start number plate p 51 11 18 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 42 S04337 10 Main work Detach the brake line from the brake line guide Remove screw 1and lower the rear wheel with the link fork as far as possible without blocking the r...

Page 55: ...m 44 3 lbf ft Loctite 2701 Attach brake line Finishing work Remove the motorcycle from the lift stand p 42 11 20 Removing the seat S04338 10 Remove screw 1 Raise the rear of the seat pull the seat back and lift it off 11 21 Mounting the seat S04339 10 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 Make sure that the seat is c...

Page 56: ...e 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 filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Preparatory wor...

Page 57: ...cover p 54 Remove the air filter p 54 V00838 01 Main work Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 119 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high grade air filter oil Oil for foam air filter p 119 Clean the air filter box Check intake flange for damage and looseness Finishing work...

Page 58: ...m to cool down before performing any work on the vehicle S04343 10 Remove screw 1 Pull off the main silencer from the manifold at exhaust sleeve 2 11 28 Installing the main silencer S04343 11 Mount the main silencer with exhaust sleeve 1 Mount and tighten screw 2 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 o...

Page 59: ... Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no 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 poisoni...

Page 60: ...y of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spilled wipe it off immediately Observe the specifications for refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel D...

Page 61: ...5 11 Mount and tighten screw 1with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft S04344 11 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount fuel hose Position the fuel tank breather in the steering stem Finishing work Mount the seat p 53 11 32 Checking for chain dirt accumulation 400678 01 Check the chain for coarse dirt accumulati...

Page 62: ...e motorcycle with a lift stand p 42 400725 01 Main work Rinse off loose dirt with a soft jet of water Remove old grease residue with chain cleaner Chain cleaner p 119 After drying apply chain spray Off road chain spray p 119 Finishing work Remove the motorcycle from the lift stand p 42 11 34 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and resul...

Page 63: ...re quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 42 Check the chain tension p 60 S04279 10 Mai...

Page 64: ...et is worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 400987 10 Pull on the top section of the chain with the specified weight A Guideline Weight chain wear measure ment 10 15 kg 22 33 lb Measure distance Bof 18 chain rollers in the lower chain section Info Chain wear is not always even so you should repeat this measurement at diff...

Page 65: ... screws chassis M6 10 Nm 7 4 lbf ft H02310 01 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 401760 01 Che...

Page 66: ...d by GASGAS Motorcycles 11 38 Checking the link fork V00857 01 Check the link fork for damage cracking and deformation If the link fork shows signs of damage cracking or deformation Change the link fork Info Always replace a damaged link fork GASGAS Motor cycles does not permit repairing link forks 11 39 Checking the throttle cable routing Warning Danger of accidents The throttle cable may slip ou...

Page 67: ... and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 119 11 41 Adjusting the basic position of the clutch lever S04274 12 Adjust the basic position of the clutch lever to the size of the rider s hand using adjusting screw 1 Info Turn the adjusting screw clockwise to increase the distance between the clu...

Page 68: ...aulic clutch Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Ri...

Page 69: ... fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Note Environmen...

Page 70: ... screw 5and mount bleeding syringe 4 V00849 10 Inject the liquid into the system until it escapes from opening Aof the master cylinder without bubbles Now and then extract fluid from the master cylinder reservoir to prevent overflow Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 ...

Page 71: ...andbrake lever with adjustment screw 1 Info Turn the adjusting screw clockwise to reduce free travel The pressure point moves away from the handlebar Turn the adjusting screw counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while rid...

Page 72: ... workshop will 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 authorized GASGAS Motorcycles workshop will be glad to help V00864 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal position Check the brake fluid level in lev...

Page 73: ...rcycles 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 contact betwee...

Page 74: ...op will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with ...

Page 75: ...mpliance 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 S04284 11 Move the brake fluid reservoir mounted on the handlebar to a hori zontal positio...

Page 76: ...ter to immediately clean up any brake fluid that has overflowed or spilled 12 8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification 402026 ...

Page 77: ...er Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 3and tighten nut 2 Guideline Nut foot brake lever stop M8 20 Nm 14 8 lbf ft Hold push rod 5and tighten nut 4 Guideline Remaining nuts chas sis M6 10 Nm 7 4 lbf ft Attach spring 1 12 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the...

Page 78: ...the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with the skin Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes If brake fluid spills on to your clothing change the clothing Warning Danger of accidents Old brake fluid reduces the b...

Page 79: ...hat worn out brake linings are replaced immediately Your authorized GASGAS Motorcycles workshop will be glad to help S04287 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 77 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake lining...

Page 80: ...ed alter the braking efficiency Not all brake linings are tested and approved for GASGAS motorcycles The structure and friction coefficient of the brake linings and thus their brake power may vary greatly from that of original brake linings If brake linings are used that differ from the original equipment compliance with the original homologation is not guaranteed In this case the vehicle no longe...

Page 81: ...t easier to mount the pin push the brake linings upwards against the retainer spring Make sure the brake linings and retainer spring are seated correctly Mount cotter pins 3 Check the brake discs p 69 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point A00056 10 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 117 M...

Page 82: ...cs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold the front wheel and remove the wheel spindle Take the front wheel out of the fork Info Do not actuate the hand brake lever when the front wheel is removed H00934 10 Remove spacers 3 13 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the brak...

Page 83: ...brake linings are correctly positioned Insert the wheel spindle Mount and tighten screw 2 Guideline Screw front wheel spindle M20x1 5 35 Nm 25 8 lbf ft Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc Remove the motorcycle from the lift stand p 42 Operate the front brake and compress the fork a few times firmly The fork legs straighten ...

Page 84: ...the rear wheel and remove the wheel spindle Take the rear wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed H00936 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 ...

Page 85: ...on p 60 Tighten nut 4 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 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 42 13 5 Checking the tire condition Info Only mount tires approved and or recommended by GASGAS Motorcycles Other tires could have a ...

Page 86: ...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 87: ...WHEELS TIRES 13 85 Check the spoke torque Guideline Spoke nipple M4 5 5 Nm 3 7 lbf ft Torque wrench kit 58429094000 ...

Page 88: ...radiator between the radiator shield and radiator Info Do not use radiator covers in difficult operating conditions The radiator cover keeps the coolant temperature in the correct range Optimal coolant tem perature 60 70 C 140 158 F V00884 10 The radiator covers are installed in front of the radiator depending on the ambient temperature Full radiator cover right side 1and half radiator cover left ...

Page 89: ...ghten screws 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 14 4 Removing the radiator cover Info Only remove left radiator shield if both radiator covers are mounted V00886 10 Remove screws 1 Remove right radiator shield 2 Remove screws 3 Remove left radiator shield 4 Remove corresponding radiator cover Position right radiator shield 2 Mount and tighten screws 1 Guideline Remaining scre...

Page 90: ...he 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 Cond...

Page 91: ...ater in the event of contact with the skin Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing Condition The engine is cold 400243 10 Stand the motorcycle upright 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...

Page 92: ...move screw 1 Take off radiator cap 2 Completely drain the coolant Mount and tighten screw 1with a new seal ring Guideline Coolant drain plug M6 8 Nm 5 9 lbf ft 14 8 Refilling with coolant 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 immediatel...

Page 93: ...e coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature Allow the cooling system and the engine to cool down before you open the radiator the radiator hoses or other components of the cooling system In the event of scalding rinse the area affected immediately with l...

Page 94: ...870 10 Loosen screw 3until coolant escapes without bubbles Mount and tighten screw 3 Guideline Screw radiator bleed ing M6 8 Nm 5 9 lbf ft Mount radiator cap 2 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running the engine Use effective exhaust extraction when starting or run ning...

Page 95: ... starting or run ning the engine in an enclosed space Start the engine and let it run at idle speed Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 93 15 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 53 Turn the tap handle of the fuel tap to the OFF position...

Page 96: ...on POS The needle position has the greatest influence in the mid throttle slide range If the engine stutters when accelerating with a partially open throttle slide the jet needle must be lowered If the engine knocks when accelerating at the full power rpm range the jet needle must be raised Cylindrical part of the needle CYL The cylindrical part of the needle has the greatest influence when the th...

Page 97: ... and the clip position have the greatest influence The influence of the first cylindrical part of the needle is less When the throttle slide is 1 2 open the position of the needle has the greatest influence The influence of the main jet and the idling jet is only minimal K00497 01 When the throttle slide is 3 4 open the influence of the main jet is greatest The clip position and the idling jet hav...

Page 98: ...00075 10 Clip position 1 5 Clip position from above The five possible clip positions are shown here The carburetor tuning depends on the defined ambient and operating conditions 15 4 Carburetor idle 402799 10 The idle setting of the carburetor has a big influence on the starting behavior stable idling and the response to throttle opening This means that an engine with a correctly set idle speed is...

Page 99: ... in to the stop p 16 Idle speed 1 400 1 500 rpm Turn idle air adjusting screw 1slowly in a clockwise direction until the idle speed begins to fall Note the position and turn the idle air adjusting screw slowly coun terclockwise until the idle speed again begins to fall Adjust to the point between these two positions with the highest idle speed Info If there is a big engine speed rise reduce the id...

Page 100: ...el vapors In case of skin contact rinse the affected area with plenty of water Rinse the eyes thoroughly with water and consult a doctor in case of fuel contact with the eyes Change your clothing in case of fuel spills on them Keep fuels correctly in a suitable canister and out of the reach of children Note Environmental hazard Improper handling of fuel is a danger to the environment Do not allow ...

Page 101: ... Switching the ignition timing map from Soft to Performance Join plug in connector 1of the ignition timing map adjustment Figure T01480 10 p 99 Performance Higher performance 15 9 Checking the basic position of the shift lever Info When driving the shift lever must not touch the rider s boot when in the basic position When the shift lever keeps touching the boot the transmission will be subject to...

Page 102: ... on the shift shaft in the required position and engage gearing Info The range of adjustment is limited The shift lever must not come into contact with any other vehicle components during the shift procedure Mount and tighten screw 1with the washers Guideline Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 ...

Page 103: ...r 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 the ...

Page 104: ...en 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 101 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 S04352 10 Main work Remove screw 1with the seal ring 401955 11 Remove ...

Page 105: ...ing 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 Finishing work Check the gear oil level p 101 ...

Page 106: ...when cleaning 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 119 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehicle always rinse...

Page 107: ...ng parts and pivot points Clean the chain p 60 Treat bare metal except for brake discs and the exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 119 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 120 ...

Page 108: ...d 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 add fuel additive Fuel additive p 119 Refuel p 28 Clean the motorcycle p 104 Change the gear oil p 101 Check the antifreeze and coolant level p 88 Check tire pressure p 84 Empty the carburetor float cha...

Page 109: ...STORAGE 18 107 18 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 42 Perform checks and maintenance measures when preparing for use p 25 Take a test ride ...

Page 110: ...he idle speed p 97 Spark plug defective Change the spark plug Ignition system defective Check the ignition coil Check the spark plug connector Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor components Loose carburetor jets Check set the carburetor components Fault in ignition system Check the ignition system Adjust the ignition Engine h...

Page 111: ... Foam formation in cooling system Drain the coolant p 89 Refill with coolant p 90 Damaged cylinder head or cylin der head gasket Check the cylinder head and cylinder head gasket Bent radiator hose Change the radiator hose Incorrect ignition point due to loose stator Adjust the ignition White smoke emission steam in exhaust gas Damaged cylinder head or cylin der head gasket Check the cylinder head ...

Page 112: ...ssion ratio 1st gear 11 29 2nd gear 14 28 3rd gear 16 26 4th gear 19 26 5th gear 21 25 6th gear 20 21 Ignition Kokusan 504 Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Cooling Water cooled Starting aid Kick starter lever 20 2 Engine tightening torques Screw adjusting lever M5x16 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 lbf ft Screw control lever M...

Page 113: ...ate clutch cover M6x55 10 Nm 7 4 lbf ft Screw intermediate clutch cover M6x60 10 Nm 7 4 lbf ft Screw kick starter intermediate gear M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter lever stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw outer clutch cover M6x25 8 Nm 5 9 lbf ft Screw outer clutch cover M6x55 8 Nm 5 9 lbf ft Screw outer clutch cover M6x60 8 Nm 5 9 lbf ft Screw radiator bleeding M6 ...

Page 114: ...1 501 2 300 m 4 925 7 546 ft ASO IJ NDL POS MJ 2 48 NRK C 3 145 2 45 NRK C 3 142 2 42 NRK C 3 142 1 5 42 NRJ C 3 140 2 42 NRJ C 3 138 1 5 40 NRJ C 3 138 751 1 500 m 2 464 4 921 ft ASO IJ NDL POS MJ 2 48 NRJ C 4 145 2 48 NRK C 3 145 2 45 NRK C 3 142 2 42 NRK C 3 142 1 5 42 NRJ C 3 140 2 42 NRJ C 3 138 301 750 m 988 2 461 ft ASO IJ NDL POS MJ 2 48 NRJ C 4 148 1 5 48 NRK C 3 148 2 48 NRK C 3 145 2 45...

Page 115: ...uel Fuel tank capacity approx 5 2 l 1 37 US gal Super unleaded 98 octane mixed with 2 stroke engine oil 1 40 p 118 20 5 Chassis Frame Central tube frame of chrome molybdenum steel tubing powder coated Fork WP Suspension XACT 5543 Shock absorber WP SuspensionXACT 5746 Suspension travel front 278 mm 10 94 in rear 305 mm 12 01 in Fork offset 14 mm 0 55 in Brake system front Disc brake with 4 piston b...

Page 116: ... in the Service section under http www gasgas com 20 7 Fork Fork article number 43 18 8U 04 Fork WP Suspension XACT 5543 Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Fork length 845 mm 33 27 in Oil capacity external mechanism right 363 10 ml 12 27 0 34 fl oz Fork oil SAE 4 48601166S1 p 118 Oil capacity e...

Page 117: ...nt brake M6 8 Nm 5 9 lbf ft Pin rear brake M6 4 Nm 3 lbf ft Remaining nuts chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M6 10 Nm 7 4 lbf ft Screw for throttle grip M6 5 Nm 3 7 lbf ft Screw ball joint of push rod on foot brake cylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw foot brake cylinder M6 10 Nm 7 4 lbf ft Screw front brake disc M6 14 Nm 10 3 lbf ft Loctite 243 Screw front fender M6 6...

Page 118: ...ver M10 45 Nm 33 2 lbf ft Loctite 243 Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Screw bottom shock absorber M12 60 Nm 44 3 lbf ft Loctite 2701 Screw top shock absorber M12 60 Nm 44 3 lbf ft Loctite 2701 Nut seat fixing M12x1 20 Nm 14 8 lbf ft Nut swingarm pivot M14x1 5 75 Nm 55 3 lbf ft Nut ...

Page 119: ...ns on the container and that has the rele vant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with other co...

Page 120: ... p 121 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corre sponding properties Super unleaded ROZ 98 RON 98 PON 94 Standard classification DIN EN 228 ROZ 98 RON 98 PON 94 Super unleaded 98 octane mixed with 2 stroke engine oil 1 40 Standard classification DIN EN 228 JASO FD p 121 1 40 Mixture ratio 1 40 Engine oil ...

Page 121: ... 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 122: ...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 123: ...t motorcycle engines the transmission and clutch are lubricated with the same oil The JASO T903 MA2 standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a classificati...

Page 124: ...24 LIST OF ABBREVIATIONS 122 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 125: ...hain checking 62 cleaning 60 Chain guide checking 62 Chain tension adjusting 61 checking 60 Choke 16 Cleaning 104 105 Clutch fluid level checking 66 fluid level correcting 66 fluid changing 67 Clutch lever 14 basic position adjusting 65 Compression damping fork adjusting 40 Coolant changing 91 draining 89 refilling 90 Coolant level checking 88 89 Cooling system 86 Customer service 9 D Difficult op...

Page 126: ... 46 Lowspeed compression damping shock absorber adjusting 33 M Main silencer glass fiber yarn filling changing 56 installing 56 removing 56 Manufacturer warranty 9 Misuse 6 Motorcycle cleaning 104 lift stand raising with 42 removing from lift stand 42 O Owner s Manual 8 P Play in throttle cable adjusting 93 checking 93 Plug in stand 17 Preparing for use advice on preparing for first use 18 after s...

Page 127: ...ring play adjusting 50 checking 49 Storage 106 Switch off button 14 T Technical data capacities 113 carburetor 112 chassis 113 chassis tightening torques 115 engine 110 engine tightening torques 110 fork 114 shock absorber 114 tires 114 Throttle cable routing checking 64 Throttle grip 14 Tire condition checking 83 Tire pressure checking 84 Transporting 28 Troubleshooting 108 109 Type label 12 U Us...

Page 128: ... 3215007en 3215007en 07 2020 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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