GAS GAS MC-E 5 Owner'S Manual Download Page 71

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BRAKE SYSTEM 14

M01696-10

Main work

–

Remove screws

–

Take off cover

with washer

and membrane

H01654-10

–

Add brake fluid up to level

Guideline

Level

(brake fluid level

below reservoir rim)

10 mm (0.39 in)

Brake fluid DOT 4 / DOT 5.1 (

p. 93)

–

Position cover with washer and membrane.

–

Mount and tighten the screws.

Info

Immediately clean up any brake fluid that has overflowed or
spilled using water.

Finishing work

–

Remove the motorcycle from the lift stand. (

p. 42)

14.14

Checking the brake linings of the rear brake

Warning

Danger of accidents

Worn-out brake linings reduce the braking effect.

–

Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop
will be glad to help.)

F02204-10

–

Check the brake linings for minimum thickness

Minimum thickness

≥

1 mm (

≥

0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings.

(

p. 70)

–

Check the brake linings for damage and cracking.
» If damage or wear is encountered:

–

Change the rear brake linings.

(

p. 70)

Summary of Contents for MC-E 5

Page 1: ...OWNER S MANUAL 2021 MC E 5 Art no 3215004en ...

Page 2: ......

Page 3: ...ments in design cannot be ruled out completely All specifications contained herein are non binding GASGAS Motorcycles GmbH specifically reserves the right to modify or delete technical specifications prices colors 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 ...

Page 4: ... indicator lamp 19 7 5 Charging level indicator 19 7 6 Power reduction 20 8 PREPARING FOR USE 21 8 1 Advice on preparing for first use 21 9 RIDING INSTRUCTIONS 23 9 1 Checks and maintenance measures when preparing for use 23 9 2 Starting the vehicle 23 9 3 Starting off 24 9 4 Applying the brakes 24 9 5 Recuperation 25 9 6 Stop park 25 9 7 Transporting 26 10 SERVICE SCHEDULE 27 10 1 Additional info...

Page 5: ...14 3 Adjusting the basic position of the hand brake lever 59 14 4 Checking the brake discs 60 14 5 Checking the front brake fluid level 60 14 6 Adding front brake fluid 62 14 7 Checking the front brake linings 63 14 8 Changing the brake linings of the front brake 63 14 9 Checking the free travel of the foot brake lever 66 14 10 Adjusting the free travel of the foot brake lever 66 14 11 Adjusting t...

Page 6: ...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 7: ...e missing you or others may not recognize dangers and may therefore be injured 2 4 Grades of risks Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken Note Identifies a danger that will lead to considerable machine and material da...

Page 8: ...y when using an electric motor If the throttle grip is closed and no recuperation p 25 is activated the vehicle continues to roll without much delay The vehicle speed decreases on account of rolling resistance and air resistance Because this vehicle does not have a manual transmission there is no clutch As with a conventional drive with a combustion engine the operating temperature rises according...

Page 9: ... help protect the future of motorcycle sport and avoid most conflicts and problems When disposing of used oil other operating and auxiliary fluids and used components comply with the applicable laws and regulations in your country When disposing of the lithium ion battery Powerpack LV observe the relevant laws and guidelines of your country Your authorized GASGAS Motorcycles dealer can dispose of ...

Page 10: ...Massive mechanical damage may cause an internal cell short circuit and as a consequence may cause the battery to self ignite Contact GASGAS Motorcycles customer service immediately if major damage to the rechargeable lithium ion battery has occurred There is no particular fire hazard for this vehicle when the rechargeable lithium ion battery Powerpack LV is intact However should the vehicle catch ...

Page 11: ...uisite for perfect operation and prevention of premature wear is that the service care and tuning work is properly carried out as described in the Owner s Manual An incorrect suspension setting can lead to damage and breakage of chas sis components Use of the vehicle under difficult conditions such as on sand or on wet and muddy surfaces can result in significantly increased wear of components suc...

Page 12: ... temperatures In order to protect the Powerpack LV the motor control reduces the power at low component temperatures If the temperature of the Powerpack LV is too low the active ride mode indicator flashes The vehicle can continue to be operated The Powerpack LV is not damaged by the power reduction The Powerpack LV heats up when the vehicle is in operation When the temperature of the Powerpack LV...

Page 13: ...VIEW OF VEHICLE 4 11 4 1 View of vehicle front left example M01864 10 1 Magnetic switch on handlebar p 15 2 Quick release of seat 3 Plug in stand holder 4 Charging socket ...

Page 14: ...01865 10 1 Quick release of seat 2 Multifunctional element p 18 3 Magnetic switch on handlebar p 15 4 Throttle grip p 15 5 Hand brake lever p 15 6 Vehicle identification number p 13 7 On Off button p 15 8 Foot brake lever p 16 9 Level viewer for brake fluid rear ...

Page 15: ...e right side of the steering head 5 2 Type label 402154 10 The type label 1is located on the front frame tube 5 3 Motor number H03863 10 The motor number 1is located on the right side of the motor below the Powerpack LV 5 4 Fork part number 401947 10 The fork part number 1is stamped on the outside of the axle clamp ...

Page 16: ...mber H01186 10 The shock absorber article number 1is stamped on the bottom of the shock absorber toward the right hand side 5 6 Battery identification number M01631 10 The battery identification number BIN 1is located on a sticker on the Powerpack LV ...

Page 17: ...switch to ready mode 6 3 On Off button M01831 10 The On Off button 1is located on the right side of the Powerpack LV Possible states Vehicle switched off In this operating state the vehicle is deacti vated Vehicle in standby mode In this operating state the vehicle is activated 6 4 Magnetic switch on handlebar M01657 10 The holder for the red magnetic switch 1is located on the left side of the han...

Page 18: ...itch 1is located under the seat By removing the gray magnetic switch under the seat you can prevent the ride mode from being changed Locking the ride mode is recommended if you have not yet gained suffi cient experience for higher ride modes with more power and torque Possible states Magnetic switch mounted under the seat When the magnetic switch is mounted under the seat the ride mode can be chan...

Page 19: ...CONTROLS 6 17 6 8 Diagnostics connector H03809 01 Diagnostics connector 1is located under the seat ...

Page 20: ... indicator lamp p 19 4 Charging level indicator p 19 7 2 Ride mode button 402133 10 The ride mode button 1determines the ride mode p 19 The ride mode button is only active if the magnetic switch under the seat p 16 is mounted Possible states The vehicle is in standby mode The ride mode button is active The vehicle is in ready mode The ride mode button is active All other vehicle conditions The rid...

Page 21: ...tion p 25 is available Ride modes 1 to 3 are indicated by the illuminated single digit When ride modes 4 5 and 6 are activated the activated ride mode is displayed as the sum of the illuminated digits Info When the magnetic switch under the seat p 16 is not mounted the ride mode cannot be changed The ride modes are switched through in ascending order after ride mode 6 the ride mode jumps back to 1...

Page 22: ... up in red charging level 0 10 7 6 Power reduction 402136 11 If the charging level p 19 of the Powerpack LV is too low or the sys tem temperature is outside of the permissible range the power is auto matically reduced The selected ride mode and the malfunction indicator lamp flash when the power has been reduced Info The blink code of malfunction indicator lamp 1can be used to determine the reason...

Page 23: ...ng 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 characteristic Different tire tread patterns can make the vehicle significantly more difficult to control Make sure that on...

Page 24: ... by pushing your child Do not start the motor until your child is able to apply the necessary front brake pressure Your child should begin by riding to another person who can help your child stop and turn Erect obstacles for your child to navigate around so that your child becomes accustomed to handling the vehicle Your child should also try to ride as slowly as possible and in a standing position...

Page 25: ...s functioning properly Check the chain for dirt p 52 Check the chain rear sprocket motor sprocket and chain guide p 55 Check the chain tension p 53 Check the tire condition p 76 Check tire pressure p 77 Check the spoke tension p 77 Info The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 43 Bleed the fork...

Page 26: ...ng Open the throttle carefully 9 4 Applying the brakes Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels Explain to your child that he or she must adapt the braking to the traffic situation and the road conditions Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency Check the brake system and do not all...

Page 27: ...horization endanger themselves and others Never leave the vehicle unattended 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 motor lithium ion battery damper or brake system before these vehicle parts have cooled down Let the vehicle parts cool down before you ...

Page 28: ...hazard and explosion risk Do not park the vehicle near to materials which are highly flammable or explosive Allow the vehicle to cool down before covering it 401475 01 Press and hold the On Off button until the multifunctional element goes out Remove the magnetic switch from the holder on the handlebar Use tension belts or other suitable devices to secure the motorcycle against falling over or rol...

Page 29: ...that the electrical system is functioning properly Check and charge the Powerpack LV Check the front brake linings p 63 Check the brake linings of the rear brake p 69 Check the brake discs p 60 Check the brake lines for damage and leakage Change the foot brake cylinder sealing cup Check the rear brake fluid level p 67 Check the free travel of the foot brake lever p 66 Check the frame p 57 Check th...

Page 30: ...interval Periodic interval 10 3 Recommended work every 12 months Every 40 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 49 Check the pinion shaft bearings O rings and the bearing seals Change the pinion shaft...

Page 31: ... fork In this system suspension is located in the left fork leg and damping in the right fork leg A significant weight advantage is achieved compared with 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 32: ...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 33: ...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 34: ...ve the motorcycle from the lift stand p 42 11 8 Checking the static sag of the shock absorber 400989 10 Measure dimension Aof rear wheel unloaded p 32 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 35: ...orber 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 Preparatory work Raise the motorcycle with a lift stand p 42 Remove the shock absorber p 51 After removing the shoc...

Page 36: ...e the shock absorber p 51 After removing the shock absorber clean it thoroughly B00292 10 Main work Choose and mount a suitable spring Guideline Spring rate Weight of rider 15 25 kg 33 55 lb 25 N mm 143 lb in Weight of rider standard 25 35 kg 55 77 lb 30 N mm 171 lb in Weight of rider 35 45 kg 77 99 lb 35 N mm 200 lb in Info The spring rate is shown on the outside of the spring Smaller weight diff...

Page 37: ...e recommended range Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic Info Check or adjust the air pressure 5 minutes at the earliest after the end of the ride and under the same conditions The air suspension is located in the left fork leg The rebound damping is located in the right fork leg Preparatory work...

Page 38: ...matically after 80 seconds Mount the protection cap Info Only mount the protection cap by hand Finishing work Remove the motorcycle from the lift stand p 42 11 14 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior M01834 10 Turn adjuster 1clockwise all the way Info Adjuster 1is located at the upper end of the right fork leg Turn cou...

Page 39: ...becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent M01659 11 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 handlebar supports Place handlebar supports in required position Mount and ...

Page 40: ...Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic Info If the seat height is adjusted on the shock absorber the seat height should also be adjusted on the fork Preparatory work Raise the motorcycle with...

Page 41: ...nd p 42 Remove the front wheel p 73 M01836 10 Main work Loosen screw 1 Loosen screw 2 Position the fork leg according to the required seat height Guideline Condition Seat position as low as possible fork fully inserted Minimum distance A between the fork and handlebar 3 mm 0 12 in Condition Seat position as high as possible fork pulled out completely Bottom edge of screw cap Bcloses flush with the...

Page 42: ...ition subframe 7at the drill holes at the desired seat height Guideline Pay attention to the wiring harness High seat position Drill holes A Low seat position Drill holes B Mount and tighten screws 6 Guideline Screw subframe M8 30 Nm 22 1 lbf ft Loctite 243 M01838 10 Position rear fairing 5 mount screws 4with bushings and tighten Guideline Rear fairing screw M6 8 Nm 5 9 lbf ft Position splash prot...

Page 43: ...ndition Low seat position Make sure that the thread adapter is removed Info Retain the thread adapter for later assembly M01839 10 Position the front fairing on holders C The holding lugs of the front fairing engage in the recesses of the rear fairing on both sides M01837 10 Mount and tighten screw 1 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Mount the seat p 52 ...

Page 44: ... of damage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 402581 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand 1into the plug in stand bracket on the left side of the vehicle Info Remove the plug in stand before riding 13 3 Bleeding the fork legs Preparatory work Raise the motorcycle with a...

Page 45: ...rt 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 94 Press the dust boots back into the installation position Remove the excess oil Finishing work Insta...

Page 46: ...heel p 73 M01840 10 Main work Remove screws 1and take off the clamp Remove screws 2and take off the brake caliper Allow the brake caliper and the brake line to hang loosely to the side Info Do not kink the brake line M01842 10 Note the installation position of the fork legs Loosen screws 3 Remove the left fork leg Loosen screws 4 Remove the right fork leg 13 8 Installing the fork legs F02179 10 Co...

Page 47: ...bf ft Loctite 243 Position the brake line and the clamp Mount and tighten screws 6 Guideline Screw brake line clamp on fork protector EJOT PT K60x20 AL 2 Nm 1 5 lbf ft Finishing work Install the front wheel p 73 13 9 Removing the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 42 Remove the front wheel p 73 Remove the fork legs p 44 Remove the start number plate p 49 R...

Page 48: ...le clamp F02885 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 94 Insert the lower triple clamp with the steering stem Mount upper steering head bearing 1 Check that the O ring at the top 2is correctly positioned Push on protective ring 3 M01844 11 Position the upper triple clamp with the handlebar Mount nut 4 but do not tighten it yet ...

Page 49: ...8 15 Nm 11 1 lbf ft M01845 10 Tighten nut 4 Guideline Nut steering head M20x1 5 10 Nm 7 4 lbf ft Tighten screw 7 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten screws 8 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Fix the magnetic switch cable to the handlebar with a new cable tie M01843 11 Posit...

Page 50: ...nfo If the vehicle is operated for a lengthy period with play in the steering head bearing the bearings and the bearing seats in the frame can become damaged over time Preparatory work Raise the motorcycle with a lift stand p 42 H01167 01 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel Play should not be detectable on the steerin...

Page 51: ...p triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 1 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Finishing work Check the steering head bearing play p 48 Remove the motorcycle from the lift stand p 42 13 13 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 45 Install the lower triple clamp p 46 Info The steering head bearing is cleaned and lubricated in the ...

Page 52: ... start number plate Holding lugs 1engage in the fender M01849 10 Mount and tighten screw 2 Guideline Screw start number plate M6 4 Nm 3 lbf ft 13 16 Removing front fender M01851 10 Remove screws 1 Take off the front fender 13 17 Installing front fender M01850 10 Position the fender with drill holes 1in the holding lugs on the start number plate ...

Page 53: ...r Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic M01852 11 Main work Push splash protector 1to the side Mount the shock absorber with screw 2 Guideline If necessary observe the installation p...

Page 54: ...t and remove it 13 21 Mounting the seat M01854 10 Hook the seat onto holding lug 1 lower the seat at the rear and push it forward Holding lug 2hangs on the front fairing M01853 11 Close quick release 3 13 22 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 53 ...

Page 55: ...rcycle 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 94 After drying apply chain spray Off road chain spray p 94 Finishing work Remove the motorcycle from the lift stand p 42 13 24 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in ac...

Page 56: ...reak 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 53 Q00401 10 Main work Loosen nut 1 Loosen nuts ...

Page 57: ... joint always make sure that the closed side of the joint faces forward riding direction Check the chain for wear If the chain is worn Change the drivetrain kit Info When a new chain is mounted the rear sprocket and motor sprocket should also be changed New chains wear out faster on old worn sprockets Q00402 10 Check the chain sliding guard for wear If the ridge is worn down to the level of the ma...

Page 58: ...ten screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 400985 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide is worn Change the chain guide M01693 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining scr...

Page 59: ...ct Repair of the frame is not authorized by GASGAS Motorcycles 13 29 Checking the link fork F02202 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 13 30 Checking the rubber grip 401197 01 Check the rubber gri...

Page 60: ...13 SERVICE WORK ON THE CHASSIS 58 M01695 10 Check that screw 1is firmly seated Guideline Screw fixed grip M4 5 Nm 3 7 lbf ft Loctite 243 Diamond Amust be located at the top ...

Page 61: ...ing the play of the hand brake lever Q00410 10 Check the play of the handbrake lever p 59 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 14 3 Adjusting the basic position of the hand brake lever Q00413 10 Remove screw 1 Take off cover 2 Q00412 10 Check the play of the handbrake lever p 59 Adjust the basic position of the hand b...

Page 62: ...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 14 5 Checking the front brake fluid level Warning Danger of accidents An insuffici...

Page 63: ...uthorized GASGAS Motorcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease cleaning agents brake fluid etc properly and in compliance with the applicable regula tions 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...

Page 64: ...ake fluid 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 cle...

Page 65: ... cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized GASGAS Motorcy cles workshop will be glad to help Warning 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 clothi...

Page 66: ...f oils grease cleaning agents brake fluid etc properly and in compliance with the applicable regula tions 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 the...

Page 67: ...cs free of oil and grease Clean the brake discs with brake cleaner when neces sary Check the brake discs p 60 M01857 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 Q00414 10 Check the brake fluid level and correct if nece...

Page 68: ... travel of the hand brake lever p 66 Attach spring 1 14 10 Adjusting 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 rear brake Set the free travel on the foot brake lever in accordance with the specification M01694 11 Detach the fo...

Page 69: ... free travel A Guideline Free travel of foot brake lever 3 5 mm 0 12 0 2 in Hold push rod 2and tighten nut 1 Attach the foot brake lever spring Check whether the basic position of the foot brake lever is suitable for the rider 14 12 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail If the brake fluid level drops be...

Page 70: ...uid 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 braking effect Make sure that brake fluid for the front and re...

Page 71: ...shing work Remove the motorcycle from the lift stand p 42 14 14 Checking the brake linings of the rear brake Warning Danger of accidents Worn out brake linings reduce the braking effect Ensure that worn out brake linings are replaced immediately Your authorized GASGAS Motorcycles workshop will be glad to help F02204 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 i...

Page 72: ...il 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 Warning Danger of accidents Brake linings which have not been approved 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 t...

Page 73: ...asic position and ensure that brake fluid does not flow out of the brake fluid reservoir extracting some if necessary F02207 11 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 Position the brake caliper on the brake disc The brake linings are correctly positioned F02206 10 Mount and tighten sc...

Page 74: ...point 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 93 Position cover with washer and membrane Mount and tighten the screws 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 42 ...

Page 75: ...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 15 2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil...

Page 76: ...e wheel spindle M01697 10 Mount and tighten screw 1 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 42 Operate the front brake and compress the fork a few times firmly The fork legs straighten Tighten screws 2 Guideline Scr...

Page 77: ... the rear wheel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed F02175 10 Remove spacers 4 15 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 F02176 11 Main work Check the wheel be...

Page 78: ... tires approved and or recommended by GASGAS Motorcycles Other tires could have a negative effect on handling characteristics The type condition and pressure of the tires all have a major impact on the handling characteristic of the motorcy cle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on handling characteristics especially on wet ...

Page 79: ...t 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 run out will form in the wheel Other spokes will become looser as a result Check spoke tension regularly and in particular on a new vehicle Your authorized GASGAS Motorcycles work shop will be glad to help 400694 01 Strike each spoke brie...

Page 80: ...er housing Do not insert any objects into the battery charger housing from the outside Do not use the battery charger if cables plugs or parts of the battery charger have been damaged or are soiled Info The battery charger contains sensitive electronics and must be handled with appropriate care The battery charger may be damaged or destroyed if it is dropped knocked or otherwise subject to mechani...

Page 81: ... A Fuse protection at mains voltage 120 V minimum 13 A Fuse protection at mains voltage 230 V minimum 10 A Note Environmental hazard A lithium ion battery Powerpack HV contains components and elements that are harmful to the environment Never throw a Powerpack HV into the household trash Dispose of the Powerpack HV properly and in compliance with the applicable regulations Your authorized GAS GAS ...

Page 82: ...ct the battery charger to the Powerpack LV Guideline Observe plug marking A Insert the plug straight so that the contacts are not bent M01728 02 Connect the power plug for the battery charger to the mains con nection Charging starts automatically The multifunctional element indicates the charging level Monitor the charging level of the Powerpack LV on the multifunctional element p 19 Info It is re...

Page 83: ...ble from the Powerpack LV Guideline Pull on the structured part of the plug Do not pull on the cable M01686 10 Mount charging plug protection cap 2 M01859 10 Check charging socket protection cap 1 If the charging socket protection cap is dirty Clean the charging socket protection cap without water or compressed air If the charging socket protection cap is damaged or worn Change the charging socket...

Page 84: ...17 1 Cooling M01866 10 The Powerpack LV 1and the electric motor 2are air cooled Cooling is effected by the air stream The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect ...

Page 85: ... 401061 01 Remove the coarse dirt particles with a gentle water jet Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Motorcycle cleaner p 94 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry motorcycle Always rinse the motorcycle with water before use After rinsing the motorcycle wi...

Page 86: ...18 CLEANING CARE 84 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 94 ...

Page 87: ...e last segment lights up yellow Tip If necessary ride the vehicle to deplete the Powerpack LV sufficiently Store the vehicle in a dry location that is not subject to large fluctua tions in temperature Guideline Ideal storage temperature 10 20 C 50 68 F Info GASGAS Motorcycles recommends jacking up the motorcy cle Raise the motorcycle with a lift stand p 42 Cover the motorcycle with a tarp or cover...

Page 88: ...r from the vehicle and mains connection wait 1 minute restart the charging process Blink code 33 System temperature too high Allow the vehicle to cool down clean the cooling surfaces Blink code 34 System temperature too low Park the vehicle in a warmer environment Blink code 41 Vehicle moved during activation Do not move the vehicle during activation Blink code 42 Motor speed outside the permissi ...

Page 89: ...TROUBLESHOOTING 20 87 Faults Possible cause Action Blink code 88 Fault in the On Off button Deactivate the vehicle wait 4 minutes reactivate the vehicle Check the On Off button for damage ...

Page 90: ...e 4 71 km h 44 1 mph Ride mode 5 73 km h 45 4 mph Ride mode 6 73 km h 45 4 mph Maximum motor speed 6 000 rpm Cooling Air cooling 21 2 Chassis Frame Central tube frame of chrome molybdenum steel tubing powder coated Fork WP XACT 5235 Shock absorber WP XACT 5735 Suspension travel front 205 mm 8 07 in rear 185 mm 7 28 in Fork offset 22 mm 0 87 in Brake system front Disc brake with 4 piston brake cali...

Page 91: ...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 5 Fork Fork article number 07 18 6U 02 Fork WP XACT 5235 Rebound damping Comfort 15 clicks Standard 12 clicks Sport 10 clicks Air pressur...

Page 92: ...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 93 21 7 Chassis tightening torques Screw brake line clamp on fork pro tector EJOT PT K60x20 AL 2 Nm 1 5 lbf ft Screw brake line clamp on link fork EJOT SF M5x10 K 2 Nm 1 5 lbf ft Screw magnetic switch on handlebar M3 0 8 Nm 0 59 lbf ft Spoke nipple M3 5 3 Nm 2 2 lbf ft Screw fixed gr...

Page 93: ... 1 lbf ft Screw chain securing guide M8 15 Nm 11 1 lbf ft Screw chain sliding piece M8 15 Nm 11 1 lbf ft Screw engine bracket M8 25 Nm 18 4 lbf ft Loctite 243 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 Powerpack LV front M8x25 20 Nm 14 8 lbf ft Screw Powerpack LV rear M...

Page 94: ...21 TECHNICAL DATA 92 Nut swingarm pivot M12x1 45 Nm 33 2 lbf ft Nut steering head M20x1 5 10 Nm 7 4 lbf ft ...

Page 95: ...DOT 4 MOTOREX Brake Fluid DOT 5 1 Fork oil SAE 4 48601166S1 Standard classification SAE p 95 SAE 4 Guideline Use only oils that comply with the specified standards see specifications on the container and that exhibit the corre sponding properties Shock absorber fluid SAE 2 5 50180751S1 Standard classification SAE p 95 SAE 2 5 Guideline Use only oils that comply with the specified standards see spe...

Page 96: ...Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Special cleaner for glossy 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...

Page 97: ... 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 98: ...25 INDEX OF SPECIAL TERMS 96 BIN Battery identification number Serial number of the Powerpack HV this is linked to the vehicle s identification number ...

Page 99: ...LIST OF ABBREVIATIONS 26 97 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 100: ...ls Yellow and orange symbols indicate an error condition that requires prompt intervention Active driving aids are also repre sented by yellow or orange symbols The malfunction indicator lamp flashes A fault is present in the vehicle electronic system ...

Page 101: ...gine Work 7 Environment 7 F Fall 6 Figures 9 Fire hazard 8 Foot brake lever 16 basic position adjusting 67 free travel adjusting 66 free travel checking 66 Fork legs air pressure adjusting 35 basic setting checking 35 bleeding 42 dust boots cleaning 43 installing 44 removing 44 Fork part number 13 Fork protector installing 44 removing 43 Frame checking 57 Front fender installing 50 removing 50 Fro...

Page 102: ...Work 7 Recuperation 25 Ride mode button 18 Ride mode display 19 Riding sag adjusting 34 Rubber grip checking 57 S Safe operation 6 Seat mounting 52 removing 52 Seat height adjusting on the fork 39 adjusting on the frame 40 adjusting on the shock absorber 38 adjustment options 38 Service 9 Service schedule 27 28 Shock absorber installing 51 removing 51 riding sag checking 33 spring preload adjustin...

Page 103: ...INDEX 101 V Vehicle Work 7 Vehicle identification number 13 View of vehicle front left 11 rear right 12 ...

Page 104: ... 3215004en 3215004en 08 2020 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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