GAS GAS MC50 2021 Owner'S Manual Download

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11 SERVICE WORK ON THE CHASSIS

11.42

Additionally securing the rubber grip

Preparatory work

–

Check the rubber grip. (

p. 59)

401198-01

Main work

–

Secure the rubber grip at two locations with the retaining wire.

Securing wire (54812016000)
Wire twister forceps (U6907854)

The twisted wire ends face away from the palms and are bent
in toward the rubber grip.

Summary of Contents for MC50 2021

Page 1: ...OWNER S MANUAL 2021 MC 50 Art no 3215005en...

Page 2: ......

Page 3: ...rs 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 pri...

Page 4: ...Additional information 24 9 2 Required work 24 9 3 Recommended work 25 10 TUNING THE CHASSIS 26 10 1 Checking the basic chassis setting with rider s weight 26 10 2 Air suspension XACT 5235 26 10 3 Co...

Page 5: ...free travel of the foot brake lever 69 12 11 Adjusting the basic position of the foot brake lever 69 12 12 Checking the rear brake fluid level 70 12 13 Adding rear brake fluid 70 12 14 Checking the b...

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

Page 7: ...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 t...

Page 8: ...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 label...

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 run...

Page 10: ...y 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...

Page 11: ...les 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...

Page 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example F02964 10 1 Fuel tank filler cap 2 Quick release of seat 3 Chain guide 4 Plug in stand p 16 5 Choke 6 Fuel tap p 15...

Page 13: ...w of vehicle rear right example F02965 10 1 Stop button p 14 2 Throttle grip p 14 3 Hand brake lever p 14 4 Vehicle identification number p 12 5 Kick starter lever p 16 6 Foot brake lever p 16 7 Level...

Page 14: ...ight side of the steering head 5 2 Type label 402154 10 The type label 1is located on the front frame tube 5 3 Engine number 401949 11 The engine number 1is located on the left side of the engine unde...

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

Page 16: ...ition circuit is closed and the engine can be started Stop button pressed In this position the ignition circuit is inter rupted a running engine stops and a non running engine will not start 6 4 Openi...

Page 17: ...vironmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system F02968 10 Turn fuel tank filler cap 1counterclockwi...

Page 18: ...ke function deactivated The choke lever is pushed in to the stop 6 8 Kick starter lever H01184 10 Kick starter lever 1is fitted on the right side of the engine The kick starter lever can be swiveled I...

Page 19: ...ng 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 Whe...

Page 20: ...me 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 l...

Page 21: ...d the specified engine performance Guideline Maximum engine performance During the first 3 operating hours 70 During the first 5 operating hours 100 Info The use of a service hour counter is recommend...

Page 22: ...ect spoke tension will strongly impair riding safety Clean the dust boots of the fork legs p 38 Bleed the fork legs p 37 Check the air filter Check the settings of all controls and ensure that they ca...

Page 23: ...s been activated deactivate it after the engine has warmed up After reaching maximum speed by fully opening the throttle grip turn the throttle back so it is open This will barely reduce the speed but...

Page 24: ...The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for th...

Page 25: ...and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected area with plent...

Page 26: ...p Check the rear brake fluid level p 70 Check the free travel of the foot brake lever p 68 Check the frame p 58 Check the link fork p 59 Check the fork bearing for play Check the shock absorber heim j...

Page 27: ...nths every 12 months Every 80 operating hours After 20 operating hours Every 20 operating hours After 10 operating hours Change the front brake fluid Change the rear brake fluid Service the fork Perfo...

Page 28: ...in the left fork leg and damping in the right fork leg As fork springs are no longer required a significant weight advantage is achieved when compared to conventional forks The response on slightly un...

Page 29: ...tached 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...

Page 30: ...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 compre...

Page 31: ...e the motorcycle from the lift stand p 37 10 8 Checking the static sag of the shock absorber 400989 10 Measure dimension Aof rear wheel unloaded p 29 Hold the motorcycle upright with aid of an assista...

Page 32: ...o The riding sag is the difference between measurements A and C Check riding sag Riding sag 80 mm 3 15 in If the riding sag differs from the specified measurement Adjust the riding sag p 31 10 10 Adju...

Page 33: ...spring preload is the difference between the relaxed spring length and the tensioned spring length Depending on the static sag and or the riding sag it may be necessary to increase or decrease the sp...

Page 34: ...om 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 t...

Page 35: ...g instructions for GASGAS techni cal accessories Adjust the air pressure as specified Guideline Air pressure 2 bar 29 psi Gradual changing of the air pressure in steps of 0 2 bar 3 psi Minimum air pre...

Page 36: ...he shock absorber rebounds 10 15 Handlebar position C00248 10 On the upper triple clamp there are 2 holes at a distance of Ato each other Hole distance A 15 mm 0 59 in The holes on the handlebar suppo...

Page 37: ...handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount screws 1and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make su...

Page 38: ...shock absorber according to the required seat height Guideline Low seat position standard A High seat position B Position screw 2 F02973 10 Mount nut 1and tighten the fitting Guideline Screw top shock...

Page 39: ...rom the lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parki...

Page 40: ...emoved the seals rings behind can start to leak Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the bra...

Page 41: ...g Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and the clamp Mount and tighten screws 3 Guideline Screw brake line bracket EJOT 1 7 Nm 1 25...

Page 42: ...03022 11 Tighten screws 2 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Tighten screws 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F03021 10 Position the brake caliper mount scr...

Page 43: ...e p 47 Remove front fender p 48 F03025 10 Main work Pull fuel tank breather 1out of the steering stem Remove nut 2 Release screw 3 take off the upper triple clamp with the handle bar and set aside Inf...

Page 44: ...the steering stem Mount upper steering head bearing 1 Check whether upper steering head seal 2is correctly positioned Push on protective ring 3 F03023 10 Position the upper triple clamp with the handl...

Page 45: ...F03021 11 Position the brake caliper mount screw bk and tighten Guideline Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Mount and tighten screw bl Guideline Screw front brake caliper M...

Page 46: ...ering head bearing If there is detectable play Adjust the steering head bearing play p 44 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily...

Page 47: ...fuel the vehicle in the vicinity of open flames or lit cigarettes Switch off the engine for refueling Make sure that no fuel is spilled particularly not on hot parts of the vehicle If any fuel is spil...

Page 48: ...g 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 Fue...

Page 49: ...ews chassis M6 10 Nm 7 4 lbf ft Position the fuel tank breather in the steering stem Finishing work Mount the seat p 50 11 16 Removing the start number plate F02980 10 Remove screw 1 Unhook the start...

Page 50: ...ender F02983 10 Remove screws 1 Take off the front fender 11 19 Installing the front fender F02984 10 Position start number plate on the fender The holding lugs of the start number plate engage in dri...

Page 51: ...tions to the suspension setting may seriously alter the handling characteristic Ride slowly to start with after making adjustments to get the feel of the new handling characteristic F02986 11 Main wor...

Page 52: ...into the fuel tank F02987 11 Close quick release 3 11 24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will en...

Page 53: ...1 26 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly...

Page 54: ...t the main silencer with sleeve 1 Mount the silent block with screw 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the collar bushings Mount and tighten screw 3 Guideline Remaining...

Page 55: ...ed washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the main silencer p 52 11 30 Removing the engine sprocket cover Preparatory work Raise the motorcycle with a li...

Page 56: ...f oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents b...

Page 57: ...Info The top part of chain 1must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 5 8 mm 0 2 0 31 in If the chain tension does not...

Page 58: ...he chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with a lift stand p 37 Remove the engine sprocket cover p 53 400227 01 Main work Check the chain rear sproc...

Page 59: ...screws chassis M6 10 Nm 7 4 lbf ft F02200 10 Check the chain sliding piece for wear If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece...

Page 60: ...e size of the chain wheel varies with the number of teeth The chain guide can be adjusted on small sprockets F02201 10 Loosen screw 1 Position the chain guide Tighten the screw Guideline Remaining scr...

Page 61: ...e cable routing and the play in throttle cable complies with the specification Preparatory work Remove the seat p 50 Turn the knurled screw on the fuel tap all the way clockwise Remove the fuel tank p...

Page 62: ...rip Preparatory work Check the rubber grip p 59 401198 01 Main work Secure the rubber grip at two locations with the retaining wire Securing wire 54812016000 Wire twister forceps U6907854 The twisted...

Page 63: ...ng the play of the hand brake lever F02996 10 Check the play of the handbrake lever p 61 Adjust the play of the hand brake lever using adjusting screw 1 Guideline Play of hand brake lever 3 5 mm 0 12...

Page 64: ...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 deformat...

Page 65: ...GASGAS Motorcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly...

Page 66: ...pills 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 wi...

Page 67: ...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...

Page 68: ...se 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 bra...

Page 69: ...livery and the manufacturer warranty shall be void Only use brake linings approved and recommended by GASGAS Motorcycles Position the new brake linings Info Always change the brake linings in pairs En...

Page 70: ...and tighten screws 1 Info Use water to immediately clean up any brake fluid that has overflowed or spilled Finishing work Remove the motorcycle from the lift stand p 37 12 9 Checking the free travel...

Page 71: ...ition of the foot brake lever p 69 12 11 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel...

Page 72: ...will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake sy...

Page 73: ...tand p 37 Check the brake linings of the rear brake p 71 F03004 10 Main work Remove screws 1 Take off cover 2with washer 3and membrane 4 H01654 10 Add brake fluid up to level A Guideline Level A brake...

Page 74: ...clothing change the clothing Warning Danger of accidents Old brake fluid reduces the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service sc...

Page 75: ...or damage the brake line Remove the brake linings Clean the brake caliper and the brake caliper bracket Allow the brake caliper and the brake line to hang loosely to the side Check the brake discs p 6...

Page 76: ...Check the brake discs p 62 Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point H01654 10 Add brake fluid up to level A Guid...

Page 77: ...discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold front wheel and remove wheel spindle Take the front wheel out of the fork Info Do not ac...

Page 78: ...rake linings are correctly positioned Insert the wheel spindle Mount and tighten screw 2 Guideline Screw front wheel spindle M10 40 Nm 29 5 lbf ft Loctite 243 Operate the hand brake lever several time...

Page 79: ...heel out of the link fork Info Do not operate the foot brake lever when the rear wheel is removed F03046 10 Remove spacers 4 13 4 Installing the rear wheel Warning Danger of accidents Oil or grease on...

Page 80: ...n p 55 Tighten nut 4 Guideline Nut rear wheel spindle M12x1 40 Nm 29 5 lbf ft Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure...

Page 81: ...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...

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

Page 83: ...ses or other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coo...

Page 84: ...ht on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level Aabove the radiator fins 10 mm 0 39 in If the coolant level does not match the specified value...

Page 85: ...yes thoroughly with water and consult a doctor immediately if coolant gets into the eyes Change clothing if coolant spills onto your clothing F03008 10 Main work Make sure that screw 1is tightened Pos...

Page 86: ...hildren 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 t...

Page 87: ...of the air to be able to escape from the cooling sys tem the vehicle must be raised at the front If the cool ing system is poorly de aerated its cooling power will be reduced and the engine may overhe...

Page 88: ...rting 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...

Page 89: ...speed F03009 10 Screw in idle air adjusting screw 2all the way and turn it to the specified basic setting Guideline Idle air adjusting screw Open 3 turns Run the engine until warm Guideline Warming u...

Page 90: ...ir temperature or altitude changes adjust the idle speed again 15 5 Checking the clutch setting F03010 10 Connect special tool 1 Tachometer 45129075000 401521 01 Let the front wheel of the vehicle mak...

Page 91: ...032 10 Remove screws 1 Remove clutch cover 2with the seal ring 15 7 Adjusting the clutch Preparatory work Remove the clutch cover p 89 F03033 10 Main work Turn clutch basket 1until adjusting screws 2b...

Page 92: ...speed is too high Turn adjusting screws 2counterclockwise Guideline 1 click decreases the slip speed by 250 350 rpm Finishing work Install the clutch cover p 90 Check the gear oil level p 91 Check th...

Page 93: ...s 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 cleanin...

Page 94: ...ne Use effective exhaust extraction when starting or run ning the engine in an enclosed space Start the engine and check for leaks Finishing work Check the gear oil level p 91 16 3 Adding the gear oil...

Page 95: ...es 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 ni...

Page 96: ...uel is poisonous and a health hazard Avoid skin eye and clothing contact with fuel Immediately consult a doctor if you swallow fuel Do not inhale fuel vapors In case of skin contact rinse the affected...

Page 97: ...e F03013 10 Remove throttle slide cover 5 Pull the throttle slide out of the carburetor Drain the remaining fuel F03016 11 Pull back the spring retainer and throttle slide spring Detach throttle cable...

Page 98: ...reached Screw on the throttle slide cover correctly F03012 12 Mount the carburetor Mount the engine breather hose and position clamp 3 F03011 11 Mount the inlet sleeve Position and tighten hose clip 4...

Page 99: ...ning 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 c...

Page 100: ...parts and pivot points Clean the chain p 54 Treat bare metal except for brake discs and the exhaust system with a corrosion inhibitor Preserving materials for paints metal and rubber p 110 Treat all...

Page 101: ...period less workshop overload This allows you to avoid long waiting periods when the next season starts 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel...

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

Page 103: ...ents Adjusting screws on the carbu retor are in turned to the wrong position Carburetor adjust the idle speed p 87 Spark plug defective Change spark plug Ignition system defective Check the ignition c...

Page 104: ...e coolant level p 82 Too little air stream Switch off engine when standing Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant p 82 Refill with coolant p 83...

Page 105: ...id Kick starter system 21 2 Engine tightening torques Screw bearing retainer M5 5 Nm 3 7 lbf ft Screw kick starter lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator clamp M5 6 Nm 4 4 lbf ft Loctite 22...

Page 106: ...retor type Dell Orto PHBG 19BS Needle position 2nd position from top Idle air adjusting screw Open 3 turns Main jet 95 Jet needle W7 Idling jet 50 Needle jet 262AU Throttle slide 40 Choke nozzle 60 21...

Page 107: ...ider weight 45 kg 99 lb 21 6 Tires Front tire Rear tire 60 100 12 36M TT MAXXIS MAXX CROSS SI 2 75 10 38J TT MAXXIS MAXX CROSS SI The tires specified represent one of the possible series production ti...

Page 108: ...0 47 in Riding sag 80 mm 3 15 in Fitted length 275 mm 10 83 in Shock absorber oil Shock absorber fluid SAE 2 5 50180751S1 p 109 21 9 Chassis tightening torques Hose clip carburetor 2 8 Nm 2 07 lbf ft...

Page 109: ...lbf ft Screw engine bracket M8 25 Nm 18 4 lbf ft Loctite 243 Screw engine sprocket cover M8 15 Nm 11 1 lbf ft Screw front brake caliper M8x60 20 Nm 14 8 lbf ft Loctite 243 Screw front brake caliper M8...

Page 110: ...ements stated see specifications on the container and that has the rele vant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze prote...

Page 111: ...ecifications on the container and that exhibit the corre sponding properties Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is e...

Page 112: ...supplier SKF LGHB 2 Long life grease Recommended supplier MOTOREX Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlub...

Page 113: ...and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Special grease 00062010053 Recommended supplier Kl ber Lubrication KL BERFOOD NH1 34 401 Universal oil s...

Page 114: ...first rate synthetic esters and specially designed additives superb combustion is achieved even under extreme operating conditions SAE The SAE viscosity classes were defined by the Society of Automoti...

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

Page 116: ...54 Chain guide adjusting 58 checking 56 Chain tension adjusting 55 checking 55 Choke 16 Cleaning 97 98 Clutch adjusting 89 setting checking 88 Clutch cover clutch cover installing 90 clutch cover remo...

Page 117: ...and 37 O Owner s Manual 8 P Play in throttle cable adjusting 86 checking 86 Plug in stand 16 Preparing for use advice on preparing for first use 17 after storage 100 checks and maintenance measures wh...

Page 118: ...ngine tightening torques 103 fork 105 shock absorber 106 tires 105 Throttle cable routing checking 59 Throttle grip 14 Tire condition checking 78 Tire pressure checking 79 Transporting 22 Troubleshoot...

Page 119: ...3215005en 3215005en 08 2020 Stallhofnerstra e 3 5230 Mattighofen Austria http www gasgas com...

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