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INDEX

146

Engine sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Environment

. . . . . . . . . . . . . . . . . . . . . . . . . . . 8

F

Figures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Foot brake lever

. . . . . . . . . . . . . . . . . . . . . . . . 19

basic position, adjusting . . . . . . . . . . . . . . . . . 84
free travel, checking . . . . . . . . . . . . . . . . . . . 83

Fork legs

basic setting, checking . . . . . . . . . . . . . . . . . . 44
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
dust boots, cleaning . . . . . . . . . . . . . . . . . . . 49
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 51
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fork protector

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 50
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Frame

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Front fender

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 56
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Front wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 90
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Fuel screen

changing . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Fuel tank

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 67
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Fuel tank filler cap

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fuel, oils, etc.

. . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fuse

changing for individual electrical power consumers 100
main fuse, changing . . . . . . . . . . . . . . . . . . . 99

H

Hand brake lever

. . . . . . . . . . . . . . . . . . . . . . . 14

free travel, adjusting . . . . . . . . . . . . . . . . . . . 78
free travel, checking . . . . . . . . . . . . . . . . . . . 78

Handlebar position

. . . . . . . . . . . . . . . . . . . . . . 46

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Headlight

range, adjusting . . . . . . . . . . . . . . . . . . . . . . 103

Headlight bulb

changing . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Headlight mask with headlight

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 101
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Headlight setting

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 103

High-speed compression damping

shock absorber, adjusting . . . . . . . . . . . . . . . . 40

Horn button

. . . . . . . . . . . . . . . . . . . . . . . . . . 15

I

Idle speed

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Idle speed adjusting screw

. . . . . . . . . . . . . . . . . 18

Implied warranty

. . . . . . . . . . . . . . . . . . . . . . . . 9

Intended use

. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

K

Key number

. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

L

Light switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Link fork

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Lower triple clamp

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 52
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Low-speed compression damping

shock absorber, adjusting . . . . . . . . . . . . . . . . 39

M

Main fuse

changing . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Main silencer

glass fiber yarn filling, changing . . . . . . . . . . . . 65
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 64
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Manufacturer warranty

. . . . . . . . . . . . . . . . . . . . 9

Misuse

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
lift stand, removing from . . . . . . . . . . . . . . . . 48
with lift stand, raising . . . . . . . . . . . . . . . . . . 48

O

Oil filter

changing . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Oil screen

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Overview of indicator lamps

. . . . . . . . . . . . . . . . 16

Owner's Manual

. . . . . . . . . . . . . . . . . . . . . . . . . 8

P

Play in throttle cable

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 110
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Preparing for use

advice on preparing for first use . . . . . . . . . . . . 26
after storage . . . . . . . . . . . . . . . . . . . . . . . . 123

Содержание 3215013en

Страница 1: ...OWNER S MANUAL 2021 EC 350F Art no 3215013en ...

Страница 2: ......

Страница 3: ...ces 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 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 ...

Страница 4: ...6 20 Unlocking the steering 20 7 COMBINATION INSTRUMENT 21 7 1 Combination instrument overview 21 7 2 Activation 21 7 3 Message on the combination instrument 21 7 4 Setting the combination instrument 21 7 5 Setting kilometers or miles 22 7 6 Setting the clock 23 7 7 Setting the service display 23 7 8 Speed time and DST distance 1 24 7 9 Speed time and DST2 distance 2 24 7 10 AVG average speed ART ...

Страница 5: ...ng the glass fiber yarn filling in the main silencer 65 12 29 Removing the fuel tank 66 12 30 Installing the fuel tank 67 12 31 Checking for chain dirt accumulation 69 12 32 Cleaning the chain 69 12 33 Checking the chain tension 70 12 34 Adjusting the chain tension 70 12 35 Checking the chain rear sprocket engine sprocket and chain guide 71 12 36 Checking the frame 74 12 37 Checking the link fork ...

Страница 6: ...ever 114 18 SERVICE WORK ON THE ENGINE 115 18 1 Changing the fuel screen 115 18 2 Checking the engine oil level 116 18 3 Changing the engine oil and oil filter cleaning the oil screen 116 18 4 Adding engine oil 118 19 CLEANING CARE 120 19 1 Cleaning the motorcycle 120 19 2 Checks and maintenance steps for winter operation 121 20 STORAGE 122 20 1 Storage 122 20 2 Preparing for use after storage 123...

Страница 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...

Страница 8: ...ety advice A number of safety instructions need to be followed to operate the product described safely Therefore read this 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 a...

Страница 9: ...ally impaired Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation when running 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 part...

Страница 10: ...s 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 vehicles there are no legal regu lations that pertain to the disposal of an end of life motorcycle Your authorized GASGAS Motorcycles dealer will be gl...

Страница 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...

Страница 12: ...4 VIEW OF VEHICLE 10 4 1 View of vehicle front left example F03273 10 1 Clutch lever p 14 2 Fuel tank filler cap 3 Air filter box cover 4 Side stand p 19 5 Engine number p 12 6 Shift lever p 18 ...

Страница 13: ...button p 14 1 Horn button p 15 1 Light switch p 15 1 Turn signal switch p 15 2 Start button p 16 2 Emergency OFF switch p 15 3 Throttle grip p 14 4 Hand brake lever p 14 5 Fork part number p 13 6 Foot brake lever p 19 7 Level viewer engine oil 8 Level viewer for brake fluid rear ...

Страница 14: ...pe label V01808 10 The Europe type label 1is fixed to the front of the steering head The Canada type label 2is fixed to the front of the chest tube 5 3 Key number H02475 10 Key number 1for the steering lock is stamped on a tag on the key ring 5 4 Engine number H01047 10 The engine number 1is embossed on the left side of the engine over the engine sprocket ...

Страница 15: ...01947 10 The fork part number 1is stamped on the inner side of the fork stub 5 6 Shock absorber article number H02222 10 Shock absorber article number 1is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Страница 16: ...is used to activate the front brake 6 3 Throttle grip F03162 10 The throttle grip 1is fitted on the right side of the handlebar 6 4 Stop button F03165 11 The stop button 1is fitted on the left side of the handlebar Possible states The stop button is in the basic position In this position the ignition circuit is closed and the engine can be started Stop button pressed In this position the ignition ...

Страница 17: ...he high beam and the tail light are switched on 6 7 Turn signal switch F03164 11 Turn signal switch 1is fitted on the left side of the handlebar Possible states Turn signal off The turn signal switch is in the central position Left turn signal on The turn signal switch is turned to the left Right turn signal on The turn signal switch is turned to the right 6 8 Emergency OFF switch F03163 10 The em...

Страница 18: ...e 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 poisoning Fuel is poisonous and...

Страница 19: ... the injection time if the engine is cold and the ambient temperature is low To help the engine burn the increased fuel quantity it must be supplied with additional oxygen by pushing the cold start button After briefly opening up the throttle and then releasing the throttle grip again or turning the throttle grip towards the front the cold start but ton returns to its original position Info Check ...

Страница 20: ...to start than an engine with the idle speed set incorrectly The idle speed is adjusted using the idle speed adjusting screw 1 Increase the idle speed by turning the idle speed adjusting screw clock wise Decrease the idle speed by turning the idle speed adjusting screw coun terclockwise 6 15 Shift lever 401950 10 Shift lever 1is mounted on the left of the engine 401950 11 The gear positions can be ...

Страница 21: ...de stand 1is attached to the left side of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand 1must be folded up and secured with rubber strap 2 6 18 Steering lock F03170 10 Steering lock 1is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible ...

Страница 22: ...o the steering lock p 19 turn it to the left push it in and turn it to the right Pull out the key for the steering lock Steering is no longer possible Info Never leave the key for the steering lock in the steering lock 6 20 Unlocking the steering 400731 01 Insert the key for the steering lock into thesteering lock p 19 turn it to the left pull it out pull it out and turn it to the right Pull out t...

Страница 23: ...on the combination instrument 401901 01 Possible states Battery voltage of the combination instrument Battery voltage of the combination instrument is too low Change combination instrument battery Service A service is due Contact an authorized GAS GAS Motorcycles workshop 7 4 Setting the combination instrument Condition The motorcycle is stationary 401909 01 Press and hold both buttons for 3 5 sec...

Страница 24: ...ncing the time Press the right button The value increases 401913 01 Wait for 5 seconds Combination instrument changes to the next menu item The symbol flashes Shortening the service interval Press the left button The value decreases Extending the service interval Press the right button The value increases 401914 01 Switching off the service interval display Press and hold the left button off appea...

Страница 25: ...tons to select the 24h or 12h display of the clock 401912 01 Wait for 5 seconds Combination instrument changes to the next menu item The symbol flashes Resetting the time Press the left button The value decreases Advancing the time Press the right button The value increases 7 7 Setting the service display Condition The motorcycle is stationary 401913 01 Press and hold both buttons for 3 5 seconds ...

Страница 26: ...3 5 seconds DST can be preset to a value between 0 0 and 39999 9 by pressing the buttons Press the right button briefly Next display mode Press the right button for 3 5 seconds DST is reset to 0 0 7 9 Speed time and DST2 distance 2 401902 01 Press one of the buttons until DST2 appears on the combination instrument KM H or M H shows the speed shows the time DST2 shows the distance 2 since the last ...

Страница 27: ... the combination instrument AVG shows the average speed since the last reset ART shows the operating hours ODO shows the total distance covered Press the left button briefly Next display mode Press the left button for 3 5 seconds The OPEN END WRENCH SYMBOL shows the remaining operating hours until the next service is due Press the right button briefly Next display mode Press the right button for 3...

Страница 28: ...ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever if you do not want to brake Warning Danger of accidents Total weight and axle loads influenc...

Страница 29: ...fo The spoke tension must be checked after half an hour of operation Run in the engine p 27 8 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine performance During the first 3 operating hours 75 Avoid fully opening the throttle 8 3 Starting power ...

Страница 30: ...or 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 Difficult operating conditions are Rides on dry sand p 28 Rides on wet sand p 29 Rides on wet and muddy circuits p 29 Rides at high temperatures or slow riding p 30 Riding at low temperatures and in snow p 30 8 5 Preparing the vehicle for ri...

Страница 31: ...tting instructions for GASGAS Techni cal Accessories 600868 01 Clean the chain Chain cleaner p 139 Mount the steel sprocket Grease the chain Universal oil spray p 140 Clean the radiator fins Straighten the bent radiator fins carefully 8 7 Preparing the vehicle for rides on wet and muddy circuits 102137 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting in...

Страница 32: ...operated frequently due to an excessively high secondary ratio Clean the chain Chain cleaner p 139 Clean the radiator fins Straighten the bent radiator fins carefully Check the coolant level p 107 8 9 Preparing the vehicle for low temperatures or snow 102137 01 Mount the air filter rain cover Air filter rain cover 79006921000 Info Observe the fitting instructions for GASGAS Techni cal Accessories ...

Страница 33: ...0 Check the tire condition p 93 Check tire pressure p 93 Check the spoke tension p 94 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 49 Bleed the fork legs p 48 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 c...

Страница 34: ...nts If you change down at high engine speed the rear wheel blocks and the engine races Do not change into a low gear at high engine speed Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized GAS GAS Motorcycles workshop First gear is used for starting off and for steep inclines Shift into a higher gear when conditions allow incline road situ...

Страница 35: ...or two gears but do not over rev the engine You will have to apply the brakes far less frequently as a result and the brake system will not overheat 9 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 D...

Страница 36: ... 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 poisoning Fuel is poisonous and a health hazard Avoid skin eye and clot...

Страница 37: ...mproper handling of fuel is a danger to the environment Do not allow fuel to enter the groundwater the soil or the sewage system Switch off the engine Open fuel tank filler cap p 16 F03269 10 Fill the fuel tank with fuel up to level A Guideline Level A 35 mm 1 38 in Total fuel tank capac ity approx 8 5 l 2 25 US gal Super unleaded ROZ 95 p 138 Close the fuel tank filler cap p 17 ...

Страница 38: ...nings p 81 Check the rear brake linings p 86 Check the brake discs p 78 Check the brake lines for damage and leakage Check the rear brake fluid level p 84 Check the free travel of the foot brake lever p 83 Check the frame p 74 Check the link fork p 74 Checking the link fork bearing for play Checking the shock absorber heim joint for play Check the shock absorber linkage Check the tire condition p ...

Страница 39: ...rcycles diagnostics tool Make a service entry in GASGAS Motorcycles Dealer net One time interval Periodic interval 10 3 Recommended work every 48 months every 12 months Every 135 operating hours Every 70 operating hours when used for motorsports After 20 operating hours After 10 operating hours Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 76 Lubricat...

Страница 40: ...10 SERVICE SCHEDULE 38 One time interval Periodic interval ...

Страница 41: ...ided into two ranges high speed and low speed High speed and low speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed compression adjuster has an effect for example when landing after a jump the rear wheel suspension compresses quickly The low speed compression adjuster has an effect for example when riding over long ground swells the rear w...

Страница 42: ...e 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 Info The effect of the high speed compression adjuster can be seen in fast compression of the shock absorber F03172 10 Using an open end wrench turn adjust...

Страница 43: ...erclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase the damping turn counterclock wise to reduce damping when the shock absorber rebounds 11 6 Measuring the dimension of the rear wheel unloaded Preparatory work Raise the motorcycle with a lift stand p 48 F03178 10...

Страница 44: ...reload of the shock absorber p 43 11 8 Checking the riding sag of the shock absorber 402417 10 Measure dimension Aof rear wheel unloaded p 41 With another person holding the motorcycle the rider wearing full protective clothing sits on the seat in a normal sitting position feet on footrests and bounces up and down a few times The rear wheel suspension levels out Another person now remeasures the d...

Страница 45: ...absorber clean it thoroughly 402659 10 Main work Loosen screw 1 Turn adjusting ring 2until the spring is no longer under tension Hook wrench 90129051000 Info If the spring cannot be fully released the spring must be removed to accurately measure the spring length Measure the total spring length while the spring is not under ten sion Tension the spring by turning adjusting ring 2to specified dimen ...

Страница 46: ...d Finishing work Install the shock absorber p 58 Check the free travel of the foot brake lever p 83 Remove the motorcycle from the lift stand p 48 Check the static sag of the shock absorber p 42 Check the riding sag of the shock absorber p 42 Adjust the rebound damping of the shock absorber p 41 11 11 Checking the basic setting of the fork Info For various reasons no exact riding sag can be determ...

Страница 47: ...t 12 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping during compression 11 13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior F03175 10 Turn red adjuster 1clockwise as far as it will go Info Adjuster 1is located at the upper end of the right fork leg The rebound damping is located in right f...

Страница 48: ...dlebar is bent or straightened the material becomes fatigued The handlebar may break as a result Change the handlebar if the handlebar is damaged or bent Preparatory work Remove the handlebar cushion F03177 10 Main work 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 ...

Страница 49: ... cables and wiring are positioned correctly Position the handlebar clamps Mount screws 1and tighten evenly Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the installed gaps are even Finishing work Mount the handlebar cushion ...

Страница 50: ...mage The parked vehicle can roll away or fall over Park the vehicle on a firm and level surface 401943 10 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle press side stand 1to the ground with your foot and lean the motorcycle on it Info When you are riding the side stand must be folded up and secured with rubber strap 12 3 Bleeding the fork legs Preparatory wo...

Страница 51: ...s 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 140 Press the dust boots back into the installation position Remove the excess oil Finishing work Install the fork protector p 50 Remove th...

Страница 52: ...rotector on the right fork leg Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 12 7 Removing the fork legs Preparatory work Remove the headlight mask with the headlight p 101 Raise the motorcycle with a lift stand p 48 Remove the front wheel p 89 F03180 10 Main work Remove screws 1and take off the clamp Remove the cable ties Remove screws 2and take off the brake c...

Страница 53: ...rews 3 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F03181 10 Position the brake caliper and mount and tighten screws 4 Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Mount the cable ties Position the brake line the wiring harness and the clamp Mount and tighten screws 5 Guideline Screw brake line bracket EJOT 1 7 Nm 1 25 lbf ft Finishing work Install the front wh...

Страница 54: ...er triple clamp with the steering stem Remove the upper steering head bearing 12 10 Installing the lower triple clamp B01605 10 Main work Clean the bearing and sealing elements check for damage and grease High viscosity grease p 139 Insert the lower triple clamp with the steering stem Mount upper steering head bearing Check whether upper steering head seal 1is correctly positioned Slide on protect...

Страница 55: ... screws 6 Guideline Screw bottom triple clamp M8 15 Nm 11 1 lbf ft F03186 10 Tighten screw 4 Guideline Screw top steering head M20x1 5 12 Nm 8 9 lbf ft Mount and tighten screw 7 Guideline Screw top steer ing stem M8 20 Nm 14 8 lbf ft Loctite 243 F03185 11 Tighten screws 8 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft F03181 11 Position the brake caliper and mount and tighten screws 9 Guide...

Страница 56: ...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 48 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 steering head bearing If there is detectable play Adjust the steering...

Страница 57: ...w top steer ing stem M8 20 Nm 14 8 lbf ft Loctite 243 Tighten screws 1 Guideline Screw top triple clamp M8 20 Nm 14 8 lbf ft Finishing work Check the steering head bearing for play p 54 Remove the motorcycle from the lift stand p 48 12 13 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 51 Install the lower triple clamp p 52 12 14 Removing the front fender Preparator...

Страница 58: ... Nm 7 4 lbf ft F03188 10 Mount and tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the headlight mask with the headlight p 101 Check the headlight setting p 103 12 16 Removing the shock absorber Preparatory work Raise the motorcycle with a lift stand p 48 F03190 10 Main work Remove the cable ties Remove screws 1along with the washers Detach the frame ...

Страница 59: ...easily F03192 10 Press angle lever 4toward the rear Press linkage lever 5downward F03193 10 Disconnect the plug in connector of the brake light switch F03194 10 Remove screws 6 Pull off foot brake cylinder from the push rod F03196 01 Remove the connecting link of the chain Info Cover the components to protect them against damage Take off the chain ...

Страница 60: ... work Carefully position the shock absorber into the vehicle from the bot tom Mount and tighten screw 1 Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 F03198 10 Position the link fork and mount the swingarm pivot Info Pay attention to flat area A Mount and tighten nut 2 Guideline Nut fork pivot M16x1 5 100 Nm 73 8 lbf ft F03196 10 Mount the chain Connect the chain with the c...

Страница 61: ...tting 5 Guideline Nut linkage lever on angle lever M14x1 5 60 Nm 44 3 lbf ft Info Pay attention to flat area B Mount and tighten screw 6 Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Info Raise the link fork slightly to be able to mount the screw more easily F03190 11 Attach frame protector in area Cand position it Mount and tighten screws 7with the washers Guideline Scr...

Страница 62: ...ll the seat back and lift it off 12 19 Mounting the seat H02218 11 Mount the front of the seat on the collar bushings of the fuel tank lower the seat at the rear and push the seat forward Make sure the seat is latched in place correctly F03201 10 Mount and tighten screw 1 Guideline Screw rear seat fixing M6 6 Nm 4 4 lbf ft ...

Страница 63: ... off the air filter box cover in area Alaterally and take it off at the front F03203 10 Condition The air filter box cover is not secured Pull off the air filter box cover in area Alaterally and take it off at the front 12 21 Installing the air filter box cover F03202 12 Condition The air filter box cover is secured Insert the air filter box cover in area Aand clip it into area B ...

Страница 64: ...as 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 work Remov...

Страница 65: ...lter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foam Preparatory work Remove the air filter box cover p 61 Remove the air filter p ...

Страница 66: ... 0 24 in Finishing work Install the air filter box cover p 61 12 26 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle F03207 10 Detach spring 1 Spring hook 50305017000C1 Remove screws 2with washers and take off main silencer with catalytic converter 12 27 Ins...

Страница 67: ... the vehicle Info Over time the fibers of the glass fiber yarn filling escape and the damper burns out Not only is the noise level higher but the performance characteristics change Preparatory work Remove main silencer p 64 V01734 10 Main work Remove screws 1 Take off silencer cap 2with O ring 3 Remove the old glass fiber yarn filling Clean the parts that need to be reinstalled and check for damag...

Страница 68: ...iately 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 Preparatory work Remove the seat p 6...

Страница 69: ... 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 doctor if you sw...

Страница 70: ...cket Mount and tighten screws 2with the collar bushings Guideline Screw fuel tank spoiler on radiator M6 6 Nm 4 4 lbf ft F03208 11 Plug in connector 3for the fuel pump Remove the wash cap set Clean the quick release coupling thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Spray silicone spray onto a lin...

Страница 71: ...ree of oil and grease Clean the brake discs with brake cleaner when necessary Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info The service life of the chain depends largely on its maintenance Preparatory work Raise the motorcycle with a lift...

Страница 72: ... it must be possible to pull up the chain at least to the point where it makes contact with chain guard B Chain wear is not always even so you should repeat this measurement at different chain positions Chain tension 55 58 mm 2 17 2 28 in If the chain tension does not meet the specification Adjust the chain tension p 70 Finishing work Remove the motorcycle from the lift stand p 48 12 34 Adjusting ...

Страница 73: ... 1 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Chain adjusters 4can be turned by 180 Finishing work Remove the motorcycle from the lift stand p 48 12 35 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle w...

Страница 74: ...ion 272 mm 10 71 in If distance Bis greater than the specified measurement Change the drivetrain kit Info When a new chain is mounted the rear sprocket and engine sprocket should also be changed New chains wear out faster on old worn sprockets F03215 10 Check the chain sliding guard for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain slidi...

Страница 75: ... sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 401760 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 F03217 01 Check that the chain guide is firmly seated If the chain guide is loose Tighten the screws on the chain guide Guideline Remaining screws chassis M6 10 Nm 7...

Страница 76: ...hange the link fork Guideline Repairs on the link fork are not permitted 12 38 Checking the throttle cable routing Preparatory work Remove the seat p 60 Remove the fuel tank p 66 F03220 01 Main work Check the throttle cable routing Both throttle cables must be routed side by side on the back of the handlebars and above the fuel tank bracket to the throttle valve body Both throttle cables must be s...

Страница 77: ...urn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and 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 41 Checking correcting the fluid level of th...

Страница 78: ...ions Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 137 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilled brake fluid immediately with water 12 42 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothi...

Страница 79: ...lic fluid Syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 137 On the clutch slave cylinder remove the protection cap remove bleeder screw 5and mount bleeding syringe 4 F03223 10 Now inject fluid into the system until it escapes from the openings 6of the master cylinder without bubbles Occasionally extract the fluid from the master cylinder reservoir to prevent overflowing Remove the bleeding syrin...

Страница 80: ...he hand brake lever with adjusting 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...

Страница 81: ...ll 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 F03262 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal position Check the brake fluid level in level viewer 1 ...

Страница 82: ...ycles 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 between ...

Страница 83: ...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 ...

Страница 84: ...n compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid corrodes paint Only use clean brake fluid from a sealed container F03228 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal po...

Страница 85: ...an up any brake fluid that has overflowed or spilled 13 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 10 Disconnect spring 1...

Страница 86: ... foot brake lever 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 13 10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system...

Страница 87: ...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 braking effect Make sure that brake flu...

Страница 88: ... brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings p 86 13 13 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will 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 cau...

Страница 89: ...o longer corresponds to its condition at delivery and the manufacturer warranty shall be void Only use brake linings approved and recommended by GASGAS Motorcycles 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 ...

Страница 90: ...ount the cotter pins Info Always change the brake linings in pairs Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point F03231 10 Correct brake fluid level to marking A Brake fluid DOT 4 DOT 5 1 p 137 Mount screw cap 1with membrane 2and O ring Info Use water to immediately clean up any brake fluid that has overflowed or sp...

Страница 91: ...ing back the brake pistons S04474 10 Loosen screw 1by several rotations Loosen screws 2 Press on screw 1to push the wheel spindle out of the axle clamp Remove screw 1 S04475 01 Warning Danger of accidents Damaged brake 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 front wheel out of the fork...

Страница 92: ...t the spacers Clean and grease the wheel spindle Long life grease p 139 Position the front wheel and insert the wheel spindle The brake linings are correctly positioned S04474 11 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 ...

Страница 93: ... sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Hold 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 H03002 10 Remove space...

Страница 94: ...d Mount the chain F03214 11 Position chain adjuster 3 Mount nut 4 but do not tighten it yet Make sure that chain adjusters 3are fitted correctly on adjusting screws 5 Check the chain tension p 70 Tighten nut 4 Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 26 in enables different secondary ratios with the same chain length Cha...

Страница 95: ...m 0 08 in If the tread depth is less than the minimum tread depth Change the tires H01144 01 Check the tire age Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT num ber The first two digits indicate the week of manufacture and the last two digits the year of manufacture GASGAS Motorcycles recommends that the tires be chang...

Страница 96: ...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 briefly using a screwdriver blade Info The frequency of the sound depends on the spoke length and spoke diameter If you hear different tone frequencies from different spokes of equal length and diameter ...

Страница 97: ...ies contain harmful substances Keep 12 V batteries out of the reach of children Keep sparks and open flames away from 12 V batteries Only charge 12 V batteries in well ventilated rooms Maintain a minimum clearance from inflammable materials when charging 12 V batteries Minimum clearance 1 m 3 ft Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage Minim...

Страница 98: ... 15 2 Installing the 12 V battery F03243 11 Main work Insert the 12 V battery into the battery compartment with the ter minals facing forward and secure with holding bracket 1 12 V battery HJTZ5S FP C p 132 Mount and tighten screw 2 Guideline Screw battery support bracket M6 6 Nm 4 4 lbf ft F03242 11 Mount relays 3and attach wiring harness 4 F03240 11 Mount starter relay 5and fuse box 6 ...

Страница 99: ... as household waste Dispose of 12 V batteries at a collection point for used batteries 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 Even when there is no load on the 12 V battery it discharges steadily each day The charging level and the...

Страница 100: ...he 12 V battery Replace the 12 V battery and dispose of the old 12 V bat tery properly If the specifications have been met Battery voltage 9 V Connect a battery charger to the 12 V battery Switch on the battery charger Guideline Maximum charging voltage 14 4 V Maximum charging current 3 0 A Maximum charging time 12 h Recharge the 12 V battery regularly when the motor cycle is not being used 6 mont...

Страница 101: ...ntenance free Never remove cover 1 Switch off the battery charger after charging and disconnect from the 12 V battery Finishing work Install the 12 V battery p 96 Mount the seat p 60 15 4 Changing main fuse Warning Fire hazard Incorrect fuses overload the electrical system Only use fuses with the required ampere value Do not bypass or repair fuses Info The main fuse protects all electrical power c...

Страница 102: ... p 60 15 5 Changing the fuses of individual electrical power consumers Info The fuse box containing the fuses of individual electrical power consumers is located under the seat Preparatory work Remove the seat p 60 F03246 10 Main work Open fuse box cover 1 Remove the faulty fuse Guideline Fuse 1 10 A EFI control unit combination instrument com bination switch optional electronic fuel injection dia...

Страница 103: ...ilable if needed Check the function of the electrical power consumer Close the fuse box cover Finishing work Mount the seat p 60 15 6 Removing the headlight mask with the headlight F03247 10 Detach the brake line and wiring harness from the headlight mask Loosen rubber straps 1 Slide the headlight mask up and swing it forward F03248 10 Detach plug in connectors 2and take off the headlight mask wit...

Страница 104: ...bulbs with your bare hands Preparatory work Remove the headlight mask with the headlight p 101 F03249 10 Main work Turn protection cap 1together with the underlying bulb socket counterclockwise all the way and remove it Pull bulb socket 2of the position light out of the reflector F03250 10 Pull out headlight bulb 3 Insert the new headlight bulb Headlight S2 socket BA20d p 132 Insert the protection...

Страница 105: ...a motorcycle with rider If the boundary between light and dark does not meet specifica tions Adjust headlight range p 103 15 10 Adjusting the headlight range Preparatory work Check the headlight setting p 103 Remove the headlight mask with the headlight p 101 S04493 10 Main work Turn bolt 1clockwise The headlight range increases Turn bolt 1counterclockwise The headlight range decreases Adjust the ...

Страница 106: ...n it counter clockwise by about 30 and pull it out of the socket Info Do not touch the reflector with your fingers and keep it free from grease Press the new turn signal bulb carefully into the socket and turn it clockwise until it stops Turn signal R10W socket BA15s p 132 Mount the orange cap Position the turn signal glass Insert the screw and first turn counterclockwise until it engages in the t...

Страница 107: ... for correct seating F03253 10 Position protection cap 2and turn all the way clockwise using a coin Press any button on the combination instrument The combination instrument is activated Position the combination instrument in the holder Mount and tighten the screws with washers Finishing work Install the headlight mask with the headlight p 101 Check the headlight setting p 103 Set the combination ...

Страница 108: ...r other components of the cooling system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with...

Страница 109: ...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...

Страница 110: ...nt Mount and tighten screw 1with a new seal ring Guideline Screw water pump cover M6 10 Nm 7 4 lbf ft 16 5 Refilling 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 immediately if coolant is swallowed Rinse the affected area immediately w...

Страница 111: ... 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 Condition The engine is cold F03254 11 Main work Position ...

Страница 112: ...inal position Adjust the play in the throttle cable p 110 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 the engine in an enclosed space Start the engine and let it run at idle speed Move the handlebar to a...

Страница 113: ...ere is play in the throttle cable at the throttle grip Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 2 Slide on sleeve 1 Check the throttle grip for smooth operation Finishing work Check the play in the throttle cable p 110 17 3 Adjusting the characteristic map of the throttle response Info On the throttle grip the characteristic map of the throttle response is changed by changin...

Страница 114: ...delivery F03258 10 Clean the outside of the handlebar and the inside of the grip tube Mount the grip tube on the handlebar Attach the throttle cables to the guide plate and route correctly Position half shells 3 mount and tighten screws 2 Guideline Screw throttle grip M6 5 Nm 3 7 lbf ft Slide on sleeve 1and check the throttle grip for ease of move ment Finishing work Check the play in the throttle...

Страница 115: ...aises the idle speed 17 5 Programming the throttle valve position Info If the control unit detects that the throttle valve position at idle speed needs to be reprogrammed then the mal function indicator lamp flashes 2x per second H02263 10 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death Always make sure there is sufficient ventilation wh...

Страница 116: ... the boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever p 114 17 7 Adjusting the basic position of the shift lever 401950 12 Remove screw 1with the washers and take off shift lever 2 401951 10 Clean gear teeth Aof the shift lever and shift shaft Mount the shift lever on the shift shaft in the required position and engage gearing Inf...

Страница 117: ... fuel spills on them Note Environmental 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 F03259 10 Clean quick release coupling 1thoroughly with compressed air Info Under no circumstances should dirt enter into the fuel line Dirt in the fuel line clogs the injection valve Disconnect the quick release coupling I...

Страница 118: ... cleaning the oil screen Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event of scalding rinse the area affected immediately with lukewarm water Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly ...

Страница 119: ...ne case Push the oil screen all the way into the engine case F03264 11 Mount and tighten screw plug 3with the O ring Guideline Screw plug oil screen M20x1 5 15 Nm 11 1 lbf ft Mount and tighten oil drain plug 1with the magnet and a new seal ring Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft F03266 10 Remove screws 5 Remove the oil filter cover with the O ring F03267 10 Pull oil fil...

Страница 120: ...il Engine oil 1 0 l 1 1 qt Engine oil SAE 10W 50 p 137 Info Too little engine oil or poor quality engine oil will result in premature wear of the engine Mount and tighten the filler plug together with the O ring 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 ef...

Страница 121: ...ine oils GASGAS Motorcycles recommends changing the engine oil if necessary Mount and tighten the filler plug together with the O ring 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 the engine in an enclose...

Страница 122: ...rly Avoid direct sunshine when cleaning the motorcycle 401061 01 Close off the exhaust system to keep water from entering 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 139 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle...

Страница 123: ...If the vehicle was operated in road salt clean it with cold water after riding Warm water would enhance the corro sive effects of salt 401060 01 Clean the motorcycle p 120 Clean brake system Info After EVERY trip on salted roads thoroughly clean the brake calipers and brake linings after they have cooled down and without removing them with cold water and dry them care fully After riding on salted ...

Страница 124: ...imes 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 139 Refuel p 34 Clean the motorcycle p 120 Change the engine oil and oil filter clean the oil screen p 116 Check the antifreeze and coolant level p 106 Check tire pressure p 93 Remove the 12 V battery p 95 Charge the 12 V battery p 97 Guidelin...

Страница 125: ...123 20 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 48 Install the 12 V battery p 96 Perform checks and maintenance measures when preparing for use p 31 Take a test ride ...

Страница 126: ... in Ignition system defective Check the ignition system Short circuit cable in wiring har ness frayed stop button or emer gency OFF switch faulty Check the wiring harness visual check Check the electrical system Error in the electronic fuel injec tion Read out the fault memory using the GAS GAS Motorcycles diagnostics tool Engine does not speed up Error in the electronic fuel injec tion Read out t...

Страница 127: ...or damage and electrical plug in connectors for corrosion and dam age Read out the fault memory using the GAS GAS Motorcycles diagnostics tool High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 116 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen p ...

Страница 128: ... Error level condition Induction manifold pressure sensor cylinder 1 input signal too low Induction manifold pressure sensor cylinder 1 input signal too high Blink code for malfunction indicator lamp 12 Malfunction indicator lamp flashes 1x long 2x short Error level condition Coolant temperature sensor input signal too low Coolant temperature sensor input signal too high Blink code for malfunction...

Страница 129: ...tion indicator lamp flashes 3x long 3x short Error level condition Injector cylinder 1 circuit fault Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long 7x short Error level condition Ignition coil 1 cylinder 1 circuit fault Blink code for malfunction indicator lamp 41 Malfunction indicator lamp flashes 4x long 1x short Error level condition Fuel pump relay shor...

Страница 130: ...ing Plain bearing Piston pin bearing Bearing bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 trochoidal pumps Primary transmission 24 73 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 6 gear transmission claw shifted Transmission ratio first gear 14 32 second gear 16 26 third gear 20 ...

Страница 131: ...le piston cooling M5 2 Nm 1 5 lbf ft Loctite 243 Screw bearing bolt oil pump idler gear M5 6 Nm 4 4 lbf ft Loctite 243 Screw clutch spring retainer M5 6 Nm 4 4 lbf ft Screw crankshaft speed sensor M5 6 Nm 4 4 lbf ft Loctite 243 Screw gear position sensor M5 5 Nm 3 7 lbf ft Loctite 243 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Screw stato...

Страница 132: ...ctite 243 Plug oil channel M10x1 15 Nm 11 1 lbf ft Loctite 243 Screw plug cam lever axis M10x1 10 Nm 7 4 lbf ft Screw rotor M10x1 70 Nm 51 6 lbf ft Collar and thread oiled cone degreased Screw unlocking of timing chain ten sioner M10x1 8 Nm 5 9 lbf ft Spark plug M10x1 12 Nm 8 9 lbf ft Coolant temperature sensor M10x1 25 12 Nm 8 9 lbf ft Nut cylinder head M10x1 25 Tightening sequence Tighten diagon...

Страница 133: ...eserve approx 1 5 l 1 6 qt 23 4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XPLOR Suspension travel front 300 mm 11 81 in rear 300 mm 11 81 in Fork offset 22 mm 0 87 in Shock absorber WPXACT 5750 Brake system Disc brakes floating brake calipers Brake discs diameter front 260 mm 10 24 in rear 220 mm 8 66 in Brake discs wear limit front 2 5 mm 0 098 in rear 3 5 mm...

Страница 134: ...instrument battery CR 2032 Battery voltage 3 V Fuse 75011088005 5 A Fuse 75011088010 10 A Fuse 58011109120 20 A Headlight S2 socket BA20d 12 V 35 35 W Position light W5W socket W2 1x9 5d 12 V 5 W Indicator lamps W2 3W socket W2x4 6d 12 V 2 3 W Turn signal R10W socket BA15s 12 V 10 W Brake tail light LED License plate lamp LED 23 6 Tires Front tire Rear tire 90 90 21 M C 54R TT MAXXIS MaxxEnduro 14...

Страница 135: ...7T 69 Shock absorber WPXACT 5750 Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 5 turns Standard 2 turns Sport 1 5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 10 mm 0 39 in Spring rate Weight of rider 65 75 kg 143 165 lb 39 N mm 223 lb in Weight of rider 75 85 kg 165 187 lb 42 N...

Страница 136: ...k fork M5 5 Nm 3 7 lbf ft Screw frame protector M5 3 Nm 2 2 lbf ft Screw ground wire in tail section M5 5 Nm 3 7 lbf ft Screw light switch M5 1 Nm 0 7 lbf ft Screw shock absorber adjusting ring M5 5 Nm 3 7 lbf ft Screw throttle valve body cover M5 2 6 Nm 1 92 lbf ft Screw turn signal switch M5 1 Nm 0 7 lbf ft Screws on main silencer M5 7 Nm 5 2 lbf ft Nut starter motor M6 4 Nm 3 lbf ft Nut throttl...

Страница 137: ... 20 Nm 14 8 lbf ft Screw manifold on cylinder head brace M8 15 Nm 11 1 lbf ft Screw side stand attachment M8 33 Nm 24 3 lbf ft Loctite 2701 Screw subframe bottom M8 30 Nm 22 1 lbf ft Loctite 2701 Screw subframe top M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem M8 20 Nm 14 8 lbf ft Loctite 243 Screw top triple clamp M8 20 Nm 14 8 lbf ft Screw wheel speed sensor on axle clamp M8 4 5 Nm 3...

Страница 138: ...23 TECHNICAL DATA 136 Screw in fitting cooling system M24x1 5 18 Nm 13 3 lbf ft Loctite 243 ...

Страница 139: ...as 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 coolants Recommended supplier MO...

Страница 140: ... the container and that exhibit the corre sponding properties Super unleaded ROZ 95 Standard classification DIN EN 228 ROZ 95 Guideline Only use super unleaded fuel that matches or is equivalent to the specified standard Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Страница 141: ...mended 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 Silicone spray ...

Страница 142: ...IARY SUBSTANCES 140 Special cleaner for glossy and matte paint finishes metal and plastic surfaces Recommended supplier MOTOREX Quick Cleaner Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Страница 143: ...ice intervals are demanded for automobile engines the focus for motorcycle engines is on high perfor mance at high engine speeds In most motorcycle engines the transmission and clutch are lubricated 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 accordi...

Страница 144: ...27 INDEX OF SPECIAL TERMS 142 OBD On board diagnosis Vehicle system which monitors the specified parameters of the vehicle electronics ...

Страница 145: ...LIST OF ABBREVIATIONS 28 143 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Страница 146: ...flashes yellow The OBD has detected an error in the vehicle electronics Come safely to a halt and contact an authorized GASGAS Motorcycles dealer The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark 29 2 Green and blue symbols Green and blue symbols reflect information The high beam indicator lamp lights up blue The high beam is switched on Turn signal indicator...

Страница 147: ...cleaning 69 Chain guide checking 71 Chain tension adjusting 70 checking 70 Characteristic map of the throttle response adjusting 111 Clutch fluid level checking correcting 75 fluid changing 76 Clutch lever 14 basic position adjusting 75 Cold start button 17 Combination instrument adjusting 21 clock setting 23 combination instrument battery changing 104 kilometers or miles setting 22 message 21 ove...

Страница 148: ...e adjusting 103 Headlight bulb changing 102 Headlight mask with headlight installing 101 removing 101 Headlight setting checking 103 High speed compression damping shock absorber adjusting 40 Horn button 15 I Idle speed adjusting 112 Idle speed adjusting screw 18 Implied warranty 9 Intended use 6 K Key number 12 L Light switch 15 Link fork checking 74 Lower triple clamp installing 52 removing 51 L...

Страница 149: ...t button 16 Starting 31 Starting power of lithium ion batteries at low temperatures 27 Steering locking 20 unlocking 20 Steering head bearing lubricating 55 Steering head bearing play adjusting 54 checking 54 Stop button 14 Storage 122 123 T Technical data capacities 131 chassis 131 chassis tightening torques 134 electrical system 132 engine 128 engine tightening torques 129 fork 132 shock absorbe...

Страница 150: ... 3215013en 3215013en 10 2020 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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