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13 SERVICE WORK ON THE CHASSIS

M01668-10

–

Remove protective ring

–

Remove the lower triple clamp with the steering stem.

–

Remove the upper steering head bearing.

13.10

Installing the lower triple 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

–

Check that the O-ring at the top

is correctly positioned.

–

Push on protective ring

M01844-11

–

Position the upper triple clamp with the handlebar.

–

Mount nut

, but do not tighten it yet.

Содержание F0001U1

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

Страница 2: ......

Страница 3: ...ents 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 p...

Страница 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 wh...

Страница 5: ...4 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...

Страница 6: ...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...

Страница 7: ...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 measu...

Страница 8: ...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 re...

Страница 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 an...

Страница 10: ...assive 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 t...

Страница 11: ...isite 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 lea...

Страница 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 fla...

Страница 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...

Страница 14: ...1865 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 1...

Страница 15: ...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 belo...

Страница 16: ...ber 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...

Страница 17: ...witch 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 v...

Страница 18: ...tch 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 suff...

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

Страница 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...

Страница 21: ...ion 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...

Страница 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 m...

Страница 23: ...g 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 Di...

Страница 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 t...

Страница 25: ...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 7...

Страница 26: ...g 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 b...

Страница 27: ...orization 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 w...

Страница 28: ...azard 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...

Страница 29: ...hat 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 t...

Страница 30: ...nterval 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...

Страница 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 un...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ...e 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 assista...

Страница 35: ...rber 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 de...

Страница 36: ...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 14...

Страница 37: ...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 m...

Страница 38: ...atically 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 f...

Страница 39: ...ecomes 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...

Страница 40: ...anger 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...

Страница 41: ...d 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 fo...

Страница 42: ...tion 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 G...

Страница 43: ...dition 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...

Страница 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 in...

Страница 45: ...t 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...

Страница 46: ...eel 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...

Страница 47: ...f 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...

Страница 48: ...e 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...

Страница 49: ...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...

Страница 50: ...fo 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 motorc...

Страница 51: ...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 s...

Страница 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...

Страница 53: ...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 t...

Страница 54: ...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...

Страница 55: ...cycle 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 c...

Страница 56: ...eak 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 regul...

Страница 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 rea...

Страница 58: ...en 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...

Страница 59: ...t 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 crac...

Страница 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...

Страница 61: ...ng 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...

Страница 62: ...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...

Страница 63: ...thorized 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...

Страница 64: ...ke 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 acc...

Страница 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 c...

Страница 66: ...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 l...

Страница 67: ...s 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...

Страница 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 n...

Страница 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...

Страница 70: ...id 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 con...

Страница 71: ...hing 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 wor...

Страница 72: ...l 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 l...

Страница 73: ...sic 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 pa...

Страница 74: ...oint 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 sc...

Страница 75: ...own 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 whee...

Страница 76: ...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 c...

Страница 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...

Страница 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...

Страница 79: ...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 sp...

Страница 80: ...r 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 Inf...

Страница 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...

Страница 82: ...t 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 ma...

Страница 83: ...le 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 t...

Страница 84: ...7 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...

Страница 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 w...

Страница 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...

Страница 87: ...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...

Страница 88: ...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 Syst...

Страница 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...

Страница 90: ...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...

Страница 91: ...ires 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...

Страница 92: ...iding 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...

Страница 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...

Страница 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...

Страница 95: ...OT 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 a...

Страница 96: ...oto 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...

Страница 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 n...

Страница 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...

Страница 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...

Страница 100: ...s 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...

Страница 101: ...ine 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 set...

Страница 102: ...ork 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 adju...

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

Страница 104: ...3215004en 3215004en 08 2020 Stallhofnerstra e 3 5230 Mattighofen Austria http www gasgas com...

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