GASGAS EC 250 Red Motorcycle Costa Mesa Owner's Manual

Owner's Manual for GASGAS models including: EC 250, EC 300, Red Motorcycle Costa Mesa, Motorcycle Costa Mesa, Red Motorcycle, EC 250, Motorcycle

21 3215011 en OM

GASGAS EC 300 2021 (01) PDF MANUAL

GASGAS EC 250 2021 (01) PDF MANUAL

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GASGAS EC 250 2021 (01)

OWNER'S MANUAL 2021
EC 250 EC 300 Art. no. 3215011en

DEAR GASGAS CUSTOMER

Congratulations DEARGASGASCUSTOMER on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports vehicle which, with appropriate care, will bring you pleasure for a long time to come.

We wish you good and safe riding at all times!

Enter the serial numbers of your vehicle below. Vehicle identification number ( p. 12)

Dealer's stamp

Engine number ( p. 12)

Key number (All EU models) ( p. 12)

The Owner's Manual contained the latest information for this model series at the time of going to print. However, minor differences due to further developments in design cannot be ruled out completely.
All specifications contained herein are non-binding. GASGAS Motorcycles GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. GASGAS Motorcycles accepts no liability for delivery options, deviations from figures and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2021 GASGAS Motorcycles GmbH, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061) GASGAS Motorcycles applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard. Issued by: TÜV Management Service
GASGAS Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen, Austria
This document is valid for the following models: EC 250 EU (F0303U7) EC 300 EU (F0403U7) EC 300 US (F0475U7)

*3215011en*
3215011en 11/2021

TABLE OF CONTENTS

1TABLEOFCONTENTS MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used................................................. 5 1.2 Formats used................................................. 5
2 SAFETY ADVICE ............................................................ 6
2.1 Use definition intended use....................... 6 2.2 Misuse............................................................ 6 2.3 Safety advice.................................................. 6 2.4 Degrees of risk and symbols ......................... 6 2.5 Tampering warning ....................................... 7 2.6 Safe operation ............................................... 7 2.7 Protective clothing ........................................ 7 2.8 Work rules ..................................................... 8 2.9 Environment .................................................. 8 2.10 Owner's Manual ............................................ 8
3 IMPORTANT NOTES ..................................................... 9
3.1 Manufacturer warranty, implied warranty ........................................................ 9
3.2 Fuel, auxiliary substances.............................. 9 3.3 Spare parts, accessories ................................ 9 3.4 Service ........................................................... 9 3.5 Figures ........................................................... 9 3.6 Customer service........................................... 9
4 VIEW OF VEHICLE ...................................................... 10
4.1 View of vehicle, front left (example) .......... 10 4.2 View of vehicle, rear right (example).......... 11
5 SERIAL NUMBERS....................................................... 12
5.1 Vehicle identification number..................... 12 5.2 Type label .................................................... 12 5.3 Key number (All EU models) ....................... 12 5.4 Engine number ............................................ 12 5.5 Fork part number ........................................ 13 5.6 Shock absorber article number................... 13
6 CONTROLS.................................................................. 14
6.1 Clutch lever.................................................. 14 6.2 Hand brake lever ......................................... 14 6.3 Throttle grip................................................. 14 6.4 Stop button (All EU models)........................ 14 6.5 Stop button (EC 300 US) ............................. 15 6.6 Horn button (All EU models)....................... 15 6.7 Light switch (All EU models)........................ 15 6.8 Light switch (EC 300 US).............................. 15 6.9 Turn signal switch (All EU models).............. 16 6.10 Emergency OFF switch (All EU models) ...... 16 6.11 Start button ................................................. 16 6.12 Overview of indicator lamps (All EU
models) ........................................................ 16 6.13 Overview of indicator lamps
(EC 300 US) .................................................. 17 6.14 Opening the fuel tank filler cap................... 17 6.15 Closing the fuel tank filler cap..................... 18 6.16 Opening 2-stroke oil tank cap ..................... 18 6.17 Closing 2-stroke oil tank cap ....................... 18

6.18 Cold start button ......................................... 19 6.19 Idle speed adjusting screw.......................... 19 6.20 Shift lever..................................................... 20 6.21 Foot brake lever .......................................... 20 6.22 Side stand .................................................... 20 6.23 Steering lock (All EU models) ...................... 21 6.24 Locking the steering (All EU models) .......... 21 6.25 Unlocking the steering (All EU models) ...... 21
7 COMBINATION INSTRUMENT.................................... 22
7.1 Combination instrument overview ............. 22 7.2 Activation..................................................... 22 7.3 Messages on the combination
instrument ................................................... 22 7.4 Setting the combination instrument .......... 22 7.5 Setting the kilometers or miles................... 23 7.6 Setting the clock .......................................... 24 7.7 Setting the service display........................... 24 7.8 Speed, time, and DST distance 1................. 25 7.9 Speed, time, and DST2 distance 2 .............. 25 7.10 AVG average speed, ART operating
hours, and ODO total distance covered ..... 26
8 PREPARING FOR USE ................................................. 27
8.1 Advice on preparing for first use ................ 27 8.2 Running in the engine ................................. 28 8.3 Starting power of lithium-ion batteries
at low temperatures.................................... 29 8.4 Preparing the vehicle for difficult
operating conditions ................................... 29 8.5 Preparing the vehicle for rides on dry
sand ............................................................. 29 8.6 Preparing the vehicle for rides on wet
sand ............................................................. 31 8.7 Preparing the vehicle for rides on wet
and muddy circuits ...................................... 32 8.8 Preparing vehicle for high temperatures
or slow riding............................................... 32 8.9 Preparing the vehicle for low
temperatures or snow ................................ 33
9 RIDING INSTRUCTIONS .............................................. 34
9.1 Checks and maintenance measures when preparing for use............................... 34
9.2 Starting the vehicle ..................................... 34 9.3 Starting off................................................... 35 9.4 Shifting, riding ............................................. 35 9.5 Braking......................................................... 36 9.6 Stopping, parking......................................... 36 9.7 Transporting ................................................ 37 9.8 Refueling...................................................... 37 9.9 Adding 2-stroke oil ...................................... 38
10 SERVICE SCHEDULE.................................................... 40
10.1 Additional information ................................ 40 10.2 Required work ............................................. 40 10.3 Recommended work ................................... 41

TABLE OF CONTENTS

11 TUNING THE CHASSIS ................................................ 43

11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10 11.11 11.12
11.13
11.14 11.15

Checking the basic chassis setting with the rider's weight ........................................ 43 Compression damping of the shock absorber ...................................................... 43 Adjusting the low-speed compression damping of the shock absorber .................. 43 Adjusting the high-speed compression damping of the shock absorber .................. 44 Adjusting the rebound damping of the shock absorber ............................................ 45 Measuring the dimension of the rear wheel unloaded........................................... 45 Checking the static sag of the shock absorber ...................................................... 46 Checking the riding sag of the shock absorber ...................................................... 46 Adjusting the spring preload of the shock absorber ........................................ 47 Adjusting the riding sag ........................... 48 Checking the basic setting of the fork ........ 48 Adjusting the compression damping of the fork ........................................................ 49 Adjusting the rebound damping of the fork............................................................... 49 Handlebar position...................................... 50 Adjusting the handlebar position ........... 50

12 SERVICE WORK ON THE CHASSIS .............................. 52

12.1 12.2
12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12
12.13 12.14 12.15 12.16 12.17 12.18 12.19 12.20 12.21 12.22 12.23 12.24
12.25

Raising the motorcycle with a lift stand ..... 52 Removing the motorcycle from the lift stand ............................................................ 52 Bleeding the fork legs.................................. 52 Cleaning the dust boots of the fork legs..... 53 Removing the fork protector ...................... 53 Installing the fork protector ........................ 54 Removing the fork legs ........................... 54 Installing the fork legs ............................. 55 Removing the lower triple clamp ............ 55 Installing the lower triple clamp ............. 56 Checking the steering head bearing play ... 58 Adjusting the steering head bearing play .......................................................... 59 Lubricating the steering head bearing .... 60 Removing front fender................................ 60 Installing front fender ................................. 60 Removing the shock absorber ................ 61 Installing the shock absorber .................. 63 Removing the seat....................................... 64 Mounting the seat....................................... 65 Removing the air filter box cover................ 65 Installing the air filter box cover ................. 66 Removing the air filter ............................ 66 Installing the air filter .............................. 67 Cleaning the air filter and air filter box ........................................................... 67 Preparing air filter box cover for securing ................................................... 68

12.26 12.27 12.28
12.29 12.30 12.31 12.32 12.33 12.34 12.35
12.36 12.37 12.38 12.39 12.40
12.41
12.42

Removing the main silencer........................ 68 Installing the main silencer ......................... 69 Changing the glass fiber yarn filling of the main silencer ..................................... 69 Removing the fuel tank ........................... 70 Installing the fuel tank ............................. 71 Checking the chain for dirt.......................... 73 Cleaning the chain....................................... 73 Checking the chain tension ......................... 74 Adjusting the chain tension ........................ 74 Checking the chain, rear sprocket, engine sprocket, and chain guide ............... 75 Checking the frame ................................. 78 Checking the link fork .............................. 78 Checking the throttle cable routing............ 78 Checking the rubber grip ............................ 79 Adjusting the basic position of the clutch lever ............................................................. 79 Checking/correcting the fluid level of the hydraulic clutch ........................................... 79 Changing the hydraulic clutch fluid ........ 80

13 BRAKE SYSTEM........................................................... 82

13.1
13.2
13.3 13.4 13.5 13.6 13.7
13.8
13.9
13.10 13.11 13.12
13.13

Checking the free travel of the hand brake lever................................................... 82 Adjusting the basic position of the hand brake lever (EC 300 US)............................... 82 Checking the brake discs............................. 82 Checking the front brake fluid level............ 83 Adding front brake fluid .......................... 83 Checking the front brake linings ................. 85 Changing the brake linings of the front brake ........................................................ 85 Checking the free travel of foot brake lever ............................................................. 87 Adjusting the basic position of the foot brake lever ............................................... 88 Checking the rear brake fluid level ............. 88 Adding rear brake fluid ........................... 89 Checking the brake linings of the rear brake............................................................ 90 Changing the rear brake linings .............. 90

14 WHEELS, TIRES........................................................... 93

14.1 Removing the front wheel ...................... 93 14.2 Installing the front wheel ........................ 94 14.3 Removing the rear wheel ........................ 94 14.4 Installing the rear wheel ......................... 95 14.5 Checking the tire condition......................... 97 14.6 Checking tire pressure................................. 97 14.7 Checking spoke tension............................... 98

15 ELECTRICAL SYSTEM .................................................. 99

15.1 Removing the 12-V battery ..................... 99 15.2 Installing the 12-V battery ................... 100 15.3 Charging the 12-V battery .................... 102 15.4 Changing main fuse .................................. 103

TABLE OF CONTENTS

15.5
15.6
15.7
15.8 15.9
15.10 15.11 15.12
15.13

Changing the fuses of individual electrical power consumers..................... 105 Removing the headlight mask with the headlight................................................... 106 Installing the headlight mask with the headlight................................................... 106 Changing the headlight bulb .................... 107 Changing the turn signal bulb (All EU models) ..................................................... 108 Checking the headlight setting ................ 108 Adjusting the headlight range.................. 109 Changing the combination instrument battery ...................................................... 109 Diagnostics connector.............................. 110

16 COOLING SYSTEM ................................................... 111

16.1 Cooling system ......................................... 111 16.2 Checking the antifreeze and coolant
level........................................................... 111 16.3 Checking the coolant level ....................... 112 16.4 Draining the coolant ............................. 112 16.5 Refilling with coolant ............................ 113 16.6 Changing the coolant ........................... 115

17 TUNING THE ENGINE.............................................. 117

17.1 Checking the play in the throttle cable.... 117 17.2 Adjusting the play in the throttle
cable ..................................................... 117 17.3 Setting the characteristic map of the
throttle response ................................. 118 17.4 Adjusting the idle speed ....................... 119 17.5 Programming ambient air pressure......... 120 17.6 Ignition curve plug-in connector.............. 120 17.7 Changing the ignition timing map............ 121 17.8 Checking the basic position of the shift
lever .......................................................... 121 17.9 Adjusting the basic position of the shift
lever ...................................................... 122

18 SERVICE WORK ON THE ENGINE ............................ 123

18.1 Changing the fuel screen ..................... 123 18.2 Checking 2-stroke oil level ....................... 124 18.3 Priming oil pump .................................. 124 18.4 Cleaning the oil screen in the oil
tank ....................................................... 126 18.5 Checking the gear oil level ....................... 128 18.6 Changing the gear oil ........................... 129 18.7 Adding the gear oil ............................... 130

19 CLEANING, CARE..................................................... 132

19.1 Cleaning the motorcycle .......................... 132 19.2 Checks and maintenance steps for
winter operation ...................................... 133

20 STORAGE................................................................. 134

20.1 Storage...................................................... 134 20.2 Preparing for use after storage................ 135

21 TROUBLESHOOTING ............................................... 136

22 BLINK CODE............................................................. 139

23 TECHNICAL DATA.................................................... 141

23.1 23.1.1 23.1.2 23.2 23.3 23.3.1 23.3.2 23.3.3 23.4 23.5 23.6 23.7 23.8 23.9

Engine ....................................................... 141 EC 250 EU ............................................ 141 All 300 models..................................... 141
Engine tightening torques........................ 142 Capacities.................................................. 144
Gear oil ................................................ 144 Coolant ................................................ 144 Fuel ...................................................... 144 Chassis ...................................................... 144 Electrical system....................................... 145 Tires .......................................................... 145 Fork ........................................................... 145 Shock absorber......................................... 146 Chassis tightening torques ....................... 146

24 SUBSTANCES ........................................................... 149

25 AUXILIARY SUBSTANCES ......................................... 151

26 STANDARDS ............................................................ 153

27 INDEX OF SPECIAL TERMS ...................................... 154

28 LIST OF ABBREVIATIONS......................................... 155

29 LIST OF SYMBOLS.................................................... 156

29.1 Red symbols.............................................. 156 29.2 Yellow and orange symbols...................... 156 29.3 Green and blue symbols........................... 156

INDEX ............................................................................... 157

MEANS OF REPRESENTATION 1

1.1

Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g., of a work step or a function).

Indicates an unexpected reaction (e.g., of a work step or a function).

Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have this work performed by an authorized GASGAS Motorcycles workshop. Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.
Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates the end of an activity, including potential reworking.

1.2

Formats used

The typographical formats used in this document are explained below.

Proprietary name

Indicates a proprietary name.

Name®

Indicates a protected name.

BrandTM

Indicates a brand available on the open market.

Underlined terms

Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.

2 SAFETY ADVICE

2.1

Use definition intended use

This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.

Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version. The derestricted version of this vehicle must only be operated in closed off areas away from public highway traffic. This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

2.2

Misuse

The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended. Any use of the vehicle beyond the intended and defined use constitutes misuse. Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.

2.3

Safety 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 any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

2.4

Degrees of risk and symbols

Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Note Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

SAFETY ADVICE 2

2.5

Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1 Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

2.6

Safe operation

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. An appropriate driver's license is needed to drive the vehicle on public roads. Have malfunctions that impair safety immediately eliminated by an authorized GASGAS Motorcycles workshop. Adhere to the information and warning labels on the vehicle.

2.7

Protective clothing

Warning
Risk of injuryMissing or poor protective clothing presents an increased safety risk. Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with pro-
tectors on all rides. Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, GASGAS Motorcycles recommends that you only operate the vehicle while wearing protective clothing.

2 SAFETY ADVICE

2.8

Work rules

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key). Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000) Unless otherwise noted, normal conditions apply to all tasks and descriptions.

Ambient temperature Ambient air pressure Relative air humidity

20 °C (68 °F) 1,013 mbar (14.69 psi) 60 ± 5 %

During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings, pins, and lock washers). In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer's instructions. If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker. After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts. After completing a repair or service work, check the operating safety of the vehicle.

2.9

Environment

If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of others. When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country. Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles dealer will be glad to advise you.

2.10 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and service your motorcycle. This is the only way to find out how best to customize the vehicle for your own use and how you can protect yourself from injury.

Tip Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need to.

If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized GASGAS Motorcycles dealer. The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be downloaded again by the new owner.
The Owner's Manual is also available for download from your authorized GASGAS Motorcycles dealer and on the GASGAS Motorcycles website. A printed copy can also be ordered from your authorized GASGAS Motorcycles dealer. International GASGAS Motorcycles website: http://www.gasgas.com

IMPORTANT NOTES 3

3.1

Manufacturer warranty, implied warranty

The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

3.2

Fuel, auxiliary substances

Note Environmental hazardImproper handling of fuel is a danger to the environment.
Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.

3.3

Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by GASGAS Motorcycles and have them installed by an authorized GASGAS Motorcycles workshop. GASGAS Motorcycles accepts no liability for other products and any resulting damage or loss. Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized GASGAS Motorcycles dealer will be glad to advise you.

The latest news GASGAS Technical Accessories on your vehicle can be found on the GASGAS Motorcycles website. International GASGAS Motorcycles 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, dusty and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle. The relevant mileage or time interval is whichever occurs first.

3.5

Figures

The figures contained in the manual may depict special equipment. In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.

3.6

Customer service

Your authorized GASGAS Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle and GASGAS Motorcycles.

A list of authorized GASGAS Motorcycles dealers can be found on the GASGAS Motorcycles website. International GASGAS Motorcycles website: http://www.gasgas.com

4 VIEW OF VEHICLE

4.1

View of vehicle, front left (example)

1 Hand brake lever ( p. 14) 2 Clutch lever ( p. 14) 3 Light switch ( p. 15) (All EU models) 3 Stop button ( p. 14) (All EU models) 3 Turn signal switch ( p. 16) (All EU models) 3 Horn button ( p. 15) (All EU models) 4 Ignition curve plug-in connector ( p. 120) 5 Side stand ( p. 20) 6 Air filter box cover 7 Shift lever ( p. 20)

S04403-10

4.2

View of vehicle, rear right (example)

VIEW OF VEHICLE 4

1 Fuel tank filler cap 2 Throttle grip ( p. 14) 3 Vehicle identification number ( p. 12) 4 Foot brake lever ( p. 20) 5 Level viewer for brake fluid, rear

S04404-10

5 SERIAL NUMBERS

5.1

Vehicle identification number

1 The vehicle identification number is stamped on the right side of the
steering head.

5.2

Type label

401945-10
1 Type label is fixed to the front of the steering head.

401946-10

5.3

Key number (All EU models)

1 The key number for the steering lock is stamped onto the key con-
nector.

H02475-10

5.4

Engine number

1 The engine number is located on the left side of the engine over the
engine sprocket.

H01047-10

5.5

Fork part number

SERIAL NUMBERS 5
1 The fork part number is stamped on the inside of the axle clamp.

401947-10

5.6

Shock absorber article number

1 Shock absorber article number is stamped on the top of the shock
absorber above the adjusting ring towards the engine side.

401948-10

6 CONTROLS

6.1

Clutch lever

1 Clutch lever is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.

S04405-10

6.2

Hand brake lever

1 Hand brake lever is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.

6.3

Throttle grip

S04406-10
1 Throttle grip is fitted on the right side of the handlebar.

S04406-11

6.4

Stop button (All EU models)

1 The stop button is 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 circuit is inter-
rupted, a running engine stops, and a non-running engine will not start.

S04407-10

CONTROLS 6

6.5

Stop button (EC 300 US)

S04408-10

6.6

Horn button (All EU models)

1 Horn button is fitted on the left side of the handlebar.
Possible states · The horn button is in the basic position · The horn button is pressed The horn is operated in this position.

S04407-12

6.7

Light switch (All EU models)

1 Light switch is fitted on the left side of the handlebar.
Possible states Low beam on Light switch is in the central position. In this position, the low beam and tail light are switched on.
High beam on Light switch is turned to the left. In this position, the high beam and the tail light are switched on.

S04407-11

6.8

Light switch (EC 300 US)

1 The light switch is located to the left of the combination instrument.
Possible states · Light off Light switch is pressed in up to the stop. In this position,
the light is switched off. · Light on Light switch is pulled out to the stop. In this position, the
low beam and tail light are switched on.

S04409-10

6 CONTROLS

6.9 6.10 6.11

Turn signal switch (All EU models)

S04410-10

1 Turn signal switch is 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.

Emergency OFF switch (All EU models)

S04411-10

1 The emergency OFF switch is fitted on the right side of the handle-
bar.
Possible states
Ignition off In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
Ignition on In this position, the ignition circuit is closed, and the engine can be started.

Start button

1 Start button is fitted on the right side of the handlebar.

Possible states · The start button · The start button
actuated.

is in the basic position is pressed In this position, the starter motor is

6.12

S04412-10

Overview of indicator lamps (All EU models)

S04409-01

Possible states
The high beam indicator lamp lights up blue The high beam is switched on.
Malfunction indicator lamp lights up/flashes yellow The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized GASGAS Motorcycles workshop.
The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark.
Turn signal indicator lamp flashes green The turn signal is switched on.

CONTROLS 6

The oil level warning lamp lights up red Oil level has reached the MINmarking. Ride for no more than until the remaining fuel in the tank is depleted and at the next
opportunity refuel with 2-stroke oil.

6.13

Overview of indicator lamps (EC 300 US)
Possible states High beam indicator lamp inoperative

S04413-01

Malfunction indicator lamp lights up/flashes yellow The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized GASGAS Motorcycles workshop.
The fuel level warning lamp lights up yellow The fuel level has reached the reserve mark.
The oil level warning lamp lights up red Oil level has reached the MINmarking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil.

6.14 Opening the fuel tank filler cap

Danger
Fire hazardFuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. If any fuel is spilled, wipe it off immediately. Observe the specifications for refueling.
Warning
Danger of poisoningFuel 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 area with plenty of water. Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes. Change your clothing in case of fuel spills on them. Keep fuels correctly in a suitable canister, and out of the reach of children.
Note Environmental hazardImproper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system.

6 CONTROLS

1 Press release button , turn the fuel tank filler cap counterclock-
wise, and lift it off.

6.15

S04414-10
Closing the fuel tank filler cap
Mount the fuel tank filler cap and turn it clockwise until release but-
1 ton engages.
Info
2 Route fuel tank breather hose without kinks.

6.16

S04414-11
Opening 2-stroke oil tank cap
1 Fold loop upward.
Turn the 2-stroke oil tank cap counterclockwise and pull it up.

6.17

S04415-10
Closing 2-stroke oil tank cap
Put the 2-stroke oil tank cap on and turn it clockwise.
1 Fold loop down.
The 2-stroke oil tank cap engages.

S04416-10

6.18 Cold start button

CONTROLS 6
1 The cold start button is fitted on the side of the throttle valve body.
If the engine is cold and the ambient temperature is low, the electronic fuel injection system extends the injection time. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pulling the cold start button.
Info If the engine is warm, the cold start button must be deactivated.
Possible states · The cold start button is activated The cold start button is pulled
out all the way and turned by a ¼ turn. · The cold start button is deactivated A further ¼ turn returns the
cold start button back to the basic position.

6.19

S03529-10

Idle speed adjusting screw

The idle setting of the throttle valve body substantially influences the vehicle's starting behavior, a stable idle speed, and the vehicle's response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.
1 The idle speed is adjusted using the idle speed adjusting screw .

Info If the idle speed is high, the engine is slow to run, the engine brake is low and the throttle response is aggressive, the adjusting screw must be turned clockwise. If the idle speed is low, the engine is running fast, the engine brake is high and the throttle response is not clean, the adjusting screw must be turned counterclockwise.

S03529-11

6 CONTROLS
6.20 Shift lever

1 Shift lever is mounted on the left side of the engine.

401950-10

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

6.21

Foot brake lever

401950-11
1 Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.

6.22 Side stand

401956-10
1 The side stand is located on the left of the vehicle.

401943-10

CONTROLS 6
The side stand is used for parking the motorcycle. Info
1 When you are riding, side stand must be folded up and 2 secured with rubber strap .

6.23

401944-10
Steering lock (All EU models)
1 Steering lock is 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.

S04417-10

6.24 Locking the steering (All EU models)

Note Danger of damageThe parked vehicle can roll away or fall over.
Park the vehicle on a firm and level surface.

Park the vehicle.
Turn handlebar as far as possible to the right.
Insert the key for the steering lock into the steering lock, turn it to the left, press it in, and turn it to the right. Pull out the key for the steering lock.
Steering is no longer possible.

400732-01

Info Never leave the key for the steering lock in the steering lock.

6.25

Unlocking the steering (All EU models)
Insert the key for the steering lock into the steering lock, turn it to the left, pull it out, and turn it to the right. Pull out the key for the steering lock. The handlebar can now be moved again.
Info Never leave the key for the steering lock in the steering lock.

400731-01

7 COMBINATION INSTRUMENT

7.1

Combination instrument overview

1 Overview of indicator lamps 2 Left button 3 Display 4 Right button

7.2

Activation

402819-10
Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

402819-01

7.3

Messages on the combination instrument

Possible states
Battery voltage of the combination instrument The battery voltage of the combination instrument is too low. Change combination instrument battery.
Service A service is due. Contact an authorized GASGAS Motorcycles workshop.

401901-01

7.4

Setting the combination instrument

Condition The motorcycle is stationary.
Press both buttons for 35 seconds. The Setup menu is displayed. The UNIT display flashes.
Press one of the buttons to select UNIT for the speed in kilometers KM/H or miles M/H.

401909-01

COMBINATION INSTRUMENT 7
Wait for 5 seconds. The combination instrument changes to the next menu item. The symbol flashes.
Press one of the buttons to select the 24h or 12h display of the clock.

401911-01 401912-01 401913-01

Wait for 5 seconds. The 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.
Wait for 5 seconds. The combination instrument changes to the next menu item. The symbol flashes.
Set the service. Shortening the service interval
Press the left button. The value decreases.
Extending the service interval Press the right button. The value increases.
Switching off the service interval display Press and hold the left button. off appears in the display.

401914-01

7.5

Setting the kilometers or miles

Info If the unit is changed, the value ODO is retained and converted accordingly.

Condition The motorcycle is stationary.

7 COMBINATION INSTRUMENT
Press both buttons for 35 seconds. The Setup menu is displayed. The UNIT display flashes.
Press one of the buttons to select UNIT for the speed in kilometers KM/H or miles M/H.

401909-01

7.6

Setting the clock

Condition The motorcycle is stationary.
Press both buttons for 35 seconds. The Setup menu is displayed. The UNIT display flashes.
Wait for the menu of the clock to flash. Press one of the buttons to select the 24h or 12h display of the
clock.

401911-01 401912-01

7.7

Setting the service display

401913-01

Condition The motorcycle is stationary.
Press both buttons for 35 seconds. The Setup menu is displayed. The UNIT display flashes.
Wait for the menu of the service display to flash. Set the service.
Shortening the service interval Press the left button. The value decreases.
Extending the service interval Press the right button. The value increases.

COMBINATION INSTRUMENT 7
Switching off the service interval display Press and hold the left button. off appears in the display.

401914-01

7.8

Speed, time, and DST distance 1

Press one of the buttons until DST appears on the combination instrument.
KM/H or M/H shows the speed. shows the time.
DST shows the distance since the last reset, such as between two refueling stops.

401901-01

Info If the value of 39999.9 is exceeded, DST is automatically reset to 0.0.

Press the left button briefly.
Press the left button for 3 5 seconds.
Press the right button briefly.
Press the right button for 3 5 seconds.

Next display mode
DST can be preset to a value between 0.0 and 39999.9 by pressing the buttons.
Next display mode
DST is reset to 0.0.

7.9

Speed, time, and DST2 distance 2

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 reset, such as between two refueling stops.

401902-01

Info If the value of 39999.9 is exceeded, DST2 is automatically reset to 0.0.

Press the left button briefly.
Press the left button for 3 5 seconds.
Press the right button briefly.

Next display mode
DST2 can be preset to a value between 0.0 and 39999.9 by pressing the buttons.
Next display mode

7 COMBINATION INSTRUMENT

7.10

Press the right DST2 is reset to 0.0. button for 3 5 seconds.

AVG average speed, ART operating hours, and ODO total distance covered

Press one of the buttons until AVG, ART and ODO appear on the combination instrument.
AVG shows the average speed since the last reset. ART shows the operating hours. ODO shows the total distance covered.

401903-01

Press the left button briefly.
Press the left button for 3 5 seconds.
Press the right button briefly.
Press the right button for 3 5 seconds.

Next display mode
The OPEN END WRENCH SYMBOL shows the remaining operating hours until the next service is due. Next display mode
AVG is reset to 0.0.

PREPARING FOR USE 8

8.1

Advice on preparing for first use

Danger
Danger of accidentsA rider who is not fit to ride poses a danger to him or herself and others. Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injuryMissing or poor protective clothing presents an increased safety risk. Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with pro-
tectors on all rides. Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashingDifferent tire tread patterns on the front and rear wheel impair the handling characteristic. Different tire tread patterns can make the vehicle significantly more difficult to control.
Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidentsAn unadapted riding style impairs the handling characteristic. Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidentsThe vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidentsThe 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 accidentsTotal weight and axle loads influence the handling characteristic. Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriationPeople 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.

Info When using your motorcycle, remember that others may feel disturbed by excessive noise.
Make sure that the pre-sales inspection work has been carried out by an authorized GASGAS Motorcycles workshop. You will receive a delivery certificate when the vehicle is handed over.
Before riding for the first time, read the entire Owner's Manual carefully. Get to know the controls. Adjust the basic position of the clutch lever. ( p. 79) (All EU models)
Adjust the free travel of the handbrake lever.

8 PREPARING FOR USE

(EC 300 US) Adjust the basic position of the hand brake lever. ( p. 82)
Adjust the basic position of the foot brake lever. ( p. 88) Adjust the basic position of the shift lever. ( p. 122) Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip.

Info When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.
Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle. Do not make any off-road trips that exceed your ability and experience. Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even
weight distribution between the front and rear wheels.

Info Motorcycles react sensitively to any changes of weight distribution.

The maximum permissible overall weight and the maximum permissible axle loads must not be exceeded. Guideline

Maximum permissible overall weight

335 kg (739 lb.)

Maximum permissible front axle load

145 kg (320 lb.)

Maximum permissible rear axle load

190 kg (419 lb.)

Check the spoke tension. ( p. 98)

Info The spoke tension must be checked after half an hour of operation.
Run the engine in. ( p. 28)

8.2

Running in the engine

During the running-in phase, do not exceed the specified engine performance. Guideline

Maximum engine performance

During the first 3 operating hours

< 70 %

During the first 5 operating hours

< 100 %

Avoid fully opening the throttle! Check the idle speed regularly.
Guideline
Idle speed

1,400 ... 1,500 rpm

Info The idle speed may change during the run-in time.
» If the idle speed changes: Adjust the idle speed. ( p. 119)

PREPARING FOR USE 8

8.3

Starting power of lithium-ion batteries at low temperatures

402555-01

Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batteries. Multiple starting attempts may be needed. Press the start button for 5 seconds, and wait 30 seconds between attempts. The pauses are necessary so that the heat created can distribute through the lithium-ion battery and the 12-V battery is not damaged. If the charged lithium-ion battery is unable to actuate the starter motor when temperatures are below 15 °C (60 °F), the battery is not faulty, but needs to be warmed up internally to increase its starting power (current output). The starting power increases as the battery warms up.

8.4

Preparing the vehicle for difficult operating conditions

Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

Seal the air filter box. Clean the air filter and air filter box. ( p. 67)

Info Check the air filter approx. every 30 minutes.
Check the electrical connector for humidity and corrosion and to ensure it is firmly seated. » If humidity, corrosion, or damage is found: Clean and dry the connector, or change it if necessary.
Difficult operating conditions are: Rides on dry sand. ( p. 29) Rides on wet sand. ( p. 31) Rides on wet and muddy circuits. ( p. 32) Rides at high temperatures or slow riding. ( p. 32) Riding at low temperatures and in snow. ( p. 33)

8.5

Preparing the vehicle for rides on dry sand

Check the radiator cap.

Value on the radiator cap

1.8 bar (26 psi)

» If the indicated value does not correspond to the setpoint value:

M01129-01

8 PREPARING FOR USE

M01104-01

Mount the air filter sand cover. Air filter sand cover (79006922000)

Info Observe the GASGAS Technical Accessories fitting instructions.

M01105-01 600868-01

Clean the chain.
Chain cleaner ( p. 151)
Mount the steel sprocket. Grease the chain.
Universal oil spray ( p. 152)
Clean the radiator fins. Straighten the bent radiator fins carefully. Condition
Regular use in sand Change the piston every 10 operating hours.

PREPARING FOR USE 8

8.6

Preparing the vehicle for rides on wet sand

Check the radiator cap.

Value on the radiator cap

1.8 bar (26 psi)

» If the indicated value does not correspond to the setpoint value:

M01129-01

Change the radiator cap. Mount the air filter rain cover.
Air filter rain cover (79006921000)

Info Observe the GASGAS Technical Accessories fitting instructions.

M01106-01 600868-01

8 PREPARING FOR USE

8.7

Preparing the vehicle for rides on wet and muddy circuits

Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info Observe the GASGAS Technical Accessories fitting instructions.

M01106-01

Mount the steel sprocket. Clean the motorcycle. ( p. 132) Straighten the bent radiator fins carefully.

600868-01

8.8

Preparing vehicle for high temperatures or slow riding

Check the radiator cap.

Value on the radiator cap

1.8 bar (26 psi)

» If the indicated value does not correspond to the setpoint value:

M01129-01

600868-01

Change the radiator cap. Adjust the secondary drive to the road conditions.
Info The transmission oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive.
Clean the chain. Chain cleaner ( p. 151)
Clean the radiator fins.

PREPARING FOR USE 8

Straighten bent radiator fins carefully. Check the coolant level. ( p. 112)

8.9

Preparing the vehicle for low temperatures or snow

Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info Observe the GASGAS Technical Accessories fitting instructions.

M01106-01

9 RIDING INSTRUCTIONS

9.1

Checks and maintenance measures when preparing for use

Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated.

H02217-01

Check the gear oil level. ( p. 128) Check the electrical system. Check the front brake fluid level. ( p. 83) Check the rear brake fluid level. ( p. 88) Check the front brake linings. ( p. 85) Check the brake linings of the rear brake. ( p. 90) Check that the brake system is functioning properly. Check the coolant level. ( p. 112) Check the chain for dirt. ( p. 73) Check the chain, rear sprocket, engine sprocket, and chain guide.
( p. 75)
Check the chain tension. ( p. 74) Check the tire condition. ( p. 97) Check tire pressure. ( p. 97) Check the spoke tension. ( p. 98)

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. 53) Bleed the fork legs. ( p. 52) Check the air filter. Check the settings of all controls and ensure that they can be oper-
ated smoothly. Check all screws, nuts, and hose clamps regularly for tightness. Check the fuel level. Check 2-stroke oil level. ( p. 124)

9.2

Starting the vehicle

Danger
Danger of poisoningExhaust 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.
Note Engine damageHigh revving speed with a cold engine negatively impacts the lifespan of the engine. Always run the engine warm at a low speed.

RIDING INSTRUCTIONS 9

401944-10 400733-01

1 Take the motorcycle off side stand and secure the side stand 2 with rubber strap .
Shift the transmission to neutral position. Condition
Ambient temperature: < 10 °C (< 50 °F) Pull the cold start button fully out and turn it by a ¼ turn.
Info If the engine is warm, the cold start button must be deactivated.
Press the start button.
Info Do not open the throttle. Press the start button for a maximum of 5 seconds. Wait for 30 seconds before a further attempt at starting. At temperatures below 15 °C (60 °F), several attempts at starting may be necessary to warm-up the lithium-ion battery and thereby increase the starting power. During the starting process, the malfunction indicator lamp lights up.

9.3

Starting off

Info Switch on the light before riding the vehicle. You will be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber strap.

Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.

9.4

Shifting, riding

Warning
Danger of accidentsIf 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.
Warning
Engine failureThe engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.
As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the tank is depleted.
At the next opportunity add 2-stroke oil before you refuel. Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully depleted in
error.

Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized GASGAS Motorcycles workshop. First-gear is used for starting off and for steep inclines.

9 RIDING INSTRUCTIONS

Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
If the cold start function was activated, deactivate the cold start button after the engine has warmed up. After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely
reduce the speed, but fuel consumption will be considerably lower. Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption. To shift down, apply the brakes and close the throttle at the same time. Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift
again. Switch off the engine if running at idle speed or stationary for a long time.
Guideline
2 min
Avoid frequent and longer slipping of the clutch. This causes the gear oil, engine and cooling system to heat up. Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

9.5

Braking

Warning
Danger of accidentsExcessively forceful application of the brakes blocks the wheels. Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidentsA spongy pressure point on the front or rear brake reduces braking efficiency. Check the brake system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidentsMoisture and dirt impair the brake system. Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
On sandy, wet or slippery surfaces, use the rear brake. Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road
speed.

9.6

Stopping, parking

Warning
Risk of misappropriationPeople who act without authorization endanger themselves and others. Do not leave the vehicle unattended if the engine is running. Protect the vehicle against access by unauthorized persons.
Warning
Danger of burnsSome vehicle components become very hot when the vehicle is operated. Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before
the vehicle parts have cooled down. Let the vehicle parts cool down before you perform any work on the vehicle.
Note Material damageThe vehicle may be damaged by incorrect procedure when parking.

RIDING INSTRUCTIONS 9

Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle.
Park the vehicle on a firm and level surface. Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note Fire hazardHot vehicle components pose a fire hazard and explosion risk. Do not park the vehicle near to materials which are highly flammable or explosive. Allow the vehicle to cool down before covering it.
Apply the brakes on the motorcycle. Shift the transmission to neutral position. (All EU models)
Press and hold the stop button while the engine is idling until the engine stops. (EC 300 US)
Press and hold the stop button while the engine is idling until the engine stops. Park the motorcycle on firm ground.

9.7

Transporting

Note Danger of damageThe parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface.
Note Fire hazardHot vehicle components pose a fire hazard and explosion risk. Do not park the vehicle near to materials which are highly flammable or explosive. Allow the vehicle to cool down before covering it.

Switch off the engine.
Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

9.8

Refueling

401475-01

9 RIDING INSTRUCTIONS

Warning
Danger of poisoningFuel 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 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.
Note Material damageInadequate fuel quality causes the fuel filter to quickly become clogged. In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system.
Refuel only with clean fuel that meets the specified standards. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note Environmental hazardImproper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Open the fuel tank filler cap. ( p. 17)

A Fill the fuel tank with fuel up to level .

Guideline

Level A

35 mm (1.38 in)

Total fuel tank capacity, approx.

8.5 l (2.25 US gal)

Super unleaded (ROZ 95) ( p. 150)

400382-10

Info Do not refuel using pre-mixed fuel.
Close the fuel tank filler cap. ( p. 18)

9.9

Adding 2-stroke oil

Warning
Engine failureThe engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.
As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the tank is depleted.
At the next opportunity add 2-stroke oil before you refuel. Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully depleted in
error.
Open 2-stroke oil tank cap. ( p. 18)

RIDING INSTRUCTIONS 9

A Fill the 2-stroke oil tank up to the lower edge of the filler neck.
Guideline Only use 2-stroke oil which is appropriate for separate lubrication.

2-stroke oil tank content approx.

0.6 l (0.6 qt.)

Close 2-stroke oil tank cap. ( p. 18)

Engine oil, 2-stroke ( p. 149)

M01516-10

10 SERVICE SCHEDULE

10.1 Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on GASGAS Motorcycles Dealer.net. Your authorized GASGAS Motorcycles dealer will be glad to advise you.

10.2 Required work

Every 10 operating hours when used for motorsports

Every 40 operating hours

Every 20 operating hours

After 5 operating hours

After 1 operating hour

Read out the fault memory using the GASGAS Motorcycles diagnostics tool. Check that the electrical system is functioning properly. Check and charge the 12-V battery. Check the front brake linings. ( p. 85) Check the brake linings of the rear brake. ( p. 90) Check the brake discs. ( p. 82) Check the brake lines for damage and leakage. Check the rear brake fluid level. ( p. 88) Check the free travel of the foot brake lever. ( p. 87) Check the frame. ( p. 78) Check the link fork. ( p. 78) Check the fork bearing for play. Check the shock absorber heim joint for play. Check the shock absorber linkage.

Check the tire condition. ( p. 97)

Check tire pressure. ( p. 97)

Check the wheel bearing for play.

Check the wheel hubs.

Check the rim run-out.

Check the spoke tension. ( p. 98)

Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 75)

Check the chain tension. ( p. 74)

Grease all moving parts (e.g. side stand, hand lever, chain, etc.) and check for smooth operation.

Check/correct the fluid level of the hydraulic clutch. ( p. 79) Check the front brake fluid level. ( p. 83) Check the free travel of the hand brake lever. ( p. 82) Check the steering head bearing for play. ( p. 58) Change the spark plug and spark plug connector. Check the reed valve housing, reed valve, and intake flange. Change the gear oil. ( p. 129) Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.

SERVICE SCHEDULE 10

Every 10 operating hours when used for motorsports

Every 40 operating hours

Every 20 operating hours

After 5 operating hours

After 1 operating hour

Check the antifreeze and coolant level. ( p. 111)

Check the cables for damage and for routing without kinks.

Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.

Clean the air filter and air filter box. ( p. 67)

Change the glass fiber yarn filling of the main silencer. ( p. 69)

Service the fork.

Perform the shock absorber service.

Check the tightness of the easily accessible, safety-relevant screws and nuts.

Change the fuel screen. ( p. 123)

Check the fuel pressure.

Check the headlight setting. ( p. 108)

Check the idle speed.

Final check: Check the vehicle for operating safety and take a test ride.

Read out the fault memory after the test ride using the GASGAS Motorcycles diagnostics tool.

Make a service entry in GASGAS Motorcycles Dealer.net.

One-time interval Periodic interval

10.3 Recommended work

Change the front brake fluid. Change the rear brake fluid. Change the hydraulic clutch fluid. ( p. 80) Lubricate the steering head bearing. ( p. 60) Clean the pressure sensor hose. Service the fork. Perform the shock absorber service. Check the electric starter drive. Change the fuel filter. Change the piston and check the cylinder. Change the oil pump; clean the oil screen. Clean the oil screen in the oil tank. ( p. 126) Clean the protection cap of the pressure sensor. Change the coolant. ( p. 115)

Every 40 operating hours when used for motorsports

Every 10 operating hours when used for motorsports

every 48 months

every 12 months

Every 80 operating hours

Every 40 operating hours

After 20 operating hours

After 10 operating hours

10 SERVICE SCHEDULE

Every 40 operating hours when used for motorsports

Every 10 operating hours when used for motorsports

every 48 months

every 12 months

Every 80 operating hours

Every 40 operating hours

After 20 operating hours

After 10 operating hours

Perform minor engine service. (Check the exhaust control for functioning and smooth operation. Check the clutch.)

Perform major engine service including removing and installing the engine.

(Change the connecting rod, conrod bearing, and crank pin. Clean the hose

connections of the pressure sensor. Check the transmission and shift mechanism.

Change all engine bearings.)

One-time interval Periodic interval

TUNING THE CHASSIS 11

11.1 Checking the basic chassis setting with the rider's weight

Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of
the suspension components must match the rider's weight.

As delivered, GASGAS offroad motorcycles are adjusted for an average rider's weight (with full protective clothing).

Guideline

Standard rider weight

75 ... 85 kg (165 ... 187 lb.)

If the rider's weight is above or below this range, the basic setting of the suspension components must be adjusted accordingly.
Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.

401030-01
11.2 Compression damping of the shock absorber
The compression damping of the shock absorber is divided 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 wheel suspension compresses slowly. These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.
11.3 Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injuryParts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

11 TUNING THE CHASSIS

1 Turn adjusting screw clockwise with a screwdriver as far as the
last perceptible click.

S04418-10

Info
2 Do not loosen fitting !

Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Guideline

Lowspeed compression damping

Comfort

17 clicks

Standard

15 clicks

Sport

13 clicks

Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.

11.4 Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injuryParts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

1 Using an open end wrench, turn adjusting screw clockwise all
the way.

S04419-10

Info
2 Do not loosen fitting !

Turn counterclockwise by the number of turns corresponding to the shock absorber type.

Guideline

Highspeed compression damping

Comfort

2.5 turns

Standard

2 turns

Sport

1.5 turns

Info Turn clockwise to increase damping; turn counterclockwise to reduce damping.

TUNING THE CHASSIS 11

11.5 Adjusting the rebound damping of the shock absorber

Caution
Risk of injuryParts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen.
Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

S04420-10

1 Turn adjusting screw clockwise up to the last perceptible click.

Turn counterclockwise 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 counterclockwise 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. 52)
Main work Position the sag gage in the rear axle and measure the distance to
marking SAG on the rear fender. Sag gauge (00029090100) Pin, sag scale (00029990010)
A Note the value as dimension .

402415-10

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

11 TUNING THE CHASSIS

11.7

Checking the static sag of the shock absorber
A Measure dimension of rear wheel unloaded. ( p. 45)
Hold the motorcycle upright with aid of an assistant. Measure the distance again between the rear axle and marking SAG
on the rear fender using the sag gage.
B Note the value as dimension .

Info
A The static sag is the difference between measurements and B.

Check the static sag.

Static sag

37 mm (1.46 in)

» If the static sag is less or more than the specified value:
Adjust the spring preload of the shock absorber. ( p. 47)

11.8

402416-10

Checking the riding sag of the shock absorber
A Measure dimension of rear wheel unloaded. ( p. 45)
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 again measures the distance between the rear axle and marking SAG on the rear fender using the sag gage.
C Note the value as dimension .

402417-10

Info
A The riding sag is the difference between measurements and C.

Check riding sag.

Riding sag

110 mm (4.33 in)

» If the riding sag differs from the specified measurement: Adjust the riding sag. ( p. 48)

TUNING THE CHASSIS 11

11.9 Adjusting the spring preload of the shock absorber
Caution
Risk of injuryParts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

Preparatory work Raise the motorcycle with a lift stand. ( p. 52) Remove the shock absorber. ( p. 61) After removing the shock absorber, clean it thoroughly.
Main work
1 Loosen screw . 2 Turn adjusting ring until 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 tension.

2 Tension the spring by turning adjusting ring to specified dimension A.

Guideline

Spring preload

10 mm (0.39 in)

402405-10

Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

1 Tighten screw .
Guideline
Screw, shock absorber M5 adjusting ring

5 Nm (3.7 lbf ft)

Finishing work Install the shock absorber. ( p. 63) Remove the motorcycle from the lift stand. (

p. 52)

11 TUNING THE CHASSIS

11.10

Adjusting the riding sag
B00292-10

Preparatory work Raise the motorcycle with a lift stand. ( p. 52) Remove the shock absorber. ( p. 61) After removing the shock absorber, clean it thoroughly.
Main work Choose and mount a suitable spring.
Guideline Spring rate Weight of rider: 65 ... 75 kg 39 N/mm (223 lb/in) (143 ... 165 lb.) Weight of rider: 75 ... 85 kg 42 N/mm (240 lb/in) (165 ... 187 lb.) Weight of rider: 85 ... 95 kg 45 N/mm (257 lb/in) (187 ... 209 lb.)

Info The spring rate is shown on the outside of the spring.

Finishing work Install the shock absorber. ( p. 63) Remove the motorcycle from the lift stand. ( p. 52) Check the static sag of the shock absorber. ( p. 46) Check the riding sag of the shock absorber. ( p. 46) Adjust the rebound damping of the shock absorber. (

p. 45)

11.11 Checking the basic setting of the fork
Info For various reasons, no exact riding sag can be determined for the fork.
As with the shock absorber, smaller differences in the rider's weight can be compensated by the spring preload.
However, if the fork frequently bottoms out (hard end stop on compression), harder springs must be fitted to avoid damage to the fork and frame.
If the fork feels unusually hard after extended periods of operation, the fork legs need to be bled.
401000-01

TUNING THE CHASSIS 11

11.12 Adjusting the compression damping of the fork
Info The hydraulic compression damping determines the fork suspension behavior.

1 Turn white adjuster clockwise as far as it will go.

S04313-10

Info
1 Adjuster is located at the upper end of the left fork leg.
The compression damping is located in left fork leg COMP (white adjuster). The rebound damping is located in right fork leg REB (red adjuster).

Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Compression damping

Comfort

18 clicks

Standard

15 clicks

Sport

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.

1 Turn red adjuster clockwise as far as it will go.

S04313-11

Info
1 Adjuster is located at the upper end of the right fork leg.
The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster).

Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline

Rebound damping

Comfort

18 clicks

Standard

15 clicks

Sport

12 clicks

Info Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

11 TUNING THE CHASSIS
11.14 Handlebar position

A On the upper triple clamp, there are 2 holes at a distance of to each
other.

Hole distance A

15 mm (0.59 in)

B The holes on the handlebar support are placed at a distance of from
the center.

Hole distance B

3.5 mm (0.138 in)

The handlebar can be mounted in four different positions. This allows the handlebar to be mounted in the most comfortable position for the rider.

M00993-10
11.15 Adjusting the handlebar position

Warning
Danger of accidentsA repaired handlebar poses a safety risk. If the handlebar 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.

1 Remove screws . 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.

2 Remove screws . Take off the handlebar supports.

Place the handlebar supports in the required position. Mount and
2 tighten screws .

Guideline

Screw, handlebar M10 support

40 Nm (29.5 lbf ft) Loctite®243TM

Info Position the left and right handlebar supports evenly.
Position the handlebar.

M00993-11

Info Make sure the cables and wiring are positioned correctly.

TUNING THE CHASSIS 11

1 Position the handlebar clamps. Mount screws and tighten
evenly.

Guideline

Screw, handlebar

20 Nm (14.8 lbf ft)

clamp

Info Make sure the gap widths are even.

12 SERVICE WORK ON THE CHASSIS

12.1 Raising the motorcycle with a lift stand

401942-01

Note Danger of damageThe parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface.
Raise the motorcycle at the frame underneath the engine.
Lift stand (A54029955100)
Neither wheel is in contact with the ground. Secure the motorcycle against falling over.

12.2 Removing the motorcycle from the lift stand

Note Danger of damageThe parked vehicle can roll away or fall over.
Park the vehicle on a firm and level surface.

Remove the motorcycle from the lift stand. Remove the lift stand.
1 To park the motorcycle, press side stand to the ground with
your foot and lean the motorcycle on it.

401943-10

Info When you are riding, the side stand must be folded up and secured with the rubber strap.

12.3 Bleeding the fork legs

Preparatory work Raise the motorcycle with a lift stand. ( p. 52)
Main work
1 Release bleeder screws .
Any excess pressure escapes from the interior of the fork. Tighten the bleeder screws.

S04313-12

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

SERVICE WORK ON THE CHASSIS 12

12.4

Cleaning the dust boots of the fork legs

Preparatory work Raise the motorcycle with a lift stand. ( Remove the fork protector. ( p. 53)

p. 52)

Main work
1 Push dust boots of both fork legs downward.

K00070-10

Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
Warning
Danger of accidentsOil 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 inner fork tubes of both fork legs.

Universal oil spray ( p. 152)

Press the dust boots back into their installation position. Remove excess oil.

Finishing work Install the fork protector. ( p. 54) Remove the motorcycle from the lift stand. (

p. 52)

12.5

Removing the fork protector
1 Remove screws and take off the clamp. 2 Remove screws and take off the left fork protector. 3 Remove screws and take off the right fork protector.

S04421-10

12 SERVICE WORK ON THE CHASSIS

12.6

Installing the fork protector
S04421-11

Position the fork protector on the left fork leg. Mount and tighten
1 screws .

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

Position the brake line, wiring harness, and clamp. Mount and
2 tighten screws .

Position the fork protector on the right fork leg. Mount and tighten
3 screws .

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

12.7 Removing the fork legs

Preparatory work Raise the motorcycle with a lift stand. ( p. 52) Remove the front wheel. ( p. 93) Remove the headlight mask with the headlight. (

p. 106)

Main work
1 Remove screws and take off the clamp.
Remove the cable tie.
2 Remove screws and take off the brake caliper.
Hang the brake caliper and the brake line loosely to the side.

S04422-10

3 Loosen screws . Remove the left fork leg. 4 Loosen screws . Remove the right fork leg.

S03475-10

SERVICE WORK ON THE CHASSIS 12

12.8

Installing the fork legs

Main work Position the fork legs.
1 Bleeder screws are positioned toward the front.

S04313-12

Info The rebound damping is located in right fork leg REB (red adjuster). The compression damping is located in left fork leg COMP (white adjuster). Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

S03475-11

2 Tighten screws .
Guideline Screw, top triple clamp M8
3 Tighten screws .
Guideline Screw, bottom triple M8 clamp

20 Nm (14.8 lbf ft) 15 Nm (11.1 lbf ft)

4 Position the brake caliper, and mount and tighten screws .

Guideline

Screw, front

brake caliper

25 Nm (18.4 lbf ft) Loctite®243TM

Mount the cable ties. Position the brake line, the wiring harness, and the clamp. Mount
5 and tighten screws .

S04422-11

Finishing work Install the front wheel. ( p. 94) Install the headlight mask with the headlight. ( Check the headlight setting. ( p. 108)

p. 106)

12.9

Removing the lower triple clamp

Preparatory work Raise the motorcycle with a lift stand. ( p. 52) Remove the front wheel. ( p. 93) Remove the headlight mask with the headlight. ( Remove the fork legs. ( p. 54) Remove front fender. ( p. 60) Remove the handlebar cushion.

p. 106)

12 SERVICE WORK ON THE CHASSIS
Main work
1 Remove screws and hang the combination instrument holder to
the side.

S03514-10

2 Remove screw .
3 Loosen screw . Take off the upper triple clamp with the handle-
bar and hang them to the side.

Info Cover the components to protect them against damage. Do not kink the cables and lines.

E00921-10

4 5 Remove O-ring . Remove protective ring .
Take off the lower triple clamp with the steering stem. Remove the upper steering head bearing.

E00922-10

12.10

Installing the lower triple clamp
Main work Clean the bearing and sealing elements, check for damage, and
grease.
High viscosity grease ( p. 151)
Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
1 Check whether upper steering head seal is correctly positioned. 2 3 Mount protective ring and O-ring .

V00359-10
56

SERVICE WORK ON THE CHASSIS 12
Position the upper triple clamp with the handlebar. Position the clutch line and the wiring harness.
4 Mount screw , but do not tighten yet.

E00921-11

Position the combination instrument holder, and mount and tighten
5 screws .

Guideline

Remaining screws,

chassis

10 Nm (7.4 lbf ft)

S04423-10

Position the fork legs.
6 Bleeder screws are positioned toward the front.

S04313-13

7 Tighten screws .
Guideline
Screw, bottom triple M8 clamp

15 Nm (11.1 lbf ft)

S03525-11

4 Tighten screw .
Guideline
Screw, top steering head

M20x1.5

12 Nm (8.9 lbf ft)

S03508-10

12 SERVICE WORK ON THE CHASSIS

8 Tighten screw .

Guideline

Screw, top steering

stem

20 Nm (14.8 lbf ft)

S03508-11

9 Tighten screws .
Guideline Screw, top triple clamp M8

20 Nm (14.8 lbf ft)

S03525-10

bk Position the brake caliper, and mount and tighten screws .

Guideline

Screw, front

brake caliper

25 Nm (18.4 lbf ft) Loctite®243TM

Mount the cable ties. Position the brake line, the wiring harness, and the clamp. Mount
bl and tighten screws .

S04422-12

Finishing work Mount the handlebar cushion. Install front fender. ( p. 60) Install the front wheel. ( p. 94) Install the headlight mask with the headlight. ( p. 106) Check that the wiring harness, throttle cables, and brake and clutch
lines can move freely and are routed correctly.
Check the steering head bearing for play. ( p. 58) Remove the motorcycle from the lift stand. ( p. 52) Check the headlight setting. ( p. 108)

12.11 Checking the steering head bearing play
Warning
Danger of accidentsIncorrect steering head bearing play impairs the handling characteristic and damages components. Correct incorrect steering head bearing play immediately. (Your authorized GASGAS Motorcycles workshop will
be glad to help.)

SERVICE WORK ON THE CHASSIS 12

Info 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.

H01167-01

Preparatory work Raise the motorcycle with a lift stand. ( p. 52)
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 head bearing play. ( p. 59)
Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions.
» If detent positions are detected: Adjust the steering head bearing play. ( p. 59) Check the steering head bearing and change if necessary.
Check the steering stop bolts for correct adjustment and locking.
Finishing work Remove the motorcycle from the lift stand. ( p. 52)

12.12

Adjusting the steering head bearing play

Preparatory work Raise the motorcycle with a lift stand. ( p. 52)

S04450-10

Main work
1 2 Loosen screws and .

3 Loosen and retighten screw .

Guideline

Screw, top steering

M20x1.5

head

12 Nm (8.9 lbf ft)

Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

1 Tighten screws .
Guideline Screw, top triple clamp M8

20 Nm (14.8 lbf ft)

2 Tighten screw .

Guideline

Screw, top steering

stem

20 Nm (14.8 lbf ft)

Finishing work Check the steering head bearing for play. ( p. 58) Remove the motorcycle from the lift stand. ( p. 52)

12 SERVICE WORK ON THE CHASSIS

12.13

Lubricating the steering head bearing
Remove the lower triple clamp. ( p. 55) Install the lower triple clamp. ( p. 56)
Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

H02387-01

12.14 Removing front fender

Preparatory work Remove the headlight mask with the headlight. (
Main work
1 Remove screws .

p. 106)

S04424-10

2 Remove screws . Take off front fender.

S04425-10

12.15 Installing front fender

Main work
1 Position front fender. Mount and tighten screws .

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

S04425-11

SERVICE WORK ON THE CHASSIS 12

2 Mount and tighten screws .

Guideline

Remaining screws,

chassis

10 Nm (7.4 lbf ft)

S04424-11

Finishing work Install the headlight mask with the headlight. ( Check the headlight setting. ( p. 108)

p. 106)

12.16

Removing the shock absorber
Preparatory work Raise the motorcycle with a lift stand. ( p. 52) Main work Remove the cable tie.
1 Remove screws and the frame protector.

S04430-10

2 Remove screw . 3 Remove fitting .

Info Raise the link fork slightly to be able to remove the screws more easily.

S04427-10

4 Press angle lever toward the rear. 5 Press linkage lever downward.

S04428-10

12 SERVICE WORK ON THE CHASSIS
(All EU models)
6 Disconnect plug-in connector on the brake light switch.

S04426-10

7 Remove screws .
Pull off foot brake cylinder from the push rod.

S04429-10

Remove the connecting link of the chain.
Info Cover the components to protect them against damage.
Take off the chain.

H03696-10

8 Remove nut and pull out the swingarm pivot.
Push the link fork back and secure it against falling over.

S04431-10

9 Hold the shock absorber and remove screw .
Remove the shock absorber carefully at the bottom.

S04432-10

SERVICE WORK ON THE CHASSIS 12

12.17

Installing the shock absorber

Main work Carefully position the shock absorber into the vehicle from the bot-
tom.

1 Mount and tighten screw .

Guideline

Screw, top shock M10 absorber

60 Nm (44.3 lbf ft) Loctite®2701TM

S04433-10

Position the link fork and mount the swingarm pivot.

S04434-10

Info
A Pay attention to flat area .

2 Mount and tighten nut .

Guideline

Nut, fork pivot

M16x1.5

100 Nm (73.8 lbf ft)

Mount the chain. Connect the chain with the connecting link.
Guideline
The closed side of the chain joint lock must face in the direction of travel.

F02306-10

(All EU models)
3 Join plug-in connector of the brake light switch.

S04426-11 S04435-10

Position the foot brake cylinder.

4 Push rod engages in the foot brake cylinder.

The dust boot is correctly positioned.

5 Mount and tighten screws .

Guideline

Remaining screws,

chassis

10 Nm (7.4 lbf ft)

12 SERVICE WORK ON THE CHASSIS

Position the angle lever and linkage lever.

6 Mount and tighten fitting .

Guideline

Nut, linkage lever on angle lever

M14x1.5

60 Nm (44.3 lbf ft)

S04436-10

Info
B Pay attention to flat area .

7 Mount and tighten screw .
Guideline
Screw, bottom M10 shock absorber

60 Nm (44.3 lbf ft) Loctite®2701TM

Info Raise the link fork slightly to be able to mount the screw more easily.

Position the frame protector.

8 Mount and tighten screws with the washers.

Guideline

Screw, frame protector M5

3 Nm (2.2 lbf ft)

Mount the new cable ties.

S04430-11

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

12.18 Removing the seat

1 Remove screw on the left side.

S04437-10

Raise the rear of the seat, pull the seat back, and lift it off.

H02218-10
64

12.19 Mounting the seat

SERVICE WORK ON THE CHASSIS 12
Mount the front of the seat on the two collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.
Make sure the seat is locked in correctly.

H02218-11

1 Mount and tighten screw on the left side.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

S04437-10

12.20

Removing the air filter box cover
Preparatory work Remove the seat. ( p. 64) Condition
The air filter box cover is secured.
1 Remove screw .

S04438-10

A Pull off the air filter box cover in area laterally and take it off at
the front.

S04438-11

12 SERVICE WORK ON THE CHASSIS

12.21

Installing the air filter box cover
Main work
A B Insert the air filter box cover in area and clip it into area .

S04438-12

Condition The air filter box cover is secured.

1 Mount and tighten screw .

Guideline

Screw, air filter box cover

EJOT PT® K60x20-Z

3 Nm (2.2 lbf ft)

S04438-10

Finishing work Mount the seat. ( p. 65)

12.22 Removing the air filter

Note Engine damageUnfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter.
Only operate the vehicle if it is equipped with an air filter.
Note Environmental hazardHazardous 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 Remove the seat. ( p. 64) Remove the air filter box cover. (

p. 65)

Main work
1 Detach retaining tab . Remove air filter with air filter support.
Remove air filter from air filter support.

S04439-10

SERVICE WORK ON THE CHASSIS 12

12.23 Installing the air filter

Main work Mount the clean air filter on the air filter support.
A Grease the air filter in area .
Long-life grease ( p. 151)

H02459-01

1 B Insert air filter and position retaining pin in bushing .
The air filter is correctly positioned.
2 Insert retaining tab . 3 2 Retaining pin is secured with retaining tab .

S04444-10

Info If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.

Finishing work Install the air filter box cover. ( Mount the seat. ( p. 65)

p. 66)

12.24 Cleaning the air filter and air filter box
Note Environmental hazardHazardous 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 seat. ( p. 64) Remove the air filter box cover. ( p. 65) Remove the air filter. ( p. 66)
Main work Wash the air filter thoroughly in special cleaning liquid and allow it
to dry properly.
Air filter cleaner ( p. 151)

102191-01

Info Only press the air filter to dry it, never wring it out.
Oil the dry air filter with a high-grade air filter oil. Oil for foam air filter ( p. 151)

12 SERVICE WORK ON THE CHASSIS

Clean the air filter box. Clean the intake flange and check it for damage and tightness.
Finishing work Install the air filter. ( p. 67) Install the air filter box cover. ( p. 66) Mount the seat. ( p. 65)

12.25

Preparing air filter box cover for securing

Preparatory work Remove the seat. ( p. 64) Remove the air filter box cover. (
Main work
A Drill a hole at marking .
Guideline Diameter

p. 65) 6 mm (0.24 in)

S04440-10

Finishing work Install the air filter box cover. ( Mount the seat. ( p. 65)

p. 66)

12.26 Removing the main silencer
Warning
Danger of burnsThe exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down before performing any work on the vehicle.
1 Remove screws . 2 Pull off the main silencer with exhaust sleeve and the spring ring
from the manifold.

S04441-10

SERVICE WORK ON THE CHASSIS 12

12.27

Installing the main silencer

1 Mount the main silencer with rubber sleeve and the spring
rings.

2 Mount and tighten screws .

Guideline

Remaining screws,

chassis

10 Nm (7.4 lbf ft)

S04442-10
12.28 Changing the glass fiber yarn filling of the main silencer
Warning
Danger of burnsThe exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down before performing any work on 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. 68)

Main work
1 2 3 Remove screws . Pull out inner tube with O-ring .

4 Pull glass fiber yarn filling from the inner tube.
Clean the parts that need to be reinstalled and check for damage.
4 Mount new glass fiber yarn filling on the inner tube.

5 Push outer tube over the inner tube with the new glass fiber
yarn filling and the O-ring.

1 Mount and tighten all screws .

Guideline

Screws on main

silencer

7 Nm (5.2 lbf ft)

V01636-10

Finishing work Install the main silencer. ( p. 69)

12 SERVICE WORK ON THE CHASSIS
12.29 Removing the fuel tank
Danger
Fire hazardFuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. If any fuel is spilled, wipe it off immediately. Observe the specifications for refueling.
Warning
Danger of poisoningFuel 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 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. 64) Main work
1 Unplug connector of the fuel pump. 2 Remove tube from the fuel tank breather.

S04445-10

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!
Disconnect the quick release coupling.

E00880-10

Info Remaining fuel may flow out of the fuel hose.
3 Mount wash cap set .
Wash cap set (81212016100)

SERVICE WORK ON THE CHASSIS 12
4 Remove screws with the collar bushings.
(All EU models) Hang the horn and horn bracket to one side.

S04446-10

5 Remove screw with the rubber bushing.

S04447-10

Pull both spoilers off laterally from the radiator mount and lift off the fuel tank.

S04448-01
12.30 Installing the fuel tank
Danger
Fire hazardFuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. If any fuel is spilled, wipe it off immediately. Observe the specifications for refueling.
Warning
Danger of poisoningFuel 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 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.

12 SERVICE WORK ON THE CHASSIS
Main work Check the throttle cable routing. ( p. 78) Position the fuel tank and fit the two spoilers to the sides in front of
the radiator bracket. Make sure that no cables or throttle cables are trapped or damaged.

S04449-01

1 Mount and tighten screw with the rubber bushing.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

(All EU models) Position the horn with the horn bracket.

S04447-11

2 Mount and tighten screws with the collar bushings.

Guideline

Remaining screws,

10 Nm (7.4 lbf ft)

chassis

S04446-11

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 lint-free cleaning cloth and lightly lubricate the O-ring of the quick-release coupling.
Silicone spray ( p. 151)
3 Join quick release coupling .

S04451-10

Info Route the cable and fuel line at a safe distance from the exhaust system.
4 Attach fuel tank breather hose . 5 Plug in connector for the fuel pump.

SERVICE WORK ON THE CHASSIS 12

Finishing work Mount the seat. ( p. 65)

12.31

Checking the chain for dirt

Check the chain for heavy soiling. » If the chain is very dirty: Clean the chain. ( p. 73)

400678-01
12.32 Cleaning the chain
Warning
Danger of accidentsLubricants on the tires reduces the road grip. Remove lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidentsOil 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.
Note Environmental hazardHazardous 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 stand. ( p. 52) Main work Rinse off loose dirt with a soft jet of water. Remove old grease residue with chain cleaner.
Chain cleaner ( p. 151) After drying, apply chain spray.
Off-road chain spray ( p. 151)

400725-01

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

12 SERVICE WORK ON THE CHASSIS

12.33 Checking the chain tension

Warning
Danger of accidentsIncorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
Check the chain tension regularly. Set the chain tension in accordance with the specification.

Preparatory work Raise the motorcycle with a lift stand. ( p. 52) Main work Pull the chain at the end of the chain sliding piece upward to mea-
A sure chain tension .

Info
1 Lower chain section must be taut.
When the chain guard is mounted, it must be possible to
pull up the chain at least to the point where it makes contact
B with chain guard .
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. 74)

E00885-10

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

12.34 Adjusting the chain tension

Preparatory work Raise the motorcycle with a lift stand. ( Check the chain tension. ( p. 74)

p. 52)

SERVICE WORK ON THE CHASSIS 12

S04452-10

Main work
1 Loosen nut .

2 Loosen nuts .

3 Adjust the chain tension by turning adjusting screws left and
right.

Guideline

Chain tension

55 ... 58 mm (2.17 ... 2.28 in)

3 Turn adjusting screws on the left and right so that the mark-
ings on the left and right chain adjusters are in the same position
A relative to reference marks . The rear wheel is then correctly
aligned.

2 Tighten nuts .

4 Make sure that chain adjusters are fitted correctly on adjusting 3 screws .

1 Tighten nut .

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.
4 Chain adjusters can be turned by 180°.

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

12.35

Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work Raise the motorcycle with a lift stand. ( p. 52)
Main work Shift the transmission into neutral. Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn: Change the drivetrain kit.

400227-01

Info The engine sprocket, rear sprocket, and chain should always be replaced together.

12 SERVICE WORK ON THE CHASSIS

A Pull on the top section of the chain with the specified weight .

Guideline

Weight, chain wear measurement

10 ... 15 kg (22 ... 33 lb.)

B Measure distance of 18 chain rollers in the lower chain section.

Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

B Maximum distance from
18 chain rollers at the longest chain section

272 mm (10.71 in)

B » If distance is greater than the specified measurement:
Change the drivetrain kit.

400987-10

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.

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 sliding guard.

Check that the chain sliding guard is firmly seated.

» If the chain sliding guard is loose:

Tighten screws on the chain sliding guard.

Guideline

Screw, chain M6 sliding guard

6 Nm (4.4 lbf ft) Loctite®243TM

E00886-10

SERVICE WORK ON THE CHASSIS 12

Check chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding piece:

Change the chain sliding piece.

Check that the chain sliding piece is firmly seated.

» If the chain sliding piece is loose:

Tighten screw on the chain sliding piece.

Guideline

Screw, chain sliding M8 piece

15 Nm (11.1 lbf ft)

E00887-10

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.

400985-01

Check that the chain guide is firmly seated.

» If the chain guide is loose:

Tighten the screws on the chain guide.

Guideline

Remaining screws, M6 chassis

10 Nm (7.4 lbf ft)

E00333-01

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

12 SERVICE WORK ON THE CHASSIS

12.36 Checking the frame

Check the frame for damage, cracks, and deformation. » If the frame shows signs of damage, cracks, or deformation: Change the frame. Guideline Repairs on the frame are not permitted.

401347-01

12.37 Checking the link fork

Check the link fork for damage, cracks, and deformation. » If the link fork shows signs of damage, cracks, or deformation: Change the link fork. Guideline Repairs on the link fork are not permitted.

401341-01

12.38

Checking the throttle cable routing
Preparatory work Remove the seat. ( p. 64) Remove the fuel tank. ( p. 70)
Main work Check the throttle cable routing.
Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.
» If the throttle cable is not routed as specified: Correct the throttle cable routing.

S04453-01

Finishing work Install the fuel tank. ( p. 71) Mount the seat. ( p. 65)

SERVICE WORK ON THE CHASSIS 12

12.39 Checking the rubber grip

Check the rubber grips on the handlebar for damage, wear, and looseness.

401197-01

Info The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar. The rubber grip can only be replaced with the sleeve or the throttle tube.

» If a rubber grip is damaged or worn: Change the rubber grip.

1 Check that screw is firmly seated.

Guideline

Screw, fixed grip M4

5 Nm (3.7 lbf ft) Loctite®243TM

A Diamond must be positioned visibly as shown in the figure.

E00889-10

12.40

Adjusting the basic position of the clutch lever
Adjust the basic position of the clutch lever to your hand size by
1 turning adjusting screw .

S04405-11

Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to increase 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 the hydraulic clutch
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed. Rinse the affected area with plenty of water in the event of contact with the skin. 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.

12 SERVICE WORK ON THE CHASSIS

Note Environmental hazardHazardous substances cause environmental damage.
Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

S04454-10

Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
1 Remove screws . 2 3 Remove cover with membrane .
Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the level of the fluid does not meet specifications: Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 149)
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 irritationBrake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed. Rinse the affected area with plenty of water in the event of contact with the skin. Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes. If brake fluid spills on to your clothing, change the clothing.
Note Environmental hazardHazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

SERVICE WORK ON THE CHASSIS 12
Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
1 Remove screws . 2 3 Take off cover with membrane .

S04454-10

4 Fill bleeding syringe with the appropriate hydraulic fluid.
Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 149) On the clutch slave cylinder, remove bleeder protection cap, release
5 4 the bleeder screw and mount bleeding syringe .

S04455-10 S04456-10

Now press the fluid into the system until it emerges from the
6 hole of the master cylinder without bubbles.
Now and then, extract fluid from the master cylinder reservoir to prevent overflow.
Remove the bleeding syringe. Tighten the bleeder screw. Mount protection cap.
Correct the fluid level of the hydraulic clutch. Guideline Fluid level below container rim 4 mm (0.16 in)
Position cover with membrane. Mount and tighten screws.

Info Clean up overflowed or spilled brake fluid immediately with water.

13 BRAKE SYSTEM

13.1 Checking the free travel of the hand brake lever

Warning
Danger of accidentsThe brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
Set the free travel on the hand brake lever in accordance with the specification.

S04457-10

A Push the hand brake lever forward and check free travel .
Free travel of hand brake lever 3 mm ( 0.12 in)
» If the free travel does not match the specification: (EC 300 US) Adjust the basic position of the hand brake lever. ( p. 82) (All EU models) Adjust the free travel of the handbrake lever.

13.2

Adjusting the basic position of the hand brake lever (EC 300 US)
Check the free travel of the hand brake lever. ( p. 82) Adjust the basic position of the hand brake lever to your hand size
1 by turning adjusting screw .

S04458-10

Info Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the hand brake 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.

13.3 Checking the brake discs

Warning
Danger of accidentsWorn-out brake discs reduce the braking effect.
Make sure that worn-out brake discs are replaced immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

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

400257-10

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

Brake discs - wear limit front rear

2.5 mm (0.098 in) 3.5 mm (0.138 in)

BRAKE SYSTEM 13

» If the brake disc thickness is less than the specified value: Change the front brake disc. Change the rear brake disc.
Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc exhibits damage, cracking, or deformation: Change the front brake disc. Change the rear brake disc.
13.4 Checking the front brake fluid level
Warning
Danger of accidentsAn insufficient brake fluid level 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 system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Danger of accidentsOld 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.)
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
1 Check the brake fluid level in level viewer . A » If an air bubble is visible in upper range of the level viewer :
Add the front brake fluid. ( p. 83)

13.5

S03517-10
Adding front brake fluid

Warning
Danger of accidentsAn insufficient brake fluid level 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 system and do not continue riding until the problem is eliminated. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

13 BRAKE SYSTEM

Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed. Rinse the affected area with plenty of water in the event of contact with the skin. 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 accidentsOld brake fluid reduces the braking effect. Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)
Note Environmental hazardHazardous 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 brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.

Preparatory work Check the front brake linings. ( p. 85)

Main work Move the brake fluid reservoir mounted on the handlebar to a hori-
zontal position.
1 Remove screws .

2 3 Take off cover with membrane .

A Add brake fluid to level .
Guideline
A Level (brake fluid level
below reservoir rim)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 149)
Position the cover with the membrane. Mount and tighten the screws.

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

S04460-10

BRAKE SYSTEM 13

13.6 Checking the front brake linings

Warning
Danger of accidentsWorn-out brake linings reduce the braking effect.
Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

13.7

S04461-10

A Check the brake linings for minimum thickness .

A Minimum thickness

1 mm ( 0.04 in)

» If the minimum thickness is less than specified: Change the brake linings of the front brake. ( p. 85)
Check the brake linings for damage and cracking. » If damage or wear is encountered: Change the brake linings of the front brake. ( p. 85)

Changing the brake linings of the front brake

Warning
Danger of accidentsIncorrect 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 irritationBrake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed. Rinse the affected area with plenty of water in the event of contact with the skin. 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 accidentsOld 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.)
Warning
Danger of accidentsOil 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.

13 BRAKE SYSTEM

Warning
Danger of accidentsBrake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no 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 hazardHazardous 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 the brake fluid and painted parts. Brake fluid corrodes paint. Only use clean brake fluid from a sealed container.

Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
1 Remove screws .
2 3 Take off cover with membrane .
Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extract some if necessary.

S04459-10

Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

4 5 Remove cotter pin , pull out pin , and remove the brake lin-
ings.
Clean the brake caliper and the brake caliper bracket.

S05112-10

6 7 Check that spring plate in the brake caliper and sliding plate
in the brake caliper bracket are seated correctly.

S04465-10
86

BRAKE SYSTEM 13

Insert the new brake linings, insert the pin, and mount the cotter pins. Guideline
Mount the outer cotter pins from the front to the rear.
Mount the inner cotter pins from the rear to the front.

S04463-01 S04464-10

Info Always change the brake linings in pairs.

Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

A Correct the brake fluid level to level .

Guideline

A Level (brake fluid level
below reservoir rim)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 149)
Position the cover with the membrane. Mount and tighten the screws.

Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

13.8 Checking the free travel of foot brake lever

Warning
Danger of accidentsThe 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

1 Disconnect spring .
Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free
A travel .
Guideline Free travel at foot brake lever 3 ... 5 mm (0.12 ... 0.2 in)
» If the free travel does not meet specifications: Adjust the basic position of the foot brake lever. ( p. 88)
1 Reconnect spring .

13 BRAKE SYSTEM
13.9 Adjusting the basic position of the foot brake lever
Warning
Danger of accidentsThe 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.
1 Detach spring .

402026-10

2 3 Loosen nut and, with push rod , turn it back until you have
maximum free travel.
To adjust the basic position of the foot brake lever to individual
4 5 requirements, loosen nut and turn screw accordingly.

Info The range of adjustment is limited.

S04466-10

3 A Turn push rod accordingly until you have free travel . If nec-
essary, adjust the basic position of the foot brake lever. Guideline
Free travel at foot brake lever 3 ... 5 mm (0.12 ... 0.2 in)

5 4 Hold screw and tighten nut .
Guideline
Nut, foot brake lever M8 stop

20 Nm (14.8 lbf ft)

3 2 Hold push rod and tighten nut .
Guideline
Remaining nuts, chas- M6 sis

10 Nm (7.4 lbf ft)

1 Attach spring .

13.10 Checking the rear brake fluid level
Warning
Danger of accidentsAn insufficient brake fluid level 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 system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)

BRAKE SYSTEM 13
Warning
Danger of accidentsOld 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.)
Stand the vehicle upright.
1 Check the brake fluid level in the viewer . A » If the fluid has dropped below marking in the level viewer:
Add rear brake fluid. ( p. 89)
S04467-10
13.11 Adding rear brake fluid
Warning
Danger of accidentsAn insufficient brake fluid level 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 system and do not continue riding until the problem is eliminated. (Your authorized GAS-
GAS Motorcycles workshop will be glad to help.)
Warning
Skin irritationBrake fluid causes skin irritation. Keep brake fluid out of the reach of children. Wear suitable protective clothing and safety glasses. Do not allow brake fluid to come into contact with the skin, the eyes or clothing. Consult a doctor immediately if brake fluid has been swallowed. Rinse the affected area with plenty of water in the event of contact with the skin. 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 accidentsOld brake fluid reduces the braking effect. Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.) Note Environmental hazardHazardous 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 brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
89

13 BRAKE SYSTEM

S04468-10

Preparatory work Check the brake linings of the rear brake. ( p. 90)
Main work Stand the vehicle upright.
1 2 Remove screw cap with membrane and the O-ring. A Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 149) Mount and tighten the screw cap with the membrane and O-ring.
Info Clean up overflowed or spilled brake fluid immediately with water.

13.12 Checking the brake linings of the rear brake

S04469-10

A Check the brake linings for minimum thickness .

A Minimum thickness

1 mm ( 0.04 in)

» If the minimum thickness is less than specified: Change the rear brake linings. ( p. 90)
Check the brake linings for damage and cracking. » If damage or wear is encountered: Change the rear brake linings. ( p. 90)

13.13 Changing the rear brake linings

BRAKE SYSTEM 13

Warning
Danger of accidentsOld 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.)
Warning
Danger of accidentsBrake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no 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 hazardHazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Position the vehicle upright.
1 2 Remove screw cap with membrane and the O-ring.
Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir, extracting some if necessary.

S04470-10

Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.
3 4 Remove cotter pin , pull out pin , and remove the brake lin-
ings. Clean the brake caliper and the brake caliper bracket.

S04471-10

13 BRAKE SYSTEM

5 6 Check that spring plate in the brake caliper and sliding plate
in the brake caliper bracket are seated correctly.

E00352-10

Insert the new brake linings, insert the pin, and mount 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.

S04472-01

A Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 149)
1 2 Mount screw cap with membrane and O-ring.

S04468-10

Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

WHEELS, TIRES 14

14.1

Removing the front wheel

Preparatory work Raise the motorcycle with a lift stand. ( p. 52)
Main work Manually press the brake caliper toward the brake disc to push back
the brake pistons.
Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

S04473-01

1 Loosen screw by several rotations. 2 Loosen screws . 1 Press on screw to push the wheel spindle out of the axle clamp. 1 Remove screw .

S04474-10

Warning
Danger of accidentsDamaged brake discs reduce the braking effect.
Always lay the wheel down in such a way that the brake disc is not damaged.

S04475-01

Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork.

Info Do not actuate the hand brake lever when the front wheel is removed.

3 Remove spacers .

H00934-10

14 WHEELS, TIRES

14.2 Installing the front wheel

Warning
Danger of accidentsOil 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.

H00935-10 S04474-11

Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: Change front wheel bearing.
1 A Clean and grease shaft seal rings and contact surfaces of the
spacers.

Long-life grease ( p. 151)

Insert the spacers. Clean and grease the wheel spindle.
Long-life grease ( p. 151)

Jack up the front wheel into the fork, position it, and insert the wheel spindle.
The brake linings are correctly positioned.

2 Mount and tighten screw .

Guideline

Screw, front wheel spindle

M20x1.5

35 Nm (25.8 lbf ft)

Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.

Remove the motorcycle from the lift stand. ( p. 52) Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.

3 Tighten screws .

Guideline

Screw, fork stub

15 Nm (11.1 lbf ft)

14.3

Removing the rear wheel

Preparatory work Raise the motorcycle with a lift stand. ( p. 52)

WHEELS, TIRES 14

Main work Manually press the brake caliper toward the brake disc to push back
the brake piston.
Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.
1 Remove nut . 2 3 Take off chain adjuster . Pull out wheel spindle far enough to
allow the rear wheel to be pushed forward. Push the rear wheel forward as far as possible. Remove the chain
from the rear sprocket.
Info Cover the components to protect them against damage.

S04476-10

Warning
Danger of accidentsDamaged 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.

4 Remove spacers .

14.4

H03002-10
Installing the rear wheel

Warning
Danger of accidentsOil 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.

14 WHEELS, TIRES

H03001-10

Main work Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn: Change the rear wheel bearing.
1 A Clean and grease shaft seal rings and contact surfaces of the
spacers.
Long-life grease ( p. 151)
Insert the spacers. Clean and grease the wheel spindle.
Long-life grease ( p. 151)
2 Position rear wheel and insert wheel spindle .
Mount the chain. The brake linings are correctly positioned.

S04477-10

3 4 Position chain adjuster . Mount nut , but do not tighten it yet.

3 Make sure that chain adjusters are fitted correctly on adjusting 5 screws .

Check the chain tension. ( p. 74)

4 Tighten nut .

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.
3 Chain adjusters can be turned by 180°.
Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

S04478-10

Finishing work Remove the motorcycle from the lift stand. ( p. 52)

WHEELS, TIRES 14

14.5 Checking the tire condition

Info Only mount tires approved and/or recommended by GASGAS Motorcycles. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle. Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

400602-10

Check the front and rear tires for cuts, embedded objects, and other damage.
» If the tires have cuts, run-in objects, or other damage:
Change the tires. Check tread depth.

Info Adhere to the legally required minimum tread depth.

Minimum tread depth

2 mm ( 0.08 in)

» If the tread depth is less than the minimum tread depth: Change the tires.

Check the tire age.

H01144-01

Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number. 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 changed after five years at the latest, regardless of the actual wear.
» If the tires are more than five years old: Change the tires.

14.6 Checking tire pressure

Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures optimal riding comfort and maximum tire service life.

400695-01

Remove protection cap. Check tire pressure when the tires are cold.

Offroad tire pressure front rear

1.0 bar (15 psi) 1.0 bar (15 psi)

» If the tire pressure does not meet specifications: Correct tire pressure.
Mount the protection cap.

14 WHEELS, TIRES

14.7 Checking spoke tension

Warning
Danger of accidentsIncorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
Check spoke tension regularly, and in particular on a new vehicle. (Your authorized GASGAS Motorcycles workshop will be glad to help.)

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, this is an indication of different spoke tensions.

400694-01

You should hear a high note.

» If the spoke tension differs:

Correct the spoke tension.

Check the spoke torque.

Guideline

Spoke nipple, front wheel

M4.5

Spoke nipple, rear wheel

M4.5

Torque wrench kit (58429094000)

6 Nm (4.4 lbf ft) 6 Nm (4.4 lbf ft)

ELECTRICAL SYSTEM 15

15.1 Removing the 12-V battery
Note Environmental hazard12 V batteries contain environmentally hazardous materials. Do not dispose of 12 V batteries as household waste. Dispose of 12 V batteries at a collection point for used batteries.
Note Environmental hazardHazardous 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 Remove the seat. ( Main work

p. 64)

S04479-10

Warning

Risk of injury12 V batteries 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.
Minimum voltage before 9 V the start of the charge

Dispose of 12 V batteries with less than the minimum voltage correctly.

1 Disconnect negative cable from the 12-V battery.
2 Pull back positive terminal cover and disconnect the positive
cable from the 12-V battery.
3 4 Pull EFI control unit upward off rubber lugs and hang to the
side.

S04480-10

15 ELECTRICAL SYSTEM

5 6 Detach wiring harness , pull off relays and hang them to the
side.

S04481-10

7 Remove screw and fold the battery compartment to the front.
Lift out the 12-V battery.

15.2

S04482-10

Installing the 12-V battery

Main work Insert the 12-V battery into the battery compartment with the ter-
1 minals facing forward and secure with holding bracket .

12-V battery (HJTZ5S-FP-C) ( p. 145)

2 Mount and tighten screw .

Guideline

Remaining screws,

chassis

10 Nm (7.4 lbf ft)

100

S04483-10

ELECTRICAL SYSTEM 15
3 Place relays on the battery compartment and attach wiring harness 4.

S04481-11

5 6 Secure EFI control unit with the rubber lugs .

S04480-11

7 Connect positive cable to the 12-V battery.

Guideline

Screw, battery terminal M5

2.5 Nm (1.84 lbf ft)

Info
A 8 Contact disk must be mounted under screw and 9 cable lug with the claws toward the battery terminal.

bk Slide positive terminal cover over the positive terminal.

bl Connect negative cable to the 12-V battery.

Guideline

Screw, battery terminal M5

2.5 Nm (1.84 lbf ft)

S04484-10

Finishing work Mount the seat. ( p. 65)

101

15 ELECTRICAL SYSTEM

15.3 Charging the 12-V battery

Warning

Risk of injury12 V batteries 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.

Minimum voltage before the start of the charge

Dispose of 12 V batteries with less than the minimum voltage correctly.

Note Environmental hazard12 V batteries contain environmentally hazardous materials.
Do not dispose of 12 V batteries as household waste.
Dispose of 12 V batteries at a collection point for used batteries.

Info Even when there is no load on the 12-V battery, it discharges steadily each day. The charging level and the method of charging are very important for the service life of the 12-V battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current or charging voltage are exceeded, the 12-V battery will be destroyed. If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately. If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and suffer a loss of capacity, destroying the battery. The 12-V battery is maintenance-free.

S00863-10

Preparatory work Remove the seat. ( p. 64) Remove the 12-V battery. (

p. 99)

Main work Check the battery voltage.
» Battery voltage: < 9 V
Do not charge the 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 Charge the 12-V battery.

102

ELECTRICAL SYSTEM 15

Guideline

The charging current, charging voltage, and charging time must not be exceeded.

Maximum charging voltage 14.4 V

Maximum charging current 3.0 A

Maximum charging time 24 h

Recharge the 12-V battery regularly when the motorcycle is not being used

6 months

Battery charger (79629974000)
This battery charger tests whether the 12-V battery retains its voltage. It is also impossible to overcharge the 12-V battery with this battery charger. The charging time may be longer at low temperatures.
This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying GASGAS Technical Accessories instructions.

Info
1 Never remove cover .

Switch off the battery charger after charging and disconnect from the 12-V battery.

Finishing work Install the 12-V battery. ( Mount the seat. ( p. 65)

p. 100)

15.4 Changing main fuse
Warning
Fire hazardIncorrect 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 consumers of the vehicle.
Preparatory work Remove the seat. ( p. 64) Main work
1 2 Pull EFI control unit upward off the rubber lugs and hang to
the side.

S04485-10

103

15 ELECTRICAL SYSTEM

3 Pull starter relay from the holder.

S04486-10

4 Take off protection caps . 5 Remove faulty main fuse .

Info
A A faulty fuse has a burned-out fuse wire . 6 A spare fuse is located in the starter relay.
Insert a new main fuse. Fuse (58011109120) ( p. 145)
Check that the electrical system is functioning properly.

Tip Insert a spare fuse so that it is available if needed.

4 Attach the protection caps . 3 Mount starter relay onto the holder and route the cable.

S04487-10

1 2 Mount the EFI control unit on the rubber lugs .

S04485-10

Finishing work Mount the seat. ( p. 65)

104

ELECTRICAL SYSTEM 15

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.

S04488-10

Preparatory work Remove the seat. ( p. 64)
Main work
1 Open fuse box cover .
Remove the faulty fuse. Guideline (All EU models) Fuse 1 - 10 A - EFI control unit, lambda sensor, oil pump, combination instrument, electronic fuel injection, diagnostics connector Fuse 2 - 10 A - horn, brake light, radiator fan (optional), turn signal (optional) Fuse 3 10 A high beam, low beam, position light, tail light, license plate lamp Fuse 4 - 5 A - fuel pump
(EC 300 US) Fuse 1 - 10 A - EFI control unit, oil pump, combination instrument, electronic fuel injection, diagnostics connector Fuse 2 - 10 A - radiator fan (optional) Fuse 3 - 10 A - low beam, position light, tail light Fuse 4 - 5 A - fuel pump
Fuses res - 10 A - spare fuse

Info
A A faulty fuse has a burned-out fuse wire .

Warning
Fire hazardIncorrect fuses overload the electrical system. Only use fuses with the required ampere value. Do not bypass or repair fuses.
Insert the spare fuse with the correct rating. Fuse (75011088010) ( p. 145) Fuse (75011088005) ( p. 145)
Tip Put a spare fuse in the fuse box so that it is available if needed.
Check the function of the electrical power consumer.
1 Close the fuse box cover .
Finishing work Mount the seat. ( p. 65)

105

15 ELECTRICAL SYSTEM

15.6

Removing the headlight mask with the headlight
Detach the brake line and wiring harness from the headlight mask.
1 Loosen rubber strap . Slide the headlight mask up and swing it
forward.

S04489-10

(All EU models)
2 Detach plug-in connectors and take off the headlight mask
with the headlight.

S04490-10

(EC 300 US)
2 Disconnect plug-in connector and take off the headlight
mask together with the headlight.

15.7

S04491-10
Installing the headlight mask with the headlight
Main work (All EU models)
1 Join plug-in connectors .

S04490-11

(EC 300 US)
1 Join plug-in connector .

106

S04491-11

ELECTRICAL SYSTEM 15
2 Position the headlight mask and secure it with rubber straps .
The holding lugs engage in the fender. Position the brake line and wiring harness in the brake line guide.

S04489-11

Finishing work Check the headlight setting. ( p. 108)

15.8 Changing the headlight bulb
Note Damage to reflectorGrease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Clean and degrease the bulbs before mounting. Do not touch the bulbs with your bare hands.
Preparatory work Remove the headlight mask with the headlight. ( p. 106)
Main work
1 Turn protection cap together with the underlying bulb socket
counterclockwise all the way and remove it.
2 Pull bulb socket of the position light out of the reflector.

S04492-10

3 Pull out headlight bulb .
Insert the new headlight bulb.
Headlight (S2 / socket BA20d) ( p. 145)
Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way.

F03250-10

Info
4 Check the sealing lip of the protection cap for correct
seating.

Insert the bulb socket of the position light into the reflector.

Finishing work Install the headlight mask with the headlight. ( Check the headlight setting. ( p. 108)

p. 106)

107

15 ELECTRICAL SYSTEM

15.9 Changing the turn signal bulb (All EU models)

Note Damage to reflectorGrease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector.
Clean and degrease the bulbs before mounting. Do not touch the bulbs with your bare hands.

Main work Remove the screw on the rear of the turn signal housing.
1 Carefully remove turn signal glass .
2 Lightly squeeze orange cap in the area of the holding lugs and
take it off. Press the turn signal bulb lightly into the socket, turn it counter-
clockwise by about 30°, and take it out of the socket.

E00360-10

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. 145)
Mount the orange cap. Position the turn signal glass. Insert the screw and first turn counterclockwise until it engages in
the thread with a small jerk. Tighten the screw lightly.
Finishing work Check that the turn signal system is functioning properly.

15.10

Checking the headlight setting

Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the height of the center of the low beam
headlight.

B Make another mark at a distance under the first marking.

Guideline

B Distance

5 cm (2 in)

400726-10

A Position the vehicle vertically at a distance away from the wall.

Guideline

A Distance

5 m (16 ft)

The rider now sits down on the motorcycle. Switch on the low beam. Check the headlight setting.
The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider.

» If the boundary between light and dark does not meet specifications:

108

ELECTRICAL SYSTEM 15

Adjust headlight range. ( p. 109)

15.11

Adjusting the headlight range

Preparatory work Check the headlight setting. ( p. 108) Remove the headlight mask with the headlight. (

p. 106)

S04493-10

Main work
1 Turn bolt clockwise.
The headlight range increases.
1 Turn bolt counterclockwise.
The headlight range decreases. Adjust the headlight range by pivoting the headlight.
Guideline
The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).

Info If you have a payload, you may have to correct the headlight range.
Install the headlight mask with the headlight. ( p. 106) Check the headlight setting. ( p. 108)

15.12

Changing the combination instrument battery
Preparatory work Remove the headlight mask with the headlight. ( p. 106)
Main work
1 Remove screws .
Pull the combination instrument upward out of the holder.

S04494-10 S04495-10

2 Using a coin, turn protection cap all the way counterclockwise
and take it off.
3 Remove combination instrument battery .
Insert the combination instrument battery with the label facing outward.
Combination instrument battery (CR 2032) ( p. 145)
Check the O-ring of the protection cap for correct seating.

109

15 ELECTRICAL SYSTEM

2 Position protection cap and 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.

S04496-10

Finishing work Install the headlight mask with the headlight. ( Check the headlight setting. ( p. 108) Set kilometers or miles. Adjust combination instrument function. Set the clock.

p. 106)

15.13 Diagnostics connector

1 Diagnostics connector is located under the seat.

H00933-12

110

COOLING SYSTEM 16

16.1 16.2

Cooling system

S04497-10

1 Water pump in the engine ensures forced circulation of the coolant.
The pressure resulting from the warming of the cooling system is reg-
2 ulated by a valve in radiator cap . This ensures that operating the
vehicle at the specified coolant temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream. The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

Checking the antifreeze and coolant level

Warning
Danger of scaldingDuring motorcycle operation, the coolant gets very hot and is under pressure. Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature. Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system. In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoningCoolant 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 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.

400243-10

Condition The engine is cold.

Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check the coolant antifreeze.

-25 ... -45 °C (-13 ... -49 °F)

» If the antifreeze in the coolant does not match the specified value:
Correct the coolant antifreeze. Check the coolant level in the radiator.

A Coolant level above the
radiator fins

10 mm (0.39 in)

» If the coolant level does not match the specified value: Correct the coolant level.

Coolant ( p. 149)

Mount the radiator cap.

111

16 COOLING SYSTEM

16.3 Checking the coolant level

400243-10

Condition The engine is cold.

Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check the coolant level in the radiator.

A Coolant level above the
radiator fins

10 mm (0.39 in)

» If the coolant level does not match the specified value: Correct the coolant level.

Coolant ( p. 149)

Mount the radiator cap.

16.4 Draining the coolant
Warning
Danger of scaldingDuring motorcycle operation, the coolant gets very hot and is under pressure. Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling
system are at operating temperature. Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or
other components of the cooling system. In the event of scalding, rinse the area affected immediately with lukewarm water.

112

COOLING SYSTEM 16

Warning
Danger of poisoningCoolant 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 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.

Position the motorcycle upright. Place an appropriate container under the water pump cover.

1 2 Remove screw . Take off radiator cap .

Completely drain the coolant.

1 Mount and tighten screw with a new seal ring.

Guideline

Screw, water pump

10 Nm (7.4 lbf ft)

cover

16.5

S04497-10
Refilling with coolant

Main work
1 Make sure that screw is tightened.
Position the motorcycle upright.

S03528-10

113

16 COOLING SYSTEM

A Pour coolant in up to measurement above the radiator fins.
Guideline 10 mm (0.39 in)

Coolant

1.2 l (1.3 qt.) Coolant ( p. 149)

400243-10

2 Push protection cap upward over the thermostat.

E00904-10 E00905-10

3 Unplug connector .

4 Remove thermostat with O-ring and wait until the coolant
escapes without bubbles.

4 Mount thermostat with the O-ring and tighten.

Guideline

Screw, cylinder head temperature sensor

M10x1.25

12 Nm (8.9 lbf ft)

3 Plug in connector . 2 Position protection cap .

A Pour coolant in up to measurement above the radiator fins.
Guideline 10 mm (0.39 in)

Coolant ( p. 149)

400243-10

5 Mount radiator cap .

S04498-10

Allow the engine to warm up and cool down again.

114

COOLING SYSTEM 16

Finishing work Check the coolant level. ( p. 112)

16.6 Changing the coolant

S04497-10

Condition The engine is cold.

1 2 Remove screw . Take off radiator cap .

Place an appropriate container under the water pump cover.

Completely drain the coolant.

1 Mount and tighten screw with a new seal ring.

Guideline

Screw, water pump

10 Nm (7.4 lbf ft)

cover

Position the motorcycle upright. Completely fill the radiator with coolant.

Coolant ( p. 149)

3 Push protection cap upward over the thermostat.

S04256-10

115

16 COOLING SYSTEM

S04259-10

4 Unplug connector .

5 Remove thermostat with O-ring and wait until the coolant
escapes without bubbles.

5 Mount thermostat with the O-ring and tighten.

Guideline

Screw, cylinder head temperature sensor

M10x1.25

12 Nm (8.9 lbf ft)

4 Plug in connector . 3 Mount protection cap .

2 Mount radiator cap .

S04498-11

Allow the engine to warm up and cool down again. Check the cooling system for leaks. Check the coolant level. ( p. 112)

116

TUNING THE ENGINE 17

17.1

Checking the play in the throttle cable

Check the throttle grip for smooth operation. Turn handlebar as far as possible to the right. Turn the throttle grip
A back and forth slightly and determine the play in throttle cable .

Play in throttle cable

3 ... 5 mm (0.12 ... 0.2 in)

» If the throttle cable play does not meet the specified value: Adjust the play in the throttle cable. ( p. 117)

400192-11

Start the engine and let it run at idle speed. Move the handlebar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes: Adjust the play in the throttle cable. ( p. 117)

17.2 Adjusting the play in the throttle cable
Info If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be removed.

S04499-10

Preparatory work Remove the seat. ( p. 64) Remove the fuel tank. ( p. 70) Check the throttle cable routing. (

p. 78)

Main work Move the handlebar to the straight-ahead position.

1 Push back sleeve .

2 Loosen nut .

3 Turn adjusting screw in as far as possible.

4 Loosen nut .

5 Turn adjusting screw in as far as possible.

3 Turn adjusting screw so that there is play in the throttle cable at
the throttle grip.
Guideline

Play in throttle cable

3 ... 5 mm (0.12 ... 0.2 in)

5 Unscrew the adjusting screw until the smooth operation or play
in throttle cable is worsened.
5 Turn adjusting screw approx. two turns further.
4 Tighten nut .
2 Tighten nut .

117

17 TUNING THE ENGINE
1 Slide on sleeve .
Check the throttle grip for smooth operation. Finishing work Check the play in the throttle cable. ( p. 117)
17.3 Setting the characteristic map of the throttle response
Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied.
Main work
1 Push back sleeve . 2 3 Remove screws and half-shells .
Detach the throttle cables and take off the grip tube.

S04500-10

4 5 Remove guide plate from handle tube .
Position the required guide plate on the grip tube. Guideline
A The label OUTSIDE must be visible. Marking must be posiB tioned at marking .
Grey guide plate (79002014000)
Alternative 1 Black guide plate (79002014100)

Info The gray guide plate opens the throttle valve more slowly. The black guide plate opens the throttle valve more quickly. The gray guide plate is mounted upon delivery.

102246-10

118

TUNING THE ENGINE 17

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.

3 2 Position half-shells , mount and tighten screws .

Guideline

Screw, throttle grip

5 Nm (3.7 lbf ft)

1 Slide on sleeve and check the throttle grip for ease of move-
ment.

S04501-10

Finishing work Check the play in the throttle cable. ( p. 117)

17.4 Adjusting the idle speed

Warning
Danger of accidentsThe engine may go out spontaneously if the idle speed is set too low. Set the idle speed to the specified value. (Your authorized GASGAS Motorcycles workshop will be glad to help.)
Run the engine until warm. The cold start button is deactivated A further ¼ turn returns the cold start button back to the basic position. ( p. 19)

1 Adjust the idle speed by turning idle speed adjusting screw .

Guideline

Idle speed

1,400 ... 1,500 rpm

Tachometer (45129075000)

S03529-11

119

17 TUNING THE ENGINE

Info Turn clockwise to decrease the idle speed. Turn counterclockwise to increase the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on overall engine running.

17.5 Programming ambient air pressure
Danger
Danger of poisoningExhaust 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.
Info If the vehicle is ridden with the engine running at various heights above sea level, the ambient pressure is programmed on an ongoing basis. If the vehicle is transported over great differences in height, the ambient pressure must be reprogrammed.
Start the vehicle at the new height above sea level and switch off the engine again.
Wait for at least five seconds. Start the vehicle again and check the response of the vehicle.
» If the response has not improved: Repeat the procedure.

17.6

H02349-01
Ignition curve plug-in connector
1 Plug-in connector of the ignition timing map adjustment is located
on the frame under the fuel tank.
Info The ignition timing map connector has no function in the homologated (restricted) condition of the motorcycle.
Possible states · Soft The plug-in connector of the ignition timing map adjustment
is disconnected to achieve better rideability. · Performance The plug-in connector of the ignition timing map
adjustment is joined to achieve higher performance.

120

S04502-10

TUNING THE ENGINE 17
17.7 Changing the ignition timing map
Info The ignition timing map connector has no function in the homologated (restricted) condition of the motorcycle.
Preparatory work Remove the seat. ( p. 64) Remove the fuel tank. ( p. 70) Switching the ignition timing map from Performance to Soft
1 Disconnect plug-in connector of the ignition timing map
adjustment. Soft better rideability
Switching the ignition timing map from Soft to Performance
1 Join plug-in connector of the ignition timing map adjust-
ment. Performance better performance

S04502-10

Finishing work Install the fuel tank. ( p. 71) Mount the seat. ( p. 65)

17.8 Checking the basic position of the shift lever

Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

A Sit on the vehicle in the riding position and determine distance
between the upper edge of your boot and the shift lever.

Distance between shift lever and upper edge of 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. 122)

400692-10

121

17 TUNING THE ENGINE
17.9 Adjusting the basic position of the shift lever
1 2 Remove screw with the washers and take off shift lever .

401950-12

A Clean gear teeth of the shift lever and shift shaft.
Mount the shift lever on the shift shaft in the required position and engage gearing.

401951-10

Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

1 Mount and tighten screw with the washers.

Guideline

Screw, shift lever M6

14 Nm (10.3 lbf ft) Loctite®243TM

122

SERVICE WORK ON THE ENGINE 18

18.1 Changing the fuel screen

Danger
Fire hazardFuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.
Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. Switch off the engine for refueling. Make sure that no fuel is spilled; particularly not on hot parts of the vehicle. If any fuel is spilled, wipe it off immediately. Observe the specifications for refueling.
Warning
Danger of poisoningFuel 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 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.
Note Environmental hazardImproper handling of fuel is a danger to the environment. Do not allow fuel to enter the groundwater, the soil, or the sewage system.

1 Clean 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!
Disconnect the quick release coupling.
Info Remaining fuel may flow out of the fuel hose.
2 Pull fuel screen out of the connecting piece.
Insert the new fuel screen all the way into the connecting piece. Spray silicone spray onto a lint-free cleaning cloth and lightly lubri-
cate the O-ring of the quick-release coupling. Silicone spray ( p. 151)
Join the quick release coupling.

E00911-10

Start the engine and check the response.

123

18 SERVICE WORK ON THE ENGINE

18.2 Checking 2-stroke oil level

Preparatory work Stand the motorcycle upright on a horizontal surface. Main work Check the 2-stroke oil level in the oil tank.

Info For a full tank of fuel, the 2-stroke oil tank must be filled up
A to at least the upper abutting edge .

S03500-10

The 2-stroke oil tank must be completely filled if possible.
» If the 2-stroke oil level is too low: Add 2-stroke oil. ( p. 38)

18.3 Priming oil pump
Warning
Engine failureThe engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the tank is
depleted. At the next opportunity add 2-stroke oil before you refuel. Time the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully depleted in
error.
Condition The engine is off. Preparatory work Remove the seat. ( p. 64) Stand the motorcycle upright on a horizontal surface. Check 2-stroke oil level. ( p. 124)

124

SERVICE WORK ON THE ENGINE 18
Main work
1 Pull the EFI control unit upward off the rubber plugs and hang to
the side.
2 Remove protection cap of the diagnostics connector.

S04503-10

3 Put throttle grip into full throttle position and secure.

S04406-12

4 Plug in wake-up connector for priming the oil pump to the diag5 nostics connector .
The combination instrument lighting is activated.
Wait for at least five seconds. Release the fixing means from the throttle grip.
The oil pump is timed.

Info The oil pump is actuated at various speeds. The procedure is clearly audible.
Wait until you can no longer hear the oil pump operating. Disconnect the wake-up connector from the diagnostics connector.

S04504-10

125

18 SERVICE WORK ON THE ENGINE

6 Check whether air bubbles are visible in the hose .
» If air bubbles are visible: Repeat the entire procedure until air bubbles are no longer visible.
Mount protection cap on the diagnostics connector. Mount the EFI control unit on the rubber lugs.

S03513-10

Finishing work Mount the seat. ( p. 65)

18.4 Cleaning the oil screen in the oil tank
Note Environmental hazardHazardous 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 Raise the motorcycle with a lift stand. ( p. 52) Remove main silencer. ( p. 68) Remove the seat. ( p. 64) Remove the fuel tank. ( p. 70) Remove the air filter box cover. ( p. 65)
Main work
1 Remove screws . 2 Loosen screws .

S04505-10

126

SERVICE WORK ON THE ENGINE 18
3 Loosen clamps of the throttle valve body. 4 Disconnect plug-in connector of the rear brake light switch.
Lift the subframe slightly and secure it.
Info
5 Pay attention to intake flange . 6 Pull throttle valve body towards the rear, out of the intake
flange, and hang it to the side.

S04507-10

7 Open hose clamp using a screwdriver.
Pull off the angle piece and collect the 2-stroke oil in a suitable container.

S04508-10

8 Remove oil screen and clean it.
Check the oil screen for damage. » If the oil screen is damaged: Change the oil screen.

S04509-10

Insert the oil screen and mount the angle piece with a new hose clamp.
Hose clamp pliers (60029057000)

S03506-10

127

18 SERVICE WORK ON THE ENGINE

6 Mount throttle valve body .
Remove the locking piece and position the subframe.

Info
5 Pay attention to intake flange .

4 Join plug-in connector of the rear brake light switch.

3 Position and tighten clamps of the throttle valve body.

Guideline

Screw, intake

flange/reed valve

housing

6 Nm (4.4 lbf ft)

S04510-10 S04505-10

1 Mount and tighten screws .
Guideline Screw, subframe M8 bottom
2 Remove screws .
2 Mount and tighten screws .
Guideline Screw, subframe M8 top

30 Nm (22.1 lbf ft) Loctite®2701TM
35 Nm (25.8 lbf ft) Loctite®2701TM

Finishing work Install the air filter box cover. ( p. 66) Install the fuel tank. ( p. 71) Add 2-stroke oil. ( p. 38) Prime the oil pump. ( p. 124) Mount the seat. ( p. 65) Install the main silencer. ( p. 69) Remove the motorcycle from the lift stand. (

p. 52)

18.5 Checking the gear oil level
Info The gear oil level must be checked when the engine is cold.
Preparatory work Stand the motorcycle upright on a horizontal surface.

128

SERVICE WORK ON THE ENGINE 18

S04511-10

Main work Detach the foot brake lever spring.
1 Remove gear oil level monitoring screw .
Check the gear oil level.

A small quantity of gear oil must run out of the drilled hole.

» If no gear oil runs out:

Add the gear oil. ( p. 130)

Mount and tighten the gear oil level monitoring screw. Guideline

Screw, gear oil level

monitoring

8 Nm (5.9 lbf ft)

Attach the foot brake lever spring.

18.6 Changing the gear oil
Warning
Danger of scaldingEngine 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 hazardHazardous substances cause environmental damage. Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Info Drain the gear oil while the engine is at operating temperature.

E00913-10

Preparatory work Park the motorcycle on a level surface. Position an appropriate container under the engine.

Main work
1 Remove gear oil drain plug with magnet.

Let the gear oil drain fully.

Thoroughly clean the gear oil drain plug with magnet.

Clean the sealing surface on the engine.

1 Mount and tighten gear oil drain plug with the magnet and a

new seal ring.

Guideline

Gear oil drain plug with M12x1.5

20 Nm (14.8 lbf ft)

magnet

129

18 SERVICE WORK ON THE ENGINE

2 Remove filler plug with the O-ring, and fill up with gear oil.

Gear oil

0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 149)

Mount and tighten the filler plug together with the O-ring.

401955-11

Start the engine and check for leaks. Finishing work Check the gear oil level. ( p. 128)

18.7 Adding the gear oil
Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Gear oil must only be topped up when the engine is cold.
Preparatory work Park the motorcycle on a level surface. Main work Detach the foot brake lever spring.
1 Remove gear oil level monitoring screw .

S04511-10 401955-11

2 Remove filler plug with the O-ring.
Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw.

Engine oil (15W/50) ( p. 149)

Mount and tighten the gear oil level monitoring screw. Guideline

Screw, gear oil level

monitoring

8 Nm (5.9 lbf ft)

2 Mount and tighten filler plug with the O-ring.
Attach the foot brake lever spring.

130

SERVICE WORK ON THE ENGINE 18
Danger
Danger of poisoningExhaust 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 check for leaks. Finishing work Check the gear oil level. ( p. 128)
131

19 CLEANING, CARE

19.1 Cleaning the motorcycle

Note Material damageComponents become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components.

Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.

Maintain a minimum distance between the nozzle of the pressure cleaner and the component.

Minimum clearance

60 cm (23.6 in)

Info To maintain the value and appearance of the motorcycle over a long period, clean it regularly. Avoid direct sunshine when cleaning the motorcycle.
Close off 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. 151)

401061-01

Info Use warm water containing normal motorcycle cleaner and a soft sponge. Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first.
After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
Remove the closure of the exhaust system.

Warning
Danger of accidentsMoisture and dirt impair the brake system. Brake carefully several times to dry out and remove dirt
from the brake linings and the brake discs.
After cleaning, ride the vehicle a short distance until the engine warms up.
Info The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.
After the motorcycle has cooled down, lubricate all moving parts and pivot points.
Clean the chain. ( p. 73)

132

CLEANING, CARE 19

Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 151)

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. 152)

(All EU models) Oil the steering lock. Universal oil spray (

p. 152)

19.2 Checks and maintenance steps for winter operation

Info If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precautions against aggressive road salt. If the vehicle has been used on salted roads, use cold water for cleaning after riding. Warm water enhances the corrosive effects of salt.

401060-01

Clean the motorcycle. ( p. 132) Clean the brakes.
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 carefully. After riding on salted roads, thoroughly clean the vehicle with cold water and dry it well.
Treat engine, link fork, and all other bare or zinc-plated parts (except the brake discs) with a wax-based corrosion inhibitor.

Info Corrosion inhibitor must not come in contact with the brake discs as this would greatly reduce the braking force.
Clean the chain. ( p. 73)

133

20 STORAGE

20.1 Storage
Warning
Danger of poisoningFuel 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 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.

Info If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed. Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

401058-01

Clean the motorcycle. ( p. 132) Change the gear oil. ( p. 129) Check the antifreeze and coolant level. ( p. 111) When refueling for the last time before taking the motorcycle out of
service, add fuel additive.
Fuel additive ( p. 151)
Refuel. ( p. 37) Add 2-stroke oil. ( p. 38) Check tire pressure. ( p. 97) Remove the 12-V battery. ( p. 99) Charge the 12-V battery. ( p. 102)
Guideline Ideal charging and storage tem- 10 ... 20 °C (50 ... 68 °F) perature of the lithium-ion battery
Store the vehicle in a dry location that is not subject to large fluctuations in temperature.

Info GASGAS Motorcycles recommends jacking up the motorcycle.
Raise the motorcycle with a lift stand. ( p. 52) Cover the vehicle with a tarp or a similar cover that is permeable to
air.

134

STORAGE 20

Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, causing engine parts and the exhaust system to rust.

20.2

Preparing for use after storage

Remove the motorcycle from the lift stand. ( p. 52) Install the 12-V battery. ( p. 100) Perform checks and maintenance measures when preparing for use. ( p. 34) Make a test ride.

401059-01

135

21 TROUBLESHOOTING

Faults The engine cannot be cranked (starter motor) The engine turns but does not start
The engine has no idle speed Engine does not speed up

Possible cause Operating error 12-V battery discharged
Main fuse is blown Starter relay faulty Starter motor faulty Operating error Quick release coupling not joined Idle speed is not set correctly Fuel supply interrupted Spark plug sooty or wet Plug gap of spark plug too wide
Faulty ignition
Short-circuit cable in wiring harness frayed, stop button or emergency OFF switch faulty The connector or ignition coil is loose or oxidized Malfunction in the electronic fuel injection
Spark plug defective Faulty ignition
Idle speed is not set correctly Malfunction in the electronic fuel injection

Action
Carry out the start procedure. ( p. 34) Charge the 12-V battery. ( p. 102) Check the charging voltage. Check the closed current. Check the stator winding of the alterna-
tor.
Change the main fuse. ( p. 103) Check the starter relay. Check the starter motor. Carry out the start procedure. ( p. 34) Join quick release coupling. Adjust the idle speed. ( p. 119) Check the fuel tank breather. Clean and dry the spark plug and spark
plug connector, or change if necessary.
Adjust plug gap. Guideline Spark plug electrode gap 0.6 mm (0.024 in)
Ignition coil - check the primary winding.
Check the spark plug connector. Check the stator winding of the alterna-
tor.
Check wiring harness (visual check). Check the electrical system.
Clean the connector and treat it with contact spray.
Check wiring for damage and electrical plug-in connectors for corrosion and damage.
Read out the fault memory using the GASGAS Motorcycles diagnostics tool.
Change the spark plug. Ignition coil - check the primary wind-
ing. Check the spark plug connector. Check the stator winding of the alterna-
tor.
Adjust the idle speed. ( p. 119) Check wiring for damage and electrical
plug-in connectors for corrosion and damage. Read out the fault memory using the GASGAS Motorcycles diagnostics tool.

136

TROUBLESHOOTING 21

Faults Engine does not speed up Engine has too little power
The engine dies during the trip Engine overheats

Possible cause Faulty ignition
Ambient pressure is incorrectly stored Air filter very dirty
Fuel filter is very dirty Fuel screen is very dirty Malfunction in the electronic fuel injection
Fuel supply interrupted Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer Faulty ignition
Diaphragm or reed valve housing damaged Ambient pressure is incorrectly stored Lack of fuel The engine takes in false air
The connector or ignition coil is loose or oxidized Ambient pressure is incorrectly stored Too little coolant in cooling system
Too little air stream Radiator fins very dirty Foam formation in cooling system
Damaged cylinder head or cylinder head gasket Bent radiator hose Thermostat defective

Action Ignition coil - check the primary wind-
ing. Check the spark plug connector. Check the stator winding of the alterna-
tor. Program ambient air pressure. ( p. 120)
Clean the air filter and air filter box. ( p. 67)
Change the fuel filter. Change the fuel screen. ( p. 123) Check wiring for damage and electrical
plug-in connectors for corrosion and damage. Read out the fault memory using the GASGAS Motorcycles diagnostics tool. Check the fuel tank breather. Check exhaust system for damage. Change the glass fiber yarn filling of the main silencer. ( p. 69) Ignition coil - check the primary winding. Check the spark plug connector. Check the stator winding of the alternator. Check the diaphragm and reed valve housing. Program ambient air pressure. ( p. 120)
Refuel. ( p. 37) Check that the intake flange is firmly
seated. Clean the connector and treat it with con-
tact spray. Program ambient air pressure. ( p. 120)
Check the cooling system for leakage. Check the coolant level. ( p. 112) Switch off engine when stationary. Clean the radiator fins. Drain the coolant. ( p. 112) Refill with coolant. ( p. 113) Check the cylinder head and cylinder head
gasket. Change the radiator hose. Check the thermostat.
Guideline Opening temperature: 70 °C (158 °F)

137

21 TROUBLESHOOTING

Faults White smoke emission (steam in exhaust gas) Gear oil exits at the vent hose Water in the gear oil Malfunction indicator lamp lights up or flashes
12-V battery discharged
Values in combination instrument deleted (time, stop watch, lap times)

Possible cause Damaged cylinder head or cylinder head gasket Too much gear oil added Damaged radial shaft seal ring or water pump Malfunction in the electronic fuel injection
The 12-V battery is not being charged by the alternator
Unwanted electrical power consumer The combination instrument battery is empty

Action Check the cylinder head and cylinder head
gasket. Check the gear oil level. ( p. 128) Check the radial shaft seal ring and the
water pump. Check wiring for damage and electrical
plug-in connectors for corrosion and damage. Read out the fault memory using the GASGAS Motorcycles diagnostics tool. Check the charging voltage. Check the stator winding of the alternator. Check the open-circuit current.
Change combination instrument battery. ( p. 109)

138

BLINK CODE 22

Info The blink codes are only displayed by the derestricted version of the vehicle.