OWNER'S MANUAL 2022

MC 125
Art. no. 3215051en
 DEAR GASGAS CUSTOMER

Congratulations on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports
DEAR GASGAS CUSTOMER

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)

The Owner's Manual contained the latest information for this model series at the time of publication. However, minor dif-
ferences 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 copy-
right 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:

MC 125 (F0101V0)

*3215051en*
3215051en

06/2021
TABLE OF CONTENTS

1 MEANS OF REPRESENTATION ..................................... 5 7.5 Preparing the vehicle for rides on wet
TABLE OF CONTENTS

sand ............................................................. 21
1.1 Symbols used................................................. 5 7.6 Preparing the vehicle for rides on wet
1.2 Formats used................................................. 5 and muddy circuits ...................................... 22
2 SAFETY ADVICE ............................................................ 6 7.7 Preparing vehicle for high temperatures
or slow riding............................................... 23
2.1 Use definition – intended use....................... 6 7.8 Preparing the vehicle for low
2.2 Misuse............................................................ 6 temperatures or snow ................................ 24
2.3 Safety advice.................................................. 6
2.4 Degrees of risk and symbols ......................... 6 8 RIDING INSTRUCTIONS .............................................. 25
2.5 Tampering warning ....................................... 7 8.1 Checks and maintenance measures
2.6 Safe operation ............................................... 7 when preparing for use............................... 25
2.7 Protective clothing ........................................ 7 8.2 Starting ........................................................ 25
2.8 Work rules ..................................................... 8 8.3 Starting off................................................... 26
2.9 Environment .................................................. 8 8.4 Shifting, riding ............................................. 26
2.10 Owner's Manual ............................................ 8 8.5 Applying the brakes..................................... 27
3 IMPORTANT NOTES ..................................................... 9 8.6 Stopping, parking......................................... 27
8.7 Transporting ................................................ 28
3.1 Manufacturer warranty, implied 8.8 Refueling...................................................... 28
warranty ........................................................ 9
3.2 Fuel, auxiliary substances.............................. 9 9 SERVICE SCHEDULE.................................................... 30
3.3 Spare parts, accessories ................................ 9 9.1 Additional information ................................ 30
3.4 Service ........................................................... 9 9.2 Required work ............................................. 30
3.5 Figures ........................................................... 9 9.3 Recommended work ................................... 31
3.6 Customer service........................................... 9
10 TUNING THE CHASSIS ................................................ 32
4 VIEW OF VEHICLE ...................................................... 10
10.1 Checking the basic chassis setting with
4.1 View of vehicle, front left (example) .......... 10 the rider's weight ........................................ 32
4.2 View of vehicle, rear right (example).......... 11 10.2 Air suspension XACT 5448........................... 32
5 SERIAL NUMBERS....................................................... 12 10.3 Compression damping of the shock
absorber ...................................................... 33
5.1 Vehicle identification number..................... 12 10.4 Adjusting the low-speed compression
5.2 Type label .................................................... 12 damping of the shock absorber .................. 33
5.3 Engine number ............................................ 12 10.5 Adjusting the high-speed compression
5.4 Fork part number ........................................ 12 damping of the shock absorber .................. 33
5.5 Shock absorber article number................... 13 10.6 Adjusting the rebound damping of the
shock absorber ............................................ 34
6 CONTROLS.................................................................. 14 10.7 Measuring the rear wheel dimension
6.1 Clutch lever.................................................. 14 unloaded...................................................... 34
6.2 Hand brake lever ......................................... 14 10.8 Checking the static sag of the shock
6.3 Throttle grip................................................. 14 absorber ...................................................... 35
6.4 Stop button.................................................. 14 10.9 Checking the riding sag of the shock
6.5 Opening the fuel tank filler cap................... 15 absorber ...................................................... 36
6.6 Closing the fuel tank filler cap..................... 15 10.10 Adjusting the spring preload of the
6.7 Fuel tap ........................................................ 16 shock absorber ........................................ 36
6.8 Choke........................................................... 16 10.11 Adjusting the riding sag ........................... 37
6.9 Shift lever..................................................... 16 10.12 Checking the basic setting of the fork ........ 38
6.10 Kick starter lever.......................................... 17 10.13 Adjusting the fork air pressure.................... 38
6.11 Foot brake lever .......................................... 17 10.14 Adjusting the compression damping of
the fork ........................................................ 39
6.12 Plug-in stand................................................ 17
10.15 Adjusting the rebound damping of the
7 PREPARING FOR USE ................................................. 18 fork............................................................... 40
10.16 Handlebar position...................................... 40
7.1 Advice on preparing for first use ................ 18
10.17 Adjusting the handlebar position ........... 40
7.2 Running in the engine ................................. 19
7.3 Preparing the vehicle for difficult 11 SERVICE WORK ON THE CHASSIS .............................. 42
operating conditions ................................... 19
11.1 Raising the motorcycle with a lift stand ..... 42
7.4 Preparing the vehicle for rides on dry
sand ............................................................. 20 11.2 Removing the motorcycle from the lift
stand ............................................................ 42

2
 TABLE OF CONTENTS

11.3 Bleeding the fork legs.................................. 42 12.7 Changing the brake linings of the front
11.4 Cleaning the dust boots of the fork legs..... 43 brake ........................................................ 74
11.5 Removing the fork legs ........................... 43 12.8 Checking the free travel of foot brake
11.6 Installing the fork legs ............................. 44 lever ............................................................. 76
11.7 Removing the fork protector ...................... 45 12.9 Adjusting the basic position of the foot
11.8 Installing the fork protector ........................ 45 brake lever ............................................... 77
11.9 Removing the lower triple clamp ............ 45 12.10 Checking the rear brake fluid level ............. 77
11.10 Installing the lower triple clamp ............. 46 12.11 Adding rear brake fluid ........................... 78
11.11 Checking steering head bearing play.......... 48 12.12 Checking the brake linings of the rear
11.12 Adjusting steering head bearing play ..... 48 brake............................................................ 79
11.13 Lubricating the steering head bearing .... 49 12.13 Changing the rear brake linings .............. 79
11.14 Removing the start number plate............... 49 13 WHEELS, TIRES........................................................... 82
11.15 Installing the start number plate ................ 49
11.16 Removing front fender................................ 50 13.1 Removing the front wheel ...................... 82
11.17 Installing front fender ................................. 50 13.2 Installing the front wheel ........................ 83
11.18 Removing the shock absorber ................ 50 13.3 Removing the rear wheel ........................ 83
11.19 Installing the shock absorber .................. 52 13.4 Installing the rear wheel ......................... 84
11.20 Removing the seat....................................... 53 13.5 Checking the tire condition......................... 86
11.21 Mounting the seat....................................... 54 13.6 Checking tire pressure................................. 86
11.22 Removing the air filter box cover................ 54 13.7 Checking spoke tension............................... 87
11.23 Installing the air filter box cover ................. 55 14 COOLING SYSTEM ...................................................... 88
11.24 Removing the air filter ............................ 56
11.25 Cleaning the air filter and air filter 14.1 Cooling system ............................................ 88
box ........................................................... 56 14.2 Radiator cover ............................................. 88
11.26 Installing the air filter .............................. 57 14.3 Installing the radiator cover........................ 88
11.27 Preparing air filter box cover for 14.4 Removing the radiator cover ...................... 89
securing ................................................... 57 14.5 Checking the antifreeze and coolant
11.28 Removing the main silencer........................ 58 level.............................................................. 89
11.29 Installing the main silencer ......................... 58 14.6 Checking the coolant level .......................... 90
11.30 Changing the glass fiber yarn filling in 14.7 Draining the coolant ................................ 91
the main silencer ..................................... 58 14.8 Refilling with coolant ............................... 92
11.31 Removing the fuel tank ........................... 59 14.9 Changing the coolant .............................. 93
11.32 Installing the fuel tank ............................. 60 15 TUNING THE ENGINE................................................. 95
11.33 Checking the chain for dirt.......................... 61
11.34 Cleaning the chain....................................... 62 15.1 Checking the play in the throttle cable....... 95
11.35 Checking the chain tension ......................... 62 15.2 Adjusting the play in the throttle
11.36 Adjusting the chain tension ........................ 63 cable ........................................................ 95
11.37 Checking the chain, rear sprocket, 15.3 Carburetor tuning........................................ 96
engine sprocket, and chain guide ............... 64 15.4 Carburetor – idle setting ............................. 98
11.38 Checking the frame ................................. 66 15.5 Carburetor - adjusting the idle speed ..... 99
11.39 Checking the link fork .............................. 66 15.6 Plug-in connector of ignition timing
11.40 Checking the throttle cable routing............ 66 map adjustment ....................................... 100
11.41 Checking the rubber grip ............................ 67 15.7 Changing the ignition timing map............ 100
11.42 Adjusting the basic position of the clutch 15.8 Checking the basic position of the shift
lever ............................................................. 68 lever .......................................................... 100
11.43 Checking/correcting the fluid level of the 15.9 Adjusting the basic position of the shift
hydraulic clutch ........................................... 68 lever ...................................................... 100
11.44 Changing the hydraulic clutch fluid ........ 69 16 SERVICE WORK ON THE ENGINE ............................ 102
12 BRAKE SYSTEM........................................................... 71 16.1 Emptying the carburetor float
12.1 Checking the free travel of the hand chamber ............................................... 102
brake lever................................................... 71 16.2 Checking the gear oil level ....................... 103
12.2 Adjusting the basic position of the hand 16.3 Changing the gear oil ........................... 103
brake lever................................................... 71 16.4 Adding the gear oil ............................... 104
12.3 Checking the brake discs............................. 71 17 CLEANING, CARE..................................................... 106
12.4 Checking the front brake fluid level............ 72
12.5 Adding front brake fluid .......................... 72 17.1 Cleaning the motorcycle .......................... 106
12.6 Checking the front brake linings ................. 74

3
TABLE OF CONTENTS

18 STORAGE................................................................. 108
18.1 Storage...................................................... 108
18.2 Preparing for use after storage................ 109
19 TROUBLESHOOTING ............................................... 110
20 TECHNICAL DATA.................................................... 112
20.1 Engine ....................................................... 112
20.2 Engine tightening torques........................ 112
20.3 Carburetor ................................................ 114
20.3.1 Carburetor tuning ............................... 114
20.3.2 Carburetor - basic setting for sandy
surfaces ............................................... 115
20.4 Capacities.................................................. 115
20.4.1 Gear oil ................................................ 115
20.4.2 Coolant ................................................ 115
20.4.3 Fuel ...................................................... 115
20.5 Chassis ...................................................... 115
20.6 Tires .......................................................... 116
20.7 Fork ........................................................... 116
20.8 Shock absorber......................................... 117
20.9 Chassis tightening torques ....................... 117
21 SUBSTANCES ........................................................... 120
22 AUXILIARY SUBSTANCES ......................................... 122
23 STANDARDS ............................................................ 124
24 LIST OF ABBREVIATIONS......................................... 125
INDEX ............................................................................... 126

4
 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).

All work marked with this symbol requires specialist 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 spe-
cial tools required.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates the end of an activity, including potential reworking.

1.2 Formats used

The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.

Name® Indicates a protected name.

Brand™ 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.

5
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
Only operate this vehicle in closed-off areas remote from public road traffic.

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 respec-
tive 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.

6
 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

Danger
Danger of accidents A 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.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any 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.

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.
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 injury Missing 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 pro-
tective clothing.

7
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)
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 regula-
tions of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regu-
lations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles dealer will be glad to
advise you.

2.10 Owner's Manual

Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful infor-
mation 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 down-
loaded again by the new owner.
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate.

The Owner's Manual is 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

8
 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 dam-
age caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

3.2 Fuel, auxiliary substances

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

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 neces-
sary 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

9
4 VIEW OF VEHICLE

4.1 View of vehicle, front left (example)

S04515-10

1 Hand brake lever ( p. 14)

2 Clutch lever ( p. 14)
3 Air filter box cover
4 Shift lever ( p. 16)
5 Choke ( p. 16)
6 Fuel tap

10
 VIEW OF VEHICLE 4

4.2 View of vehicle, rear right (example)

S04516-10

1 Seat
2 Fuel tank filler cap
3 Stop button ( p. 14)
4 Throttle grip ( p. 14)
5 Kick starter lever ( p. 17)
6 Foot brake lever ( p. 17)
7 Shock absorber compression adjuster
8 Shock absorber rebound adjuster
9 Level viewer for brake fluid, rear

11
5 SERIAL NUMBERS

5.1 Vehicle identification number

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

401945-10

5.2 Type label

The type label 1 is fixed to the front of the steering head.

401946-10

5.3 Engine number

The engine number 1 is stamped on the left side of the engine under
the engine sprocket.

401949-10

5.4 Fork part number

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

401947-10

12
 SERIAL NUMBERS 5

5.5 Shock absorber article number

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

401948-10

13
6 CONTROLS

6.1 Clutch lever

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

S04517-10

6.2 Hand brake lever

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

S04518-10

6.3 Throttle grip

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

S04518-11

6.4 Stop button

The stop button 1 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.

S04519-10

14
 CONTROLS 6

6.5 Opening the fuel tank filler cap

Danger
Fire hazard Fuel 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 poisoning Fuel 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 hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

– Turn fuel tank filler cap 1 counterclockwise and lift it off.

S04520-10

6.6 Closing the fuel tank filler cap

– Mount fuel tank filler cap 1 and turn it clockwise until the fuel
tank is tightly closed.

Info
Route fuel tank breather hose 2 without kinks.

S04520-11

15
6 CONTROLS

6.7 Fuel tap

The fuel tap is on the left side of the fuel tank.
Open or close the fuel supply to the carburetor using knurled screw 1
on the fuel tap.
Possible states
• Fuel tap is closed – Fuel cannot flow from the fuel tank to the car-
buretor.
• Fuel tap is open – Fuel can flow from the fuel tank to the carbure-
tor. The fuel tank empties completely.

S04521-10

6.8 Choke
Choke 1 is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through
which the engine can draw extra fuel. This results in a richer fuel-air mix-
ture, which is needed for a cold start.

Info
If the engine is warm, the choke function must be deactivated.

Possible states
K01129-10 • Choke function activated – The choke lever is pulled out to the
stop.
• Choke function deactivated – The choke lever is pushed in to the
stop.

6.9 Shift lever

Shift lever 1 is mounted on the left 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.

401950-11

16
 CONTROLS 6

6.10 Kick starter lever

Kick starter lever1 is fitted on the right side of the engine.
The kick starter lever can be swiveled.

Info
Before riding, swing the kick starter lever inwards towards the
engine.

401954-10

6.11 Foot brake lever

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

401956-10

6.12 Plug-in stand

The holder for the plug-in stand 1 is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.
The plug-in stand is used as a fork locker when transporting the motor-
cycle.

Info
Remove the plug-in stand before riding.

H02629-10

17
7 PREPARING FOR USE

7.1 Advice on preparing for first use

Danger
Danger of accidents A 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 injury Missing 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 crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.

Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.

Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.

Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever if you do not want to brake.

Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.

Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.

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. 68)
– Adjust the basic position of the hand brake lever. ( p. 71)
– Adjust the basic position of the foot brake lever. ( p. 77)
– Adjust the basic position of the shift lever. ( p. 100)

18
 PREPARING FOR USE 7

– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging
trips.

Info
Your motorcycle is not approved for use on public roads.
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.
– Do not take luggage along.
– Do not exceed the maximum permissible weight and the maximum permissible axle loads.
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. 87)

Info
The spoke tension must be checked after half an hour of operation.

– Run the engine in. ( p. 19)

7.2 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 %

Info
The use of a service hour counter is recommended in order to be able to check the mileage at any time.

– Avoid fully opening the throttle.

7.3 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 signifi-
cantly 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.

– Prepare air filter box cover for securing. ( p. 57)

– Clean the air filter and air filter box. ( p. 56)

Info
Check the air filter approx. every 30 minutes.

– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.

19
7 PREPARING FOR USE

» If humidity, corrosion, or damage is found:

– Clean and dry the connector, or change it if necessary.
– Make sure that no radiator covers are installed.
Difficult operating conditions are:
– Rides on dry sand. ( p. 20)
– Rides on wet sand. ( p. 21)
– Rides on wet and muddy circuits. ( p. 22)
– Riding at high temperatures or slow riding. ( p. 23)
– Riding at low temperatures and in snow. ( p. 24)

7.4 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:

Warning
Danger of scalding During motorcycle operation,
the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or
M01129-01
other cooling system components if the engine
or the cooling system are at operating temper-
ature.
– 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.

– Change the radiator cap.

– Mount the air filter dust cover.
Air filter dust cover (79006920000)

Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.

M01104-01

– Mount the air filter sand cover.

Air filter sand cover (79006922000)

Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.

M01105-01

20
 PREPARING FOR USE 7

– Adjust the carburetor jetting and setting.

Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.

M01107-01

– Clean the chain.

Chain cleaner ( p. 122)
– Mount the steel sprocket.
– Grease the chain.
Universal oil spray ( p. 123)
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
600868-01 Condition
Regular use in sand
– Change the piston every 10 operating hours.

7.5 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:

Warning
Danger of scalding During motorcycle operation,
the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or
M01129-01
other cooling system components if the engine
or the cooling system are at operating temper-
ature.
– 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.

– Change the radiator cap.

21
7 PREPARING FOR USE

– Mount the air filter rain cover.

Air filter rain cover (79006921000)

Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.

M01106-01

– Adjust the carburetor jetting and setting.

Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.

M01107-01

– Clean the chain.

Chain cleaner ( p. 122)
– Mount the steel sprocket.
– Grease the chain.
Universal oil spray ( p. 123)
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
600868-01 Condition
Regular use in sand
– Change the piston every 10 operating hours.

7.6 Preparing the vehicle for rides on wet and muddy circuits
– Mount the air filter rain cover.
Air filter rain cover (79006921000)

Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.

M01106-01

22
 PREPARING FOR USE 7

– Adjust the carburetor jetting and setting.

Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.

M01107-01

– Mount the steel sprocket.

– Clean the motorcycle. ( p. 106)
– Straighten the bent radiator fins carefully.

600868-01

7.7 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:

Warning
Danger of scalding During motorcycle operation,
the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or
M01129-01
other cooling system components if the engine
or the cooling system are at operating temper-
ature.
– 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.

– Change the radiator cap.

– Adjust the secondary drive to the road conditions.

Info
The engine oil heats up quickly when the clutch is operated
frequently due to an excessively high secondary ratio.

– Clean the chain.

Chain cleaner ( p. 122)

600868-01
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
– Check the coolant level. ( p. 90)

23
7 PREPARING FOR USE

7.8 Preparing the vehicle for low temperatures or snow

– Mount the air filter rain cover.
Air filter rain cover (79006921000)

Info
Observe the fitting instructions for GASGAS Techni-
cal Accessories.

M01106-01

– Adjust the carburetor jetting and setting.

Info
The recommended carburetor tuning is available from your
authorized GASGAS Motorcycles workshop.

M01107-01

24
 RIDING INSTRUCTIONS 8

8.1 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.

– Check the gear oil level. ( p. 103)

– Check the front brake fluid level. ( p. 72)
– Check the rear brake fluid level. ( p. 77)
– Check the front brake linings. ( p. 74)
– Check the brake linings of the rear brake. ( p. 79)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 90)
– Check the chain for dirt. ( p. 61)
H02217-01
– Check the chain, rear sprocket, engine sprocket, and chain guide.
( p. 64)
– Check the chain tension. ( p. 62)
– Check the tire condition. ( p. 86)
– Check tire pressure. ( p. 86)
– Check the spoke tension. ( p. 87)

Info
The spoke tension must be checked regularly as incorrect
spoke tension will strongly impair riding safety.

– Clean the dust boots of the fork legs. ( p. 43)

– Bleed the fork legs. ( p. 42)
– 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.

8.2 Starting

Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.

Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the
fuel evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.

25
8 RIDING INSTRUCTIONS

The motorcycle has been out of use for more than 1 week
– Empty the carburetor float chamber. ( p. 102)
– Turn the knurled screw on the fuel tap all the way counterclockwise.
Fuel can flow from the fuel tank to the carburetor.
– Remove plug-in stand 1.
– Shift the transmission into neutral.
Condition
The engine is cold
– Pull the choke lever out as far as possible.
– Press the kick starter lever robustly through its full range.

Info
H02629-10 Do not open the throttle.

8.3 Starting off

Info
The plug-in stand must be removed before riding.
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.

8.4 Shifting, riding

Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
– Do not change into a low gear at high engine speed.

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

– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
– If the choke function has been activated, deactivate it after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is 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 or lengthy 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.

26
 RIDING INSTRUCTIONS 8

8.5 Applying the brakes

Warning
Danger of accidents Excessively 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 accidents A 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 accidents Moisture 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 mostly if possible.
– Always finish braking before you go into a bend. Change down to a lower gear appropriate to your road speed.
– Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the
engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.

8.6 Stopping, parking

Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.

Warning
Danger of burns Some 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
Fire hazard Hot 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.

Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for 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.

– Apply the brakes on the motorcycle.

– Shift the transmission to neutral position.
– Press and hold the stop button while the engine is idling until the engine stops.
– Turn the knurled screw on the fuel tap all the way clockwise.
– Rest the vehicle on the plug-in stand.

27
8 RIDING INSTRUCTIONS

8.7 Transporting

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

Note
Fire hazard Hot 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.

– Mount plug-in stand on the fork legs.
Plug-in stand (79029094000)

Info
The plug-in stand is included.
Make sure the brake line runs in front of the plug-in stand
and does not become wedged.
H02628-01

– Use tension belts or other suitable devices to secure the motorcycle

against falling over or rolling away.

Info
Only tighten the tension belts to the point that the plug-in
stand is firmly in contact with the fender and the tires.
Pay attention to the alignment of the plug-in stand to the
fender.

401475-01

8.8 Refueling

Danger
Fire hazard Fuel 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 poisoning Fuel 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.

28
 RIDING INSTRUCTIONS 8

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

– Switch off the engine.

– Open the fuel tank filler cap. ( p. 15)
– Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A 35 mm (1.38 in)

Total fuel tank capac- 7.5 l Super unleaded (98

ity, approx. (1.98 US gal) octane) mixed with
2-stroke engine oil
(1:40) ( p. 121)
400382-10
Engine oil, 2-stroke ( p. 120)
– Close the fuel tank filler cap. ( p. 15)

29
9 SERVICE SCHEDULE

9.1 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.
The use of a service hour counter is recommended in order to be able to check the mileage at any time.
Service hour counter (A54012920000)

9.2 Required work

after every race
Every 40 operating hours
Every 20 operating hours
Every 10 operating hours
After 1 operating hour
Change the gear oil. ( p. 103) ● ● ●
Check the front brake linings. ( p. 74) ● ● ● ●
Check the brake linings of the rear brake. ( p. 79) ● ● ● ●
Check the brake discs. ( p. 71) ● ● ● ●
Check the brake lines for damage and leakage. ● ● ● ●
Check the rear brake fluid level. ( p. 77) ● ● ● ●
Check the free travel of the foot brake lever. ( p. 76) ● ● ● ●
Check the frame. ( p. 66) ● ● ● ●
Check the link fork. ( p. 66) ● ● ● ●
Check the fork bearing for play. ● ●
Check the shock absorber heim joint for play. ● ● ● ●
Check the shock absorber linkage. ● ● ● ●
Check the tire condition. ( p. 86) ○ ● ● ● ●
Check tire pressure. ( p. 86) ○ ● ● ● ●
Check the wheel bearing for play. ● ● ● ●
Check the wheel hubs. ● ● ● ●
Check the rim run-out. ○ ● ● ● ●
Check the spoke tension. ( p. 87) ○ ● ● ● ●
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 64) ● ● ● ●
Check the chain tension. ( p. 62) ○ ● ● ● ●
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. ● ● ● ●
Check/correct the fluid level of the hydraulic clutch. ( p. 68) ● ● ● ●
Check the front brake fluid level. ( p. 72) ● ● ● ●
Check the free travel of the hand brake lever. ( p. 71) ● ● ● ●
Check steering head bearing play. ( p. 48) ○ ● ● ● ●
Change the spark plug and spark plug connector. ● ● ●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and ○ ● ● ● ●
incorrect routing.
Check the antifreeze and coolant level. ( p. 89) ○ ● ● ● ●
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. 56) ● ● ● ●

30
 SERVICE SCHEDULE 9

after every race

Every 40 operating hours
Every 20 operating hours
Every 10 operating hours
After 1 operating hour
Change the glass fiber yarn filling in the main silencer. ( p. 58) ● ●
Service the fork. ●
Perform the shock absorber service. ●
Check the tightness of the easily accessible, safety-relevant screws and nuts. ○ ● ● ● ●
Check the idle speed. ○ ● ● ● ●
Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ●
Make a service entry in GASGAS Motorcycles Dealer.net. ○ ● ● ● ●
○ One-time interval
● Periodic interval

9.3 Recommended work

every 48 months
every 12 months
after every race
Every 40 operating hours
After 20 operating hours / Every 20 operating hours
After 10 operating hours / Every 10 operating hours
Change the front brake fluid. ● ●
Change the rear brake fluid. ● ●
Change the hydraulic clutch fluid. ( p. 69) ● ●
Lubricate the steering head bearing. ( p. 49) ● ●
Service the fork. ○
Perform the shock absorber service. ○
Check/adjust the carburetor components. ● ● ●
Change the needle jet. ●
Change the coolant. ( p. 93) ●
Perform minor engine service. (Check the inlet membrane. Check the clutch. Under difficult ● ● ● ●
operating conditions: Change the piston and check the cylinder and Z dimension.)
Perform the intermediate engine service. (Change the piston and check the cylinder and Z ● ●
dimension. Check the exhaust control for functioning and smooth operation.)
Perform major engine service including removing and installing the engine. (Change the ●
connecting rod, conrod bearing, and crank pin. Check the transmission and shift mecha-
nism. Change all engine bearings.)
○ One-time interval
● Periodic interval

31
10 TUNING THE CHASSIS

10.1 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 aver-
age 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

10.2 Air suspension XACT 5448

Air suspension WP Suspension XACT 5448 is used in the fork.
In this system, suspension is located in the left fork leg and damping in
the right fork leg.
As fork springs are no longer required, a significant weight advantage is
achieved when compared to conventional forks. The response on slightly
uneven surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air
cushion. A steel spring is located in the left fork leg as an end stop.

Info
If the fork is frequently overloaded, then the air pressure in the
fork must be increased to avoid damage to the fork and frame.

The air pressure in the fork can be quickly adjusted to the rider's weight,
surface conditions and the rider's preference using a fork airpump. The
fork does not have to be dismantled. The time consuming mounting of
harder or softer fork springs is not required.
If the air chamber loses air due to a damaged seal, the fork will still not
sag. In this case the air is retained in the fork. The suspension travel is
maintained as far as possible. The damping becomes harder and the
M01110-01 riding comfort reduces.
As with a conventional fork, the damping can be adjusted in rebound
and compression stages.
The rebound adjuster is located at the lower end of the right fork leg.
The compression adjuster is located at the upper end of the right fork
leg.

32
 TUNING THE CHASSIS 10

10.3 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 sus-
pension 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.

10.4 Adjusting the low-speed compression damping of the shock absorber

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

Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock
absorber.

– Turn adjusting screw 1 clockwise with a screwdriver as far as the

last perceptible click.

Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of clicks corresponding to the
shock absorber type.
Guideline
S04522-10
Lowspeed compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

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

10.5 Adjusting the high-speed compression damping of the shock absorber

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

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

33
10 TUNING THE CHASSIS

– Turn adjusting screw 1 all the way clockwise with a socket wrench.
Info
Do not loosen fitting 2!
– Turn counterclockwise by the number of turns corresponding to the
shock absorber type.
Guideline
Highspeed compression damping
S04523-10
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn

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

10.6 Adjusting the rebound damping of the shock absorber

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

– Turn adjusting screw 1 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
S04524-10

Info
Turn clockwise to increase the damping; turn counterclock-
wise to reduce damping when the shock absorber rebounds.

10.7 Measuring the rear wheel dimension unloaded

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)

34
 TUNING THE CHASSIS 10

Main work
– Position the sag gage in the rear axle and measure the distance to
marking SAG on the rear fender.
Sag gauge (00029090000)
Pin, sag scale (00029990010)
– Note down the value as dimension A.

402415-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

10.8 Checking the static sag of the shock absorber

– Measure dimension A of rear wheel unloaded. ( p. 34)
– 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.
– Note the value as dimension B.
Info
The static sag is the difference between measurements A
and B .

– Check the static sag.

Static sag 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
( p. 36)

402416-10

35
10 TUNING THE CHASSIS

10.9 Checking the riding sag of the shock absorber

– Measure dimension A of rear wheel unloaded. ( p. 34)
– 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.
– Note the value as dimension C.
Info
The riding sag is the difference between measurements A
and C.

– Check riding sag.

Guideline
Riding sag 105 mm (4.13 in)
» If the riding sag differs from the specified measurement:
– Adjust the riding sag. ( p. 37)
402417-10

10.10 Adjusting the spring preload of the shock absorber

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

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. 42)
– Remove the shock absorber. ( p. 50)
– After removing the shock absorber, clean it thoroughly.

36
 TUNING THE CHASSIS 10

Main work
– Loosen screw 1.
– Turn adjusting ring 2 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 ten-
sion.
– Tension the spring by turning adjusting ring 2 to specified dimen-
sionA .
Guideline
Spring preload 7 mm (0.28 in)

Info
Depending on the static sag and/or the riding sag, it may be
402659-10
necessary to increase or decrease the spring preload.

– Tighten screw 1.
Guideline
Screw, shock absorber M5 5 Nm (3.7 lbf ft)
adjusting ring

Finishing work
– Install the shock absorber. ( p. 52)
– Remove the motorcycle from the lift stand. ( p. 42)

10.11 Adjusting the riding sag

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
– Remove the shock absorber. ( p. 50)
– 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 36 N/mm (206 lb/in)
(143 … 165 lb.)
Weight of rider: 75 … 85 kg 39 N/mm (223 lb/in)
(165 … 187 lb.)
B00292-10 Weight of rider: 85 … 95 kg 42 N/mm (240 lb/in)
(187 … 209 lb.)

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

Finishing work
– Install the shock absorber. ( p. 52)
– Remove the motorcycle from the lift stand. ( p. 42)

37
10 TUNING THE CHASSIS

– Check the static sag of the shock absorber. ( p. 35)

– Check the riding sag of the shock absorber. ( p. 36)
– Adjust the rebound damping of the shock absorber. ( p. 34)

10.12 Checking the basic setting of the fork

Info
For various reasons, no exact riding sag can be determined for the fork.

– Smaller differences in the rider's weight can be compensated for by

the fork air pressure.
– However, if the fork frequently bottoms out (hard end stop on com-
pression), the fork air pressure must be increased, within the speci-
fied values, 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

10.13 Adjusting the fork air pressure

Warning
Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic
and overload components.
– Only make adjustments within the recommended range.
– Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.

Info
Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine.
The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Remove protection cap 1.
– Push together fork airpump 2 fully.
Fork airpump (79412966100)

Info
The fork airpump is included as part of the motorcycle's
accessory pack.
S04525-10
– Connect the fork airpump to the left fork leg.
The fork airpump indicator switches on automatically.
A little air escapes from the fork leg when connecting.

38
 TUNING THE CHASSIS 10

Info
This is due to the volume of the hose and not due to a
defect in the fork airpump or the fork.
Read the accompanying GASGAS Technical Accessories
instructions.

– Adjust the air pressure as specified.

Guideline
Air pressure 8.3 bar (120 psi)
Gradual changing of the air 0.2 bar (3 psi)
pressure in steps of
Minimum air pressure 7 bar (102 psi)
Maximum air pressure 12 bar (174 psi)

Info
Never adjust the air pressure to a value outside the stated
range.

– Disconnect the fork airpump from the left fork leg.

When disconnecting, excess pressure will escape from the hose
– the fork leg itself does not lose any air.
The fork airpump indicator switches off automatically after
80 seconds.
– Mount the protection cap.

Info
Only mount the protection cap by hand.

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

10.14 Adjusting the compression damping of the fork

Info
The hydraulic compression damping determines the fork suspension behavior.

– Turn adjusting screw 1 clockwise all the way.

Info
Adjusting screw 1 is located at the upper end of the right
fork leg.

– Turn counterclockwise by the number of clicks corresponding to the

fork type.
Guideline
S04526-10
Compression damping
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks

39
10 TUNING THE CHASSIS

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

10.15 Adjusting the rebound damping of the fork

Info
The hydraulic rebound damping determines the fork suspension behavior.

– Turn adjusting screw 1 clockwise all the way.

Info
Adjusting screw 1 is located at the lower end of the right
fork leg.

– Turn counterclockwise by the number of clicks corresponding to the

fork type.
Guideline
Z01370-10
Rebound damping
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks

Info
Turn clockwise to increase the damping; turn counterclock-
wise to reduce damping when the shock absorber rebounds.

10.16 Handlebar position

The holes on the handlebar supports are placed at a distance of A
from the center.
Hole distance A 3.5 mm (0.138 in)
The handlebar can be mounted in 2 different positions. In this way, the
handlebar can be mounted in the most comfortable position for the
rider.

H01188-10

10.17 Adjusting the handlebar position

Warning
Danger of accidents A 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.

Preparatory work
– Remove the handlebar cushion.

40
 TUNING THE CHASSIS 10

Main work
– Remove screws 1 . Remove the handlebar clamp. Remove the han-
dlebar and lay it to one side.

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

– Remove screws 2. Take off handlebar supports 3.

– Position rubber bushings 4 and push through nuts 5 from
below.
– Place the handlebar supports in the required position.

Info
The handlebar supports are longer and higher on one side.
Position the left and right handlebar supports evenly.

– Mount and tighten screws 2.

Guideline
H01189-10 Screw, handlebar M10 40 Nm (29.5 lbf ft)
support Loctite®243™

– Position the handlebar.

Info
Make sure the cables and wiring are positioned correctly.

– Position the handlebar clamp.

– Mount screws 1 but do not tighten yet.
– First bolt the handlebar clamp with screws 1 onto the longer,
higher side of the handlebar supports so that both parts touch.
Guideline
Screw, handlebar M8 20 Nm (14.8 lbf ft)
clamp
– Tighten screws 1 evenly.
Guideline
Screw, handlebar M8 20 Nm (14.8 lbf ft)
clamp

Finishing work
– Mount the handlebar cushion.

41
11 SERVICE WORK ON THE CHASSIS

11.1 Raising the motorcycle with a lift stand

Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for 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.

– 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.

401942-01

11.2 Removing the motorcycle from the lift stand

Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for 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.

– Remove the motorcycle from the lift stand.

– Remove the lift stand.
– To park the motorcycle, insert plug-in stand 1 into the left side of
the wheel spindle.

Info
Remove the plug-in stand before riding.

H02629-10

11.3 Bleeding the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Release bleeder screws 1.
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.

H01182-12

42
 SERVICE WORK ON THE CHASSIS 11

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

11.4 Cleaning the dust boots of the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
– Remove the fork protector. ( p. 45)
Main work
– Push dust boots 1 of both fork legs downward.
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.

M01134-10

Warning
Danger of accidents Oil or grease on the brake discs
reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when neces-
sary.

– Clean and oil the dust boots and inner fork tubes of both fork legs.
Universal oil spray ( p. 123)
– Press the dust boots back into their normal position.
– Remove excess oil.
Finishing work
– Install the fork protector. ( p. 45)
– Remove the motorcycle from the lift stand. ( p. 42)

11.5 Removing the fork legs

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
– Remove the front wheel. ( p. 82)
Main work
– Remove screws 1 and take off the clamp.
– Remove screws 2 and take off the brake caliper.
– Allow the brake caliper and brake line to hang loosely to the side.

Info
Do not actuate the hand brake lever when the front wheel is
removed.
S04527-10

43
11 SERVICE WORK ON THE CHASSIS

– Loosen screws 3. Remove the left fork leg.

– Loosen screws 4. Remove the right fork leg.

S04528-10

11.6 Installing the fork legs

Main work
– Position the fork legs.
Air bleeder screw 1 of the right fork leg is positioned to the
front.
Valve A of the left fork leg faces the front.
Info
Grooves are milled into the side of the upper end of the fork
H01182-10
legs. The second milled groove (from the top) must be flush
with the upper edge of the upper triple clamp.
The air suspension is located in the left fork leg. The pres-
sure and rebound damping is located in the right fork leg.

– Tighten screws 2.
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
– Tighten screws 3.
Guideline
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
clamp
S04528-11

– Position the brake caliper. Mount and tighten screws 4.

Guideline
Screw, front M8 25 Nm (18.4 lbf ft)
brake caliper Loctite®243™

– Position the brake line and the clamp. Mount and tighten
screws 5 .

S04527-11

Finishing work
– Install the front wheel. ( p. 83)

44
 SERVICE WORK ON THE CHASSIS 11

11.7 Removing the fork protector

– Remove screws 1. Remove the clamp.
– Remove screws 2. Take off the left fork protector.
– Remove screws 3. Take off the right fork protector.

F00024-10

11.8 Installing the fork protector

– Position the fork protection on the left fork leg. Mount and tighten
screws 1 .
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Position the brake line and clamp. Mount and tighten screws 2.
– Position the fork protector on the right fork leg. Mount and tighten

F00024-11
screws 3 .
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

11.9 Removing the lower triple clamp

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
– Remove the front wheel. ( p. 82)
– Remove the fork legs. ( p. 43)
– Remove the start number plate. ( p. 49)
– Remove front fender. ( p. 50)
– Remove the handlebar cushion.
Main work
– Remove screw 1.
– Remove screw 2.
– Take off the upper triple clamp with the handlebar and hang them
to the side.

Info
Cover the components to protect them against damage.
S04530-10
Do not kink the cables and lines.

45
11 SERVICE WORK ON THE CHASSIS

– Remove O-ring 3. Remove protective ring 4.

– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

M01117-10

11.10 Installing the lower triple clamp

Main work
– Clean the bearing and sealing elements, check for damage, and
grease.
High viscosity grease ( p. 122)
– Insert the lower triple clamp with the steering stem. Mount upper
steering head bearing.
– Check whether upper steering head seal1 is correctly positioned.
– Slide on protective ring 2 and O-ring 3.

102146-10

– Position the upper triple clamp with the handlebar.

– Mount screw 4, but do not tighten yet.

S04531-10

– Position the fork legs.

Air bleeder screw 5 of the right fork leg is positioned to the
front.
Valve A of the left fork leg faces the front.
Info
The air suspension AER valve is located in the left fork leg.
Grooves are milled into the side of the upper end of the fork
H01182-11
legs. The second milled groove (from the top) must be flush
with the upper edge of the upper triple clamp.

46
 SERVICE WORK ON THE CHASSIS 11

– Tighten screws 6.
Guideline
Screw, bottom triple M8 15 Nm (11.1 lbf ft)
clamp

S04532-10

– Tighten screw 4.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head

S04533-10

– Mount and tighten screw 7.

Guideline
Screw, top steer- M8 20 Nm (14.8 lbf ft)
ing stem Loctite®243™

S04533-11

– Tighten screws 8.
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)

S04532-11

– Position the brake caliper. Mount and tighten screws 9.

Guideline
Screw, front M8 25 Nm (18.4 lbf ft)
brake caliper Loctite®243™

– Position the brake line and the clamp. Mount and tighten
screws bk .

S04527-12

Finishing work
– Check that the wiring harness, throttle cables, and brake and clutch
lines can move freely and are routed correctly.
– Install front fender. ( p. 50)
– Install the front wheel. ( p. 83)

47
11 SERVICE WORK ON THE CHASSIS

– Check steering head bearing play. ( p. 48)

– Remove the motorcycle from the lift stand. ( p. 42)
– Install the start number plate. ( p. 49)
– Mount the handlebar cushion.

11.11 Checking steering head bearing play

Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages com-
ponents.
– Correct incorrect steering head bearing play immediately. (Your authorized GASGAS Motorcycles workshop will
be glad to help.)

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.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
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 steering head bearing play. ( p. 48)
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire
H01167-01
steering range. There should be no detectable detent positions.
» If detent positions are detected:
– Adjust steering head bearing play. ( p. 48)
– Check the steering head bearing and change if necessary.
Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

11.12 Adjusting steering head bearing play

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
– Remove the handlebar cushion.
Main work
– Loosen screws 1.
– Remove screw 2.
– Loosen and retighten screw 3.
Guideline
Screw, top steering M20x1.5 12 Nm (8.9 lbf ft)
head

S04534-10

48
 SERVICE WORK ON THE CHASSIS 11

– Using a plastic hammer, tap lightly on the upper triple clamp to

avoid stresses.
– Tighten screws 1.
Guideline
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
– Mount and tighten screw 2.
Guideline
Screw, top steer- M8 20 Nm (14.8 lbf ft)
ing stem Loctite®243™

Finishing work
– Check steering head bearing play. ( p. 48)
– Remove the motorcycle from the lift stand. ( p. 42)
– Mount the handlebar cushion.

11.13 Lubricating the steering head bearing

– Remove the lower triple clamp. ( p. 45)
– Install the lower triple clamp. ( p. 46)

Info
The steering head bearing is cleaned and lubricated in the
course of removal and installation.

H02387-01

11.14 Removing the start number plate

– Remove screw 1.
– Disconnect the brake line at the start number plate. Take off the
start number plate.

S04535-10

11.15 Installing the start number plate

– Connect the brake line at the start number plate.
– Position the start number plate.
The holding lugs engage in the fender.
– Mount and tighten screw 1.

S04536-10

49
11 SERVICE WORK ON THE CHASSIS

11.16 Removing front fender

Preparatory work
– Remove the start number plate. ( p. 49)
Main work
– Remove screws 1 and 2. Remove front fender.

S04537-10

11.17 Installing front fender

Main work
– Position front fender. Mount and tighten screws 1 and 2.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

S04537-10

Finishing work
– Install the start number plate. ( p. 49)

11.18 Removing the shock absorber

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Remove the cable ties.
– Remove screws 1 along with the washers.
– Take off the left frame protector.
– Push the right frame protector to the front and take off at the bot-
tom.

S04538-10

– Remove screw 2.
– Remove fitting 3.

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

S04569-10

50
 SERVICE WORK ON THE CHASSIS 11

– Press angle lever 4 toward the rear.

– Press linkage lever 5 downward.

S04570-10

– Remove screws 6 and pull foot brake cylinder off the push rod.

S04540-10

– Remove the connecting link of the chain.

– Take off the chain.

Info
Cover the components to protect them against damage.

M01149-01

– Remove nut 7 and pull out the swingarm pivot.

– Push the link fork back and secure it against falling over.

S04571-10

– Hold the shock absorber and remove screw 8.

S04541-10

51
11 SERVICE WORK ON THE CHASSIS

– Remove the shock absorber carefully at the bottom.

S04542-01

11.19 Installing the shock absorber

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

S04543-01

– Mount and tighten screw 1.

Guideline
Screw, top shock M10 60 Nm (44.3 lbf ft)
absorber Loctite®2701™

S04541-11

– Position the link fork and mount the swingarm pivot.

Info
Pay attention to flat area A.
– Mount and tighten nut 2.
Guideline
Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft)
V01527-10

– 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.

M01149-01

52
 SERVICE WORK ON THE CHASSIS 11

– Position the foot brake cylinder.

Push rod 3 engages in the foot brake cylinder.
The dust boot is correctly positioned.
– Mount and tighten screws 4.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

K01148-10

– Position the angle lever and linkage lever.

– Mount and tighten fitting 5.
Guideline
Nut, linkage lever on M14x1.5 60 Nm (44.3 lbf ft)
angle lever

Info

K00864-10
Pay attention to flat area B.
– Mount and tighten screw 6.
Guideline
Screw, bottom M10 60 Nm (44.3 lbf ft)
shock absorber Loctite®2701™

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

– Position the left frame protector.

– Insert the right frame protector from below and push it to the rear.
– Mount and tighten screws 7 with the washers.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
– Mount the new cable ties.

S04538-11

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

11.20 Removing the seat

– Remove screw 1.

S04544-10

53
11 SERVICE WORK ON THE CHASSIS

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

H02218-10

11.21 Mounting the seat

– Mount the front of the seat on the collar bushing of the fuel tank,
lower the seat at the rear, and push the seat forward.
– Make sure that the seat is locked in correctly.

H02218-11

– Mount and tighten screw 1.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

S04544-10

11.22 Removing the air filter box cover

Condition
The air filter box cover is secured.
– Remove the seat. ( p. 53)
– Remove screw 1.

S04545-10

54
 SERVICE WORK ON THE CHASSIS 11

– Pull off the air filter box cover in area A sideways and take off
toward the front.

S04546-10

Condition
The air filter box cover is not secured.
– Pull off the air filter box cover in area A sideways and take off
toward the front.

S04547-10

11.23 Installing the air filter box cover

Condition
The air filter box cover is secured.
– Insert the air filter box cover in area A and clip it into area B.

S04546-11

– Mount and tighten screw 1.

Guideline
Screw, air filter box EJOT PT® 3 Nm (2.2 lbf ft)
cover K60x20-Z
– Mount the seat. ( p. 54)

S04546-12

Condition
The air filter box cover is not secured.
– Insert the air filter box cover in area A and clip it into area B.

S04547-11

55
11 SERVICE WORK ON THE CHASSIS

11.24 Removing the air filter

Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Only operate the vehicle if it is equipped with an air filter.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Preparatory work
– Remove the air filter box cover. ( p. 54)
Main work
– Detach retaining tab 1. Remove air filter with air filter support.
– Take off air filter from air filter support.

S04548-10

11.25 Cleaning the air filter and air filter box

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work
– Remove the air filter box cover. ( p. 54)
– Remove the air filter. ( p. 56)
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it
to dry properly.
Air filter cleaner ( p. 122)

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.
K00518-01
Oil for foam air filter ( p. 122)
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.

56
 SERVICE WORK ON THE CHASSIS 11

Finishing work
– Install the air filter. ( p. 57)
– Install the air filter box cover. ( p. 55)

11.26 Installing the air filter

Main work
– Mount the clean air filter on the air filter support.
– Grease the air filter in area A.
Long-life grease ( p. 122)

102178-10

– Insert the air filter and position the top retaining pin 1 in bush-
ing B .
The air filter is correctly positioned.
– Secure the bottom retaining pin with holding tab 2.
Info
If the air filter is not mounted correctly, dust and dirt may
enter the engine and result in damage.
S04549-10

Finishing work
– Install the air filter box cover. ( p. 55)

11.27 Preparing air filter box cover for securing

Preparatory work
– Remove the air filter box cover. ( p. 54)
Main work
– Drill a hole at marking A.
Guideline
Diameter 6 mm (0.24 in)

S02308-10

Finishing work
– Install the air filter box cover. ( p. 55)

57
11 SERVICE WORK ON THE CHASSIS

11.28 Removing the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.

– Remove screws 1 with the washers.

– Pull off the main silencer from the manifold at exhaust sleeve 2.

S04550-10

11.29 Installing the main silencer

– Position the main silencer in exhaust sleeve 1.
– Mount and tighten screws 2 with the washers.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

S04551-10

11.30 Changing the glass fiber yarn filling in the main silencer

Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.

Info
Over time, the fibers of the rock wool escape into the air, and the main silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.

Preparatory work
– Remove the main silencer. ( p. 58)

58
 SERVICE WORK ON THE CHASSIS 11

Main work
– Remove screws 1. Pull out inner tube 2.
– Remove the glass fiber yarn filling 3 from the inner tube.
– Clean the parts that need to be reinstalled and check for damage.
– Fit the new glass fiber yarn filling 3 into the inner tube.
– Slide outer tube 4 over the inner tube with the new glass fiber
yarn filling.
– Mount and tighten all screws 1.
Guideline
Screws on main M5 7 Nm (5.2 lbf ft)
silencer

H01759-10

Finishing work
– Install the main silencer. ( p. 58)

11.31 Removing the fuel tank

Danger
Fire hazard Fuel 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 poisoning Fuel 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. 53)
– Turn the knurled screw on the fuel tap all the way clockwise.

59
11 SERVICE WORK ON THE CHASSIS

Main work
– Pull off the fuel hose.

Info
Remaining fuel may flow out of the fuel hose.

– Remove screws 1.

S04552-10

– Remove screw 2 with the rubber bushing.

– Pull the fuel tank breather hose off the fuel tank lid.

S04553-10

– Pull both spoilers laterally off the radiator and take off the fuel tank
upwards.

S04554-10

11.32 Installing the fuel tank

Danger
Fire hazard Fuel 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 poisoning Fuel 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.

60
 SERVICE WORK ON THE CHASSIS 11

Main work
– Check the throttle cable routing. ( p. 66)
– Position the fuel tank and fit the two spoilers laterally to the radia-
tor.
– Make sure that no cables or throttle cables are trapped or damaged.

S04554-11

– Attach the fuel tank breather hose.

– Mount and tighten screw 1 with the rubber bushing.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

S04553-11

– Mount and tighten screws 2.

Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Connect the fuel hose.

S04552-11

Finishing work
– Mount the seat. ( p. 54)

11.33 Checking the chain for dirt

– Check the chain for heavy soiling.
» If the chain is very dirty:
– Clean the chain. ( p. 62)

400678-01

61
11 SERVICE WORK ON THE CHASSIS

11.34 Cleaning the chain

Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Info
The service life of the chain depends largely on its maintenance.

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
Chain cleaner ( p. 122)
– After drying, apply chain spray.
Off-road chain spray ( p. 122)

400725-01

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

11.35 Checking the chain tension

Warning
Danger of accidents Incorrect 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 bear-
ings 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. 42)

62
 SERVICE WORK ON THE CHASSIS 11

Main work
– Pull the chain at the end of the chain sliding piece upward to mea-
sure chain tension A
.
Guideline
Lower chain section 1 must be taut.
Info
Chain wear is not always even, so you should repeat this
K01197-10 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. 63)
Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

11.36 Adjusting the chain tension

Warning
Danger of accidents Incorrect 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 bear-
ings 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. 42)
– Check the chain tension. ( p. 62)
Main work
– Loosen nut 1.
– Loosen nuts 2.
– Adjust the chain tension by turning adjusting screws 3 left and
right.
Guideline
Chain tension 55 … 58 mm (2.17 … 2.28 in)
Turn adjusting screws 3 on the left and right so that the mark-
ings on the left and right chain adjusters are in the same position
relative to reference marks A . The rear wheel is then correctly
aligned.
– Tighten nuts 2.
– Make sure that chain adjusters 4 are fitted correctly on adjusting
screws 3
.
– Tighten nut 1.
Guideline
H00016-10
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

63
11 SERVICE WORK ON THE CHASSIS

Info
The wide adjustment range of the chain adjusters (32 mm
(1.26 in)) enables different secondary ratios with the same
chain length.
Chain adjusters 4 can be turned by 180°.

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
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.

Info
The engine sprocket, rear sprocket, and chain
should always be replaced together.
400227-01

– Pull on the top section of the chain with the specified weight A.
Guideline
Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.)
ment
– Measure distance B 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.

Maximum distance B from 272 mm (10.71 in)

18 chain rollers at the longest
chain section
» If distance B is greater than the specified measurement:
– Change the drivetrain kit.

Info
400987-10
When a new chain is mounted, the rear sprocket
and engine sprocket should also be changed.
New chains wear out faster on an old, worn rear
sprocket or engine sprocket.

64
 SERVICE WORK ON THE CHASSIS 11

– 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 10 Nm (7.4 lbf ft)
sliding guard Loctite®243™

V01528-10

– Check the chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the
chain sliding piece:
– Change the chain sliding piece.
– 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 15 Nm (11.1 lbf ft)
piece

K01199-10

– Check the chain guide with a slide gage for dimension C.

Minimum thickness C of the 6 mm (0.24 in)
chain guide
» If the measured value is less than the specification:
– Change the chain guide.

402421-10

65
11 SERVICE WORK ON THE CHASSIS

– 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 10 Nm (7.4 lbf ft)
chassis
Remaining nuts, M6 10 Nm (7.4 lbf ft)
chassis
102192-01

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

11.38 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.

S02306-01

11.39 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.

S02305-01

11.40 Checking the throttle cable routing

Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specification.

Preparatory work
– Remove the seat. ( p. 53)
– Turn the knurled screw on the fuel tap all the way clockwise.
– Remove the fuel tank. ( p. 59)

66
 SERVICE WORK ON THE CHASSIS 11

Main work
– Check the throttle cable routing.
The throttle cable must be routed along the back of the handle-
bar, to the right of the frame, above the fuel tank bracket, and
to the carburetor. The throttle cable must be secured on the fuel
tank bracket with a rubber strap.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.

S04555-10

Finishing work
– Install the fuel tank. ( p. 60)
– Mount the seat. ( p. 54)

11.41 Checking the rubber grip

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

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.
401197-01
» If a rubber grip is damaged or worn:
– Change the rubber grip.
– Check that screw 1 is firmly seated.
Guideline
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™

Diamond A must be located at the top.

102245-10

67
11 SERVICE WORK ON THE CHASSIS

11.42 Adjusting the basic position of the clutch lever

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

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.
F00009-11 Turn the adjusting screw by hand only, and do not apply any
force.
Do not make any adjustments while riding.

11.43 Checking/correcting the fluid level of the hydraulic clutch

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

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.

– Move the clutch fluid reservoir mounted on the handlebar to a hori-

zontal position.
– Remove screws1.
– Remove cover 2 with membrane 3.
– Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the fluid level does not meet specifications:
H01330-10 – Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– Position the cover with the membrane. Mount and tighten the
screws.

68
 SERVICE WORK ON THE CHASSIS 11

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

11.44 Changing the hydraulic clutch fluid

Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective 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 hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and 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 hori-

zontal position.
– Remove screws1.
– Remove cover 2 with membrane 3.

H01330-10

– Fill bleeding syringe 4 with the appropriate hydraulic fluid.

Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– On the clutch slave cylinder, remove bleeder screw 5 and mount
bleeding syringe 4.

S04556-10

69
11 SERVICE WORK ON THE CHASSIS

– Now inject the liquid into the system until it emerges from the drill
hole 6 of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir to
prevent overflow.
– Remove the bleeding syringe. Mount and tighten screws bleeder
screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
L01223-10 Fluid level below container rim 4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the
screws.

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

70
 BRAKE SYSTEM 12

12.1 Checking the free travel of the hand brake lever

Warning
Danger of accidents The 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.

– Push the hand brake lever forward and check free travel A.
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
» If the free travel does not match the specification:
– Adjust the basic position of the hand brake lever. ( p. 71)

S04557-10

12.2 Adjusting the basic position of the hand brake lever

– Check the free travel of the hand brake lever. ( p. 71)
– Adjust the basic position of the hand brake lever to your hand size
by turning adjusting screw 1.

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.
S04557-11 The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.

12.3 Checking the brake discs

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

– Check the front and rear brake disc thickness at multiple points for
the dimension .A
Info
Wear reduces the thickness of the brake disc around the
contact surface of the brake linings.

Brake discs - wear limit

front 2.5 mm (0.098 in)
H00938-10
rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:

71
12 BRAKE SYSTEM

– 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.

12.4 Checking the front brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops 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 accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)

Preparatory work
– Check the front brake linings. ( p. 74)
Main work
– Move the brake reservoir mounted on the handlebar to a horizontal
position.
– Check the brake fluid level in level viewer 1.
» If the brake fluid level has dropped below the marking A:
– Add front brake fluid. ( p. 72)

S04558-10

12.5 Adding front brake fluid

Warning
Danger of accidents An 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.)

72
 BRAKE SYSTEM 12

Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, 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. 74)
Main work
– Move the brake reservoir mounted on the handlebar to a horizontal
position.
– Remove screws 1.
– Take off cover 2 with membrane 3.
– Add brake fluid to level A.
Guideline
Level A (brake fluid level 5 mm (0.2 in)
below reservoir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 120)

– Position the cover with the membrane. Mount and tighten the
screws.

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

K00470-10

73
12 BRAKE SYSTEM

12.6 Checking the front brake linings

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

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the brake linings of the front brake. ( p. 74)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the brake linings of the front brake. ( p. 74)
H01333-10

12.7 Changing the brake linings of the front brake

Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy-
cles workshop will be glad to help.)

Warning
Skin irritation Brake fluid 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 accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

74
 BRAKE SYSTEM 12

Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the
brake linings, and 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 hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between 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 hori-

zontal position.
– Remove screws 1.
– Take off cover 2 with membrane 3.
– 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.

K00469-10 Info
Make sure that you do not press the brake caliper against
the spokes when pushing back the brake pistons.

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

101737-10

– Check that spring plate 6 in the brake caliper and brake pad slid-
ing plate 7 in the brake caliper bracket are seated correctly.

100397-01

75
12 BRAKE SYSTEM

– Insert the new brake linings, insert pin, and mount cotter pins.

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.

101738-01

– Correct the brake fluid level to level A.

Guideline
Level A (brake fluid level 5 mm (0.2 in)
below reservoir rim)

Brake fluid DOT 4 / DOT 5.1 ( p. 120)

– Position the cover with the membrane. Mount and tighten the
screws.
K00521-10
Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.

12.8 Checking the free travel of foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.

– Disconnect spring 1.
– Move the foot brake lever back and forth between the end stop
and the contact to the foot brake cylinder piston and check free
travel .A
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.
402026-10
( p. 77)
– Reconnect spring 1.

76
 BRAKE SYSTEM 12

12.9 Adjusting the basic position of the foot brake lever

Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel 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
– Loosen nut 2 and, with push rod 3, turn it back until you have
maximum free travel.
– To adjust the basic position of the foot brake lever to individual
requirements, loosen nut 4 and turn screw 5 accordingly.

Info
The range of adjustment is limited.

– Turn push rod 3 accordingly until you have free travel A. 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)
– Hold screw 5 and tighten nut 4.
Guideline
Nut, foot brake lever M8 20 Nm (14.8 lbf ft)
stop
K00523-10 – Hold push rod 3 and tighten nut 2.
Guideline
Remaining nuts, chas- M6 10 Nm (7.4 lbf ft)
sis
– Attach spring 1.

12.10 Checking the rear brake fluid level

Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops 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 accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)

Preparatory work
– Check the brake linings of the rear brake. ( p. 79)

77
12 BRAKE SYSTEM

Main work
– Stand the vehicle upright.
– Check the brake fluid level in level viewer 1.
» If the brake fluid has dropped below marking A:
– Add rear brake fluid. ( p. 78)

S04559-10

12.11 Adding rear brake fluid

Warning
Danger of accidents An 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 irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the
eyes.
– If brake fluid spills on to your clothing, change the clothing.

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, 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 brake linings of the rear brake. ( p. 79)

78
 BRAKE SYSTEM 12

Main work
– Stand the vehicle upright.
– Remove screw cap 1 with membrane 2 and the O-ring.
– Add brake fluid to level A.
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– Mount the screw cap with the membrane and the O-ring.

Info
S04561-10
Clean up overflowed or spilled brake fluid immediately with
water.

12.12 Checking the brake linings of the rear brake

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

– Check the brake linings for minimum thickness A.

Minimum thickness A ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

– Change the rear brake linings. ( p. 79)
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the rear brake linings. ( p. 79)
M01180-10

12.13 Changing the rear brake linings

Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy-
cles workshop will be glad to help.)

Warning
Skin irritation Brake fluid 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.

79
12 BRAKE SYSTEM

Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule.
(Your authorized GASGAS Motorcycles workshop will be glad to help.)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, 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 corrodes paint.
Only use clean brake fluid from a sealed container.

– Position the vehicle vertically.

– Remove screw cap 1 with membrane 2 and the O-ring.

S04560-10

– Manually press the brake caliper toward the brake disc to push back
the brake piston. Ensure that brake fluid does not flow out of the
brake fluid reservoir; extract some if necessary.

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

– Remove cotter pins 3, pull out pin 4, and remove the brake lin-
101740-10 ings.
– Clean the brake caliper and the brake caliper bracket.
– Check that spring plate 5 in the brake caliper and brake pad slid-
ing plate 6 in the brake caliper bracket are seated correctly.

Info
The arrow on the spring plate points in the direction of rota-
tion of the brake disc.

101741-10

80
 BRAKE SYSTEM 12

– Insert the new brake linings, insert pin 4, and mount cotter
pins3 .

Info
Always change the brake linings in pairs.
Make sure that decoupling plate 7is mounted on the pis-
ton side brake lining.

– Operate the foot brake lever repeatedly until the brake linings are in
M01181-10 contact with the brake disc and there is a pressure point.
– Correct brake fluid level to marking A.
Brake fluid DOT 4 / DOT 5.1 ( p. 120)
– Mount and tighten screw cap 1 with membrane 2 and the O-
ring.

Info
Use water to immediately clean up any brake fluid that has
overflowed or spilled.
K01185-10

81
13 WHEELS, TIRES

13.1 Removing the front wheel

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)
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.

H01337-10

– Loosen screw 1 by several rotations.

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

K00454-10

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

– Hold the front wheel and remove the wheel spindle. Take the front
H01340-10 wheel out of the fork.

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

– Remove spacers 3.

H00934-10

82
 WHEELS, TIRES 13

13.2 Installing the front wheel

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

– Check the wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn:
– Change front wheel bearing.
– Clean and grease shaft seal rings 1 and contact surfaces A of the
spacers.
Long-life grease ( p. 122)
– Insert the spacers.
H00935-10
– Clean and grease the wheel spindle.
Long-life grease ( p. 122)

– Position the front wheel and insert the wheel spindle.

The brake linings are correctly positioned.
– Mount and tighten screw 2.
Guideline
Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft)
spindle
– Operate the hand brake lever several times until the brake linings
are seated correctly against the brake disc.
K00454-11
– Remove the motorcycle from the lift stand. ( p. 42)
– Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
– Tighten screws 3.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)

13.3 Removing the rear wheel

Preparatory work
– Raise the motorcycle with a lift stand. ( p. 42)

83
13 WHEELS, TIRES

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.

– Remove nut 1.
– Take off chain adjuster 2 . Pull out wheel spindle 3 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.

Warning
H00027-10 Danger of accidents Damaged brake discs reduce the
braking effect.
– Always lay the wheel down in such a way that the brake
disc is not damaged.

– Hold the rear wheel and remove the wheel spindle. Take the rear
wheel out of the link fork.

Info
Do not operate the foot brake lever when the rear wheel is
removed.

– Remove spacers 4.

H03002-10

13.4 Installing the rear wheel

Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.

84
 WHEELS, TIRES 13

Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the rear wheel bearing.
– Clean and grease shaft seal rings 1 and contact surfaces A of the
spacers.
Long-life grease ( p. 122)
– Insert the spacers.
H03001-10
– Clean and grease the wheel spindle.
Long-life grease ( p. 122)

– Position rear wheel and insert wheel spindle 2.

The brake linings are correctly positioned.
– Mount the chain.

H00006-10

– 3. Mount nut 4, but do not tighten it yet.

Position chain adjuster
– Make sure that chain adjusters 3 are fitted correctly on adjusting
screws 5.
– Check the chain tension. ( p. 62)
– Tighten nut 4 .
Guideline
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

Info
The wide adjustment range of the chain adjusters (32 mm
(1.26 in)) enables different secondary ratios with the same
chain length.
Chain adjusters 3 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.

H00007-10

Finishing work
– Remove the motorcycle from the lift stand. ( p. 42)

85
13 WHEELS, TIRES

13.5 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 motorcy-
cle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

– 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.

400602-10

– Check the tire age.

Info
The tire date of manufacture is usually contained in the tire
label and is indicated by the last four digits of the DOT num-
ber. The first two digits indicate the week of manufacture
and the last two digits the year of manufacture.
GASGAS Motorcycles recommends that the tires be changed
after five years at the latest, regardless of the actual wear.
H01144-01
» If the tires are more than five years old:
– Change the tires.

13.6 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.

– Remove the protection cap.

– Check the tire pressure when the tires are cold.
Offroad tire pressure
front 1.0 bar (15 psi)
rear 1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
400695-01 – Mount the protection cap.

86
 WHEELS, TIRES 13

13.7 Checking spoke tension

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

– 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 differ-
ent 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 M4.5 6 Nm (4.4 lbf ft)
wheel
Spoke nipple, rear M4.5 6 Nm (4.4 lbf ft)
wheel

Torque wrench kit (58429094000)

87
14 COOLING SYSTEM

14.1 Cooling system

Water pump 1in the engine ensures forced circulation of the coolant.
The pressure resulting from the warming of the cooling system is reg-
ulated by a valve in radiator cap 2
. 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
S04562-10 reduce the cooling effect.

14.2 Radiator cover

Info
Do not use radiator covers in difficult operating conditions.

The radiator cover is mounted in front of the left radiator between the
radiator shield and radiator.
The radiator cover keeps the coolant temperature in the correct range.
Coolant temperature 65 … 70 °C (149 … 158 °F)

K00459-01

The radiator cover is installed in front of the left radiator, depending on

the ambient temperature.

Full radiator cover1 < 7 °C (< 45 °F)

Half radiator cover 2 7 … 16 °C (45 … 61 °F)

No radiator cover > 16 °C (> 61 °F)

M01121-10
Info
Do not use both radiator covers at the same time.

14.3 Installing the radiator cover

– Remove screws 1.
– Remove screws 2.
– Take off radiator shield 3.

K00460-10

88
 COOLING SYSTEM 14

– Position the matching radiator cover ( p. 88).

The larger holding lug is located at the top left.

Info
Do not use both radiator covers at the same time.

H01341-10

– 3.
Position radiator shield
– Mount and tighten screws 2.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Mount and tighten screws 1.
Guideline
K00460-10 Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

14.4 Removing the radiator cover

– Remove screws 1.
– Remove screws 2.
– Take off radiator shield 3.
– Remove the radiator cover.
– 3.
Position radiator shield
– Mount and tighten screws 2.
Guideline
K00460-10 Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis
– Mount and tighten screws 1.
Guideline
Remaining screws, M6 10 Nm (7.4 lbf ft)
chassis

14.5 Checking the antifreeze and coolant level

Warning
Danger of scalding During 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.

89
14 COOLING SYSTEM

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with 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.
– 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.
400243-10

Coolant level A above the 10 mm (0.39 in)

radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
Coolant ( p. 120)
– Mount the radiator cap.

14.6 Checking the coolant level

Warning
Danger of scalding During 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 poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with 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.

90
 COOLING SYSTEM 14

– Stand the motorcycle upright on a horizontal surface.

– Remove the radiator cap.
– Check the coolant level in the radiator.

Coolant level A above the 10 mm (0.39 in)

radiator fins
» If the coolant level does not match the specified value:
– Correct the coolant level.
400243-10 Coolant ( p. 120)
– Mount the radiator cap.

14.7 Draining the coolant

Warning
Danger of scalding During 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 poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with 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.
– Remove screw 1. Take off radiator cap 2.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Drain plug, water M6 10 Nm (7.4 lbf ft)
pump cover

S04562-11

91
14 COOLING SYSTEM

14.8 Refilling with coolant

Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately 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.

– Make sure that screw 1 is tightened.

– Position the motorcycle upright.
– Completely fill the radiator with coolant.
Coolant ( p. 120)

S04563-10

– Loosen screw 2 until coolant escapes without bubbles.

– Mount and tighten screw 2.
Guideline
Bleeder screw, cylinder M6 8 Nm (5.9 lbf ft)
head
– Completely fill the radiator with coolant.
Coolant ( p. 120)
S04564-10

– Mount radiator cap 3.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
K01179-10 ning the engine in an enclosed space.

– Allow the engine to warm up and cool down again.

– Check the coolant level. ( p. 90)

92
 COOLING SYSTEM 14

14.9 Changing the coolant

Warning
Danger of scalding During 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 poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with 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.
– Remove screw 1. Take off radiator cap 2.
– Place an appropriate container under the water pump cover.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump M6 10 Nm (7.4 lbf ft)
cover

S04562-11
– Position the motorcycle upright.
– Completely fill the radiator with coolant.
Coolant ( p. 120)

– Loosen screw 3 until coolant escapes without bubbles.

– Mount and tighten screw 3.
Guideline
Bleeder screw, cylinder M6 8 Nm (5.9 lbf ft)
head
– Completely fill the radiator with coolant.
Coolant ( p. 120)
S04564-11

93
14 COOLING SYSTEM

– Mount radiator cap 2.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
S04253-10 ning the engine in an enclosed space.

– Allow the engine to warm up and cool down again.

– Check the cooling system for leaks.
– Check the coolant level. ( p. 90)

94
 TUNING THE ENGINE 15

15.1 Checking the play in the throttle cable

– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Turn the throt-
tle grip back and forth slightly and determine the play in throttle
cable A
.
Play in throttle cable 2 … 3 mm (0.08 … 0.12 in)
» If the throttle cable play does not meet the specified value:
– Adjust the play in the throttle cable. ( p. 95)

400192-11
Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.

– Start the engine and let it run at idle speed. Move the handlebar to
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. 95)

15.2 Adjusting the play in the throttle cable

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

Preparatory work
– Remove the seat. ( p. 53)
– Turn the knurled screw on the fuel tap all the way clockwise.
– Remove the fuel tank. ( p. 59)
– Check the throttle cable routing. ( p. 66)
Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1.
– Ensure that the throttle cable sleeve is pushed all the way into bar-
rel adjuster 2
.
– Loosen nut 3.

S04565-10

95
15 TUNING THE ENGINE

– Turn barrel adjuster 2so that there is play A in the throttle

cable at the throttle grip.
Guideline
Play in throttle cable 2 … 3 mm (0.08 … 0.12 in)
– Tighten nut 3.
– Slide on sleeve 1.

400192-11

Finishing work
– Check the throttle grip for smooth operation.
– Install the fuel tank. ( p. 60)
– Mount the seat. ( p. 54)
– Check the play in the throttle cable. ( p. 95)

15.3 Carburetor tuning

Effects of carburetor tuning

H01400-01

The different carburetor components must be tuned both to one another and for the use intended.
Main jet MJ
The main jet MJ has the greatest influence with the throttle slide open (full throttle).
If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger
main jet needs to be used. If the insulator is dark brown or sooty, a smaller main jet needs to be used.
Needle position POS
The needle position has the greatest influence in the mid throttle slide range.
If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine
knocks when accelerating at the full power rpm range, the jet needle must be raised.
Cylindrical part of the needle CYL
The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.

96
 TUNING THE ENGINE 15

Idling jet IJ
The idling jet has the greatest influence in the low to mid throttle slide range.
If the engine stutters at idle speed or when accelerating with a partially open throttle slide, a smaller idling jet must be
used. If the engine knocks in this power range, then a larger idling jet must be used.
Idle air adjusting screw open ASO
The idle air adjusting screw has the greatest influence at idle speed.
Influence of throttle slide adjustment

K00495-01

The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip
position have only minimal influence.
When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the great-
est influence.

K00496-01

When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first
cylindrical part of the needle is less.
When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and
the idling jet is only minimal.

K00497-01

When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only
minimal influence.
When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only
minimal influence.

Needle overview
The jet needles available are shown in the following table.

97
15 TUNING THE ENGINE

402674-01

Column 2 corresponds to a needle in the standard position.

Column 1 corresponds to a needle which is half a clip leaner.
Column 3 corresponds to a needle which is half a clip richer.
Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical
part of the needle, the richer the mixture preparation. The larger the diameter of the first cylindrical part of the needle, the
leaner the mixture preparation. The first cylindrical part of the needle has the greatest influence in the lowest load range.

Info
The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1
corresponds to the leanest. The optimal carburetor tuning is shown under the respective model.

Clip position
1... 5 Clip position from above
The five possible clip positions are shown here.
The carburetor tuning depends on the defined ambient and operating
conditions.

B00075-10

15.4 Carburetor – idle setting

The idle setting of the carburetor significantly influences the vehicle’s
starting behavior, the stability of the idle speed, and the vehicle’s
response when accelerating. This means that an engine with a correctly
set idle speed will be easier to start than one with an incorrectly set idle
speed.

Info
The carburetor and its components are subject to increased
wear caused by engine vibration. Wear can result in malfunc-
402799-10 tioning.

The factory setting for the carburetor is set for the following values.
Height above sea level 301 … 750 m (988 … 2,461 ft)
Ambient temperature 16 … 24 °C (61 … 75 °F)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
( p. 121)

The idle speed is adjusted with adjusting screw 1 .

The idle mixture is adjusted using the idle air adjusting screw 2.

98
 TUNING THE ENGINE 15

15.5 Carburetor - adjusting the idle speed

– Screw in idle air adjusting screw 1 all the way and turn it to the
specified basic setting.

Info
The basic adjustment is shown under the respective model.

– Run the engine until warm.

Guideline
Warming-up phase ≥ 5 min
402799-11

Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.

– Adjust the idle speed with adjusting screw 2.

Guideline
Choke function deactivated – The choke lever is pushed in to the
stop. ( p. 16)
Idle speed 1,400 … 1,500 rpm
– Turn idle air adjusting screw 1 slowly in a clockwise direction until
the idle speed begins to fall.
– Note the position and turn the idle air adjusting screw slowly coun-
terclockwise until the idle speed again begins to fall.
– Adjust to the point between these two positions with the highest
idle speed.

Info
If there is a big engine speed rise, reduce the idle speed to a
normal level and repeat the above steps.
If the procedure described here does not lead to satisfactory
results, the cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end with-
out any change of engine speed, mount a smaller idling jet.
After changing the jet, start from the beginning with the
adjusting steps.
Following extreme air temperature or altitude changes,
adjust the idle speed again.

99
15 TUNING THE ENGINE

15.6 Plug-in connector of ignition timing map adjustment

Plug-in connector 1of the ignition timing map adjustment is located
on the frame under the fuel tank.
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.

S04566-10

15.7 Changing the ignition timing map

Switching the ignition timing map from Performance to Soft
– Disconnect plug-in connector 1
of the ignition timing map adjustment. (Figure S04566-10 p. 100)
Soft – better rideability
Switching the ignition timing map from Soft to Performance
– Join plug-in connector 1of the ignition timing map adjustment. (Figure S04566-10 p. 100)
Performance – better performance

15.8 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.

– Sit on the vehicle in the riding position and determine distance A

between the upper edge of your boot and the shift lever.
Distance between shift lever 10 … 20 mm (0.39 … 0.79 in)
and upper edge of boot
» If the distance does not meet specifications:
– Adjust the basic position of the shift lever. ( p. 100)

400692-10

15.9 Adjusting the basic position of the shift lever

– Remove screw 1 with the washers and take off shift lever 2.

401950-12

100
 TUNING THE ENGINE 15

– Clean gear teeth A of the shift lever and shift shaft.

– Mount the shift lever on the shift shaft in the required position and
engage gearing.

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

401951-10 – Mount and tighten screw 1 with washers.

Guideline
Screw, shift lever M6 14 Nm (10.3 lbf ft)
Loctite®243™

101
16 SERVICE WORK ON THE ENGINE

16.1 Emptying the carburetor float chamber

Danger
Fire hazard Fuel 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 poisoning Fuel 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 hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Info
Carry out work with a cold engine.
Water in the float chamber results in malfunctioning.

Preparatory work
– Turn the knurled screw on the fuel tap all the way clockwise.
Fuel no longer flows from the fuel tank to the carburetor.
Main work
– Place a cloth under the carburetor to capture the draining fuel.
– Remove screw plug 1.
– Fully drain the fuel.
– Mount and tighten the screw plug.

K00472-10

102
 SERVICE WORK ON THE ENGINE 16

16.2 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.
Main work
– Remove gear oil level monitoring screw 1.
– 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. 104)
– Mount and tighten the gear oil level monitoring screw.
S04567-10
Guideline
Screw, gear oil level M6 8 Nm (5.9 lbf ft)
monitoring

16.3 Changing the gear oil

Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

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

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

103
16 SERVICE WORK ON THE ENGINE

Main work
– Remove gear oil drain plug 1 with magnet.
– Remove gear oil drain plug 2.
– Let the gear oil drain fully.
– Thoroughly clean the gear oil drain plug.
– Clean the sealing surface on the engine.
– Mount and tighten gear oil drain plug 1 with the magnet and a
new seal ring.
Guideline
Gear oil drain plug with M12x1.5 20 Nm (14.8 lbf ft)
magnet
– Mount and tighten gear oil drain plug 2 with a new seal ring.
Guideline
Gear oil drain plug M10x1 15 Nm (11.1 lbf ft)

S04568-10

– Remove filler plug 3 with the O-ring, and fill up with gear oil.
Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50)
( p. 120)
– Mount and tighten the filler plug together with the O-ring.

Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
K00530-10
– 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 it for leaks.

Finishing work
– Check the gear oil level. ( p. 103)

16.4 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.

104
 SERVICE WORK ON THE ENGINE 16

Main work
– Remove gear oil level monitoring screw 1.

S04567-10

– Remove filler plug 2 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. 120)
– Mount and tighten the gear oil level monitoring screw.
Guideline
Screw, gear oil level M6 8 Nm (5.9 lbf ft)
401955-11
monitoring
– Mount and tighten filler plug 2 together with the O-ring.
Finishing work

Danger
Danger of poisoning Exhaust gases are toxic and inhaling
them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when
running the engine.
– Use effective exhaust extraction when starting or run-
ning the engine in an enclosed space.

– Start the engine and check it for leaks.

105
17 CLEANING, CARE

17.1 Cleaning the motorcycle

Note
Material damage Components 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)

Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli-
cable regulations.

Info
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. 122)

Info
Use warm water containing normal motorcycle cleaner and
401061-01 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.
– Empty the carburetor float chamber. ( p. 102)
– Remove the closure of the exhaust system.

Warning
Danger of accidents Moisture 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. 62)

106
 CLEANING, CARE 17

– Treat bare metal (except for brake discs and the exhaust system)
with a corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 122)
– 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. 122)

107
18 STORAGE

18.1 Storage

Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you 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 neces-
sary, you should do this during the storage period (less workshop overload). In this way, you can avoid long work-
shop waiting times at the start of the new season.

– When refueling for the last time before taking the motorcycle out of
service, add fuel additive.
Fuel additive ( p. 122)
– Refuel. ( p. 28)
– Clean the motorcycle. ( p. 106)
– Change the gear oil. ( p. 103)
– Check the antifreeze and coolant level. ( p. 89)
– Empty the carburetor float chamber. ( p. 102)
401058-01
– Check tire pressure. ( p. 86)
– Store the vehicle in a dry location that is not subject to large fluctua-
tions in temperature.

Info
GASGAS Motorcycles recommends jacking up the motorcy-
cle.

– Raise the motorcycle with a lift stand. ( p. 42)

– Cover the vehicle with a tarp or a similar cover that is permeable to
air.

Info
Do not use non-porous materials since they prevent humid-
ity 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 pro-
duced during combustion will condense, causing engine
parts and the exhaust system to rust.

108
 STORAGE 18

18.2 Preparing for use after storage

– Remove the motorcycle from the lift stand. ( p. 42)
– Perform checks and maintenance measures when preparing for use.
( p. 25)
– Take a test ride.

401059-01

109
19 TROUBLESHOOTING

Faults Possible cause Action

Engine turns but does not start Operating error – Carry out start procedure. ( p. 25)
The motorcycle has been in disuse – Empty the carburetor float chamber.
for an extended period and old ( p. 102)
fuel is in the float chamber
Fuel supply interrupted – Check the fuel tank breather.
– Clean the fuel tap.
– Check/adjust the carburetor components.
Spark plug sooty or wet – Clean and dry the spark plug and spark
plug connector, or change if necessary.
Plug gap of spark plug too wide – Adjust plug gap.
Guideline
Spark plug electrode gap
0.60 mm (0.0236 in)
Fault in ignition system – Check the ignition system.
Short-circuit cable in wiring har- – Check the stop button.
ness frayed, stop button faulty
The connector or ignition coil is – Clean the connector and treat it with con-
loose or oxidized tact spray.
Water in carburetor or jets – Check/set the carburetor components.
blocked
Engine has no idle speed Idling jet blocked – Check/set the carburetor components.
Adjusting screws on carburetor – Carburetor - adjust the idle speed.
distorted ( p. 99)
Spark plug defective – Change the spark plug.
Ignition system defective – Check the ignition coil.
– Check the spark plug connector.
Engine does not speed up Carburetor running over because – Check/set the carburetor components.
float needle dirty or worn
Loose carburetor jets – Check/set the carburetor components.
Fault in ignition system – Check the ignition system.
Engine has too little power Fuel supply interrupted – Check the fuel tank breather.
– Clean the fuel tap.
– Check/adjust the carburetor components.
Air filter very dirty – Clean the air filter and air filter box.
( p. 56)
Exhaust system leaky, deformed – Check exhaust system for damage.
or too little glass fiber yarn filling – Change the glass fiber yarn filling in the
in main silencer main silencer. ( p. 58)
Fault in ignition system – Check the ignition system.
Diaphragm or reed valve housing – Check the diaphragm and reed valve hous-
damaged ing.
Engine stalls or is popping into the Lack of fuel – Turn the knurled screw on the fuel tap all
carburetor the way counterclockwise.
– Refuel. ( p. 28)
Engine takes in bad air – Check the intake flange and carburetor for
tightness.
The connector or ignition coil is – Clean the connector and treat it with con-
loose or oxidized tact spray.

110
 TROUBLESHOOTING 19

Faults Possible cause Action

Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.
– Check the coolant level. ( p. 90)
Too little air stream – Switch off engine when stationary.
Radiator fins very dirty – Clean the radiator fins.
Foam formation in cooling system – Drain the coolant. ( p. 91)
– Refill with coolant. ( p. 92)
Damaged cylinder head or cylin- – Check the cylinder head and cylinder head
der head gasket gasket.
Bent radiator hose – Change the radiator hose.
White smoke emission (steam in Damaged cylinder head or cylin- – Check the cylinder head and cylinder head
exhaust gas) der head gasket gasket.
Gear oil exits at the vent hose Too much gear oil added – Check the gear oil level. ( p. 103)
Water in the gear oil Damaged radial shaft seal ring or – Check the radial shaft seal ring and the
water pump water pump.

111
20 TECHNICAL DATA

20.1 Engine
Design 1-cylinder 2-stroke engine, water-cooled, with reed intake
and exhaust control
Displacement 124.8 cm³ (7.616 cu in)
Stroke 54.5 mm (2.146 in)
Bore 54 mm (2.13 in)
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Cast aluminum
Piston rings 2 half keystone rings
X (upper edge of piston to upper edge of cylinder) 0 … 0.10 mm (0 … 0.0039 in)
Z (height of control flap) 36.5 mm (1.437 in)
Primary transmission 23:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6-gear transmission, claw shifted
Transmission ratio
first-gear 14:32
second-gear 15:30
third-gear 17:28
fourth-gear 19:27
fifth-gear 19:23
sixth-gear 22:24
Ignition Contactless controlled fully electronic ignition with digital
ignition adjustment
Spark plug NGK BR9 ECMVX
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Kick starter system

20.2 Engine tightening torques

Screw, inner membrane sheets EJOTDELTA PT® 35x25 1 Nm (0.7 lbf ft)
Screw, membrane support plate EJOTDELTA PT® 30x12 1 Nm (0.7 lbf ft)
Screw, outer membrane sheets EJOTDELTA PT® 30x6 1 Nm (0.7 lbf ft)
Screw, clutch spring retainer M5 6 Nm (4.4 lbf ft)
Screw, control lever, exhaust control M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, crankshaft speed sensor M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, exhaust control cap M5 5 Nm (3.7 lbf ft)
Screw, exhaust control cover M5 4 Nm (3 lbf ft)
Screw, locking lever M5 6 Nm (4.4 lbf ft)
Loctite®243™
Screw, retaining bracket, rotary valve M5 6 Nm (4.4 lbf ft)
Loctite®2701™
Screw, stator M5 6 Nm (4.4 lbf ft)
Loctite®243™

112
 TECHNICAL DATA 20

Screw, water pump wheel M5 6 Nm (4.4 lbf ft)

Loctite®243™
Bleeder screw, cylinder head M6 8 Nm (5.9 lbf ft)
Drain plug, water pump cover M6 10 Nm (7.4 lbf ft)
Nut, adjusting screw, power valve M6 8 Nm (5.9 lbf ft)
Screw, alternator cover M6 8 Nm (5.9 lbf ft)
Screw, bearing retainer M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, clutch cover M6x20 10 Nm (7.4 lbf ft)
Screw, clutch cover M6x25 10 Nm (7.4 lbf ft)
Screw, clutch cover M6x30 10 Nm (7.4 lbf ft)
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)
Screw, control lever, exhaust control M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, engine case M6 10 Nm (7.4 lbf ft)
Screw, exhaust flange M6 10 Nm (7.4 lbf ft)
Screw, gear oil level monitoring M6 8 Nm (5.9 lbf ft)
Screw, intake flange/reed valve hous- M6 6 Nm (4.4 lbf ft)
ing
Screw, kick starter stop plate M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, outer clutch cover M6x20 8 Nm (5.9 lbf ft)
Screw, outer clutch cover M6x50 8 Nm (5.9 lbf ft)
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, shift lever M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, stop plate of exhaust control M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
Vacuum connection, housing breather M6 2 Nm (1.5 lbf ft)
Screw, cylinder head M7 18 Nm (13.3 lbf ft)
Nut, cylinder base M8 23 Nm (17 lbf ft)
Screw, cylinder base M8 10 Nm (7.4 lbf ft)
Screw, kick starter lever M8 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, engine sprocket M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Gear oil drain plug M10x1 15 Nm (11.1 lbf ft)
Nut, rotor M12x1 60 Nm (44.3 lbf ft)
Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft)
Spark plug M14x1.25 25 Nm (18.4 lbf ft)
Nut, primary gear wheel M16LHx1.5 130 Nm (95.9 lbf ft)
Loctite®243™
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)
Loctite®243™

113
20 TECHNICAL DATA

20.3 Carburetor
Carburetor type MIKUNI TMX 38
Carburetor identification number TMX 38 87
Needle position 2nd position from top
Jet needle 6BFY43‑71 (6BFY42‑71)
Main jet 500 (480, 490, 520, 540, 560)
Idling jet 35 (30 / 32.5 / 37.5 / 40)
Choke nozzle 80
Needle jet S‑7
Idle air adjusting screw
open 1.5 turns

20.3.1 Carburetor tuning

MIKUNI TMX 38
37 … 49 °C
−20 … −7 °C −6 … 5 °C 6 … 15 °C (43 16 … 24 °C 25 … 36 °C
ASL TEMP (99 …
(−4 … 19 °F) (21 … 41 °F) … 59 °F) (61 … 75 °F) (77 … 97 °F)
120 °F)
2,301 … ASO 1.5 2 2 2 1.5
IJ 35 32.5 30 30 30
3,000 m
NDL 43-71 43-71 43-71 43-71 42-71
(7,549 …
POS 2 2 2 2 2
9,843 ft) MJ 500 500 490 480 480
1,501 … ASO 2 1.5 2 2 2 1.5
IJ 37.5 35 32.5 30 30 30
2,300 m
NDL 43-71 43-71 43-71 43-71 43-71 42-71
(4,925 …
POS 2 2 2 2 2 2
7,546 ft) MJ 520 500 500 490 480 480
751 … ASO 1.5 2 1.5 2 2 2
IJ 35 37.5 35 32.5 30 30
1,500 m
NDL 42-71 43-71 43-71 43-71 43-71 43-71
(2,464 …
POS 3 2 2 2 2 2
4,921 ft) MJ 520 520 500 500 490 480
ASO 1.5 1.5 2 1,5 2 2
301 … IJ 37.5 35 37.5 35 32.5 30
750 m (988 NDL 42-71 42-71 43-71 43‑71 43-71 43-71
… 2,461 ft) POS 3 3 2 2 2 2
MJ 540 520 520 500 500 490
ASO 1.5 1.5 2 1.5 2 2
IJ 37.5 35 37.5 35 32.5 30
0 … 300 m
NDL 42-71 42-71 43-71 43-71 43-71 43-71
(0 … 984 ft)
POS 3 3 2 2 2 2
MJ 560 540 540 520 500 490

ASL Sea level

TEMP Temperature
ASO Idle air adjusting screw open
IJ Idling jet
NDL Needle
POS Needle position from top
MJ Main jet

114
 TECHNICAL DATA 20

Info
Do not use on sandy terrain.

20.3.2 Carburetor - basic setting for sandy surfaces

Idle air adjusting screw
Open 2 turns
Idling jet 37.5
Jet needle 6BFY42‑71
Needle position 3rd position from top
Main jet 580

Info
If the engine is not running smoothly, use a smaller main jet.

20.4 Capacities

20.4.1 Gear oil

Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 120)

20.4.2 Coolant
Coolant 1.2 l (1.3 qt.) Coolant ( p. 120)

20.4.3 Fuel
Total fuel tank capacity, approx. 7.5 l (1.98 US gal) Super unleaded (98 octane) mixed with
2-stroke engine oil (1:40) ( p. 121)

20.5 Chassis
Frame Central tube frame made of chrome molybdenum steel
tubing
Fork WP XACT AER
Shock absorber WP XACT 5750
Suspension travel
front 310 mm (12.2 in)
rear 300 mm (11.81 in)
Fork offset 22 mm (0.87 in)
Brake system Disc brakes, floating brake calipers
Brake discs - diameter
front 260 mm (10.24 in)
rear 220 mm (8.66 in)
Brake discs - wear limit
front 2.5 mm (0.098 in)
rear 3.5 mm (0.138 in)
Offroad tire pressure
front 1.0 bar (15 psi)
rear 1.0 bar (15 psi)

115
20 TECHNICAL DATA

Secondary ratio 13:51

Chain 5/8 x 1/4"
Rear sprockets available 48, 50, 52
Steering head angle 63.9°
Wheelbase 1,485 ± 10 mm (58.46 ± 0.39 in)
Seat height unloaded 950 mm (37.4 in)
Ground clearance unloaded 375 mm (14.76 in)
Weight without fuel, approx. 87.5 kg (192.9 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)

20.6 Tires
Front tire Rear tire
80/100 - 21 51M TT 100/90 - 19 57M TT
Dunlop MAXXCROSS MX‑ST+ Dunlop MAXXCROSS MX‑ST+
The tires specified represent one of the possible series production tires. Additional information is available in the Service
section under:
http://www.gasgas.com

20.7 Fork
Fork article number A540C101U406000
Fork WP XACT AER
Compression damping
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks
Rebound damping
Comfort 17 clicks
Standard 12 clicks
Sport 7 clicks
Air pressure 8.3 bar (120 psi)
Fork length 950 mm (37.4 in)

Oil capacity external mechanism left 230 +− 10

50 ml (7.78 − 1.69 fl. oz.)
+ 0.34
Fork oil (SAE 4) (48601166S1)
( p. 121)
Oil capacity external mechanism right 230 +− 10
50 ml (7.78 − 1.69 fl. oz.)
+ 0.34
Fork oil (SAE 4) (48601166S1)
( p. 121)
Grease capacity, left cartridge 5 g (0.18 oz) Special grease (00062010053)
( p. 123)
Oil capacity, right cartridge 380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1)
( p. 121)

116
 TECHNICAL DATA 20

20.8 Shock absorber

Shock absorber article number 18.18.7U.01
Shock absorber WP XACT 5750
Lowspeed compression damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Highspeed compression damping
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Rebound damping
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Spring preload 7 mm (0.28 in)
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.) 36 N/mm (206 lb/in)
Weight of rider: 75 … 85 kg (165 … 187 lb.) 39 N/mm (223 lb/in)
Weight of rider: 85 … 95 kg (187 … 209 lb.) 42 N/mm (240 lb/in)
Spring length
Weight of rider: 65 … 75 kg (143 … 165 lb.) 255 mm (10.04 in)
Weight of rider: 75 … 85 kg (165 … 187 lb.) 260 mm (10.24 in)
Weight of rider: 85 … 95 kg (187 … 209 lb.) 260 mm (10.24 in)
Gas pressure 10 bar (145 psi)
Static sag 35 mm (1.38 in)
Riding sag 105 mm (4.13 in)
Fitted length 477 mm (18.78 in)
Shock absorber fluid ( p. 121) SAE 2.5

20.9 Chassis tightening torques

Hose clamp, radiator 2.4 Nm (1.77 lbf ft)
Screw, seat fixing EJOT EJOFORM PT® K60x23/18 2.5 Nm (1.84 lbf ft)
Screw, stop button M3 0.4 Nm (0.3 lbf ft)
Hose clip, inlet sleeve to carburetor M4 2.8 Nm (2.07 lbf ft)
Screw, carburetor cover M4 1.3 Nm (0.96 lbf ft)
Screw, fixed grip M4 5 Nm (3.7 lbf ft)
Loctite®243™
Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft)
Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft)
Remaining nuts, chassis M5 5 Nm (3.7 lbf ft)
Remaining screws, chassis M5 5 Nm (3.7 lbf ft)
Screw, brake line guide on link fork M5 5 Nm (3.7 lbf ft)
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
Screws on main silencer M5 7 Nm (5.2 lbf ft)

117
20 TECHNICAL DATA

Nut, carburetor cover on throttle M6 3 Nm (2.2 lbf ft)

cable wire
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Screw, absorbing element on frame M6 6 Nm (4.4 lbf ft)
Screw, absorbing element on mani- M6 6 Nm (4.4 lbf ft)
fold
Screw, ball joint of push rod on foot M6 10 Nm (7.4 lbf ft)
brake cylinder Loctite®243™
Screw, brake lever M6 5 Nm (3.7 lbf ft)
Screw, chain guide M6 10 Nm (7.4 lbf ft)
Screw, chain guide on link fork at the M6 10 Nm (7.4 lbf ft)
rear Loctite®243™
Screw, chain sliding guard M6 10 Nm (7.4 lbf ft)
Loctite®243™
Screw, clutch lever M6 5 Nm (3.7 lbf ft)
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, fuel tank spoiler on radiator M6 6 Nm (4.4 lbf ft)
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Loctite®243™
Screw, seat fixing M6 6 Nm (4.4 lbf ft)
Screw, throttle grip M6 5 Nm (3.7 lbf ft)
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft)
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
Loctite®2701™
Nut, rim lock M8 12 Nm (8.9 lbf ft)
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft)
Remaining screws, chassis M8 25 Nm (18.4 lbf ft)
Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft)
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft)
Screw, engine brace on engine M8x20 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, engine brace on frame M8x15 25 Nm (18.4 lbf ft)
Loctite®2701™
Screw, engine sprocket cover M8 15 Nm (11.1 lbf ft)
Screw, fork stub M8 15 Nm (11.1 lbf ft)
Screw, front brake caliper M8 25 Nm (18.4 lbf ft)
Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft)
Screw, manifold M8 15 Nm (11.1 lbf ft)
Screw, subframe bottom M8x18 30 Nm (22.1 lbf ft)
Loctite®2701™
Screw, subframe top M8x20 35 Nm (25.8 lbf ft)
Loctite®2701™
Screw, top steering stem M8 20 Nm (14.8 lbf ft)
Loctite®243™
Screw, top triple clamp M8 20 Nm (14.8 lbf ft)
Engine bracket screw M10 60 Nm (44.3 lbf ft)
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft)

118
 TECHNICAL DATA 20

Remaining screws, chassis M10 45 Nm (33.2 lbf ft)

Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Loctite®243™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft)
Loctite®2701™
Nut, angle lever to link fork M14x1.5 60 Nm (44.3 lbf ft)
Nut, frame on linkage lever M14x1.5 60 Nm (44.3 lbf ft)
Nut, linkage lever on angle lever M14x1.5 60 Nm (44.3 lbf ft)
Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft)
Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft)
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
Screw-in fitting, cooling system M24x1.5 18 Nm (13.3 lbf ft)
Loctite®243™
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

119
21 SUBSTANCES

Brake fluid DOT 4 / DOT 5.1

Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the
corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX®
– Brake Fluid DOT 5.1

Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuit-
able antifreeze causes corrosion, deposits and frothing.
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and
lubrication properties.
– Only use coolant that complies with the requirements stated (see specifications on the container) and that has the rele-
vant properties.
Antifreeze protection to at least −25 °C (−13 °F)

The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be
diluted.

The use of premixed coolant is recommended.

Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other
coolants.

Recommended supplier
MOTOREX®
– COOLANT M3.0

Engine oil (15W/50)

Standard/classification
– JASO T903 MA2 ( p. 124)
– SAE ( p. 124) (15W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the
corresponding properties.
Recommended supplier
MOTOREX®
– Top Speed 4T

Engine oil, 2-stroke

Standard/classification
– JASO FD ( p. 124)
Guideline
– Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
Recommended supplier
MOTOREX®
– Cross Power 2T

120
 SUBSTANCES 21

Fork oil (SAE 4) (48601166S1)

Standard/classification
– SAE ( p. 124) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre-
sponding properties.

Shock absorber fluid (SAE 2.5) (50180751S1)

Standard/classification
– SAE ( p. 124) (SAE 2.5)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre-
sponding properties.

Super unleaded (ROZ 98 / RON 98 / PON 94)

Standard/classification
– DIN EN 228 (ROZ 98 / RON 98 / PON 94)

Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
Standard/classification
– DIN EN 228
– JASO FD ( p. 124) (1:40)
Mixture ratio
1:40 Engine oil, 2-stroke ( p. 120)
Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 121)
Recommended supplier
MOTOREX®
– Cross Power 2T

121
22 AUXILIARY SUBSTANCES

Air filter cleaner

Recommended supplier
MOTOREX®
– Racing Bio Dirt Remover

Chain cleaner
Recommended supplier
MOTOREX®
– Chain Clean

Fuel additive
Recommended supplier
MOTOREX®
– Fuel Stabilizer

High viscosity grease

Recommended supplier
SKF®
– LGHB 2

Long-life grease
Recommended supplier
MOTOREX®
– Bike Grease 2000

Motorcycle cleaner
Recommended supplier
MOTOREX®
– Moto Clean

Off-road chain spray

Recommended supplier
MOTOREX®
– Chainlube Offroad

Oil for foam air filter

Recommended supplier
MOTOREX®
– Racing Bio Liquid Power

Preserving materials for paints, metal and rubber

Recommended supplier
MOTOREX®
– Moto Protect

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX®
– Quick Cleaner

122
 AUXILIARY SUBSTANCES 22

Special grease (00062010053)

Recommended supplier
Klüber Lubrication®
– KLÜBERFOOD NH1 34‑401

Universal oil spray

Recommended supplier
MOTOREX®
– Joker 440 Synthetic

123
23 STANDARDS

JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 stan-
dard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle
specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high perfor-
mance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.

SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to
their viscosity. The viscosity describes only one property of oil and says nothing about quality.

JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing.
Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme
operating conditions.

124
 LIST OF ABBREVIATIONS 24

Art. no. Article number

ca. circa
cf. compare
e.g. for example
etc. et cetera
i.a. inter alia
no. number
poss. possibly

125
INDEX

Clutch
INDEX

A fluid level, checking/correcting . . . . . . . . . . . . . 68

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 fluid, changing . . . . . . . . . . . . . . . . . . . . . . . 69
Air filter Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 basic position, adjusting . . . . . . . . . . . . . . . . . 68
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Compression damping
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 56 fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . 39
Air filter box Coolant
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 changing . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Air filter box cover draining . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 55 refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
preparing for securing . . . . . . . . . . . . . . . . . . 57 Coolant level
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 54 checking . . . . . . . . . . . . . . . . . . . . . . . . 89-90
Air suspension XACT 5448 . . . . . . . . . . . . . . . . . . 32 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 88
Antifreeze Customer service . . . . . . . . . . . . . . . . . . . . . . . . 9
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 89 D
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . 9 Defined use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B Difficult operating conditions ............... 19
Basic chassis setting dry sand . . . . . . . . . . . . ............... 20
rider's weight, checking with . . . . . . . . . . . . . . 32 high temperatures . . . . . ............... 23
low temperature . . . . . . ............... 24
Brake discs
muddy surfaces . . . . . . . ............... 22
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 71
slow speed . . . . . . . . . . ............... 23
Brake fluid snow . . . . . . . . . . . . . . ............... 24
front brake, adding . . . . . . . . . . . . . . . . . . . . 72 wet sand . . . . . . . . . . . ............... 21
rear brake, adding . . . . . . . . . . . . . . . . . . . . 78 wet surfaces . . . . . . . . . ............... 22
Brake fluid level E
front brake, checking . . . . . . . . . . . . . . . . . . . 72
rear brake, checking . . . . . . . . . . . . . . . . . . . 77 Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Brake linings
front brake, checking . . . . . . . . . . . . . . . . . . . 74 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . 12
of the front brake, changing . . . . . . . . . . . . . . 74 Engine sprocket
of the rear brake, changing . . . . . . . . . . . . . . . 79 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 64
rear brake, checking . . . . . . . . . . . . . . . . . . . 79 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C F
Capacity Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Filling up
gear oil . . . . . . . . . . . . . . . . . . . . . . . 104, 115 fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Carburetor Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjusting the idle speed . . . . . . . . . . . . . . . . . 99 basic position, adjusting . . . . . . . . . . . . . . . . . 77
float chamber, emptying . . . . . . . . . . . . . . . . 102 free travel, checking . . . . . . . . . . . . . . . . . . . 76
idle setting . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fork
Carburetor tuning . . . . . . . . . . . . . . . . . . . . . . . 96 air pressure, adjusting . . . . . . . . . . . . . . . . . . 38
Chain article number . . . . . . . . . . . . . . . . . . . . . . . 12
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 64 basic setting, checking . . . . . . . . . . . . . . . . . . 38
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Fork legs
Chain guide bleeding . . . . . . . .. . . . . . . . . . . . . . . . . . . 42
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 64 dust boots, cleaning . . . . . . . . . . . . . . . . . . . 43
Chain tension installing . . . . . . .. . . . . . . . . . . . . . . . . . . 44
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 63 removing . . . . . . .. . . . . . . . . . . . . . . . . . . 43
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Fork protector
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 45
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 45

126
 INDEX

Frame removing . . . . . . . . . . . . . . . . . . . . . . . . . . 58
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Manufacturer warranty . . . . . . . . . . . . . . . . . . . . 9
Front fender Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Motorcycle
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 50 cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Front wheel from lift stand, removing . . . . . . . . . . . . . . . . 42
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 83 raising with lift stand . . . . . . . . . . . . . . . . . . . 42
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 82
O
Fuel tank Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . 8
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 60
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 59 P

Fuel tank filler cap Play in throttle cable

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 95
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Preparing for use
G advice on preparing for first use . . . . . . . . . . . . 18
after storage . . . . . . . . . . . . . . . . . . . . . . . . 109
Gear oil checks and maintenance measures when preparing
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . 7
Gear oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 103 R

H Radiator cover . . . . . . . . . . . . . . . . . . . . . . . . . 88
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . 14 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 89
basic position, adjusting . . . . . . . . . . . . . . . . . 71
Rear sprocket
free travel, checking . . . . . . . . . . . . . . . . . . . 71
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Handlebar position . . . . . . . . . . . . . . . . . . . . . . 40
Rear wheel
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 40
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 84
High-speed compression damping removing . . . . . . . . . . . . . . . . . . . . . . . . . . 83
shock absorber, adjusting . . . . . . . . . . . . . . . . 33
Rebound damping
I fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . 40
Ignition timing map shock absorber, adjusting . . . . . . . . . . . . . . . . 34
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Riding sag
plug-in connector . . . . . . . . . . . . . . . . . . . . . 100 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Implied warranty . . . . . . . . . . . . . . . . . . . . . . . . 9 Rubber grip
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 67
K S
Kick starter lever . . . . . . . . . . . . . . . . . . . . . . . 17 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . 7
L Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Link fork
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 53
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lower triple clamp
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 45 basic position, adjusting . . . . . . . . . . . . . . . . . 100
basic position, checking . . . . . . . . . . . . . . . . . 100
Low-speed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . . . 33 Shock absorber
article number . . . . . . . . . . .. . . . . . . . . . . . 13
M compression damping, general . . . . . . . . . . . . 33
Main silencer installing . . . . . . . . . . . . . .. . . . . . . . . . . . 52
glass fiber yarn filling, changing . . . . . . . . . . . . 58 removing . . . . . . . . . . . . . .. . . . . . . . . . . . 50
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 58 riding sag, checking . . . . . . . .. . . . . . . . . . . . 36

127
INDEX

spring preload, adjusting . . . . . . . . . . . . . . . . 36

static sag, checking . . . . . . . . . . . . . . . . . . . . 35
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Start number plate
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 49
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Steering head bearing
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 48
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Stop button . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
T
Technical data
capacities . . . . . . . . . . .... . . . . . . . . . . . . 115
carburetor . . . . . . . . . .... . . . . . . . . . . . . 114
chassis . . . . . . . . . . . . .... . . . . . . . . . . . . 115
chassis tightening torques ... . . . . . . . . . . . . 117
engine . . . . . . . . . . . . .... . . . . . . . . . . . . 112
engine tightening torques .... . . . . . . . . . . . . 112
fork . . . . . . . . . . . . . .... . . . . . . . . . . . . 116
shock absorber . . . . . . .... . . . . . . . . . . . . 117
tires . . . . . . . . . . . . . .... . . . . . . . . . . . . 116
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 110-111
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
V
Vehicle identification number . . . . . . . . . . . . . . . 12
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . 10
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . 11
W
Work rules ............................ 8

128
*3215051en*
3215051en

06/2021

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