GAS GAS MC 250F 2021 Owner's Manual
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GAS GAS MC 250F 2021 Owner's Manual

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OWNER'S MANUAL 2021
MC 250F
EX 250F
Art. no. 3215009en

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Summary of Contents for GAS GAS MC 250F 2021

  • Page 1 OWNER'S MANUAL 2021 MC 250F EX 250F Art. no. 3215009en...
  • Page 3 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Preparing the vehicle for difficult TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 operating conditions ........22 Symbols used..........5 Preparing the vehicle for rides on dry Formats used..........5 sand ............. 22 Preparing the vehicle for rides on wet SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS SERVICE WORK ON THE CHASSIS ......44 12.2 Adjusting the basic position of the hand brake lever........... 77 11.1 Raising the motorcycle with a lift stand ..44 12.3 Checking the brake discs......77 11.2 Removing the motorcycle from the lift 12.4 Checking the front brake fluid level....
  • Page 6 TABLE OF CONTENTS SERVICE WORK ON THE ENGINE ......107 17.1 Changing the fuel screen ..... 107 17.2 Checking the engine oil level ....108 17.3 Changing the engine oil and oil filter, cleaning the oil screen ......109 17.4 Adding engine oil........

  • Page 7: Means Of Representation 1

    MEANS OF REPRESENTATION 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.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use (MC) 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.

  • Page 9: Tampering Warning

    SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: 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 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 10: Work Rules

    2 SAFETY ADVICE 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.

  • Page 11: Important Notes 3

    IMPORTANT NOTES 3 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.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) A00758-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Cold start button ( p. 17) Engine number ( p. 12) Shift lever ( p.

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) A00856-10 Shock absorber compression adjuster Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Vehicle identification number ( p. 12) Type label ( p. 12) Fork article number ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number Engine number is located on the left side of the engine over the engine sprocket.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. A00795-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. A00798-10 Throttle grip The throttle grip...

  • Page 17: Start Button

    CONTROLS 6 Start button Start button is fitted on the right side of the handlebar. Possible states • The start button is in the basic position is pressed – In this position, the starter motor is • The start button actuated.

  • Page 18: Closing The Fuel Tank Filler Cap

    6 CONTROLS (MC) – Turn fuel tank filler cap counterclockwise and lift it off. A00769-10 (EX) – Press release button , turn the fuel tank filler cap counter- clockwise, and lift it off. A00761-10 Closing the fuel tank filler cap (MC) –...

  • Page 19: Cold Start Button

    CONTROLS 6 Cold start button (MC) The cold start button is fitted to the bottom of the throttle valve body. A00772-10 (EX) The cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low.

  • Page 20: Idle Speed Adjusting Screw

    6 CONTROLS 6.10 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 21: Foot Brake Lever

    CONTROLS 6 6.12 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.13 Plug-in stand (MC) The support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle.

  • Page 22: Preparing For Use

    7 PREPARING FOR USE 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. –...

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more challenging ride. Info This vehicle 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.

  • Page 24: Starting Power Of Lithium-Ion Batteries At Low Temperatures

    7 PREPARING FOR USE Starting power of lithium-ion batteries at low temperatures Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batteries.

  • Page 25: Preparing The Vehicle For Rides On Wet Sand

    PREPARING FOR USE 7 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for GASGAS Techni- cal Accessories. 102138-01 – Clean the chain. Chain cleaner ( p. 132) – Mount the steel sprocket. –...

  • Page 26: Preparing The Vehicle For Rides On Wet And Muddy Circuits

    7 PREPARING FOR USE 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. 102137-01 – Mount the steel sprocket. –...

  • Page 27: Riding Instructions 8

    RIDING INSTRUCTIONS 8 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. –...

  • Page 28: Starting Off

    8 RIDING INSTRUCTIONS (MC) – Remove plug-in stand H02629-10 (EX) – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission into neutral. Condition Ambient temperature: < 20 °C (< 68 °F) –...

  • Page 29: Applying The Brakes

    RIDING INSTRUCTIONS 8 – 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. – Only open the throttle as much as the engine can handle – abrupt throttle grip opening increases fuel consumption. –...

  • Page 30: Transporting

    8 RIDING INSTRUCTIONS – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. –...

  • Page 31: Refueling

    RIDING INSTRUCTIONS 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.

  • Page 32: Service Schedule

    9 SERVICE SCHEDULE 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.

  • Page 33: Recommended Work

    SERVICE SCHEDULE 9 after every race Every 40 operating hours Every 30 operating hours Every 20 operating hours Every 10 operating hours After 1 operating hour ○ ● ● ● ● ● Check all hoses (e.g. fuel, cooling, bleeder, drainage hoses, etc.) and sleeves for cracking, tightness, and correct routing.
  • Page 34 9 SERVICE SCHEDULE every 48 months every 12 months Every 100 operating hours Every 50 operating hours After 20 operating hours After 10 operating hours ● Perform major engine service including removing and installing the engine. (Change valves, valve springs, valve spring seats, and valve spring retainers. Change the connecting rod, conrod bearing and crank pin.

  • Page 35: Tuning The Chassis 10

    TUNING THE CHASSIS 10 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.

  • Page 36: Compression Damping Of The Shock Absorber

    10 TUNING THE CHASSIS 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.

  • Page 37: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    TUNING THE CHASSIS 10 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. –...

  • Page 38: Measuring The Dimension Of The Rear Wheel Unloaded

    10 TUNING THE CHASSIS Guideline Rebound damping (MC) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (EX) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase the damping; turn counterclock- wise to reduce damping when the shock absorber rebounds. 10.7 Measuring the dimension of the rear wheel unloaded Preparatory work...

  • Page 39: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 36) – Hold the motorcycle upright with aid of an assistant. – Remeasure the distance between the rear axle and the marking on the rear fender using the sag gage.

  • Page 40: Adjusting The Spring Preload Of The Shock Absorber

    10 TUNING THE CHASSIS 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. –...

  • Page 41: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the shock absorber. p. 54) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 42: Adjusting The Fork Air Pressure

    10 TUNING THE CHASSIS 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. –...

  • Page 43: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 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. 44) 10.14 Adjusting the compression damping of the fork Info...

  • Page 44: Handlebar Position

    10 TUNING THE CHASSIS – Turn adjusting screw clockwise all the way. Info Adjusting screw 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 (MC) Comfort...

  • Page 45: Adjusting The Handlebar Position

    TUNING THE CHASSIS 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 –...

  • Page 46: 11 Service Work On The Chassis

    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. –...

  • Page 47: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 (EX) – Remove the motorcycle from the lift stand. – Remove the lift stand. – To park the motorcycle, press side stand to the ground with your foot and lean the motorcycle on it. Info When you are riding, the side stand must be folded up and secured with the rubber strap.

  • Page 48: Removing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS – Press the dust boots back into their installation position. – Remove excess oil. Finishing work – Install the fork protector. ( p. 46) – Remove the motorcycle from the lift stand. ( p. 44) 11.5 Removing the fork protector –...

  • Page 49: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws and take off the clamp. – Remove screws and take off the brake caliper. – Allow the brake caliper and the brake line to hang loosely to the side. Info Do not actuate the hand brake lever when the front wheel is removed.

  • Page 50: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) ® Loctite 243™ brake caliper – Position the brake line and the clamp. Mount and tighten screws Guideline Screw, brake line EJOT...

  • Page 51: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 132) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 52 11 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head A00804-10 – Mount and tighten screw Guideline Screw, top steer- 20 Nm (14.8 lbf ft) Loctite ® 243™ ing stem A00805-10 –...

  • Page 53: Checking The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 11.11 Checking the 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...

  • Page 54: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Check the steering head bearing play. ( p. 51) Finishing work – Mount the handlebar cushion. – Remove the motorcycle from the lift stand. ( p.

  • Page 55: Removing Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.16 Removing front fender Preparatory work – Remove the start number plate. ( p. 52) Main work – Remove screws . Take off the front fender. A00780-10 11.17 Installing front fender Main work – Position front fender.

  • Page 56: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Remove the cable ties. – Remove screws along with the washers. – Detach the frame protector in area and take it off.

  • Page 57: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. A00814-10 11.19 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bot- tom.

  • Page 58: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – Position the angle lever and linkage lever. – Mount and tighten fitting Guideline Nut, linkage lever on M14x1.5 60 Nm (44.3 lbf ft) angle lever Info Pay attention to flat area A00818-10 – Mount and tighten screw Guideline Screw, bottom...

  • Page 59: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11 – 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.

  • Page 60: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area sideways and take off toward the front. A00782-11 Condition The air filter box cover is not secured. – Pull off the air filter box cover in area sideways and take off toward the front.

  • Page 61: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 (EX) Condition The air filter box cover is secured. – Insert the air filter box cover in area and clip it into area A00782-12 – Mount and tighten screw Guideline Screw, air filter box EJOT PT ®...

  • Page 62: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab – Remove air filter with air filter support. – Remove air filter from air filter support. A00783-10 11.25 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 63: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 132) H02459-01 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.

  • Page 64: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS – Detach spring Spring hook (50305017000C1) – Remove screws with the washers and take off the main silencer. G05067-10 11.29 Installing the main silencer – Position the main silencer. – Mount screws with the washers, but do not tighten yet. –...

  • Page 65: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove all the screws on the main silencer. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.
  • Page 66 11 SERVICE WORK ON THE CHASSIS Main work (MC) – Unplug connector of the fuel pump. – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! A00785-10 –...

  • Page 67: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Remove screw with the rubber bushing. A00788-11 – Remove screws with the collar bushings. A00789-10 – Pull both spoilers laterally off the radiator and lift off the fuel tank. A00790-10 11.32 Installing the fuel tank Danger Fire hazard Fuel is highly flammable.
  • Page 68 11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 72) – 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. –...

  • Page 69: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 – Plug in connector for the fuel pump. – Remove the wash cap set. Clean the quick release coupling thor- oughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 70: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p.

  • Page 71: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 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.

  • Page 72: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 73 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.

  • Page 74: Checking The Frame

    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, 10 Nm (7.4 lbf ft) chassis A00792-10 Finishing work –...

  • Page 75: Checking The Rubber Grips

    SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rub- ber strap of the fuel tank support.

  • Page 76: Adjusting The Basic Position Of The Clutch Lever

    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 Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

  • Page 77: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 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. –...
  • Page 78 11 SERVICE WORK ON THE CHASSIS – Now press the fluid into the system until it emerges from hole of the master cylinder without bubbles. – Occasionally extract the fluid from the master cylinder reservoir to prevent overflowing. – Tighten the bleeder screw and remove the bleeding syringe with the hose.

  • Page 79: Brake System 12

    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. –...

  • Page 80: Checking The Front Brake Fluid Level

    12 BRAKE SYSTEM rear 3.5 mm (0.138 in) » If the brake disc thickness is less than the specification: – Change the front brake disc. – Change the rear brake disc. – Check the front and rear brake discs for damage, cracking, and deformation.
  • Page 81 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. –...

  • Page 82: Checking The Front Brake Linings

    12 BRAKE SYSTEM – Position cover with membrane . Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water. A00829-10 12.6 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. –...
  • Page 83 BRAKE SYSTEM 12 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. –...

  • Page 84: Checking The Free Travel Of Foot Brake Lever

    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. A00830-12 –...

  • Page 85: Adjusting The Basic Position Of The Foot Brake Lever

    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. –...

  • Page 86: Adding Rear Brake Fluid

    12 BRAKE SYSTEM Main work – Stand the vehicle upright. – Check the brake fluid level in level viewer » If the brake fluid has dropped below marking – Add rear brake fluid. p. 84) A00832-10 12.11 Adding rear brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail.

  • Page 87: Checking The Brake Linings Of The Rear Brake

    BRAKE SYSTEM 12 Main work – Stand the vehicle upright. – Remove screw cap with membrane and the O-ring. – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 130) – Mount and tighten the screw cap with the membrane and O-ring. Info A00833-10 Clean up overflowed or spilled brake fluid immediately with...
  • Page 88 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.) Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect.
  • Page 89 BRAKE SYSTEM 12 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Make sure that decoupling plate is mounted on the pis- ton side brake lining. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 90: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) 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.

  • Page 91: Installing The Front Wheel

    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. –...

  • Page 92: Installing The Rear Wheel

    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. –...
  • Page 93 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 and contact surfaces of the spacers.

  • Page 94: Checking The Tire Condition

    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.

  • Page 95: Checking The Spoke Tension

    WHEELS, TIRES 13 13.7 Checking the 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.

  • Page 96: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the 12-V battery Caution Danger of burns The voltage regulator gets very hot when the vehicle is driven. – Allow the voltage regulator to cool down before performing any work. Note Environmental hazard 12 V batteries contain environmentally hazardous materials. –...

  • Page 97: Charging The 12-V Battery

    ELECTRICAL SYSTEM 14 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 98: Changing Main Fuse

    14 ELECTRICAL SYSTEM (EU) battery charger (79629974000) Alternative 1 (US) battery charger (79629974500) These battery chargers test whether the 12-V battery retains its voltage. It is also impossible to overcharge the 12-V battery with these battery chargers. The charging time may be longer at low temperatures.

  • Page 99: Diagnostics Connector

    ELECTRICAL SYSTEM 14 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. Fuse (58011109110) ( p.

  • Page 100: 15 Cooling System

    15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is reg- ulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 101: Checking The Coolant Level

    COOLING SYSTEM 15 15.3 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.

  • Page 102: Refilling With Coolant

    15 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. –...

  • Page 103: Changing The Coolant

    COOLING SYSTEM 15 15.6 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.

  • Page 104: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 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 Play in throttle cable 3 …...

  • Page 105: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 16 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...

  • Page 106: Adjusting The Idle Speed

    16 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be posi- tioned at marking Black guide plate (79002014100) Alternative 1 Grey guide plate (79002014000) Info The gray guide plate opens the throttle valve more slowly.

  • Page 107: Programming The Throttle Valve Position

    TUNING THE ENGINE 16 – Run the engine until warm. The cold start button is deactivated – The cold start button is in its basic position. ( p. 17) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. –...

  • Page 108: Checking The Basic Position Of The Shift Lever

    16 TUNING THE ENGINE 16.6 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. –...

  • Page 109: Service Work On The Engine 17

    SERVICE WORK ON THE ENGINE 17 17.1 Changing the fuel screen 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. –...

  • Page 110: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE 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.

  • Page 111: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    SERVICE WORK ON THE ENGINE 17 Condition The engine is cold. – Check the engine oil level. The engine oil reaches the middle of level viewer » If the engine oil does not reach the middle of the level viewer: –...
  • Page 112 17 SERVICE WORK ON THE ENGINE – Remove screw plug with oil screen and the O-rings. – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surfaces. G05104-10 – Position oil screen with the O-rings on a pin wrench. –...

  • Page 113: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with engine oil. – Fill the oil filter with engine oil and position the oil filter in the hous- ing.
  • Page 114 17 SERVICE WORK ON THE ENGINE 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.

  • Page 115: Cleaning, Care 18

    CLEANING, CARE 18 18.1 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. –...
  • Page 116 18 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber ( p. 132) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 117: Storage 19

    STORAGE 19 19.1 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. –...

  • Page 118: Putting Into Operation After Storage

    19 STORAGE 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. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust.

  • Page 119: Troubleshooting 20

    TROUBLESHOOTING 20 Faults Possible cause Action – The engine does not turn when Operating error Carry out start procedure. ( p. 25) the start button is pressed – 12-V battery discharged Charge the 12-V battery. p. 95) – Check the charging voltage. –...
  • Page 120 20 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary. – Engine oil level too high Check the engine oil level. ( p. 108) – Engine oil too thin (low viscosity) Change the engine oil and oil filter, clean the oil screen.

  • Page 121: Blink Code 21

    BLINK CODE 21 Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Throttle valve position programming necessary Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – circuit fault Error level condition Blink code for malfunction indicator lamp...
  • Page 122 21 BLINK CODE Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 123: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 52.3 mm (2.059 in) Bore 78 mm (3.07 in) Compression ratio 14.4:1 Idle speed 2,250 … 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)

  • Page 124: Engine Tightening Torques

    22 TECHNICAL DATA 22.2 Engine tightening torques Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for alternator cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for balancer shaft lubrica- 2 Nm (1.5 lbf ft) Loctite ®...
  • Page 125 TECHNICAL DATA 22 Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, timing chain failure protection 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, valve cover 8 Nm (5.9 lbf ft) Screw, water pump cover 10 Nm (7.4 lbf ft) Stud, cylinder head...

  • Page 126: Capacities

    22 TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 130) 22.3.2 Coolant Coolant 0.95 l (1 qt.) Coolant ( p. 130) 22.3.3 Fuel Total fuel tank capacity, approx. (MC) Super unleaded (ROZ 95) ( p.

  • Page 127: Electrical System

    TECHNICAL DATA 22 Maximum permissible overall weight 335 kg (739 lb.) 22.5 Electrical system 12-V battery HJTZ5S-FP-C Lithium-ion battery Battery voltage: 12 V Nominal capacity: 2.0 Ah Maintenance-free Fuse 58011109110 10 A Malfunction indicator lamp 22.6 Tires Validity Front tire Rear tire (MC) 80/100 - 21 51M TT...

  • Page 128: Shock Absorber

    22 TECHNICAL DATA 22.7.2 Fork article number A540C175U406000 Fork WP XACT AER Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Air pressure 9.8 bar (142 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism right...

  • Page 129: Chassis Tightening Torques

    TECHNICAL DATA 22 Riding sag 105 mm (4.13 in) Fitted length 477 mm (18.78 in) Shock absorber oil Shock absorber fluid (SAE 2.5) (50180751S1) ( p. 131) 22.8.2 Shock absorber article number 18.18.7U.75 Shock absorber WP XACT 5750 Lowspeed compression damping Comfort 17 clicks Standard...
  • Page 130 22 TECHNICAL DATA Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, battery terminal 2.5 Nm (1.84 lbf ft) Screw, brake line guide on link fork 5 Nm (3.7 lbf ft) Screw, frame protector 3 Nm (2.2 lbf ft)
  • Page 131 TECHNICAL DATA 22 Screw, side stand attachment (EX) 33 Nm (24.3 lbf ft) Loctite ® 2701™ Screw, subframe bottom 30 Nm (22.1 lbf ft) Loctite ® 2701™ Screw, subframe top 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, top steering stem 20 Nm (14.8 lbf ft) Loctite ®...

  • Page 132: 23 Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – 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 ®...
  • Page 133 SUBSTANCES 23 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 134) (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 95) Standard/classification –...

  • Page 134: 24 Auxiliary Substances

    24 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 ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 135 AUXILIARY SUBSTANCES 24 Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier MOTOREX ®...

  • Page 136: 25 Standards

    25 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.

  • Page 137: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics...

  • Page 138: 27 List Of Abbreviations

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 139: List Of Symbols 28

    LIST OF SYMBOLS 28 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also repre- sented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehi- cle electronics.

  • Page 140: Index

    INDEX Chain tension INDEX adjusting ......69 checking ......68 12-V battery Characteristic map of the throttle response charging .
  • Page 141 INDEX Fork legs Lower triple clamp air pressure, adjusting ....40 installing ......49 basic setting, checking .
  • Page 142 INDEX Rubber grips Throttle cable routing checking ......73 checking ......72 Throttle grip .
  • Page 143 *3215009en* 3215009en 05/2021 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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Ex 250f 2021Mc 250f eu 2021Ex 250f us 2021F0275u1 2021F0201u5 2021

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