GAS GAS MC 125 2021 Owner's Manual
  1. Manuals
  2. Brands
  3. GAS GAS Manuals
  4. Motorcycle
  5. MC 125 2021
  6. Owner's manual

GAS GAS MC 125 2021 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

OWNER'S MANUAL 2021
MC 125
Art. no. 3215008en

Advertisement

Table of Contents
loading

Related Manuals for GAS GAS MC 125 2021

Summary of Contents for GAS GAS MC 125 2021

  • Page 1 OWNER'S MANUAL 2021 MC 125 Art. no. 3215008en...
  • 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 rides on wet TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 sand ............. 21 Symbols used..........5 Preparing the vehicle for rides on wet Formats used..........5 and muddy circuits ........22 Preparing vehicle for high temperatures SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS 11.3 Bleeding the fork legs........42 12.7 Changing the brake linings of the front brake ............74 11.4 Cleaning the dust boots of the fork legs..43 12.8 Checking the free travel of foot brake 11.5 Removing the fork legs ......
  • Page 6 TABLE OF CONTENTS STORAGE..............108 18.1 Storage............108 18.2 Preparing for use after storage....109 TROUBLESHOOTING ..........110 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 ..........

  • 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 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) S04515-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Air filter box cover Shift lever ( p. 16) Choke ( p. 16) Fuel tap...

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S04516-10 Seat Fuel tank filler cap Stop button ( p. 14) Throttle grip ( p. 14) Kick starter lever ( p. 17) Foot brake lever ( p. 17) Shock absorber compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear...

  • 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 The engine number is stamped on the left side of the engine under 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 Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. S04517-10 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. S04518-10 Throttle grip Throttle grip...

  • Page 17: Opening The Fuel Tank Filler Cap

    CONTROLS 6 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. –...

  • Page 18: Fuel Tap

    6 CONTROLS 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 on the fuel tap. Possible states Fuel tap is closed – Fuel cannot flow from the fuel tank to the car- •...

  • Page 19: Kick Starter Lever

    CONTROLS 6 6.10 Kick starter lever Kick starter lever 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 is located in front of the right footrest.

  • Page 20: 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 21: Running In The Engine

    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.

  • Page 22: Preparing The Vehicle For Rides On Dry Sand

    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.

  • Page 23: Preparing The Vehicle For Rides On Wet Sand

    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.

  • Page 24: Preparing The Vehicle For Rides On Wet And Muddy Circuits

    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.

  • Page 25: Preparing Vehicle For High Temperatures Or Slow Riding

    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 Preparing vehicle for high temperatures or slow riding –...

  • Page 26: Preparing The Vehicle For Low Temperatures Or Snow

    7 PREPARING FOR USE 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.

  • 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 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. –...

  • Page 29: Applying The Brakes

    RIDING INSTRUCTIONS 8 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. –...

  • Page 30: Transporting

    8 RIDING INSTRUCTIONS 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. –...
  • Page 31 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.

  • 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 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. ●...

  • Page 34: 10 Tuning The Chassis

    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.

  • Page 35: Compression Damping Of The Shock Absorber

    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.

  • Page 36: Adjusting The Rebound Damping Of The Shock Absorber

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

  • Page 37: Checking The Static Sag Of The Shock Absorber

    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) Sag gage pin (00029990010) – Note down the value as dimension 402415-10 Finishing work –...

  • Page 38: Checking The Riding Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.9 Checking the riding sag of the shock absorber – Measure dimension 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.

  • Page 39: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 Main work – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (90129051000) Info If the spring cannot be fully released, the spring must be removed to accurately measure the spring length. –...

  • Page 40: Checking The Basic Setting Of The Fork

    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...

  • Page 41: Adjusting The Compression Damping Of The Fork

    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)

  • Page 42: Adjusting The Rebound Damping Of The Fork

    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 clockwise all the way. Info Adjusting screw is located at the lower end of the right...
  • Page 43 TUNING THE CHASSIS 10 Main work – Remove screws . 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. –...

  • Page 44: 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 45: Cleaning The Dust Boots Of The Fork Legs

    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) –...

  • Page 46: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. S04528-10 11.6 Installing the fork legs Main work – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.

  • Page 47: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.7 Removing the fork protector – Remove screws . Remove the clamp. – Remove screws . Take off the left fork protector. – Remove screws . Take off the right fork protector. F00024-10 11.8 Installing the fork protector –...

  • Page 48: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS – Remove O-ring . Remove protective ring – 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 –...
  • Page 49 SERVICE WORK ON THE CHASSIS 11 – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp S04532-10 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head S04533-10 – Mount and tighten screw Guideline Screw, top steer- 20 Nm (14.8 lbf ft)

  • Page 50: Checking Steering Head Bearing Play

    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...

  • Page 51: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. – Tighten screws Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Mount and tighten screw Guideline Screw, top steer- 20 Nm (14.8 lbf ft) Loctite...

  • Page 52: Removing Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.16 Removing front fender Preparatory work – Remove the start number plate. ( p. 49) Main work – Remove screws . Remove front fender. S04537-10 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)
  • Page 53 SERVICE WORK ON THE CHASSIS 11 – Press angle lever toward the rear. – Press linkage lever downward. S04570-10 – Remove screws and pull foot brake cylinder off the push rod. S04540-10 – Remove the connecting link of the chain. –...

  • Page 54: Installing The Shock Absorber

    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 Guideline Screw, top shock 60 Nm (44.3 lbf ft)

  • Page 55: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. The dust boot is correctly positioned. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis K01148-10 –...

  • Page 56: Mounting The Seat

    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.

  • Page 57: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 – Pull off the air filter box cover in area 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 sideways and take off toward the front.

  • Page 58: Removing The Air Filter

    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.

  • Page 59: Installing The Air Filter

    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. –...

  • Page 60: Removing The Main Silencer

    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. –...

  • Page 61: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Pull out inner tube – Remove the glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –...

  • Page 62: Installing The Fuel Tank

    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 S04552-10 – Remove screw with the rubber bushing. – Pull the fuel tank breather hose off the fuel tank lid. S04553-10 –...

  • Page 63: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 Main work – Check 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 –...

  • Page 64: Cleaning The Chain

    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. –...

  • Page 65: Adjusting The Chain Tension

    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 Guideline Lower chain section must be taut. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 66: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    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 can be turned by 180°. Finishing work – Remove the motorcycle from the lift stand. ( p.
  • Page 67 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 68: 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 Remaining nuts, 10 Nm (7.4 lbf ft) chassis 102192-01...

  • Page 69: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS 11 Main work – Check 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.

  • Page 70: 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 71: Changing The Hydraulic Clutch Fluid

    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. –...
  • Page 72 11 SERVICE WORK ON THE CHASSIS – Now inject the liquid into the system until it emerges from the drill hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...

  • Page 73: 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 74: Checking The Front Brake Fluid Level

    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. –...
  • Page 75 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 76: Checking The Front Brake Linings

    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 ≥...
  • Page 77 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.

  • Page 78: 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. 101738-01 –...

  • Page 79: 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 80: 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. 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.

  • Page 81: 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. 120) – Mount the screw cap with the membrane and the O-ring. Info S04561-10 Clean up overflowed or spilled brake fluid immediately with...
  • Page 82 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.
  • Page 83 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 84: 13 Wheels, Tires

    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.

  • Page 85: 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 86: 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 87 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 88: 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 89: Checking Spoke Tension

    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.

  • Page 90: 14 Cooling System

    14 COOLING SYSTEM 14.1 Cooling system Water pump in 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 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 91: Removing The Radiator Cover

    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 – Position radiator shield – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft)

  • Page 92: Checking The Coolant Level

    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. –...

  • Page 93: Draining The Coolant

    COOLING SYSTEM 14 – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. 10 mm (0.39 in) Coolant level above the radiator fins » If the coolant level does not match the specified value: –...

  • Page 94: Refilling With Coolant

    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. –...

  • Page 95: Changing The Coolant

    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.
  • Page 96 14 COOLING SYSTEM – Mount radiator cap 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 97: Tuning The Engine 15

    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 Play in throttle cable 2 …...

  • Page 98: Carburetor Tuning

    15 TUNING THE ENGINE – Turn barrel adjuster so that there is play in the throttle cable at the throttle grip. Guideline Play in throttle cable 2 … 3 mm (0.08 … 0.12 in) – Tighten nut – Slide on sleeve 400192-11 Finishing work –...
  • Page 99 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.

  • Page 100: Carburetor - Idle Setting

    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.

  • Page 101: Carburetor - Adjusting The Idle Speed

    TUNING THE ENGINE 15 15.5 Carburetor - adjusting the idle speed – Screw in idle air adjusting screw 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.

  • Page 102: Plug-In Connector Of Ignition Timing Map Adjustment

    15 TUNING THE ENGINE 15.6 Plug-in connector of ignition timing map adjustment Plug-in connector of 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 •...
  • Page 103 TUNING THE ENGINE 15 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.

  • Page 104: 16 Service Work On The Engine

    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. –...

  • Page 105: Checking The Gear Oil Level

    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 –...

  • Page 106: Adding The Gear Oil

    16 SERVICE WORK ON THE ENGINE Main work – Remove gear oil drain plug with magnet. – Remove gear oil drain plug – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug. – Clean the sealing surface on the engine. –...
  • Page 107 SERVICE WORK ON THE ENGINE 16 Main work – Remove gear oil level monitoring screw S04567-10 – Remove filler plug with the O-ring. – Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw. Engine oil (15W/50) ( p.

  • Page 108: 17 Cleaning, Care

    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. –...
  • Page 109 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.

  • Page 110: 18 Storage

    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. –...

  • Page 111: Preparing For Use After Storage

    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...

  • Page 112: 19 Troubleshooting

    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.
  • Page 113 TROUBLESHOOTING 19 Faults Possible cause Action Too little coolant in cooling system – Engine overheats 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.

  • Page 114: 20 Technical Data

    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...
  • Page 115 TECHNICAL DATA 20 Screw, water pump wheel 6 Nm (4.4 lbf ft) Loctite ® 243™ Bleeder screw, cylinder head 8 Nm (5.9 lbf ft) Drain plug, water pump cover 10 Nm (7.4 lbf ft) Nut, adjusting screw, power valve 8 Nm (5.9 lbf ft) Screw, alternator cover 8 Nm (5.9 lbf ft) Screw, bearing retainer...

  • Page 116: Carburetor

    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 Needle jet S‑7...

  • Page 117: Carburetor - Basic Setting For Sandy Surfaces

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

  • Page 118: Tires

    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.

  • Page 119: Shock Absorber

    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...
  • Page 120 20 TECHNICAL DATA Screw, ball joint of push rod on foot 10 Nm (7.4 lbf ft) Loctite ® 243™ brake cylinder Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ®...
  • Page 121 TECHNICAL DATA 20 Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

  • Page 122: 21 Substances

    21 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 123 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 –...

  • Page 124: 22 Auxiliary Substances

    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 ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 125 AUXILIARY SUBSTANCES 22 Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 126: 23 Standards

    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.

  • Page 127: List Of Abbreviations 24

    LIST OF ABBREVIATIONS 24 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 128: Index

    INDEX Clutch INDEX fluid level, checking/correcting ... . . 68 fluid, changing ..... . . 69 Accessories .
  • Page 129 INDEX Frame removing ......58 checking ......66 Manufacturer warranty .
  • Page 130 INDEX static sag, checking ....35 Spare parts ......9 Spoke tension checking .
  • Page 131 *3215008en* 3215008en 10/2020 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

Table of Contents