GAS GAS MC 85 2021 Owner's Manual
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GAS GAS MC 85 2021 Owner's Manual

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OWNER'S MANUAL 2021
MC 85
Art. no. 3215007en

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Summary of Contents for GAS GAS MC 85 2021

  • Page 1 OWNER'S MANUAL 2021 MC 85 Art. no. 3215007en...
  • 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, sporty DEAR GASGAS CUSTOMER motorcycle that will continue to give you and your child pleasure for a long time if you maintain it properly. We hope your child has many safe and enjoyable rides! 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 ............. 22 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 12.6 Checking the front brake linings ....72 11.4 Cleaning the dust boots of the fork legs..43 12.7 Changing the brake linings of the front brake ............72 11.5 Removing the fork legs ......
  • Page 6 TABLE OF CONTENTS STORAGE..............106 18.1 Storage............106 18.2 Preparing for use after storage....107 TROUBLESHOOTING ..........108 TECHNICAL DATA............ 110 20.1 Engine ............110 20.2 Engine tightening torques......110 20.3 Carburetor ..........112 20.3.1 Carburetor tuning ....... 112 20.3.2 Basic carburetor 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) S04315-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Shift lever ( p. 16) Choke ( p. 16) Fuel tap ( p.

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S04316-10 Switch-off button ( p. 14) Throttle grip ( p. 14) Fork part number ( p. 12) Foot brake lever ( p. 17) Kick starter lever ( p. 17) 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 Type label is located on the front frame tube. 402154-10 Engine number The engine number is located on the left side of the engine under the engine sprocket.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. H02222-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. S04274-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. S04275-10 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. Using the tap handle on the fuel tap, you can open or close the fuel supply to the carburetor. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the •...

  • Page 19: Kick Starter Lever

    CONTROLS 6 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-11 6.10 Kick starter lever Kick starter lever is fitted on the right side of the engine. The kick starter lever can be swiveled.

  • Page 20: Preparing For Use

    7 PREPARING FOR USE Advice on preparing for first use Warning Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk. Children often underestimate or fail to recognize dangerous situations. – Your child must already be able to ride a bicycle.
  • Page 21 PREPARING FOR USE 7 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. –...

  • Page 22: Running In The Engine

    7 PREPARING FOR USE 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.
  • Page 23 PREPARING FOR USE 7 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 temper- ature.

  • Page 24: Preparing The Vehicle For Rides On Wet Sand

    7 PREPARING FOR USE Preparing the vehicle for rides on wet sand – Make sure that no radiator covers ( p. 86) are installed. – 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.

  • 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. – Clean the motorcycle. ( p. 104) – Straighten the bent radiator fins carefully. M01107-01 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 – Adjust the carburetor jetting and setting. Info The recommended carburetor tuning is available from your authorized GASGAS Motorcycles workshop. M01107-01...

  • 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. 98) – Turn handle of the fuel tap to the ONposition. 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. – Explain to your child that he or she must adapt the braking to the traffic situation and the road conditions. Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.

  • Page 30: Transporting

    8 RIDING INSTRUCTIONS – Park the motorcycle on firm ground. 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. –...
  • Page 31 RIDING INSTRUCTIONS 8 – Fill the fuel tank with fuel up to measurement Guideline 35 mm (1.38 in) Measurement of Fuel tank capacity, 5.2 l Super unleaded (98 approx. (1.37 US gal) octane) mixed with 2-stroke engine oil (1:40) ( 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 After 10 operating hours / Every 10 operating hours ● Service the fork. ● Perform the shock absorber service. ○ ● ● ● Check the tightness of the easily accessible, safety-relevant screws and nuts. ○...

  • Page 34: 10 Tuning The Chassis

    10 TUNING THE CHASSIS 10.1 Checking the basic chassis setting with 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 clockwise all the way. Info Do not loosen fitting – Turn counterclockwise by the number of turns corresponding to the shock absorber type. Guideline High-speed compression damping S04322-10 Comfort 2.5 turns Standard 2 turns Sport 1.5 turns...

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

    TUNING THE CHASSIS 10 Main work – Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover. – Note the value as dimension 400988-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • 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 – Measure the full spring length while it is under tension and note down the value. – 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 Info The spring rate is shown on the outside of the spring. Smaller weight differences can be compensated by changing the spring preload. Finishing work – Install the shock absorber. p. 53) – Remove the motorcycle from the lift stand. ( p.
  • Page 41 TUNING THE CHASSIS 10 Main work – Remove protection cap – Push together fork airpump fully. Fork airpump (79412966100) Info The fork airpump is included as part of the motorcycle's accessory pack. S04324-10 – Connect the fork airpump to the left fork leg. The fork airpump switches on automatically.

  • Page 42: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Take off protection cap – Turn adjusting screw clockwise all the way. Info The adjusting screw is located at the lower end of the right fork leg.

  • Page 43: Handlebar Position

    TUNING THE CHASSIS 10 10.16 Handlebar position On the upper triple clamp, there are 2 holes at a distance of to each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar supports are placed at a distance of from the center.

  • Page 44: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Neither wheel is in contact with the ground.

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

    SERVICE WORK ON THE CHASSIS 11 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 of both fork legs downward.

  • 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. S04327-10 11.6 Installing the fork legs – 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 – 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 –...

  • Page 48: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the front wheel. p. 80) – Remove the fork legs. p. 43) – Remove the start number plate.

  • Page 49: 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. 119) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing –...
  • Page 50 11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp S04327-12 – Tighten nut Guideline Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) S03419-10 – Position the fuel tank breather in the steering stem. –...

  • Page 51: Checking The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 – Clean and grease the wheel spindle. Long-life grease ( p. 119) – Position the front wheel. – Insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle S04328-11 –...

  • Page 52: Adjusting The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS 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: –...

  • Page 53: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 11.13 Greasing the steering head bearing – Remove the lower triple clamp. p. 46) – Install the lower triple clamp. p. 47) H02387-01 11.14 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove it. S04332-10 11.15 Installing the start number plate...

  • Page 54: Removing Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.16 Removing front fender Preparatory work – Remove the start number plate. ( p. 51) Main work – Remove screws – Remove screws . Take off the front fender. S04335-10 11.17 Installing front fender Main work –...

  • Page 55: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.19 Installing the shock absorber Main work – Push splash protector to the side and position the shock absorber. Mount and tighten screw Guideline Screw, top shock 60 Nm (44.3 lbf ft) ® Loctite 2701™...

  • Page 56: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.22 Removing the air filter box cover – Pull off the air filter box cover laterally in areas and take it off toward the front. S04340-10 11.23 Installing the air filter box cover – Attach the air filter box cover in areas and snap it into place in areas...

  • Page 57: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 11 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.

  • Page 58: Removing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS – Insert the air filter and position top retaining pin in bushing The air filter is correctly positioned. – Secure the bottom retaining pin with holding tab Info If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.

  • Page 59: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Preparatory work – Remove main silencer. ( p. 56) Main work – Remove screws – Take off outer tube – Remove glass fiber yarn filling from inner tube – Clean the parts that need to be reinstalled and check for damage. –...

  • Page 60: 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 S04344-10 – Remove screw with the rubber bushing. – Remove the hose from the fuel tank breather. S04345-10 –...

  • Page 61: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. ( p. 64) – Position the fuel tank and fit the two spoilers to the sides of the radi- ator mount. – Make sure that no cables or throttle cables are trapped or damaged. S04346-11 –...

  • Page 62: Cleaning The Chain

    11 SERVICE WORK ON THE CHASSIS 11.33 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 63: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Main work – Pull the chain at the end of the chain sliding guard upward to mea- sure chain tension Info Lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 64: 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 65 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 66: 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 V00861-01 Finishing work –...

  • Page 67: Checking The Rubber Grip

    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.

  • Page 68: Checking The Fluid Level Of The Hydraulic Clutch

    11 SERVICE WORK ON THE CHASSIS 11.42 Checking the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs. – Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horizontal position. –...

  • Page 69: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 – Move the clutch fluid reservoir mounted on the handlebar to a hori- zontal position. – Remove screws – Remove cover with membrane – Correct the fluid up to level Guideline 4 mm (0.16 in) Level (fluid level below container rim)
  • Page 70 11 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a hori- zontal position. – Remove screws – Remove cover with membrane S04281-11 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 71: 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 72: Checking The Front Brake Fluid Level

    12 BRAKE SYSTEM » If the brake disc thickness is less than the specified value: – Change the front brake disc. – Change the rear brake disc. – Check the front and rear brake discs for damage, cracking, and deformation. »...
  • Page 73 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 74: 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 75 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 76: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM Info To make it easier to mount the pin, push the brake linings against the retainer spring. Make sure the brake linings and retainer spring are seated correctly. – Mount cotter pins – Position the brake caliper. –...

  • Page 77: 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 78: Adding Rear Brake Fluid

    12 BRAKE SYSTEM – Stand the vehicle upright. – Check the brake fluid level in level viewer Move the frame protector slightly to the side to make it eas- ier to see the marking. » If the brake fluid has dropped below the marking –...

  • Page 79: Checking The Rear Brake Linings

    BRAKE SYSTEM 12 Main work – Stand the vehicle upright. – Remove screws – Take off the cover with the washer and membrane – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 117) – Mount the cover with the washer and membrane.
  • Page 80 12 BRAKE SYSTEM 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 81 BRAKE SYSTEM 12 – Remove cotter pin – Press back the brake linings by slightly tilting the brake caliper later- ally on the brake disc. – Remove pin – Remove brake linings and the retainer spring. – Clean brake caliper. –...

  • Page 82: 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 – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp. –...

  • Page 83: Removing The Rear Wheel

    WHEELS, TIRES 13 – 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 and contact surfaces of the spacers. Long-life grease ( p.

  • Page 84: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Remove nut – Take off chain adjuster . Pull out wheel spindle far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.

  • Page 85: Checking The Tire Condition

    WHEELS, TIRES 13 – Clean and grease the wheel spindle. Long-life grease ( p. 119) – Position rear wheel and mount the chain. The brake linings are correctly positioned. – Insert wheel spindle V00880-10 – Position chain adjuster . Mount nut , but do not tighten it yet.

  • Page 86: Checking Tire Pressure

    13 WHEELS, TIRES – 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.
  • Page 87 WHEELS, TIRES 13 – Check the spoke torque. Guideline Spoke nipple M4.5 5 Nm (3.7 lbf ft) Torque wrench kit (58429094000)

  • Page 88: 14 Cooling System

    14 COOLING SYSTEM 14.1 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 89: Removing The Radiator Cover

    COOLING SYSTEM 14 – Position the corresponding radiator cover ( p. 86). The holding lugs point toward the frame. H02356-01 – Position left radiator shield – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position right radiator shield –...

  • Page 90: Checking The Antifreeze And Coolant Level

    14 COOLING SYSTEM Guideline Remaining screws, 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.

  • Page 91: Checking The Coolant Level

    COOLING SYSTEM 14 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.

  • Page 92: Refilling With Coolant

    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: Changing The Coolant

    COOLING SYSTEM 14 – Loosen screw until coolant escapes without bubbles. – Mount and tighten screw Guideline Screw, radiator bleed- 8 Nm (5.9 lbf ft) – Completely fill the radiator with coolant. Coolant ( p. 117) – V00870-10 Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
  • Page 94 14 COOLING SYSTEM Main work – Position the motorcycle upright. – Place an appropriate container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw, water pump 10 Nm (7.4 lbf ft)

  • Page 95: 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 96: Carburetor Tuning

    15 TUNING THE ENGINE Finishing work – Install the fuel tank. p. 58) – Mount the seat. ( p. 53) – Check the play in the throttle cable. ( p. 93) 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).
  • Page 97 TUNING THE ENGINE 15 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.

  • Page 98: Carburetor - Idle

    15 TUNING THE ENGINE 402797-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 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.

  • Page 99: Carburetor - Adjusting The Idle Speed

    TUNING THE ENGINE 15 Carburetor – adjusting the idle speed 15.5 – Screw in idle air adjusting screw all the way and turn it to the specified basic setting. Guideline Idle air adjusting screw open 2 turns – Run the engine until warm. Guideline ≥...

  • Page 100: Emptying The Carburetor Float Chamber

    15 TUNING THE ENGINE 15.6 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 101: Plug-In Connector Of Ignition Timing Map Adjustment

    TUNING THE ENGINE 15 15.7 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 102 15 TUNING THE ENGINE – 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 103: Service Work On The Engine 16

    SERVICE WORK ON THE ENGINE 16 16.1 Checking the gear oil level Condition The engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove screw with the seal ring. – Check the gear oil level. Gear oil must not run out of the hole.

  • Page 104: Adding The Gear Oil

    16 SERVICE WORK ON THE ENGINE Guideline Oil drain plug with 20 Nm (14.8 lbf ft) magnet – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) p. 117) –...
  • Page 105 SERVICE WORK ON THE ENGINE 16 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 106: 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 107 CLEANING, CARE 17 – Push back the protection caps on the handlebar controls to allow water to evaporate. – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 60) – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.

  • Page 108: 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 109: 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 110: 19 Troubleshooting

    19 TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Carry out the start procedure. ( p. 25) – Motorcycle was out of use for a Empty the carburetor float chamber. long time and there is old fuel in p.
  • Page 111 TROUBLESHOOTING 19 Faults Possible cause Action – Engine stalls or is popping into the The connector or ignition coil is Clean the connector and treat it with con- carburetor loose or oxidized tact spray. Too little coolant in cooling system – Engine overheats Check the cooling system for leaks.

  • Page 112: 20 Technical Data

    20 TECHNICAL DATA 20.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 84.93 cm³ (5.1828 cu in) Stroke 48.95 mm (1.9272 in) Bore 47 mm (1.85 in) Idle speed 1,400 … 1,500 rpm Crankshaft bearing 1 grooved ball bearing / 1 roller bearing Conrod bearing Needle bearing...
  • Page 113 TECHNICAL DATA 20 Screw, power valve stop plate M5x12 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, water pump wheel 6 Nm (4.4 lbf ft) Loctite ® 243™ Coolant drain plug 8 Nm (5.9 lbf ft) Nut, adjusting screw, power valve 8 Nm (5.9 lbf ft) Screw, alternator cover 8 Nm (5.9 lbf ft)

  • Page 114: Carburetor

    20 TECHNICAL DATA 20.3 Carburetor Carburetor type KEIHIN PWK 28 Needle position 3rd position from top Idle air adjusting screw open 2 turns Main jet 142 (140, 145, 148) Jet needle NRKC (NRJC) Idling jet 48 (45, 50) Throttle slide Choke nozzle 20.3.1 Carburetor tuning...

  • Page 115: Basic Carburetor Setting For Sandy Surfaces

    TECHNICAL DATA 20 Info Do not use on sandy terrain. 20.3.2 Basic carburetor setting for sandy surfaces Idle air adjusting screw 2 turns Idling jet Jet needle NRJ C Needle position 4th position from top Main jet Info If the engine is not running smoothly, use a smaller main jet. 20.4 Capacities 20.4.1...

  • Page 116: Tires

    20 TECHNICAL DATA rear 1.0 bar (15 psi) Secondary ratio 13:49 Chain 1/2 x 5/16” Rear sprockets available 44, 45, 46, 47, 48, 49, 50, 51 Steering head angle 66° Wheelbase 1,290 ± 10 mm (50.79 ± 0.39 in) Seat height, unloaded 890 mm (35.04 in) Ground clearance, unloaded 362 mm (14.25 in)

  • Page 117: Chassis Tightening Torques

    TECHNICAL DATA 20 Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Spring preload 11 mm (0.43 in) Spring rate Weight of rider: < 45 kg (< 99 lb.) 35 N/mm (200 lb/in) Weight of rider: 45 …...
  • Page 118 20 TECHNICAL DATA Screw, rear brake caliper 18 Nm (13.3 lbf ft) Loctite ® 243™ Screw, rear sprocket 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, subframe 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, top triple clamp 17 Nm (12.5 lbf ft) Steering stem clamp screw 20 Nm (14.8 lbf ft)

  • Page 119: Substances 21

    SUBSTANCES 21 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 120 21 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 121) (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 121: Auxiliary Substances 22

    AUXILIARY SUBSTANCES 22 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 122 22 AUXILIARY SUBSTANCES 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 123: Standards 23

    STANDARDS 23 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 124: 24 List Of Abbreviations

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

  • Page 125: Index

    INDEX Cleaning ......104-105 INDEX Clutch Accessories ......9 fluid level, checking .
  • Page 126 INDEX Fork protector installing ......45 Main silencer removing ......45 glass fiber yarn filling, changing .
  • Page 127 INDEX Shock absorber installing ......53 removing ......52 riding sag, checking .
  • Page 128 *3215007en* 3215007en 07/2020 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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