GAS GAS MC 50 2022 Owner's Manual
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GAS GAS MC 50 2022 Owner's Manual

GAS GAS MC 50 2022 Owner's Manual

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OWNER'S MANUAL 2022
MC 50
Art. no. 3215048en

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Summary of Contents for GAS GAS MC 50 2022

  • Page 1 OWNER'S MANUAL 2022 MC 50 Art. no. 3215048en...
  • 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 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 Riding ............21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Applying the brakes........21 Symbols used..........5 Stopping, parking......... 22 Formats used..........5 Transporting ..........22 Refueling............23 SAFETY ADVICE ............6 Use definition – intended use....... 6 SERVICE SCHEDULE............
  • Page 5 TABLE OF CONTENTS 11.16 Removing the start number plate....47 13.3 Removing the rear wheel ......76 11.17 Installing the start number plate ....47 13.4 Installing the rear wheel ......77 11.18 Removing front fender........ 48 13.5 Checking the tire condition......78 11.19 Installing the front fender ......
  • Page 6 TABLE OF CONTENTS AUXILIARY SUBSTANCES ......... 110 STANDARDS ............112 LIST OF ABBREVIATIONS......... 113 INDEX ................114...

  • 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 the safety of your child, have these jobs performed in 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) V02172-10 Fuel tank filler cap Quick release of seat Chain guide Choke Fuel tap ( p. 15)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) V02173-10 Stop button ( p. 14) Throttle grip ( p. 14) Hand brake lever ( p. 14) Vehicle identification number ( p. 12) Kick starter lever ( p. 16) Foot brake lever ( 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 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 article number is stamped on the bottom of the shock absorber toward the right-hand side. H01186-10...

  • Page 16: Controls

    6 CONTROLS Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The hand brake lever is used to activate the front brake. F02966-10 Throttle grip Throttle grip is fitted on the right side of the handlebar. F02966-11 Stop button The stop button...

  • Page 17: Closing The Fuel Tank Filler Cap

    CONTROLS 6 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 18: Choke

    6 CONTROLS Choke Choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mix- ture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 19: Preparing For Use 7

    PREPARING FOR USE 7 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 20 7 PREPARING FOR USE 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 the motorcycle, remember that others may be disturbed by excessive noise. –...

  • Page 21: Running In The Engine

    PREPARING FOR USE 7 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 22: Riding Instructions

    8 RIDING INSTRUCTIONS 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 23: Starting Off

    RIDING INSTRUCTIONS 8 Preliminary work – Raise the motorcycle with a lift stand. ( p. 37) The motorcycle has been out of use for more than 1 week – Empty the carburetor float chamber. – Turn the knurled screw on the fuel tap all the way counterclockwise. Fuel can flow from the fuel tank to the carburetor.

  • Page 24: Stopping, Parking

    8 RIDING INSTRUCTIONS Warning Danger of accidents Moisture and dirt impair the brake system. – Explain to your child that he or she must brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. –...

  • Page 25: Refueling

    RIDING INSTRUCTIONS 8 – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away. 401475-01 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 26: 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 27: Recommended Work

    SERVICE SCHEDULE 9 Every 80 operating hours Every 40 operating hours Every 20 operating hours After 10 operating hours ● ● Service the fork. ● Perform the shock absorber service. ○ ● ● ● Check the tightness of the easily accessible, safety-relevant screws and nuts. ○...

  • Page 28: 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 29: 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 30: Adjusting The Rebound Damping Of The Shock Absorber

    10 TUNING THE CHASSIS – Push the splash protector to the side. – Using an open end wrench, 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.

  • Page 31: Measuring The Dimension Of The Rear Wheel Unloaded

    TUNING THE CHASSIS 10 10.7 Measuring the dimension of the rear wheel unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) Main work – Measure the vertical distance between the rear axle and a fixed point, such as a marking on the side cover.

  • Page 32: 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. 29) – 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 33: 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 retaining ring – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T304) Hook wrench (T1533) Info If the spring cannot be fully released, the spring must be...

  • Page 34: 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. 49) – Remove the motorcycle from the lift stand. ( p.
  • Page 35 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. F02971-10 – Connect the fork airpump to the left fork leg. The fork airpump indicator switches on automatically.

  • Page 36: Adjusting The Rebound Damping Of The Fork

    10 TUNING THE CHASSIS 10.14 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn adjuster clockwise all the way. Info Adjuster is located at the upper end of the right fork leg. –...

  • Page 37: Adjusting The Seat Height

    TUNING THE CHASSIS 10 – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. – Remove screws .
  • Page 38 10 TUNING THE CHASSIS – Hold the rear wheel with the link fork and remove screw – Position the shock absorber according to the required seat height. Guideline Low seat position (standard) High seat position – Position screw F02974-10 – Mount nut and tighten the fitting.

  • Page 39: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 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 40: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 37) 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) –...

  • Page 41: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 – Remove screws on the right fork leg. Take off the fork protector. F02977-10 11.6 Installing the fork protector – Position fork protector on the right fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F02977-11...

  • Page 42: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. F03022-10 11.8 Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the rear. Info The second milled groove in the fork leg must be flush with the upper edge of the upper triple clamp.

  • Page 43: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) – Remove the front wheel. p. 75) – Remove the fork legs. p. 39) – Remove the start number plate.

  • Page 44: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 110) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing –...
  • Page 45 SERVICE WORK ON THE CHASSIS 11 – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) clamp F03024-10 – Tighten nut Guideline Nut, steering head M20x1.5 10 Nm (7.4 lbf ft) – Position the fuel tank breather in the steering stem. F03027-10 –...

  • Page 46: Checking The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS 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 47: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 Guideline Screw, top triple clamp 20 Nm (14.8 lbf ft) – Position the fuel tank breather in the steering stem. Finishing work – Check the steering head bearing play. ( p. 44) – Remove the motorcycle from the lift stand. ( p.

  • Page 48: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screw F02978-10 – Raise the fuel tank. – Pull off fuel hose Info Remaining fuel may flow out of the fuel hose. – Pull fuel tank breather out of the steering stem. –...

  • Page 49: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 – Mount fuel hose F02979-11 – Position the fuel tank. – Make sure that no cables or throttle cables are trapped or damaged. – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...

  • Page 50: Removing Front Fender

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, start number 4 Nm (3 lbf ft) plate F02982-10 11.18 Removing front fender – Remove screws . Take off the front fender. F02983-10 11.19 Installing the front fender –...

  • Page 51: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.20 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) Main work – Pull brake line out of the holder. – Remove nut – Remove screw and lower the link fork carefully.

  • Page 52: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS Finishing work – Remove the motorcycle from the lift stand. ( p. 37) 11.22 Removing the seat – Open quick release and raise the rear of the seat. – Pull back the seat and remove it. F02987-10 11.23 Mounting the seat...

  • Page 53: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Main work – Press rear holding lug together slightly and swing the air filter box cover upward. – Pull out the front holding lug and take off the air filter box cover. – Take off the air filter. F02989-10 11.25 Installing the air filter...

  • Page 54: Removing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 51) – Mount the seat. ( p. 50) 11.27 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. –...

  • Page 55: Removing The Engine Sprocket Cover

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws with toothed washers from the silencer cap – Remove end cap and outer tube – Remove glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –...

  • Page 56: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS 11.32 Checking the chain for dirt – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 54) 400678-01 11.33 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.

  • Page 57: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.34 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear- ings wear more quickly.

  • Page 58: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 5 … 8 mm (0.2 … 0.31 in) Turn the adjusting screws on the left and right so that the F02198-10 markings on the left and right chain adjusters...
  • Page 59 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 60: Adjusting The Chain Guide

    11 SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the chain guide. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F02201-01 Finishing work – Install the engine sprocket cover.

  • Page 61: Checking The Link Fork

    SERVICE WORK ON THE CHASSIS 11 11.39 Checking the link fork – Check the link fork for damage, cracks, and deformation. » If the link fork shows signs of damage, cracks, or deformation: – Change the link fork. Guideline Repairs on the link fork are not permitted. F02203-01 11.40 Checking the throttle cable routing...

  • Page 62: Additionally Securing The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS 11.42 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 59) Main work – Secure the rubber grip at two locations with the retaining wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the palms and are bent in toward the rubber grip.

  • Page 63: Brake System 12

    BRAKE SYSTEM 12 12.1 Checking play of handbrake 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 64: Checking The Brake Discs

    12 BRAKE SYSTEM – Position cover . Mount and tighten screw F02996-11 12.4 Checking the brake discs Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized GASGAS Motorcycles work- shop will be glad to help.) –...
  • Page 65 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 66: Adding The Front Brake Fluid

    12 BRAKE SYSTEM 12.6 Adding the front brake fluid Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 67: Checking The Front Brake Linings

    BRAKE SYSTEM 12 Info Clean up the overflowed or spilled brake fluid immediately with water. 12.7 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.) –...
  • Page 68 12 BRAKE SYSTEM 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 69 BRAKE SYSTEM 12 – Remove lock ring – Remove screw – Remove the brake linings. – Clean the brake caliper and the brake caliper bracket. 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.

  • Page 70: Checking The Free Travel Of The Foot Brake Lever

    12 BRAKE SYSTEM – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Secure the hand brake lever in the activated position. The brake caliper straightens. –...

  • Page 71: Adjusting The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM 12 12.10 Adjusting the free travel 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 72: Checking The Rear Brake Fluid Level

    12 BRAKE SYSTEM 12.12 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 73: Checking The Brake Linings Of The Rear Brake

    BRAKE SYSTEM 12 Note Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the appli- cable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 74: Changing The Rear Brake Linings

    12 BRAKE SYSTEM – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If the minimum thickness is less than specified: – Change the rear brake linings. p. 72) – Check the brake linings for damage and cracking. »...
  • Page 75 BRAKE SYSTEM 12 Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint. Only use clean brake fluid from a sealed container.
  • Page 76 12 BRAKE SYSTEM – Mount and tighten screw Guideline Screw, rear brake M6x16 10 Nm (7.4 lbf ft) ® Loctite 243™ caliper – Mount and tighten screw Guideline Screw, rear brake M6x40 10 Nm (7.4 lbf ft) Loctite ® 243™ caliper F02206-10 –...

  • Page 77: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 37) Main work – Loosen screw by several rotations. – Loosen screws – Press on screw to push the wheel spindle out of the axle clamp. –...

  • Page 78: Removing The Rear Wheel

    13 WHEELS, TIRES – 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 79: Installing The Rear Wheel

    WHEELS, TIRES 13 – Pull out wheel spindle far enough to allow the rear wheel to be pushed forward. – Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket. Info Cover the components to protect them against damage. F02210-10 Warning Danger of accidents Damaged brake discs reduce the...

  • Page 80: Checking The Tire Condition

    13 WHEELS, TIRES – Clean and grease the wheel spindle. Long-life grease ( p. 110) – Position rear wheel and mount the chain. The brake linings are correctly positioned. – Insert wheel spindle F02210-11 – Position chain adjuster . Mount nut , but do not tighten it yet.

  • Page 81: Checking Tire Pressure

    WHEELS, TIRES 13 – 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 82 13 WHEELS, TIRES – Check the spoke torque. Guideline Spoke nipple M3.5 3 Nm (2.2 lbf ft) Torque wrench kit (58429094000)

  • Page 83: Cooling System 14

    COOLING SYSTEM 14 14.1 Cooling system The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regu- lated by a valve in the radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 84: Checking The Coolant Level

    14 COOLING SYSTEM 14.3 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 85: Refilling With Coolant

    COOLING SYSTEM 14 Condition The engine is cold. – Position the motorcycle upright. – Place an appropriate container under the water pump cover. – Remove screw . Take off the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring.

  • Page 86: Changing The Coolant

    14 COOLING SYSTEM – Check the coolant level. ( p. 82) 14.6 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 87 COOLING SYSTEM 14 – Move the vehicle into the position shown and secure it against rolling away. Height difference must be reached. Guideline 50 cm (19.7 in) Height difference Info For all of the air to be able to escape from the cooling sys- tem, the vehicle must be raised at the front.

  • Page 88: 15 Tuning The Engine

    15 TUNING THE ENGINE 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 3 …...

  • Page 89: Carburettor - Idle Speed

    TUNING THE ENGINE 15 Finishing work – Install the fuel tank. p. 46) – Mount the seat. ( p. 50) – Check the play in the throttle cable. ( p. 86) Carburettor – idle speed 15.3 The idle setting of the carburetor has a big influence on the starting behavior, stable idle speed, and the response to throttle opening.

  • Page 90: Checking The Clutch Setting

    15 TUNING THE ENGINE – Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.

  • Page 91: Removing The Clutch Cover

    TUNING THE ENGINE 15 15.6 Removing the clutch cover Note Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to enter the groundwater, the soil, or the sewage system. Info Fuel can emerge via the carburetor. Capture emerging fuel using a suitable container.

  • Page 92: Installing The Clutch Cover

    15 TUNING THE ENGINE – Turn adjusting screws clockwise. Guideline 1 click increases the slip 250 … 350 rpm speed by Info The springs may not be pretensioned by more than 17 clicks from the stop using the adjusting screws. Condition If the slip speed is too high: –...

  • Page 93: 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 – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. »...

  • Page 94: Adding The Gear Oil

    16 SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.20 l (0.21 qt.) Gear oil (ATF Dexron 3) p. 109) Info Too little gear oil or poor-quality gear oil results in prema- ture wear to the transmission.
  • Page 95 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 96: 17 Carburetor

    17 CARBURETOR 17.1 Removing the carburetor 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 97: Installing The Carburetor

    CARBURETOR 17 – Push back hose clamp and pull off the vent hose. – Pull the carburetor out of the intake flange. – Pull the carburetor forward out of the inlet sleeve. F03012-10 – Remove throttle slide cover – Pull the throttle slide out of the carburetor. –...
  • Page 98 17 CARBURETOR – Position the throttle slide and throttle slide cover. – Tighten throttle slide cover hand-tight. – Measure the distance between the carburetor housing and the throttle slide cover. » : ≤ 3 mm (≤ 0.12 in) Distance If the specified value is not reached: –...

  • Page 99: 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 100 18 CLEANING, CARE – 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. 54) – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.

  • Page 101: 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 102: Preparing For Use After Storage

    19 STORAGE 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 37) – Perform checks and maintenance measures when preparing for use. p. 20) – Take a test ride. 401059-01...

  • Page 103: Troubleshooting 20

    TROUBLESHOOTING 20 Faults Possible cause Action – Engine turns but does not start Operating error Carry out start procedure. ( p. 20) – Motorcycle was out of use for a Empty the carburetor float chamber. long time and there is old fuel in the float chamber –...
  • Page 104 20 TROUBLESHOOTING Faults Possible cause Action – Engine stalls or is popping into the Lack of fuel Turn the knurled screw on the fuel tap all carburetor the way counterclockwise. – Refuel. ( p. 23) – Engine takes in bad air Check the intake flange and carburetor for tightness.

  • Page 105: Technical Data 21

    TECHNICAL DATA 21 21.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake Displacement 49.0 cm³ (2.99 cu in) Stroke 40 mm (1.57 in) Bore 39.5 mm (1.555 in) Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast...

  • Page 106: Carburetor With Carburetor Tuning

    21 TECHNICAL DATA Screw, water pump cover 10 Nm (7.4 lbf ft) Screw, cylinder head 18 Nm (13.3 lbf ft) Nuts, cylinder base 20 Nm (14.8 lbf ft) Screw, clutch basket 35 Nm (25.8 lbf ft) Stud bolt, cylinder base 10 Nm (7.4 lbf ft) Spark plug M10x1...

  • Page 107: Tires

    TECHNICAL DATA 21 front Disc brake with 4-piston brake caliper rear Disc brake with 2-piston brake caliper Brake disc diameters front 160 mm (6.3 in) rear 160 mm (6.3 in) Brake discs - wear limits front 2.2 mm (0.087 in) rear 2.2 mm (0.087 in) Offroad tire pressure...

  • Page 108: Shock Absorber

    21 TECHNICAL DATA 21.8 Shock absorber Shock absorber article number 03.18.7U.02 Shock absorber WP XACT 5735 Low-speed compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks High-speed compression damping Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks...
  • Page 109 TECHNICAL DATA 21 Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, main silencer silent block 6 Nm (4.4 lbf ft) Screw, rear brake caliper M6x16 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, rear brake caliper M6x40 10 Nm (7.4 lbf ft) Loctite...

  • Page 110: 22 Substances

    22 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 111 SUBSTANCES 22 Gear oil (ATF Dexron 3) Standard/classification – Dexron III (ATF Dexron 3) Guideline – Use only ATF gear oils that comply with the specified standards (see specifications on the container) and that possess the necessary properties. Recommended supplier MOTOREX ®...

  • Page 112: 23 Auxiliary Substances

    23 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 113 AUXILIARY SUBSTANCES 23 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 114: 24 Standards

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

  • Page 115: List Of Abbreviations 25

    LIST OF ABBREVIATIONS 25 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 116: Index

    INDEX setting, checking ..... 88 INDEX Clutch cover Accessories ......9 clutch cover, installing .
  • Page 117 INDEX Fuel tank filler cap Plug-in stand ......16 closing ......15 Preparing for use opening .
  • Page 118 INDEX Stop button ......14 Storage ......99 Technical data capacities .
  • Page 119 *3215048en* 3215048en 04/2021 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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