GAS GAS MC 250F FACTORY EDITION 2023 Owner's Manual
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GAS GAS MC 250F FACTORY EDITION 2023 Owner's Manual

GAS GAS MC 250F FACTORY EDITION 2023 Owner's Manual

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OWNER'S MANUAL 2023
MC 250F FACTORY EDITION
Art. no. 3215098en

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Summary of Contents for GAS GAS MC 250F FACTORY EDITION 2023

  • Page 1 OWNER'S MANUAL 2023 MC 250F FACTORY EDITION Art. no. 3215098en...
  • 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 Starting power of lithium-ion batteries TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 at low temperatures........21 Symbols used..........5 Preparing the vehicle for difficult Formats used..........5 operating conditions ........22 Preparing the vehicle for rides on dry SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS 10.14 Adjusting the compression damping of 11.45 Checking the link fork ......76 the fork ............43 11.46 Checking the throttle cable routing.... 76 10.15 Adjusting the rebound damping of the 11.47 Checking the rubber grips......77 fork...............
  • Page 6 TABLE OF CONTENTS TUNING THE ENGINE..........108 INDEX ................143 16.1 Checking the play in the throttle cable..108 16.2 Adjusting the play in the throttle cable ............. 108 16.3 Adjusting the characteristic map of the throttle response ......... 109 16.4 Changing the mapping ......

  • 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). Indicates work that requires expert 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: Safe Operation

    SAFETY ADVICE 2 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) W00230-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Cold start button ( p. 17) Engine number ( p. 12) Shift lever ( p.

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) W00231-10 Shock absorber compression adjuster Combination switch ( p. 15) Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Vehicle identification number ( p. 12) Steering head label ( 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 Steering head label The steering head label is attached to the front of the steering head. 401946-10 Engine number Engine number is located on the left side of the engine over the engine sprocket.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber. F03756-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. F03647-10 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. F03648-10 Throttle grip The throttle grip...

  • Page 17: Start Button

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

  • Page 18: Combination Instrument

    6 CONTROLS Combination instrument The combination instrument is attached in front of the handlebar. The combination instrument shows the total number of operating hours of the engine. The operating hour counter begins counting when the engine is started and stops when the engine is switched off. Info Nothing can be cleared or adjusted on the combination instru- ment.

  • Page 19: Closing The Fuel Tank Filler Cap

    CONTROLS 6 6.10 Closing the fuel tank filler cap – Mount fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed. Info Route fuel tank breather hose without kinks. W00206-10 6.11 Cold start button The cold start button is fitted to the bottom of the throttle valve body.

  • Page 20: Idle Speed Adjusting Screw

    6 CONTROLS 6.12 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 21: Foot Brake Lever

    CONTROLS 6 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Plug-in stand The support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle.

  • Page 22: Preparing For Use

    7 PREPARING FOR USE Advice on preparing for first use Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. –...

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more challenging ride. Info This vehicle is not approved for use on public roads. When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.

  • Page 24: Preparing The Vehicle For Difficult Operating Conditions

    7 PREPARING FOR USE Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in signifi- cantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

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

    PREPARING FOR USE 7 – Clean the chain. Chain cleaner ( p. 137) – Mount the steel sprocket. – Grease the chain. Universal oil spray ( p. 138) – Clean the radiator fins. – Straighten the bent radiator fins carefully. 600868-01 Preparing the vehicle for rides on wet sand –...

  • Page 26: Preparing Vehicle For High Temperatures Or Slow Riding

    7 PREPARING FOR USE Preparing vehicle for high temperatures or slow riding – Adjust the secondary drive to the road conditions. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary ratio. –...

  • 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: Activating Launch Control

    8 RIDING INSTRUCTIONS – Remove plug-in stand – Shift the transmission into neutral. Condition Ambient temperature: < 20 °C (< 68 °F) – Push the cold start button in all the way. H02629-10 – Press start button . Info Press the start button for a maximum of 5 seconds. Wait for 15 seconds before a further attempt at starting.

  • Page 29: Activating Traction Control

    RIDING INSTRUCTIONS 8 Activating traction control Info The traction control reduces excessive slip on the rear wheel in favor of more control and propulsion, particularly in wet conditions. When traction control is switched off, the rear wheel may spin more during high acceleration and on surfaces with low grip.

  • Page 30: Quickshifter

    8 RIDING INSTRUCTIONS Quickshifter When the quickshifter is activated, you can shift up without actuating the clutch. Info The quickshifter is not activated when shifting up from first to second gear, and the clutch lever must be used when shifting up instead.

  • Page 31: Applying The Brakes

    RIDING INSTRUCTIONS 8 The cold start button goes to the basic position. – After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed, but fuel consumption will be considerably lower. –...

  • Page 32: Stopping, Parking

    8 RIDING INSTRUCTIONS – Use the braking effect of the engine on long downhill stretches. Shift back one or two gears, but do not overrev the engine when doing so. This means that significantly less braking is required and the brake system does not overheat. 8.11 Stopping, parking Warning...

  • Page 33: Refueling

    RIDING INSTRUCTIONS 8 – Switch off the engine. – Mount plug-in stand on the fork legs. Plug-in stand (A46029094000) Info The plug-in stand is included. Make sure the brake line runs in front of the plug-in stand and does not become wedged. H02628-01 –...
  • Page 34 8 RIDING INSTRUCTIONS – Switch off the engine. – Open the fuel tank filler cap. ( p. 16) – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Dimension Super unleaded (ROZ 95) ( p. 136) 7.9 l (2.09 US gal) –...

  • Page 35: Service Schedule 9

    SERVICE SCHEDULE 9 Additional information Any further work that results from the service work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. If the vehicle is used in particularly harsh conditions such as heavy rain, mud, sand, snow, extreme temperatures, frequent full load etc., shorter service intervals than those in the table may be necessary.
  • Page 36 9 SERVICE SCHEDULE every 24 months Every 90 operating hours Every 45 operating hours Every 15 operating hours After 1 operating hour ○ ● ● ● Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 74) ○ ●...

  • Page 37: Tuning The Chassis 10

    TUNING THE CHASSIS 10 10.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight.

  • Page 38: Compression Damping Of The Shock Absorber

    10 TUNING THE CHASSIS 10.3 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed. The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly.

  • Page 39: Adjusting The Rebound Damping Of The Shock Absorber

    TUNING THE CHASSIS 10 – Turn adjuster clockwise all the way to the stop. – Turn counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Highspeed compression damping Comfort 2 turns Standard 1.5 turns Sport 1 turn F03639-10 Info Turn clockwise to increase damping;...

  • Page 40: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS Main work – Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090200) – Note the value as dimension F03630-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 41: Checking The Riding Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.9 Checking the riding sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 37) – 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 42: Adjusting The Riding Sag

    10 TUNING THE CHASSIS 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 43: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 10 Guideline Spring rate Weight of rider: 65 … 75 kg 39 N/mm (223 lb/in) (143 … 165 lb.) Weight of rider: 75 … 85 kg 42 N/mm (240 lb/in) (165 … 187 lb.) Weight of rider: 85 … 95 kg 45 N/mm (257 lb/in) (187 …...
  • Page 44 10 TUNING THE CHASSIS Info Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine. The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg. Preparatory work –...

  • Page 45: Adjusting The Compression Damping Of The Fork

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

  • Page 46: Handlebar Position

    10 TUNING THE CHASSIS 10.16 Handlebar position The holes on the handlebar support are placed at a distance of from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions. This allows the handlebar to be mounted in the most comfortable position for the rider.
  • Page 47 TUNING THE CHASSIS 10 Main work – Remove screws . Take off handlebar clamp . Take off 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 48 10 TUNING THE CHASSIS Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)

  • Page 49: 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 50: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. F03665-10 Finishing work – Remove the motorcycle from the lift stand. ( p. 47) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 51: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork protector – Remove screws and take off the clamp. – Remove screws and take off the left fork protector. – Remove screws and take off the right fork protector. W00204-10 11.6 Installing the fork protector –...

  • Page 52: Installing The Engine Guard

    11 SERVICE WORK ON THE CHASSIS 11.8 Installing the engine guard – Position the engine guard on the frame. – Mount screws , but do not tighten yet. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount screws with bushings, but do not tighten yet.

  • Page 53: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.11 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the front wheel. p. 92) Main work – Remove screws and take off the clamp. –...

  • Page 54: Removing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) brake caliper Loctite ® 243™ – Position the brake line and the clamp. Mount and tighten screws W00220-11 Finishing work –...

  • Page 55: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.14 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 137) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
  • Page 56 11 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head W00184-10 – Mount and tighten screw Guideline Screw, top steer- 20 Nm (14.8 lbf ft) ing stem Loctite ® 243™ W00184-11 –...

  • Page 57: Checking The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 11.15 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 58: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Check the steering head bearing play. ( p. 55) Finishing work – Mount the handlebar cushion. – Remove the motorcycle from the lift stand. ( p.

  • Page 59: Removing Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.20 Removing front fender Preparatory work – Remove the start number plate. ( p. 56) Main work – Remove screws . Take off the front fender. F03675-10 11.21 Installing front fender Main work – Position front fender.

  • Page 60: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.22 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) – Remove the frame protector. ( p. 50) – Remove the right side panel. ( p. 62) –...

  • Page 61: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. W00218-10 11.23 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bot- tom.

  • Page 62: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – Position the angle lever and linkage lever. – Mount and tighten fitting Guideline Nut, linkage lever on M16x1.5 60 Nm (44.3 lbf ft) angle lever Info Pay attention to flat area F03704-10 – Mount and tighten screw Guideline Screw, bottom...

  • Page 63: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11 – Slide the seat toward the rear and lift it off. W00198-10 11.25 Mounting the seat Main work – Attach the seat to the collar bushings and simultaneously slide it back. The holding lugs engage in the recesses. –...

  • Page 64: Removing The Right Side Panel

    11 SERVICE WORK ON THE CHASSIS 11.26 Removing the right side panel Preparatory work – Remove the frame protector. ( p. 50) Main work – Detach right side panel in area and slide it in area to the rear. – Take the right side panel off.

  • Page 65: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 – Detach the air filter box cover in area and slide it in area to the rear. – Take off the air filter box cover. W00209-10 Condition The air filter box cover is not secured. –...

  • Page 66: Preparing Air Filter Box Cover For Securing

    11 SERVICE WORK ON THE CHASSIS Condition The air filter box cover is not secured. – Position the air filter box cover in area and slide it forward. – Press the air filter box cover in area into the rubber bush- ings.

  • Page 67: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS 11 Main work – Detach retaining tab – Remove air filter with air filter support. – Remove air filter from air filter support. W00216-10 11.32 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 68: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.33 Installing the air filter Main work – Mount the clean air filter on the air filter support. Info The marking on the air filter support must face upwards. – Grease the air filter in area Long-life grease ( p.

  • Page 69: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 Main work – Detach spring Spring hook (50305017000C1) – Remove screws with the washers and take off the main silencer. W00212-10 11.35 Installing the main silencer Main work – Position the main silencer. – Mount screws with washers, but do not tighten yet.

  • Page 70: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Main work – Drill out all rivets on the main silencer and remove silencer cap with O-ring – Remove glass fiber yarn from the silencer cap. – Pull glass fiber yarn filling out of outer tube –...
  • Page 71 SERVICE WORK ON THE CHASSIS 11 Main work – Unplug fuel pump connector – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! H04981-10 –...

  • Page 72: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.38 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 73: Checking For Chain Dirt Accumulation

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

  • Page 74: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Rinse off loose dirt with a soft jet of water. –...

  • Page 75: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.42 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear- ings wear more quickly.

  • Page 76: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.43 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 77 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 78: 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 Screw, chain guide M6x16 10 Nm (7.4 lbf ft) on link fork at the rear Screw, chain guide...

  • Page 79: Checking The Rubber Grips

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

  • Page 80: Programming The Quickshifter

    11 SERVICE WORK ON THE CHASSIS 11.48 Programming the quickshifter Info If the shifting performance of the quickshifter starts to decrease, it must be reprogrammed. – Carry out start procedure. ( p. 25) – Press and hold the QS button for at least 10 seconds.

  • Page 81: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.
  • Page 82 11 SERVICE WORK ON THE CHASSIS – Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horizontal position. – Remove screws – Take off cover with membrane H04933-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 83: 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 84: Checking The Front Brake Fluid Level

    12 BRAKE SYSTEM » If the brake disc thickness is less than the specification: – Change the front brake disc. – Change the rear brake disc. – Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc exhibits damage, cracking, or deformation: –...
  • Page 85 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 86: Checking That The Brake Linings Of The Front Brake Are Secured

    12 BRAKE SYSTEM 12.6 Checking that the brake linings of the front brake are secured 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 87 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 88: 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. 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.

  • Page 89: Adjusting The Basic Position Of The Foot Brake Lever

    BRAKE SYSTEM 12 – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »...

  • Page 90: Checking The Rear Brake Fluid Level

    12 BRAKE SYSTEM 12.10 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake fluid level will cause the brake system to fail. If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

  • Page 91: Checking That The Brake Linings Of The Rear Brake Are Secured

    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 92: Changing The Rear Brake Linings

    12 BRAKE SYSTEM 12.13 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy- cles workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 93 BRAKE SYSTEM 12 – Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.

  • Page 94: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) 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 95: 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. Main work –...

  • Page 96: Removing The Rear Wheel

    13 WHEELS, TIRES 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 47) 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 97: Installing The Rear Wheel

    WHEELS, TIRES 13 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –...

  • Page 98: 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 99: Checking The Spoke Tension

    WHEELS, TIRES 13 13.7 Checking the spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam- age. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel.

  • Page 100: 14 Electrical System

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

  • Page 101: Installing The 12-V Battery

    ELECTRICAL SYSTEM 14 14.2 Installing the 12-V battery Main work – Pull up battery holding bracket , insert the 12-V battery into the battery compartment with the terminals facing upwards and secure with battery holding bracket 12-V battery (HJTZ5S-FP-C) ( p.

  • Page 102: Charging The 12-V Battery

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

  • Page 103: Changing The Main Fuse

    ELECTRICAL SYSTEM 14 (EU) battery charger (A54029974000) Alternative 1 (US) battery charger (A54029974500) These battery chargers test whether the 12-V battery retains its voltage. It is also impossible to overcharge the 12-V battery with these battery chargers. The charging time may be longer at low temperatures.

  • Page 104: Changing The Fuse Of The Fuel Pump

    14 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. W00228-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...

  • Page 105: Diagnostics Connector

    ELECTRICAL SYSTEM 14 Preparatory work – Remove the air filter box cover. ( p. 62) – Remove the seat. ( p. 60) Main work – Take off protection cap – Remove the faulty fuse Info A faulty fuse has a burned-out fuse wire –...

  • Page 106: 15 Cooling System

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

  • Page 107: Checking The Coolant Level

    COOLING SYSTEM 15 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 108: Refilling With Coolant

    15 COOLING SYSTEM Warning Danger of poisoning Coolant is harmful to health. – 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 109: Changing The Coolant

    COOLING SYSTEM 15 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 110: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throt- tle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 111: Adjusting The Characteristic Map Of The Throttle Response

    TUNING THE ENGINE 16 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
  • Page 112 16 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be posi- tioned at marking Black guide plate (A46002014000) Alternative 1 Gray guide plate (A48002014000) Info The gray guide plate opens the throttle valve more slowly.

  • Page 113: Changing The Mapping

    TUNING THE ENGINE 16 16.4 Changing the mapping Info The desired engine characteristic can be activated using the combination switch. The setting most recently selected is activated again when restarting. Traction control can also be activated in each mapping. The mapping can also be changed during the ride. Activating STANDARD mapping: –...

  • Page 114: Programming The Throttle Valve Position

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

  • Page 115: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. If the shift lever is permanently touching the boot, the transmission will be subject to excessive load; this can cause a malfunction of the quickshifter.

  • Page 116: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 117: Checking The Engine Oil Level

    SERVICE WORK ON THE ENGINE 17 17.2 Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm. Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
  • Page 118 17 SERVICE WORK ON THE ENGINE Main work – Position an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. Info Do not remove screws H04991-10 – Remove screw plug with oil screen and the O-rings.
  • Page 119 SERVICE WORK ON THE ENGINE 17 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surfaces. H04996-10 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓...

  • Page 120: Adding Engine Oil

    17 SERVICE WORK ON THE ENGINE 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. – Remove filler plug with the O-ring. – Add the same engine oil used when the last oil change was carried out.

  • Page 121: 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 122 18 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber ( p. 137) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 123: Storage 19

    STORAGE 19 19.1 Storage Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...

  • Page 124: Putting Into Operation After Storage

    19 STORAGE 19.2 Putting into operation after storage – Install the 12-V battery. p. 99) – Remove the motorcycle from the lift stand. ( p. 47) – Perform checks and maintenance measures when preparing for use. p. 25) – Take a test ride. 401059-01...

  • Page 125: Troubleshooting 20

    TROUBLESHOOTING 20 Faults Possible cause Action – The engine does not turn when Operating error Carry out start procedure. ( p. 25) the start button is pressed – 12-V battery discharged Charge the 12-V battery. p. 100) – Check the charging voltage. –...
  • Page 126 20 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 115) – Engine oil too thin (low viscosity) Change the engine oil and oil filter, clean the oil screen. p.

  • Page 127: Blink Code 21

    BLINK CODE 21 Combination switch, left side – buttons pressed longer than 20 seconds Error level condition Blink code for malfunction indicator lamp Malfunction indicator lamp flashes continuously THREF – malfunction Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor –...
  • Page 128 21 BLINK CODE Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 129: Technical Data 22

    TECHNICAL DATA 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 249.91 cm³ (15.2505 cu in) Stroke 48.5 mm (1.909 in) Bore 81 mm (3.19 in) Compression ratio 14.5:1 Idle speed 2,250 … 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 32.5 mm (1.28 in)
  • Page 130 22 TECHNICAL DATA Oil nozzle for main bearing lubrication 2 Nm (1.5 lbf ft) Loctite ® 243™ Screw, oil nozzle bent for piston cool- 2.5 Nm (1.84 lbf ft) Loctite ® 243™ Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 131 TECHNICAL DATA 22 Screw, camshaft bearing bridge M7x1 Tightening sequence: Tighten diagonally. 1st tightening stage 5 Nm (3.7 lbf ft) 2nd tightening stage 14 Nm (10.3 lbf ft) Lubricated with engine oil Crankshaft clamp screw plug 10 Nm (7.4 lbf ft) Screw, tensioning rail 15 Nm (11.1 lbf ft) Loctite...

  • Page 132: Capacities

    22 TECHNICAL DATA 22.3 Capacities 22.3.1 Engine oil Engine oil 1.0 l (1.1 qt.) Engine oil (SAE 10W/50) ( p. 135) 22.3.2 Coolant Coolant 0.9 l (1 qt.) Coolant ( p. 135) 22.3.3 Fuel Super unleaded (ROZ 95) ( p. 136) 7.9 l (2.09 US gal) 22.4 Chassis...

  • Page 133: Electrical System

    TECHNICAL DATA 22 22.5 Electrical system 12-V battery HJTZ5S-FP-C Lithium-ion battery Battery voltage: 12 V Nominal capacity: 2.0 Ah Maintenance-free Fuse 58011109110 10 A Fuse 58011109105 Combination instrument lighting and indicator lamps 22.6 Tires Front tire Rear tire 80/100 - 21 51M TT 110/90 - 19 62M TT Dunlop GEOMAX MX33F Dunlop GEOMAX MX33...

  • Page 134: Shock Absorber

    22 TECHNICAL DATA 22.8 Shock absorber Shock absorber article number A460C455W408000 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 135 TECHNICAL DATA 22 Screw, frame protector 3 Nm (2.2 lbf ft) Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) Screw, throttle valve body cover 2.6 Nm (1.92 lbf ft) Screws on main silencer 7 Nm (5.2 lbf ft) Nut, starter cable on starter motor 4 Nm (3 lbf ft) Nut, throttle cable on throttle valve...
  • Page 136 22 TECHNICAL DATA Screw, top steering stem 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, top triple clamp 17 Nm (12.5 lbf ft) Engine carrying screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, bottom shock absorber...

  • Page 137: Substances 23

    SUBSTANCES 23 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 138 23 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 139) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre- sponding properties. Super unleaded (ROZ 95) Standard/classification –...

  • Page 139: Auxiliary Substances 24

    AUXILIARY SUBSTANCES 24 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 140 24 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 141: Standards 25

    STANDARDS 25 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 142: 26 Index Of Special Terms

    26 INDEX OF SPECIAL TERMS Launch control Vehicles electronics functions for achieving the best possi- ble acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics Quickshifter Function of the engine electronics for shifting up without clutch actuation Traction Control Auxiliary function of the motor control that reduces engine...

  • Page 143: List Of Abbreviations 27

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

  • Page 144: 28 List Of Symbols

    28 LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also repre- sented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehi- cle electronics.
  • Page 145 INDEX Chain guide INDEX checking ......74 Chain tension 12-V battery adjusting ......73 starting power .
  • Page 146 INDEX Factory Start ......Idle speed activating ......27 adjusting .
  • Page 147 INDEX checks and maintenance measures when preparing Start button ......15 for use ......25 Start number plate Protective clothing .
  • Page 148 *3215098en* 3215098en 29.11.2022 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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