GAS GAS ES 700 2023 Owner's Manual
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GAS GAS ES 700 2023 Owner's Manual

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OWNER'S MANUAL 2023
ES 700
Art. no. 3215133en

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  • Page 1 OWNER'S MANUAL 2023 ES 700 Art. no. 3215133en...
  • 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 6.13 Seat release ..........22 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.14 Grab handles ..........22 Symbols used..........5 6.15 Passenger foot pegs ........22 Formats used..........5 6.16 Shift lever............. 22 6.17 Foot brake lever .......... 23 SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS 10.7 Adjusting the rebound damping of the 12.11 Adding rear brake fluid ......74 shock absorber ..........48 12.12 Checking that the brake linings of the 10.8 Handlebar position........48 rear brake are secured ........ 75 10.9 Adjusting the handlebar position ...
  • Page 6 TABLE OF CONTENTS 17.2 Changing the engine oil and oil filter, cleaning the oil screens ......106 17.3 Adding engine oil........109 CLEANING, CARE............. 110 18.1 Cleaning the motorcycle ......110 18.2 Checks and maintenance steps for winter operation ........111 STORAGE..............

  • 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 The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on gentle terrain (un- paved roads). This vehicle is not suitable for use on race tracks. Info This vehicle is only authorized for operation on public roads in its homologated version.

  • Page 9: Overview Of Labels

    SAFETY ADVICE 2 Overview of labels W00147-01 Information, chain tension Information, suspension setting Information, noise emission Type label, USA Type label, Canada Information, emission control Information, putting into operation Information, chain tension W00171-10 Information, suspension setting W00131-10...
  • Page 10 2 SAFETY ADVICE W00138-10 Information, noise emission W00139-10 Type label, USA W00140-10 Type label, Canada W00141-10 Information, emission control...

  • Page 11: Reporting Safety Defects

    SAFETY ADVICE 2 Information, putting into operation S02190-01 Reporting safety defects If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you must immedi- ately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying GASGAS North America. If the NHTSA receives multiple similar complaints, it may open an investigation.

  • Page 12: Consumer Rights

    2 SAFETY ADVICE Scope of the manufacturer’s warranty – Five (5) years or 30,000 kilometers (18,641 miles), whichever occurs first. If you have any questions regarding the manufacturer warranty for the exhaust monitoring system, please address these to: GASGAS North America, c/o KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA Phone: (888) 985-6090 U.S.

  • Page 13: Protective Clothing

    SAFETY ADVICE 2 Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. An appropriate driver's license is needed to drive the vehicle on public roads. Have malfunctions that impair safety immediately eliminated by an authorized GASGAS Motorcycles workshop.

  • Page 14: Owner's Manual

    2 SAFETY ADVICE 2.16 Owner's Manual Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful infor- mation and many tips on how to operate, handle, and service your motorcycle. This is the only way to find out how best to customize the vehicle for your own use and how you can protect yourself from injury.

  • Page 15: 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 16: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) W00145-10 Hand brake lever ( p. 18) Clutch lever ( p. 18) Fuel tank filler cap Side stand ( p. 23) Compression damping of the shock absorber ( p. 46) Shift lever ( p.

  • Page 17: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) W00146-10 Ignition and steering lock ( p. 20) Fork compression adjuster Light switch ( p. 19) Turn signal switch ( p. 19) Horn button ( p. 18) Combination switch ( p.

  • Page 18: 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 USA type label is located on the right side of the frame. The type label Canada is located on the left side of the frame.

  • Page 19: Engine Number

    SERIAL NUMBERS 5 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 401949-10 Fork part number The fork part number is stamped on the inner side of the fork stub. 401947-10 Shock absorber article number The shock absorber article number is on the left side of the shock...

  • Page 20: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. V02701-10 Hand brake lever The hand break lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake.

  • Page 21: Light Switch

    CONTROLS 6 Light switch The light switch is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned upward. In this posi- tion, the high beam and tail light are switched on.

  • Page 22: Combination Switch

    6 CONTROLS Combination switch The combination switch is fitted on the left side of the handlebar. Possible states STREET – Riding mode STREET and traction control are activated when LED 1 lights up. STREET without TC – When LEDs 1 and TC light up, riding 1 TC mode STREET is active and traction control is deactivated.

  • Page 23: Abs Button

    CONTROLS 6 6.11 ABS button The ABS button is fitted next to the combination instrument on the left. Info The ABS button is also used as the ABS warning lamp ( p. 66). S02157-10 6.12 Overview of indicator lights Possible states ABS warning lamp lights up/flashes yellow –...

  • Page 24: Seat Release

    6 CONTROLS 6.13 Seat release The loop unlocks the seat. W00174-10 6.14 Grab handles The grab handles are used for moving the motorcycle around. If you carry a passenger, the passenger can hold onto the grab handles during the trip. V02717-10 6.15 Passenger foot pegs...

  • Page 25: Foot Brake 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 6.17 Foot brake lever Foot brake lever is located in front of the right footrest. The rear brake is engaged with the foot brake lever. 401956-10 6.18 Side stand...

  • Page 26: Closing The Fuel Tank Filler Cap

    6 CONTROLS 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 27: Activation

    CONTROLS 6 6.21.2 Activation Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. S02156-10 6.21.3 Messages on the combination instrument Possible states Battery voltage of the combination instrument – The bat- tery voltage of the combination instrument is too low.

  • Page 28: Setting Kilometers Or Miles

    6 CONTROLS – Wait for 5 seconds. The combination instrument changes to the next menu item. symbol flashes. Resetting the time – Press the left button. The value decreases. Advancing the time – Press the right button. The value increases. 401912-01 –...

  • Page 29: Setting The Clock

    CONTROLS 6 6.21.6 Setting the clock Condition The motorcycle is stationary. – Press and hold both buttons for 3 – 5 seconds. The Setup menu is displayed. The UNIT display flashes. – Wait for the menu of the clock to flash. –...

  • Page 30: Speed, Time, And Dst Distance 1

    6 CONTROLS 6.21.8 Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the combination instrument. KM/H or M/H shows the speed. shows the time. DST shows the distance since the last reset, such as between two refuel- ing stops.

  • Page 31: Avg Average Speed, Art Operating Hours, And Odo Total Distance Covered

    CONTROLS 6 6.21.10 AVG average speed, ART operating hours, and ODO total distance covered – Press one of the buttons until AVG, ART and ODO appear on the combination instrument. AVG shows the average speed since the last reset. ART shows the operating hours. ODO shows the total distance covered.

  • Page 32: 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 33: Running In The Engine

    PREPARING FOR USE 7 Running in the engine – During the run-in phase, do not exceed the specified vehicle speed in the respective gear. Guideline During the first 1,000 km (620 mi) Maximum speed per gear First gear 45 km/h (28 mph) Second gear 65 km/h (40.4 mph) Third gear...
  • Page 34 7 PREPARING FOR USE Warning Fire hazard The hot exhaust system may burn luggage. – Fasten your luggage in such a way that it cannot be burned or singed by the hot exhaust system. – If luggage is carried, ensure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

  • Page 35: 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 roadworthy. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 36: Starting Off

    8 RIDING INSTRUCTIONS – Turn the emergency OFF switch to the position . – Switch on the ignition by turning the ignition key to the position . Guideline To avoid malfunctions in the control unit communication, do not switch the ignition off and on in rapid succession. After you switch on the ignition, you can hear the fuel pump operating for about two seconds.

  • Page 37: Shifting, Riding

    RIDING INSTRUCTIONS 8 Shifting, riding Warning Danger of accidents Abrupt load alterations can cause the vehicle to get out of control. – Avoid abrupt load alterations and sudden braking actions. – Adapt your speed to the road conditions. Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races. –...
  • Page 38 8 RIDING INSTRUCTIONS Warning Danger of accidents Improper mounting of cases, tank rucksacks or other luggage impairs the handling charac- teristics. Luggage mounted incorrectly can slip while the vehicle is in motion. – Mount and secure all luggage according to the manufacturer's instructions. –...

  • Page 39: Quickshifter

    RIDING INSTRUCTIONS 8 – Avoid frequent and lengthy slipping of the clutch. This causes the engine oil, engine and cooling system to heat up. – Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

  • Page 40: Motorcycle Traction Control

    8 RIDING INSTRUCTIONS Motorcycle traction control The motorcycle traction control (cornering MTC) lowers the engine torque in case of loss of traction in the rear wheel. Depending on the riding mode, different amounts of slip are allowed when the traction control is activated.

  • Page 41: Stopping, Parking

    RIDING INSTRUCTIONS 8 Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. The ABS effectiveness is only ensured if it is switched on. – Leave the ABS switched on in order to benefit from the protective effect. Warning Danger of accidents The rear wheel can lock due to the engine braking effect.

  • Page 42: Transport

    8 RIDING INSTRUCTIONS – Switch off the ignition by turning the ignition key to the position . Info If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers. This discharges the 12-V battery. You should therefore always switch off the engine with the ignition lock –...

  • Page 43: Refueling

    RIDING INSTRUCTIONS 8 – Ensure that the broken down vehicle is properly secured on the trailer or transport vehicle. – Observe local regulations for the recovery of broken down vehicles. H04927-01 8.11 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
  • Page 44 8 RIDING INSTRUCTIONS – Switch off the engine. – Open the fuel tank filler cap. ( p. 23) – Fill the fuel tank with fuel up to level Guideline 20 mm (0.79 in) Dimension Fuel tank capacity, 13.1 l Super unleaded (ROZ approx.

  • Page 45: 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. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on GASGAS Motorcycles Dealer.net.
  • Page 46 9 SERVICE SCHEDULE every 48 months every 24 months every 12 months every 30,000 km (18,600 mi) every 20,000 km (12,400 mi) every 10,000 km (6,200 mi) after 1,000 km (620 mi) ○ ● ● ● ● ● ● Check the chain tension. ( p.

  • Page 47: Tuning The Chassis 10

    TUNING THE CHASSIS 10 10.1 Fork/shock absorber The fork and the shock absorber offer many options for adapting the chassis to the riding style and the payload. Info The recommendations for the suspension setting are shown in table . The table is located on the underside of the front rider's seat.

  • Page 48: Compression Damping Of The Shock Absorber

    10 TUNING THE CHASSIS – Turn red adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the right fork leg. The rebound damping is located in right fork leg REB (red adjusting screw).

  • Page 49: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    TUNING THE CHASSIS 10 – Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click. Info Do not loosen fitting – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline V02712-10 Low-speed compression damping Comfort 25 clicks...

  • Page 50: Adjusting The Rebound Damping Of The Shock Absorber

    10 TUNING THE CHASSIS 10.7 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...
  • Page 51 TUNING THE CHASSIS 10 – Remove screws . Take off the handlebar clamp. Remove the han- dlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. – Remove screws .

  • Page 52: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with rear lifting gear Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Insert the adapter in a suitable lifting gear and screw into the link fork on both sides.

  • Page 53: Removing The Motorcycle From The Lift Stand

    SERVICE WORK ON THE CHASSIS 11 11.4 Removing the motorcycle from the lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Remove the motorcycle from the lift stand and rest it on side stand –...

  • Page 54: Removing Fork Protector

    11 SERVICE WORK ON THE CHASSIS 11.6 Removing fork protector – Remove screws and take off the clamp. – Remove screws on the left fork leg. Take off the fork protector. – Remove screws on the right fork leg. Take off the fork protector. V02714-10 11.7 Installing the fork protector...

  • Page 55: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 11.9 Removing the seat – Pull on loop and raise the rear of the seat. – Pull the seat back and lift it off. W00174-10 11.10 Mounting the seat – Hook the seat using holding lugs on to bushings , lower the seat at the rear and push it forward.

  • Page 56: Storing The Tool Set

    11 SERVICE WORK ON THE CHASSIS – Open the tool set compartment and take out tool set V02731-10 11.12 Storing the tool set Preparatory work – Remove the seat. ( p. 53) Main work – Remove screws Info A tool for removing and mounting these screws is located in holder on the underside of the seat.

  • Page 57: Take Off The Side Cover

    SERVICE WORK ON THE CHASSIS 11 11.13 Take off the side cover Preparatory work – Remove the seat. ( p. 53) Main work – Remove screws – Pull the left side cover out from the rubber bushing in area – Pull off the left side cover upwards from the special screw in area –...

  • Page 58: Removing The Front Fender

    11 SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Screw, radiator shield M6x20 4.5 Nm (3.32 lbf ft) – Repeat these steps on the opposite side. V02735-11 Finishing work – Mount the seat. ( p. 53) 11.15 Removing the front fender Preparatory work –...

  • Page 59: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.17 Removing the air filter Preparatory work – Remove the seat. ( p. 53) Main work – Remove screws – Remove the upper part of the air filter box V02718-10 Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 60: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS 11.19 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 58) 400678-01 11.20 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. –...

  • Page 61: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.21 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 62: 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 mm (0.2 in) Turn the adjusting screws on the left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks...
  • Page 63 SERVICE WORK ON THE CHASSIS 11 – Pull on the top section of the chain with the specified weight Guideline Weight of chain wear measure- 15 kg (33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
  • Page 64 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 65: Adjusting Chain Guide

    SERVICE WORK ON THE CHASSIS 11 11.24 Adjusting chain guide – Remove screws . Take off the chain guide. Condition Number of teeth: ≤ 44 teeth – Insert nut in hole . Position the chain guide. – Mount and tighten screws Guideline Screw, chain guide 10 Nm (7.4 lbf ft)

  • Page 66: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.26 Adjusting the basic position of the clutch lever – Adjust basic position of the clutch lever to your hand size by turning adjusting screw Info Do not make any adjustments while riding. Push the clutch lever forward and turn the adjusting wheel. The range of adjustment is limited.

  • Page 67: Removing Engine Guard

    SERVICE WORK ON THE CHASSIS 11 – Remove screws – Take off cover with membrane – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) » If the fluid level does not meet specifications: – Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 68: 12 Brake System

    12 BRAKE SYSTEM 12.1 Anti-lock braking system (ABS) The ABS module , consisting of a hydraulic unit, an ABS control unit, and a return pump, is located under the seat. One wheel speed sen- is located in each case on the front and the rear wheel. Warning Danger of accidents Changes to the vehicle impair the func- tion of the ABS.

  • Page 69: Adjusting The Basic Position Of The Hand Brake Lever

    BRAKE SYSTEM 12 Info The motorcycle has an additional 5-D sensor. The 5-D sensor makes the ABS control dependent on the angle of inclination and pitch. This can prevent locking and slipping of the wheels during braking when the vehicle is inclined (riding in curves) within the physical limitations.

  • Page 70: Checking The Front Brake Fluid Level

    12 BRAKE SYSTEM 12.4 Checking the front 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 71: Checking That The Brake Linings Of The Front 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 72: Changing The Brake Linings Of The Front Brake

    12 BRAKE SYSTEM – Check the brake linings for lining thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness » If it is less than the minimum thickness: – Change the brake linings of the front brake. p. 70) – Check the brake linings for damage and cracking.
  • Page 73 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: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM Info Use water to immediately clean up any brake fluid that has overflowed or spilled. 12.8 Checking the free travel of 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 75: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM 12 – Loosen fittings on foot brake cylinder – To adjust the basic position of the foot brake lever to individual requirements, loosen nut and turn screw accordingly. Info The range of adjustment is limited. The screw must be screwed into the footrest bracket by at least four turns.

  • Page 76: Adding Rear Brake Fluid

    12 BRAKE SYSTEM 12.11 Adding rear 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 MIN marking, the brake system is leaking or the brake linings are worn down.

  • Page 77: Checking That The Brake Linings Of The Rear Brake Are Secured

    BRAKE SYSTEM 12 12.12 Checking that the brake linings of the rear 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.) Warning Danger of accidents Damaged brake discs reduce the braking effect.
  • Page 78 12 BRAKE SYSTEM 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. 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 79 BRAKE SYSTEM 12 – Check that spring plate in the brake caliper and brake pad slid- ing plate in the brake caliper bracket are seated correctly. – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs.

  • Page 80: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) 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 81: Installing The Front Wheel

    WHEELS, TIRES 13 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 82: Installing The Rear Wheel

    13 WHEELS, TIRES – Manually press the brake caliper toward the brake disc to push back the brake piston. – Remove screw and pull wheel speed sensor out of the hole. – Remove nut . Take off chain adjuster – Pull out wheel spindle to the point where the chain adjuster is no longer in contact with the adjusting screw.
  • Page 83 WHEELS, TIRES 13 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal ring and contact surface of the spacer. Long-life grease ( p.

  • Page 84: Checking The Rear Hub Damping Rubber Pieces

    13 WHEELS, TIRES – Position the brake line in the guide. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. V02737-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 85: Checking The Tire Condition

    WHEELS, TIRES 13 13.6 Checking the tire condition Warning Danger of accidents If a tire bursts while riding, the vehicle becomes uncontrollable. – Ensure that damaged or worn tires are replaced immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.) Warning Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.

  • Page 86: Checking Tire Pressure

    13 WHEELS, TIRES 13.7 Checking tire pressure Info Low tire pressure leads to abnormal wear and overheating of the tire. Correct tire pressure ensures optimal riding comfort and maximum tire service life. – Remove the protection cap. – Check the tire pressure when the tires are cold. Tire pressure, offroad, solo front 1.5 bar (22 psi)

  • Page 87: Using Tire Repair Spray

    WHEELS, TIRES 13 13.9 Using tire repair spray Warning Danger of accidents Incorrect use of tire repair spray will result in the repaired tire losing pressure. Tire repair spray cannot be used for all types of damage. – Observe the instructions and specifications of the manufac- turer of the tire repair spray.

  • Page 88: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 89: Installing The 12-V Battery

    ELECTRICAL SYSTEM 14 14.2 Installing the 12-V battery Main work – Insert the 12-V battery into the battery compartment with the ter- minals facing to the rear. 12-V battery (YTZ10S) ( p. 121) S03294-01 – Position washer , positive cable , and ABS connection cable –...

  • Page 90: Charging The 12-V Battery

    14 ELECTRICAL SYSTEM 14.3 Charging the 12-V battery Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep 12 V batteries out of the reach of children. – Wear suitable protective clothing and safety glasses. – Avoid contact with battery acid and battery gases.

  • Page 91: Changing The Main Fuse

    ELECTRICAL SYSTEM 14 Guideline The charging current, charging voltage, and charging time must not be exceeded. Recharge the 12-V battery reg- 3 months ularly when the motorcycle is not being used Finishing work – Install the 12-V battery. p. 87) –...

  • Page 92: Changing The Abs Fuses

    14 ELECTRICAL SYSTEM Finishing work – Mount the seat. ( p. 53) – Set the clock. ( p. 27) 14.5 Changing the ABS fuses Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. –...

  • Page 93: Changing The Fuses Of Individual Electrical Power Consumers

    ELECTRICAL SYSTEM 14 14.6 Changing the fuses of individual electrical power consumers Info The fuse box containing the fuses of individual electrical power consumers is located under the seat. Preparatory work – Remove the seat. ( p. 53) Main work –...

  • Page 94: Removing The Headlight Mask With The Headlight

    14 ELECTRICAL SYSTEM Put a spare fuse in the fuse box so that it is available if needed. – Check the function of the electrical power consumer. – Close the fuse box cover. Finishing work – Mount the seat. ( p.

  • Page 95: Changing The Headlight Bulb

    ELECTRICAL SYSTEM 14 – Position the headlight mask. Info Pay attention to routing of the brake line. – Mount and tighten screws Guideline Screw, headlight mask 2 Nm (1.5 lbf ft) V02740-11 Finishing work – Check the headlight setting. ( p.

  • Page 96: Changing The Position Light Lamp

    14 ELECTRICAL SYSTEM 14.10 Changing the position light lamp Note Impairments to reflectors and lamps Grease on the reflector reduces the emitted light. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. Grease residue on the bulb reduces heat dissipation and increases the heat of the bulb, thus reducing its service life. –...

  • Page 97: Checking The Headlight Setting

    ELECTRICAL SYSTEM 14 Main work – Remove the screw on the rear of the turn signal housing. – Carefully swing turn signal glass forward and take it off. – Press the turn signal bulb lightly into the socket, turn it counter- clockwise by about 30°, and pull it out of the socket.

  • Page 98: Adjusting The Headlight Range

    14 ELECTRICAL SYSTEM 14.13 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 95) Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower mark for a motorcycle with rider (instructions on how to apply the mark: Checking the headlight setting).

  • Page 99: Acc1 And Acc2

    ELECTRICAL SYSTEM 14 – Position protection cap and turn all the way clockwise using a coin. – Press any button on the combination instrument. The combination instrument is activated. – Position the combination instrument in the holder. – Mount and tighten the screws with washers. –...

  • Page 100: 15 Cooling System

    15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is reg- ulated by a valve in radiator cap . Heat expansion causes excess coolant to flow into compensating tank .

  • Page 101: Checking The Coolant Level

    COOLING SYSTEM 15 – Place the motorcycle on a horizontal surface using the side stand. – Remove the cover of compensating tank – Check the antifreeze in the coolant. −25 … −45 °C (−13 … −49 °F) » If the antifreeze in the coolant does not match the specified value: –...

  • Page 102: Draining The Coolant

    15 COOLING SYSTEM Condition The engine is cold. – Place the motorcycle on a horizontal surface using the side stand. – Check the coolant level in compensating tank The coolant level must be between the two markings. » If the coolant level does not match the specified value: –...

  • Page 103: Filling/Bleeding The Cooling System

    COOLING SYSTEM 15 Main work – Position the motorcycle upright. – Position an appropriate container under the engine. – Remove screw . Take off the radiator cap. – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Screw plug, water M10x1...

  • Page 104: Changing The Coolant

    15 COOLING SYSTEM 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 105 COOLING SYSTEM 15 – Mount and tighten screw with a new seal ring. Guideline Screw plug, water M10x1 15 Nm (11.1 lbf ft) pump drain hole 600616-10 – Stand the motorcycle on a level surface using the side stand. – Refill with coolant.

  • Page 106: 16 Tuning The Engine

    16 TUNING THE ENGINE 16.1 Changing the riding mode Info The desired riding mode can be activated via the MAP button on the combination switch. The setting most recently selected is activated again when restarting. The riding mode can also be changed during the ride. Condition Throttle grip closed.

  • Page 107: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 16.3 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 (optional).

  • Page 108: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Checking the engine oil level Info The engine oil level must be checked when the engine is warm. Condition The engine is at operating temperature. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work –...
  • Page 109 SERVICE WORK ON THE ENGINE 17 – Thoroughly clean the oil drain plug with magnet. – Mount the oil drain plug with the magnet and seal ring and tighten Guideline Oil drain plug with M12x1.5 20 Nm (14.8 lbf ft) magnet S02209-01 –...
  • Page 110 17 SERVICE WORK ON THE ENGINE – Position oil screen with the O-rings. – Mount and tighten screw plug with the O-ring. Guideline Plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) S03324-10 – Position oil screen with the O-rings. –...

  • Page 111: Adding Engine Oil

    SERVICE WORK ON THE ENGINE 17 17.3 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. Main work – Remove filler plug with the O-ring, and fill up with engine oil. –...

  • Page 112: 18 Cleaning, Care

    18 CLEANING, CARE 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 113: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 18 – After the motorcycle has cooled down, lubricate all moving parts and pivot points. – Clean the chain. ( p. 58) – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber ( p.

  • Page 114: 19 Storage

    19 STORAGE 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 115: Preparing For Use After Storage

    STORAGE 19 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 51) – Charge the 12-V battery. p. 88) – Install the 12-V battery. p. 87) – Set the clock. ( p. 27) –...

  • Page 116: 20 Troubleshooting

    20 TROUBLESHOOTING Faults Possible cause Action – The engine does not turn when Operating error Carry out start procedure. ( p. 33) the start button is pressed – 12 V battery discharged Charge the 12-V battery. p. 88) – Check the open-circuit current. –...
  • Page 117 TROUBLESHOOTING 20 Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 106) – Engine oil too thin (low viscosity) Change the engine oil and the oil filter, clean the oil screens. p.

  • Page 118: 21 Technical Data

    21 TECHNICAL DATA 21.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 692.7 cm³ (42.271 cu in) Stroke 80 mm (3.15 in) Bore 105 mm (4.13 in) Compression ratio 12.7:1 Idle speed Coolant temperature: ≥ 70 °C (≥ 158 °F) 1,650 ± 50 rpm Control OHC, intake with cam levers, exhaust controlled by rocker arm, chain drive...

  • Page 119: Engine Tightening Torques

    TECHNICAL DATA 21 21.2 Engine tightening torques Screw, membrane fixation 2 Nm (1.5 lbf ft) Loctite ® 243™ Hose clamp, intake flange 2.5 Nm (1.84 lbf ft) Oil nozzle for clutch lubrication 0.4 Nm (0.3 lbf ft) Oil nozzle for conrod bearing lubrica- 0.8 Nm (0.59 lbf ft) tion Locking screw for bearing...
  • Page 120 21 TECHNICAL DATA Screw, engine case 10 Nm (7.4 lbf ft) Screw, engine case M6x25 10 Nm (7.4 lbf ft) Screw, engine case M6x30 10 Nm (7.4 lbf ft) Screw, engine case M6x70 10 Nm (7.4 lbf ft) Screw, engine case M6x80 10 Nm (7.4 lbf ft) Screw, engine sprocket cover and...

  • Page 121: Capacities

    TECHNICAL DATA 21 Screw, cylinder head Tightening sequence: Tighten diagonally, beginning with the rear screw on the timing chain shaft. 1st stage 15 Nm (11.1 lbf ft) 2nd stage 30 Nm (22.1 lbf ft) 3rd stage 45 Nm (33.2 lbf ft) 4th stage 60 Nm (44.3 lbf ft) Thread greased...

  • Page 122: Fuel

    21 TECHNICAL DATA 21.3.3 Fuel Fuel tank capacity, approx. 13.1 l (3.46 US gal) Super unleaded (ROZ 95) ( p. 128) Fuel reserve, approx. 1.4 l (1.5 qt.) 21.4 Chassis Frame Lattice frame made of chrome molybdenum steel tubing, powder-coated Fork WP SuspensionXPLOR 5348 Shock absorber...

  • Page 123: Electrical System

    TECHNICAL DATA 21 21.5 Electrical system 12-V battery YTZ10S Battery voltage: 12 V Nominal capacity: 8.6 Ah Maintenance-free Combination instrument battery CR 2430 Battery voltage: 3 V Fuse 58011109130 30 A Fuse 58011109125 25 A Fuse 58011109115 15 A Fuse 75011088015 15 A Fuse...

  • Page 124: Shock Absorber

    21 TECHNICAL DATA Hard 6.5 N/mm (37.1 lb/in) Fork length 895 mm (35.24 in) Fork oil per fork leg 640 ml (21.64 fl. oz.) Fork oil (SAE 4) (48601166S1) p. 127) 21.8 Shock absorber Shock absorber article number 15.18.7S.10 Shock absorber WP SuspensionXPLOR 5746 High-speed compression damping Comfort...
  • Page 125 TECHNICAL DATA 21 Screw, fixed grip 5 Nm (3.7 lbf ft) Loctite ® 243™ Spoke nipple, front wheel M4.5 4 Nm (3 lbf ft) Spoke nipple, rear wheel M4.5 4 Nm (3 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, brake line holder on link fork...
  • Page 126 21 TECHNICAL DATA Screw, combination instrument M6x8 5 Nm (3.7 lbf ft) holder on triple clamp Screw, compensating tank radiator 2 Nm (1.5 lbf ft) Screw, electrical holder in fuel tank 2 Nm (1.5 lbf ft) Screw, electrical holder under 12-V 10 Nm (7.4 lbf ft) battery Screw, front brake disc...
  • Page 127 TECHNICAL DATA 21 Screw, foot brake lever 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, fork stub 15 Nm (11.1 lbf ft) Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, front footrest bracket 25 Nm (18.4 lbf ft) Loctite ®...
  • Page 128 21 TECHNICAL DATA Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) Nut, rear wheel spindle M25x1.5 90 Nm (66.4 lbf ft)

  • Page 129: Substances 22

    SUBSTANCES 22 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 130 22 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 130) (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 131: Auxiliary Substances 23

    AUXILIARY SUBSTANCES 23 Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier MOTOREX ® – Moto Clean Off-road chain spray Recommended supplier MOTOREX...

  • Page 132: 24 Standards

    24 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 stan- dard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high perfor- mance at high engine speeds.

  • Page 133: Index Of Special Terms 25

    INDEX OF SPECIAL TERMS 25 Anti-lock braking system Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces Motorcycle Traction Control Auxiliary function of the motor control that reduces engine torque with spinning rear wheel On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics...

  • Page 134: 26 List Of Abbreviations

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

  • Page 135: List Of Symbols 27

    LIST OF SYMBOLS 27 27.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The coolant temperature warning lamp lights up red – The coolant temperature has reached a criti- cal value. Stop immediately (taking care not to endanger yourself or other road users in the process), switch off the engine, allow it to cool down and check the coolant level.

  • Page 136: Index

    INDEX Chain guide INDEX adjusting ......63 checking ......60 12-V battery Chain tension charging .
  • Page 137 INDEX Foot brake lever ......basic position, adjusting ....72 Main fuse free travel, checking .
  • Page 138 INDEX Seat Traction control mounting ......53 adjusting ......104 removing .
  • Page 139 *3215133en* 3215133en 25.10.2022 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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