GAS GAS EX 250 2023 Owner's Manual
  1. Manuals
  2. Brands
  3. GAS GAS Manuals
  4. Motorcycle
  5. EX 250 2023
  6. Owner's manual

GAS GAS EX 250 2023 Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
OWNER'S MANUAL 2023
EX 250
EX 300
Art. no. 3215096en

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EX 250 2023 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for GAS GAS EX 250 2023

Summary of Contents for GAS GAS EX 250 2023

  • Page 1 OWNER'S MANUAL 2023 EX 250 EX 300 Art. no. 3215096en...
  • 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........20 Symbols used..........5 Preparing the vehicle for difficult Formats used..........5 operating conditions ........21 Preparing the vehicle for rides on dry SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS 10.16 Handlebar position........41 BRAKE SYSTEM............73 10.17 Adjusting the handlebar position ... 42 12.1 Checking the free travel of the hand brake lever........... 73 SERVICE WORK ON THE CHASSIS ......43 12.2 Adjusting the basic position of the hand 11.1 Raising the motorcycle with a lift stand ..
  • Page 6 TABLE OF CONTENTS 16.7 Changing the ignition timing map.... 105 16.8 Checking the basic position of the shift lever ............105 16.9 Adjusting the basic position of the shift lever ............106 SERVICE WORK ON THE ENGINE ......107 17.1 Changing the fuel screen .....

  • 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 This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

  • Page 9: Tampering Warning

    SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 10: Work Rules

    2 SAFETY ADVICE Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key). Special tools are necessary for certain tasks.

  • Page 11: Important Notes 3

    IMPORTANT NOTES 3 Manufacturer warranty, implied warranty The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary dam- age caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) E01984-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Side stand ( p. 18) Shift lever ( p. 17) Engine number ( p.

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) E01985-10 2-stroke oil tank cap Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Foot brake lever ( p. 18) Level viewer for brake fluid, rear...

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is embossed on the left side of the engine above the engine sprocket.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. J00075-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The front brake is engaged using the hand brake lever. J00077-10 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: Closing The Fuel Tank Filler Cap

    6 CONTROLS – Press release button , turn the fuel tank filler cap counterclock- wise, and lift it off. V01646-10 Closing the fuel tank filler cap – Mount filler cap and turn it clockwise until the release button engages. Info Route fuel tank breather hose without kinks.

  • Page 19: Cold Start Button

    CONTROLS 6 6.11 Cold start button The cold start button is fitted on the side of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pulling the cold start button.

  • Page 20: Foot Brake Lever

    6 CONTROLS 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 Side stand The side stand is located on the left of the vehicle. 401943-10 The side stand is used for parking the motorcycle.

  • Page 21: Preparing For Use 7

    PREPARING FOR USE 7 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 22: Running In The Engine

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

  • Page 23: Preparing The Vehicle For Difficult Operating Conditions

    PREPARING FOR USE 7 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 24: Preparing The Vehicle For Rides On Wet Sand

    7 PREPARING FOR USE – Mount the air filter dust cover. Air filter dust cover (79006920000) Info Observe the fitting instructions for GASGAS Techni- cal Accessories. M01104-01 – Mount the air filter sand cover. Air filter sand cover (79006922000) Info Observe the fitting instructions for GASGAS Techni- cal Accessories.

  • Page 25: Preparing The Vehicle For Rides On Wet And Muddy Circuits

    PREPARING FOR USE 7 – Mount the air filter rain cover. Air filter rain cover (79006921000) Info Observe the fitting instructions for GASGAS Techni- cal Accessories. M01106-01 – Clean the chain. Chain cleaner ( p. 133) – Mount the steel sprocket. –...

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

    7 PREPARING FOR USE Preparing vehicle for high temperatures or slow riding – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the indicated value does not correspond to the setpoint value: Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

  • Page 27: Riding Instructions 8

    RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 28: Starting Off

    8 RIDING INSTRUCTIONS – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission to neutral position. Condition Ambient temperature: < 10 °C (< 50 °F) – Pull the cold start button fully out and turn it by a ¼ turn. Info If the engine is warm, the cold start button must be 401944-10...

  • Page 29: Braking

    RIDING INSTRUCTIONS 8 Guideline ≥ 2 min – Avoid frequent or lengthy slipping of the clutch. This causes the gear 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. Braking Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels.

  • Page 30: Transporting

    8 RIDING INSTRUCTIONS – Shift the transmission to neutral position. – Press and hold the stop button while the engine is idling until the engine stops. – Park the motorcycle on firm ground. Transporting Note Danger of damage The parked vehicle can roll away or fall over. –...

  • Page 31: Adding 2-Stroke Oil

    RIDING INSTRUCTIONS 8 – Switch off the engine. – Open the fuel tank filler cap. ( p. 15) – Fill the fuel tank with fuel up to level Guideline 35 mm (1.38 in) Dimension Total fuel tank capac- 8.5 l Super unleaded (ROZ ity, approx.

  • Page 32: Service Schedule

    9 SERVICE SCHEDULE Additional information Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments.

  • Page 33: Recommended Work

    SERVICE SCHEDULE 9 Every 40 operating hours Every 20 operating hours Every 10 operating hours After 5 operating hours After 1 operating hour ○ ● ● ● Check the antifreeze and coolant level. ( p. 95) ● ● ● Check the cables for damage and for routing without kinks. ○...
  • Page 34 9 SERVICE SCHEDULE every 48 months every 12 months Every 80 operating hours Every 40 operating hours After 20 operating hours / Every 20 operating hours After 10 operating hours / Every 10 operating hours ● Perform major engine service including removing and installing the engine. Change the piston and check the cylinder.

  • Page 35: 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 36: 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 37: Adjusting The Rebound Damping Of The Shock Absorber

    TUNING THE CHASSIS 10 – Turn adjusting screw all the way clockwise with a socket wrench. Info Do not loosen fitting – Turn counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Highspeed compression damping F01840-11 Comfort 2.5 turns Standard...

  • Page 38: 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 gage (00029090200) – Note the value as dimension 402415-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 39: 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. 35) – 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 40: 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 41: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 10 – Check the riding sag of the shock absorber. ( p. 37) – Adjust the rebound damping of the shock absorber. ( p. 35) 10.12 Checking the basic setting of the fork Info For various reasons, no exact riding sag can be determined for the fork. –...

  • Page 42: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying GASGAS Technical Accessories instructions. – Adjust the air pressure as specified. Guideline Air pressure 9.6 bar (139 psi)

  • Page 43: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 10 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the lower end of the right fork leg.

  • Page 44: Adjusting The Handlebar Position

    10 TUNING THE CHASSIS 10.17 Adjusting the handlebar position Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged or bent. Preparatory work –...

  • Page 45: 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 46: 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. H01182-12 Finishing work – Remove the motorcycle from the lift stand. ( p. 43) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 47: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) – Remove the front wheel. p. 84) Main work – Remove screws and take off the clamp. –...

  • Page 48: Removing The Fork Protector

    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 I01081-10 Finishing work –...

  • Page 49: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 Main work – Take off cable holder in front of the left radiator. – Remove screw – Remove screw – Remove the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage.
  • Page 50 11 SERVICE WORK ON THE CHASSIS – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info The air suspension AER valve is located in the left fork leg. Grooves are milled into the side of the upper end of the fork legs.

  • Page 51: Checking The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 – 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 I01080-10 Finishing work –...

  • Page 52: Adjusting Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS 11.12 Adjusting steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) – Remove the handlebar cushion. Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5...

  • Page 53: Installing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.15 Installing the start number plate – Connect the brake line at the start number plate. – Position the start number plate. The holding lugs engage in the fender. – Mount and tighten screw E02011-10 11.16 Removing front fender...
  • Page 54 11 SERVICE WORK ON THE CHASSIS Main work – Remove the cable ties. – Remove screws along with the washers. – Take off the left frame protector. – Take off the right frame protector. E02000-10 – Remove screw – Remove fitting Info Raise the swingarm slightly to be able to remove the screws more easily.

  • Page 55: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove nut and pull out the swingarm pivot. – Push the link fork back and secure it against falling over. E02014-10 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. E02001-10 11.19 Installing the shock absorber...

  • Page 56: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. The dust boot is correctly positioned. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis I01023-10 –...

  • Page 57: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 11 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 11.21 Mounting the seat – Mount the front of the seat on the collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward.

  • Page 58: Installing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area sideways and take off toward the front. E02017-11 Condition The air filter box cover is not secured. – Pull off the air filter box cover in area sideways and take off toward the front.

  • Page 59: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter. – Only operate the vehicle if it is equipped with an air filter. Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 60: Installing The Air Filter

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 58) – Install the air filter box cover. ( p. 56) 11.26 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 61: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.28 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. –...

  • Page 62: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screws . Pull out inner tube with O-ring – Pull glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –...
  • Page 63 SERVICE WORK ON THE CHASSIS 11 Main work – Unplug connector of the fuel pump. – 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! V01590-10 –...

  • Page 64: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.32 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 65: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screws Guideline Screw, fuel tank spoiler 6 Nm (4.4 lbf ft) on radiator E02023-11 – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the quick release coupling using compressed air.

  • Page 66: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 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 The service life of the chain depends largely on its maintenance. Preparatory work –...

  • Page 67: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Remove the motorcycle from the lift stand. ( p. 43) 11.36 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 68: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »...
  • Page 69 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 70: 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 M6x19 10 Nm (7.4 lbf ft) guide on link Loctite ®...

  • Page 71: Checking The Rubber Grip

    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, above the fuel tank bracket on the right of the frame to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 72: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.42 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

  • Page 73: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 11.44 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing. –...
  • Page 74 11 SERVICE WORK ON THE CHASSIS – Now press the fluid into the system until it emerges from hole of the master cylinder without bubbles. – Occasionally extract the fluid from the master cylinder reservoir to prevent overflowing. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –...

  • Page 75: 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 76: Checking The Front Brake Fluid Level

    12 BRAKE SYSTEM – Change the front brake disc. – Change the rear brake disc. – Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc exhibits damage, cracking, or deformation: – Change the front brake disc. –...
  • Page 77 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 78: Checking The Front Brake Linings

    12 BRAKE SYSTEM 12.6 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 79 BRAKE SYSTEM 12 Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed.
  • Page 80 12 BRAKE SYSTEM – Check that spring plate in the brake caliper and brake pad slid- ing plate in the brake caliper bracket are seated correctly. 100397-01 – Insert the new brake linings, insert pin , and mount cotter pins Guideline Mount the outer cotter pins from the front to the rear.

  • Page 81: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 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 82: 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 83: Checking The Brake Linings Of The Rear Brake

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

  • Page 84: 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 85 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 86: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) 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 87: 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 88: Installing The Rear Wheel

    13 WHEELS, TIRES Main work – Manually press the brake caliper toward the brake disc to push back the brake piston. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston. –...
  • Page 89 WHEELS, TIRES 13 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surfaces of the spacers.

  • Page 90: 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 91: Checking Spoke Tension

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

  • Page 92: 14 Electrical System

    14 ELECTRICAL SYSTEM 14.1 Removing 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 93: Charging The 12-V Battery

    ELECTRICAL SYSTEM 14 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 94: Changing Main Fuse

    14 ELECTRICAL SYSTEM Guideline The charging current, charging voltage, and charging time must not be exceeded. Maximum charging voltage 14.4 V Maximum charging current 3.0 A Maximum charging time 24 h Recharge the 12-V battery 6 months regularly when the motor- cycle is not being used Battery charger (A54029974000) This battery charger tests whether the 12-V battery retains...

  • Page 95: Changing The Fuses Of Individual Electrical Power Consumers

    ELECTRICAL SYSTEM 14 – 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. – Insert a new main fuse. Fuse (58011109110) ( p.
  • Page 96 14 ELECTRICAL SYSTEM Info A faulty fuse has a burned-out fuse wire Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. – Insert the spare fuse with the correct rating. Fuse (75011088010) ( p.

  • Page 97: Cooling System 15

    COOLING SYSTEM 15 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 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 98: Checking The Coolant Level

    15 COOLING SYSTEM 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 99: Refilling With Coolant

    COOLING SYSTEM 15 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 100 15 COOLING SYSTEM – Pour coolant in up to level above the radiator fins. Guideline 10 mm (0.39 in) Coolant 1.2 l (1.3 qt.) Coolant ( p. 131) 400243-10 – Push protection cap upward over the coolant temperature sen- sor. V01681-10 –...

  • Page 101: Changing The Coolant

    COOLING SYSTEM 15 Finishing work – Check the coolant level. ( p. 96) 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 102 15 COOLING SYSTEM – Push protection cap upward over the coolant temperature sen- sor. E01426-10 – Unplug connector – Remove coolant temperature sensor with the O-ring and wait until the coolant escapes without bubbles. – Mount and tighten coolant temperature sensor with the O-ring.

  • Page 103: Tuning The Engine 16

    TUNING THE ENGINE 16 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 2 …...

  • Page 104: Adjusting The Characteristic Map Of The Throttle Response

    16 TUNING THE ENGINE – Slide on sleeve – Check the throttle grip for smooth operation. Finishing work – Check the play in the throttle cable. ( p. 101) 16.3 Adjusting the characteristic map of the throttle response Info On the throttle grip, the characteristic map of the throttle response is changed by changing the guide plate. A guide plate with a different characteristic map is supplied.

  • Page 105: Adjusting The Idle Speed

    TUNING THE ENGINE 16 – Clean the outside of the handlebar and the inside of the grip tube. Mount the grip tube on the handlebar. – Attach the throttle cables to the guide plate and route correctly. – Position half-shells , mount and tighten screws Guideline Screw, throttle grip...

  • Page 106: Programming Ambient Air Pressure

    16 TUNING THE ENGINE Info Turn clockwise to decrease the idle speed. Turn counterclockwise to increase the idle speed. Make the setting in small steps. An incorrect idle speed can have a negative impact on over- all engine running. 16.5 Programming ambient air pressure Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

  • Page 107: Changing The Ignition Timing Map

    TUNING THE ENGINE 16 16.7 Changing the ignition timing map Preparatory work – Remove the seat. ( p. 54) – Remove the fuel tank. p. 60) Switching the ignition timing map from Performance to Soft – Disconnect plug-in connector of the ignition timing map adjustment.

  • Page 108: Adjusting The Basic Position Of The Shift Lever

    16 TUNING THE ENGINE 16.9 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing.

  • Page 109: Service Work On The Engine 17

    SERVICE WORK ON THE ENGINE 17 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 110: Checking 2-Stroke Oil Level

    17 SERVICE WORK ON THE ENGINE 17.2 Checking 2-stroke oil level Warning Engine failure The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light lights up, the 2-stroke oil is sufficient for the remaining tank of fuel. –...
  • Page 111 SERVICE WORK ON THE ENGINE 17 Main work – Pull EFI control unit upward off the rubber lugs and hang to the side. – Remove protection cap of the diagnostics connector. V01689-10 – Put throttle grip into full throttle position and secure. E01996-11 –...

  • Page 112: Cleaning The Oil Screen In The Oil Tank

    17 SERVICE WORK ON THE ENGINE – Check whether air bubbles are visible in the hose » If air bubbles are visible: – Repeat the entire procedure until air bubbles are no longer visible. – Mount protection cap on the diagnostics connector. –...
  • Page 113 SERVICE WORK ON THE ENGINE 17 – Loosen clamps of the throttle valve body. – Lift the subframe slightly and secure it. Info Pay attention to intake flange – Pull throttle valve body towards the rear, out of the intake flange, and hang it to the side.

  • Page 114: Checking The Gear Oil Level

    17 SERVICE WORK ON THE ENGINE – Mount throttle valve body – Remove the locking piece and position the subframe. Info Pay attention to intake flange – Position and tighten clamps of the throttle valve body. Guideline Screw, intake 6 Nm (4.4 lbf ft) flange/reed valve housing E02040-10...

  • Page 115: Changing The Gear Oil

    SERVICE WORK ON THE ENGINE 17 Main work – Remove gear oil level monitoring screw – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. » If no gear oil runs out: –...

  • Page 116: Adding The Gear Oil

    17 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or run- ning the engine in an enclosed space.
  • Page 117 SERVICE WORK ON THE ENGINE 17 – Start the engine and check it for leaks.

  • Page 118: 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 119 CLEANING, CARE 18 Preserving materials for paints, metal and rubber ( p. 133) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p.

  • Page 120: 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 121: Preparing For Use After Storage

    STORAGE 19 19.2 Preparing for use after storage – Install the 12 V battery. p. 90) – Remove the motorcycle from the lift stand. ( p. 43) – Perform checks and maintenance measures when preparing for use. p. 25) – Make a test ride.

  • Page 122: 20 Troubleshooting

    20 TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked Operating error Carry out the start procedure. ( p. 25) (starter motor) – 12-V battery discharged Charge the 12-V battery. p. 91) – Check the charging voltage. – Check the closed current.
  • Page 123 TROUBLESHOOTING 20 Faults Possible cause Action – Engine has too little power Diaphragm or reed valve housing Check the diaphragm and reed valve hous- damaged ing. – Ambient pressure is incorrectly Program ambient air pressure. ( p. 104) stored – The engine dies during the trip Lack of fuel Refuel.

  • Page 124: 21 Blink Code

    21 BLINK CODE Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine control unit Error level condition Blink code for malfunction indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition Crankcase pressure sensor - short circuit to ground...
  • Page 125 BLINK CODE 21 Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil – circuit fault Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – synchronization faulty Error level condition Crankshaft speed sensor –...

  • Page 126: 22 Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake, exhaust control and transfer duct injection Displacement (EX 250 US) 249 cm³ (15.19 cu in) Displacement (EX 300 US) 293.15 cm³ (17.8892 cu in) Stroke 72 mm (2.83 in) Hole (EX 250 US) 66.4 mm (2.614 in) Hole (EX 300 US)
  • Page 127 TECHNICAL DATA 22 Screw, exhaust control bearing sup- 6 Nm (4.4 lbf ft) port Loctite ® 243™ Screw, exhaust control cap 5 Nm (3.7 lbf ft) Screw, exhaust control cover 4 Nm (3 lbf ft) Screw, injection valve holder 5 Nm (3.7 lbf ft) Loctite ®...

  • Page 128: Capacities

    22 TECHNICAL DATA Screw, cylinder head temperature M10x1.25 12 Nm (8.9 lbf ft) sensor Nut, rotor M12x1 60 Nm (44.3 lbf ft) Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) Spark plug M14x1.25 25 Nm (18.4 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft)

  • Page 129: Electrical System

    TECHNICAL DATA 22 Wheelbase 1,485 ± 10 mm (58.46 ± 0.39 in) Seat height unloaded 950 mm (37.4 in) Ground clearance unloaded 370 mm (14.57 in) Weight without fuel, approx. 101.3 kg (223.3 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) Maximum permissible overall weight...

  • Page 130: Shock Absorber

    22 TECHNICAL DATA 22.8 Shock absorber Shock absorber article number 18.18.7U.73 Shock absorber WP XACT 5750 Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks...
  • Page 131 TECHNICAL DATA 22 Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) Screws on main silencer 7 Nm (5.2 lbf ft) Nut, cable on starter motor 4 Nm (3 lbf ft) Remaining nuts, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 10 Nm (7.4 lbf ft) Screw, ball joint of push rod on foot...
  • Page 132 22 TECHNICAL DATA Screw, subframe top M8x20 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, top steering stem 20 Nm (14.8 lbf ft) Loctite ® 243™ Screw, top triple clamp 20 Nm (14.8 lbf ft) Engine bracket screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis...

  • Page 133: 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 134 23 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 135) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre- sponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 135: 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 136 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 137: 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 138: 26 Index Of Special Terms

    26 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics...

  • Page 139: 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 140: 28 List Of Symbols

    28 LIST OF SYMBOLS 28.1 Red symbols Red symbols indicate an error condition that requires immediate intervention. The oil level warning lamp lights up red – Oil level has reached the MINmarking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil. 28.2 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention.

  • Page 141: Index

    INDEX INDEX Capacity 12 V battery coolant ......98, 126 installing ......90 gear oil .
  • Page 142 INDEX Foot brake lever ......basic position, adjusting ....79 Idle speed free travel, checking .
  • Page 143 INDEX removing ......85 engine ......124 engine tightening torques .
  • Page 144 *3215096en* 3215096en 31.08.2022 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

This manual is also suitable for:

Ex 300 2023Ex 250 us 2023Ex 300 us 2023F0475w1 2023F0475w2 2023F0375w3 2023 ... Show all

Table of Contents