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Related Manuals for GAS GAS MC 350F 2024
Summary of Contents for GAS GAS MC 350F 2024
- Page 1 OWNER'S MANUAL 2024 MC 350F EX 350F Art. no. 3215161en...
- 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.
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Page 4: Table Of Contents
TABLE OF CONTENTS Starting power of lithium-ion batteries TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 at low temperatures........21 Symbols used..........5 Preparing the vehicle for difficult Formats used..........5 operating conditions ........22 Preparing the vehicle for rides on dry SAFETY ADVICE ............ - Page 5 TABLE OF CONTENTS 10.17 Adjusting the handlebar position ... 42 11.48 Changing the hydraulic clutch fluid ..77 SERVICE WORK ON THE CHASSIS ......45 BRAKE SYSTEM............79 11.1 Raising the motorcycle with a lift stand ..45 12.1 Checking the free travel of the hand brake lever...........
- Page 6 TABLE OF CONTENTS 16.5 Programming the throttle valve position ............. 109 16.6 Checking the basic position of the shift lever ............110 16.7 Adjusting the basic position of the shift lever ............110 SERVICE WORK ON THE ENGINE ......112 17.1 Changing the fuel screen .....
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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 (MC 350F) This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic. -
Page 9: Tampering Warning
SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. -
Page 10: Work Rules
2 SAFETY ADVICE Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with transpon- der key) or the motor must be at a standstill (models without ignition lock or transponder 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) I00479-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Cold start button ( p. 17) Engine number ( p. 12) Shift lever ( p. -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE 4 View of vehicle, rear right (example) I00480-10 Shock absorber compression adjuster Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Vehicle identification number ( p. 12) Steering head label ( p. -
Page 14: Serial Numbers
5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Steering head label The steering head label is attached to the front of the steering head. 401946-10 Engine number Engine number is located on the left side of the engine over the engine sprocket. -
Page 15: Shock Absorber Article Number
SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber. F03756-10... -
Page 16: Controls
6 CONTROLS Clutch lever 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 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 19: Cold Start Button
CONTROLS 6 (EX 350 F US) – Mount the fuel tank filler cap and turn it clockwise until release button engages. Info Route fuel tank breather hose without kinks. A01320-10 6.10 Cold start button The cold start button is fitted to the bottom of the throttle valve body. -
Page 20: Idle Speed Adjusting Screw
6 CONTROLS 6.11 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly. -
Page 21: Foot Brake Lever
CONTROLS 6 6.13 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 6.14 Plug-in stand (MC 350F) The support for plug-in stand is the left side of the wheel spindle. The plug-in stand is used to park the motorcycle. -
Page 22: Preparing For Use
7 PREPARING FOR USE Advice on preparing for first use Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. –... -
Page 23: Running In The Engine
PREPARING FOR USE 7 – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more challenging ride. Info This vehicle is not approved for use on public roads. When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other. -
Page 24: Preparing The Vehicle For Difficult Operating Conditions
7 PREPARING FOR USE Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in signifi- cantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service. -
Page 25: Preparing The Vehicle For Rides On Wet Sand
PREPARING FOR USE 7 – Clean the chain. Chain cleaner ( p. 137) – Mount the steel sprocket. – Grease the chain. Universal oil spray ( p. 138) – Clean the radiator fins. – Straighten the bent radiator fins carefully. 600868-01 Preparing the vehicle for rides on wet sand –... -
Page 26: Preparing Vehicle For High Temperatures Or Slow Riding
7 PREPARING FOR USE Preparing vehicle for high temperatures or slow riding – Adjust the secondary drive to the road conditions. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary ratio. –... -
Page 27: Riding Instructions 8
RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 28: Starting Off
8 RIDING INSTRUCTIONS (MC 350F) – Remove plug-in stand H02629-10 (EX 350 F US) – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission into neutral. Condition Ambient temperature: < 20 °C (< 68 °F) –... -
Page 29: Applying The Brakes
RIDING INSTRUCTIONS 8 – If the cold start button was pushed while starting, open the throttle briefly and release the throttle grip or turn the throttle grip forward. The cold start button goes to the basic position. – After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed, but fuel consumption will be considerably lower. -
Page 30: Transporting
8 RIDING INSTRUCTIONS 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. – Park the vehicle on a firm and level surface. –... -
Page 31: Refueling
RIDING INSTRUCTIONS 8 Refueling 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. – Switch off the engine for refueling. -
Page 32: Service Schedule
9 SERVICE SCHEDULE Additional information Any further work that results from the service work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. If the vehicle is used in particularly harsh conditions such as heavy rain, mud, sand, snow, extreme temperatures, frequent full load etc., shorter service intervals than those in the table may be necessary. - Page 33 SERVICE SCHEDULE 9 every 24 months Every 90 operating hours Every 45 operating hours Every 15 operating hours After 1 operating hour ○ ● ● ● Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 72) ○ ●...
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Page 34: 10 Tuning The Chassis
10 TUNING THE CHASSIS 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 35: Compression Damping Of The Shock Absorber
TUNING THE CHASSIS 10 10.3 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed. The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly. -
Page 36: Adjusting The Rebound Damping Of The Shock Absorber
10 TUNING THE CHASSIS – Turn adjuster clockwise all the way to the stop. – Turn counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Highspeed compression damping (MC 350F) Comfort 2 turns Standard 1.5 turns Sport 1 turn F03639-10... -
Page 37: Measuring The Dimension Of The Rear Wheel Unloaded
TUNING THE CHASSIS 10 10.7 Measuring the dimension of the rear wheel unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender. -
Page 38: Checking The Riding Sag Of The Shock Absorber
10 TUNING THE CHASSIS 10.9 Checking the riding sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 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 39: Adjusting The Riding Sag
TUNING THE CHASSIS 10 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 40: Checking The Basic Setting Of The Fork
10 TUNING THE CHASSIS Main work – Select and mount a suitable spring. Guideline Spring rate (MC 350F) Weight of rider: 65 … 75 kg 42 N/mm (240 lb/in) (143 … 165 lb.) Weight of rider: 75 … 85 kg 45 N/mm (257 lb/in) (165 …... -
Page 41: Adjusting The Fork Air Pressure (Mc 350F)
TUNING THE CHASSIS 10 10.13 Adjusting the fork air pressure (MC 350F) Warning Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic. Modifications which are not coordinated with others to the suspension setting may cause a serious deterioration in the handling characteristic and overload components. -
Page 42: Adjusting The Compression Damping Of The Fork
10 TUNING THE CHASSIS Info Only mount the protection cap by hand. Finishing work – Remove the motorcycle from the lift stand. ( p. 45) 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (MC 350F) –... -
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. (MC 350F) – Turn adjuster clockwise all the way to the stop. Info Adjuster is located at the lower end of the right fork leg. -
Page 44: Handlebar Position
10 TUNING THE CHASSIS 10.16 Handlebar position The holes on the handlebar support are placed at a distance of from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions. This allows the handlebar to be mounted in the most comfortable position for the rider. - Page 45 TUNING THE CHASSIS 10 Main work – Remove screws . Take off handlebar clamp . Take off the han- dlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
- Page 46 10 TUNING THE CHASSIS Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)
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Page 47: 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 48: Bleeding The Fork Legs
11 SERVICE WORK ON THE CHASSIS (EX 350 F US) – Remove the motorcycle from the lift stand. – Remove the lift stand. – To park the motorcycle, press side stand to the ground with your foot and lean the motorcycle on it. Info When you are riding, the side stand must be folded up and secured with the rubber strap. -
Page 49: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS 11 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 neces- sary. -
Page 50: Removing The Frame Protector
11 SERVICE WORK ON THE CHASSIS 11.7 Removing the frame protector – Remove the cable ties. – Remove screws with the bushings. – Take off the left frame protector. – Push the right frame protector to the front and take off at the bot- tom. -
Page 51: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 11 11.10 Installing the fork legs Main work (MC 350F) – 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 Grooves are milled into the side of the upper end of the F03665-11... -
Page 52: Removing The Lower Triple Clamp
11 SERVICE WORK ON THE CHASSIS 11.11 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) – Remove the front wheel. p. 90) – Remove the fork legs. p. 48) – Remove the start number plate. - Page 53 SERVICE WORK ON THE CHASSIS 11 – Position the upper triple clamp and handlebar. – Mount screw , but do not tighten it yet. Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head W00435-10 (MC 350F) – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.
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Page 54: Checking The Steering Head Bearing Play
11 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top steer- 20 Nm (14.8 lbf ft) ing stem Loctite ® 243™ W00437-10 – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. –... -
Page 55: Adjusting The Steering Head Bearing Play
SERVICE WORK ON THE CHASSIS 11 Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. -
Page 56: Lubricating The Steering Head Bearing
11 SERVICE WORK ON THE CHASSIS 11.15 Lubricating the steering head bearing – Remove the lower triple clamp. p. 50) – Install the lower triple clamp. p. 50) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp. H02387-01 11.16 Removing the start number plate... -
Page 57: Installing Front Fender
SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Take off the front fender. F03675-10 11.19 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F03675-10 Finishing work... -
Page 58: Removing The Shock Absorber
11 SERVICE WORK ON THE CHASSIS 11.20 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) – Remove the frame protector. ( p. 48) – Remove the right side panel. ( p. 60) –... -
Page 59: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS 11 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. W00218-10 11.21 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bot- tom. -
Page 60: Removing The Seat
11 SERVICE WORK ON THE CHASSIS – Position the angle lever and linkage lever. – Mount and tighten fitting Guideline Nut, linkage lever on M16x1.5 80 Nm (59 lbf ft) angle lever Info Pay attention to flat area F03704-10 – Mount and tighten screw Guideline Screw, bottom... -
Page 61: Mounting The Seat
SERVICE WORK ON THE CHASSIS 11 – Slide the seat toward the rear and lift it off. W00439-11 11.23 Mounting the seat Main work – Attach the seat to the collar bushings and simultaneously slide it forward. The holding lugs engage in the recesses. –... -
Page 62: Removing The Right Side Panel
11 SERVICE WORK ON THE CHASSIS 11.24 Removing the right side panel Preparatory work – Remove the frame protector. ( p. 48) Main work – Detach right side panel in area and slide it in area to the rear. – Take the right side panel off. -
Page 63: Installing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 11 – Detach the air filter box cover in area and slide it in area to the rear. – Take off the air filter box cover. W00443-10 Condition The air filter box cover is not secured. –... -
Page 64: Preparing Air Filter Box Cover For Securing
11 SERVICE WORK ON THE CHASSIS Condition The air filter box cover is not secured. – Position the air filter box cover in area and slide it forward. – Press the air filter box cover in area into the rubber bush- ings. -
Page 65: Cleaning The Air Filter And Air Filter Box
SERVICE WORK ON THE CHASSIS 11 Main work – Detach retaining tab – Remove air filter with air filter support. – Remove air filter from air filter support. W00216-10 11.30 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. –... -
Page 66: Installing The Air Filter
11 SERVICE WORK ON THE CHASSIS 11.31 Installing the air filter Main work – Mount the clean air filter on the air filter support. Info The marking on the air filter support must face upwards. – Grease the air filter in area Long-life grease ( p. -
Page 67: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS 11 Main work – Detach spring Spring hook (50305017000C1) – Remove screws with the washers and take off the main silencer. W00445-10 11.33 Installing the main silencer Main work – Position the main silencer. – Mount screws with washers, but do not tighten yet. -
Page 68: Removing The Fuel Tank
11 SERVICE WORK ON THE CHASSIS Main work – Remove the screws on the main silencer. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube. - Page 69 SERVICE WORK ON THE CHASSIS 11 Main work – Unplug fuel pump connector – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! H04981-10 –...
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Page 70: Installing The Fuel Tank
11 SERVICE WORK ON THE CHASSIS 11.36 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 71: Checking For Chain Dirt Accumulation
SERVICE WORK ON THE CHASSIS 11 – Plug in fuel pump connector – Remove the wash cap set. Clean the quick release coupling thor- oughly with compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve! –... -
Page 72: Checking The Chain Tension
11 SERVICE WORK ON THE CHASSIS Info The service life of the chain depends largely on its maintenance. Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Rinse off loose dirt with a soft jet of water. –... -
Page 73: Adjusting The Chain Tension
SERVICE WORK ON THE CHASSIS 11 11.40 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 74: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
11 SERVICE WORK ON THE CHASSIS 11.41 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket and engine sprocket for wear. »... - Page 75 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.
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Page 76: Checking The Frame
11 SERVICE WORK ON THE CHASSIS – Check that the chain guide is firmly seated. » If the chain guide is loose: – Tighten the screws on the chain guide. Guideline Screw, chain guide M6x16 10 Nm (7.4 lbf ft) on link fork at the rear Screw, chain guide... -
Page 77: Checking The Rubber Grips
SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rub- ber strap of the fuel tank support. -
Page 78: Adjusting The Basic Position Of The Clutch Lever
11 SERVICE WORK ON THE CHASSIS 11.46 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 79: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 11 11.48 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid is a harmful substance. – 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 80 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. – Tighten the bleeder screw and remove the bleeding syringe with the hose.
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Page 81: 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 82: Checking The Front Brake Fluid Level
12 BRAKE SYSTEM » If the brake disc thickness is less than the specification: – Change the front brake disc. – Change the rear brake disc. – Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc exhibits damage, cracking, or deformation: –... - Page 83 BRAKE SYSTEM 12 Warning Skin irritation Brake fluid is a harmful substance. – 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. –...
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Page 84: Checking That The Brake Linings Of The Front Brake Are Secured
12 BRAKE SYSTEM 12.6 Checking that the brake linings of the front brake are secured Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.) –... - Page 85 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 Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint. –...
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Page 86: Checking The Free Travel Of Foot Brake Lever
12 BRAKE SYSTEM – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. To make it easier to mount the pin, push the brake linings against the retainer spring. Make sure the brake linings and retainer spring are seated correctly. -
Page 87: Adjusting The Basic Position Of The Foot Brake Lever
BRAKE SYSTEM 12 – Disconnect spring – Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel Guideline Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in) »... -
Page 88: 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 89: Checking That The Brake Linings Of The Rear Brake Are Secured
BRAKE SYSTEM 12 Warning Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized GASGAS Motorcycles workshop will be glad to help.) –... -
Page 90: 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 is a harmful substance. - Page 91 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.
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Page 92: 13 Wheels, Tires
13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) 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 93: Installing The Front Wheel
WHEELS, TIRES 13 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –... -
Page 94: Removing The Rear Wheel
13 WHEELS, TIRES 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) 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 95: Installing The Rear Wheel
WHEELS, TIRES 13 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –... -
Page 96: 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 97: Checking The Spoke Tension
WHEELS, TIRES 13 13.7 Checking the spoke tension Warning Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary dam- age. The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. -
Page 98: 14 Electrical System
14 ELECTRICAL SYSTEM 14.1 Removing the 12-V battery Caution Danger of burns The voltage regulator gets very hot when the vehicle is operated. – Allow the voltage regulator to cool down before performing any work. Note Environmental hazard 12 V batteries contain environmentally hazardous materials. –... -
Page 99: Installing The 12-V Battery
ELECTRICAL SYSTEM 14 14.2 Installing the 12-V battery Main work – Pull up battery holding bracket , insert the 12-V battery into the battery compartment with the terminals facing upwards and secure with battery holding bracket 12-V battery (HJTZ5S-FP-C) ( p. -
Page 100: Charging The 12-V Battery
14 ELECTRICAL SYSTEM 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms. -
Page 101: Changing The Main Fuse
ELECTRICAL SYSTEM 14 (EU) battery charger (A54029974000) Alternative 1 (US) battery charger (A54029974500) These battery chargers test whether the 12-V battery retains its voltage. It is also impossible to overcharge the 12-V battery with these battery chargers. The charging time may be longer at low temperatures. -
Page 102: Changing The Fuse Of The Fuel Pump
14 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. W00228-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –... -
Page 103: Diagnostics Connector
ELECTRICAL SYSTEM 14 Preparatory work – Remove the air filter box cover. ( p. 60) – Remove the seat. ( p. 58) Main work – Take off protection cap – Remove the faulty fuse Info A faulty fuse has a burned-out fuse wire –... -
Page 104: 15 Cooling System
15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is reg- ulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 105: Checking The Coolant Level
COOLING SYSTEM 15 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets 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 106: Refilling With Coolant
15 COOLING SYSTEM Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –... -
Page 107: Changing The Coolant
COOLING SYSTEM 15 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature. -
Page 108: 16 Tuning The Engine
16 TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throt- tle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …... -
Page 109: Adjusting The Characteristic Map Of The Throttle Response
TUNING THE ENGINE 16 Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –... - Page 110 16 TUNING THE ENGINE – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be posi- tioned at marking Black guide plate (A46002014000) Alternative 1 Gray guide plate (A48002014000) Info The gray guide plate opens the throttle valve more slowly.
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Page 111: Adjusting The Idle Speed
TUNING THE ENGINE 16 16.4 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized GASGAS Motorcycles workshop will be glad to help.) –... -
Page 112: Checking The Basic Position Of The Shift Lever
16 TUNING 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 113 TUNING THE ENGINE 16 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
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Page 114: 17 Service Work On The Engine
17 SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 115: Checking The Engine Oil Level
SERVICE WORK ON THE ENGINE 17 17.2 Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm. Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –... - Page 116 17 SERVICE WORK ON THE ENGINE Main work – Position an appropriate container under the engine. – Remove screw plug with oil screen and the O-rings. – Remove oil drain plug with the magnet and seal ring. W00543-10 – Remove oil drain plug with the magnet and seal ring.
- Page 117 SERVICE WORK ON THE ENGINE 17 – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surfaces. W00545-10 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓...
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Page 118: Adding Engine Oil
17 SERVICE WORK ON THE ENGINE 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. – Remove filler plug with the O-ring. – Add the same engine oil used when the last oil change was carried out. -
Page 119: Cleaning, Care 18
CLEANING, CARE 18 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... - Page 120 18 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber ( p. 137) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
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Page 121: Storage 19
STORAGE 19 19.1 Storage Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –... -
Page 122: Putting Into Operation After Storage
19 STORAGE Info Do not use non-porous materials since they prevent humid- ity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust. -
Page 123: Troubleshooting 20
TROUBLESHOOTING 20 Faults Possible cause Action – The engine does not turn when Operating error Carry out start procedure. ( p. 25) the start button is pressed – 12-V battery discharged Charge the 12-V battery. p. 98) – Check the charging voltage. –... - Page 124 20 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 113) – Engine oil too thin (low viscosity) Change the engine oil and oil filter, clean the oil screen. p.
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Page 125: Blink Code 21
BLINK CODE 21 Combination switch, left side – buttons pressed longer than 20 seconds Error level condition Blink code for malfunction indicator lamp Malfunction indicator lamp flashes continuously THREF – internal malfunction of the engine control unit Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short... - Page 126 21 BLINK CODE Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...
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Page 127: Technical Specifications 22
TECHNICAL SPECIFICATIONS 22 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 349.7 cm³ (21.34 cu in) Stroke 57.5 mm (2.264 in) Bore 88 mm (3.46 in) Compression ratio 14.6:1 Idle speed 2,250 … 2,350 rpm Control DOHC, four valves controlled via cam lever, drive via timing chain Valve diameter, intake 36.3 mm (1.429 in) -
Page 128: Engine Tightening Torques
22 TECHNICAL SPECIFICATIONS 22.2 Engine tightening torques Hose clip, intake flange 3 Nm (2.2 lbf ft) Nozzle, crank chamber ventilation 2 Nm (1.5 lbf ft) Loctite ® 243™ Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) Loctite ® 243™... - Page 129 TECHNICAL SPECIFICATIONS 22 Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Screw, starter motor - intermediate 10 Nm (7.4 lbf ft) gear Loctite ®...
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Page 130: Capacities
22 TECHNICAL SPECIFICATIONS Oil drain plug M14x1.5 15 Nm (11.1 lbf ft) Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Nut, primary gear wheel M18LHx1.5 120 Nm (88.5 lbf ft) Loctite ® 243™ Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) Plug, timing chain tensioner M24x1.5... -
Page 131: Electrical System
TECHNICAL SPECIFICATIONS 22 Offroad tire pressure front 1.0 bar (15 psi) rear 1.0 bar (15 psi) Secondary ratio (MC 350F) 14:52 Secondary ratio (EX 350 F US) 13:47 Chain 5/8 x 1/4" Available rear sprockets 48, 49, 50, 51, 52 Steering head angle 63.9°... -
Page 132: Fork
22 TECHNICAL SPECIFICATIONS 22.7 Fork 22.7.1 MC 350F Fork article number A460C107X406000 Fork WP XACT AER Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Air pressure 10.3 bar (149 psi) Fork length 950 mm (37.4 in) -
Page 133: Shock Absorber
TECHNICAL SPECIFICATIONS 22 22.8 Shock absorber 22.8.1 MC 350F Shock absorber article number A460C407X408000 Shock absorber WP XACT LDS Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping... -
Page 134: Chassis Tightening Torques
22 TECHNICAL SPECIFICATIONS Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 42 N/mm (240 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 45 N/mm (257 lb/in) Weight of rider: 85 … 95 kg (187 … 209 lb.) 48 N/mm (274 lb/in) Spring length 240 mm (9.45 in) - Page 135 TECHNICAL SPECIFICATIONS 22 Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, fuel tank spoiler on radiator 6 Nm (4.4 lbf ft) Screw, ground wire on frame 10 Nm (7.4 lbf ft) Screw, hand lever 5 Nm (3.7 lbf ft) Screw, push rod ball joint on the rear 10 Nm (7.4 lbf ft) brake cylinder...
- Page 136 22 TECHNICAL SPECIFICATIONS Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Nut, rear wheel spindle M22x1.5 80 Nm (59 lbf ft) Screw-in fitting, cooling system M24x1.5 7.5 Nm (5.53 lbf ft)
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Page 137: Substances 23
SUBSTANCES 23 Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®... - Page 138 23 SUBSTANCES Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 139) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre- sponding properties. Super unleaded (ROZ 95) Standard/classification –...
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Page 139: Auxiliary Substances 24
AUXILIARY SUBSTANCES 24 Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier... - Page 140 24 AUXILIARY SUBSTANCES Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – Klüberfood NH1 34‑401 Universal oil spray Recommended supplier MOTOREX ®...
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Page 141: Standards 25
STANDARDS 25 JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 stan- dard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high perfor- mance at high engine speeds. -
Page 142: 26 Index Of Special Terms
26 INDEX OF SPECIAL TERMS On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics... -
Page 143: List Of Abbreviations 27
LIST OF ABBREVIATIONS 27 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 144: 28 List Of Symbols
28 LIST OF SYMBOLS 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also repre- sented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehi- cle electronics. -
Page 145: Index
INDEX Chain guide INDEX checking ......72 Chain tension 12-V battery adjusting ......71 starting power . - Page 146 INDEX free travel, checking ....84 Indicator lamps overview ......15 Fork article number .
- Page 147 INDEX Rebound damping fork, adjusting ..... . . 41 Technical accessories ..... . 9 shock absorber, adjusting .
- Page 148 *3215161en* 3215161en 27.09.2023 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...
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