GAS GAS MC 450F 2024 Owner's Manual
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GAS GAS MC 450F 2024 Owner's Manual

GAS GAS MC 450F 2024 Owner's Manual

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OWNER'S MANUAL
2024
MC 450F
EX 450F
MC 450F FACTORY EDITION
Art. no. 3215162en

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  • Page 1 OWNER'S MANUAL 2024 MC 450F EX 450F MC 450F FACTORY EDITION Art. no. 3215162en...
  • Page 3 DEAR GASGAS CUSTOMER DEAR GASGAS CUSTOMER Congratulations on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports 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 TABLE OF CONTENTS 6.18 Factory Start (FACTORY EDITION) ....20 MEANS OF REPRESENTATION ........5 PREPARING FOR USE ..........21 Symbols used..........5 Formats used..........5 Advice on preparing for first use ....21 Running in the engine ......... 22 SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS 10.8 Checking the static sag of the shock 11.36 Changing the glass fiber yarn filling of absorber ............40 the main silencer ........72 10.9 Checking the rider sag of the shock 11.37 Removing the fuel tank ......
  • Page 6 TABLE OF CONTENTS 14.6 Diagnostics connector......110 23.8 Shock absorber......... 144 14.7 Connectivity Unit Offroad (CUO) ..... 111 23.8.1 MC-F ............ 144 23.8.2 EX-F............144 COOLING SYSTEM ........... 113 23.8.3 FACTORY EDITION ....... 145 15.1 Cooling system ......... 113 23.9 Chassis tightening torques .......

  • 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 (All MC‑F models) 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) W00427-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Cold start button ( p. 18) 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) W00428-10 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 The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. F03647-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. F03648-10 Throttle grip The throttle grip...

  • Page 17: Start Button

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

  • Page 18: Overview Of Indicator Lamps (Factory Edition)

    6 CONTROLS Overview of indicator lamps (FACTORY EDITION) Possible states Malfunction indicator lamp lights up/flashes orange – The OBD has detected a malfunction in the vehicle electronics. The malfunction indicator lamp also lights up if traction control is activated and the speed limiter intervenes. TC indicator lamp lights up orange –...

  • Page 19: Closing The Fuel Tank Filler Cap

    CONTROLS 6 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 20: Cold Start Button

    6 CONTROLS 6.12 Cold start button The cold start button is fitted to the bottom 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 pushing the cold start button.

  • Page 21: Shift Lever

    CONTROLS 6 6.14 Shift lever Shift lever is mounted on the left side of the engine. 401950-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 401950-13 6.15 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 22: Side Stand (Ex-F)

    6 CONTROLS 6.17 Side stand (EX-F) The side stand is located on the left of the vehicle. 401943-10 The side stand is used for parking the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber strap 401944-10 6.18 Factory Start (FACTORY EDITION)

  • Page 23: 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 24: Running In The Engine

    7 PREPARING FOR USE – 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 25: 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 26: Preparing The Vehicle For Rides On Wet Sand

    7 PREPARING FOR USE – Clean the chain. Chain cleaner ( p. 152) – Mount the steel sprocket. – Grease the chain. Universal oil spray ( p. 153) – Clean the radiator fins. – Straighten the bent radiator fins carefully. 600868-01 Preparing the vehicle for rides on wet sand –...

  • Page 27: Preparing Vehicle For High Temperatures Or Slow Riding

    PREPARING FOR USE 7 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 28: Riding Instructions

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

  • Page 29: Activating Launch Control (Factory Edition)

    RIDING INSTRUCTIONS 8 (All MC‑F models) – Remove plug-in stand H02629-10 (EX-F) – 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 30: Activating Traction Control (Factory Edition)

    8 RIDING INSTRUCTIONS – Press and hold the TC button and the QS button simultane- ously. The TC indicator lamp and the QS indicator lamp flash when launch control is activated. Info The launch control is deactivated automatically for a few seconds after the vehicle has started.

  • Page 31: Starting Off

    RIDING INSTRUCTIONS 8 – Check lock button to ensure it can move easily. – Bend over the handlebars while sitting on the motorcycle. Grip the rim and compress the fork. Press lock button and decompress slowly until the lock button engages in lock ring When the fork compresses for the first time, the lock button is released automatically.

  • Page 32: Shifting, Riding

    8 RIDING INSTRUCTIONS Shifting, riding Warning Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races. – Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine, and contact an authorized GASGAS Motorcycles workshop.

  • Page 33: Applying The Brakes

    RIDING INSTRUCTIONS 8 8.10 Applying the brakes Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. – Adjust application of the brakes to the respective riding situation and riding surface conditions. Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. –...

  • Page 34: Transporting

    8 RIDING INSTRUCTIONS 8.12 Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive.
  • Page 35 RIDING INSTRUCTIONS 8 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 36: 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 37 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. 79) ○ ●...

  • Page 38: 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 39: 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 40: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    10 TUNING THE CHASSIS 10.5 Adjusting the high-speed compression damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...

  • Page 41: Measuring The Dimension Of The Rear Wheel Unloaded

    TUNING THE CHASSIS 10 – Turn adjuster clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping (MC-F) Comfort 17 clicks Standard 15 clicks Sport 13 clicks F03640-10 Rebound damping (EX-F) Comfort...

  • Page 42: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 39) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and marking SAG on the rear fender using the sag gage.

  • Page 43: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS 10 10.10 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...

  • Page 44: Adjusting The Riding Sag

    10 TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 50) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the frame protector. ( p. 54) –...

  • Page 45: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS 10 10.12 Checking the basic setting of the fork Info For various reasons, no exact rider sag can be determined for the fork. – Smaller differences in the rider's weight can be compensated for by the fork air pressure. –...
  • Page 46 10 TUNING THE CHASSIS Guideline Air pressure 10.4 bar (151 psi) Gradual changing of the air 0.2 bar (3 psi) pressure in steps of Minimum air pressure 7 bar (102 psi) Maximum air pressure 12 bar (174 psi) Info Never adjust the air pressure to a value outside the stated range.

  • Page 47: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only mount the protection cap by hand. Finishing work –...

  • Page 48: Adjusting The Rebound Damping Of The Fork

    10 TUNING THE CHASSIS Guideline Compression damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping during compression. 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (All MC‑F models) –...

  • Page 49: Handlebar Position

    TUNING THE CHASSIS 10 Guideline Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 10.16 Handlebar position The holes on the handlebar support are placed at a distance of from the center.
  • Page 50 10 TUNING THE CHASSIS 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 51 TUNING THE CHASSIS 10 Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)

  • Page 52: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 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 53: Bleeding The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 (EX-F) – 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 54: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the fork protector. ( p. 52) Main work – Push dust boots of both fork legs downward.

  • Page 55: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.6 Installing the fork protector – Position the fork protector on left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line and the clamp. Mount and tighten screws –...

  • Page 56: Removing The Frame Protector

    11 SERVICE WORK ON THE CHASSIS 11.9 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 57: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 – Loosen screws . Remove the left fork leg. – Loosen screws . Remove the right fork leg. W00432-10 11.12 Installing the fork legs Main work (MC-F) – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.
  • Page 58 11 SERVICE WORK ON THE CHASSIS (MC-F / EX-F) – Tighten screws Guideline Screw, top triple 20 Nm (14.8 lbf ft) clamp – Tighten screws Guideline Screw, bottom triple 15 Nm (11.1 lbf ft) W00432-11 clamp (FACTORY EDITION) – Tighten screws Guideline Screw, top triple 17 Nm (12.5 lbf ft)

  • Page 59: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 11.13 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) – Remove the front wheel. p. 98) – Remove the fork legs. p. 54) – Remove the start number plate.
  • Page 60 11 SERVICE WORK ON THE CHASSIS – 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 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.
  • Page 61 SERVICE WORK ON THE CHASSIS 11 – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. – Tighten screws Guideline (MC-F / EX-F) Screw, top triple 20 Nm (14.8 lbf ft) clamp (FACTORY EDITION) W00433-10 Screw, top triple 17 Nm (12.5 lbf ft) clamp...

  • Page 62: Checking The Steering Head Bearing Play

    11 SERVICE WORK ON THE CHASSIS 11.15 Checking the steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages com- ponents. – Correct incorrect steering head bearing play immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing...

  • Page 63: Lubricating The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11 Guideline (MC-F / EX-F) Screw, top triple 20 Nm (14.8 lbf ft) clamp (FACTORY EDITION) Screw, top triple 17 Nm (12.5 lbf ft) clamp – Check the steering head bearing play. ( p. 60) Finishing work –...

  • Page 64: Removing The Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.20 Removing the front fender Preparatory work – Remove the start number plate. ( p. 61) Main work (FACTORY EDITION) – Disconnect plug-in connector (antenna of the Connectivity Unit). W00589-10 – Remove screws . Take off the front fender. F03675-10...

  • Page 65: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 11 11.21 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F03675-10 (FACTORY EDITION) – Join plug-in connector (antenna of the Connectivity Unit). W00589-10 Finishing work –...

  • Page 66: Installing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS – Remove screws – Pull off brake cylinder from the push rod. W00187-10 – Remove the connecting link of the chain. – Take off the chain. Info Cover the components to protect them against damage. F03702-01 –...
  • Page 67 SERVICE WORK ON THE CHASSIS 11 – Position the link fork and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, fork pivot M16x1.5 100 Nm (73.8 lbf ft) F03705-10 – Mount the chain. –...

  • Page 68: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 50) 11.24 Removing the seat 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. Preparatory work –...

  • Page 69: Removing The Right Side Panel

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw and lock washer Guideline Screw, seat fixing 8 Nm (5.9 lbf ft) W00439-10 Finishing work – Install the air filter box cover. ( p. 68) 11.26 Removing the right side panel Preparatory work –...

  • Page 70: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.28 Removing the air filter box cover Condition The air filter box cover is secured. – Remove screw W00443-11 – Detach the air filter box cover in area and slide it in area to the rear. –...

  • Page 71: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw Guideline ® Screw, air filter box EJOT PT 3 Nm (2.2 lbf ft) cover K60x20-Z W00443-11 Condition The air filter box cover is not secured. – Position the air filter box cover in area and slide it forward.

  • Page 72: Removing The Air Filter

    11 SERVICE WORK ON THE CHASSIS 11.31 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 73: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Install the air filter. p. 71) – Install the air filter box cover. ( p. 68) 11.33 Installing the air filter Main work – Mount the clean air filter on the air filter support. Info The marking on the air filter support must face upwards.

  • Page 74: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Main work – Detach spring Spring hook (50305017000C1) – Remove screws with the washers and take off the main silencer. W00445-10 11.35 Installing the main silencer Main work – Position the main silencer. – Mount screws with washers, but do not tighten yet.
  • Page 75 SERVICE WORK ON THE CHASSIS 11 Main work (MC-F / EX-F) – 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 76: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.37 Removing 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 77: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Remove screw with the rubber bushing. W00213-10 – Remove screws with the collar bushings. W00446-10 – Pull both spoilers laterally off the radiator and lift off the fuel tank. W00446-12 11.38 Installing the fuel tank Danger Fire hazard Fuel is highly flammable.
  • Page 78 11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 82) – Position the fuel tank and fit the two spoilers laterally to the radia- tor. – Make sure that no cables or throttle cables are trapped or damaged. –...

  • Page 79: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 11.39 Checking for chain dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 77) 400678-01 11.40 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.

  • Page 80: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.41 Checking the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear- ings wear more quickly.

  • Page 81: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 11 Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 58 … 61 mm (2.28 … 2.4 in) Turn adjusting screws on the left and right so that the mark- ings on the left and right chain adjusters are in the same position relative to reference marks...
  • Page 82 11 SERVICE WORK ON THE CHASSIS – Pull on the top section of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.
  • Page 83 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 84: Checking The Frame

    11 SERVICE WORK ON THE CHASSIS 11.44 Checking the frame – Check the frame for damage, cracks, and deformation. » If the frame shows signs of damage, cracks, or deformation: – Change the frame. Guideline Repairs on the frame are not permitted. F03645-01 11.45 Checking the link fork...

  • Page 85: 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 86: Programming The Quickshifter

    11 SERVICE WORK ON THE CHASSIS 11.48 Programming the quickshifter Info If the shifting performance of the quickshifter starts to decrease, it must be reprogrammed. – Carry out start procedure. ( p. 26) – Press and hold the QS button for at least 10 seconds.

  • Page 87: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 – Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horizontal position. – Remove screws – Take off cover with membrane – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) »...
  • Page 88 11 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 150) – On the clutch slave cylinder, remove the protection cap and mount bleeding syringe with an appropriate hose piece on bleeder screw –...

  • Page 89: 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 90: 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 91 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. –...

  • Page 92: 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 93 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. –...

  • Page 94: 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 95: 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 96: 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 97: 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 98: 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 99 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 100: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 50) Main work (MC-F / EX-F) – 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 101 WHEELS, TIRES 13 (FACTORY EDITION) – 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. H04986-10 –...

  • Page 102: Installing The Front Wheel

    13 WHEELS, TIRES 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. (MC-F / EX-F) –...

  • Page 103: Removing The Rear Wheel

    WHEELS, TIRES 13 Long-life grease ( p. 152) – Position the front wheel and insert the wheel spindle. The brake linings are correctly positioned. – Position the brake disc guard. F03724-01 – Mount and tighten screw Guideline Screw, front wheel M20x1.5 35 Nm (25.8 lbf ft) spindle...

  • Page 104: 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 105 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 106: 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 107: 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 108: 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 109: 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 upward and secure with battery holding bracket Info Ensure that the cable is routed correctly. W00224-11 –...

  • Page 110: 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 111: Changing The Main Fuse

    ELECTRICAL SYSTEM 14 (US) battery charger (A54029974500) Alternative 1 (EU) battery charger (A54029974000) 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 112: Changing The Fuse Of The Fuel Pump

    14 ELECTRICAL SYSTEM 14.5 Changing the fuse of the fuel pump Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. – Do not bypass or repair fuses. Caution Danger of burns The voltage regulator gets very hot when the vehicle is operated. –...

  • Page 113: Connectivity Unit Offroad (Cuo)

    ELECTRICAL SYSTEM 14 14.7 Connectivity Unit Offroad (CUO) M02091-10 Connectivity Unit Offroad is attached on the right fork leg. GPS unit is mounted on the fender. The app provided by the manufacturer guides you through the operation of the Connectivity Unit Offroad. Possible states is pressed briefly (<1.5 s) –...
  • Page 114 14 ELECTRICAL SYSTEM lights up blue – The GPS module is active but the position is not detected. • Indicator lamp lights up green – The GPS module is active and the position is detected. • Indicator lamp All indicator lamps flash blue – The Connectivity Unit Offroad is prepared for reset to factory settings. •...

  • Page 115: Cooling System 15

    COOLING SYSTEM 15 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 116: Checking The Coolant Level

    15 COOLING SYSTEM 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 117: 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 118: Changing The Coolant

    15 COOLING SYSTEM Finishing work (FACTORY EDITION) – Install the engine guard. ( p. 53) 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 119 COOLING SYSTEM 15 Finishing work (FACTORY EDITION) – Install the engine guard. ( p. 53)

  • Page 120: 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 121: 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 122 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 Gray guide plate (A48002014000) Alternative 1 Black guide plate (A46002014000) Info The gray guide plate opens the throttle valve more slowly.

  • Page 123: 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 124: 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 125 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.

  • Page 126: 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 127: 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 128 17 SERVICE WORK ON THE ENGINE Main work – Position an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. F03774-10 – Remove screw plug with the O-ring. Info Do not remove screw F03775-10 –...
  • Page 129 SERVICE WORK ON THE ENGINE 17 – Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil screen M20x1.5 15 Nm (11.1 lbf ft) – Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with M12x1.5...

  • Page 130: Adding Engine 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 131: 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 132 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. 152) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 133: 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 134: 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 135: Troubleshooting 20

    TROUBLESHOOTING 20 Faults Possible cause Action – The engine does not turn when Operating error Carry out start procedure. ( p. 26) the start button is pressed – 12-V battery discharged Charge the 12-V battery. p. 108) – Check the charging voltage. –...
  • Page 136 20 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 125) – Engine oil too thin (low viscosity) Change the engine oil and the oil filter, clean the oil screens. p.

  • Page 137: 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 138 21 BLINK CODE Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 139: Troubleshooting Cuo (Factory Edition) 22

    TROUBLESHOOTING CUO (FACTORY EDITION) 22 Malfunctions are indicated by indicator lamp flashing red. Info The individual flashes are 0.5 seconds long (0.25 seconds on, 0.25 seconds off). The pause until the blink code repeats is 2 seconds. M02092-10 Faults Possible cause Action –...

  • Page 140: 23 Technical Specifications

    23 TECHNICAL SPECIFICATIONS 23.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm³ (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 13.6:1 Idle speed 2,200 … 2,300 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...
  • Page 141 TECHNICAL SPECIFICATIONS 23 Oil nozzle for timing chain lubrication 2 Nm (1.5 lbf ft) ® Loctite 243™ Screw, bearing retainer 6 Nm (4.4 lbf ft) ® Loctite 243™ Screw, clutch adjusting ring M5x16 6 Nm (4.4 lbf ft) Screw, clutch spring retainer 8 Nm (5.9 lbf ft) Screw, gear position sensor M5x14...

  • Page 142: Capacities

    23 TECHNICAL SPECIFICATIONS Screw, valve cover 10 Nm (7.4 lbf ft) Screw, water pump cover M6x20 10 Nm (7.4 lbf ft) Screw, water pump cover M6x25 10 Nm (7.4 lbf ft) ® Loctite 243™ Screws, section of the engine case 10 Nm (7.4 lbf ft) Plug, oil channel 9 Nm (6.6 lbf ft)

  • Page 143: Chassis

    TECHNICAL SPECIFICATIONS 23 Super unleaded (ROZ 95) ( p. 151) 7.2 l (1.9 US gal) 23.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork (MC-F) WP XACT AER Fork (EX-F) WP XPLOR CC Fork (FACTORY EDITION) WP XACT AER Suspension travel (All MC‑F models) Front...

  • Page 144: Electrical System

    23 TECHNICAL SPECIFICATIONS 23.5 Electrical system Fuse 58011109110 10 A Fuse 58011109105 Combination instrument lighting and indicator lamps 23.6 Tires Validity Front tire Rear tire (MC-F) 80/100 - 21 M/C 51M TT 110/90 - 19 M/C 62M TT MAXXIS MAXXCROSS MX‑ST+ MAXXIS MAXXCROSS MX‑ST (EX-F) 80/100 - 21 51M TT...

  • Page 145: Factory Edition

    TECHNICAL SPECIFICATIONS 23 Standard 12 clicks Sport 7 clicks Rebound damping Comfort 23 clicks Standard 18 clicks Sport 13 clicks Spring length with preload spacer(s) 478 mm (18.82 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 75 …...

  • Page 146: Shock Absorber

    23 TECHNICAL SPECIFICATIONS 23.8 Shock absorber 23.8.1 MC-F Shock absorber article number A460C409X408000 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 Comfort...

  • Page 147: Factory Edition

    TECHNICAL SPECIFICATIONS 23 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 148: Chassis Tightening Torques

    23 TECHNICAL SPECIFICATIONS 23.9 Chassis tightening torques ® Remaining screws, chassis EJOT PT K60x25‑Z 2 Nm (1.5 lbf ft) ® Screw, air filter box cover EJOT PT K60x20-Z 3 Nm (2.2 lbf ft) ® Screw, air filter box, on subframe EJOT PT K60x20AL 5 Nm (3.7 lbf ft)
  • Page 149 TECHNICAL SPECIFICATIONS 23 Brake lever stop nut 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) ® Loctite 2701™ Nut, rim lock 12 Nm (8.9 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, bottom triple clamp...

  • Page 150: Declarations Of Conformity Cuo (Factory Edition)

    24 DECLARATIONS OF CONFORMITY CUO (FACTORY EDITION) 24.1 Country-specific declarations of conformity - Connectivity Unit Offroad W00603-10...

  • Page 151: Fcc Statements Cuo (Factory Edition) 25

    FCC STATEMENTS CUO (FACTORY EDITION) 25 25.1 FCC statements - Connectivity Unit Offroad Declaration regarding modifications Alterations and modifications not expressly approved by the relevant authority may result in the user being prohibited from operating the equipment. Declaration regarding interference This device complies with article 15 of the FCC regulations.

  • Page 152: 26 Substances

    26 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 ®...
  • Page 153 SUBSTANCES 26 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 154) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre- sponding properties. Super unleaded (ROZ 95) Standard/classification –...

  • Page 154: 27 Auxiliary Substances

    27 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier ® MOTOREX – Racing Bio Dirt Remover Chain cleaner Recommended supplier ® MOTOREX – Chain Clean Fuel additive Recommended supplier ® MOTOREX – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 155 AUXILIARY SUBSTANCES 27 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 156: 28 Standards

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

  • Page 157: Index Of Special Terms 29

    INDEX OF SPECIAL TERMS 29 Launch control Vehicles electronics functions for achieving the best possi- ble acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics Quickshifter Function of the engine electronics for shifting up without clutch actuation Traction Control Auxiliary function of the motor control that reduces engine...

  • Page 158: 30 List Of Abbreviations

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

  • Page 159: List Of Symbols 31

    LIST OF SYMBOLS 31 31.1 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 160 DECLARATION OF CONFORMITY Kind of equipment: Connectivity Unit for KTM vehicles Type-designation: Connectivity Unit Offroad Type number: A46014086010 A46014087020 Manufacturer or Authorised representative: KTM AG Address: Stallhofnerstrasse 3 5230 Mattighofen, Austria This declaration of conformity is issued under the sole responsibility of the manufacturer.
  • Page 161 UK DECLARATION OF CONFORMITY Kind of equipment: Connectivity Unit for KTM vehicles Type-designation: Connectivity Unit Offroad Type number: A46014086010 A46014087020 Manufacturer or Authorised representative: KTM AG Address: Stallhofnerstrasse 3 5230 Mattighofen, Austria This declaration of conformity is issued under the sole responsibility of the manufacturer.

  • Page 162: Index

    INDEX INDEX Chain guide checking ......79 Chain tension 12-V battery adjusting ......78 starting power .
  • Page 163 INDEX Factory Start ......Idle speed activating ......28 adjusting .
  • Page 164 INDEX Putting into operation Start number plate after storage ......132 installing ......61 removing .
  • Page 165 *3215162en* 3215162en 15.02.2024 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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