GAS GAS MC 125 2024 Owner's Manual
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GAS GAS MC 125 2024 Owner's Manual

GAS GAS MC 125 2024 Owner's Manual

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OWNER'S MANUAL
2024
MC 125
Art. no. 3215157en

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Summary of Contents for GAS GAS MC 125 2024

  • Page 1 OWNER'S MANUAL 2024 MC 125 Art. no. 3215157en...
  • Page 3 DEAR GASGAS CUSTOMER Congratulations on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports DEAR GASGAS CUSTOMER vehicle which, with appropriate care, will bring you pleasure for a long time to come. We wish you good and safe riding at all times! Enter the serial numbers of your vehicle below.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Starting power of lithium-ion batteries TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 at low temperatures........20 Symbols used..........5 Preparing the vehicle for difficult Formats used..........5 operating conditions ........21 Preparing the vehicle for rides on dry SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS SERVICE WORK ON THE CHASSIS ......43 BRAKE SYSTEM............74 11.1 Raising the motorcycle with a lift stand ..43 12.1 Checking the free travel of the hand brake lever........... 74 11.2 Removing the motorcycle from the lift stand ............
  • Page 6 TABLE OF CONTENTS 17.5 Checking the basic position of the shift lever ............107 17.6 Adjusting the basic position of the shift lever ............108 SERVICE WORK ON THE ENGINE ......109 18.1 Changing the fuel screen ..... 109 18.2 Checking the gear oil level .......

  • Page 7: Means Of Representation 1

    MEANS OF REPRESENTATION 1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g., of a work step or a function). Indicates an unexpected reaction (e.g., of a work step or a function). Indicates work that requires expert knowledge and technical understanding. In the interest of your own safety, have this work performed by an authorized GASGAS Motorcycles workshop.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Safe Operation

    SAFETY ADVICE 2 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

  • Page 10: Work Rules

    2 SAFETY ADVICE Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with 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) S05824-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Shift lever ( p. 17) Engine number ( p. 12)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S05825-10 Shock absorber compression Combination switch ( p. 15) Fork air pressure adjuster Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Vehicle identification number Idle speed adjusting screw ( 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 embossed on the left side of the engine above the engine sprocket.

  • Page 15: Shock Absorber Article Number

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

  • Page 16: Controls

    6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. J00075-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The front brake is engaged using the hand brake lever. J00077-10 Throttle grip The throttle grip...

  • Page 17: Start Button

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

  • Page 18: Opening The Fuel Tank Filler Cap

    6 CONTROLS Opening the fuel tank filler cap 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 19: Cold Start Button

    CONTROLS 6 6.11 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 20: Foot Brake Lever

    6 CONTROLS The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 6.14 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.15 Plug-in stand...

  • Page 21: Preparing For Use 7

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

  • Page 22: Running In The Engine

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

  • Page 23: Preparing The Vehicle For Difficult Operating Conditions

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

  • Page 24: Preparing The Vehicle For Rides On Wet Sand

    7 PREPARING FOR USE – Clean the chain. Chain cleaner ( p. 130) – Mount the steel sprocket. – Grease the chain. Universal oil spray ( p. 131) – Clean the radiator fins. – Straighten the bent radiator fins carefully. 600868-01 Condition Regular use in sand...

  • Page 25: Preparing Vehicle For High Temperatures Or Slow Riding

    PREPARING FOR USE 7 – Mount the steel sprocket. – Clean the motorcycle. ( p. 113) – Straighten the bent radiator fins carefully. 600868-01 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 26: 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 27: Starting Off

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

  • Page 28: Braking

    8 RIDING INSTRUCTIONS – 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. – Only open the throttle as much as the engine can handle – abrupt throttle grip opening increases fuel consumption. –...

  • Page 29: Transporting

    RIDING INSTRUCTIONS 8 – Park the vehicle on a firm and level surface. – Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. –...

  • Page 30: Refueling

    8 RIDING INSTRUCTIONS 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 31: Service Schedule 9

    SERVICE SCHEDULE 9 Additional information Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments.
  • Page 32 9 SERVICE SCHEDULE every 24 months Every 90 operating hours Every 45 operating hours After 15 operating hours / Every 15 operating hours After 1 operating hour ○ ● ● ● Check the chain, rear sprocket, engine sprocket, and chain guide. ( p.

  • Page 33: Tuning The Chassis 10

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

  • Page 34: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    10 TUNING THE CHASSIS – Turn adjuster clockwise up to the last perceptible click. – Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks F03639-11 Info Turn clockwise to increase damping;...

  • Page 35: 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 Comfort 17 clicks Standard 15 clicks Sport 13 clicks F03640-10 Info Turn clockwise to increase the damping;...

  • Page 36: Checking The Static Sag Of The Shock Absorber

    10 TUNING THE CHASSIS 10.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 33) – 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 37: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS 10 10.9 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 38: Adjusting The Riding Sag

    10 TUNING THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 43) 10.10 Adjusting the riding sag Preparatory work – Remove the frame protector. ( p. 55) – Remove the right side panel. ( p. 55) – Remove main silencer.

  • Page 39: Air Suspension Xact

    TUNING THE CHASSIS 10 10.11 Air suspension XACT Air suspension WP Suspension XACT is used in the fork. In this system, the suspension is located in the left fork leg and damping in the right fork leg. As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks.
  • Page 40 10 TUNING THE CHASSIS Info Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine. The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg. Preparatory work –...

  • Page 41: Adjusting The Compression Damping Of The Fork

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

  • Page 42: 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 43 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 or lines. –...
  • Page 44 10 TUNING THE CHASSIS Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)

  • Page 45: Service Work On The Chassis 11

    SERVICE WORK ON THE CHASSIS 11 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –...

  • Page 46: Cleaning The Dust Boots Of The Fork Legs

    11 SERVICE WORK ON THE CHASSIS Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. – Tighten the bleeder screws. A01215-10 Finishing work – Remove the motorcycle from the lift stand. ( p. 43) 11.4 Cleaning the dust boots of the fork legs Preparatory work...

  • Page 47: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11 11.5 Removing the fork protector – Remove screws . Remove the clamp. – Remove screws . Take off the left fork protector. – Remove screws . Take off the right fork protector. F00024-10 11.6 Installing the fork protector –...

  • Page 48: Installing The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.8 Installing the fork legs Main work – 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 fork legs.

  • Page 49: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screw . Detach the wiring harness. – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and hang them to the side. Info Cover the components to protect them against damage. I00184-10 Do not kink the cables or lines.
  • Page 50 11 SERVICE WORK ON THE CHASSIS – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 51: Checking The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) brake caliper Loctite ® 243™ – Position the brake line and the clamp. Mount and tighten screws W00080-12 Finishing work –...

  • Page 52: Adjusting Steering Head Bearing Play

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

  • Page 53: Installing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11 11.15 Installing the start number plate – Connect the brake line at the start number plate. – Position the start number plate. The holding lugs engage in the fender. – Mount and tighten screw Guideline Remaining screws, EJOT PT K60x25 2 Nm (1.5 lbf ft)
  • Page 54 11 SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove fitting Info Raise the swingarm slightly to be able to remove the screws more easily. W00036-10 – Remove screws – Pull off foot brake cylinder from the push rod. W00051-10 –...

  • Page 55: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 11.19 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bot- tom. – Mount and tighten screw Guideline Screw, top shock 60 Nm (44.3 lbf ft) absorber Loctite ®...

  • Page 56: Removing The Seat

    11 SERVICE WORK ON THE CHASSIS Guideline Screw, bottom 60 Nm (44.3 lbf ft) shock absorber Loctite ® 2701™ Info Raise the link fork slightly to be able to mount the screw more easily. Finishing work – Install the main silencer. ( p.

  • Page 57: Removing The Frame Protector

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05837-10 Finishing work – Install the air filter box cover. ( p. 57) 11.22 Removing the frame protector – Remove the cable ties. –...

  • Page 58: Installing The Right Side Panel

    11 SERVICE WORK ON THE CHASSIS 11.25 Installing the right side panel Main work – Slide right side panel forward and hook into area – Engage the side panel in area Guideline Ensure that the side panel is correctly hooked in to areas S05844-11 Finishing work –...

  • Page 59: Installing The Air Filter Box Cover

    SERVICE WORK ON THE CHASSIS 11 11.27 Installing the air filter box cover Condition The air filter box cover is secured. – Slide the air filter box cover forward and hook into area – Engage the air filter box cover in area Guideline Ensure that the air filter box cover is correctly hooked in to areas...

  • Page 60: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab . Remove air filter with air filter support. – Take off air filter from air filter support. S05841-10 11.29 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 61: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 11.30 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 130) F03686-10 – Insert the air filter and position the top retaining pin in bush- The air filter is correctly positioned.

  • Page 62: Installing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Main work – Remove screws with the washers. – Pull off the main silencer from the manifold at exhaust sleeve S05845-10 11.33 Installing the main silencer Main work – Position the main silencer in exhaust sleeve –...

  • Page 63: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Pull out inner tube with O-ring – Pull glass fiber yarn filling out of the inner tube. – Clean the parts that need to be reinstalled and check for damage. –...

  • Page 64: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 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! –...
  • Page 65 SERVICE WORK ON THE CHASSIS 11 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 66: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS – Install the frame protector. ( p. 55) 11.37 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 64) 400678-01 11.38 Cleaning the chain...

  • Page 67: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.39 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 68: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws left and right. Guideline Chain tension 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 69 SERVICE WORK ON THE CHASSIS 11 – 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 70 11 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.

  • Page 71: Checking The Frame

    SERVICE WORK ON THE CHASSIS 11 11.42 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. W00062-10 11.43 Checking the link fork...

  • Page 72: Checking The Rubber Grip

    11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars, above the fuel tank bracket on the right of the frame to the throttle valve body. The throttle cable must be secured on the fuel tank bracket with a rubber strap.

  • Page 73: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 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 74: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS 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 75 SERVICE WORK ON THE CHASSIS 11 Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

  • Page 76: 12 Brake System

    12 BRAKE SYSTEM 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 77: Checking The Front Brake Fluid Level

    BRAKE SYSTEM 12 – Change the front brake disc. – Change the rear brake disc. – Check the front and rear brake discs for damage, cracking, and deformation. » If the brake disc exhibits damage, cracking, or deformation: – Change the front brake disc. –...
  • Page 78 12 BRAKE SYSTEM 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 79: Checking That The Brake Linings Of The Front Brake Are Secured

    BRAKE SYSTEM 12 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 80 12 BRAKE SYSTEM Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed.
  • Page 81 BRAKE SYSTEM 12 – Check that spring plate in the brake caliper and brake pad slid- ing plate in the brake caliper bracket are seated correctly. 100397-01 – Insert the new brake linings, insert pin , and mount cotter pins Guideline Mount the outer cotter pins from the front to the rear.

  • Page 82: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM 12.8 Checking the free travel of foot brake lever Warning Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake. –...

  • Page 83: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM 12 Guideline Rear brake lever stop 20 Nm (14.8 lbf ft) – Attach spring 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 84 12 BRAKE SYSTEM 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 85: Checking That The Brake Linings Of The Rear Brake Are Secured

    BRAKE SYSTEM 12 12.12 Checking that the brake linings of the rear brake are secured Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.) –...
  • Page 86 12 BRAKE SYSTEM Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid corrodes paint. Only use clean brake fluid from a sealed container.
  • Page 87 BRAKE SYSTEM 12 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Make sure that decoupling plate is mounted on the pis- ton side brake lining. – Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.

  • Page 88: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 43) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 89: Installing The Front Wheel

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

  • Page 90: 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 91 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 92: 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 93: Checking Spoke Tension

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

  • Page 94: 14 Cooling System

    14 COOLING SYSTEM 14.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is reg- ulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 95: Checking The Coolant Level

    COOLING SYSTEM 14 14.3 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 96: Refilling With Coolant

    14 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 97: Changing The Coolant

    COOLING SYSTEM 14 – Loosen screw until coolant escapes without bubbles. – Mount and tighten screw Guideline Bleeder screw, cylinder 8 Nm (5.9 lbf ft) head – Completely fill the radiator with coolant. Coolant ( p. 128) S05856-10 – Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
  • Page 98 14 COOLING SYSTEM – Remove screw . Take off radiator cap – Place an appropriate container under the water pump cover. – Completely drain the coolant. – Mount and tighten screw with a new seal ring. Guideline Bleeder screw, water M6x25 8 Nm (5.9 lbf ft) pump cover...

  • Page 99: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Removing the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 100: Installing The 12-V Battery

    15 ELECTRICAL SYSTEM 15.2 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 12-V battery (HJTZ5S-FP-C) S05860-11 –...

  • Page 101: Charging The 12-V Battery

    ELECTRICAL SYSTEM 15 15.3 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 102: Changing The Main Fuse

    15 ELECTRICAL SYSTEM Guideline The charging current, charging voltage, and charging time must not be exceeded. Maximum charging voltage 14.4 V Maximum charging current 3.0 A Maximum charging time 24 h Recharge the 12-V battery 6 months regularly when the motor- cycle is not being used –...

  • Page 103: Changing The Fuse Of The Fuel Pump

    ELECTRICAL SYSTEM 15 Main work – Remove the protection caps. – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. – Insert a new main fuse. S05863-10 Fuse (58011109110) –...

  • Page 104: Diagnostics Connector

    15 ELECTRICAL SYSTEM Main work – Take off protection cap – Remove the faulty fuse Info A faulty fuse has a burned-out fuse wire – Insert the new fuse for the fuel pump. Fuse (58011109105) – Check that the electrical system is functioning properly. –...

  • Page 105: Exhaust Control 16

    EXHAUST CONTROL 16 16.1 Programming the end positions of the exhaust control Info If work has been carried out on the exhaust control, the end positions must be reprogrammed. Condition The engine is off. Preparatory work – Remove the air filter box cover. ( p.
  • Page 106 16 EXHAUST CONTROL – Wait until you can no longer hear the exhaust control engine operat- ing. – Disconnect wake-up connector from diagnostics connector – Mount diagnostics connector on the holder. – Mount engine control unit on the bracket. G05895-11 Finishing work –...

  • Page 107: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 Changing the mapping Info The desired engine characteristic can be altered using the combination switch. Changing the mapping also affects the response of the exhaust control. The setting most recently selected is activated again when restarting. The mapping can also be changed during the ride.

  • Page 108: Adjusting The Play In The Throttle Cable

    17 TUNING THE ENGINE 17.3 Adjusting the play in the throttle cable Info If the correct routing of the throttle cable has already been secured, the fuel tank does not need to be removed. Preparatory work – Remove the frame protector. ( p.

  • Page 109: Adjusting The Idle Speed

    TUNING THE ENGINE 17 17.4 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 110: Adjusting The Basic Position Of The Shift Lever

    17 TUNING THE ENGINE 17.6 Adjusting the basic position of the shift lever – Remove screw with the washers and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage gearing.

  • Page 111: Service Work On The Engine 18

    SERVICE WORK ON THE ENGINE 18 18.1 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 112: Checking The Gear Oil Level

    18 SERVICE WORK ON THE ENGINE 18.2 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Remove gear oil level monitoring screw –...

  • Page 113: Adding The Gear Oil

    SERVICE WORK ON THE ENGINE 18 Main work – Remove gear oil drain plug with magnet. – Remove filler plug with the O-ring. – Let the gear oil drain fully. – Thoroughly clean the gear oil drain plug with magnet. –...
  • Page 114 18 SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring. – Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw. Engine oil (15W/50) ( p. 128) – Mount and tighten the gear oil level monitoring screw. Guideline Screw, gear oil level 8 Nm (5.9 lbf ft)

  • Page 115: Cleaning, Care 19

    CLEANING, CARE 19 19.1 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 116 19 CLEANING, CARE Preserving materials for paints, metal and rubber ( p. 130) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Special cleaner for glossy and matte paint finishes, metal and plastic surfaces ( p.

  • Page 117: Storage 20

    STORAGE 20 20.1 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 118: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 43) – Perform checks and maintenance measures when preparing for use. p. 24) – Take a test ride. 401059-01...

  • Page 119: Troubleshooting 21

    TROUBLESHOOTING 21 Faults Possible cause Action – The engine does not turn over Operating error Carry out start procedure. ( p. 24) when the start button is actuated – 12-V battery discharged Charge the 12-V battery. p. 99) – Check the charging voltage. –...
  • Page 120 21 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Radiator fins very dirty Clean the radiator fins. – Foam formation in cooling system Drain the coolant. p. 93) – Refill with coolant. p. 94) – Damaged cylinder head or cylin- Check the cylinder head and cylinder head der head gasket gasket.

  • Page 121: Blink Code 22

    BLINK CODE 22 Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine control unit Error level condition Blink code for malfunction indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition Crankcase pressure sensor - short circuit to ground...
  • Page 122 22 BLINK CODE Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil – circuit fault Error level condition Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – synchronization faulty Error level condition Crankshaft speed sensor –...

  • Page 123: Technical Specifications 23

    TECHNICAL SPECIFICATIONS 23 23.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Idle speed 1,400 … 1,500 rpm Exhaust valve - Beginning of adjustment 7,200 rpm Crankshaft bearing 1 grooved ball bearing/1 roller bearing...
  • Page 124 23 TECHNICAL SPECIFICATIONS Screw, control lever, exhaust control 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, cover, actuator 6 Nm (4.4 lbf ft) Screw, crankshaft speed sensor 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, exhaust control cover 6 Nm (4.4 lbf ft) Screw, locking lever 6 Nm (4.4 lbf ft)

  • Page 125: Capacities

    TECHNICAL SPECIFICATIONS 23 Nut, primary gear wheel M18LHx1.5 120 Nm (88.5 lbf ft) Loctite ® 243™ 23.3 Capacities 23.3.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 128) 23.3.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p.

  • Page 126: Tires

    23 TECHNICAL SPECIFICATIONS 23.5 Tires Front tire Rear tire 80/100 - 21 M/C 51M TT 100/90 - 19 M/C 57M TT MAXXIS MAXXCROSS MX‑ST+ MAXXIS MAXXCROSS MX‑ST+ The tires specified represent one of the possible series production tires. For alternative manufacturers, if any, contact an authorized dealer or qualified tire dealership.

  • Page 127: Chassis Tightening Torques

    TECHNICAL SPECIFICATIONS 23 Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 36 N/mm (206 lb/in) Weight of rider: 75 … 85 kg (165 … 187 lb.) 39 N/mm (223 lb/in) Weight of rider: 85 …...
  • Page 128 23 TECHNICAL SPECIFICATIONS Screw, chain guide on link fork at the M6x45 10 Nm (7.4 lbf ft) front Screw, chain guide on link fork at the M6x16 10 Nm (7.4 lbf ft) rear Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite ®...
  • Page 129 TECHNICAL SPECIFICATIONS 23 Nut, pull rod on triangular lever M16x1.5 60 Nm (44.3 lbf ft) Nut, triangular lever on link fork M16x1.5 80 Nm (59 lbf ft) 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, wheel spindle, rear...

  • Page 130: 24 Substances

    24 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 MOTOREX ®...
  • Page 131 SUBSTANCES 24 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 132) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corre- sponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 132: 25 Auxiliary Substances

    25 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 133 AUXILIARY SUBSTANCES 25 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 134: 26 Standards

    26 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 135: Index Of Special Terms 27

    INDEX OF SPECIAL TERMS 27 On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics...

  • Page 136: 28 List Of Abbreviations

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

  • Page 137: List Of Symbols 29

    LIST OF SYMBOLS 29 29.1 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 138: Index

    INDEX Chain guide INDEX checking ......66 Chain tension 12-V battery adjusting ......65 charging .
  • Page 139 INDEX Fork air pressure, adjusting ....37 Idle speed article number ..... . . 12 adjusting .
  • Page 140 INDEX removing ......87 chassis ......123 chassis tightening torques .
  • Page 141 *3215157en* 3215157en 31.08.2023 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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