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OWNER'S MANUAL 2024 MC 250F MC 250F Factory Edition EX 250F Art. no. 3215160en...
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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.
TABLE OF CONTENTS TABLE OF CONTENTS 6.18 Factory Start (FACTORY EDITION) ....21 MEANS OF REPRESENTATION ........5 PREPARING FOR USE ..........22 Symbols used..........5 Formats used..........5 Advice on preparing for first use ....22 Running in the engine ......... 23 SAFETY ADVICE ............
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TABLE OF CONTENTS 10.8 Checking the static sag of the shock 11.36 Changing the glass fiber yarn filling of absorber ............41 the main silencer ........74 10.9 Checking the rider sag of the shock 11.37 Removing the fuel tank ......
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TABLE OF CONTENTS 14.5 Changing the fuse of the fuel pump ..112 23.7 Fork ............146 14.6 Diagnostics connector......113 23.7.1 All MC-F standard models....146 14.7 Connectivity Unit Offroad (CUO) ..... 114 23.7.2 EX-F............146 23.7.3 FACTORY EDITION ....... 147 COOLING SYSTEM ...........
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.
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.
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.
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.
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.
4 VIEW OF VEHICLE View of vehicle, front left (example) I00479-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Cold start button ( p. 18) Engine number ( p. 12) Shift lever ( p.
VIEW OF VEHICLE 4 View of vehicle, rear right (example) I00480-10 Shock absorber compression adjuster Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Vehicle identification number ( p. 12) Steering head label ( p.
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.
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...
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.
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 –...
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. –...
6 CONTROLS (EX-F) – Mount the fuel tank filler cap and turn it clockwise until release button engages. Info Route fuel tank breather hose without kinks. A01320-10 6.12 Cold start button The cold start button is fitted to the bottom of the throttle valve body.
CONTROLS 6 6.13 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.
6 CONTROLS 6.15 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 6.16 Plug-in stand (All MC‑F models) The support for plug-in stand is the left side of the wheel spindle.
CONTROLS 6 6.18 Factory Start (FACTORY EDITION) The Factory Start is mounted on the right fork protector. Possible states Factory Start is deactivated – The fork is in the normal operat- • ing mode. Factory Start is activated – The fork is compressed and the •...
7 PREPARING FOR USE Advice on preparing for first use Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. –...
PREPARING FOR USE 7 – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more challenging ride. Info This vehicle is not approved for use on public roads. When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.
7 PREPARING FOR USE Preparing the vehicle for difficult operating conditions Info Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in signifi- cantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
PREPARING FOR USE 7 – Clean the chain. Chain cleaner ( p. 156) – Mount the steel sprocket. – Grease the chain. Universal oil spray ( p. 157) – Clean the radiator fins. – Straighten the bent radiator fins carefully. 600868-01 Preparing the vehicle for rides on wet sand –...
7 PREPARING FOR USE Preparing vehicle for high temperatures or slow riding – Adjust the secondary drive to the road conditions. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary ratio. –...
RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...
8 RIDING INSTRUCTIONS (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) –...
RIDING INSTRUCTIONS 8 – 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.
8 RIDING INSTRUCTIONS – 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.
RIDING INSTRUCTIONS 8 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.
8 RIDING INSTRUCTIONS 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. –...
RIDING INSTRUCTIONS 8 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.
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8 RIDING INSTRUCTIONS 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. –...
SERVICE SCHEDULE 9 Additional information Any further work that results from the service work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. 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.
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9 SERVICE SCHEDULE 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. 81) ○ ●...
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.
10 TUNING THE CHASSIS 10.3 Compression damping of the shock absorber The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed. The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly.
TUNING THE CHASSIS 10 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. –...
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 Rebound damping (All MC-F standard models) Comfort 17 clicks Standard 15 clicks Sport 13 clicks F03640-10...
TUNING THE CHASSIS 10 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 40) – 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.
10 TUNING THE CHASSIS 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. –...
TUNING THE CHASSIS 10 – Install the frame protector. ( p. 55) – Remove the motorcycle from the lift stand. ( p. 51) 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) –...
10 TUNING THE CHASSIS 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. –...
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TUNING THE CHASSIS 10 Guideline Air pressure 10.3 bar (149 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.
10 TUNING THE CHASSIS 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 –...
TUNING THE CHASSIS 10 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) –...
10 TUNING THE CHASSIS 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.
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TUNING THE CHASSIS 10 Main work – Remove screws . Take off handlebar clamp . Take off the han- dlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
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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)
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. –...
11 SERVICE WORK ON THE CHASSIS (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.
SERVICE WORK ON THE CHASSIS 11 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) – Remove the fork protector. ( p. 53) Main work – Push dust boots of both fork legs downward.
11 SERVICE WORK ON THE CHASSIS 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 –...
SERVICE WORK ON THE CHASSIS 11 11.8 Installing the engine guard (FACTORY EDITION) – Position the engine guard on the frame. – Mount screws , but do not tighten yet. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Mount screws with bushings, but do not tighten yet.
11 SERVICE WORK ON THE CHASSIS 11.11 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) – Remove the front wheel. p. 100) Main work – Remove screws and take off the clamp. –...
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SERVICE WORK ON THE CHASSIS 11 (FACTORY EDITION) – 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.
11 SERVICE WORK ON THE CHASSIS (FACTORY EDITION) – Fit rubber strap with the Connectivity Unit to the right fork leg. Guideline Distance to the upper triple 19 mm (0.75 in) clamp W00590-10 – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft)
SERVICE WORK ON THE CHASSIS 11 – Remove steering head seal – Remove the lower triple clamp with steering stem. – Remove the upper steering head bearing. S05333-10 11.14 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease.
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11 SERVICE WORK ON THE CHASSIS – Tighten screws Guideline (All standard models) Screw, bottom triple 15 Nm (11.1 lbf ft) clamp (FACTORY EDITION) Screw, bottom triple 12 Nm (8.9 lbf ft) clamp W00433-11 – Tighten screw Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head...
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 S05330-12 Finishing work –...
11 SERVICE WORK ON THE CHASSIS 11.16 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) – Take off the handlebar cushion. Main work – Loosen screws – Remove screw –...
SERVICE WORK ON THE CHASSIS 11 11.18 Removing the start number plate – Remove screw – Unhook the start number plate from the brake line and remove it. W00195-10 11.19 Installing the start number plate – Position the brake line in the holder on the start number plate.
11 SERVICE WORK ON THE CHASSIS – Remove screws . Take off the front fender. F03675-10 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)
SERVICE WORK ON THE CHASSIS 11 Finishing work – Install the start number plate. ( p. 63) 11.22 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) – Remove the frame protector. ( p.
11 SERVICE WORK ON THE CHASSIS – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. W00218-10 11.23 Installing the shock absorber Main work – Carefully position the shock absorber into the vehicle from the bot- tom.
SERVICE WORK ON THE CHASSIS 11 – Position the angle lever and linkage lever. – Mount and tighten fitting Guideline Nut, linkage lever on M16x1.5 80 Nm (59 lbf ft) angle lever Info Pay attention to flat area F03704-10 – Mount and tighten screw Guideline Screw, bottom...
11 SERVICE WORK ON THE CHASSIS – Slide the seat toward the rear and lift it off. W00439-11 11.25 Mounting the seat Main work – Attach the seat to the collar bushings and simultaneously slide it forward. The holding lugs engage in the recesses. –...
SERVICE WORK ON THE CHASSIS 11 11.26 Removing the right side panel Preparatory work – Remove the frame protector. ( p. 55) Main work – Detach right side panel in area and slide it in area to the rear. – Take the right side panel off.
11 SERVICE WORK ON THE CHASSIS – Detach the air filter box cover in area and slide it in area to the rear. – Take off the air filter box cover. W00443-10 Condition The air filter box cover is not secured. –...
SERVICE WORK ON THE CHASSIS 11 Condition The air filter box cover is not secured. – Position the air filter box cover in area and slide it forward. – Press the air filter box cover in area into the rubber bush- ings.
11 SERVICE WORK ON THE CHASSIS Main work – Detach retaining tab – Remove air filter with air filter support. – Remove air filter from air filter support. W00216-10 11.32 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage. –...
SERVICE WORK ON THE CHASSIS 11 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. – Grease the air filter in area Long-life grease ( p.
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.
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SERVICE WORK ON THE CHASSIS 11 Main work (All standard models) – 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.
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. –...
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.
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11 SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 84) – 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. –...
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. 79) 400678-01 11.40 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.
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.
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...
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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.
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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.
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...
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.
11 SERVICE WORK ON THE CHASSIS 11.48 Programming the quickshifter (FACTORY EDITION) Info If the shifting performance of the quickshifter starts to decrease, it must be reprogrammed. – Carry out start procedure. ( p. 27) – Press and hold the QS button for at least 10 seconds.
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) »...
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11 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 154) – On the clutch slave cylinder, remove the protection cap and mount bleeding syringe with an appropriate hose piece on bleeder screw –...
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. –...
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: –...
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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. –...
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.) –...
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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. –...
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.
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) »...
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.
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.) –...
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.
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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.
13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 51) Main work (All standard models) – 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.
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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 –...
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. (All standard models) –...
WHEELS, TIRES 13 Long-life grease ( p. 156) – 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...
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. –...
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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.
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.
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.
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. –...
ELECTRICAL SYSTEM 14 14.2 Installing the 12-V battery Main work – Pull up battery holding bracket , insert the 12-V battery into the battery compartment with the terminals facing upwards and secure with battery holding bracket 12-V battery (HJTZ5S-FP-C) ( p.
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.
ELECTRICAL SYSTEM 14 (EU) battery charger (A54029974000) Alternative 1 (US) battery charger (A54029974500) These battery chargers test whether the 12-V battery retains its voltage. It is also impossible to overcharge the 12-V battery with these battery chargers. The charging time may be longer at low temperatures.
14 ELECTRICAL SYSTEM Main work – Pull starter relay from the holder. W00228-10 – Take off protection caps – Remove faulty main fuse Info A faulty fuse has a burned-out fuse wire A spare fuse is located in the starter relay. –...
ELECTRICAL SYSTEM 14 Preparatory work – Remove the air filter box cover. ( p. 69) – Remove the seat. ( p. 67) Main work – Take off protection cap – Remove the faulty fuse Info A faulty fuse has a burned-out fuse wire –...
14 ELECTRICAL SYSTEM 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) –...
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ELECTRICAL SYSTEM 14 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. •...
15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is reg- ulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
COOLING SYSTEM 15 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
15 COOLING SYSTEM Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
COOLING SYSTEM 15 Finishing work (FACTORY EDITION) – Install the engine guard. ( p. 55) 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.
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15 COOLING SYSTEM Finishing work (FACTORY EDITION) – Install the engine guard. ( p. 55)
TUNING THE ENGINE 16 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throt- tle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...
16 TUNING THE ENGINE 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. –...
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TUNING THE ENGINE 16 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be posi- tioned at marking Black guide plate (A46002014000) Alternative 1 Gray guide plate (A48002014000) Info The gray guide plate opens the throttle valve more slowly.
16 TUNING THE ENGINE 16.4 Changing the mapping (FACTORY EDITION) Info The desired engine characteristic can be activated using the combination switch. The setting most recently selected is activated again when restarting. Traction control can also be activated in each mapping. The mapping can also be changed during the ride.
TUNING THE ENGINE 16 – Run the engine until warm. The cold start button is deactivated – The cold start button is in its basic position. ( p. 18) Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. –...
16 TUNING THE ENGINE 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. If the shift lever is permanently touching the boot, the transmission will be subject to excessive load; this can cause a malfunction of the quickshifter.
SERVICE WORK ON THE ENGINE 17 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...
17 SERVICE WORK ON THE ENGINE 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. –...
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SERVICE WORK ON THE ENGINE 17 Main work – Position an appropriate container under the engine. – Remove screw plug with oil screen and the O-rings. – Remove oil drain plug with the magnet and seal ring. W00543-10 – Remove screw plug with the O-ring.
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17 SERVICE WORK ON THE ENGINE – Pull oil filter out of the oil filter housing. Lock ring plier (51012011000) – Allow the engine oil to drain completely. – Thoroughly clean the parts and the sealing surfaces. W00545-10 – Lay the motorcycle on its side and fill the oil filter housing to about ⅓...
SERVICE WORK ON THE ENGINE 17 17.4 Adding engine oil Info Too little engine oil or poor-quality engine oil will result in premature wear of the engine. – Remove filler plug with the O-ring. – Add the same engine oil used when the last oil change was carried out.
18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
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CLEANING, CARE 18 – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber ( p. 156) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
19 STORAGE 19.1 Storage Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...
STORAGE 19 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.
20 TROUBLESHOOTING Faults Possible cause Action – The engine does not turn when Operating error Carry out start procedure. ( p. 27) the start button is pressed – 12-V battery discharged Charge the 12-V battery. p. 110) – Check the charging voltage. –...
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TROUBLESHOOTING 20 Faults Possible cause Action – High oil consumption Engine oil level too high Check the engine oil level. ( p. 128) – Engine oil too thin (low viscosity) Change the engine oil and oil filter, clean the oil screen. p.
22 TROUBLESHOOTING CUO (FACTORY EDITION) 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 –...
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.
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 ®...
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SUBSTANCES 26 Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 158) (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 –...
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.
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...
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...
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.
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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.
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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.
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