GAS GAS MC 250 2024 Owner's Manual
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GAS GAS MC 250 2024 Owner's Manual

GAS GAS MC 250 2024 Owner's Manual

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OWNER'S MANUAL
2024
MC 250
EX 250
EX 300
Art. no. 3215158en

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Summary of Contents for GAS GAS MC 250 2024

  • Page 1 OWNER'S MANUAL 2024 MC 250 EX 250 EX 300 Art. no. 3215158en...
  • 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 Running in the engine ......... 21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Starting power of lithium-ion batteries Symbols used..........5 at low temperatures........21 Formats used..........5 Preparing the vehicle for difficult operating conditions ........22 SAFETY ADVICE ............
  • Page 5 TABLE OF CONTENTS 10.16 Handlebar position........42 11.48 Changing the hydraulic clutch fluid ..74 10.17 Adjusting the handlebar position ... 42 BRAKE SYSTEM............76 SERVICE WORK ON THE CHASSIS ......45 12.1 Checking the free travel of the hand brake lever...........
  • Page 6 TABLE OF CONTENTS 17.3 Adjusting the play in the throttle cable ............. 107 17.4 Adjusting the idle speed ....... 108 17.5 Checking the basic position of the shift lever ............108 17.6 Adjusting the basic position of the shift lever ............

  • 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 Misuse The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended. Any use of the vehicle beyond the intended and defined use constitutes misuse. Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respec- tive use.

  • Page 9: Safe Operation

    SAFETY ADVICE 2 Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases. Removal or puncturing of parts of the intake system. Lack of proper maintenance. Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

  • Page 10: Environment

    2 SAFETY ADVICE During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings, pins, and lock washers). In the case of certain screws, a screw adhesive (e.g. Loctite ®...

  • 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) S05871-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Shift lever ( p. 18) Engine number ( p. 12)

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

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) S05872-10 Shock absorber compression Fork air pressure adjuster Fork compression adjuster Start button ( p. 15) Stop button ( p. 14) Throttle grip ( p. 14) Vehicle identification number Fork rebound adjustment 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 The engine number is embossed on the left side of the engine above the engine sprocket.

  • Page 15: Shock Absorber Article Number

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

  • Page 16: Controls

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

  • Page 17: Start Button

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

  • Page 18: 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: Closing The Fuel Tank Filler Cap

    CONTROLS 6 6.10 Closing the fuel tank filler cap (MC 250) – Mount fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed. Info Route fuel tank breather hose without kinks. S05828-11 (All EX models) –...

  • Page 20: Idle Speed Adjusting Screw

    6 CONTROLS 6.12 Idle speed adjusting screw The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehicle’s response when the throttle is opened. An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

  • Page 21: Foot Brake Lever

    CONTROLS 6 6.14 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 (MC 250) The holder for the plug-in stand is the left side of the wheel spindle.

  • Page 22: Preparing For Use

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

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 – Get used to the handling 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 24: Preparing The Vehicle For Difficult Operating Conditions

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

  • Page 25: Preparing The Vehicle For Rides On Wet Sand

    PREPARING FOR USE 7 – Clean the chain. Chain cleaner ( p. 132) – Mount the steel sprocket. – Grease the chain. Universal oil spray ( p. 133) – Clean the radiator fins. – Straighten the bent radiator fins carefully. 600868-01 Condition Regular use in sand...

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

    7 PREPARING FOR USE – Mount the steel sprocket. – Clean the motorcycle. ( p. 114) – 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 27: Riding Instructions 8

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

  • Page 28: Starting Off

    8 RIDING INSTRUCTIONS (MC 250) – Take the motorcycle off side stand and secure the side stand with rubber strap H02629-10 (All EX models) – Take the motorcycle off side stand and secure the side stand with rubber strap – Shift the transmission to neutral position.

  • Page 29: Shifting, Riding

    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 you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized GAS- GAS Motorcycles workshop.

  • Page 30: Stopping, Parking

    8 RIDING INSTRUCTIONS Stopping, parking Warning Risk of injury People who act without authorization may not be familiar with the vehicle. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. Warning Danger of burns Some vehicle components become hot when the vehicle is operated.

  • Page 31: Refueling

    RIDING INSTRUCTIONS 8 – Use tension belts or other suitable devices to secure the motor- cycle against falling over or rolling away. Info Only tighten the tension belts to the point that the plug- in stand is in contact with the fender and tires. Pay attention to the alignment of the plug-in stand to the fender.

  • Page 32: Service Schedule

    9 SERVICE SCHEDULE Additional information Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments.
  • Page 33 SERVICE SCHEDULE 9 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 34: 10 Tuning The Chassis

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

  • Page 35: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    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 Lowspeed compression damping (MC 250) Comfort 17 clicks Standard 15 clicks Sport 13 clicks F03639-11...

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

    10 TUNING THE CHASSIS 10.5 Adjusting the rebound 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 37: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 Finishing work – Remove the motorcycle from the lift stand. ( p. 45) 10.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 34) – Hold the motorcycle upright with aid of an assistant. –...

  • Page 38: Adjusting The Spring Preload Of The Shock Absorber

    10 TUNING THE CHASSIS 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 39: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 – Remove the motorcycle from the lift stand. ( p. 45) 10.10 Adjusting the riding sag Preparatory work – Remove the frame protector. ( p. 57) – Remove the right side panel. ( p. 57) – Remove main silencer.

  • Page 40: Air Suspension Xact

    10 TUNING THE CHASSIS 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 41 TUNING THE CHASSIS 10 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 42: Adjusting The Compression Damping Of The Fork

    10 TUNING THE CHASSIS 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (MC 250) – Turn adjuster clockwise all the way to the stop. Info Adjuster is located at the upper end of the right fork leg.

  • Page 43: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 10 10.15 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. (MC 250) – Turn adjuster clockwise all the way to the stop. Info Adjuster is located at the lower end of the right fork leg.

  • Page 44: Handlebar Position

    10 TUNING THE CHASSIS 10.16 Handlebar position The holes on the handlebar support are placed at a distance of from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions. This allows the handlebar to be mounted in the most comfortable position for the rider.
  • Page 45 TUNING THE CHASSIS 10 Main work – Remove screws . Take off handlebar clamp . Take off the han- dlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables or lines. –...
  • Page 46 10 TUNING THE CHASSIS Adjusting the handlebar position with the handlebar clamp – Place the handlebar support in the required position. Info The handlebar support is longer and higher on one side. – Mount and tighten the screws with the bushings Guideline Screw, handle- 40 Nm (29.5 lbf ft)

  • Page 47: Service Work On The Chassis 11

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

  • Page 48: Bleeding The Fork Legs

    11 SERVICE WORK ON THE CHASSIS 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Release bleeder screws Any excess pressure escapes from the interior of the fork. –...

  • Page 49: 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. E01988-10 11.6 Installing the fork protector –...

  • Page 50: 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 51: 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 52 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 53: Checking The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 – Position the brake caliper. Mount and tighten screws Guideline Screw, front 25 Nm (18.4 lbf ft) brake caliper Loctite ® 243™ – Position the brake line and the clamp. Mount and tighten screws I01080-10 Finishing work –...

  • Page 54: 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. 45) – Remove the handlebar cushion. Main work – Loosen screws – Remove screw – Loosen and retighten screw Guideline Screw, top steering M20x1.5...

  • Page 55: 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 on EJOT PT K60x25 2 Nm (1.5 lbf ft)
  • Page 56 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 57: 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 58: 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 59: Removing The Frame Protector

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screw with the wedge lock washers. Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis S05837-10 Finishing work – Install the air filter box cover. ( p. 58) 11.22 Removing the frame protector –...

  • Page 60: 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 61: Removing The Air Filter

    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 S05877-11 Condition The air filter box cover is not secured. – Slide the air filter box cover forward and hook into area –...

  • Page 62: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS 11.29 Cleaning the air filter and air filter box 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.

  • Page 63: Preparing Air Filter Box Cover For Securing

    SERVICE WORK ON THE CHASSIS 11 Finishing work – Install the air filter box cover. ( p. 58) 11.31 Preparing air filter box cover for securing Preparatory work – Remove the air filter box cover. ( p. 58) Main work –...

  • Page 64: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Finishing work – Install the right side panel. ( p. 58) – Install the frame protector. ( p. 57) 11.34 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets hot when the vehicle is driven. –...

  • Page 65: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 11.35 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 66: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS (MC 250) – Remove screw with the rubber bushing. S05848-10 – Remove screws with the collar bushings. – Pull both spoilers laterally off the radiator and lift off the fuel tank. S05849-10 11.36 Installing the fuel tank Danger Fire hazard Fuel is highly flammable.
  • Page 67 SERVICE WORK ON THE CHASSIS 11 – 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. – Attach the fuel tank breather hose to the fuel tank lid. –...

  • Page 68: Checking The Chain For Dirt

    11 SERVICE WORK ON THE CHASSIS 11.37 Checking the chain for dirt – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 66) 400678-01 11.38 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip. –...

  • Page 69: 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 70: 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 55 … 58 mm (2.17 … 2.28 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 71 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 72 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 73: 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. F03645-01 11.43 Checking the link fork...

  • Page 74: 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. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 75: 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 76: 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 77 SERVICE WORK ON THE CHASSIS 11 Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

  • Page 78: 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 79: 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 80 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 81: 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 82 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 83: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM 12 – Insert the new brake linings. – Insert pins and mount cotter pins Guideline Mount the outer cotter pins from the front to the rear. Mount the inner cotter pins from the rear to the front. Info Always change the brake linings in pairs.

  • Page 84: Adjusting The Basic Position Of The Foot Brake Lever

    12 BRAKE SYSTEM – 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 85: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM 12 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 86: Checking That The Brake Linings Of The Rear Brake Are Secured

    12 BRAKE SYSTEM 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 87: Changing The Rear Brake Linings

    BRAKE SYSTEM 12 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 88 12 BRAKE SYSTEM – 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 89: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 45) Main work – Manually press the brake caliper toward the brake disc to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

  • Page 90: 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. –...

  • Page 91: Installing The Rear Wheel

    WHEELS, TIRES 13 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 92 13 WHEELS, TIRES 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 93: Checking The Tire Condition

    WHEELS, TIRES 13 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 94: Checking Spoke Tension

    13 WHEELS, TIRES 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 95: Electrical System 14

    ELECTRICAL SYSTEM 14 14.1 Removing the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 96: Installing The 12-V Battery

    14 ELECTRICAL SYSTEM 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 12-V battery (HJTZ5S-FP-C) ( p.

  • Page 97: Charging The 12-V Battery

    ELECTRICAL SYSTEM 14 14.3 Charging the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 98: Changing The Main Fuse

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

  • Page 99: Changing The Fuse Of The Fuel Pump

    ELECTRICAL SYSTEM 14 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) ( p.

  • Page 100: Diagnostics Connector

    14 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) ( p. 125) – Check that the electrical system is functioning properly. –...

  • Page 101: Exhaust Control 15

    EXHAUST CONTROL 15 15.1 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 102 15 EXHAUST CONTROL – Mount diagnostics connector on the holder. – Attach the engine control unit to the holder. R06533-11 Finishing work – Mount the seat. ( p. 56) – Install the air filter box cover. ( p. 58)

  • Page 103: Cooling System 16

    COOLING SYSTEM 16 16.1 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 104: Checking The Coolant Level

    16 COOLING SYSTEM 16.3 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 105: Refilling With Coolant

    COOLING SYSTEM 16 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 106: Changing The Coolant

    16 COOLING SYSTEM – Loosen screw until coolant escapes without bubbles. – Mount and tighten screw Guideline Bleeder screw, cylinder 10.5 Nm (7.74 lbf ft) head – Completely fill the radiator with coolant. Coolant ( p. 130) S05888-10 – Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
  • Page 107 COOLING SYSTEM 16 – 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 Screw, water pump M6x40 10 Nm (7.4 lbf ft) cover, short...

  • Page 108: 17 Tuning The Engine

    17 TUNING THE ENGINE 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 109: Adjusting The Play In The Throttle Cable

    TUNING THE ENGINE 17 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 110: Adjusting The Idle Speed

    17 TUNING THE ENGINE 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 111: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 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 112: 18 Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 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 113: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 18 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 114: Adding The Gear Oil

    18 SERVICE WORK ON THE ENGINE – Remove filler plug with the O-ring, and fill up with gear oil. Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) p. 130) – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
  • Page 115 SERVICE WORK ON THE ENGINE 18 Finishing work 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 116: 19 Cleaning, Care

    19 CLEANING, CARE 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 117 CLEANING, CARE 19 Preserving materials for paints, metal and rubber ( p. 132) – 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 118: 20 Storage

    20 STORAGE 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 119: Preparing For Use After Storage

    STORAGE 20 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. Because the engine will not warm up sufficiently, the water vapor pro- duced during combustion will condense, causing engine parts and the exhaust system to rust.

  • Page 120: 21 Troubleshooting

    21 TROUBLESHOOTING Faults Possible cause Action – The engine does not turn over Operating error Carry out start procedure. ( p. 25) when the start button is actuated – 12-V battery discharged Charge the 12-V battery. p. 95) – Check the charging voltage. –...
  • Page 121 TROUBLESHOOTING 21 Faults Possible cause Action – Engine overheats Too little air stream Switch off engine when stationary. – Radiator fins very dirty Clean the radiator fins. – Foam formation in cooling system Drain the coolant. p. 102) – Refill with coolant. p.

  • Page 122: 22 Blink Code

    22 BLINK CODE Blink code for malfunction indicator lamp 14 Malfunction indicator lamp flashes 1x long, 4x short Crankcase pressure sensor – difference too high between sensor and engine control unit Error level condition Blink code for malfunction indicator lamp 09 Malfunction indicator lamp flashes 9x short Error level condition Crankcase pressure sensor - short circuit to ground...
  • Page 123 BLINK CODE 22 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 124: 23 Technical Specifications

    23 TECHNICAL SPECIFICATIONS 23.1 Engine Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement (MC 250, EX 250 US) 249 cm³ (15.19 cu in) Displacement (EX 300 US) 293.15 cm³ (17.8892 cu in) Stroke 72 mm (2.83 in) Hole (MC 250, EX 250 US) 66.4 mm (2.614 in) Hole (EX 300 US)

  • Page 125: Engine Tightening Torques

    TECHNICAL SPECIFICATIONS 23 23.2 Engine tightening torques Screw, inner reed paddles EJOT DELTA PT ® 3.5x25 1 Nm (0.7 lbf ft) Screw, membrane support plate EJOT DELTA PT ® 3x12 1 Nm (0.7 lbf ft) Screw, outer reed paddles EJOT DELTA PT ®...

  • Page 126: Capacities

    23 TECHNICAL SPECIFICATIONS Screw, cylinder head 27 Nm (19.9 lbf ft) Nut, cylinder base 38 Nm (28 lbf ft) Screw, drive chain engine sprocket 60 Nm (44.3 lbf ft) Loctite ® 2701™ Stud, cylinder base 12 Nm (8.9 lbf ft) Nut, rotor M12x1 60 Nm (44.3 lbf ft)

  • Page 127: Electrical System

    TECHNICAL SPECIFICATIONS 23 Offroad tire pressure front 1.0 bar (15 psi) rear 1.0 bar (15 psi) Secondary ratio 14:49 Chain 5/8 x 1/4" Rear sprockets available 48, 50, 51, 52 Steering head angle 63.9° Wheelbase 1,493 ± 10 mm (58.78 ± 0.39 in) Seat height unloaded 956 mm (37.64 in) Ground clearance unloaded (MC 250)

  • Page 128: All Ex Models

    23 TECHNICAL SPECIFICATIONS Standard 18 clicks Sport 13 clicks Air pressure 10.5 bar (152 psi) Fork length 950 mm (37.4 in) Oil capacity external mechanism left ml (8.11 fl. oz.) Fork oil (SAE 4) (48601166S1) + 10 + 0.34 − 50 −...

  • Page 129: All Ex Models

    TECHNICAL SPECIFICATIONS 23 Sport 1 turn Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm (0.31 in) Spring rate Weight of rider: 65 … 75 kg (143 … 165 lb.) 42 N/mm (240 lb/in) Weight of rider: 75 …...

  • Page 130: Chassis Tightening Torques

    23 TECHNICAL SPECIFICATIONS 23.9 Chassis tightening torques Screw, fuel pump EJOT 2.5 Nm (1.84 lbf ft) Screw, intake air temperature sensor EJOTPT ® K50x18-T20 0.7 Nm (0.52 lbf ft) Screw, seat fixing EJOT EJOFORM PT ® K60x23/18 2.5 Nm (1.84 lbf ft) Screw, start/stop button EJOT PT ®...
  • Page 131 TECHNICAL SPECIFICATIONS 23 Screw, front brake caliper 25 Nm (18.4 lbf ft) Loctite ® 243™ Screw, handlebar clamp 20 Nm (14.8 lbf ft) Screw, manifold 15 Nm (11.1 lbf ft) Screw, side stand (All EX models) 33 Nm (24.3 lbf ft) Loctite ®...

  • Page 132: 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 133 SUBSTANCES 24 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 134) (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 134: 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 135 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 136: 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 137: 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 138: 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 139: 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 140: Index

    INDEX Chain guide INDEX checking ......68 Chain tension 12-V battery adjusting ......67 charging .
  • Page 141 INDEX Fork legs Indicator lamps bleeding ......46 overview ......15 dust boots, cleaning .
  • Page 142 INDEX Refueling engine tightening torques ....123 fork ......125 fuel .
  • Page 143 *3215158en* 3215158en 21.09.2023 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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