GAS GAS EX 300 2023 Owner's Manual
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GAS GAS EX 300 2023 Owner's Manual

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OWNER'S MANUAL 2023
EX 250
EX 300
Art. no. 3215096en

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Summarization of Contents

1 MEANS OF REPRESENTATION
1.1 Symbols Used
Explains symbols used in the manual.
1.2 Formats Used
Explains typographical formats used in the document.
2 SAFETY ADVICE
Safety Information and Risk Levels
Covers intended use, misuse, general safety, and risk symbol explanations.
Safe Operation and Protective Measures
Details tampering warnings, safe operation practices, and protective clothing.
Operational Guidelines and Vehicle Care
Outlines work rules, environmental considerations, and owner's manual guidance.
3 IMPORTANT NOTES
Key Information and Support
Covers warranty, fuel, parts, service, figures, and customer support.
4 VIEW OF VEHICLE
4.1 Front Left Vehicle View
Illustrates the front-left view of the vehicle with labeled parts.
4.2 Rear Right Vehicle View
5 SERIAL NUMBERS
Locating Vehicle Identification and Part Numbers
Details the location of VIN, type label, fork, and engine numbers.
5.5 Shock Absorber Article Number Location
6 CONTROLS
Handlebar Controls Overview
Describes clutch, brake levers, throttle grip, and stop button.
Start Button and Indicator Lights
Fuel and Oil Tank Cap Operations
6.7 Opening the Fuel Tank Filler Cap
Cold Start Button and Idle Speed Adjustment
6.13 Shift Lever
Foot Brake Lever and Side Stand
7 PREPARING FOR USE
7.1 Advice on Preparing for First Use
Essential advice and safety before first ride.
Engine Break-in and Battery Performance
Preparing for Difficult Riding Conditions
7.6 Preparing for Wet Sand Riding
7.7 Preparing for Wet and Muddy Circuits
Preparing for Extreme Temperatures and Conditions
8 RIDING INSTRUCTIONS
Pre-Ride Checks and Starting Procedure
Essential pre-ride checks and starting instructions.
Starting Off and Shifting Gears
Braking and Stopping/Parking
Transporting and Refueling
8.9 Adding 2-Stroke Oil
9 SERVICE SCHEDULE
9.1 Additional Information
Supplementary service schedule info.
9.2 Required Work
Essential maintenance tasks by hours.
9.3 Recommended Work
10 TUNING THE CHASSIS
Basic Chassis Setup and Air Suspension
Adjusting chassis based on rider weight and air suspension features.
Shock Absorber Damping Concepts and Adjustment
Shock Absorber Damping Adjustment and Measurement
10.8 Checking the Static Sag of the Shock Absorber
Checking and Adjusting Riding Sag and Spring Preload
10.11 Adjusting the Riding Sag
Fork Setting Checks and Air Pressure Adjustment
10.14 Adjusting the Compression Damping of the Fork
10.15 Adjusting the Rebound Damping of the Fork
10.16 Handlebar Position Adjustment
10.17 Adjusting the Handlebar Position
11 SERVICE WORK ON THE CHASSIS
Motorcycle Lifting and Fork Leg Service
Raising motorcycle, removing from stand, bleeding fork legs.
11.4 Cleaning Fork Dust Boots
Fork Leg Removal and Installation
Fork Protector and Lower Triple Clamp Service
Lower Triple Clamp and Steering Head Bearing Check
Steering Head Bearing Adjustment and Start Plate Removal
Start Plate, Fender, and Shock Absorber Service
11.19 Installing the Shock Absorber
11.20 Removing the Seat
11.21 Mounting the Seat
11.22 Removing the Air Filter Box Cover
11.23 Installing the Air Filter Box Cover
11.24 Removing the Air Filter
11.25 Cleaning the Air Filter and Air Filter Box
11.26 Installing the Air Filter
11.27 Preparing Air Filter Box Cover for Securing
11.28 Removing the Main Silencer
11.29 Installing the Main Silencer
11.30 Changing the Glass Fiber Yarn Filling of the Main Silencer
11.31 Removing the Fuel Tank
11.32 Installing the Fuel Tank
11.33 Checking the Chain for Dirt
11.34 Cleaning the Chain
11.35 Checking the Chain Tension
11.36 Adjusting the Chain Tension
11.37 Checking the Chain, Rear Sprocket, Engine Sprocket, and Chain Guide
11.38 Checking the Frame
11.39 Checking the Link Fork
11.40 Checking the Throttle Cable Routing
11.41 Checking the Rubber Grip
11.42 Adjusting the Basic Position of the Clutch Lever
11.43 Checking/Correcting the Fluid Level of Hydraulic Clutch
11.44 Changing the Hydraulic Clutch Fluid
12 BRAKE SYSTEM
12.1 Checking the Free Travel of the Hand Brake Lever
Checks and adjusts free travel of the hand brake lever.
12.2 Adjusting the Basic Position of the Hand Brake Lever
12.3 Checking the Brake Discs
12.4 Checking the Front Brake Fluid Level
12.5 Adding Front Brake Fluid
12.6 Checking the Front Brake Linings
12.7 Changing the Brake Linings of the Front Brake
12.8 Checking the Free Travel of Foot Brake Lever
12.9 Adjusting the Basic Position of the Foot Brake Lever
12.10 Checking the Rear Brake Fluid Level
12.11 Adding Rear Brake Fluid
12.12 Checking the Brake Linings of the Rear Brake
12.13 Changing the Rear Brake Linings
13 WHEELS, TIRES
13.1 Removing the Front Wheel
Steps for removing the front wheel.
13.2 Installing the Front Wheel
13.3 Removing the Rear Wheel
13.4 Installing the Rear Wheel
13.5 Checking the Tire Condition
13.6 Checking Tire Pressure
13.7 Checking Spoke Tension
13.8 Diagnostics Connector
14 ELECTRICAL SYSTEM
14.1 Removing the 12-V Battery
Steps for removing the 12-V battery.
14.2 Installing the 12 V Battery
14.3 Charging the 12-V Battery
14.4 Changing Main Fuse
14.5 Changing the Fuses of Individual Electrical Power Consumers
15 COOLING SYSTEM
15.1 Cooling System
Explains the function of the cooling system and coolant circulation.
15.2 Checking the Antifreeze and Coolant Level
15.3 Checking the Coolant Level
15.4 Draining the Coolant
15.5 Refilling with Coolant
15.6 Changing the Coolant
16 TUNING THE ENGINE
16.1 Checking the Play in the Throttle Cable
Checks and adjusts play in the throttle cable.
16.2 Adjusting the Play in the Throttle Cable
16.3 Adjusting the Characteristic Map of the Throttle Response
16.4 Adjusting the Idle Speed
16.5 Programming Ambient Air Pressure
16.6 Plug-in Connector of Ignition Timing Map Adjustment
16.7 Changing the Ignition Timing Map
16.8 Checking the Basic Position of the Shift Lever
16.9 Adjusting the Basic Position of the Shift Lever
17 SERVICE WORK ON THE ENGINE
17.1 Changing the Fuel Screen
Provides safety warnings and steps for changing the fuel screen.
17.2 Checking 2-stroke Oil Level
17.3 Priming Oil Pump
17.4 Cleaning the Oil Screen in the Oil Tank
17.5 Checking the Gear Oil Level
17.6 Changing the Gear Oil
17.7 Adding the Gear Oil
18 CLEANING, CARE
18.1 Cleaning the Motorcycle
Provides instructions and safety notes for cleaning the motorcycle.
19 STORAGE
19.1 Storage
Provides steps and safety information for storing the motorcycle for extended periods.
19.2 Preparing for Use After Storage
20 TROUBLESHOOTING
Engine Not Cranking or Starting Issues
Diagnoses and resolves issues related to engine cranking and starting.
Engine Performance Issues
21 BLINK CODE
Malfunction Indicator Lamp Blink Codes
Lists blink codes for malfunctions and their corresponding error conditions.
Malfunction Indicator Lamp Blink Codes (Continued)
22 TECHNICAL DATA
22.1 Engine Specifications
Details engine design, displacement, stroke, bore, and other key parameters.
Engine Tightening Torques
22.3 Capacities
22.4 Chassis Specifications
22.5 Electrical System Details
22.6 Tire Specifications
22.7 Fork Specifications
22.8 Shock Absorber Specifications
22.9 Chassis Tightening Torques
23 SUBSTANCES
Brake Fluid DOT 4 / DOT 5.1
Specifies standard classifications and recommended suppliers for brake fluid.
Coolant Specifications
Engine Oil (15W/50) and 2-Stroke Engine Oil
24 AUXILIARY SUBSTANCES
Air Filter Cleaner and Chain Cleaner
Lists recommended suppliers for air filter cleaner and chain cleaner.
Fuel Additive and Greases
Motorcycle Cleaner and Chain Sprays
Filter Oil and Protective Materials
Silicone Spray
Special Cleaners and Greases
Universal Oil Spray
25 STANDARDS
JASO T903 MA2 Standard
Explains the JASO T903 MA2 standard for motorcycle engine oils.
SAE Viscosity Classes
JASO FD Classification
26 INDEX OF SPECIAL TERMS
OBD - On-board Diagnosis
Defines On-board Diagnosis (OBD) as a vehicle system monitoring electronics.
27 LIST OF ABBREVIATIONS
28 LIST OF SYMBOLS
Red Symbols
Indicates error conditions requiring immediate intervention.
Yellow and Orange Symbols

Table of Contents