GASGAS EC 250 2022 (01) PDF DOCUMENT

This document is valid for the following models:

EC 250 EU (F0303V7)

EC 250 US (F0375V7)

EC 300 EU (F0403V7)

EC 300 US (F0475V7)

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).

Wrench Symbol: 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.

Book Symbol: Indicates a page reference (more information is provided on the specified page).

i Symbol: Indicates information with more details or tips.

» Symbol: Indicates the result of a testing step.

V Symbol: Indicates a voltage measurement.

A Symbol: Indicates a current measurement.

Arrow Symbol: Indicates the end of an activity, including potential reworking.

Danger: Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning: Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution: Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note: Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Note (Environmental): Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

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.

This vehicle is only authorized for operation on public roads in the homologated (restricted) version. The derestricted version of this vehicle must only be operated in closed off areas away from public highway traffic. This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

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.

– Do not operate the vehicle if you are physically or mentally impaired.

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 running the engine in an enclosed space.

Warning – Danger of burns: Some vehicle components become very hot when the vehicle is operated.

– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.

– Let the vehicle parts cool down before you perform any work on the vehicle.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. An appropriate driver’s license is needed to drive the vehicle on public roads. Have malfunctions that impair safety immediately eliminated by an authorized workshop.

Warning – Risk of injury: Missing or poor protective clothing presents an increased safety risk.

– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

– Always wear protective clothing that is in good condition and meets the legal regulations.

Unless specified otherwise, the ignition must be turned off during all work or the engine must be at a standstill.

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 is required. Observe the manufacturer’s instructions.

If thread locker has already been applied to a new part, do not apply any additional thread locker.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After completing a repair or service work, check the operating safety of the vehicle.

The standard ambient conditions for tasks and descriptions are:

Ambient temperature: 20 °C (68 °F)

Ambient air pressure: 1,013 mbar (14.69 psi)

Relative air humidity: 60 ± 5 %

The stop button is fitted on the left side of the handlebar.

Possible states (All EU and US models):

– The stop button is in the basic position – In this position, the ignition circuit is closed and the engine can be started.

– Stop button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

The horn button is fitted on the left side of the handlebar.

Possible states:

– The horn button is in the basic position.

– The horn button is pressed – The horn is operated in this position.

All EU models:

The light switch is fitted on the left side of the handlebar.

Possible states:

– Low beam on: Light switch is in the central position. The low beam and tail light are switched on.

– High beam on: Light switch is turned to the left. The high beam and the tail light are switched on.

All US models:

The light switch is located to the left of the combination instrument.

Possible states:

– Light off: Light switch is pressed in up to the stop. The light is switched off.

– Light on: Light switch is pulled out to the stop. The low beam and tail light are switched on.

The turn signal switch is fitted on the left side of the handlebar.

Possible states:

– Turn signal off: The turn signal switch is in the central position.

– Left turn signal, on: The turn signal switch is turned to the left.

– Right turn signal, on: The turn signal switch is turned to the right.

The emergency OFF switch is fitted on the right side of the handlebar.

Possible states:

– Ignition off: In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

– Ignition on: In this position, the ignition circuit is closed, and the engine can be started.

The start button is fitted on the right side of the handlebar.

Possible states:

– The start button is in the basic position.

– The start button is pressed – In this position, the starter motor is actuated.

All EU models:

– High beam indicator lamp (blue): The high beam is switched on.

– Malfunction indicator lamp (yellow): The OBD has detected an error. Come safely to a halt and contact a workshop.

– Fuel level warning lamp (yellow): The fuel level has reached the reserve mark.

– Turn signal indicator lamp (green): The turn signal is switched on.

– Oil level warning lamp (red): Oil level has reached the MIN marking. Ride for no more than until the remaining fuel is depleted and then refuel with 2-stroke oil.

All US models:

– High beam indicator lamp: inoperative.

– Malfunction indicator lamp (yellow): The OBD has detected an error. Come safely to a halt and contact a workshop.

– Fuel level warning lamp (yellow): The fuel level has reached the reserve mark.

– Oil level warning lamp (red): Oil level has reached the MIN marking. Ride for no more than until the remaining fuel is depleted and then refuel with 2-stroke oil.

Opening:

Press the release button, turn the fuel tank filler cap counterclockwise, and lift it off.

Closing:

Mount the fuel tank filler cap and turn it clockwise until the release button engages. Ensure the fuel tank breather hose is routed without kinks.

Opening:

1. Fold the loop upward.

2. Turn the 2-stroke oil tank cap counterclockwise and pull it up.

Closing:

1. Put the 2-stroke oil tank cap on and turn it clockwise.

2. Fold the loop down. The cap will engage.

The cold start button is fitted on the side of the throttle valve body. If the engine is cold and the ambient temperature is low, the electronic fuel injection system extends the injection time. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pulling the cold start button. If the engine is warm, the cold start button must be deactivated.

Possible states:

– Activated: The cold start button is pulled out all the way and turned by a ¼ turn.

– Deactivated: A further ¼ turn returns the cold start button back to the basic position.

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. The idle speed is adjusted using the idle speed adjusting screw.

– If the idle speed is high, the engine is slow to run, the engine brake is low and the throttle response is aggressive, the adjusting screw must be turned clockwise.

– If the idle speed is low, the engine is running fast, the engine brake is high and the throttle response is not clean, the adjusting screw must be turned counterclockwise.

The side stand is used for parking the motorcycle. When you are riding, the side stand must be folded up and secured with the rubber strap.

Locking the steering:

1. Park the vehicle on a firm and level surface.

2. Turn the handlebar as far as possible to the right.

3. Insert the key for the steering lock into the steering lock, turn it to the left, press it in, and turn it to the right. Pull out the key.

Steering is no longer possible. Never leave the key in the steering lock.

Unlocking the steering:

1. Insert the key for the steering lock into the steering lock, turn it to the left, pull it out, and turn it to the right. Pull out the key.

The handlebar can now be moved again. Never leave the key in the steering lock.

The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

Possible messages:

– Battery symbol: The battery voltage of the combination instrument is too low. Change the combination instrument battery.

– Wrench symbol: A service is due. Contact an authorized workshop.

Condition: The motorcycle is stationary.

1. Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes.

2. Press one of the buttons to select UNIT for the speed in kilometers KM/H or miles M/H.

3. Wait for 5 seconds. The combination instrument changes to the next menu item. The clock symbol flashes.

4. Press one of the buttons to select the 24h or 12h display of the clock.

5. Wait for 5 seconds. The combination instrument changes to the next menu item. The clock time symbol flashes.

– To reset the time: Press the left button (value decreases).

– To advance the time: Press the right button (value increases).

6. Wait for 5 seconds. The combination instrument changes to the next menu item. The service interval symbol flashes.

7. Set the service interval:

– To shorten the interval: Press the left button (value decreases).

– To extend the interval: Press the right button (value increases).

8. To switch off the service interval display, press and hold the left button. “off” appears in the display.

Press one of the buttons until DST or DST2 appears on the combination instrument. This shows the distance since the last reset, such as between two refueling stops. If the value of 39999.9 is exceeded, the distance is automatically reset to 0.0.

DST functions:

– Press the left button briefly: Next display mode.

– Press the left button for 3–5 seconds: DST can be preset to a value between 0.0 and 39999.9 by pressing the buttons.

– Press the right button briefly: Next display mode.

– Press the right button for 3–5 seconds: DST is reset to 0.0.

DST2 functions:

– Press the left button briefly: Next display mode.

– Press the left button for 3–5 seconds: DST2 can be preset to a value between 0.0 and 39999.9 by pressing the buttons.

– Press the right button briefly: Next display mode.

– Press the right button for 3-5 seconds: DST2 is reset to 0.0.

Press one of the buttons until AVG, ART, and ODO appear on the combination instrument.

– AVG shows the average speed since the last reset.

– ART shows the operating hours.

– ODO shows the total distance covered.

Functions:

– Press the left button briefly: Next display mode.

– Press the left button for 3–5 seconds: The OPEN END WRENCH SYMBOL shows the remaining operating hours until the next service is due.

– Press the right button briefly: Next display mode.

– Press the right button for 3–5 seconds: AVG is reset to 0.0.

– Make sure that the pre-sales inspection work has been carried out by an authorized workshop.

– Before riding for the first time, read the entire Owner’s Manual carefully.

– Get to know the controls.

– Adjust the basic position of the clutch lever.

– Adjust the basic position of the hand brake lever.

– Adjust the basic position of the foot brake lever.

– Adjust the basic position of the shift lever.

– Get used to handling the motorcycle on a suitable surface before undertaking a more challenging trip.

– Ride as slowly as possible and in a standing position to get a better feel for the motorcycle.

– Do not make any off-road trips that exceed your ability and experience.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

– Ensure luggage is secured firmly and close to the center of the vehicle with even weight distribution.

– Do not exceed the maximum permissible overall weight and axle loads.

– Check the spoke tension after half an hour of operation.

– Run the engine in according to the manual.

During the running-in phase, do not exceed the specified engine performance.

Guideline – Maximum engine performance:

– During the first 3 operating hours: < 70 %

– During the first 5 operating hours: < 100 %

Avoid fully opening the throttle!

Check the idle speed regularly. The idle speed may change during the run-in time.

Guideline – Idle speed: 1,400 … 1,500 rpm

If the idle speed changes, adjust it.

At temperatures below 15 °C (60 °F), the starting power of lithium-ion batteries drops. Multiple starting attempts may be needed. Press the start button for 5 seconds, and wait 30 seconds between attempts. The pauses are necessary so that the heat created can distribute through the lithium-ion battery and the 12-V battery is not damaged. The starting power increases as the battery warms up.

Use of the vehicle under difficult conditions (sand, wet, muddy surfaces) can result in significantly increased wear. It may be necessary to inspect or replace parts before the next scheduled service.

– Clean the air filter and air filter box. Check the air filter approx. every 30 minutes.

– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated. If found, clean and dry the connector, or change it if necessary.

Difficult operating conditions are:

– Rides on dry sand

– Rides on wet sand

– Rides on wet and muddy circuits

– Rides at high temperatures or slow riding

– Riding at low temperatures and in snow

1. Check the radiator cap. The value on the cap should be 1.8 bar (26 psi). If not, change the radiator cap.

2. For dry sand, mount the air filter dust cover (79006920000) and air filter sand cover (79006922000).

3. For wet sand, mount the air filter rain cover (79006921000).

4. Clean the chain.

5. Mount the steel sprocket.

6. Grease the chain.

7. Clean the radiator fins and straighten any bent fins carefully.

8. For regular use in sand, change the piston every 10 operating hours.

– Mount the air filter rain cover (79006921000).

– Mount the steel sprocket.

– Clean the motorcycle.

– Straighten the bent radiator fins carefully.

1. Check the radiator cap. The value on the cap should be 1.8 bar (26 psi). If not, change the radiator cap.

2. Adjust the secondary drive to the road conditions.

3. Clean the chain.

4. Clean the radiator fins.

– Mount the air filter rain cover (79006921000).

– Straighten bent radiator fins carefully.

– Check the coolant level.

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.

– Check the gear oil level.

– Check the electrical system.

– Check the front and rear brake fluid level.

– Check the front and rear brake linings.

– Check that the brake system is functioning properly.

– Check the coolant level.

– Check the chain for dirt.

– Check the chain, rear sprocket, engine sprocket, and chain guide.

– Check the chain tension.

– Check the tire condition and pressure.

– Check the spoke tension (incorrect tension will strongly impair riding safety).

– Clean the dust boots of the fork legs.

– Bleed the fork legs.

– Check the air filter.

– Check the settings of all controls and ensure they can be operated smoothly.

– Check all screws, nuts, and hose clamps regularly for tightness.

– Check the fuel level.

– Check 2-stroke oil level.

Danger of poisoning: Always ensure sufficient ventilation or use exhaust extraction when running the engine in an enclosed space.

Note on engine damage: Always run the engine warm at a low speed. High revving with a cold engine negatively impacts its lifespan.

1. Take the motorcycle off the side stand and secure the stand with the rubber strap.

2. Shift the transmission to neutral position.

3. If the ambient temperature is below 10 °C (50 °F), pull the cold start button fully out and turn it by a ¼ turn. If the engine is warm, the cold start button must be deactivated.

4. Press the start button. Do not open the throttle.

Press the start button for a maximum of 5 seconds. Wait 30 seconds before another attempt. At temperatures below 15 °C (60 °F), several attempts may be necessary to warm up the lithium-ion battery. During starting, the malfunction indicator lamp lights up.

Starting off:

Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.

Shifting and Riding:

– Shift into a higher gear when conditions allow. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.

– If the cold start function was activated, deactivate it after the engine has warmed up.

– After reaching maximum speed, turn the throttle back to ¾ open to reduce fuel consumption.

– To shift down, apply the brakes and close the throttle at the same time. Pull the clutch lever, shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.

– Switch off the engine if running at idle speed or stationary for a long time (≥ 2 min).

– Avoid frequent and longer slipping of the clutch.

– Ride at a low engine speed instead of a high engine speed with a slipping clutch.

Warning – Engine failure: The engine will not be lubricated unless there is 2-stroke oil in the oil tank. If the oil level warning light comes on, add 2-stroke oil at the next opportunity before refueling.

– Adjust application of the brakes to the respective riding situation and surface conditions. Excessively forceful application can block the wheels.

– On sandy, wet or slippery surfaces, use the rear brake.

– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

– If you notice moisture and dirt impairing the brake system, brake carefully several times to dry out and remove dirt from the brake linings and brake discs.

– If you notice a spongy pressure point on the front or rear brake, check the brake system and do not continue riding until the problem is eliminated.

1. Apply the brakes on the motorcycle.

2. Shift the transmission to neutral position.

3. (All EU/US models) Press and hold the stop button while the engine is idling until the engine stops.

4. Park the motorcycle on firm ground.

Parking Safety:

– Park the vehicle on a firm and level surface.

– Ensure that nobody sits on the vehicle when it is parked on a stand.

– Do not park the vehicle near highly flammable or explosive materials.

– Allow the vehicle to cool down before covering it.

1. Park the vehicle on a firm and level surface.

2. Switch off the engine.

3. Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

Danger – Fire hazard: Fuel is highly flammable. Do not fuel near open flames. Switch off the engine. Wipe up spills immediately.

1. Open the fuel tank filler cap.

2. Fill the fuel tank with fuel up to 35 mm (1.38 in) from the top.

– Total fuel tank capacity, approx.: 8.5 l (2.25 US gal)

– Fuel type: Super unleaded (ROZ 95)

– Do not refuel using pre-mixed fuel.

3. Close the fuel tank filler cap.

Warning – Engine failure: The engine will not be lubricated without 2-stroke oil. If the warning light comes on, add oil at the next opportunity.

1. Open the 2-stroke oil tank cap.

2. Fill the 2-stroke oil tank up to the lower edge of the filler neck.

– Guideline: Only use 2-stroke oil appropriate for separate lubrication.

– 2-stroke oil tank content approx.: 0.6 l (0.6 qt.)

– Oil type: Engine oil, 2-stroke

3. Close the 2-stroke oil tank cap.

Different service intervals may apply depending on local operating conditions. The following is a general guide. (○ = One-time interval, ● = Periodic interval)

The following is a general guide for recommended work. (○ = One-time interval, ● = Periodic interval)

When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. For optimal riding characteristics, the basic settings of the suspension components must match the rider’s weight (with full protective clothing).

The standard rider weight is 75 … 85 kg (165 … 187 lb.).

If your weight is above or below this range, the suspension components must be adjusted accordingly. Small weight differences can be compensated by adjusting spring preload, but for large differences, the springs must be replaced.

Adjusting Low-Speed Compression:

1. Turn the adjusting screw clockwise with a screwdriver as far as the last perceptible click.

2. Turn counterclockwise by the number of clicks corresponding to your preference. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

– Comfort: 17 clicks

– Standard: 15 clicks

– Sport: 13 clicks

Adjusting High-Speed Compression:

1. Using an open end wrench, turn the adjusting screw clockwise all the way.

2. Turn counterclockwise by the number of turns corresponding to your preference. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

– Comfort: 2.5 turns

– Standard: 2 turns

– Sport: 1.5 turns

1. Turn the adjusting screw clockwise up to the last perceptible click.

2. Turn counterclockwise by the number of clicks corresponding to your preference. Turn clockwise to increase damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

– Comfort: 17 clicks

– Standard: 15 clicks

– Sport: 13 clicks

Measuring Unloaded Dimension (A):

1. Raise the motorcycle with a lift stand.

2. Position a sag gauge in the rear axle and measure the distance to the “SAG” marking on the rear fender. Note this value as dimension A.

3. Remove the motorcycle from the lift stand.

Checking Static Sag:

1. With an assistant holding the motorcycle upright, measure the distance between the rear axle and the “SAG” marking again. Note this as dimension B.

2. The static sag is the difference between measurements A and B. The target value is 37 mm (1.46 in). If it differs, adjust the spring preload.

Checking Riding Sag:

1. With the rider in full gear seated normally on the bike (feet on footrests), have an assistant measure the distance between the rear axle and the “SAG” marking. Note this as dimension C.

2. The riding sag is the difference between measurements A and C. The target value is 110 mm (4.33 in). If it differs, adjust the riding sag.

1. Raise the motorcycle with a lift stand and remove the shock absorber.

2. Clean the shock absorber thoroughly.

3. Loosen the screw on the adjusting ring.

4. Turn the adjusting ring with a hook wrench until the spring is no longer under tension.

5. Tension the spring by turning the adjusting ring to the specified dimension.

– Guideline for Spring preload: 10 mm (0.39 in)

6. Tighten the screw on the adjusting ring to 5 Nm (3.7 lbf ft).

7. Install the shock absorber and remove the motorcycle from the lift stand.

1. Raise the motorcycle, remove the shock absorber, and clean it.

2. Choose and mount a suitable spring based on rider weight. The spring rate is shown on the outside of the spring.

3. Install the shock absorber and remove the motorcycle from the lift stand.

4. Check the static sag and riding sag again and adjust the rebound damping of the shock absorber.

The compression damping is located in the left fork leg (COMP, white adjuster). The rebound damping is located in the right fork leg (REB, red adjuster).

Adjusting Compression Damping:

1. Turn the white adjuster clockwise as far as it will go.

2. Turn counterclockwise by the number of clicks for your preference. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

– Comfort: 18 clicks

– Standard: 15 clicks

– Sport: 12 clicks

Adjusting Rebound Damping:

1. Turn the red adjuster clockwise as far as it will go.

2. Turn counterclockwise by the number of clicks for your preference. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

– Comfort: 18 clicks

– Standard: 15 clicks

– Sport: 12 clicks

The handlebar can be mounted in four different positions. On the upper triple clamp, there are 2 holes at a distance of 15 mm (0.59 in) from each other. The holes on the handlebar support are placed at a distance of 3.5 mm (0.138 in) from the center.

Adjustment Procedure:

1. Remove screws and handlebar clamps. Remove the handlebar and lay it to one side, covering components to protect them.

2. Remove screws and take off the handlebar supports.

3. Place the handlebar supports in the required position. Mount and tighten the screws to 40 Nm (29.5 lbf ft) using Loctite®243™. Position supports evenly.

4. Position the handlebar, ensuring cables and wiring are positioned correctly.

5. Position the handlebar clamps. Mount and tighten screws evenly to 20 Nm (14.8 lbf ft). Ensure gap widths are even.

Raising:

1. Park the vehicle on a firm and level surface.

2. Raise the motorcycle at the frame underneath the engine using a lift stand until neither wheel is in contact with the ground.

3. Secure the motorcycle against falling over.

Removing:

1. Park the vehicle on a firm and level surface.

2. Remove the motorcycle from the lift stand.

3. Remove the lift stand.

4. To park the motorcycle, press the side stand to the ground with your foot and lean the motorcycle on it.

1. Raise the motorcycle with a lift stand.

2. Release the bleeder screws. Any excess pressure escapes from the interior of the fork.

3. Tighten the bleeder screws.

4. Remove the motorcycle from the lift stand.

1. Raise the motorcycle with a lift stand and remove the fork protector.

2. Push the dust boots of both fork legs downward.

3. Clean and oil the dust boots and inner fork tubes of both fork legs.

4. Press the dust boots back into their installation position and remove excess oil.

5. Install the fork protector and remove the motorcycle from the lift stand.

Removing:

1. Remove the screw on the left side.

2. Raise the rear of the seat, pull the seat back, and lift it off.

Installing:

1. Mount the front of the seat on the two collar bushings of the fuel tank, lower the seat at the rear, and push the seat forward. Make sure the seat is locked in correctly.

2. Mount and tighten the screw on the left side to 10 Nm (7.4 lbf ft).

Removing:

1. Remove the seat.

2. Remove the screw securing the air filter box cover.

3. Pull off the air filter box cover laterally and take it off at the front.

Installing:

1. Insert the air filter box cover in area A and clip it into area B.

2. Mount and tighten the screw to 3 Nm (2.2 lbf ft).

3. Mount the seat.

Note on engine damage: Only operate the vehicle with an air filter equipped.

Removing:

1. Remove the seat and the air filter box cover.

2. Detach the retaining tab. Remove the air filter with its support.

3. Remove the air filter from the air filter support.

Cleaning:

1. Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Only press the air filter to dry it, never wring it out.

2. Oil the dry air filter with a high-grade air filter oil.

3. Clean the air filter box and the intake flange, checking for damage and tightness.

Installing:

1. Mount the clean air filter on the air filter support.

2. Grease the air filter in the designated area with long-life grease.

3. Insert the air filter and position the retaining pin in its bushing. The air filter must be correctly positioned.

4. Insert the retaining tab, ensuring the retaining pin is secured.

5. Install the air filter box cover and mount the seat.

Warning – Danger of burns: Allow the exhaust system to cool down before work.

1. Remove the main silencer.

2. Remove the screws. Pull out the inner tube with its O-ring.

3. Pull the old glass fiber yarn filling from the inner tube.

4. Clean the parts and check for damage.

5. Mount new glass fiber yarn filling on the inner tube.

6. Push the outer tube over the inner tube with the new filling and O-ring.

7. Mount and tighten all screws to 7 Nm (5.2 lbf ft).

8. Install the main silencer.

Warning: Incorrect chain tension can damage components and cause accidents.

Checking:

1. Raise the motorcycle with a lift stand.

2. Pull the chain upward at the end of the chain sliding piece. The lower chain section must be taut.

3. Measure the chain tension. It should be 55 … 58 mm (2.17 … 2.28 in). Repeat this measurement at different chain positions.

4. If the tension is incorrect, adjust it.

Adjusting:

1. Loosen the rear wheel spindle nut and the nuts on the chain adjusters.

2. Adjust the chain tension by turning the adjusting screws on the left and right. Ensure the markings on both chain adjusters are in the same position relative to the reference marks for proper alignment.

3. Make sure the chain adjusters are fitted correctly on the adjusting screws.

4. Tighten the adjuster nuts.

5. Tighten the rear wheel spindle nut to 80 Nm (59 lbf ft).

6. Remove the motorcycle from the lift stand.

1. Shift the transmission into neutral.

2. Pull on the top section of the chain with a weight of 10 … 15 kg (22 … 33 lb.).

3. Measure the distance of 18 chain rollers in the lower chain section. The maximum distance should be 272 mm (10.71 in). If it is greater, change the drivetrain kit (chain, sprockets).

4. Check the chain sliding guard for wear. If the lower edge of the chain pins is in line with or below the guard, change it. Ensure it’s firmly seated and tighten screws to 6 Nm (4.4 lbf ft) with Loctite®243™ if loose.

5. Check the chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the piece, change it. Ensure it’s firmly seated and tighten the screw to 15 Nm (11.1 lbf ft) if loose.

6. Check the chain guide for wear (wear can be seen on the front). If the light part of the guide is worn, change it. Ensure it’s firmly seated and tighten screws to 10 Nm (7.4 lbf ft) if loose.

1. Remove the seat and fuel tank.

2. 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 cables must be secured behind the rubber strap of the fuel tank support.

3. If not routed as specified, correct the routing.

4. Install the fuel tank and mount the seat.

Adjust the basic position of the clutch lever to your hand size by turning the adjusting screw.

– Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

– Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

The range of adjustment is limited. Turn the screw by hand only, and do not apply any force. Do not make any adjustments while riding.

Checking/Correcting Fluid Level:

1. Move the clutch fluid reservoir on the handlebar to a horizontal position.

2. Remove screws, cover, and membrane.

3. Check the fluid level. It should be 4 mm (0.16 in) below the container rim. If not, correct the fluid level using Brake fluid DOT 4 / DOT 5.1.

4. Position the cover with the membrane and tighten the screws. Clean up any spilled fluid immediately.

Changing Hydraulic Fluid:

1. Move the clutch fluid reservoir to a horizontal position. Remove screws, cover, and membrane.

2. Fill a bleeding syringe with appropriate hydraulic fluid.

3. On the clutch slave cylinder, remove the bleeder protection cap, release the bleeder screw, and mount the bleeding syringe.

4. Press the fluid into the system until it emerges from the master cylinder hole without bubbles. Extract fluid from the reservoir periodically to prevent overflow.

5. Remove the bleeding syringe. Tighten the bleeder screw and mount the protection cap.

6. Correct the fluid level to 4 mm (0.16 in) below the rim.

7. Position the cover with the membrane and tighten screws. Clean up any spilled fluid.

Checking:

Push the hand brake lever forward and check the free travel. It should be ≥ 3 mm (≥ 0.12 in). If it does not match, adjust the basic position.

Adjusting:

Adjust the basic position of the hand brake lever to your hand size by turning the adjusting screw.

– Turn clockwise to increase the distance between the lever and handlebar.

– Turn counterclockwise to decrease the distance.

The range is limited. Adjust by hand only and do not make adjustments while riding.

Check the front and rear brake disc thickness at multiple points. Wear reduces the thickness around the contact surface of the brake linings.

Brake discs – wear limit:

– front: 2.5 mm (0.098 in)

– rear: 3.5 mm (0.138 in)

If the thickness is less than the specified value, change the respective brake disc. Also, check for damage, cracking, and deformation. If any are found, change the brake disc.

Warning: An insufficient brake fluid level will cause the brake system to fail. Old brake fluid reduces braking effect.

Checking:

1. Move the brake fluid reservoir on the handlebar to a horizontal position.

2. Check the brake fluid level in the level viewer. If an air bubble is visible in the upper range of the viewer, add front brake fluid.

Adding:

1. Check the front brake linings.

2. Move the brake fluid reservoir to a horizontal position.

3. Remove the screws, take off the cover with the membrane.

4. Add brake fluid (DOT 4 / DOT 5.1) up to 5 mm (0.2 in) below the reservoir rim.

5. Position the cover with the membrane and tighten the screws. Clean up any spilled fluid immediately.

Checking:

Check the brake linings for minimum thickness. The minimum thickness should be ≥ 1 mm (≥ 0.04 in). If less, or if damage/cracking is found, change the brake linings.

Changing:

1. Move the brake fluid reservoir to a horizontal position, remove the cover.

2. Manually press the brake caliper toward the brake disc to push back the brake pistons. Extract some fluid if necessary to prevent overflow.

3. Remove the cotter pin, pull out the pin, and remove the brake linings.

4. Clean the brake caliper and bracket.

5. Check that the spring plate and sliding plate in the caliper and bracket are seated correctly.

6. Insert the new brake linings (always change in pairs), insert the pin, and mount the cotter pins (outer from front to rear, inner from rear to front).

7. Operate the hand brake lever repeatedly until a pressure point is felt.

8. Correct the brake fluid level and reinstall the reservoir cover.

Warning: If there is no free travel, pressure builds up in the rear brake system, causing it to fail.

Checking:

1. Disconnect the spring.

2. Move the foot brake lever back and forth to check the free travel. It should be 3 … 5 mm (0.12 … 0.2 in).

3. If it does not meet specifications, adjust the basic position. Reconnect the spring.

Adjusting:

1. Detach the spring.

2. Loosen the nut on the push rod and turn the push rod back for maximum free travel.

3. To adjust the basic position, loosen the nut on the stop screw and turn the screw accordingly.

4. Turn the push rod until the free travel is 3 … 5 mm. If necessary, adjust the basic position screw.

5. Hold the stop screw and tighten its nut to 20 Nm (14.8 lbf ft).

6. Hold the push rod and tighten its nut to 10 Nm (7.4 lbf ft).

7. Attach the spring.

Checking:

1. Stand the vehicle upright.

2. Check the brake fluid level in the viewer. If the fluid has dropped below the MIN marking, add rear brake fluid.

Adding:

1. Check the rear brake linings.

2. Stand the vehicle upright.

3. Remove the screw cap with membrane and O-ring.

4. Add brake fluid (DOT 4 / DOT 5.1) to the level marking.

5. Mount and tighten the screw cap with membrane and O-ring. Clean up any spilled fluid.

Checking:

Check the brake linings for minimum thickness. It should be ≥ 1 mm (≥ 0.04 in). If less, or if damage/cracking is found, change the brake linings.

Changing:

1. Position the vehicle upright. Remove the screw cap from the brake fluid reservoir.

2. Press the brake piston back into its basic position, extracting fluid if necessary to prevent overflow.

3. Remove the cotter pin, pull out the pin, and remove the brake linings.

4. Clean the brake caliper and bracket.

5. Check that the spring plate and sliding plate are seated correctly.

6. Insert the new brake linings (always change in pairs), insert the pin, and mount the cotter pins.

7. Operate the foot brake lever repeatedly until a pressure point is felt.

8. Add brake fluid to the correct level and mount the reservoir screw cap.

Removing:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper toward the disc to push back the pistons.

3. Loosen the wheel spindle screw by several rotations. Loosen the fork stub screws.

4. Press on the spindle screw to push the wheel spindle out of the axle clamp. Remove the screw.

5. Hold the front wheel and remove the wheel spindle. Take the wheel out of the fork. Do not actuate the hand brake lever while the wheel is removed.

6. Remove the spacers.

Installing:

1. Check the wheel bearing for damage and wear. Change if necessary.

2. Clean and grease the shaft seal rings and contact surfaces of the spacers.

3. Insert the spacers. Clean and grease the wheel spindle.

4. Jack up the front wheel into the fork, position it, and insert the wheel spindle. Ensure brake linings are correctly positioned.

5. Mount and tighten the wheel spindle screw to 35 Nm (25.8 lbf ft).

6. Operate the hand brake lever several times to seat the brake linings.

7. Remove the motorcycle from the lift stand. Operate the front brake and compress the fork a few times firmly to straighten the fork legs.

8. Tighten the fork stub screws to 15 Nm (11.1 lbf ft).

Removing:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper toward the disc to push back the piston.

3. Remove the nut from the wheel spindle and take off the chain adjuster.

4. Pull out the wheel spindle far enough to allow the wheel to be pushed forward.

5. Push the rear wheel forward and remove the chain from the rear sprocket.

6. Hold the rear wheel and remove the wheel spindle. Take the wheel out of the link fork. Do not operate the foot brake lever while the wheel is removed.

7. Remove the spacers.

Installing:

1. Check the wheel bearing for damage/wear. Change if necessary.

2. Clean and grease the shaft seal rings and contact surfaces of the spacers.

3. Insert the spacers. Clean and grease the wheel spindle.

4. Position the rear wheel, insert the wheel spindle, and mount the chain. Ensure brake linings are correctly positioned.

5. Position the chain adjuster. Mount the nut but do not tighten it yet.

6. Check the chain tension and adjust if necessary. Ensure chain adjusters are fitted correctly.

7. Tighten the rear wheel spindle nut to 80 Nm (59 lbf ft).

8. Operate the foot brake lever repeatedly to seat the brake linings.

9. Remove the motorcycle from the lift stand.

Tire Condition:

– Only mount approved and/or recommended tires.

– Check tires for cuts, embedded objects, and other damage. Change tires if necessary.

– Check tread depth. The minimum tread depth is ≥ 2 mm (≥ 0.08 in). Change tires if depth is less.

– Check tire age (last four digits of DOT number). Change tires after five years at the latest, regardless of wear.

Tire Pressure:

Correct tire pressure ensures optimal riding comfort and maximum tire service life. Check pressure when tires are cold.

– Remove the protection cap.

– Check tire pressure. Offroad tire pressure should be:

– front: 1.0 bar (15 psi)

– rear: 1.0 bar (15 psi)

– If pressure does not meet specifications, correct it.

– Mount the protection cap.

Warning: Incorrectly tensioned spokes impair handling and can result in damage.

1. Strike each spoke briefly using a screwdriver blade. You should hear a high note. Different tone frequencies from spokes of equal length and diameter indicate different tensions.

2. If the spoke tension differs, correct it.

3. Check the spoke torque with a torque wrench.

– Spoke nipple, front wheel (M4.5): 6 Nm (4.4 lbf ft)

– Spoke nipple, rear wheel (M4.5): 6 Nm (4.4 lbf ft)

Removing:

1. Remove the seat.

2. Disconnect the negative cable from the 12-V battery.

3. Pull back the positive terminal cover and disconnect the positive cable.

4. Pull the EFI control unit upward off the rubber lugs and hang it to the side.

5. Detach the wiring harness, pull off the relays, and hang them to the side.

6. Remove the screw and fold the battery compartment to the front.

7. Lift out the 12-V battery.

Installing:

1. Insert the 12-V battery (HJTZ5S-FP-C) into the battery compartment with the terminals facing forward and secure with the holding bracket.

2. Mount and tighten the screw to 10 Nm (7.4 lbf ft).

3. Place the relays on the battery compartment and attach the wiring harness.

4. Secure the EFI control unit with the rubber lugs.

5. Connect the positive cable to the 12-V battery. The contact disk must be mounted under the screw and cable lug with the claws toward the battery terminal. Tighten the screw to 2.5 Nm (1.84 lbf ft).

6. Slide the positive terminal cover over the positive terminal.

7. Connect the negative cable to the 12-V battery and tighten the screw to 2.5 Nm (1.84 lbf ft).

8. Mount the seat.

Warning – Risk of injury: 12 V batteries contain harmful substances. Keep away from children, sparks, and open flames. Charge in well-ventilated rooms with a minimum clearance of 1 m (3 ft) from flammable materials. Do not charge a battery if its voltage is already below 9 V.

1. Remove the seat and the 12-V battery.

2. Check the battery voltage.

– If voltage is < 9 V: Do not charge. Replace the battery.

– If voltage is ≥ 9 V: Charge the 12-V battery.

3. Use a suitable battery charger (79629974000) for lithium iron phosphate batteries.

– Maximum charging voltage: 14.4 V

– Maximum charging current: 3.0 A

– Maximum charging time: 24 h

4. Switch off the battery charger after charging and disconnect it.

5. Install the 12-V battery and mount the seat.

Warning – Fire hazard: Only use fuses with the required ampere value. Do not bypass or repair fuses.

1. Remove the seat.

2. Pull the EFI control unit upward off the rubber lugs and hang it to the side.

3. Pull the starter relay from its holder.

4. Take off the protection caps.

5. Remove the faulty main fuse (a faulty fuse has a burned-out fuse wire). A spare fuse is located in the starter relay.

6. Insert a new main fuse (20 A – 58011109120).

7. Check that the electrical system is functioning properly.

8. Attach the protection caps.

9. Mount the starter relay onto the holder and route the cable.

10. Mount the EFI control unit on the rubber lugs.

11. Mount the seat.

The fuse box is located under the seat.

1. Remove the seat.

2. Open the fuse box cover.

3. Remove the faulty fuse. A spare 10 A fuse is available.

Fuse assignments (All EU models):

– Fuse 1 – 10 A – EFI, lambda sensor, oil pump, combination instrument, fuel injection, diagnostics

– Fuse 2 – 10 A – horn, brake light, radiator fan, turn signal

– Fuse 3 – 10 A – high/low beam, position/tail light, license plate lamp

– Fuse 4 – 5 A – fuel pump

Fuse assignments (All US models):

– Fuse 1 – 10 A – EFI, oil pump, combination instrument, fuel injection, diagnostics

– Fuse 2 – 10 A – radiator fan (optional)

– Fuse 3 – 10 A – low beam, position/tail light

– Fuse 4 – 5 A – fuel pump

4. Insert the spare fuse with the correct rating (10 A: 75011088010, 5 A: 75011088005).

5. Check the function of the electrical power consumer.

6. Close the fuse box cover and mount the seat.

Removing:

1. Detach the brake line and wiring harness from the headlight mask.

2. Loosen the rubber strap. Slide the headlight mask up and swing it forward.

3. (All EU models) Detach plug-in connectors and take off the headlight mask.

4. (All US models) Disconnect the plug-in connector and take off the headlight mask.

Installing:

1. Join the plug-in connectors.

2. Position the headlight mask and secure it with the rubber straps. The holding lugs engage in the fender.

3. Position the brake line and wiring harness in the brake line guide.

4. Check the headlight setting.

Note: Do not touch bulbs with bare hands. Clean and degrease bulbs before mounting.

1. Remove the headlight mask with the headlight.

2. Turn the protection cap with the underlying bulb socket counterclockwise and remove it.

3. Pull the bulb socket of the position light out of the reflector.

4. Pull out the headlight bulb.

5. Insert the new headlight bulb (S2 / socket BA20d).

6. Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way. Check the sealing lip of the cap for correct seating.

7. Insert the bulb socket of the position light into the reflector.

8. Install the headlight mask and check the headlight setting.

1. Remove the screw on the rear of the turn signal housing.

2. Carefully remove the turn signal glass.

3. Lightly squeeze the orange cap in the area of the holding lugs and take it off.

4. Press the turn signal bulb lightly into the socket, turn it counter-clockwise about 30°, and take it out.

5. Press the new turn signal bulb (R10W / socket BA15s) carefully into the socket and turn it clockwise until it stops.

6. Mount the orange cap.

7. Position the turn signal glass and tighten the screw lightly.

8. Check that the turn signal system is functioning properly.

Checking:

1. Park the vehicle on a horizontal surface in front of a light-colored wall.

2. Make a mark at the height of the center of the low beam headlight.

3. Make another mark 5 cm (2 in) below the first mark.

4. Position the vehicle 5 m (16 ft) away from the wall.

5. The rider sits on the motorcycle. Switch on the low beam.

6. Check the headlight setting. The boundary between light and dark must be exactly on the lower mark. If not, adjust the range.

Adjusting:

1. Remove the headlight mask.

2. Turn the adjustment bolt to pivot the headlight.

– Clockwise: headlight range increases.

– Counterclockwise: headlight range decreases.

3. Install the headlight mask and check the setting again.

1. Remove the headlight mask with the headlight.

2. Remove the screws and pull the combination instrument upward out of its holder.

3. Using a coin, turn the protection cap all the way counterclockwise and take it off.

4. Remove the old combination instrument battery.

5. Insert the new combination instrument battery (CR 2032) with the label facing outward.

6. Check the O-ring of the protection cap for correct seating.

7. Position the protection cap and turn it all the way clockwise using a coin.

8. Press any button on the combination instrument to activate it.

9. Position the combination instrument in the holder and tighten the screws with washers.

10. Install the headlight mask, check the headlight setting, and set the kilometers/miles and clock on the instrument.

Warning: Coolant gets very hot and is under pressure. Do not open the system when hot. Coolant is toxic.

Condition: The engine is cold.

1. Stand the motorcycle upright on a horizontal surface.

2. Remove the radiator cap.

3. Check the coolant antifreeze protection. It should be between -25 … -45 °C (-13 … -49 °F). If not, correct the antifreeze.

4. Check the coolant level in the radiator. It should be 10 mm (0.39 in) above the radiator fins. If not, correct the level with appropriate coolant.

5. Mount the radiator cap.

Draining:

1. Position the motorcycle upright with an appropriate container under the water pump cover.

2. Remove the screw and take off the radiator cap. Completely drain the coolant.

3. Mount and tighten the screw with a new seal ring to 10 Nm (7.4 lbf ft).

Refilling/Changing:

1. Ensure the drain screw is tightened. Position the motorcycle upright.

2. Pour in coolant (approx. 1.2 L / 1.3 qt) up to 10 mm (0.39 in) above the radiator fins.

3. Push the protection cap upward over the thermostat.

4. Unplug the connector and remove the thermostat with its O-ring. Wait until coolant escapes without bubbles.

5. Mount the thermostat with O-ring and tighten the cylinder head temperature sensor screw to 12 Nm (8.9 lbf ft).

6. Plug in the connector and position the protection cap.

7. Pour coolant in again up to 10 mm (0.39 in) above the radiator fins.

8. Mount the radiator cap.

9. Allow the engine to warm up and cool down. Check the cooling system for leaks and check the coolant level again.

Checking:

1. Turn the handlebar as far as possible to the right. Turn the throttle grip back and forth slightly to determine the play. It should be 3 … 5 mm (0.12 … 0.2 in).

2. Start the engine at idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. If it does, adjust the play.

Adjusting:

1. Move the handlebar to the straight-ahead position.

2. Push back the sleeve on the throttle cable.

3. Loosen the upper nut and turn the adjusting screw in as far as possible.

4. Loosen the lower nut and turn its adjusting screw in as far as possible.

5. Turn the upper adjusting screw until there is 3 … 5 mm of play in the throttle cable.

6. Unscrew the lower adjusting screw until smooth operation or play is worsened, then turn it two turns further.

7. Tighten both nuts and slide the sleeve back on.

The characteristic map is changed by changing the guide plate in the throttle grip. A grey guide plate (slower response, mounted on delivery) and a black guide plate (quicker response) are available.

1. Push back the sleeve on the throttle grip.

2. Remove the screws and half-shells of the throttle grip housing.

3. Detach the throttle cables and take off the grip tube.

4. Remove the guide plate from the handle tube.

5. Position the required guide plate on the grip tube. The label OUTSIDE must be visible and markings must align.

6. Clean the outside of the handlebar and inside of the grip tube. Mount the grip tube.

7. Attach the throttle cables to the guide plate and route them correctly.

8. Position the half-shells, mount and tighten the screws to 5 Nm (3.7 lbf ft).

9. Slide on the sleeve and check the throttle grip for ease of movement. Check the play in the throttle cable.

Warning: If the idle speed is too low, the engine may go out spontaneously.

1. Run the engine until warm. Ensure the cold start button is deactivated.

2. Adjust the idle speed by turning the idle speed adjusting screw. The target is 1,400 … 1,500 rpm.

– Turn clockwise to decrease idle speed.

– Turn counterclockwise to increase idle speed.

– Make the setting in small steps.

If the vehicle is transported over great differences in height, the ambient pressure must be reprogrammed.

1. Start the vehicle at the new height above sea level and switch off the engine again.

2. Wait for at least five seconds.

3. Start the vehicle again and check the response of the vehicle.

4. If the response has not improved, repeat the procedure.

The plug-in connector for the ignition timing map adjustment is located on the frame under the fuel tank. This has no function in the homologated (restricted) condition.

Possible states:

– Soft: The plug-in connector is disconnected to achieve better rideability.

– Performance: The plug-in connector is joined to achieve higher performance.

Procedure:

1. Remove the seat and the fuel tank.

2. To switch from Performance to Soft, disconnect the plug-in connector.

3. To switch from Soft to Performance, join the plug-in connector.

4. Install the fuel tank and mount the seat.

Checking:

Sit on the vehicle in the riding position and determine the distance between the upper edge of your boot and the shift lever. The distance should be 10 … 20 mm (0.39 … 0.79 in). If it does not meet specifications, adjust the basic position.

Adjusting:

1. Remove the screw with the washers and take off the shift lever.

2. Clean the gear teeth of the shift lever and shift shaft.

3. Mount the shift lever on the shift shaft in the required position and engage gearing. The range of adjustment is limited.

4. Mount and tighten the screw with washers to 14 Nm (10.3 lbf ft) using Loctite®243™.

1. Clean the quick release coupling thoroughly with compressed air.

2. Disconnect the quick release coupling. Remaining fuel may flow out.

3. Pull the fuel screen out of the connecting piece.

4. Insert the new fuel screen all the way into the connecting piece.

5. Lightly lubricate the O-ring of the quick-release coupling with silicone spray.

6. Join the quick release coupling.

7. Start the engine and check the response.

Warning – Engine failure: The engine will not be lubricated unless there is 2-stroke oil in the oil tank.

1. Stand the motorcycle upright on a horizontal surface.

2. Check the 2-stroke oil level in the oil tank. For a full tank of fuel, the 2-stroke oil tank must be filled up to at least the upper abutting edge. It is best to completely fill the 2-stroke oil tank.

3. If the 2-stroke oil level is too low, add 2-stroke oil.

This procedure is necessary if the 2-stroke oil hose has been removed or the tank has been fully depleted.

Condition: The engine is off.

1. Remove the seat, stand the motorcycle upright, and check the 2-stroke oil level.

2. Pull the EFI control unit upward and hang it to the side. Remove the protection cap of the diagnostics connector.

3. Put the throttle grip into the full throttle position and secure it.

4. Plug the wake-up connector for priming the oil pump into the diagnostics connector. The combination instrument lighting will activate.

5. Wait for at least five seconds.

6. Release the throttle grip. The oil pump is now timed. The procedure is clearly audible.

7. Wait until you can no longer hear the oil pump operating.

8. Disconnect the wake-up connector.

9. Check the oil hose for air bubbles. If visible, repeat the entire procedure.

10. Mount the protection cap on the diagnostics connector and mount the EFI control unit.

11. Mount the seat.

1. Raise the motorcycle and remove the main silencer, seat, fuel tank, and air filter box cover.

2. Remove the upper subframe screws and loosen the lower subframe screws.

3. Loosen the clamps of the throttle valve body, disconnect the rear brake light switch plug-in connector, and lift the subframe slightly, paying attention to the intake flange.

4. Pull the throttle valve body towards the rear, out of the intake flange, and hang it to the side.

5. Open the hose clamp on the oil line, pull off the angle piece, and collect the 2-stroke oil in a container.

6. Remove the oil screen and clean it. Check it for damage; if damaged, change it.

7. Insert the oil screen and mount the angle piece with a new hose clamp.

8. Reassemble all components in reverse order, tightening screws to specified torques. Add 2-stroke oil and prime the oil pump.

Checking (Engine Cold):

1. Stand the motorcycle upright.

2. Detach the foot brake lever spring.

3. Remove the gear oil level monitoring screw. A small quantity of gear oil should run out. If not, add gear oil.

4. Mount and tighten the screw to 8 Nm (5.9 lbf ft) and attach the spring.

Changing (Engine at Operating Temperature):

1. Park the motorcycle on a level surface with a container underneath.

2. Remove the gear oil drain plug with magnet and let the oil drain fully.

3. Thoroughly clean the drain plug and the sealing surface on the engine.

4. Mount and tighten the drain plug with a new seal ring to 20 Nm (14.8 lbf ft).

5. Remove the filler plug with O-ring and fill up with 0.80 L (0.85 qt.) of gear oil (Engine oil 15W/50).

6. Mount and tighten the filler plug with O-ring.

7. Start the engine, check for leaks, and then check the gear oil level.

Adding (Engine Cold):

1. Park the motorcycle on a level surface.

2. Detach the foot brake lever spring and remove the gear oil level monitoring screw.

3. Remove the filler plug with O-ring.

4. Add gear oil (Engine oil 15W/50) until it emerges from the drill hole of the level monitoring screw.

5. Mount and tighten the level monitoring screw to 8 Nm (5.9 lbf ft).

6. Mount and tighten the filler plug with O-ring and attach the foot brake lever spring.

Note on material damage: If using a pressure cleaner, maintain a minimum distance of 60 cm (23.6 in) and do not direct the jet onto electrical components, connectors, cables, or bearings.

1. Close off the exhaust system to keep water from entering.

2. Remove coarse dirt with a gentle water jet.

3. Spray heavily soiled parts with a commercial motorcycle cleaner and clean with a brush.

4. After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.

5. Remove the closure of the exhaust system.

6. After cleaning, ride the vehicle a short distance until the engine warms up to evaporate water from inaccessible locations.

7. After the motorcycle has cooled down, lubricate all moving parts and pivot points.

8. Clean the chain.

9. Treat bare metal (except brake discs and exhaust) with a corrosion inhibitor. Treat plastic and powder-coated parts with a mild cleaning and care product.

If you use the motorcycle in winter, salt can be expected on the roads. Use cold water for cleaning after riding on salted roads, as warm water enhances corrosion.

– Clean the motorcycle and brakes. After EVERY trip on salted roads, thoroughly clean brake calipers and linings with cold water and dry them carefully.

– Treat the engine, link fork, and other bare or zinc-plated parts (except brake discs) with a wax-based corrosion inhibitor.

– Clean the chain.

1. Clean the motorcycle.

2. Change the gear oil.

3. Check the antifreeze and coolant level.

4. When refueling for the last time, add fuel additive.

5. Refuel and add 2-stroke oil.

6. Check tire pressure.

7. Remove and charge the 12-V battery. The ideal storage temperature for the battery is 10 … 20 °C (50 … 68 °F).

8. Store the vehicle in a dry location not subject to large temperature fluctuations.

9. Raise the motorcycle with a lift stand.

10. Cover the vehicle with a tarp or a similar cover that is permeable to air. Do not use non-porous materials.

1. Remove the motorcycle from the lift stand.

2. Install the 12-V battery.

3. Perform checks and maintenance measures as you would before any ride.

4. Make a test ride.

Possible cause: Operating error.

Action: Carry out the start procedure.

Possible cause: 12-V battery discharged.

Action: Charge the 12-V battery. Check the charging voltage, closed current, and stator winding of the alternator.

Possible cause: Main fuse is blown.

Action: Change the main fuse.

Possible cause: Starter relay faulty.

Action: Check the starter relay.

Possible cause: Starter motor faulty.

Action: Check the starter motor.

Possible cause: Operating error.

Action: Carry out the start procedure.

Possible cause: Quick release coupling not joined.

Action: Join quick release coupling.

Possible cause: Idle speed is not set correctly.

Action: Adjust the idle speed.

Possible cause: Fuel supply interrupted.

Action: Check the fuel tank breather.

Possible cause: Spark plug sooty or wet.

Action: Clean and dry the spark plug and connector, or change if necessary.

Possible cause: Plug gap of spark plug too wide.

Action: Adjust plug gap to 0.6 mm (0.024 in).

Possible cause: Faulty ignition.

Action: Check ignition coil, spark plug connector, and stator winding.

Possible cause: Short-circuit in wiring harness, stop button, or emergency OFF switch.

Action: Check wiring harness and electrical system.

Possible cause: Connector or ignition coil is loose or oxidized.

Action: Clean the connector and treat with contact spray.

Possible cause: Malfunction in the electronic fuel injection.

Action: Check wiring for damage/corrosion. Read out the fault memory.

Possible cause: Spark plug defective.

Action: Change the spark plug.

Possible cause: Faulty ignition.

Action: Check ignition coil, spark plug connector, and stator winding.

Possible cause: Idle speed is not set correctly.

Action: Adjust the idle speed.

Possible cause: Malfunction in the electronic fuel injection.

Action: Check wiring for damage/corrosion. Read out the fault memory.

Possible cause: Faulty ignition.

Action: Check ignition coil, spark plug connector, and stator winding.

Possible cause: Ambient pressure is incorrectly stored.

Action: Program ambient air pressure.

Possible cause: Air filter very dirty.

Action: Clean the air filter and air filter box.

Possible cause: Fuel filter is very dirty.

Action: Change the fuel filter.

Possible cause: Fuel screen is very dirty.

Action: Change the fuel screen.

Possible cause: Malfunction in the electronic fuel injection.

Action: Check wiring for damage/corrosion. Read out fault memory.

Possible cause: Fuel supply interrupted.

Action: Check the fuel tank breather.

Possible cause: Exhaust system leaky, deformed, or too little glass fiber yarn filling.

Action: Check exhaust system for damage. Change the glass fiber yarn filling.

Possible cause: Faulty ignition.

Action: Check ignition coil, spark plug connector, and stator winding.

Possible cause: Diaphragm or reed valve housing damaged.

Action: Check the diaphragm and reed valve housing.

Possible cause: Ambient pressure is incorrectly stored.

Action: Program ambient air pressure.

Possible cause: Lack of fuel.

Action: Refuel.

Possible cause: The engine takes in false air.

Action: Check that the intake flange is firmly seated.

Possible cause: The connector or ignition coil is loose or oxidized.

Action: Clean the connector and treat with contact spray.

Possible cause: Ambient pressure is incorrectly stored.

Action: Program ambient air pressure.

Possible cause: Too little coolant in cooling system.

Action: Check the cooling system for leakage. Check the coolant level.

Possible cause: Too little air stream.

Action: Switch off engine when stationary.

Possible cause: Radiator fins very dirty.

Action: Clean the radiator fins.

Possible cause: Foam formation in cooling system.

Action: Drain and refill with coolant.

Possible cause: Damaged cylinder head or cylinder head gasket.

Action: Check the cylinder head and cylinder head gasket.

Possible cause: Bent radiator hose.

Action: Change the radiator hose.

Possible cause: Thermostat defective.

Action: Check the thermostat. Opening temperature: 70 °C (158 °F).

Fault: White smoke emission (steam in exhaust gas).

Possible cause: Damaged cylinder head or cylinder head gasket.

Action: Check the cylinder head and cylinder head gasket.

Fault: Gear oil exits at the vent hose.

Possible cause: Too much gear oil added.

Action: Check the gear oil level.

Fault: Water in the gear oil.

Possible cause: Damaged radial shaft seal ring or water pump.

Action: Check the radial shaft seal ring and the water pump.

Fault: Malfunction indicator lamp lights up or flashes.

Possible cause: Malfunction in the electronic fuel injection.

Action: Check wiring for damage/corrosion. Read out the fault memory.

Fault: 12-V battery discharged.

Possible cause: The 12-V battery is not being charged by the alternator.

Action: Check the charging voltage and the stator winding of the alternator.

Fault: 12-V battery discharged.

Possible cause: Unwanted electrical power consumer.

Action: Check the open-circuit current.

Fault: Values in combination instrument deleted.

Possible cause: The combination instrument battery is empty.

Action: Change combination instrument battery.

The blink codes are only displayed by the derestricted version of the vehicle.