GASGAS EC 300 2021 (01) PDF DOCUMENT

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.

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 respective use.

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.

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

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

2. the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1. Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases.

2. Removal or puncturing of parts of the intake system.

3. Lack of proper maintenance.

4. Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

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 (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000)

Unless otherwise noted, normal conditions apply to all tasks and descriptions.

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®) is required. Observe the manufacturer’s instructions.

If thread locker (e.g., Precote®) 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 vehicle identification number is stamped on the right side of the steering head.

The type label is fixed to the front of the steering head.

The key number for the steering lock is stamped onto the key connector.

The engine number is located on the left side of the engine over the engine sprocket.

The fork part number is stamped on the inside of the axle clamp.

The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side.

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

Possible states:

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

Possible states:

– 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.

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

Possible states:

– Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on.

– High beam on – Light switch is turned to the left. In this position, the high beam and the tail light are switched on.

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. In this position, the light is switched off.

– Light on – Light switch is pulled out to the stop. In this position, 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.

Possible states:

– The high beam indicator lamp lights up blue – The high beam is switched on.

– Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized workshop.

– The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

– Turn signal indicator lamp flashes green – The turn signal is switched on.

– The oil level warning lamp lights up red – Oil level has reached the MIN marking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil.

Possible states:

– High beam indicator lamp – inoperative

– Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized workshop.

– The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

– The oil level warning lamp lights up red – Oil level has reached the MIN marking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil.

Danger – Fire hazard: Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

– Switch off the engine for refueling.

– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

– If any fuel is spilled, wipe it off immediately.

– Observe the specifications for refueling.

Procedure:

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

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.

1. Fold the loop upward.

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

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

2. Fold the loop down.

The 2-stroke oil tank cap engages.

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:

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

– The cold start button is 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 steering lock is fitted on the left side of the steering head and is used to lock the steering, making riding impossible.

Note: The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface.

Procedure:

1. Park the vehicle.

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 for the steering lock.

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

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 for the steering lock.

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

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 time symbol flashes.

6. To reset the time, press the left button (value decreases). To advance the time, press the right button (value increases).

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

8. Set the service. To shorten the service interval, press the left button (value decreases). To extend the service interval, press the right button (value increases).

9. 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 appears on the combination instrument.

– KM/H or M/H shows the speed.

– The clock symbol shows the time.

– DST shows the distance since the last reset, such as between two refueling stops.

If the value of 39999.9 is exceeded, DST is automatically reset to 0.0.

Press one of the buttons until DST2 appears on the combination instrument.

– KM/H or M/H shows the speed.

– The clock symbol shows the time.

– DST2 shows the distance 2 since the last reset, such as between two refueling stops.

If the value of 39999.9 is exceeded, DST2 is automatically 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.

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

– You will receive a delivery certificate when the vehicle is handed over.

– 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.

(All EU models)

– Adjust the free travel of the handbrake lever.

(EC 300 US)

– 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.

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

– Avoid fully opening the throttle!

– Check the idle speed regularly.

The idle speed may change during the run-in time. If the idle speed changes, adjust it.

Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batteries.

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.

If the charged lithium-ion battery is unable to actuate the starter motor when temperatures are below 15 °C (60 °F), the battery is not faulty, but needs to be warmed up internally to increase its starting power (current output). The starting power increases as the battery warms up.

Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

– Seal the air filter box.

– 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 humidity, corrosion, or damage is found, clean and dry the connector, or change it if necessary.

Difficult operating conditions include:

– 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. Mount the air filter dust cover (79006920000).

3. Mount the air filter sand cover (79006922000).

4. Clean the chain using a chain cleaner.

5. Mount the steel sprocket.

6. Grease the chain with universal oil spray.

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

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

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

2. Mount the air filter rain cover (79006921000).

3. Clean the chain using a chain cleaner.

4. Mount the steel sprocket.

5. Grease the chain with universal oil spray.

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

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

1. Mount the air filter rain cover (79006921000).

2. Mount the steel sprocket.

3. Clean the motorcycle.

4. 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. The transmission oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive.

3. Clean the chain.

4. Clean the radiator fins.

5. Straighten bent radiator fins carefully.

6. Check the coolant level.

Mount the air filter rain cover (79006921000).

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.

– Check the gear oil level.

– Check the electrical system.

– Check the front brake fluid level.

– Check the rear brake fluid level.

– Check the front brake linings.

– Check the brake linings of the rear brake.

– 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.

– Check tire pressure.

– Check the spoke tension. (Incorrect spoke 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 that they can be operated smoothly.

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

– Check the fuel level.

– Check 2-stroke oil level.

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

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

2. Shift the transmission to neutral position.

3. If the ambient temperature is < 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 for 30 seconds before a further attempt at starting. At temperatures below 15 °C (60 °F), several attempts may be necessary to warm-up the lithium-ion battery. During the starting process, the malfunction indicator lamp lights up.

Switch on the light before riding the vehicle. You will be seen earlier by other motorists. When you are riding, the side stand must be folded up and secured with the rubber strap.

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

– 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 the cold start button after the engine has warmed up.

– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed, but fuel consumption will be considerably lower.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

– To shift down, apply the brakes and close the throttle at the same time.

– Pull the clutch lever and 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. This causes the gear oil, engine and cooling system to heat up.

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

Warning: Excessively forceful application of the brakes blocks the wheels. Adjust application of the brakes to the respective riding situation and riding surface conditions.

Warning: A spongy pressure point on the front or rear brake reduces braking efficiency. Check the brake system and do not continue riding until the problem is eliminated.

Warning: Moisture and dirt impair the brake system. Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

– 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.

1. Apply the brakes on the motorcycle.

2. Shift the transmission to neutral position.

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

4. (EC 300 US) Press and hold the stop button while the engine is idling until the engine stops.

5. Park the motorcycle on firm ground.

Notes on parking:

– Park the vehicle on a firm and level surface.

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

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

– Allow the vehicle to cool down before covering it.

Note: The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface.

Note: Hot vehicle components pose a fire hazard and explosion risk. Do not park the vehicle near to materials which are highly flammable or explosive. Allow the vehicle to cool down before covering it.

1. Switch off the engine.

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

Note: Inadequate fuel quality causes the fuel filter to quickly become clogged. Refuel only with clean fuel that meets the specified standards.

1. Open the fuel tank filler cap.

2. Fill the fuel tank with fuel up to the specified level.

Do not refuel using pre-mixed fuel.

3. Close the fuel tank filler cap.

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 lights up, the 2-stroke oil is sufficient for the remaining tank of fuel.

– As soon as the oil level warning light lights up, ride for no longer than until the remaining fuel in the tank is depleted.

– At the next opportunity add 2-stroke oil before you refuel.

– Prime the oil pump if the 2-stroke oil hose has been removed or the 2-stroke oil tank has been fully depleted in error.

Procedure:

1. Open 2-stroke oil tank cap.

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

3. Close 2-stroke oil tank cap.

○ One-time interval ● Periodic interval

○ One-time interval ● Periodic interval

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.

– As delivered, the motorcycle is adjusted for an average rider’s weight (with full protective clothing).

– If your weight is above or below this range, the basic setting of the suspension components must be adjusted accordingly.

– Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.

The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

1. Turn adjusting screw clockwise with a screwdriver as far as the last perceptible click. Do not loosen the fitting.

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

1. Using an open end wrench, turn the adjusting screw clockwise all the way. Do not loosen the fitting.

2. Turn counterclockwise by the number of turns corresponding to the shock absorber type.

Turn clockwise to increase damping; turn counterclockwise to reduce damping.

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

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

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 (rear wheel unloaded).

3. Remove the motorcycle from the lift stand.

4. Hold the motorcycle upright with the aid of an assistant.

5. Measure the distance again between the rear axle and the “SAG” marking on the rear fender using the sag gauge. Note this value as dimension B.

6. The static sag is the difference between measurements A and B.

7. Check the static sag.

8. If the static sag is less or more than the specified value, adjust the spring preload of the shock absorber.

1. Measure dimension A of the rear wheel unloaded (as in the static sag check).

2. With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times. The rear wheel suspension will level out.

3. Another person again measures the distance between the rear axle and the “SAG” marking on the rear fender using the sag gauge. Note this value as dimension C.

4. The riding sag is the difference between measurements A and C.

5. Check the riding sag.

6. If the riding sag differs from the specified measurement, adjust the riding sag.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the shock absorber and clean it thoroughly.

Main work:

1. Loosen the screw on the adjusting ring.

2. Turn the adjusting ring until the spring is no longer under tension using a hook wrench (90129051000).

3. Measure the total spring length while it is not under tension.

4. Tension the spring by turning the adjusting ring to the specified dimension A.

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

5. Tighten the screw.

Finishing work:

– Install the shock absorber.

– Remove the motorcycle from the lift stand.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the shock absorber and clean it thoroughly.

Main work:

– Choose and mount a suitable spring. The spring rate is shown on the outside of the spring.

Finishing work:

– Install the shock absorber.

– Remove the motorcycle from the lift stand.

– Check the static sag of the shock absorber.

– Check the riding sag of the shock absorber.

– Adjust the rebound damping of the shock absorber.

The adjuster is located at the upper end of the left fork leg (COMP, white adjuster).

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

2. Turn counterclockwise by the number of clicks corresponding to the fork type.

Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.

The adjuster is located at the upper end of the right fork leg (REB, red adjuster).

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

2. Turn counterclockwise by the number of clicks corresponding to the fork type.

Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

Warning: A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued and may break. Change the handlebar if it is damaged or bent.

1. Remove screws and take off the handlebar clamps. Remove the handlebar and lay it to one side. Cover components to protect them and do not kink cables and lines.

2. Remove screws and take off the handlebar supports.

3. Place the handlebar supports in the required position. Mount and tighten the screws.

Position the left and right handlebar supports evenly.

4. Position the handlebar. Make sure the cables and wiring are positioned correctly.

5. Position the handlebar clamps. Mount screws and tighten evenly. Make sure the gap widths are even.

Note: The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface.

1. Raise the motorcycle at the frame underneath the engine using a lift stand (A54029955100).

2. Ensure neither wheel is in contact with the ground.

3. Secure the motorcycle against falling over.

Note: The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface.

1. Remove the motorcycle from the lift stand.

2. Remove the lift stand.

3. To park the motorcycle, press the side stand to the ground with your foot and lean the motorcycle on it. When riding, the side stand must be folded up and secured with the rubber strap.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

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

2. Tighten the bleeder screws.

Finishing work:

– Remove the motorcycle from the lift stand.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the fork protector.

Main work:

1. Push the dust boots of both fork legs downward. The dust boots remove dust and coarse dirt particles. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

2. Clean and oil the dust boots and inner fork tubes of both fork legs using Universal oil spray.

3. Press the dust boots back into their installation position.

4. Remove excess oil.

Finishing work:

– Install the fork protector.

– Remove the motorcycle from the lift stand.

Removing:

1. Remove screws and take off the clamp.

2. Remove screws and take off the left fork protector.

3. Remove screws and take off the right fork protector.

Installing:

1. Position the fork protector on the left fork leg. Mount and tighten screws.

2. Position the brake line, wiring harness, and clamp. Mount and tighten screws.

3. Position the fork protector on the right fork leg. Mount and tighten screws.

Removing:

1. Raise the motorcycle with a lift stand.

2. Remove the front wheel.

3. Remove the headlight mask with the headlight.

4. Remove screws and take off the clamp.

5. Remove the cable tie.

6. Remove screws and take off the brake caliper. Hang the brake caliper and the brake line loosely to the side.

7. Loosen the top and bottom triple clamp screws. Remove the left and right fork legs.

Installing:

1. Position the fork legs. Bleeder screws should be positioned toward the front. The second milled groove (from the top) of the fork legs must be flush with the upper edge of the upper triple clamp.

2. Tighten the top triple clamp screws (M8) to 20 Nm (14.8 lbf ft).

3. Tighten the bottom triple clamp screws (M8) to 15 Nm (11.1 lbf ft).

4. Position the brake caliper, and mount and tighten screws (M8) to 25 Nm (18.4 lbf ft) using Loctite® 243™.

5. Mount the cable ties.

6. Position the brake line, wiring harness, and clamp. Mount and tighten screws.

7. Install the front wheel, headlight mask, and check the headlight setting.

Preparatory work: Raise the motorcycle with a lift stand.

Main work:

1. Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing.

– If there is detectable play, adjust the steering head bearing play.

2. Move the handlebar to and fro over the entire steering range. It must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions.

– If detent positions are detected, adjust the steering head bearing play and check the bearing, changing if necessary.

3. Check the steering stop bolts for correct adjustment and locking.

Finishing work: Remove the motorcycle from the lift stand.

Preparatory work: Raise the motorcycle with a lift stand.

Main work:

1. Loosen the top triple clamp screws and the top steering stem screw.

2. Loosen and retighten the top steering head screw.

3. Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

4. Tighten the top triple clamp screws.

5. Tighten the top steering stem screw.

Finishing work:

– Check the steering head bearing for play.

– Remove the motorcycle from the lift stand.

1. Remove the screw on the left side.

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

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.

2. Make sure the seat is locked in correctly.

3. Mount and tighten the screw on the left side.

Preparatory work: Remove the seat.

Condition: The air filter box cover is secured.

1. Remove the screw.

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

Main work:

1. Insert the air filter box cover in its area and clip it into place.

2. Mount and tighten the screw.

Finishing work: Mount the seat.

Note: Unfiltered intake air has a negative effect on the service life of the engine. Only operate the vehicle if it is equipped with an air filter.

Preparatory work:

– Remove the seat.

– Remove the air filter box cover.

Main work:

1. Detach the retaining tab. Remove the air filter with the air filter support.

2. Remove the air filter from the air filter support.

Main work:

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 the bushing. The air filter should be correctly positioned.

4. Insert the retaining tab. The retaining pin should be secured with the retaining tab.

Finishing work:

– Install the air filter box cover.

– Mount the seat.

Note: Do not clean the air filter with fuel or petroleum since these substances attack the foam.

Preparatory work:

– Remove the seat.

– Remove the air filter box cover.

– Remove the air filter.

Main work:

1. Wash the air filter thoroughly in special cleaning liquid (Air filter cleaner) 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 (Oil for foam air filter).

3. Clean the air filter box.

4. Clean the intake flange and check it for damage and tightness.

Finishing work:

– Install the air filter.

– Install the air filter box cover.

– Mount the seat.

Warning: The exhaust system gets very hot when the vehicle is driven. Allow the exhaust system to cool down before performing any work.

Removing:

1. Remove screws.

2. Pull off the main silencer with exhaust sleeve and the spring ring from the manifold.

Installing:

1. Mount the main silencer with the rubber sleeve and the spring rings.

2. Mount and tighten screws.

Preparatory work: Remove the main silencer.

Main work:

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

2. Pull the glass fiber yarn filling from the inner tube.

3. Clean the parts that need to be reinstalled and check for damage.

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

5. Push the outer tube over the inner tube with the new glass fiber yarn filling and the O-ring.

6. Mount and tighten all screws.

Finishing work: Install the main silencer.

Preparatory work: Remove the seat.

Main work:

1. Unplug the connector of the fuel pump.

2. Remove the tube from the fuel tank breather.

3. Clean the quick release coupling thoroughly with compressed air. Under no circumstances should dirt enter the fuel line.

4. Disconnect the quick release coupling. Remaining fuel may flow out of the fuel hose.

5. Mount wash cap set (81212016100).

6. Remove screws with the collar bushings.

7. (All EU models) Hang the horn and horn bracket to one side.

8. Remove the screw with the rubber bushing.

9. Pull both spoilers off laterally from the radiator mount and lift off the fuel tank.

Main work:

1. Check the throttle cable routing.

2. Position the fuel tank and fit the two spoilers to the sides in front of the radiator bracket. Make sure that no cables are trapped or damaged.

3. Mount and tighten the screw with the rubber bushing.

4. (All EU models) Position the horn with the horn bracket.

5. Mount and tighten screws with the collar bushings.

6. Remove the wash cap set.

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

8. Spray silicone spray onto a lint-free cleaning cloth and lightly lubricate the O-ring of the quick-release coupling.

9. Join the quick release coupling. Route the cable and fuel line at a safe distance from the exhaust system.

10. Attach the fuel tank breather hose.

11. Plug in the connector for the fuel pump.

Finishing work: Mount the seat.

Checking for dirt: Check the chain for heavy soiling. If the chain is very dirty, clean it.

Cleaning the chain:

The service life of the chain depends largely on its maintenance.

1. Raise the motorcycle with a lift stand.

2. Rinse off loose dirt with a soft jet of water.

3. Remove old grease residue with chain cleaner.

4. After drying, apply off-road chain spray.

5. Remove the motorcycle from the lift stand.

Warning: Incorrect chain tension damages components and results in accidents. If the chain is too tight, components wear more quickly. If it’s too loose, it can fall off, locking the rear wheel or damaging the engine.

1. Raise the motorcycle with a lift stand.

2. Pull the chain at the end of the chain sliding piece upward to measure chain tension. The lower chain section must be taut. Chain wear is not always even, so repeat this measurement at different chain positions.

3. If the chain tension does not meet the specification, adjust it.

4. Remove the motorcycle from the lift stand.

1. Raise the motorcycle with a lift stand and check the chain tension.

2. Loosen the rear wheel spindle nut and the chain adjuster nuts.

3. Adjust the chain tension by turning the adjusting screws on the left and right.

Turn the adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks. The rear wheel is then correctly aligned.

4. Tighten the chain adjuster nuts.

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

6. Tighten the rear wheel spindle nut.

7. Remove the motorcycle from the lift stand.

1. Raise the motorcycle with a lift stand and shift the transmission into neutral.

2. Check the chain, rear sprocket, and engine sprocket for wear. If worn, change the drivetrain kit. The engine sprocket, rear sprocket, and chain should always be replaced together.

3. To check chain wear, pull on the top section of the chain with a weight of 10 … 15 kg (22 … 33 lb.).

4. Measure the distance of 18 chain rollers in the lower chain section. Repeat at different chain positions.

If the distance is greater than specified, change the drivetrain kit.

5. 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 is firmly seated and tighten screws if loose (M6, 6 Nm, Loctite® 243™).

6. 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 is firmly seated and tighten the screw if loose (M8, 15 Nm).

7. Check the chain guide for wear. Wear can be seen on the front of the guide. If the light part is worn, change it. Ensure it is firmly seated and tighten screws if loose (M6, 10 Nm).

8. Remove the motorcycle from the lift stand.

Frame:

– Check the frame for damage, cracks, and deformation. If signs are present, the frame must be changed. Repairs on the frame are not permitted.

Link Fork:

– Check the link fork for damage, cracks, and deformation. If signs are present, the link fork must be changed. Repairs on the link fork are not permitted.

Preparatory work: Remove the seat and fuel tank.

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.

– If the throttle cable is not routed as specified, correct the throttle cable routing.

Finishing work: Install the fuel tank and mount the seat.

Check the rubber grips on the handlebar for damage, wear, and looseness. The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar. The rubber grip can only be replaced with the sleeve or the throttle tube.

– If a rubber grip is damaged or worn, change the rubber grip.

– Check that the fixed grip screw is firmly seated. The diamond mark must be positioned visibly as shown in the figure.

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 adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding.

Note: The fluid level rises with increasing wear of the clutch facing discs. Never use DOT 5 brake fluid. Only use clean brake fluid from a sealed container.

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

2. Remove screws.

3. Remove cover with membrane.

4. Check the fluid level.

5. If the level of the fluid does not meet specifications, correct the fluid level of the hydraulic clutch using Brake fluid DOT 4 / DOT 5.1.

6. Position the cover with the membrane. Mount and tighten the screws. Clean up overflowed or spilled brake fluid immediately with water.

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

2. Remove screws, and take off the cover with the membrane.

3. Fill a bleeding syringe (50329050000) with the appropriate hydraulic fluid (Brake fluid DOT 4 / DOT 5.1).

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

5. Press the fluid into the system until it emerges from the hole of the master cylinder without bubbles. Now and then, extract fluid from the master cylinder reservoir to prevent overflow.

6. Remove the bleeding syringe. Tighten the bleeder screw. Mount the protection cap.

7. Correct the fluid level of the hydraulic clutch.

8. Position the cover with the membrane. Mount and tighten screws. Clean up any spilled fluid immediately with water.

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

Brake fluid DOT 4 / DOT 5.1

– Standard/classification: DOT

– Guideline: Use only brake fluid that complies with the specified standard and exhibits the corresponding properties.

Coolant

– Guideline: Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Antifreeze protection should be at least −25 °C (−13 °F).

Engine oil (15W/50) for Gearbox

– Standard/classification: JASO T903 MA2, SAE 15W/50

– Guideline: Use only engine oils that comply with the specified standards.

Engine oil, 2-stroke

– Standard/classification: JASO FD

– Guideline: Only use high-grade, fully synthetic 2-stroke engine oil from a reputable brand.

Fork oil (SAE 4) (48601166S1)

– Standard/classification: SAE 4

Shock absorber fluid (SAE 2.5) (50180751S1)

– Standard/classification: SAE 2.5

Super unleaded (ROZ 95)

– Standard/classification: DIN EN 228 (ROZ 95)

– Guideline: Only use super unleaded fuel that matches or is equivalent to the specified standard. Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use. Do not use fuel containing methanol or more than 10% ethanol.

Air filter cleaner: MOTOREX® Racing Bio Dirt Remover

Chain cleaner: MOTOREX® Chain Clean

Fuel additive: MOTOREX® Fuel Stabilizer

High viscosity grease: SKF® LGHB 2

Long-life grease: MOTOREX® Bike Grease 2000

Motorcycle cleaner: MOTOREX® Moto Clean

Off-road chain spray: MOTOREX® Chainlube Offroad

Oil for foam air filter: MOTOREX® Racing Bio Liquid Power

Preserving materials for paints, metal and rubber: MOTOREX® Moto Protect

Silicone spray: MOTOREX® Silicone Spray

Special cleaner for glossy and matte paint finishes, metal and plastic surfaces: MOTOREX® Quick Cleaner

Universal oil spray: MOTOREX® Joker 440 Synthetic

JASO T903 MA2: A separate specification for motorcycles. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds. In most motorcycle engines, the transmission and clutch are lubricated with the same oil. The JASO T903 MA2 standard meets these special requirements.

SAE: The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.

JASO FD: JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

Red symbols: Indicate an error condition that requires immediate intervention.

– Oil level warning lamp lights up red – Oil level has reached the MIN marking. Ride for no more than until the remaining fuel in the tank is depleted and at the next opportunity refuel with 2-stroke oil.

Yellow and orange symbols: Indicate an error condition that requires prompt intervention.

– Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized workshop.

– The fuel level warning lamp lights up yellow – The fuel level has reached the reserve mark.

Green and blue symbols: Reflect information.

– The high beam indicator lamp lights up blue – The high beam is switched on.

– Turn signal indicator lamp flashes green – The turn signal is switched on.