GAS GAS MC 450F 2022 User manual

OWNER'S MANUAL 2022
MC 450F
EX 450F
MC 450F TROY LEE DESIGNS
Art. no. 3215055en

DEAR GASGAS CUSTOMER
*3215055en*
3215055en
11/2021
DEAR GASGAS CUSTOM ER
Congratulations on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports
vehicle which, with appropriate care, will bring you pleasure for a long time to come.
We wish you good and safe riding at all times!
Enter the serial numbers of your vehicle below.
Vehicle identification number ( p. 12) Dealer's stamp
Engine number ( p. 12)
The Owner's Manual contained the latest information for this model series at the time of publication. However, minor dif-
ferences due to further developments in design cannot be ruled out completely.
All specifications contained herein are non-binding. GASGAS Motorcycles GmbH specifically reserves the right to modify or
delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and
without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without
prior notice. GASGAS Motorcycles accepts no liability for delivery options, deviations from figures and descriptions, as well
as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular
scope of supply.
© 2021 GASGAS Motorcycles GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copy-
right owner.
ISO 9001(12 100 6061)
GASGAS Motorcycles applies quality assurance processes that lead to the highest possible product quality as
defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
GASGAS Motorcycles GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
MC 450F (F0301V5)
EX 450F US (F0375V2)
MC 450F TROY LEE DESIGNS (F0301V6)

TABLE OF CONTENTS
2
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used................................................. 5
1.2 Formats used................................................. 5
2 SAFETY ADVICE ............................................................ 6
2.1 Use definition –intended use....................... 6
2.2 Misuse............................................................ 6
2.3 Safety advice.................................................. 6
2.4 Degrees of risk and symbols ......................... 6
2.5 Tampering warning ....................................... 7
2.6 Safe operation ............................................... 7
2.7 Protective clothing ........................................ 7
2.8 Work rules ..................................................... 8
2.9 Environment.................................................. 8
2.10 Owner's Manual ............................................ 8
3 IMPORTANT NOTES ..................................................... 9
3.1 Manufacturer warranty, implied
warranty ........................................................ 9
3.2 Fuel, auxiliary substances.............................. 9
3.3 Spare parts, accessories................................ 9
3.4 Service ........................................................... 9
3.5 Figures ........................................................... 9
3.6 Customer service........................................... 9
4 VIEW OF VEHICLE ...................................................... 10
4.1 View of vehicle, front left (example) .......... 10
4.2 View of vehicle, rear right (example).......... 11
5 SERIAL NUMBERS....................................................... 12
5.1 Vehicle identification number..................... 12
5.2 Type label .................................................... 12
5.3 Engine number ............................................ 12
5.4 Fork article number..................................... 12
5.5 Shock absorber article number................... 13
6 CONTROLS.................................................................. 14
6.1 Clutch lever.................................................. 14
6.2 Hand brake lever ......................................... 14
6.3 Throttle grip................................................. 14
6.4 Stop button.................................................. 14
6.5 Start button ................................................. 15
6.6 Combination switch (MC 450F
TROY LEE DESIGNS) ..................................... 15
6.7 Overview of indicator lamps ....................... 16
6.8 Service hour counter (MC 450F
TROY LEE DESIGNS) ..................................... 16
6.9 Opening the fuel tank filler cap................... 16
6.10 Closing the fuel tank filler cap..................... 17
6.11 Cold start button ......................................... 18
6.12 Idle speed adjusting screw.......................... 19
6.13 Shift lever..................................................... 19
6.14 Foot brake lever .......................................... 20
6.15 Plug-in stand (MC)....................................... 20
6.16 Side stand (EX)............................................. 20
6.17 Factory Start (MC 450F
TROY LEE DESIGNS) ..................................... 21
7 PREPARING FOR USE ................................................. 22
7.1 Advice on preparing for first use ................ 22
7.2 Running in the engine ................................. 23
7.3 Starting power of lithium-ion batteries
at low temperatures.................................... 24
7.4 Preparing the vehicle for difficult
operating conditions ................................... 24
7.5 Preparing the vehicle for rides on dry
sand ............................................................. 24
7.6 Preparing the vehicle for rides on wet
sand ............................................................. 25
7.7 Preparing the vehicle for rides on wet
and muddy circuits...................................... 26
7.8 Preparing vehicle for high temperatures
or slow riding............................................... 26
7.9 Preparing the vehicle for low
temperatures or snow ................................ 26
8 RIDING INSTRUCTIONS .............................................. 27
8.1 Checks and maintenance measures
when preparing for use............................... 27
8.2 Starting the vehicle ..................................... 27
8.3 Activating launch control (MC 450F
TROY LEE DESIGNS) ..................................... 28
8.4 Activating traction control (MC 450F
TROY LEE DESIGNS) ..................................... 29
8.5 Activating the Factory Start (MC 450F
TROY LEE DESIGNS) ..................................... 29
8.6 Starting off................................................... 30
8.7 Shifting, riding ............................................. 30
8.8 Applying the brakes..................................... 31
8.9 Stopping, parking......................................... 31
8.10 Transporting ................................................ 32
8.11 Refueling...................................................... 32
9 SERVICE SCHEDULE.................................................... 34
9.1 Additional information................................ 34
9.2 Required work ............................................. 34
9.3 Recommended work ................................... 35
10 TUNING THE CHASSIS................................................ 37
10.1 Checking the basic chassis setting with
the rider's weight ........................................ 37
10.2 Air suspension XACT.................................... 37
10.3 Compression damping of the shock
absorber ...................................................... 38
10.4 Adjusting the low-speed compression
damping of the shock absorber .................. 38
10.5 Adjusting the high-speed compression
damping of the shock absorber .................. 39
10.6 Adjusting the rebound damping of the
shock absorber ............................................ 39
10.7 Measuring the dimension of the rear
wheel unloaded........................................... 40
10.8 Checking the static sag of the shock
absorber ...................................................... 41
10.9 Checking the riding sag of the shock
absorber ...................................................... 41

TABLE OF CONTENTS
3
10.10 Adjusting the spring preload of the
shock absorber ........................................ 42
10.11 Adjusting the riding sag ........................... 43
10.12 Checking the basic setting of the fork ........ 44
10.13 Adjusting the fork air pressure.................... 44
10.14 Adjusting the compression damping of
the fork ........................................................ 45
10.15 Adjusting the rebound damping of the
fork............................................................... 46
10.16 Handlebar position...................................... 47
10.17 Adjusting the handlebar position ........... 47
11 SERVICE WORK ON THE CHASSIS .............................. 49
11.1 Raising the motorcycle with a lift stand ..... 49
11.2 Removing the motorcycle from the lift
stand ............................................................ 49
11.3 Bleeding the fork legs.................................. 50
11.4 Cleaning the dust boots of the fork legs..... 50
11.5 Removing the fork protector ...................... 51
11.6 Installing the fork protector........................ 51
11.7 Removing motor guard (MC 450F
TROY LEE DESIGNS) ..................................... 51
11.8 Installing the motor guard (MC 450F
TROY LEE DESIGNS) ..................................... 52
11.9 Removing the fork legs ........................... 52
11.10 Installing the fork legs ............................. 53
11.11 Removing the lower triple clamp ............ 54
11.12 Installing the lower triple clamp ............. 55
11.13 Checking the steering head bearing play ... 58
11.14 Adjusting the steering head bearing
play .......................................................... 59
11.15 Lubricating the steering head bearing .... 60
11.16 Removing the start number plate............... 60
11.17 Installing the start number plate ................ 61
11.18 Removing front fender................................ 61
11.19 Installing front fender ................................. 62
11.20 Removing the shock absorber ................ 62
11.21 Installing the shock absorber .................. 63
11.22 Removing the seat....................................... 65
11.23 Mounting the seat....................................... 65
11.24 Removing the air filter box cover................ 66
11.25 Installing the air filter box cover ................. 67
11.26 Removing the air filter ............................ 67
11.27 Cleaning the air filter and air filter
box ........................................................... 68
11.28 Installing the air filter .............................. 69
11.29 Preparing air filter box cover for
securing ................................................... 69
11.30 Removing the main silencer........................ 69
11.31 Installing the main silencer ......................... 70
11.32 Changing the glass fiber yarn filling of
the main silencer ..................................... 71
11.33 Removing the fuel tank ........................... 72
11.34 Installing the fuel tank ............................. 74
11.35 Checking for chain dirt accumulation......... 76
11.36 Cleaning the chain....................................... 76
11.37 Checking the chain tension......................... 77
11.38 Adjusting the chain tension ........................ 77
11.39 Checking the chain, rear sprocket,
engine sprocket, and chain guide ............... 78
11.40 Checking the frame ................................. 81
11.41 Checking the link fork .............................. 81
11.42 Checking the throttle cable routing............ 81
11.43 Checking the rubber grips........................... 82
11.44 Adjusting the basic position of the clutch
lever ............................................................. 82
11.45 Checking/correcting the fluid level of the
hydraulic clutch ........................................... 82
11.46 Changing the hydraulic clutch fluid ........ 83
12 BRAKE SYSTEM........................................................... 85
12.1 Checking the free travel of the hand
brake lever................................................... 85
12.2 Adjusting the basic position of the hand
brake lever................................................... 85
12.3 Checking the brake discs............................. 85
12.4 Checking the front brake fluid level............ 86
12.5 Adding front brake fluid .......................... 86
12.6 Checking the front brake linings ................. 88
12.7 Changing the brake linings of the front
brake ........................................................ 88
12.8 Checking the free travel of foot brake
lever ............................................................. 92
12.9 Adjusting the basic position of the foot
brake lever ............................................... 93
12.10 Checking the rear brake fluid level ............. 93
12.11 Adding rear brake fluid ........................... 94
12.12 Checking the brake linings of the rear
brake............................................................ 95
12.13 Changing the rear brake linings .............. 95
13 WHEELS, TIRES........................................................... 98
13.1 Removing the front wheel ...................... 98
13.2 Installing the front wheel ........................ 99
13.3 Removing the rear wheel ..................... 100
13.4 Installing the rear wheel ...................... 101
13.5 Checking the tire condition...................... 102
13.6 Checking tire pressure.............................. 103
13.7 Checking the spoke tension ..................... 103
14 ELECTRICAL SYSTEM ............................................... 105
14.1 Removing the 12-V battery .................. 105
14.2 Installing the 12-V battery ................... 105
14.3 Charging the 12-V battery .................... 106
14.4 Changing main fuse.................................. 107
14.5 Diagnostics connector.............................. 108
15 COOLING SYSTEM................................................... 109
15.1 Cooling system ......................................... 109
15.2 Checking the antifreeze and coolant
level........................................................... 109
15.3 Checking the coolant level....................... 110
15.4 Draining the coolant ............................. 110
15.5 Refilling with coolant ............................ 111
15.6 Changing the coolant ............................... 112

TABLE OF CONTENTS
4
16 TUNING THE ENGINE.............................................. 114
16.1 Checking the play in the throttle cable.... 114
16.2 Adjusting the play in the throttle
cable ..................................................... 114
16.3 Adjusting the characteristic map of the
throttle response ................................. 115
16.4 Changing the mapping ............................. 116
16.5 Adjusting the idle speed ....................... 117
16.6 Programming the throttle valve
position..................................................... 117
16.7 Checking the basic position of the shift
lever .......................................................... 118
16.8 Adjusting the basic position of the shift
lever ...................................................... 118
17 SERVICE WORK ON THE ENGINE ............................ 120
17.1 Changing the fuel screen ..................... 120
17.2 Checking the engine oil level ................... 121
17.3 Changing the engine oil and oil filter,
cleaning the oil screens ........................ 122
17.4 Adding engine oil...................................... 125
18 CLEANING, CARE..................................................... 126
18.1 Cleaning the motorcycle .......................... 126
19 STORAGE................................................................. 128
19.1 Storage...................................................... 128
19.2 Putting into operation after storage........ 129
20 TROUBLESHOOTING ............................................... 130
21 BLINK CODE............................................................. 132
22 TECHNICAL DATA.................................................... 134
22.1 Engine ....................................................... 134
22.2 Engine tightening torques........................ 134
22.3 Capacities.................................................. 136
22.3.1 Engine oil ............................................. 136
22.3.2 Coolant ................................................ 136
22.3.3 Fuel ...................................................... 136
22.4 Chassis ...................................................... 136
22.5 Electrical system....................................... 137
22.6 Tires .......................................................... 137
22.7 Fork........................................................... 138
22.7.1 MC 450F .............................................. 138
22.7.2 MC 450F TROY LEE DESIGNS............... 138
22.7.3 EX......................................................... 139
22.8 Shock absorber......................................... 139
22.8.1 MC 450F .............................................. 139
22.8.2 MC 450F TROY LEE DESIGNS............... 140
22.8.3 EX......................................................... 140
22.9 Chassis tightening torques....................... 141
23 SUBSTANCES........................................................... 144
24 AUXILIARY SUBSTANCES......................................... 146
25 STANDARDS ............................................................ 148
26 INDEX OF SPECIAL TERMS ...................................... 149
27 LIST OF ABBREVIATIONS......................................... 150
28 LIST OF SYMBOLS.................................................... 151
28.1 Yellow and orange symbols...................... 151
INDEX ............................................................................... 152

MEANS OF REPRESENTATION 1
5
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g., of a work step or a function).
Indicates an unexpected reaction (e.g., of a work step or a function).
Indicates work that requires expert knowledge and technical understanding. In the interest of your own
safety, have this work performed by an authorized GASGAS Motorcycles workshop. Your motorcycle will
be cared for there to the highest degree by specially trained experts using the special tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential reworking.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are
explained in the glossary.

2 SAFETY ADVICE
6
2.1 Use definition –intended use
(MC)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies
with the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
(EX)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies
with the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.
2.2 Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respec-
tive use.
2.3 Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction
and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the
relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do not
remove any information or warning labels. If they are missing, you or others may not recognize dangers and may
therefore be injured.
2.4 Degrees of risk and symbols
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
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

SAFETY ADVICE 2
7
2.5 Tampering warning
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.
2.6 Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
–Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
–Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
–Always make sure there is sufficient ventilation when running the engine.
–Use effective exhaust extraction when starting or 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.
Have malfunctions that impair safety immediately eliminated by an authorized GASGAS Motorcycles workshop.
Adhere to the information and warning labels on the vehicle.
2.7 Protective clothing
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 pro-
tectors on all rides.
–Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, GASGAS Motorcycles recommends that you only operate the vehicle while wearing pro-
tective clothing.

2 SAFETY ADVICE
8
2.8 Work rules
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.
Ambient temperature 20 °C (68 °F)
Ambient air pressure 1,013 mbar (14.69 psi)
Relative air humidity 60 ± 5 %
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.
2.9 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of
the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of
others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regula-
tions of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regu-
lations that pertain to the disposal of an end-of-life motorcycle. Your authorized GASGAS Motorcycles workshop will be glad
to advise you.
2.10 Owner's Manual
Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful infor-
mation and many tips on how to operate, handle, and service your motorcycle. This is the only way to find out how best to
customize the vehicle for your own use and how you can protect yourself from injury.
Tip
Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need to.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized
GASGAS Motorcycles dealer.
The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be down-
loaded again by the new owner.
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate.
The Owner's Manual is also available for download from your authorized GASGAS Motorcycles dealer and on the GAS-
GAS Motorcycles website. A printed copy can also be ordered from your authorized GASGAS Motorcycles dealer.
International GASGAS Motorcycles website: http://www.gasgas.com

IMPORTANT NOTES 3
9
3.1 Manufacturer warranty, implied warranty
The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and
confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary dam-
age caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2 Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by
GASGAS Motorcycles and have them installed by an authorized GASGAS Motorcycles workshop. GASGAS Motorcycles
accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized
GASGAS Motorcycles dealer will be glad to advise you.
The latest news GASGAS Technical Accessories on your vehicle can be found on the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the
engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to
damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces, can result in significantly
increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it
may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always neces-
sary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized GASGAS Motorcycles dealer will be happy to answer any questions you may have regarding your vehicle
and GASGAS Motorcycles.
A list of authorized GASGAS Motorcycles dealers can be found on the GASGAS Motorcycles website.
International GASGAS Motorcycles website: http://www.gasgas.com

4 VIEW OF VEHICLE
10
4.1 View of vehicle, front left (example)
A00873-10
1Hand brake lever ( p. 14)
2Clutch lever ( p. 14)
3Fuel tank filler cap
4Air filter box cover
5Cold start button ( p. 18)
6Engine number ( p. 12)
7Shift lever ( p. 19)

VIEW OF VEHICLE 4
11
4.2 View of vehicle, rear right (example)
A00872-10
1Shock absorber compression adjuster
2Stop button ( p. 14)
3Start button ( p. 15)
4Throttle grip ( p. 14)
5Vehicle identification number ( p. 12)
6Type label ( p. 12)
6Fork article number ( p. 12)
7Idle speed adjusting screw ( p. 19)
8Foot brake lever ( p. 20)
9Engine oil level viewer
bk Shock absorber rebound adjuster

5 SERIAL NUMBERS
12
5.1 Vehicle identification number
401945-10
The vehicle identification number 1is stamped on the right side of the
steering head.
5.2 Type label
401946-10
The type label 1is fixed to the front of the steering head.
5.3 Engine number
H00940-10
The engine number 1is stamped on the left side of the engine.
5.4 Fork article number
401947-10
The fork article number 1is stamped on the inside of the axle clamp.

SERIAL NUMBERS 5
13
5.5 Shock absorber article number
401948-10
Shock absorber article number 1is stamped on the top of the shock
absorber above the adjusting ring towards the engine side.

6 CONTROLS
14
6.1 Clutch lever
A00795-10
The clutch lever 1is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
6.2 Hand brake lever
A00798-10
Hand brake lever 1is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3 Throttle grip
A00759-10
The throttle grip 1is fitted on the right side of the handlebar.
6.4 Stop button
A00796-10
(All standard models)
The stop button 1is fitted on the left side of the handlebar.

CONTROLS 6
15
S05124-10
(MC 450F TROY LEE DESIGNS)
The stop button 1is 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 inter-
rupted, a running engine stops, and a non-running engine will not
start.
6.5 Start button
A00759-11
Start button 1is 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.
6.6 Combination switch (MC 450F TROY LEE DESIGNS)
H02887-01
The combination switch is fitted on the left side of the handlebar.
Possible states
1STANDARD –STANDARD mapping is activated when LED 1
lights up.
1 TC STANDARD with TC –STANDARD mapping with traction
control is activated when LED 1and TC light up.
2ADVANCED –ADVANCED mapping is activated, when LED 2
lights up.
2 TC ADVANCED with TC –ADVANCED mapping with traction
control is activated when LED 2and TC light up.
The engine characteristic can be changed using button MAP on the com-
bination switch.
The launch control and the traction control can also be activated using
the combination switch.

6 CONTROLS
16
6.7 Overview of indicator lamps
A00760-10
Possible states
Malfunction indicator lamp lights up/flashes orange –The
OBD has detected a malfunction in the vehicle electronics.
(EX)
Fuel level warning lamp lights up orange –The fuel
level has reached the reserve mark.
6.8 Service hour counter (MC 450F TROY LEE DESIGNS)
S05125-10
The service hour counter 1is fitted in front of the handlebar.
It shows the total number of service hours of the engine.
The service hour counter begins counting when the engine is started and
stops when the engine is switched off.
Info
The value indicated by the service hour counter cannot be
cleared or adjusted.
6.9 Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
–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.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to enter the groundwater, the soil, or the sewage system.

CONTROLS 6
17
A00769-10
(MC)
–Turn fuel tank filler cap 1counterclockwise and lift it off.
A00761-10
(EX)
–Press release button 1, turn the fuel tank filler cap counter-
clockwise, and lift it off.
6.10 Closing the fuel tank filler cap
A00771-10
(MC)
–Mount fuel tank filler cap 1and turn it clockwise until the fuel
tank is tightly closed.
Info
Route fuel tank breather hose 2without kinks.
A00770-10
(EX)
–Mount the fuel tank filler cap and turn it clockwise until release
button 1engages.
Info
Route fuel tank breather hose 2without kinks.

6 CONTROLS
18
6.11 Cold start button
A00882-10
(MC)
The cold start button 1is fitted to the bottom of the throttle valve
body.
A00883-10
(EX)
The cold start button 1is fitted to the bottom of the throttle valve
body.
The electronic fuel injection system extends the injection time if the
engine is cold and the ambient temperature is low. To help the engine
burn the increased fuel quantity, it must be supplied with additional
oxygen by pushing the cold start button.
After briefly opening up the throttle and then releasing the throttle grip
again, or turning the throttle grip towards the front, the cold start but-
ton returns to its original position.
Info
Check whether the cold start button has returned to its basic
position.
Possible states
• The cold start button is activated –The cold start button is pushed
in all the way.
• The cold start button is deactivated –The cold start button is in its
basic position.