GAS GAS TXT 2018 Series Page 3 Workshop Manual Download

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Workshop manual

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introduction

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leGAl noticeS

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noticeS And wArninGS

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SAfety ruleS

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mAintenAnce

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recommended “work method”

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VEhiclE / EnginE idEnTificaTion...................................................................................................................................8

tiGhteninG torque

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SPeciAl toolS

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mAintenAnce

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mAintenAnce ProGrAmme

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Periodic inSPection

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cArburettor diSASSembly And inSPection

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reed block diSASSembly And inSPection

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exhAuSt SyStem diSASSembly And inSPection

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cylinder heAd diSASSembly And inSPection

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cylinder And PiSton diSASSembly And inSPection

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StArter SyStem diSASSembly And inSPection

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clutch ASSembly diSASSembly And inSPection

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crAnkcASe diSASSembly And inSPection

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mAintenAnce of the frAme

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electricAl diAGrAmS

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Contents

Summary of Contents for TXT 2018 Series

Page 1: ...Trial 80 125 250 280 300cc txt SERIES 2018 Workshop Manual...

Page 2: ...in part is prohibited without the written permission of the copyright holder The company has the right without prior notice to change the technical content of the products The models in the images may...

Page 3: ...ogramme 13 Periodic inspection 14 Carburettor disassembly and inspection 18 Reed block disassembly and inspection 24 Exhaust system disassembly and inspection 25 Cylinder head disassembly and inspecti...

Page 4: ...Workshop manual 4 General information...

Page 5: ...ch repair process By choosing the new GG you have just joined the great GG team and as a user of the number one brand of off road motorcycles you deserve the special care that we would like to offer y...

Page 6: ...with brake fluid Use gloves if possible as contact of brake fluid with the skin is not recommended Make sure that coolant does not spill onto hot parts as this produces an invisible flame that cannot...

Page 7: ...ngine All surfaces that support gaskets seals and O rings should be cleaned After removing them replace all sealing spacer washers and external tooth lock washers Fit bearings and seals in such a way...

Page 8: ...lumn A You can identify your specific engine model by means of a code located on the front of the engine below the exhaust elbow as shown in the image 1 Always quote the engine serial number when orde...

Page 9: ...REW Rear brake caliper guide M8 25 SCREW Rear brake caliper retainer M6 12 SCREW Stand guide bushing M8 25 SCREW Stand bottom M8 25 SCREW Stand int swinging arm M6 12 SCREW Front brake pump clamp M5 6...

Page 10: ...Workshop manual 10 SPECIAL TOOLS...

Page 11: ...Magneto flywheel puller Ref MT280234045 Primary transmission sprocket puller Ref MT280250006 Tool set for 250cc 280cc 300cc engines Ref 865207 Primary sprocket puller Ref MT95005GG CHA 1 Primary nut...

Page 12: ...Workshop manual 12 maintenance...

Page 13: ...lant Every race 1 year Cooling system If is necessary Decarbonisation of the cylinder head Exhaust port 60 hours 60 hours Piston 60 hours 1 year 180 h Piston rings 60 hours Every six months Cylinder 6...

Page 14: ...mal colour is light brown Clean Spark plug Clean spark plug with spark plug cleaner or steel brush Measure Play between electrodes A with feeler gauge Out of specification Adjust play Play between ele...

Page 15: ...ngine causing excessive wear and damage Inspect it periodically Clean if necessary Clean the filter in a ventilated area and make sure that there are no sparks or flames near the work place including...

Page 16: ...rod arrow completely Remove the inner visor to access the filter Clean inside the filter box with a damp cloth Remove the filter by unscrewing the bar 1 Remove the cage from the air filter 2 Clean the...

Page 17: ...lat surface NOTE MAKE SURE THAT THE MOTORCYCLE IS PARALLEL TO THE GROUND TO ENSURE CORRECT CHECKING OF THE OIL LEVEL Checking the oil level 1 If the motorcycle has just been used wait a few minutes 2...

Page 18: ...ettor disassembly and inspection CARBURETTOR Disconnect the fuel line and fuel tap and remove the carburettor Loosen securing clamps 1 and 2 of the carburettor from the inlet and air filter nozzles Re...

Page 19: ...me adjustment screw compensator from the low speed idle circuit 2 check its position by counting the necessary turns to screw it to the stop without forcing it Note down this measurement and remove it...

Page 20: ...s total surface area Thoroughly clean all of the components of the carburettor with solvent take care not to damage the carburettor float chamber gasket or the cold start piston valve O ring With comp...

Page 21: ...reme weather conditions Replace the conical dosing needle if there is any damage to its circumference Check that there are no scratches on the conical tip of the minimum circuit air adjustment screw a...

Page 22: ...obtained Remove the foam from the air filter wash in a mixture of soap and water drain and dry completely then soak with special filter oil and reinsert it Adjust the idle speed following the procedur...

Page 23: ...ube Throttle valve 3 5 Air screw 1v 1 4v from closed Float level Competition 250 cc Type of carburettor Dell Orto PHBL26BS KEHIN PWK28 Main jet 120 125 Idle jet 35 45 Needle D36 JJH Needle position 3r...

Page 24: ...e securing screws after which you can release the reed valve Check that the reed petals are not cracked deformed or broken If they are replace them Remove the fixing screws of the opening limiter and...

Page 25: ...r structure of the motorcycle by unscrewing the bolts that hold it Disconnect the clamp that secures the air filter to the carburettor Remove the filter box structure by disconnecting the electrical w...

Page 26: ...that hold the exhaust elbow to the cylinder Once the previous step has been carried out release the exhaust elbow from the muffler by pulling it as shown in the photograph Then remove the muffler Exha...

Page 27: ...s it at the top as shown in the image Continue unscrewing the upper bolt from the rear brake pump to release the muffler from the bottom Then extract the screw from the shock absorber that secures the...

Page 28: ...e frame Once the exhaust assembly has been removed from the motorcycle check that the system s gaskets and couplings are in good condition to prevent leaks Also check the exhaust system for any deform...

Page 29: ...with a nylon hammer carefully tap the metal part downwards as shown in the photograph Once the back part of the muffler has been removed from the exhaust system the fibre can be extracted Replace the...

Page 30: ...Workshop manual 30 Cylinder head disassembly and inspection...

Page 31: ...between the cylinder head and radiator Disconnect the high voltage cable from the spark plug cap and remove it First loosen and then diagonally remove the 6 M6 screws and remove the cylinder head cove...

Page 32: ...r Maximum warpage 0 05 mm CYLINDER AND PISTON Drain the coolant from the engine Remove the cylinder head cover from the cylinder head Release the cylinder by unscrewing the 4 nuts that secure it as sh...

Page 33: ...crankcase to prevent objects from accidentally falling inside Remove the circlips from the pin and then continue with the pin piston and connecting rod end bearing If it is necessary to push the pin...

Page 34: ...n of the connecting rod end If there is damage to the surface from contact with the needle roller bearing replace it Visually check the condition of the needle roller bearing of the connecting rod end...

Page 35: ...uge Check the cylinder s degree of wear with an alesometer Calibrate it beforehand using the dimensions contained in the cylinder piston families table Carry out the check on two axes and at three hei...

Page 36: ...080 250cc MODEL FAMILY CYLINDER PISTON CLEARANCE CLEARANCE ASSEMBLY MAXIMUM 72 510 0 005 72 460 0 005 0 050 0 100 0 080 72 520 0 005 72 470 0 005 0 050 0 100 0 080 72 530 0 005 72 480 0 005 0 050 0 1...

Page 37: ...Workshop manual 37 Starter system disassembly and inspection For models with electric starter...

Page 38: ...nd side of the engine To release the magneto flywheel cover remove the screws marked with arrows in the photograph Unscrew the bolt located in the centre of the flywheel Once the bolt is removed you c...

Page 39: ...the extractor a spanner and a ratchet unscrew the central nut and release the starter sprocket and ignition rotor To remove the stator coil assembly loosen and remove the screws marked with arrows in...

Page 40: ...r proper operation and in the event of a fault replace altogether the component where the problem is located Reassemble the assembly paying special attention to the condition of the cot ter pin on the...

Page 41: ...2 2 2 2 Clutch assembly disassembly and inspection CLUTCH ASSEMBLY Drain the coolant from the engine Drain the transmission oil by removing the two plugs clutch semi crankcase and crankcase base Remov...

Page 42: ...ovide access to the assembly of primary transmission elements and clutch Remove the clutch assembly by removing the central nut that secures the clutch 3 Remove the driven clutch plate Pay attention t...

Page 43: ...e coloured or is deformed or its external crenellation is damaged Check the clutch discs for warpage max 0 05mm using a gauge on a flat sur face Visually check the teeth If there are any signs of ther...

Page 44: ...ylinder and piston Remove the magneto flywheel alternator Extract the bearing from the clutch sprocket remove the circlip and then the needle bearing Once the needle bearings have been extracted we wi...

Page 45: ...te kick start sprocket assembly 1 release the seeger 2 and once the washer has been removed extract the kick start sprocket assembly Once the above operation has been carried out you can remove the be...

Page 46: ...ion To be able to remove the sprocket 2 you must first extract the seeger 1 Once the above operation has been carried out you can remove the sprocket using puller 1 Ref MT280250006 This is how it shou...

Page 47: ...the positioner and the selector shaft secured by means of a seeger and washer 2 Once the above operation has been carried out you can remove the selector spring Once all of the above disassembly steps...

Page 48: ...move the 9 screws that secure the left hand crankcase Pay special attention to screw 5 It incorporates a copper washer This is how it should appear after the left hand crankcase has been removed You c...

Page 49: ...rkshop manual 49 Crankcase disassembly and inspection Remove the desmodromic Pay special attention to possible wear of the fork If it shows wear replace it To reassemble repeat the same steps in rever...

Page 50: ...ake pads to be fitted Check the brake fluid level in the reservoir as this operation causes the level to rise Remove pad pins 1 and brake pads 5 Clean the inside of the brake caliper especially around...

Page 51: ...4 Caliper piston Remove the rear wheel see pp 54 55 Push piston 4 completely inwards to enable the new brake pads to be fitted Check the brake fluid level in the reservoir as this operation causes th...

Page 52: ...and secure them with the pad pins Fit the brake caliper bracket aligning its slot with the swinging arm tab Fit the rear wheel see pp 54 55 Engage the brake pedal to seat the caliper pistons against...

Page 53: ...making fitting difficult WARNING Dirt on the brake disc or pad reduces braking ability which could lead to serious injury or death Throw away the dirty pads and clean the dirty discs with a high quali...

Page 54: ...e axle clamping screw to the specified torque Tightening torque 23Nm 2 REMOVING THE REAR WHEEL Lift the rear wheel off the ground and rest it on a block or maintenance stand positioned under the engin...

Page 55: ...left hand adjuster side bushing and wheel Apply grease to the axle nut thread and seating surfaces Fit the chain s right hand adjuster and axle nut Fit the transmission chain If the master link retai...

Page 56: ...ORK Dust covers The table below shows the cleaning intervals for the fork dust covers Failure to regularly clean the dust covers will result in dirt entering the fork This dirt can compromise the smoo...

Page 57: ...e dust cover seating and upper edge of the oil seal Move the dust cover to one side and insert the cloth Turn the dust cover until all traces of dirt inside the sealing lips are removed Lubricate the...

Page 58: ...or too long without changing it leads to reduced fork performance and oil thickening which can cause leaks Proceed as follows Perform a general cleaning of the suspension Protect the surface of the pi...

Page 59: ...lace the two components in the same clean place Hold rod E to prevent it from falling as shown in the figure Pour the oil into a tray at the same time move rod E back and forth as shown in the figure...

Page 60: ...ssion unit inwards and remove the seeger from its housing Remove the compression assembly Place the cartridge in an oil collection device and have the rod inserted in the cartridge tube for complete d...

Page 61: ...bottom of the cartridge Lift the edge of the dust cover and remove it from the seating of the bar Remove the seeger from its housing Secure the tube at the top to protect it as shown in the figure whi...

Page 62: ...oil seal Squeeze the pipe in a vice casing X checking that the non discharge side is against bushings B With firm blows of the outer tube insert bushing B into its place Check that it is completely i...

Page 63: ...t the oil seal into the tube with the spring facing up and close the tube in a vice with the help of casing X with the drainage towards the seal With moderate movements of the outer tube insert oil se...

Page 64: ...the dust cover spreading the grease by tuning it from right to left Insert the dust cover into place using the flat side of a screwdriver to help position it Insert the cartridge into the tube until...

Page 65: ...vice making sure not to distort it and pro tecting it with a cloth Insert an axle into the wheel pin hole and fix it with a tightening torque of 23 5 25 5 Nm Place the suspension bar in a vertical pos...

Page 66: ...proper level see table below from the top edge of the pipe keep the tube and rod at the end of the stroke Screw the cover completely by hand after having the lock nut in the fully un screwed position...

Page 67: ...oo long without changing it leads to reduced fork performance and oil thickening which can cause leaks Proceed as follows Perform a general cleaning of the suspension Protect the surface of the pipe b...

Page 68: ...Maintenance of the frame Completely remove cover A and put it in a clean place Remove tapered spacer B and put it in a clean place Remove spacer C and put it in a clean place Remove washer D and put i...

Page 69: ...owly extract spring E Wipe off oil from the spring with a cloth Put all parts in a clean place Pour the oil into a container as shown in the figure To prevent damage to the environment collect the use...

Page 70: ...frame Squeeze the two clamps in a vice protecting them with a cloth Unscrew the pump nut with a 12 mm spanner Remove the screw and oil seal Remove the complete pump unit Turn the fork the opposite way...

Page 71: ...from the seating of the bar Remove the seeger from its housing Secure the tube at the top to protect it as shown in the figure while deliver ing firm blows to the bar Remove the oil seal and outer tub...

Page 72: ...vice casing X checking that the non discharge side is against bushings B With firm blows of the outer tube insert bushing B into its place Check that it is completely inserted Insert ring nut C agains...

Page 73: ...be in a vice with the help of casing X with the drainage towards the seal With moderate movements of the outer tube insert oil seal D into its place This operation does not require much force Avoid hi...

Page 74: ...left Insert the dust cover into place using the flat side of a screwdriver to help position it Insert the end of the cone and then the cartridge into the outer tube Squeeze the outer tube in a vice p...

Page 75: ...ral times and position it at the end of the stop Bring the oil up to the proper level see table below from the edge to the top of the tube Following the sequence shown in the photographs below insert...

Page 76: ...Workshop manual 76 Maintenance of the frame Completely tighten the tube cover using a 17 mm spanner with a tightening torque of 11 7 13 7 Nm...

Page 77: ...of 9 mm of preloading see spring and preloading table Preloading is the difference in length in mm between a spring when it is ten sioned and when it is at rest The rebound or extension is adjusted wi...

Page 78: ...Workshop manual 78 Electrical diagrams...

Page 79: ...Workshop manual 79 TXT approved electrical system...

Page 80: ...Workshop manual 80 TXT ignition electrical system...

Page 81: ...Workshop manual 81 CONTACT approved electrical system...

Page 82: ...Workshop manual 82 CONTACT ignition electrical system...

Page 83: ...Workshop manual 83 TXT 80 School electrical system...

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GAS GAS TXT 2018 Series, Workshop Manual

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