GAS GAS TXT Racing 125 2020 Page 58 Owner'S Manual Download | Manualshive

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11 SERVICE WORK ON THE CHASSIS

56

11.31

Adjusting the chain tension

Warning

Danger of accidents

Incorrect chain tension damages components and results in accidents.

If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bear-
ings wear more quickly. Some components may break if overloaded.

If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel
locks or the engine will be damaged.

–

Check the chain tension regularly.

–

Set the chain tension in accordance with the specification.

Preparatory work

–

Raise the motorcycle with a lift stand. (

–

Check the chain tension. (

E01384-12

Main work

–

Loosen screw

1

.

E01388-11

–

Adjust the chain tension by turning eccentrics

2

left and right.

Guideline

Chain tension

10 … 20 mm (0.39 … 0.79 in)

Turn eccentrics left and right so that the eccentrics are on the
same detent. The rear wheel is then correctly aligned.

–

Tighten screw

1

.

Guideline

Screw, rear wheel spin-
dle

M10

50 Nm (36.9 lbf ft)

Finishing work

–

Remove the motorcycle from the lift stand. (

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Summary of Contents for TXT Racing 125 2020

Page 1: ...OWNER S MANUAL 2020 TXT RACING 125 TXT RACING 250 TXT RACING 280 TXT RACING 300 TXT GP 125 TXT GP 250 TXT GP 280 TXT GP 300 Art no 3215003en ...

Page 2: ......

Page 3: ...ment 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 illustrations and descriptions as well as misprints and other errors The models portrayed partly contain special equipment that does not belong to the reg...

Page 4: ... 16 Shift lever 17 6 17 Kick starter lever 17 6 18 Foot brake lever 17 6 19 Side stand 18 6 20 Locking the steering Option Homologized 18 6 21 Unlocking the steering Option Homologized 18 6 22 Opening the fuel tank filler cap 19 6 23 Closing the fuel tank filler cap 19 6 24 Combination instrument Option Homologized 20 7 PREPARING FOR USE 21 7 1 Advice on preparing for first use 21 7 2 Running in t...

Page 5: ... 1 Checking the free travel of the hand brake lever 61 12 2 Adjusting the free travel of the hand brake lever 61 12 3 Adjusting the basic position of the hand brake lever 61 12 4 Removing front brake disc guard 62 12 5 Installing the front brake disc guard 62 12 6 Removing front brake caliper 62 12 7 Installing the front brake caliper 62 12 8 Checking the front brake fluid level 63 12 9 Adding fro...

Page 6: ...OR 102 24 CAPACITIES 103 24 1 Gear oil 103 24 2 Coolant 103 24 3 Fuel 103 25 CHASSIS 104 26 TIRES 105 27 FORK 106 27 1 All GP models 106 27 2 All RACING models 106 28 SHOCK ABSORBER 107 28 1 TXT GP 125 107 28 2 TXT GP 250 280 300 107 28 3 All RACING models 107 29 CHASSIS TIGHTENING TORQUES 108 30 SUBSTANCES 110 31 AUXILIARY SUBSTANCES 112 32 STANDARDS 114 33 LIST OF ABBREVIATIONS 115 INDEX 116 ...

Page 7: ...pecially trained experts using the spe cial 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 i...

Page 8: ... 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 loca...

Page 9: ...ger 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 sy...

Page 10: ...nflicts 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 used components and if applicable the end of life motor cycle comply with the respective laws and regulations of the respective country 2 10 Owner s Manual It is im...

Page 11: ... 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 and muddy surfaces...

Page 12: ...0 1 Hand brake lever p 13 2 Clutch lever p 13 3 Fuel tank filler cap 4 Air filter box cover 5 Shock absorber rebound adjustment 6 Choke button p 16 Option Not homologized 7 Shift lever p 17 8 Fuel tap p 16 9 Engine number p 12 bk Light switch p 14 Option Not homologized ...

Page 13: ...325 10 1 Magnetic switch p 13 Option Not homologized 2 Throttle grip p 13 3 Vehicle identification number p 12 3 Type label p 12 4 Map switch p 15 Option Not homologized 5 Fork article number p 12 6 Kick starter lever p 17 7 Foot brake lever p 17 8 Side stand p 18 ...

Page 14: ... on the right side of the steering head 5 2 Type label 401946 10 Type label 1is fixed to the front of the steering head 5 3 Engine number E01326 10 The engine number 1is stamped onto the engine case at the top 5 4 Fork article number 401947 10 The fork article number 1is stamped on the inside of the axle clamp ...

Page 15: ...e is engaged using the hand brake lever 6 3 Throttle grip E01329 11 The throttle grip 1is fitted on the right side of the handlebar 6 4 Magnetic switch Option Not homologized E01328 11 The holder for the magnetic switch 1is located on the left side of the handlebar Possible states Magnetic switch mounted When the magnetic switch is mounted the vehicle can be started and ridden Magnetic switch remo...

Page 16: ...on In this position the ignition circuit is closed and the engine can be started The switch off button is pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start 6 6 Light switch Option Not homologized E01330 10 The light switch 1is mounted on the frame on the left behind the steering head Possible states Light on Light switch is ...

Page 17: ... the steering head Possible states Map switch tilted backwards The ignition timing map Performance is active in this position Map switch tilted forwards The ignition timing map Soft is active in this position The engine characteristic can be altered with the map switch Info The map switch has no function in the homologated restricted condition of the motorcycle 6 11 Malfunction indicator lamp Opti...

Page 18: ...01327 10 Choke 1is fitted on the left side of the carburetor Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel This results in a richer fuel air mix ture which is needed for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pulled out to the stop Ch...

Page 19: ...een the first and second gears 6 17 Kick starter lever 401954 10 Kick starter lever 1is fitted on the right side of the engine The kick starter lever can be swiveled Info Before riding swing the kick starter lever inwards towards the engine 6 18 Foot brake lever 401956 10 Foot brake lever 1is located in front of the right footrest The rear brake is engaged with the foot brake lever ...

Page 20: ...ert 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 Info Never leave the key for the steering lock in the steering lock 6 21 Unlocking the steering Option Homologized 400731 01 Insert the key for the steering lock into the steering lock turn it to the left pull it out...

Page 21: ...l 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 environ...

Page 22: ...r The area Adisplays the total distance traveled in kilometers or miles The area Bshows the current speed in km h or mph The speedometer is updated every 0 5 seconds Info The displayed units kilometers km h or miles mph cannot be changed and depend on the country version Nothing can be cleared or adjusted on the combination instru ment ...

Page 23: ... speed to the road conditions and your riding ability Warning Danger of accidents The vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents The brake system fails in the event of overheating If the foot brake lever is not released the brake linings drag continuously Take your foot off the foot brake lever when you are not braking Warning Danger of acc...

Page 24: ...ceed the specified engine performance Guideline Maximum engine performance During the first three operating hours 70 During the first five operating hours 100 Avoid fully opening the throttle Check the idle speed regularly Guideline Idle speed 900 1 100 rpm Info The idle speed may change during the run in time If the idle speed changes Carburetor adjust the idle speed p 89 7 3 Preparing the vehicl...

Page 25: ...n the dust boots of the fork legs p 38 Check the air filter Check the settings of all controls and ensure that they can be oper ated smoothly Check all screws nuts and hose clips regularly for tightness Check the fuel level 8 2 Starting 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 ...

Page 26: ...rkshop First gear is used for starting off and for steep inclines Shift into a higher gear when conditions allow incline road situation etc To do so release the throttle while simulta neously pulling the clutch lever shift into the next gear release the clutch lever and open the throttle If the choke function has been activated deactivate it after the engine has warmed up After reaching maximum sp...

Page 27: ... unauthorized persons 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 Note Material damage The vehicle may be damaged by incorrect procedure ...

Page 28: ...he 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 swal...

Page 29: ...ank with fuel up to a maximum of level A Guideline Dimension A 35 mm 1 38 in Total fuel tank capac ity approx 2 4 l 2 5 qt Super unleaded 98 octane mixed with 2 stroke engine oil 1 67 p 111 Engine oil 2 stroke p 110 Close the fuel tank filler cap p 19 ...

Page 30: ...vel p 69 Check the free travel of the foot brake lever p 68 Check the frame p 57 Check the link fork p 57 Check the fork bearing for play Check the heim joint on the shock absorber for play Check the shock absorber linkage Check the tire condition p 78 Check the tire pressure p 79 Check the wheel bearing for play Check the wheel hubs Check the rim run out Check the spoke tension p 79 Check the cha...

Page 31: ...and take for a test ride Make a service entry in GASGAS Motorcycles Dealer net Periodic interval 9 3 Recommended work Every 40 operating hours when used for motorsports Every 120 operating hours Every 60 operating hours every 48 months every 12 months Change the front brake fluid Change the rear brake fluid Change the hydraulic clutch fluid p 59 Lubricate the steering head bearing p 45 Check adjus...

Page 32: ...usted 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 10 2 Adjusting the rebound damping of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen P...

Page 33: ...gen Please follow the description provided Your authorized GASGAS Motorcycles workshop will be glad to help E01746 10 Turn adjusting screw 1clockwise up to the last perceptible click Turn counterclockwise by the appropriate number of clicks Guideline Compression damping TXT GP 125 Standard 15 clicks Compression damping TXT GP 250 280 300 Standard 15 clicks Info Turn clockwise to increase damping t...

Page 34: ...e shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly The shock absorber is filled with highly compressed nitrogen Please follow the description provided Your authorized GASGAS Motorcycles workshop will be glad to help Info Note the current adjustment before changing the spring preload e g measure the spring length Info D...

Page 35: ...tance between the rear axle and the rear fender using the sag gage Note the value as dimension C Info The riding sag is the difference between measurements A and C Check riding sag Guideline Riding sag All RACING models 70 75 mm 2 76 2 95 in Riding sag TXT GP 125 70 75 mm 2 76 2 95 in Riding sag TXT GP 250 280 300 70 75 mm 2 76 2 95 in If the riding sag differs from the specified measurement Adjus...

Page 36: ...in Weight of rider 80 85 kg 176 187 lb 70 N mm 400 lb in Weight of rider 85 100 kg 187 220 lb 72 5 N mm 414 lb in Spring rate TXT GP 250 280 300 Weight of rider 55 70 kg 121 154 lb 67 5 N mm 385 4 lb in Weight of rider 70 80 kg 154 176 lb 70 N mm 400 lb in Weight of rider 80 85 kg 176 187 lb 72 5 N mm 414 lb in Weight of rider 85 100 kg 187 220 lb 75 N mm 428 lb in Finishing work Install the shock...

Page 37: ...f the fork E01336 10 Turn adjusting screw 1clockwise all the way Info Adjusting screw 1is located at the upper end of the right fork leg Turn counterclockwise by the appropriate number of clicks Guideline Rebound damping All RACING models Standard 19 clicks Rebound damping All GP models Standard 19 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 11 Adjusti...

Page 38: ...wise as far as it will go Info The adjusting screw 1is located on the underside of the left fork leg Turn counterclockwise by the appropriate number of clicks Guideline Fluid barrier All RACING models Standard 2 5 turns Fluid barrier All GP models Standard 2 5 turns Info Turning it counterclockwise increases the damping of the fluid barrier the end position damping and the puncture resistance of t...

Page 39: ...ting screw 1is located at the lower end of the right fork leg Turn counterclockwise by the number of rotations corresponding to the fork type Guideline Compression damping Standard 1 75 turns Info Turn clockwise to increase damping turn counterclockwise to reduce damping during compression ...

Page 40: ...rocedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the vehicle Park the vehicle on a firm and level surface Ensure that nobody sits on the vehicle when the vehicle is parked on a stand E01323 01 Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle...

Page 41: ...y work Raise the motorcycle with a lift stand p 38 Remove the front wheel p 75 Remove front brake disc guard p 62 Remove front brake caliper p 62 Remove the front fender p 46 Remove the headlight mask p 45 E01412 10 Main work Loosen screws 1 Remove the fork leg on the left while carefully sliding the brake line guide 2from the fork leg Loosen screws 3 Remove the right fork leg 11 5 Installing the ...

Page 42: ...front wheel p 75 Install the front brake caliper p 62 Install the brake disc guard at the front p 62 Install the front fender p 46 Install the headlight mask p 46 11 6 Removing the lower triple clamp Preparatory work Raise the motorcycle with a lift stand p 38 Remove the front wheel p 75 Remove front brake disc guard p 62 Remove front brake caliper p 62 Remove the front fender p 46 Remove the head...

Page 43: ...ve screw 3 Remove steering head nut 4and carefully remove upper triple clamp E01351 10 Remove adjusting ring 5 E01350 10 Remove the lower triple clamp downwards from the steering head Remove protection cap 6and remove upper tapered roller bear ing 7 ...

Page 44: ...nt and tighten adjusting ring 3until there is no play in the steering head bearing Position the upper triple clamp E01349 12 Mount steering head nut 4 but do not tighten yet Install the fork legs p 39 E01413 10 Tighten steering head nut 4 Guideline Nut steering head M20 50 Nm 36 9 lbf ft Mount and tighten screw 5 Guideline Screw steering stem M6 12 Nm 8 9 lbf ft E01348 11 Position the handlebars i...

Page 45: ...and p 38 H01167 01 Main work 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 p 43 Move the handlebar to and fro over the entire steering range It must be possible to move the handlebar easily over the entire steering...

Page 46: ...e Do not kink the cables and lines E01349 10 Remove screw 3 Remove the steering head screw 4 E01353 10 Tighten adjusting ring 5until there is no play in the steering head bearing E01349 10 Using a plastic hammer tap lightly on the upper triple clamp to avoid stresses Tighten the steering head screw 4 Guideline Nut steering head M20 50 Nm 36 9 lbf ft Tighten screw 3 Guideline Screw steering stem M6...

Page 47: ...nd p 38 11 10 Lubricating the steering head bearing H02387 01 Remove the lower triple clamp p 40 Install the lower triple clamp p 42 Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp 11 11 Removing the headlight mask E01344 12 Remove cable tie s 1 Remove the headlight mask towards the front and hang it carefully to the side...

Page 48: ...ask in area A E01344 12 Secure the headlight mask to the fork legs with cable ties 1 11 13 Removing the front fender E01345 10 Remove screws 1and take off the fender 11 14 Installing the front fender E01345 10 Position the front fender Mount and tighten screws 1 Guideline Front fender M6 10 Nm 7 4 lbf ft ...

Page 49: ...cure it Remove screw 3 Remove the shock absorber from the top carefully 11 16 Installing the shock absorber E01393 11 Main work Position the shock absorber carefully from above Mount and tighten screw 1 Guideline Screw bottom shock absorber M10 50 Nm 36 9 lbf ft Push the foot brake cylinder 2onto the push rod 3 Unlock and lower the rear wheel Finishing work Install the main silencer p 52 Install t...

Page 50: ...f the carburetor Disconnect plug in connector 3 Lift the air filter box off the frame 11 18 Installing the air filter box E01356 11 Join plug in connector 1 Carefully position the air filter box on the frame and slide the inlet sleeve onto the carburetor E01354 10 Mount and tighten screws 2 Guideline Screw air filter box M6 8 Nm 5 9 lbf ft E01355 11 Position and tighten hose clamp 3 ...

Page 51: ... filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine Dust and dirt will enter the engine without an air filter Never start to use the vehicle without an air filter Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli...

Page 52: ...e E01358 11 Position the air filter cover in the air filter box mount screw 2 and tighten Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the air filter box cover p 49 11 23 Cleaning the air filter and air filter box Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly a...

Page 53: ...alve for draining liquids Finishing work Install the air filter p 50 Install the air filter box cover p 49 11 24 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down before performing any work on the vehicle Preparatory work Turn tap handle of the fuel tap to the OFF position Remove the fuel tank p 52 R...

Page 54: ... M6 12 Nm 8 9 lbf ft Tighten screws 4and 5 Guideline Screw foot brake cylin der M6 10 Nm 7 4 lbf ft E01379 11 Tighten screws 6 Guideline Screw manifold M8 12 Nm 8 9 lbf ft Finishing work Install the air filter box p 48 Install the fuel tank p 53 11 26 Removing the fuel tank Danger Fire hazard Fuel is highly flammable The fuel in the fuel tank expands when warm and can escape if overfilled Do not f...

Page 55: ...y work Turn tap handle of the fuel tap to the OFF position E01362 10 Main work Push hose clamp 1toward the rear and pull off the fuel hose Info Remaining fuel may flow out of the fuel hose E01361 10 Pull off air release hose 2 Remove screw 3 Lift the fuel tank at the front and remove it from the frame 11 27 Installing the fuel tank Danger Fire hazard Fuel is highly flammable The fuel in the fuel t...

Page 56: ...nt and tighten screw 1 Guideline Screw fuel tank fasten ing M6 8 Nm 5 9 lbf ft Attach vent hose 2 Guideline Route vent hose free of kinks E01362 11 Attach fuel hose and secure with hose clamp 3 11 28 Checking the chain for dirt 400678 01 Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain p 54 11 29 Cleaning the chain Warning Danger of accidents Lubricants on th...

Page 57: ...mponents and results in accidents If the chain is tensioned too much the chain engine sprocket rear sprocket transmission and rear wheel bear ings wear more quickly Some components may break if overloaded If the chain is too loose the chain may fall off the engine sprocket or the rear sprocket As a result the rear wheel locks or the engine will be damaged Check the chain tension regularly Set the ...

Page 58: ...he rear wheel locks or the engine will be damaged Check the chain tension regularly Set the chain tension in accordance with the specification Preparatory work Raise the motorcycle with a lift stand p 38 Check the chain tension p 55 E01384 12 Main work Loosen screw 1 E01388 11 Adjust the chain tension by turning eccentrics 2left and right Guideline Chain tension 10 20 mm 0 39 0 79 in Turn eccentri...

Page 59: ...nk fork shows signs of damage cracking or deformation Change the link fork Info Always replace a damaged link fork GASGAS Motor cycles does not permit repairing link forks 11 34 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage wear and looseness If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 112 11...

Page 60: ... 11 Main work Adjust the basic position of the clutch lever to your hand size by turning adjusting screw 1 Info 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 Do not use force Do not make any adjustm...

Page 61: ...ews 1 11 39 Changing the hydraulic clutch fluid Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Do not use brake fluid E01364 10 Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horizontal position Remove screws 1 T...

Page 62: ... bubbles Occasionally extract the fluid from the master cylinder reservoir to prevent overflowing Remove the bleeding syringe Tighten the bleeder screw Mount the protection cap Correct the fluid level of the hydraulic clutch Guideline Fluid level below container rim 4 mm 0 16 in Position cover 2with the membrane Mount and tighten screws 1 ...

Page 63: ... counterclockwise to increase free travel The pressure point moves towards the handlebar The range of adjustment is limited Do not use force Do not make any adjustments while riding Hold adjusting screw 2and tighten nut 1 12 3 Adjusting the basic position of the hand brake lever E01403 11 Main work Adjust basic position of the hand brake lever to your hand size by turning adjusting screw 1 Info Tu...

Page 64: ...er Preparatory work Remove front brake disc guard p 62 E01343 01 Main work Press back the brake linings by slightly tilting the brake caliper later ally on the brake disc Pull the brake caliper carefully up from the brake disc and hang to the side Info Cover the components to protect them against damage 12 7 Installing the front brake caliper Warning Danger of accidents Oil or grease on the brake ...

Page 65: ... the braking effect Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule Your authorized GASGAS Motorcycles workshop will be glad to help E01368 10 Move the brake fluid reservoir mounted on the handlebar to a hori zontal position Check the brake fluid level in level viewer 1 If an air bubble is visible in upper range of the level viewer A Add f...

Page 66: ...torcycles workshop will be glad to help Note Environmental hazard Hazardous substances cause environmental damage Dispose of oils grease filters fuel cleaning agents brake fluid etc correctly and in compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact betw...

Page 67: ...hop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do not allow brake fluid to come into contact with the skin the eyes or clothing Consult a doctor immediately if brake fluid has been swallowed Rinse the affected area with plenty of water in the event of contact with...

Page 68: ...tly and in compliance with the appli cable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Remove front brake disc guard p 62 Remove front brake calipe...

Page 69: ...zed GASGAS Motorcycles work shop will be glad to help Condition Preparatory work Remove front brake disc guard p 62 400257 10 Main work Check front and rear brake disc thickness at multiple points for the dimension A Info Wear reduces the thickness of the brake disc around the contact surface of the brake linings Brake discs wear limit front 2 7 mm 0 106 in rear 2 7 mm 0 106 in If the brake disc t...

Page 70: ...t brake lever p 68 12 14 Adjusting the basic position of the foot brake lever Warning Danger of accidents The brake system fails in the event of overheating If there is no free travel on the foot brake lever pressure builds up in the brake system on the rear brake Set the free travel on the foot brake lever in accordance with the specification E01374 10 Loosen nut 1and with push rod 2 turn it back...

Page 71: ...fluid level will cause the brake system to fail If the brake fluid level drops below the specified marking or the specified value the brake system is leaking or the brake linings are worn down Check the brake system and do not continue riding until the problem is eliminated Your authorized GAS GAS Motorcycles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation ...

Page 72: ...brake fluid from a sealed container Preparatory work Check the brake linings of the rear brake p 71 E01398 10 Main work Remove screw 1with nut 2 Pull the push rod out of the foot brake cylinder and remove the foot brake lever to the front E01399 10 Remove screws 3with plastic bushing 4 Carefully remove the brake cylinder and hold it vertically E01400 10 Remove screws 5and cover 6with membrane 7 E0...

Page 73: ...the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail Ensure that service work and repairs are performed professionally Your authorized GASGAS Motorcy cles workshop will be glad to help Warning Skin irritation Brake fluid causes skin irritation Keep brake fluid out of the reach of children Wear suitable protective clothing and safety glasses Do ...

Page 74: ...ned for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Only use clean brake fluid from a sealed container Preparatory work Raise the motorcycle with a lift stand p 38 Remove the rear wheel p 76 E01398 10 Main work Remove screw 1with nut 2 Pull the push rod out of the foot brake cylinder and remove the foot brake lever to the front E01399 10 Remove s...

Page 75: ...sure that the clamping spring is locked in groove A Position the brake caliper on the link fork and mount and tighten screw 8 Guideline Screw rear brake caliper M6 12 Nm 8 9 lbf ft E01377 12 Add brake fluid to level B Brake fluid DOT 4 DOT 5 1 p 110 Position cover 6with membrane 7and mount and tighten screws 5 Info Use water to immediately clean up any brake fluid that has overflowed or spilled E0...

Page 76: ...12 BRAKE SYSTEM 74 E01398 10 Position foot brake lever insert push rod into foot brake cylinder Mount and tighten screw 1with nut 2 Guideline Screw foot brake lever M8 25 Nm 18 4 lbf ft ...

Page 77: ...of accidents Oil or grease on the brake discs reduces the braking effect Always keep the brake discs free of oil and grease Clean the brake discs with brake cleaner when necessary H00935 18 Check the wheel bearing for damage and wear If the wheel bearing is damaged or worn Change front wheel bearing Clean and grease the wheel spindle Long life grease p 112 Jack up the front wheel into the fork pos...

Page 78: ...wheel forward as far as possible Remove the chain from the rear sprocket Info Cover the components to protect them against damage Warning Danger of accidents Damaged brake discs reduce the braking effect Always lay the wheel down in such a way that the brake disc is not damaged Holding the rear wheel withdraw the wheel spindle to the right Take the rear wheel out of the link fork Info Do not opera...

Page 79: ... bearing is damaged or worn Change the rear wheel bearing Clean and grease shaft seal rings 1and contact surfaces Aof the spacers Long life grease p 112 Insert the spacers E01387 11 Lift the rear wheel into the link fork position it and insert wheel spindle 2with eccentric 3 Mount the chain The brake linings are correctly positioned E01384 11 Mount screw 4with spacer 5 but do not tighten yet Opera...

Page 80: ...haracteristics The type condition and pressure of the tires all have a major impact on the handling characteristic of the motorcy cle The tires mounted on the front and rear wheels must have a similar profile Worn tires have a negative effect on handling characteristics especially on wet surfaces 400602 10 Check the front and rear tires for cuts embedded objects and other damage If the tires have ...

Page 81: ...e service life 400695 01 Remove protection cap Check tire pressure when the tires are cold Street tire pressure All EU models Front 1 2 bar 17 psi rear 1 2 bar 17 psi Offroad tire pressure front 0 42 bar 6 1 psi rear 0 30 bar 4 4 psi If the tire pressure does not meet specifications Correct tire pressure Mount the protection cap 13 7 Checking the spoke tension Warning Danger of accidents Incorrect...

Page 82: ...ameter If you hear different tone frequencies from different spokes of equal length and diameter this is an indication of differ ent spoke tensions You should hear a high note If the spoke tension differs Correct the spoke tension Check the spoke torque Guideline Spoke nipple front wheel M4 5 2 Nm 1 5 lbf ft Spoke nipple rear wheel M4 5 3 Nm 2 2 lbf ft ...

Page 83: ...ELECTRICAL SYSTEM 14 81 14 1 Diagnostics connector E01385 10 The diagnostics connector 1is located on the right hand side above the radiator fan ...

Page 84: ...system In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of c...

Page 85: ... In the event of scalding rinse the area affected immediately with lukewarm water Warning Danger of poisoning Coolant is toxic and a health hazard Keep coolant out of the reach of children Do not allow coolant to come into contact with the skin the eyes and clothing Consult a doctor immediately if coolant is swallowed Rinse the affected area immediately with plenty of water in the event of contact...

Page 86: ...en starting or run ning the engine in an enclosed space Allow the engine to warm up and cool down again Check the antifreeze and coolant level p 82 15 5 Changing the coolant Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other cooling system components if the engine or the cooling system are at o...

Page 87: ...n plug M6 10 Nm 7 4 lbf ft Completely fill the radiator with coolant and mount and tighten radi ator cap screw 1 Coolant p 110 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 run ning the engine in an enclosed space ...

Page 88: ...ctive exhaust extraction when starting or run ning the engine in an enclosed space Start the engine and let it run at idle speed Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the throttle cable play p 86 16 2 Adjusting the throttle cable play E01401 10 Main work Move the handlebar to the straight ahead position Push bac...

Page 89: ... the mid throttle slide range If the engine stutters when accelerating with a partially open throttle slide the jet needle must be lowered If the engine knocks when accelerating at the full power rpm range the jet needle must be raised Cylindrical part of the needle CYL The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed Idling jet IJ The idling j...

Page 90: ...he influence of the first cylindrical part of the needle is less When the throttle slide is 1 2 open the position of the needle has the greatest influence The influence of the main jet and the idling jet is only minimal K00497 01 When the throttle slide is 3 4 open the influence of the main jet is greatest The clip position and the idling jet have only minimal influence When the throttle slide is ...

Page 91: ...els open 1 25 turns Run the engine until warm Guideline Warming up phase 5 min 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 run ning the engine in an enclosed space Adjust the idle speed with adjusting screw 2 Gui...

Page 92: ...tion When the shift lever keeps touching the boot the transmission will be subject to an excessive load 400692 10 Sit on the vehicle in the riding position and determine distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet specifications Adjust the basic position of the shift lever...

Page 93: ...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 n...

Page 94: ... a level surface E01396 11 Main work Remove filler plug 1 Add gear oil until the gear oil level in level viewer 2is between the upper Aand lower Bedge Gear oil API GL 5 SAE 75W 90 p 110 Mount and tighten filler plug 1 17 4 Changing the gear oil Warning Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden Wear suitable protective clothing and safety gloves In the event ...

Page 95: ...plug 1with a new seal ring Guideline Drain plug for gear oil M8 12 Nm 8 9 lbf ft E01396 12 Remove filler plug 2and fill up with gear oil Gear oil 0 37 l 0 39 qt Gear oil API GL 5 SAE 75W 90 p 110 Mount and tighten filler plug 2 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 t...

Page 96: ...nshine when cleaning the motorcycle 401061 01 Close off exhaust system to keep water from entering Remove the coarse dirt particles with a gentle water jet Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush Motorcycle cleaner p 112 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to a dry vehic...

Page 97: ...orrosion inhibitor Preserving materials for paints metal and rubber p 112 Treat all plastic parts and powder coated parts with a mild cleaning and care product Special cleaner for glossy and matte paint finishes metal and plastic surfaces p 112 Oil the steering lock Universal oil spray p 113 ...

Page 98: ...less workshop overload This allows you to avoid long waiting periods when the next season starts 401058 01 When refueling for the last time before taking the motorcycle out of service add fuel additive Fuel additive p 112 Refuel p 26 Clean the motorcycle p 94 Change the gear oil p 92 Check the antifreeze and coolant level p 82 Empty the carburetor float chamber p 91 Check the tire pressure p 79 St...

Page 99: ...STORAGE 19 97 19 2 Preparing for use after storage 401059 01 Remove the motorcycle from the lift stand p 38 Perform checks and maintenance measures when preparing for use p 23 Take a test ride ...

Page 100: ...s no idle speed Idling jet blocked Check adjust the carburetor components Adjusting screws on the carbu retor are in turned to the wrong position Carburetor adjust the idle speed p 89 Faulty spark plug Change the spark plug Faulty ignition Check the ignition coil Check the spark plug connector Engine has too little power Fuel supply interrupted Check the fuel tank breather Clean the fuel tap Check...

Page 101: ...n the coolant p 83 Refill with coolant p 84 Damaged cylinder head or cylin der head gasket Check the cylinder head and cylinder head gasket Bent radiator hose Change the radiator hose White smoke development steam in the exhaust gas Damaged cylinder head or cylin der head gasket Check the cylinder head and cylinder head gasket Gear oil emerges from the vent hose Too much gear oil added Check the g...

Page 102: ...els 60 mm 2 36 in Hole All 125 models 54 mm 2 13 in Hole All 250 models 72 5 mm 2 854 in Hole All 280 models 76 mm 2 99 in Hole All 300 models 79 mm 3 11 in Primary transmission 27 75 Clutch Multidisc clutch in oil bath hydraulically operated Transmission 6 gear transmission GASGAS Four Six System Transmission ratio first gear 35x27x28 16x24x23 second gear 14 36 third gear 16 35 fourth gear 36x26x...

Page 103: ...mbrane fixation M5 8 Nm 5 9 lbf ft Screw shift drum locating M5 7 Nm 5 2 lbf ft Screw shift lever M5 8 Nm 5 9 lbf ft Screw shift lever M5 6 Nm 4 4 lbf ft Screw stator M5 8 Nm 5 9 lbf ft Screw water pump impeller M5 8 Nm 5 9 lbf ft Coolant drain plug M6 10 Nm 7 4 lbf ft Screw cylinder head M6 15 Nm 11 1 lbf ft Screw kick starter lever M6 12 Nm 8 9 lbf ft Drain plug for gear oil M8 12 Nm 8 9 lbf ft ...

Page 104: ...top Jet needle JJH Main jet All 125 models 125 Main jet All 250 models 125 Main jet All 280 models 125 Main jet All 300 models 125 Idling jet All 125 models 52 Idling jet All 250 models 45 Idling jet All 280 models 45 Idling jet All 300 models 48 Idle air adjusting screw All 280 models open 1 turn Idle air adjusting screw All 125 250 300 models open 1 25 turns ...

Page 105: ... 0 39 qt Gear oil API GL 5 SAE 75W 90 p 110 24 2 Coolant Coolant 0 4 l 0 4 qt Coolant p 110 24 3 Fuel Total fuel tank capacity approx 2 4 l 2 5 qt Super unleaded 98 octane mixed with 2 stroke engine oil 1 67 p 111 Fuel reserve approx 0 15 l 0 16 qt ...

Page 106: ...ear 150 mm 5 91 in Brake discs wear limit front 2 7 mm 0 106 in rear 2 7 mm 0 106 in Street tire pressure All EU models Front 1 2 bar 17 psi rear 1 2 bar 17 psi Offroad tire pressure front 0 42 bar 6 1 psi rear 0 30 bar 4 4 psi Secondary drive ratio 10 39 Chain 5 8 x 1 4 Wheelbase 1 320 10 mm 51 97 0 39 in Seat height unloaded 630 mm 24 8 in Ground clearance unloaded 325 mm 12 8 in Weight without ...

Page 107: ...45L TT Michelin Trial Competition X11 4 00 R 18 M C 64L TL Michelin Trial Competition X11 The tires specified represent one of the possible series production tires Additional information is available in the Service section under http www gasgas com ...

Page 108: ...2 5 turns Spring preload Standard 5 5 turns Air chamber length Air chamber length left 130 mm Air chamber length right 75 mm 27 2 All RACING models Fork article number BT20000GG CJT 1 Fork Tech 39 mm Rebound damping Standard 19 clicks Fluid barrier Standard 2 5 turns Spring preload Standard 5 5 turns Air chamber length Air chamber length left 130 mm Air chamber length right 75 mm ...

Page 109: ...3V Rebound damping Standard 23 clicks Compression damping Standard 15 clicks Spring preload 7 mm 0 28 in Spring rate Weight of rider 55 70 kg 121 154 lb 67 5 N mm 385 4 lb in Weight of rider 70 80 kg 154 176 lb 70 N mm 400 lb in Weight of rider 80 85 kg 176 187 lb 72 5 N mm 414 lb in Weight of rider 85 100 kg 187 220 lb 75 N mm 428 lb in Static sag 10 15 mm 0 39 0 59 in Riding sag 70 75 mm 2 76 2 ...

Page 110: ...er M6 10 Nm 7 4 lbf ft Screw fuel tank fastening M6 8 Nm 5 9 lbf ft Screw main silencer M6 12 Nm 8 9 lbf ft Screw radiator bracket M6 10 Nm 7 4 lbf ft Screw rear brake caliper M6 12 Nm 8 9 lbf ft Screw rear fender center M6 10 Nm 7 4 lbf ft Screw rear fender side M6 6 Nm 4 4 lbf ft Screw stand fastening on link fork M6 12 Nm 8 9 lbf ft Screw steering stem M6 12 Nm 8 9 lbf ft Screw top triple clamp...

Page 111: ...bell crank M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 50 Nm 36 9 lbf ft Screw engine mounting bracket M10 50 Nm 36 9 lbf ft Screw pull rod on bell crank M10 45 Nm 33 2 lbf ft Screw rear wheel spindle M10 50 Nm 36 9 lbf ft Screw top shock absorber M10 50 Nm 36 9 lbf ft Screw link fork M14 50 Nm 36 9 lbf ft Nut swingarm pivot M16x1 5 70 Nm 51 6 lbf ft Wheel spindle front M18 50 Nm 36 9 lb...

Page 112: ...cifications on the container and that has the rele vant properties Antifreeze protection to at least 25 C 13 F The mixture ratio must be adjusted to the necessary antifreeze protection Use distilled water if the coolant needs to be diluted The use of premixed coolant is recommended Observe the coolant manufacturer specifications for antifreeze protection dilution and miscibility compatibility with...

Page 113: ...rresponding properties Recommended supplier MOTOREX Hydraulic Fluid 75 Super unleaded ROZ 98 RON 98 PON 94 Standard classification DIN EN 228 ROZ 98 RON 98 PON 94 Super unleaded 98 octane mixed with 2 stroke engine oil 1 67 Standard classification DIN EN 228 JASO FD p 114 1 67 Mixture ratio 1 67 Engine oil 2 stroke p 110 Super unleaded ROZ 98 RON 98 PON 94 p 111 Recommended supplier MOTOREX Cross ...

Page 114: ...rcycle cleaner Recommended supplier MOTOREX Moto Clean Off road chain spray Recommended supplier MOTOREX Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX Racing Bio Liquid Power Preserving materials for paints metal and rubber Recommended supplier MOTOREX Moto Protect Rubber grip adhesive 00062030051 Recommended supplier KTM AG GRIP GLUE Special cleaner for glossy and matte p...

Page 115: ...AUXILIARY SUBSTANCES 31 113 Universal oil spray Recommended supplier MOTOREX Joker 440 Synthetic ...

Page 116: ... first rate synthetic esters and specially designed additives superb combustion is achieved even under extreme operating conditions 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 ...

Page 117: ...LIST OF ABBREVIATIONS 33 115 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 118: ... 54 Chain tension adjusting 56 checking 55 Choke button 16 Choke lever 16 Clutch fluid level checking correcting 58 fluid changing 59 Clutch lever 13 basic position adjusting 58 free travel adjusting 58 free travel checking 57 Combination instrument 20 Compression damping fork adjusting 36 shock absorber adjusting 31 Coolant changing 84 draining 83 refilling 84 Coolant level checking 82 Cooling sy...

Page 119: ...from lift stand removing 38 lift stand raising with 38 O Owner s Manual 8 P Preparing for use advice on preparing for first use 21 after storage 97 checks and maintenance measures when preparing for use 23 Protective clothing 7 R Rear wheel installing 77 removing 76 Rebound damping fork adjusting 35 shock absorber adjusting 30 Refueling fuel 26 Riding sag adjusting 33 Rubber grip checking 57 S Saf...

Page 120: ...ngine 100 engine tightening torques 101 fork 106 shock absorber 107 tires 105 Throttle cable play adjusting 86 checking 86 Throttle grip 13 Tire condition checking 78 Tire pressure checking 79 Transporting 26 Turn signal switch 15 Type label 12 V Vehicle identification number 12 View of vehicle front left 10 rear right 11 W Work rules 8 ...

Page 121: ... 3215003en 3215003en 06 2020 Stallhofnerstraße 3 5230 Mattighofen Austria http www gasgas com ...

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