GAS GAS TXT RACING 2015 User Manual Download | Manualshive

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The regulation is done
by turning one screw
(B) located in the

center of the suspension tube
cap.The bleeder (A) is used to
purge air that may be trapped
inside the slider.

C

The front suspension
is adjusted manually

Right (hydraulic extension).
Left (hydraulic compression).

C

The preload on the shock absorber
is adjusted by turning the toothed
rings (C) with the aid of two special
spanners.

Starting from the standard preload of 8.5mm,
tighten it up or loosen it off depending on the
weight of the rider, up to a maximum of 9mm
preload (see springs and preloads table).
Preload refers to the difference in length in
mm between the spring when compressed
and at rest.

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Summary of Contents for TXT RACING 2015

Page 1: ...TXT RACING 2015 TXT RACING 2015 ...

Page 2: ......

Page 3: ...e fruit of many years of competition and experimentation in this demanding discipline as well as the many great successes achieved thanks to great trial riders who have contributed with their expertise to the basic data that have allowed us to create a high level motorbike a GAS GAS which counts on its low weight as a significant key factor Congratulations for making the right choice With your ski...

Page 4: ...ld these warnings not be heeded the guarantee may be automatically invalidated Various notes These are the indications necessary for the optimal control and adjustment operations together with those tasks of conservation and maintenance of the motorbike in order that you may obtain the greatest possible satisfaction from your vehicle The aim of this Manual is to help the user to minimise or avoid ...

Page 5: ...ank dismantle 24 Radiator fill in 24 Spark dismantle 25 Spark check 25 Air filter box dismantle 26 Carburettor dismantle 27 Carburettor capacity check 27 Carburettor cleaning 27 Inlet valves dismantle 28 Inlet valves 28 Clutch operations 29 Discs and clutch spring 29 Air bleed 29 Water pump draining 29 Front suspension 30 31 Rear suspension 32 Swing arm articulations 33 Articulation lubrication 34...

Page 6: ...ts that become apparent within the period established in the Law decree 23 2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance with the Directive 1999 44 EC for other members of the European Community For countries outside the European Community the Warranty Period will be determined by the existing regulations in those countries Neverthe...

Page 7: ... the specifications set out in the User s Manual e The vehicle has been altered or modified in any way or fitted with components other than those expressly authorised by GG as accepted components of the vehicle f The vehicle has been stored or transported in a way that is not in accordance to the corresponding technical requirements g The vehicle has been used for special purposes other than ordin...

Page 8: ...of a claim under Warranty or to arrange an inspection of the defect by an expert from GG Any additional obligations arising out of guarantees on parts replaced free of charge or any other service rendered free of charge are excluded from the effects of this present warranty The Warranty on parts replaced within the Warranty Period will end at the expiry date for the Warranty Period of the product ...

Page 9: ...re recommended in order to guarantee the correct operation of the engine It is important to warm the engine to the optimum operation temperature every time the motorbike is used Synthetic or semi synthetic 2 stroke oil should be used at 2 in the oil petrol mix 9 RECOMMENDS THE USE OF OIL ...

Page 10: ...e and stroke 76 x 60 mm 300 cc engine Cylinder size 294 1 cc Bore and stroke 79 x 60 mm Carburetor diameter of the diffuser 28 125cc 300cc 21 80cc Lubrication system Mixture 50 1 2 Ignition system Digital magnetic flywheel CDI TRANSMISSION Transmission type 6 gears Four Six system by GAS GAS Patented Clutch type Hydrauliccommand 1 3discs variableprogres withdiaphragmsystembyGASGAS Patented Final d...

Page 11: ...ara la 80cc Rear Variable progressive system with mono shock multiadjustable Suspension stroke Front 177 mm 125cc 300cc 180mm 80cc Rear 164 mm Front fork oil SAE 5 W GRO FORK FLUID Front fork oil level Ø40 mm 160 mm air chamber aluminium bar Ø33 mm 80cc 155 mm air chamber BRAKES Type Disc brake Disc diameter Front Ø185mm 125cc 300cc Ø175mm 80cc 4 piston calipers Rear ø150mm 2 piston calipers DIMEN...

Page 12: ...ght 27 Front tyre air valve 28 Rear brake disc 29 Sidestand arm 30 Swingarm 31 Rear brake pedal 32 Kickstart pedal 33 Water pump 34 Exhaust pipe elbow 35 Front wheel axle 10 11 12 13 14 15 16 17 18 19 20 5 6 7 8 9 22 23 25 21 28 29 30 31 34 35 32 33 24 26 27 12 Front brake disc 13 Cylinder 14 Carburetor 15 Chain guide 16 Chain tensioner 17 Chain 18 Rear sprocket cover 19 Rear sprocket 20 Rear rim ...

Page 13: ...6 Light controls 47 Clutch pump 48 Handlebar 49 Left suspension regulation 50 Multifunction 51 Warning indicators 52 Right suspension regulation 53 Front brake pump 54 Throttle cover 55 Front brake lever 56 Throttle grip 57 Silencer 58 Right foot peg 59 Rear brake pedal 60 Exhaust pipe elbow 61 CDI Switch 44 45 46 47 48 49 50 51 53 54 55 61 56 38 39 40 42 43 57 58 59 41 36 37 60 52 ...

Page 14: ...lutch Engine protector plate Every year 30 hours Every race Every race Every race Every race Every race 30 hours Every race Every race Every race 30 hours 60 hours Every race Every race Every race Every race If is necessary 30 hours If is necessary If is necessary If is necessary If is necessary First 5 hours If is necessary First 5 hours im a fall Every cleaning Every cleaning Every cleaning Ever...

Page 15: ...ery race Every race Every race Every race Every race Every race Every race 60 hours Every race Every race Every race Every race Every race Every race Every race Every race If is necessary If is necessary If is necessary If is necessary 5 hours If is necessary If is necessary If is necessary If is necessary Im a fall Every cleaning Every cleaning Every cleaning Every cleaning 500 hours 100 hours If...

Page 16: ...lso been printed on the front and this information must coincide with that contained in the vehicle documents We recommend that this information be entered in the box below Key identification numbers The motorcycle carries one key set The identification number appears right on the key joints This number may be quoted when ordering a spare to replace a lost key except some racing models 16 The new ...

Page 17: ...his switch to the right and likewise to start the left hand indicator move this switch to the left 8 All light controls have been located on the left hand grip the various positions available are reached by sliding the main switch which is on the left end of the grip The control panel includes lighting turn signal horn and engine stop switches C C C 17 ...

Page 18: ... system could be damaged I Use premium gasoline with an octane rating equal to or higher than that shown in the table Gasoline is extremely flammable and can be explosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light C OCTANE RATING METHOD Antiknock In...

Page 19: ... turn in counterclockwise direction To close it place cap with the words GAS GAS in the upper position and turn the tab in clockwise direction It is important to check periodically the condition of the cap sealing O ring to insure proper sealing This engine is designed to burn a mixture of combustible fuels lead free petrol and oil C C ...

Page 20: ... tap A must be pointing down for normal operation When turned forwards it opens the reserve to the rear turns off the fuel 8 C Reserve Open Closed The choke B is a device for aiding the starting when cold The enigne will r e a c h a n o r m a l temperature in a short time and it won t damage anything 8 C 80cc carburetor model ...

Page 21: ...ap A must be pointing down for normal operation When turned forwards it opens the reserve to the rear turns off the fuel 8 C Reserve Open Closed The choke B is a device for aiding the starting when cold The enigne will r e a c h a n o r m a l temperature in a short time and it won t damage anything 8 C 125 300cc carburetor model ...

Page 22: ...xceed 3mm This play must never be eliminated Like the c l u t c h lever the front brake lever must be in the ideal position Again the play must not exceed 3mm This play must never be eliminated C This is the position the kick start should be in when not being used 8 I C Mínimo 3 mm 7 ...

Page 23: ... using the window The level should be in the middle of the window If it is too high drain the excess If it is too low add the necessary quantity by opening the oil cap Use the same type and make of lubricant as that which is already in the engine 8 8 C When topping up the oil open the cap A 8 C The engine crankcase drain cap is situated on the lower left hand side The drainage hole in the crankcas...

Page 24: ...ect installation once clean In the lower part of the filter chamber there is a leaf that acts as the escape valve for the liquids and or other mate rials that may build up in the filter cham ber Check that this valve is working properly It is important to periodic lly check the air filter Open the door on the motorbike as ...

Page 25: ... which is inserted in the fuel cock The third step is to unscrew the screw B fastening the front upper part of the tank Once the fuel tank is released lift it at the front section and remove the tank completely out the of the chassis C 8 When filling the radiator use cooling fluid designed for lightweight alloy motors I The engine must be cool before removing the radiator cap or when replacing rad...

Page 26: ... 7mm I It is necesassary to periodically check the spark plug condition This must be done removing the spark plug from the upper part of the cylinder head First disconnect the spark plug cap and remove area first Clean the spark plug with compressed air to remove dirt and prevent foreign material from entering inside the engine compartment C ...

Page 27: ...h are used to anchor the filter box to the chassis 3 Pull the filter box straight up just enough until the rear wiring connector is visible Fig 2 4 Disconnect the connector Fig 1 5 Remove the filter box completely C The carburetor is now exposed and can be separated from the motor assembly by loosening the reed port clamp Loosen the two screws of the carburetor cap to allow the removal of the body...

Page 28: ...ing the inside of the carburetor housing It is important to check the level of petrol within the carburetor The float should be at 18 5mm 18 5mm C C C I Extreme precautions must be taken to dry the inside of the carburetor thoroughly Water droplets dirt or other forign material may enter and damage the reed box and consequently cause damages to the piston and cylinder assembly Fig 3 ...

Page 29: ...hen handling these parts C I The distance between reeds and the reed keepershouldbe6 5mm for all types of displacement models Reeds must be kept in perfect conditions with no signs of nicks scratches broken or folded sections Otherwise the reed assembly must be replaced with a new one 28 7 The reed box assembly is composed of only one body the stops To inspect the assembly remove it by removing th...

Page 30: ...when handling these parts C I The distance between reeds and the reed keeper should be 6 5 mm for all types of displacement models Reeds must be kept in perfect conditions with no signs of nicks scratches broken or folded sections Otherwise the reed assembly must be replaced with a new one 7 The reed box assembly is composed of only one body the stops To inspect the assembly remove it by removing ...

Page 31: ...r trapped inside must be purged by connecting wrench spanner and bleeding the system C A The circle indicates where the engine oil should be poured in C 7 Check clutch discs for possible wear after many hours of use For correct operation the minimum measurement should be 9 83 mm C ...

Page 32: ... 30 575 mm Level of air chamber 155 mm FRONT FORK ø 33 mm Measure without the spring and the hydraulic rod extended 80cc model ...

Page 33: ...of air chamber 160 mm 575 mm FRONT FORK ø 40 mm aluminium bars For a medium weight of 75 Kg we should preload the spring to 2 5 mm Measure without the spring and the hydraulic rod extended 30a 125 300cc model ...

Page 34: ...aulic extension Left hydraulic compression C The preload on the shock absorber is adjusted by turning the toothed rings C with the aid of two special spanners Starting from the standard preload of 8 5mm tighten it up or loosen it off depending on the weight of the rider up to a maximum of 9mm preload see springs and preloads table Preload refers to the difference in length in mm between the spring...

Page 35: ... AND SPRINGS DEPENDING ON RIDER WEIGHT 125cc 32 Adjust the rebound or extension by means of screw The standard position is 30 clicks from closed From this starting position open up clicks to get a faster extension or rebound and close up clicks to get a slower extension or rebound It is advisable to work with a maximum of 10 clicks on either side of the standard position ...

Page 36: ...important to periodically remove and verify the condition of the swingarm bearings and pieces The linkage at the lower part of rear suspension must be periodically cleaned inspected and lubricated with grease C 33 ...

Page 37: ...il to lubricate the following 1 All pivot points of the brake and clutch levers C 2 The pivot of the gear shift lever C 8 C 8 3 Also the rear brake pedal bearings C 4 Apply grease to the footrest springs and fixtures 8 ...

Page 38: ...ting pedal 7 Lubricate the handlebar with a fine coat of oil to allow smooth operation of the throttle control C 7 6 The drive chain must be cleaned and lubricated thouroughly and frequently since it is exposed to the elements and constant abrassion 8 C 8 ...

Page 39: ...equently lubricate the chain tensioner spring because it is under great stress C 7 9 Oil and clean the throttle control frequently it is especially recommended to do so after the bike has been cleaned with water under high pressure C 7 ...

Page 40: ...37 The chain master link clip must be placed in opposite direction of the wheel travel C 7 To regulate the chain slack and center the rear wheel use the shaft excentrics which can be easily adjusted C 7 ...

Page 41: ...cked to insure optimum Fig 1 Bad condition Fig 2 Good condition C Front tyre 2 75 x 21 TRIAL 2 50 x 19 TRIAL 80cc Rear tyre 4 00 x 18 TRIAL tubeless 3 50 x 17 TRIAL 80cc Front wheel pressure 0 450 bar normal 0 420 bar competition 0 500 bar 80cc Rear wheel pressure 0 350 bar normal 0 300 bar competition 0 500 bar 80cc ...

Page 42: ...rent inspection window 7 Brake pad wear front and rear must be checked from time to time to insure an efficient braking power under all circumstances C 8 The brake calipers have been furnished with bleeder valves to eliminate the air trapped in the brake system 7 7 C C ...

Page 43: ...s located at the cylinder support Verify fluid level periodically and refill if necessary C Put the bike in vertical position to be able to see the liquid real level in order to check the tank level It must be between MIN and MAX C MIN MAX ...

Page 44: ...ELECTRICAL INSTALLATION COMTETITION 41 ...

Page 45: ... 42 ELECTRICAL INSTALLATION HOMOLOGATION ...

Page 46: ...ELECTRICAL INSTALLATION IGNITION 43 ...

Page 47: ... 7 8 25 7 8 3 4 7 8 7 8 7 8 40 10 7 8 12 12 13 7 8 11 5 13 25 PART NAME Front wheel axle Chassis to swingarm fastener Upper shock absorber fastener Lower shock absorber fastener Connecting rods caps Handlebars Hand levers Radiator fasteners Front bridge wing Brake pedal Muffler fasteners Rear wheel axle Rear brake caliper fastener Front brake caliper fastener Exhaust pipe elbow fastener Engine fas...

Page 48: ...heels do not touch the ground if possible place cardboard under the wheels Cover the motorcycle to protect it from dust and dirt When starting off after an extended storage Remove the plastic bag from the exhaust pipe Tighten the spark plug Fill the fuel tank General lubrication Inspect tyre pressure and inflate to the specified pressure if necessary To avoid excessive ageing of the plastic parts ...

Page 49: ...ice is water resistant but not waterproof Do not wash with pressure washer Do not leave the device in direct sunlight when the motorcycle is stopped Avoid contact with gasoline degreasers or other cleaning chemical products that could be cause damages in the device Always remember to pay attention to the road when you re driving QUICK GUIDE SETUP MENU To enter into the setup menu Endurance II hold...

Page 50: ...or 24H SETTING the time Set the clock to the desired time by pressing 1 to 2 SETTING the maintenance reminder method Select the desired maintenance reminder method using the buttons 1 or 2 ODO Odometer kilometers based ART Accumulated driving time hours based SETTING the maintenance reminder Select the value until the next maintenance This value is based on time or mileage depending on the method ...

Page 51: ... the DST Use buttons 1 and 2 to increase and decrease the DST Press the 3 button to return to main menu Screeb 2 DST2 DST2 Distance Traveled 2 The multifunction ENDURANCE II can accumulate data from two different travel distances Press and hold buttons 1 and 2 for three seconds to reset DST2 driving time and average speed Hold the button 3 to set the DST Use buttons 1 and 2 to increase and decreas...

Page 52: ...alized workshop Go to a specialized workshop Go to a specialized workshop Drain old fuel out of the tank With the fuel tank filled with new fuel the engine will start immediately Clean and dry or replace the spark plug In order to relieve the engine accelerate to max speed press the starter pedal 5 or 10 times Then start the engine as described above If the engine fails to start remove the spark p...

Page 53: ...in jet set too high Replace the rotor Drain the fuel tank and fill up with new fuel Clean the fuel system and verify its operation Clean or replace the air cleaner Verify its operation Verify if the exhaust system is damaged Replace the muffler fiberglass packing if necessary Disassembly the carburetor and clean all jets Replace the crankshaft bearings Verify the clutch operation Go to a specializ...

Page 54: ... steering bearings Bent steering stem Go to a specialized workshop Replace the shift fork Go to a specialized workshop Replace the gearshift lever Adjust or replace the selector position spring Replace the spring in the reverse selector mechanism Replace the spring in the reverse selector mechanism Replace the gear drum Replace the spring in the gear selector ratchet Replace the shift fork Replace...

Page 55: ...t Abnormal motorcycle noises Handlebar vibration Pour excess oil until reaching the correct oil level Drain fork oil and fill with correct fork oil viscosity Replace the front fork Go to a specialized workshop Check tire air pressure Adjust rear shock absorber Fill with fork oil until reaching the correct oil level Drain fork oil and fill with correct fork oil viscosity Replace the front fork Go t...

Page 56: ...n Incorrect brake adjustment Tighten steering bracket and steering stem locknut to the correct torque values Tighten steering bracket and steering stem locknut to the correct torque values Replace the chassis Go to a specialized workshop Adjust the steering Go to a specialized workshop Replace the steering stem Go to a specialized workshop Replace the front fork Align the wheels Replace the discs ...

Page 57: ...tance of 30 centimeters minimum this will insure the correct gloss of the plastics and adherence of the self adhesive labels that decorate the motorcycle SAFE RIDING OF THIS MOTORCYCLE Safe riding of a motorcycle does not only depend on the vehicle The driver s intelligence and common sense are key factors to be taken into consideration It is recommended that you practice your favorite sport weari...

Page 58: ...case of loss breakage or malfunction it is recommended that the owner contact his official dealer to correct this problem Manufacture identification plate 1 Catalyzed with with secondary air Available 1 Muffler Available 1 Carburettor jets Available 1 Front and rear turn signals Available 1 License plate holder Available 1 Speedometer Available 1 Electrical installation homologated lights Availabl...

Page 59: ...6 Bolt 6 ULS screw 6x16 7 Phillips screw M6 x 25 8 Philips screw 6 3x16 9 Front left turn signal 11 Trial license holder homologated 12 Stand spring 13 ULS screw 8x12 8 8 14 Self locking M6 nut with galvanized washer 15 Mirrors 16 Carburettor kit Note N A USA also some competition only models BT93900RA3010 T0803020 ...

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