GAS GAS TXTPRO - 2009 Manual Download

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Summary of Contents for TXTPRO - 2009

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Page 3: ...ny 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 skills at the co...

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: ...ng 23 Fuel tank 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 31 Swing arm articulations 32 Articulation lu...

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: ...e recommended in order to guarantee the correct working of the engine It is important to warm the engine to the optimum working 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: ...cc Bore and stroke 76 x 60 mm 300 cc engine Cylinder size 294 1 cc Bore and stroke 79 x 60 mm Carburettor diameter of the diffusor 26 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 Hydraulic command 1 3 discs variable progressive with diaphragm system by GAS GAS Patented Driving ...

Page 11: ...280 300 Rear Variable progressive system with mono shock multiadjustable Suspension stroke Front 177 mm Rear 164 mm Front fork oil SAE 5 Front fork oil level ø 40 mm 125 200 180 mm air chamber steel bar ø 40 mm 250 280 300 160 mm air chamber aluminium bar BRAKES Type Disc brake Disc diameter Front ø185 mm 4 piston calipers Rear ø150 mm 2 piston calipers DIMENSIONS Overall height 1180 mm Overall wi...

Page 12: ... headlight 10 Front tyre 11 Front brake disc cover 12 Front brake disc 13 Cylinder 14 Carburettor 15 Chain guide 16 Chain slide 17 Chain 18 Rear sprocket cover 19 Rear sprocket 20 Rear rim 21 Rear tyre 22 Exhaust protection 23 Frame 24 Middle silencier 25 Radiator 26 Headlight 27 Front tyre air valve 28 Rear brake disc 29 Sidestand lever 30 Swingarm 31 Rear brake lever 32 Kickstart pedal 33 Water ...

Page 13: ... Ignition cover 42 Fuel tank 43 Fuel tank cap 44 Left hanle grip 45 Clutch lever 46 Light controls 47 Clutch pump 48 Handlebar 49 Left bottle regulation 50 Multifunction 51 Warning indicators 52 Right bottle 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 ...

Page 14: ...Clutch 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 Eve...

Page 15: ...Every 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 ...

Page 16: ...n 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 moped 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 16 The new GAS GAS TXT Pro carries the a p p r o ...

Page 17: ...e left hand grip This is an orange colour button To start the right hand indicator move this switch to the right and likewise to start the left hand indicator move this switch to the left 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 C C C ...

Page 18: ...locking 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 Antik...

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 tu burn a mixture of combustible fuels lead free petrol and oil C C 8 ...

Page 20: ... fuel tap A must be forward rearward for normal operation When turned upwards it opens the reserve downwards it turns off the fuel 8 A B C C Reserve Open Closed The choke B is a device for aiding the engine start if this is cold The enigne w i l l g e t a g o o d temperature in a short time and it won t damage 8 C ...

Page 21: ...mm 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 7 3 mm minium C 7 3 mm minium This is the position the kick start should be in when not being used 8 I C ...

Page 22: ...ait a few minutes To check the oil level unscrew the cap B and examine the level of oil using the dip stick The level should be between the marked maximum and minimum levels 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 When topping up the oil open the cap A 8 E n ...

Page 23: ...Clean with water and detergent then dry and lubricate with oil designed for filters Ensure its correct collocation 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 materials that may build up in the filter chamber Check this valve is working properly C ...

Page 24: ...ck that the gasoline cap and fuel cock are closed properly Next pull out the fuel tube end A which is inserted in the fuel cock The third step is to unscrew the Allen screw M6 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 inside of the chassis C The engine must be cool before removing the radiator cap...

Page 25: ...ry to periodically check the spark plug condition This must be done removing the spark plug from its housing in the upper part of the cylinder head First disconnect the spark plug cap and remove the spark plug using an adequate wrench Clean the spark plug with compressed air to remove dirt and prevent foreign material to enter inside the engine compartment C I ...

Page 26: ...r the filter box to the chassis 3 Pull the filter box straight up just enough until the rear intallation connecting fixture is visible 4 Disconnect the fixture Fig 1 5 Remove the filter box completely Fig 2 C Fig 1 Fig 2 The carburettor is now exposed and can be separated from the motor assembly by loosening the reed box port clamp Loosen the two screws of the carburettor upper cover to allow the ...

Page 27: ...tor very thoroughly To do so use compressed air It is important to check the level of petrol within the carburettor The float should be at 18 5mm C C C I Extreme precautions must be taken to dry the inside of the carburettor 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 28: ...andling 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 reeds and reed keepers To inspect the assembly remove it by...

Page 29: ...air bleeder Check clutch discs for possible wear after many hours of use For correct operation the minimum measure should be between 9 75 to 9 85 mm C 17 5 9 75 0 1 0 A C A The circle indicates where the engine oil should be poured in 29 C Spring height of the clutch stack should measure between 4 3 and 4 4 mm C 1 0 7 7 7 ...

Page 30: ...of air chamber 160 mm 575 mm Level of air chamber 180 mm 575 mm FRONT FORK ø 40 mm 125 200 FRONT FORK ø 40 mm aluminium bars 250 280 300 For a medium weight of 75 Kg we should preload the spring to 2 5 mm 30 ...

Page 31: ... is adjusted manually Right hydraulic extension Left hydraulic compression C A B 7 7 The preloading of the damper spring is measured by the rotation of the toothed rings C with the aid of a special wrench 7 C shock absorber The hidraulic brake compression can be adjusted by turning the screw D located in the lowest area of the shock absorber it should be at the mid point of his career 7 C D ...

Page 32: ...te to periodically remove and verify the condition of the swingarm bearings and holders 7 The link adjustments at the lower part of rear suspension must be periodically cleaned verified and lubricated with grease 7 C C 32 ...

Page 33: ...ase to the footrests springs and fixtures 8 Use special oil to lubricate the following 1 All linkages of the brake and clutch levers C 2 The linkage of the gear shift lever C 8 C 8 8 3 Also the rear brake pedal bearings ...

Page 34: ...allow smooth operation of the gasoline control C 7 6 The secondary chain must be cleaned and lubricated thouroughly and frequently since it is exposed to inclemency and constant rubbing 8 C 34 C 5 Apply grease to the linkage of the engine starting lever 8 ...

Page 35: ...o frequently lubricate the chain tensor spring because ii is under great stress C 7 9 Oil and clean the gas control frequently it is especially recommended to do so after the bike has been cleaned with water under high pressure C 7 ...

Page 36: ... 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 graduated C 7 7 The chain tension must allow a slack near the tensor of about 2 cm C 36 ...

Page 37: ...ssure 0 450 bar normal 0 420 bar competition Rear wheel pressure 0 350 bar normal 0 300 bar competition 7 A l l t y r e s c o n d i t i o n s must checked to insure optimum road adherence possible Fig 1 Bad condition Fig 2 Good condition C Front tyre 2 75 x 21 TRIAL Rear tyre 4 00 x 18 TRIAL tubeless Fig 1 Fig 2 ...

Page 38: ...te the air trapped in the brake circuit 7 The front brake fluid level can be verified watching through the transparent inspection window 7 7 Pad brakes wear front and rear must be checked from time to time to insure an efficient braking power under all circumstances C 8 C C ...

Page 39: ...nder support Verify fluid level periodically and refill if necessary C To verify the reservoir level you must remove the fuel tank and place de oil reservoir in horizontal position to check the real fluid level Must be filled between the marks MIN MAX C MIN MAX ...

Page 40: ... 7 8 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...

Page 41: ...e wheels do not touch the ground if possible place cardboards 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 pa...

Page 42: ... motor running save the data to the memory even when the device is switched off When the multifunction apparatus is not activated it displays a clock The value of the wheel circumference can be altered as well as the system of measurement metric or British The ambient temperature is displayed on the upper left hand part of the screen The screen can display the engine temperature from an optional t...

Page 43: ...RECISION CHARACTERISTICS CURRENT SPEED SPD 4 399 9 kmph or mph 0 1 kmph or mph 0 1 TACHOMETER RPM 0 19999 rpm 10 rpm 0 1 TACHOMETER BAR 0 12000 rpm Variable 0 1 MAXIMUM SPEED MS 4 399 9 kmph or mph 0 1 kmph or mph 0 1 DISTANCE TRAVELLED DST 0 0 19999 km or mi 0 1 kmph or mph 0 1 TIME RUNNING TT 0 9999 hours 59 minutes 1 second 0 1 ODOMETER ODO 0 0 999999 1 0 1 OPERATION TIME RT 0 999 hours 59 minu...

Page 44: ...eter It shows the total mileage accumulated by the vehicle The data is stored in the memory even when the device is not running ART Time of use controller Calculates the total time in operation It starts counting from the moment the motor is turned on RT Total time of use controller It calculates the vehicle s operation time since the last RESET operation It starts counting from the moment that mo...

Page 45: ...onds and then release Selecting the values for the wheel circumference Enter the value for the wheel circumference by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Note If you do not know the value of the wheel circumference see the section on Measuring the wheel circumference Selecting the speed unit To change between kmph and mph press but...

Page 46: ...ss button 3 Confirm by pressing button 2 Setting the pulse per revolution PPR The gauge receives one electrical pulse for each revolution on the engine PPR Default value for 2 and 4 stroke engines 1 PPR Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Setting the pulse per revolution PPR Note This step is only to be taken if ...

Page 47: ...nfirm by pressing button 2 Selecting the warning temperature Note This step can only be taken on vehicles fitted with the optional temperature sensor When the engine temperature exceeds the set value the warning LED on the left lights up Default value 90 C 190ºF Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Selecting the r...

Page 48: ...aximum speed Distance Chronometer Maximum temperature Maximum rpm Confirm the reset by pressing buttons 1 and 2 simultaneously Total reset of the display Press the RESET button using a suitable object The display will start from zero except for the data for total accumulated distance and time Internal battery The display is powered by an internal 3 V battery type CR2032 When the voltage in the int...

Page 49: ...y for 3 seconds when the button is pressed If the lighting is connected to the 12V system on the vehicle it will be brighter and stay on for up to 20 minutes after the vehicle has come to a full halt Sleep Mode If the multifunction display does not receive any information for 20 minutes signal from wheels turning or a button pressed the screen goes off showing only the time When the vehicle starts...

Page 50: ...ialized 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 ...

Page 51: ... Main 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 specia...

Page 52: ...orn 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 Repl...

Page 53: ...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 54: ...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 55: ...nce 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 wearing...

Page 56: ...eakage or malfunction it is recommended that the owner contact his official dealer to correct this problema Besides the homologated vehicle you have received a complementary kit for a racing version of this same vehicle Be advised that this version is not homologated Manufacture identification plate 1 Catalyzed with with secondary air Available 1 Muffler Available 1 Carburettor jets Available 1 Fr...

Page 57: ...9 Front left turn signal 10 Turn signal box 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BT280634018 BT280634018 BT280334015 BT280634019 T2206000 x2 T0506016N x2 T0706025 x3 T0706316 x2 BT280634019 L300720 MT120690100 BT280520003 BE25610039 T0508012 T22060...

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GAS GAS TXTPRO - 2009, Manual

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