Related Manuals for GAS GAS TXT Racing 125 2020
Summary of Contents for GAS GAS 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 3 DEAR GASGAS CUSTOMER Congratulations on your decision to purchase a GASGAS motorcycle. You are now the owner of a state-of-the-art sports DEAR GASGAS CUSTOMER vehicle which, with appropriate care, will bring you pleasure for a long time to come. We wish you good and safe riding at all times! Enter the serial numbers of your vehicle below.
-
Page 4: Table Of Contents
TABLE OF CONTENTS 6.18 Foot brake lever .......... 17 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.19 Side stand ............ 18 Symbols used..........5 6.20 Locking the steering (Option: Formats used..........5 Homologized) ..........18 6.21 Unlocking the steering (Option: SAFETY ADVICE ............ - Page 5 TABLE OF CONTENTS SERVICE WORK ON THE CHASSIS ......38 12.8 Checking the front brake fluid level.... 63 12.9 Adding front brake fluid ......63 11.1 Raising the motorcycle with a lift stand ..38 12.10 Checking the front brake linings ....65 11.2 Removing the motorcycle from the lift 12.11...
- Page 6 TABLE OF CONTENTS STORAGE..............96 19.1 Storage............96 19.2 Preparing for use after storage....97 TROUBLESHOOTING ..........98 TECHNICAL DATA............ 100 21.1 Engine ............100 ENGINE TIGHTENING TORQUES......101 CARBURETOR ............102 CAPACITIES.............. 103 24.1 Gear oil ............. 103 24.2 Coolant .............
-
Page 7: Means Of Representation 1
MEANS OF REPRESENTATION 1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g., of a work step or a function). Indicates an unexpected reaction (e.g., of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have this work performed by an authorized GASGAS Motorcycles workshop. -
Page 8: Safety Advice
2 SAFETY ADVICE Use definition – intended use (All EU models) This vehicle has been designed and built to withstand the normal stresses and strains of trial use. Info This vehicle is only authorized for operation on public roads in the homologated (restricted) version. The derestricted version of this vehicle must only be operated in closed off areas away from public highway traffic. -
Page 9: Tampering Warning
SAFETY ADVICE 2 Tampering warning Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof: The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. -
Page 10: Work Rules
2 SAFETY ADVICE Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key). Special tools are necessary for certain tasks. -
Page 11: Important Notes 3
IMPORTANT NOTES 3 Manufacturer and implied warranty The work specified in the service schedule may only be carried out in an authorized GASGAS Motorcycles workshop and confirmed in the GASGAS Motorcycles Dealer.net, as otherwise all warranty claims will be void. Damage or secondary dam- age caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty. -
Page 12: View Of Vehicle
4 VIEW OF VEHICLE View of vehicle, front left (example) E01324-10 Hand brake lever ( p. 13) Clutch lever ( p. 13) Fuel tank filler cap Air filter box cover Shock absorber rebound adjustment Choke button ( p. 16) (Option: Not homologized) Shift lever ( p. -
Page 13: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE 4 View of vehicle, rear right (example) E01325-10 Magnetic switch ( p. 13) (Option: Not homologized) Throttle grip ( p. 13) Vehicle identification number ( p. 12) Type label ( p. 12) Map switch ( p. 15) (Option: Not homologized) Fork article number ( p. -
Page 14: Serial Numbers
5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label Type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped onto the engine case at the top. -
Page 15: Controls 6
CONTROLS 6 Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. E01328-10 Hand brake lever The hand brake lever is located on the right side of the handlebar. The front brake is engaged using the hand brake lever. -
Page 16: Switch-Off Button (Option: Homologized)
6 CONTROLS Warning Risk of injury If the magnetic switch remains in the holder during a fall, the vehicle is not immediately deactivated. – Make sure that the loop of the magnetic switch is securely attached to the user’s protective clothing or wrist so that the magnetic switch is disconnected from the holder in the event of a fall. -
Page 17: Horn Button (Option: Homologized)
CONTROLS 6 Horn button (Option: Homologized) Horn button is fitted on the left side of the handlebar. Possible states • The horn button is in the basic position is pressed – The horn is operated in this posi- • The horn button tion. -
Page 18: Steering Lock (Option: Homologized)
6 CONTROLS 6.12 Steering lock (Option: Homologized) The steering lock is located on the underside of the lower triple clamp. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible. E01407-10 6.13 Fuel tap The fuel tap is on the left side of the fuel tank. -
Page 19: Shift Lever
CONTROLS 6 6.16 Shift lever Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-11 6.17 Kick starter lever Kick starter lever is fitted on the right side of the engine. -
Page 20: Side Stand
6 CONTROLS 6.19 Side stand The side stand is located on the right of the vehicle. E01323-01 The side stand is used for parking the motorcycle. Info The side stand must be folded up during motorcycle use. E01322-01 6.20 Locking the steering (Option: Homologized) Preparatory work –... -
Page 21: Opening The Fuel Tank Filler Cap
CONTROLS 6 6.22 Opening the fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 22: Combination Instrument (Option: Homologized)
6 CONTROLS 6.24 Combination instrument (Option: Homologized) The combination instrument is attached in front of the handlebar. The area displays the total distance traveled in kilometers or miles. The area shows 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. -
Page 23: Preparing For Use 7
PREPARING FOR USE 7 Advice on preparing for first use Danger Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others. – Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication. –... -
Page 24: Running In The Engine
7 PREPARING FOR USE – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more challenging ride. Info When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other. -
Page 25: Riding Instructions 8
RIDING INSTRUCTIONS 8 Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 26: Starting Off
8 RIDING INSTRUCTIONS Fuel can flow from the fuel tank to the carburetor. – Swing up the side stand. – Shift the transmission into neutral. Condition The engine is cold (Option: Not homologized) – Pull the choke lever out as far as possible. (Option: Homologized) –... -
Page 27: Braking
RIDING INSTRUCTIONS 8 Braking Warning Danger of accidents Excessively forceful application of the brakes blocks the wheels. – Adjust application of the brakes to the respective riding situation and riding surface conditions. Warning Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. –... -
Page 28: Transporting
8 RIDING INSTRUCTIONS Transporting Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. –... - Page 29 RIDING INSTRUCTIONS 8 – Fill the fuel tank with fuel up to a maximum of level Guideline 35 mm (1.38 in) Dimension Total fuel tank capac- 2.4 l (2.5 qt.) Super unleaded (98 ity, approx. octane) mixed with 2-stroke engine oil (1:67) ( p.
-
Page 30: Service Schedule
9 SERVICE SCHEDULE Additional information Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. -
Page 31: Recommended Work
SERVICE SCHEDULE 9 after every race Every 100 operating hours Every 60 operating hours Every 20 operating hours ● ● ● Check the headlight setting. ● ● ● ● Check that the throttle cables are undamaged, routed without kinks, and set correctly. ●... -
Page 32: 10 Tuning The Chassis
10 TUNING THE CHASSIS 10.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight. -
Page 33: Adjusting The Compression Damping Of The Shock Absorber (All Gp Models)
TUNING THE CHASSIS 10 (All RACING models) – Turn adjusting screw clockwise up to the last perceptible click. – Turn counterclockwise by the appropriate number of clicks. Guideline Rebound damping Standard 20 clicks Info E01334-10 Turn clockwise to increase damping; turn counterclock- wise to reduce damping. -
Page 34: Checking The Static Sag Of The Shock Absorber
10 TUNING THE CHASSIS 10.5 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 31) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and the rear fender using the sag gage. -
Page 35: Checking The Riding Sag Of The Shock Absorber
TUNING THE CHASSIS 10 (All RACING models) – Loosen retaining ring – Adjust the spring preload by turning adjusting ring Guideline Spring preload 7.5 mm (0.295 in) Info Turn counterclockwise to increase the spring preload. Turning clockwise reduces the spring preload. E01335-10 The necessary tools are included. - Page 36 10 TUNING THE CHASSIS – Remove the shock absorber. p. 47) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring. Guideline Spring rate (All RACING models) Weight of rider: 55 … 70 kg 65 N/mm (371 lb/in) (121 …...
-
Page 37: Basic Setting Of The Fork
TUNING THE CHASSIS 10 10.9 Basic setting of the fork For various reasons, no exact riding sag can be determined for the fork. As with the shock absorber, smaller differences in the rider's weight can be compensated by the spring preload. However, if the fork frequently bottoms out (hard end stop on com- pression), harder springs must be fitted to avoid damage to the fork and frame. -
Page 38: Adjusting Fork Fluid Barrier
10 TUNING THE CHASSIS Info Turn clockwise to increase the spring preload; turn counter- clockwise to reduce the spring preload. Adjusting the spring preload has no influence on the absorp- tion setting of the rebound. Basically, however, you should set the rebound damping higher with a higher spring preload. - Page 39 TUNING THE CHASSIS 10 – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the lower end of the right fork leg. – Turn counterclockwise by the number of rotations corresponding to the fork type. Guideline E01745-10 Compression damping Standard...
-
Page 40: 11 Service Work On The Chassis
11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure 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. –... -
Page 41: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS 11 Warning Danger 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 neces- sary. -
Page 42: Removing The Lower Triple Clamp
11 SERVICE WORK ON THE CHASSIS Guideline Screw, top triple clamp 12 Nm (8.9 lbf ft) – Tighten screws Guideline Screw, bottom triple 10 Nm (7.4 lbf ft) clamp Info Grooves are milled into the side of the upper end of the fork legs. - Page 43 SERVICE WORK ON THE CHASSIS 11 – Remove screw – Remove steering head nut and carefully remove upper triple clamp. E01349-10 – Remove adjusting ring E01351-10 – Remove the lower triple clamp downwards from the steering head. – Remove protection cap and remove upper tapered roller bear- E01350-10...
-
Page 44: Installing The Lower Triple Clamp
11 SERVICE WORK ON THE CHASSIS 11.7 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 112) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing –... -
Page 45: Checking The Steering Head Bearing Play
SERVICE WORK ON THE CHASSIS 11 – Mount handlebar cushion in area E01347-13 Finishing work – Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly. 11.8 Checking the steering head bearing play Warning Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages com- ponents. - Page 46 11 SERVICE WORK ON THE CHASSIS Main work – Remove handlebar cushion E01347-12 – Remove screws – Take off handlebar and place it to the rear carefully. Info Cover the components to protect them against damage. Do not kink the cables and lines. E01348-10 –...
-
Page 47: Lubricating The Steering Head Bearing
SERVICE WORK ON THE CHASSIS 11 – Position the handlebar, mount and tighten screws Guideline Screw, handlebar 25 Nm (18.4 lbf ft) clamp E01348-10 – Mount handlebar cushion in area E01347-14 Finishing work – Check the steering head bearing play. ( p. -
Page 48: Installing The Headlight Mask
11 SERVICE WORK ON THE CHASSIS 11.12 Installing the headlight mask – Hook in the headlight mask in area E01352-10 – Secure the headlight mask to the fork legs with cable ties E01344-12 11.13 Removing the front fender – Remove screws and take off the fender. -
Page 49: Removing The Shock Absorber
SERVICE WORK ON THE CHASSIS 11 11.15 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 38) – Turn tap handle of the fuel tap to the OFF position. – Remove the fuel tank. p. -
Page 50: Installing The Air Filter Box
11 SERVICE WORK ON THE CHASSIS – Remove screws E01354-10 – Lift the air filter box from the frame until the plug-in connector is visible while pulling the inlet sleeve off the carburetor. – Disconnect plug-in connector – Lift the air filter box off the frame. E01356-10 11.18 Installing the air filter box... -
Page 51: Removing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 11 11.19 Removing the air filter box cover – Remove screw – Take off the air filter box cover by lifting it forwards. E01357-10 11.20 Installing the air filter box cover – Suspend the air filter box cover at the rear and mount and tighten the screw Guideline Remaining screws,... -
Page 52: Installing The Air Filter
11 SERVICE WORK ON THE CHASSIS – Remove screw – Remove air filter with air filter support from the air filter box. – Remove air filter from air filter support. E01359-10 11.22 Installing the air filter Main work – Mount the clean air filter on the air filter support. –... -
Page 53: Removing The Main Silencer
SERVICE WORK ON THE CHASSIS 11 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 112) Info Only press the air filter to dry it, never wring it out. –... -
Page 54: Installing The Main Silencer
11 SERVICE WORK ON THE CHASSIS 11.25 Installing the main silencer Main work – Position the shock absorber and mount screw , but do not tighten it yet. – Mount screw with nut but do not tighten it yet. – Mount screw with the spacer, but do not tighten yet. -
Page 55: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS 11 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –... -
Page 56: Checking The Chain For Dirt
11 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. –... -
Page 57: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 11 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 The service life of the chain depends largely on its maintenance. Preparatory work –... -
Page 58: Adjusting The Chain Tension
11 SERVICE WORK ON THE CHASSIS 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. -
Page 59: Checking The Frame
SERVICE WORK ON THE CHASSIS 11 11.32 Checking the frame – Check the frame for cracks and deformation. » If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. -
Page 60: Adjusting The Free Travel Of The Clutch Lever
11 SERVICE WORK ON THE CHASSIS 11.36 Adjusting the free travel of the clutch lever – Check the free travel of the clutch lever. ( p. 57) – Loosen nut – Adjust the free travel of the clutch lever with adjusting screw Info Turn the adjusting screw clockwise to reduce free travel. -
Page 61: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS 11 – Move the hydraulic clutch fluid reservoir mounted on the handlebar into a horizontal position. – Remove screws – Take off cover with membrane. – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) »... - Page 62 11 SERVICE WORK ON THE CHASSIS – Now press the fluid into the system until it emerges from hole of the master cylinder without 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.
-
Page 63: Brake System 12
BRAKE SYSTEM 12 12.1 Checking the free travel of the hand brake lever – Pull the hand brake lever and check the free travel ≥ 3 mm (≥ 0.12 in) Free travel of hand brake lever » If the free travel does not match the specification: –... -
Page 64: Removing Front Brake Disc Guard
12 BRAKE SYSTEM 12.4 Removing front brake disc guard – Remove screws and take off the brake disc guard to the rear. E01340-10 12.5 Installing the front brake disc guard – Position the brake disc guard at the front. – Mount and tighten screws Guideline Screw, front brake... -
Page 65: Checking The Front Brake Fluid Level
BRAKE SYSTEM 12 Main work – Position the brake caliper on the brake disc carefully. E01343-01 Finishing work – Install the brake disc guard at the front. p. 62) 12.8 Checking the front brake fluid level Warning Danger of accidents An insufficient brake 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. - Page 66 12 BRAKE SYSTEM 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. –...
-
Page 67: Checking The Front Brake Linings
BRAKE SYSTEM 12 12.10 Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized GASGAS Motorcycles workshop will be glad to help.) – Check the brake linings for minimum thickness ≥... - Page 68 12 BRAKE SYSTEM Warning Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for GASGAS motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings. If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed.
-
Page 69: Checking Brake Discs
BRAKE SYSTEM 12 Guideline 5 mm (0.2 in) Level (brake fluid level below reservoir rim) Brake fluid DOT 4 / DOT 5.1 ( p. 110) – Position cover with the membrane. Mount and tighten screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled. -
Page 70: Checking The Free Travel Of The Foot Brake Lever
12 BRAKE SYSTEM 12.13 Checking the free travel 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. –... -
Page 71: Checking The Rear Brake Fluid Level
BRAKE SYSTEM 12 12.15 Checking the rear brake fluid level Warning Danger of accidents An insufficient brake 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. - Page 72 12 BRAKE SYSTEM 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.
-
Page 73: Checking The Brake Linings Of The Rear Brake
BRAKE SYSTEM 12 – Mount and tighten screws with plastic bushing Guideline Screw, foot brake cylin- 10 Nm (7.4 lbf ft) – Position foot brake lever; insert push rod into foot brake cylinder. – Mount and tighten screw with nut Guideline Screw, foot brake lever 25 Nm (18.4 lbf ft) - Page 74 12 BRAKE SYSTEM 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.
- Page 75 BRAKE SYSTEM 12 – Remove screw – Carefully remove the brake caliper from the link fork. E01381-10 – Remove clamping spring to the right. – Push back brake piston and remove brake linings. – Clean brake caliper. E01382-10 – Insert the new brake linings. Info Always change the brake linings in pairs.
- Page 76 12 BRAKE SYSTEM – Position foot brake lever; insert push rod into foot brake cylinder. – Mount and tighten screw with nut Guideline Screw, foot brake lever 25 Nm (18.4 lbf ft) E01398-10...
-
Page 77: Wheels, Tires 13
WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 38) Main work – Loosen screw by several rotations. – Loosen wheel spindle – Press the left-hand side of wheel spindle to push the wheel spin- dle out of the axle clamp. -
Page 78: Removing The Rear Wheel
13 WHEELS, TIRES Guideline Screw, axle clamp 23 Nm (17 lbf ft) 13.3 Removing the rear wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 38) Main work – Remove screw with spacer E01384-10 – Turn eccentrics so that the greatest possible chain play is present. -
Page 79: Installing The Rear Wheel
WHEELS, TIRES 13 13.4 Installing the rear wheel Warning Danger 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. Main work –... -
Page 80: Checking The Tire Condition
13 WHEELS, TIRES – Make sure that eccentrics are fitted correctly to the screws of link fork – Adjust the chain tension. ( p. 56) – Tighten screw Guideline Screw, rear wheel spin- 50 Nm (36.9 lbf ft) E01388-10 Finishing work –... -
Page 81: Checking Tire Pressure
WHEELS, TIRES 13 – Check the tire age. Info The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT num- ber. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. - Page 82 13 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of differ- ent spoke tensions.
-
Page 83: Electrical System 14
ELECTRICAL SYSTEM 14 14.1 Diagnostics connector The diagnostics connector is located on the right-hand side above the radiator fan. E01385-10... -
Page 84: 15 Cooling System
15 COOLING SYSTEM 15.1 Cooling system Water pump in the engine ensures forced circulation of the coolant. The pressure in the cooling system resulting from heat is regulated by a valve in the radiator. E01394-10 15.2 Checking the antifreeze and coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. -
Page 85: Draining The Coolant
COOLING SYSTEM 15 – Check the coolant level in the radiator. 5 mm (0.2 in) Coolant level above the radiator fins » If the coolant level does not match the specified value: – Correct the coolant level. – Mount and tighten radiator cap screw 400243-10 15.3 Draining the coolant... -
Page 86: Refilling With Coolant
15 COOLING SYSTEM 15.4 Refilling with coolant 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. –... - Page 87 COOLING SYSTEM 15 Condition The engine is cold. – Position the motorcycle upright. – Place an appropriate container under the water pump cover. – Remove radiator cap screw – Remove screw – Completely drain the coolant. – Mount and tighten screw with a new seal ring.
-
Page 88: 16 Tuning The Engine
16 TUNING THE ENGINE 16.1 Checking the throttle cable play – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throt- tle grip back and forth slightly and determine the play in throttle cable Throttle cable play 2 …... -
Page 89: Carburetor Tuning
TUNING THE ENGINE 16 16.3 Carburetor tuning Effects of carburetor tuning H01400-01 The different carburetor components must be tuned both to one another and for the use intended. Main jet MJ The main jet MJ has the greatest influence with the throttle slide open (full throttle). If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger main jet needs to be used. - Page 90 16 TUNING THE ENGINE Influence of throttle slide adjustment K00495-01 The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position have only minimal influence. When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the great- est influence.
-
Page 91: Carburettor - Idle Speed
TUNING THE ENGINE 16 Carburettor – idle speed 16.4 The idle setting of the carburetor significantly influences the vehicle’s starting behavior, the stability of the idle speed, and the vehicle’s response when accelerating. An engine with a correctly set idle speed will be easier to start than one with an incorrectly set idle speed. -
Page 92: Checking The Basic Position Of The Shift Lever
16 TUNING THE ENGINE Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle air adjusting screw to the end with- out any change of engine speed, mount a smaller idling jet. -
Page 93: Service Work On The Engine 17
SERVICE WORK ON THE ENGINE 17 17.1 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 94: Checking The Gear Oil Level
17 SERVICE WORK ON THE ENGINE 17.2 Checking the gear oil level Condition Engine stopped a few minutes ago. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work – Check the gear oil level in level viewer The gear oil level is between the upper edge of the level viewer and the bottom... - Page 95 SERVICE WORK ON THE ENGINE 17 Condition The engine is at operating temperature. Preparatory work – Park the motorcycle on a level surface. – Position an appropriate container under the engine. Main work – Remove gear oil drain plug – Let the gear oil drain fully.
-
Page 96: 18 Cleaning, Care
18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... - Page 97 CLEANING, CARE 18 – Treat bare metal (except for brake discs and the exhaust system) with a corrosion 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.
-
Page 98: 19 Storage
19 STORAGE 19.1 Storage Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –... -
Page 99: Preparing For Use After Storage
STORAGE 19 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 38) – Perform checks and maintenance measures when preparing for use. p. 23) – Take a test ride. 401059-01... -
Page 100: 20 Troubleshooting
20 TROUBLESHOOTING Faults Possible cause Action – Engine does not start Operating error Carry out start procedure. ( p. 23) – The motorcycle has been in disuse Empty the carburetor float chamber. for an extended period and old p. 91) fuel is in the float chamber –... - Page 101 TROUBLESHOOTING 20 Faults Possible cause Action Too little coolant in cooling system – Engine overheats Check the cooling system for tightness. – Check the antifreeze and coolant level. p. 82) – Too little air stream Switch off the engine when standing. –...
-
Page 102: 21 Technical Data
21 TECHNICAL DATA 21.1 Engine Design 1-cylinder 2-stroke gasoline engine, water-cooled, with membrane inlet Displacement (All 125 models) 124.8 cm³ (7.616 cu in) Displacement (All 250 models) 247.7 cm³ (15.116 cu in) Displacement (All 280 models) 272.2 cm³ (16.611 cu in) Displacement (All 300 models) 294.1 cm³... -
Page 103: Engine Tightening Torques 22
ENGINE TIGHTENING TORQUES 22 Screw, clutch spring 6 Nm (4.4 lbf ft) Screw for shift shaft spring 7 Nm (5.2 lbf ft) Screw for spring shift lock 8 Nm (5.9 lbf ft) Screw, alternator cover 8 Nm (5.9 lbf ft) Screw, clutch cover 8 Nm (5.9 lbf ft) Screw, crankshaft speed sensor... -
Page 104: 23 Carburetor
23 CARBURETOR Carburetor type KEIHIN PWK 28 Needle position (All 300 models) Fourth position from top Needle position (All 125/250/280 models) 3rd position from top Jet needle Main jet (All 125 models) Main jet (All 250 models) Main jet (All 280 models) Main jet (All 300 models) Idling jet (All 125 models) Idling jet (All 250 models) -
Page 105: Capacities 24
CAPACITIES 24 24.1 Gear oil Gear oil 0.37 l (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. -
Page 106: 25 Chassis
25 CHASSIS Frame Tubular frame made of chrome molybdenum steel Fork (All RACING models) Tech 39 mm Fork (All GP models) Tech 39 mm Suspension travel (All GP models) front 167 mm (6.57 in) rear 174 mm (6.85 in) Suspension travel (All RACING models) front 177 mm (6.97 in) rear... -
Page 107: Tires 26
TIRES 26 Front tire Rear tire 2.75 - 21 M/C 45L TT 4.00 R 18 M/C 64L TL Michelin Trial Competition X11 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: 27 Fork
27 FORK 27.1 All GP models Fork article number BT20000GG-CKR-1 Fork Tech 39 mm Compression damping Standard 1.75 turns 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: Shock Absorber 28
SHOCK ABSORBER 28 28.1 TXT GP 125 Shock absorber article number BT30000GG-DBG-1 Shock absorber Reiger 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.) 65 N/mm (371 lb/in) Weight of rider: 70 …... -
Page 110: 29 Chassis Tightening Torques
29 CHASSIS TIGHTENING TORQUES Screw, rear brake line guide 5 Nm (3.7 lbf ft) Spoke nipple, front wheel M4.5 2 Nm (1.5 lbf ft) Spoke nipple, rear wheel M4.5 3 Nm (2.2 lbf ft) Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, brake disc guard, rear wheel... - Page 111 CHASSIS TIGHTENING TORQUES 29 Banjo bolt,.clutch master cylinder 18 Nm (13.3 lbf ft) Banjo bolt,.clutch slave cylinder 20 Nm (14.8 lbf ft) Remaining nuts, chassis 45 Nm (33.2 lbf ft) Remaining screws, chassis 45 Nm (33.2 lbf ft) Screw, bell crank 45 Nm (33.2 lbf ft) Screw, bottom shock absorber 50 Nm (36.9 lbf ft)
-
Page 112: 30 Substances
30 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®... - Page 113 SUBSTANCES 30 Hydraulic fluid (15) Standard/classification – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. Recommended supplier MOTOREX ® – Hydraulic Fluid 75 Super unleaded (ROZ 98 / RON 98 / PON 94) Standard/classification –...
-
Page 114: 31 Auxiliary Substances
31 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer Long-life grease Recommended supplier MOTOREX ® – Bike Grease 2000 Motorcycle cleaner Recommended supplier... - Page 115 AUXILIARY SUBSTANCES 31 Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...
-
Page 116: 32 Standards
32 STANDARDS JASO FD JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. -
Page 117: List Of Abbreviations 33
LIST OF ABBREVIATIONS 33 Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 118: Index
INDEX fluid, changing ..... . . 59 INDEX Clutch lever ......Accessories . - Page 119 INDEX Front wheel installing ......75 Owner's Manual ......8 removing .
- Page 120 INDEX Storage ......96 Switch-off button ..... . . 14 Technical data capacities .
- Page 121 *3215003en* 3215003en 06/2020 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...