GAS GAS TXT RACING 2015 User Manual

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TXT RACING 2015

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Summary of Contents for GAS GAS TXT RACING 2015

Page 1 TXT RACING 2015 TXT RACING 2015...
Page 3 GAS GAS thank you for the trust you have placed in us. Thank you for your trust in us, and welcome to GAS GAS Motorbikes. By choosing the new GAS GAS TXT RACING 2015 you have become part of the great GAS GAS family and, as...
Page 4 Manual. However, GAS GAS Motos, S.A. reserves the right to make modifications without any prior warning being given to consumers and without incurring any additional obligations in so doing.
Page 5 Contents Thanks to consumer Carburettor dismantle Important notice Carburettor capacity check Warranty regulations 6 to 8 Carburettor cleaning Recommendations Inlet valves dismantle Technical specifications 10 & 11 Inlet valves Component location 12 & 13 Clutch operations Maintenance guide 14 & 15 Discs and clutch spring Serial number Air bleed...
Page 6 Warranty terms of the manufacturer GASGAS Motos, S.A. The company GAS GAS MOTOS, S.A. (hereafter referred to as “GG”), with this present document guarantees the consumer, the purchaser of a vehicle manufactured by GG, that both the materials and the manufacturing are free of defects in accordance with the highest standards of quality.
Page 7 Obligation of the purchaser GG will have the right to reject any claims under Warranty in the event that: a) The purchaser has failed to submit the vehicle to any of the inspections and/or maintenance work required in the Users’ Manual, or has exceeded the date set for such inspections or maintenance work.
Page 8 e) Any damages caused as a result of the defects, as well as any expenses incurred either directly or indirectly as a consequence of the defects (for example, communication costs, accommodation expenses, car hire costs, public transport costs, breakdown truck fees,, courier costs, etc.), as well as other financial losses (for example, those caused by the loss of the use of the vehicle, loss of income, time lost, etc.) f) Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle (for example, small or hidden imperfections, noise or vibrations that are normal in use, etc.)
Page 9 Recommendations for the reliable operartion of your GAS GAS. •Eight hours of running-in are 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.
Page 10 Digital magnetic flywheel CDI TRANSMISSION Transmission type 6 gears, Four / Six system by GAS GAS* (Patented). Clutch type Hydraulic command, 1/3 discs, variable progres. with diaphragm system by GAS GAS* (Patented). Final drive system By chain Gear ratio 1st. 2,996 (35x27x28/16x24x23) 2nd.
Page 11 Primary reduction ratio 2,777 (75/27) Final reduction ratio 3,818 (42/11). 125cc - 300cc 6,667 (60/9). 80cc Overall drive ratio 8,704 (6th. gear). 125cc - 300cc 15,2 (6th gear). 80cc Transmission oil Capacity 400 cc. Type 75W GRO GEAR EXTREME FRAME Type Tubular profile made with Cr-Mo.
Page 12 12 Front brake disc 24 Middle silencier 1 Front fender 13 Cylinder 25 Radiator 2 Front brake caliper 14 Carburetor 26 Headlight 3 Front suspension left 15 Chain guide 27 Front tyre air valve 16 Chain tensioner 28 Rear brake disc 4 Front suspension bar 17 Chain 29 Sidestand arm...
Page 13 36 Rear fender 47 Clutch pump 37 Axle nut rear wheel 48 Handlebar 38 Left foot peg 49 Left suspension regulation 39 Air filter box cover 50 Multifunction 40 Shift pedal 51 Warning indicators 41 Ignition cover 52 Right suspension regulation 42 Fuel tank 53 Front brake pump 43 Fuel tank cap...
Page 14 The maintenance table and adjustments are easy to carry out and must be done to insure the motorcycle is in good running condition. MAINTENANCE TABLE Part Check / Adjust Replace / Clean Grease / Inspect Change Lubricate Rear shock absorber Every year Every 2 years 30 hours...
Page 15 MAINTENANCE TABLE Part Check / Adjust Replace / Clean Grease / Inspect Change Lubricate Exhaust Every race 500 hours Packing 100 hours Air filter Every race If is damaged Every race Every cleaning Steering assembly Every race If is necessary Brake hose Every race If is necessary...
Page 16 Enter the vehicle identification number (serial The new GAS GAS number), the particulars shown on the model TXT RACING 2015 label, and the ignition-key identification number carries the appropriate in the spaces provided, in order to simplify certification plate your future orders for spare parts or as a useful reference...
Page 17 All light controls have been The indicator control located on the left-hand grip; the has been located on various positions available are the underside of the reached by sliding the main left-hand grip. This is an orange- switch, which is on the left end colour button.
Page 18 L o c a t e d u n d e r t h e suspension lower right side Fuel tank capacity : 2,4 liters bracket. For correct operation, it is necessary Use premium gasoline with an octane rating equal to or higher to turn the handlebar completely than that shown in the table.
Page 19 1/4 turn in counterclockwise designed to burn direction. To close it, place cap with the words GAS GAS in m i x t u r e the upper position, and turn the tab in clockwise direction.
Page 20 80cc carburetor model The choke (B) is a device for aiding the starting when cold. The enigne will r e a c h n o r m a l temperature in a short time and it won’t damage anything. The idle and petrol-air mixture can be adjusted by the screw as shown in the illustration.
Page 21 125 - 300cc carburetor model The choke (B) is a device for aiding the starting when cold. The enigne will r e a c h n o r m a l temperature in a short time and it won’t damage anything.
Page 22 Mínimo 3 mm L i k e t h e c l u t c h lever, the front brake lever must be in the ideal position. Again, the play must not exceed 3mm, The clutch lever must be adjusted to your liking, but the free play should not This play must exceed 3mm.
Page 23 When topping up the oil, open the cap (A). The engine crankcase Engine Oil drain cap is situated on capacity the lower left-hand side. 400cc. The drainage hole in the crankcase allows emptying. To check the oil level, first make sure the motorbike is perpendicular to the ground.
Page 24 It is important to periodic lly check the air filter. Open the door on the motorbike as shown in the photo. Clean with water and detergent, then dry and lubricate with oil designed for filters. Ensure its correct 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-...
Page 25 Remove the fuel tank, located in the upper area of the chassis, before servicing the motor or any other internal part of the motorcycle. To do this, first check 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.
Page 26 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.
Page 27 To carry out any type of operations on and improve access to the carburetor, it is recommended to remove the filter box. You must follow these steps: 1.- Loosen the admission port clamp. 2.- Unscrew 4 tapered Allen screws M6 which 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.
Page 28 It is important to check the level of petrol within the carburetor. The float should be at 18.5mm. Fig. 3 It is necessary to clean the carburetor very thoroughly. To do so use compressed air. Extreme precautions must be taken to dry the inside of the carburetor thoroughly.
Page 29 80cc model The reed box assembly is composed of only one body, the Since this is the last stops. To inspect the assembly remove it by removing the point of access to the 4 screws (A) wich attach it to the rear of the left and right inside of the cylinder, crankcases.
Page 30 125 - 300cc model The reed box assembly is composed of only one body, the Since this is the last stops. To inspect the assembly remove it by removing the point of access to the 4 screws wich attach it to the rear of the left and right inside of the cylinder, crankcases.
Page 31 9,88 0.05 Check clutch discs for After any removal or assembly operations on the clutch air possible wear after trapped inside must be purged by many hours of use. For connecting wrench (spanner) and correct operation the minimum bleeding the system. measurement should be 9,83 mm.
Page 32 80cc model *Level of air chamber 155 mm. FRONT FORK ø 33 mm 575 mm. *Measure without the spring and the hydraulic rod extended -30-...
Page 33 125 - 300cc model *Level of air chamber 160 mm. FRONT FORK ø 40 mm. aluminium bars 575 mm. 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-...
Page 34 The preload on the shock absorber The front suspension is adjusted by turning the toothed is adjusted manually rings (C) with the aid of two special spanners. Right (hydraulic extension). Starting from the standard preload of 8.5mm, Left (hydraulic compression). 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).
Page 35 Adjust the rebound or extension by means of screw. The standard position is 30 clicks from closed. From this starting REIGER SHOCK ABSORBER position, open up clicks to get a IDEAL PRELOADS AND SPRINGS DEPENDING ON RIDER WEIGHT faster extension or rebound, and Rider weight without equip.(Kg) k (daN/mm) spring Spring preload (mm)
Page 36 The linkage at the lower part of rear suspension must be periodically cleaned, inspected and lubricated with grease. It is very important to periodically remove and verify the condition of the swingarm bearings and pieces. -33-...
Page 37 Use special oil to 2) The pivot of the lubricate the gear shift lever. following: 1) All pivot points of the brake and clutch levers. 4) Apply grease to the footrest springs 3) Also the rear brake and fixtures. p e d a l ( b e a r i n g s ) . - 34 -...
Page 38 6) The drive chain must be cleaned and 5) Apply grease to the linkage of lubricated thouroughly and frequently the engine starting pedal. since it is exposed to the elements and constant abrassion. 7) Lubricate the handlebar with a fine coat of oil to allow smooth operation of the throttle control.
Page 39 8) It is also recommended to frequently lubricate the chain tensioner spring because it is under great stress. 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. - 36 -...
Page 40 To regulate the chain slack The chain master link clip and center the rear wheel m u s t b e p l a c e d i n use the shaft excentrics opposite direction of the which can be easily wheel travel.
Page 41 A l l t y r e c o n d i t i o n s must checked to insure optimum. Fig. 1 - Bad condition Fig. 2 - Good condition Tyre pressure should be checked periodically to insure the best. Front wheel pressure: 0,450 bar - normal 0,420 bar - competition...
Page 42 Brake pad wear, front and rear, must be checked from time to time to insure an efficient braking power under all circumstances. The brake calipers have been furnished with bleeder valves to eliminate the air trapped in the brake The front brake fluid level system.
Page 43 The rear brake fluid reservoir is located at the cylinder support. Verify fluid level periodically and refill if necessary. 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 -40-...
Page 44 ELECTRICAL INSTALLATION. COMTETITION. - 41 -...
Page 45 ELECTRICAL INSTALLATION. HOMOLOGATION. -42-...
Page 46 ELECTRICAL INSTALLATION (IGNITION) - 43 -...
Page 47 Torques PART NAME PART NAME Front wheel axle 40 - 50 Spark plug Chassis to swingarm fastener 60 - 70 Ignition fasteners 7 - 8 Upper shock absorber fastener 40 - 50 Cluth fasteners 7 - 8 Lower shock absorber fastener 40 - 50 Cylinder stud bolt fasteners Connecting rods caps...
Page 48 STORAGE For extended storage of the motorcycle, you must do the following: - Clean the motorcycle thoroughly. - Start the engine for about 5 minutes to warm up the transmission oil and then drain it (see “crankcase drain cap” page 22). - Fill with new transmission oil.
Page 49 Multifunction gauge (Only on certain models and markets) QUICK GUIDE: SETUP MENU The multifunction device is water resistant, has 3 buttons To enter into the setup menu Endurance II, hold buttons 1, with a brightly lit LCD. 2 and 3 for three seconds. Be sure to hold the 3 buttons at the same time.
Page 50 ADJUSTING the distance units: Select the units (kilometers or miles) with 1 or 2 buttons. SET the front tire size: Select the size with button 1 or 2 (2300m). ADJUST the clock format: Select the desired format using the buttons 1 or 2 (12H or 24H). SETTING the time: Set the clock to the desired time by pressing 1 to 2.
Page 51 SCREENS IN NORMAL MODE: Screen 1: DST DST (Distance Traveled). DST function accumulates the distance data since the last reset while you’re riding a motorcycle. Press and hold buttons 1 and 2 for three seconds to reset DST (Distance 1 ). Hold the button 3 to set the DST.
Page 52 TROUBLESHOOTING NOTE This is not an exhaustive list of malfunctions, it only shows the most common problems. POSSIBLE CAUSE REMEDY MALFUNCTION Engine does not start - Seized crankshaft. - Go to a specialized workshop. - Seized cylinder / piston / jornal bearing. - Go to a specialized workshop.
Page 53 MALFUNCTION POSSIBLE CAUSE REMEDY The engine operates irregularly - Ignition rotor damaged. - Replace the rotor. - Water in fuel. - Drain the fuel tank and fill up with new fuel. Engine lacks power or poor - Fuel supply defective. - Clean the fuel system and verify its operation.
Page 54 MALFUNCTION POSSIBLE CAUSE REMEDY Gears do not engage correctly - Clutch does not disengage. - Go to a specialized workshop. - Bent or seized shift fork. - Replace the shift fork. - Gear seized at the transmission. - Go to a specialized workshop. - Damaged gearshift lever.
Page 55 MALFUNCTION POSSIBLE CAUSE REMEDY Shock absorber set too hard - Excessive front fork oil. - Pour excess oil until reaching the correct oil level. - Front fork oil viscosity too high. - Drain fork oil and fill with correct fork oil viscosity. - Bent front fork.
Page 56 MALFUNCTION POSSIBLE CAUSE REMEDY Handlebar vibration - Excessive steering axles tolerances. - Tighten steering bracket and steering stem locknut to the correct torque values. - Loose handlebar bracket, and loose - Tighten steering bracket and steering stem locknut to the handlebar stem locknut.
Page 57 In different sections of this manual you will find data and work specifications that must be done at an autorized GAS GAS dealer, because of this and to extend the useful life of the motorcycle, all periodical inspections must be carried out by specially trained professionals at a GAS GAS Post-Sale Service Shop.
Page 58 HOMOLOGATION (Only for homologated version) The vehicle you have just acquired has been homologated under the directives of the EU and complies with all the homologation requirements demanded. Compulsory homologation elements required, among others, when travelling on a public road and to meet periodical vehicle inspection approval at state controlled plants are listed below.
Page 59 HOMOLOGATION 1 - Front right turn signal 2 - Rear right turn signal 3 - Trial rear pilot 4 - Rear left turn signal 5 - M6 Bolt 6 - ULS screw 6x16 Phillips screw M6 x 25 8- Philips screw 6.3x16 9- Front left turn signal 11- Trial license holder homologated 12- Stand spring...