Table of Contents
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Table of Contents
Related Manuals for GAS GAS TXT 2018 Series
Summary of Contents for GAS GAS TXT 2018 Series
- Page 1 2018 Workshop Manual txt SERIES Trial 80 125 250 280 300cc...
- Page 2 2017 GAS GAS All rights reserved Reprinting and reproduction of any kind, either in whole or in part, is prohibited without the written permission of the copyright holder. The company has the right, without prior notice, to change the technical content of the products.
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Page 3: Table Of Contents
Workshop manual Contents GenerAl informAtion ..............................4 introduction ................................... 5 leGAl noticeS ................................... 5 noticeS And wArninGS..............................5 SAfety ruleS ..................................6 mAintenAnce ..................................6 recommended “work method” ...........................7 VEhiclE / EnginE idEnTificaTion...........................8 tiGhteninG torque ................................. 8 SPeciAl toolS .................................. 10 mAintenAnce .................................. 12 mAintenAnce ProGrAmme ............................ -
Page 4: General Information
Workshop manual General information... -
Page 5: Introduction
ToRRoT ElEcTRic EURoPa S.a. thanks you for your confidence. This manual was created by ToRRoT ElEcTRic EURoPa S.a. to be used by official services of the gaS gaS (gg) brand. it is assumed that whoever reads this publication for enjoyment or for the repair of gg vehicles has a basic knowledge of the principles of mechanics and the methods used in the repair of these vehicles. -
Page 6: Safety Rules
Workshop manual Safety rules DANGER it is necessary to follow certain safety and maintenance rules when doing repair work on vehicles. here are some of the most important: SAFETY - if it is necessary to carry out work on the engine while it is still running, make sure that the premises have adequate ventilation and, if necessary, use smoke extractors. -
Page 7: Recommended "Work Method
Workshop manual recommended “work method” - Remove all dirt, mud, dust and other foreign material before disassembly. Use appropriate tools and cleaning equipment. - When removing parts, always keep them together in their pairs. This includes gears, cylinders, pistons and other parts subjected to natural wear in their pairs. -
Page 8: Vehicle / Engine Identification
Workshop manual Vehicle / engine identification Make a note of the vehicle’s identification number (serial no.), information on the model label and key identification details in the spaces provided for this purpose for ease of ordering spare parts or as a reference in the event of theft of the motorcycle. - Page 9 Workshop manual TYPE ASSEMBLY PHASE MEASUREMENT RATED TORQUE (Nm) Screw Rear lower handlebar clamp Screw front upper handlebar clamp Screw clutch pump clamp Screw front wheel axle M18x1.5 Screw Suspension mudguard support Screw Bottom suspension clamp Screw Top suspension clamp Top steering cap nut M20x1 Screw...
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Page 10: Special Tools
Workshop manual SPeCial toolS -10-... - Page 11 Workshop manual Special tools - Magneto flywheel puller. Ref: MT280234045 - Primary transmission sprocket puller. Ref: MT280250006 - Tool set for 250cc-280cc-300cc engines. Ref. 865207 - Primary sprocket puller. Ref. MT95005GG-CHA-1 - Primary nut removal tool. Ref. MT95010GG-CHA-1 -11-...
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Page 12: Maintenance
Workshop manual maintenanCe -12-... -
Page 13: Maintenance Programme
Workshop manual maintenance programme Grease / Element Check / Inspect Adjust Replace/Change Clean Lubricate Throttle operation Every race If is necessary Every race Carburettor / Jet Every race If is necessary 30 hours Air filter Every race If is necessary Every race Every wash Reed block... -
Page 14: Periodic Inspection
Workshop manual Periodic inspection ATTENTION: Before removing the spark plug, blow compressed air around it to remove any dirt, making sure that it does not fall into the engine. Remove: - Spark plug cap. - Spark plug. Check: - Spark plug type incorrect =>... - Page 15 Workshop manual Periodic inspection AIR FILTER Cleaning the filter - It is important to periodically check the air filter. - Inspect the filter and replace it if damaged to prevent dirt from entering the carburettor. - To clean it, use water and detergent, dry it and lubricate it with special filter oil.
- Page 16 Workshop manual Periodic inspection - Remove the filter rod (arrow) completely. - Remove the inner visor to access the filter. - clean inside the filter box with a damp cloth. Remove the filter by unscrewing the bar (1) - Remove the cage from the air filter. (2) clean the filter in a filter cleaning bath using a soft brush.
- Page 17 Workshop manual Periodic inspection - View of the filter components once clean. - for reassembly, follow the same steps in reverse. TRANSMISSION OIL LEVEL for the transmission and clutch to work properly, keep the transmission oil at the optimum level and replace it periodically. a motorcycle with insufficient, deteriorated or contaminated transmission oil can accelerate wear and damage transmission.
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Page 18: Carburettor Disassembly And Inspection
Workshop manual Carburettor disassembly and inspection CARBURETTOR - disconnect the fuel line and fuel tap, and remove the carburettor. - loosen securing clamps (1) and (2) of the carburettor from the inlet and air filter nozzles. - Remove the carburettor. -18-... - Page 19 Workshop manual Carburettor disassembly and inspection * for models with Keihin PWK28 carburettor - compress the gas valve return spring against the cover and remove the throttle cable terminal through the channel in the gas valve. - Remove the securing clamp from the piston valve of the cold start system. (starter) and remove the assembly (1).
- Page 20 Workshop manual Carburettor disassembly and inspection - check that the cone at the end of the fuel flow control pin and the float connector stud spring are in good condition, if not, replace with new ones. - Check the condition of the fuel flow system piston valve. Replace it if there is any damage to the vulcanised sealing seating or on the metal body of the piston itself (scratches and/or corrosion exceeding 25% of its total surface area).
- Page 21 Workshop manual Carburettor disassembly and inspection - check the position of the circlip on the conical dosing needle. - By moving the circlip upwards on the needle, a weaker mixture will be produced and, by moving it downwards on the needle, a richer mixture will be obtained;...
- Page 22 Workshop manual Carburettor disassembly and inspection - Reassemble the carburettor completely. Re-mount the carburettor onto the engine, making sure that the fuel lines and tap depressor activation are properly connected. - check that the air volume adjustment screw (compensator) on the low speed (idle) circuit is in the same position as before it was removed (if in doubt, consult the vehicle characteristics table to determine the standard position).
- Page 23 Workshop manual Carburation table 125 cc Type of carburettor KEihin PWK28 Main jet idle jet needle needle position 3rd from above Throttle valve air screw 1v+1/4v , 1v+1/2v float level 250 cc Type of carburettor dell’orto PhBl26BS KEhin PWK28 Main jet idle jet needle needle position...
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Page 24: Reed Block Disassembly And Inspection
Workshop manual reed block disassembly and inspection REED BLOCK - Remove the carburettor from the engine. - Remove the inlet nozzle securing screws, after which you can release the reed valve. - Check that the reed petals are not cracked, deformed or broken. If they are, replace them. -
Page 25: Exhaust System Disassembly And Inspection
Workshop manual exhaust system disassembly and inspection EXHAUST SYSTEM - Remove the rear structure of the motorcycle by unscrewing the bolts that hold - disconnect the clamp that secures the air filter to the carburettor. - Remove the filter box structure by disconnecting the electrical wiring. -25-... - Page 26 Workshop manual exhaust system disassembly and inspection - Unscrew the bolts that hold the exhaust elbow to the cylinder. - once the previous step has been carried out, release the exhaust elbow from the muffler by pulling it, as shown in the photograph. - Then remove the muffler.
- Page 27 Workshop manual exhaust system disassembly and inspection - Release the muffler from the screw that holds it at the top, as shown in the image. - continue unscrewing the upper bolt from the rear brake pump to release the muffler from the bottom. - Then extract the screw from the shock absorber that secures the muffler to the frame.
- Page 28 Workshop manual exhaust system disassembly and inspection - once the bolts have been removed, extract the muffler from the rear part of the motorcycle frame. - Once the exhaust assembly has been removed from the motorcycle, check that the system’s gaskets and couplings are in good condition to prevent leaks.
- Page 29 Workshop manual exhaust system disassembly and inspection - To change the exhaust fibre, remove the screws that secure the rear plastic part of the muffler to the metal part (see photograph). - Then, with a nylon hammer, carefully tap the metal part downwards, as shown in the photograph.
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Page 30: Cylinder Head Disassembly And Inspection
Workshop manual Cylinder head disassembly and inspection -30-... - Page 31 Workshop manual Cylinder head disassembly and inspection CYLINDER HEAD - Empty the coolant by removing the hose located in the water pump. - Place a tray underneath to collect it. - Remove the hose between the cylinder head and radiator. - disconnect the high-voltage cable from the spark plug (cap), and remove it.
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Page 32: Cylinder And Piston Disassembly And Inspection
Workshop manual Cylinder head disassembly and inspection - Using a feeler gauge and straight edge ruler, check for warping on the bearing planes, both on the cylinder head and on the cylinder. Maximum warpage 0.05 mm. Cylinder and piston disassembly and inspection CYLINDER AND PISTON - drain the coolant from the engine. - Page 33 Workshop manual Cylinder and piston disassembly and inspection - Check the cylinder on the inside and make sure it is not scratched. If there are any scratches or signs of wear, replace it. - Place a clean cloth in the opening of the crankcase to prevent objects from accidentally falling inside.
- Page 34 Workshop manual Cylinder and piston disassembly and inspection - Remove the gasket from the base of the cylinder. - gently clean and remove any gasket debris and carbon deposits (avoid scratch- ing the circumference of the piston). - Visually check the condition of the connecting rod end. if there is damage to the surface from contact with the needle roller bearing, replace it.
- Page 35 Workshop manual Cylinder and piston disassembly and inspection - Verify the distance between the tips of the rings (0.15mm/0.35mm), inserting them in an aligned manner inside the cylinder and checking the distance with a feeler gauge. - Check the cylinder’s degree of wear with an alesometer. Calibrate it beforehand using the dimensions contained in the cylinder-piston families table.
- Page 36 Workshop manual Cylinder and piston disassembly and inspection 80cc MODEL FAMILY cleArAnce Tolerance category cylinder PiSton ASSembly mAximum 42.970 +0.01 42.940 0.030 0.080 42.980 +0.01 42.950 0.030 0.080 42.990 +0.01 42.960 0.030 0.080 43.000 +0.01 42.970 0.030 0.080 125cc MODEL FAMILY cleArAnce cylinder PiSton...
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Page 37: Starter System Disassembly And Inspection
Workshop manual Starter system disassembly and inspection * for models with electric starter -37-... - Page 38 Workshop manual Starter system disassembly and inspection * for models with electric starter STARTER SYSTEM - Remove the gear shift pedal and the magneto flywheel alternator cover on the left-hand side of the engine. - To release the magneto flywheel cover, remove the screws marked with arrows in the photograph.
- Page 39 Workshop manual Starter system disassembly and inspection - To unscrew the central nut, you will need puller Ref: MT280234045 - Using the extractor, a spanner and a ratchet, unscrew the central nut and release the starter sprocket and ignition rotor. - To remove the stator coil assembly, loosen and remove the screws (marked with arrows in the photograph) that secure it to its support.
- Page 40 Workshop manual Starter system disassembly and inspection - Release the ignition pick-up. - loosening and extracting the two bolts that secure it to the semi-crankcase. - once all of the fixing bolts are released, you can remove the stator assembly and ignition pick-up.
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Page 41: Clutch Assembly Disassembly And Inspection
Workshop manual Clutch assembly disassembly and inspection CLUTCH ASSEMBLY - drain the coolant from the engine. - drain the transmission oil by removing the two plugs (clutch semi-crankcase and crankcase base). - Remove the water pump assembly. (1) -41-... - Page 42 Workshop manual Clutch assembly disassembly and inspection - Remove the screws from the clutch cover (2), cover and gasket. This will provide access to the assembly of primary transmission elements, and clutch. - Remove the clutch assembly by removing the central nut that secures the clutch.
- Page 43 Workshop manual Clutch assembly disassembly and inspection - Extract the driving clutch plate, and remove all of the screws to access the discs. - Replace the disc if it has lost some of its lining, has thermal fatigue (coloured) or is deformed, or its external crenellation is damaged. - check the clutch discs for warpage, max.
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Page 44: Crankcase Disassembly And Inspection
Workshop manual Crankcase disassembly and inspection CRANKCASES - Remove the thermodynamic assembly (cylinder head, cylinder and piston). - Remove the magneto flywheel alternator. - Extract the bearing from the clutch sprocket, remove the circlip and then the needle bearing. - once the needle bearings have been extracted, we will remove the kick-start sprocket assembly. - Page 45 Workshop manual Crankcase disassembly and inspection - To remove the intermediate kick-start sprocket assembly (1), release the seeger (2) and, once the washer has been removed, extract the kick-start sprocket assembly. - once the above operation has been carried out, you can remove the bearing and the corresponding washer.
- Page 46 Workshop manual Crankcase disassembly and inspection - To be able to remove the sprocket (2), you must first extract the seeger (1) - once the above operation has been carried out, you can remove the sprocket, using puller (1) Ref: MT280250006 - This is how it should be left after the sprocket has been removed.
- Page 47 Workshop manual Crankcase disassembly and inspection - Remove the positioner and the selector shaft secured by means of a seeger and washer (2). - once the above operation has been carried out, you can remove the selector spring. - once all of the above disassembly steps have been carried out, this is what the crankcase will look like.
- Page 48 Workshop manual Crankcase disassembly and inspection - Remove the 9 screws that secure the left-hand crankcase. - Pay special attention to screw (5). It incorporates a copper washer. - This is how it should appear after the left-hand crankcase has been removed. You can now extract the gear shift assembly.
- Page 49 Workshop manual Crankcase disassembly and inspection - Remove the desmodromic. - Pay special attention to possible wear of the fork. If it shows wear, replace it. - To reassemble, repeat the same steps in reverse. -49-...
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Page 50: Maintenance Of The Frame
Workshop manual maintenance of the frame BRAKE PADS (1) Pad pin (2) Screws (3) disc cover (4) front brake caliper Changing the front brake pads - clean the brake disc with a high-quality degreasing compound if it is fouled with oil or grease. change the pads if they are dirty. - Page 51 Workshop manual maintenance of the frame BRAKE PADS Changing the rear brake pads (1) Brake caliper (2) adjustment tab/slot (3) Pad pin (4) caliper piston - Remove the rear wheel. (see pp. 54-55) - Push piston (4) completely inwards to enable the new brake pads to be fitted. - check the brake fluid level in the reservoir, as this operation causes the level to rise.
- Page 52 Workshop manual maintenance of the frame (1) Brake pads (2) Pad pin - fit the new pads and secure them with the pad pins. - fit the brake caliper bracket, aligning its slot with the swinging arm tab. - fit the rear wheel (see pp. 54-55). - Engage the brake pedal to seat the caliper pistons against the pads.
- Page 53 Workshop manual maintenance of the frame REMOVING THE FRONT WHEEL - Remove the fixing screws of brake caliper (1) and (2), and the disc cover. - loosen axle fixing screws (3) and (4). Place the motorcycle on its stand and keep the front wheel off the ground. Remove the axle and brake caliper to release the front wheel.
- Page 54 Workshop manual maintenance of the frame - fit front brake caliper (7) and the disc cover (8). - Tighten mounting screws (9) to the specified torque. Tightening torque 25 Nm. +/-2 With the front brake engaged, move the fork up and down several times to seat the axle and check the operation of the front brake.
- Page 55 Workshop manual maintenance of the frame WARNING Dirt on the brake disc or pad reduces braking ability, which could lead to serious injury or death. Throw away the dirty pads and clean the dirty discs with a high-quality brake degreaser. FITTING THE REAR WHEEL - fit the rear brake caliper, aligning it with the caliper slide guide.
- Page 56 Workshop manual maintenance of the frame 5. Top suspension clamp 6. headlight holder 7. Bottom suspension clamp - Remove the front wheel (see p. 53). - Remove the front headlight holder, bridge and front mudguard. - loosen the top and bottom clamp fixing screws. - Remove the fork tube by pulling downwards.
- Page 57 Workshop manual maintenance of the frame - Use a cloth to clean away any traces of mud from the dust cover seating and upper edge of the oil seal. - Move the dust cover to one side and insert the cloth. Turn the dust cover until all traces of dirt inside the sealing lips are removed.
- Page 58 Workshop manual maintenance of the frame - insert the dust cover into place, using the flat side of a screwdriver to help position it. MAINTENANCE OF THE FORK Oil and seal change, right-hand side - The table below shows the recommended oil change intervals. Leaving the oil for too long without changing it leads to reduced fork performance and oil thickening, which can cause leaks.
- Page 59 Workshop manual maintenance of the frame - Remove cover (a) enough to disengage lock nut (B). - insert a 14 mm spanner into lock nut (B) and a 17 mm spanner into cover (a). - Place the two components in the same clean place. - hold rod (E) to prevent it from falling, as shown in the figure.
- Page 60 Workshop manual maintenance of the frame - Remove the cartridge from the tube. - Turn the fork and remove the hydraulic end of stroke cone. - Push the compression unit inwards and remove the seeger from its housing. - Remove the compression assembly. - Place the cartridge in an oil collection device and have the rod inserted in the cartridge tube for complete drainage of the oil.
- Page 61 Workshop manual maintenance of the frame - insert the end of the cone into the bottom of the cartridge. - lift the edge of the dust cover and remove it from the seating of the bar. - Remove the seeger from its housing. - Secure the tube at the top to protect it (as shown in the figure), while deliver- ing firm blows to the bar.
- Page 62 Workshop manual maintenance of the frame - Remove all insulating parts of the tube (a-B-c-d-E). Replace part (a) with a new one. - grease the bushing seatings and oil seal. - Squeeze the pipe in a vice, casing (X) checking that the non-discharge side is against bushings (B).
- Page 63 Workshop manual maintenance of the frame - insert ring nut (c) against bushing (B), making sure that the edge of the ring nut is facing upwards. - insert the oil seal into the tube (with the spring facing up) and close the tube in a vice with the help of casing (X), with the drainage towards the seal.
- Page 64 Workshop manual maintenance of the frame - grease the tube with grease suitable for seals. - fit the dust cover spreading the grease by tuning it from right to left. - insert the dust cover into place, using the flat side of a screwdriver to help position it.
- Page 65 Workshop manual - Press the cartridge axle against the bottom of the outer tube to fix the car- tridge screw. - lightly squeeze the outer tube in a vice, making sure not to distort it and pro- tecting it with a cloth. - insert an axle into the wheel pin hole and fix it with a tightening torque of 23.5 ÷...
- Page 66 Workshop manual maintenance of the frame - complete the filling of the oil and proceed as indicated below - holding the suspension in a vertical position, compress tube (f) and rod (E) until the end of the stroke. - Bring the oil up to the proper level (see table below) from the top edge of the pipe (keep the tube and rod at the end of the stroke).
- Page 67 Workshop manual maintenance of the frame - completely tighten the tube cover with a 17 mm spanner at a torque of 11.7 ÷ 13.7 Nm. MAINTENANCE OF THE FORK Oil and seal change, left-hand side - The table below shows the recommended oil change intervals. Leaving the oil for too long without changing it leads to reduced fork performance and oil thickening, which can cause leaks.
- Page 68 Workshop manual maintenance of the frame - completely remove cover (a) and put it in a clean place. - Remove tapered spacer (B) and put it in a clean place. - Remove spacer (c) and put it in a clean place. - Remove washer (d) and put it in a clean place.
- Page 69 Workshop manual maintenance of the frame - Slowly extract spring (E). - Wipe off oil from the spring with a cloth. - Put all parts in a clean place. - Pour the oil into a container as shown in the figure. To prevent damage to the environment, collect the used oil and send it to a waste treatment centre.
- Page 70 Workshop manual maintenance of the frame - Squeeze the two clamps in a vice, protecting them with a cloth. - Unscrew the pump nut with a 12 mm spanner. - Remove the screw and oil seal. - Remove the complete pump unit. - Turn the fork the opposite way and remove the end of the stroke cone.
- Page 71 Workshop manual maintenance of the frame - lift the edge of the dust cover and remove it from the seating of the bar. - Remove the seeger from its housing. - Secure the tube at the top to protect it (as shown in the figure), while deliver- ing firm blows to the bar.
- Page 72 Workshop manual maintenance of the frame - grease the bushing seatings and oil seal. - Squeeze the pipe in a vice, casing (X) checking that the non-discharge side is against bushings (B). - With firm blows of the outer tube, insert bushing (B) into its place. check that it is completely inserted.
- Page 73 Workshop manual maintenance of the frame - insert the oil seal into the tube (with the spring facing up) and close the tube in a vice with the help of casing (X), with the drainage towards the seal. - With moderate movements of the outer tube, insert oil seal (d) into its place. This operation does not require much force.
- Page 74 Workshop manual maintenance of the frame - fit the dust cover spreading the grease by tuning it from right to left. - insert the dust cover into place, using the flat side of a screwdriver to help position it. - insert the end of the cone and then the cartridge into the outer tube. - Squeeze the outer tube in a vice, protecting it with a cloth.
- Page 75 Workshop manual maintenance of the frame - Screw the plug with a tightening torque of 23.5 ÷ 25.5 Nm. - Place the suspension in a vertical position and add some new oil. Use OJ 01 (SAE 5) oil. Motorcycle model Year Oil level Type of oil...
- Page 76 Workshop manual maintenance of the frame - completely tighten the tube cover using a 17 mm spanner with a tightening torque of 11.7 ÷ 13.7 Nm. -76-...
- Page 77 Workshop manual maintenance of the frame REAR SHOCK ABSORBER Settings and configuration - The preloading of the shock absorber is adjusted by rotating toothed rings (C) with two special spanners. - Starting from the standard preloading of 7.5 mm for 300-280-250 and 7 mm for 125, tighten or loosen, depending on the weight of the rider, reaching a maximum of 9 mm of preloading.
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Page 78: Electrical Diagrams
Workshop manual eleCtriCal diaGramS -78-... - Page 79 Workshop manual tXt approved electrical system -79-...
- Page 80 Workshop manual tXt ignition electrical system -80-...
- Page 81 Workshop manual ContaCt approved electrical system -81-...
- Page 82 Workshop manual ContaCt ignition electrical system -82-...
- Page 83 Workshop manual tXt - 80 - School electrical system -83-...