GAS GAS TXT RACING 125 Owner's Manual
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GAS GAS TXT RACING 125 Owner's Manual

GAS GAS TXT RACING 125 Owner's Manual

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OWNER'S MANUAL 2021
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. 3215017en

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  • Page 1 OWNER'S MANUAL 2021 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. 3215017en...
  • Page 3 GASGAS Motorcycles GmbH Stallhofnerstraße 3 5230 Mattighofen, Austria This document is valid for the following models: TXT RACING 125 EU (F0103UG) TXT RACING 125 US (F0175UG) TXT RACING 250 EU (F0303UH) TXT RACING 250 US (F0375UH) TXT RACING 280 EU (F0303UI)

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 6.19 Side stand ............ 18 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 6.20 Locking the steering (Option: Symbols used..........5 Homologized) ..........18 Formats used..........5 6.21 Unlocking the steering (Option: Homologized) ..........18 SAFETY ADVICE ............6 6.22 Opening the fuel tank filler cap....
  • Page 5 TABLE OF CONTENTS 11.2 Removing the motorcycle from the lift 12.6 Removing front brake caliper ....68 stand ............40 12.7 Installing the front brake caliper ..... 68 11.3 Cleaning the dust boots of the fork legs..40 12.8 Checking the front brake fluid level.... 69 11.4 Removing the fork legs ......
  • Page 6 21.8.1 All GP models ........113 21.8.2 All RACING models ......113 21.9 Shock absorber......... 113 21.9.1 TXT RACING 125 EU......113 21.9.2 TXT RACING 250/280/300 EU ..... 114 21.9.3 TXT GP 125 .......... 114 21.9.4 TXT GP 250/280/300......114 21.9.5...

  • 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: Stop 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 – Turn tap handle of the fuel tap to the ON position. 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) –...

  • Page 27: Braking

    RIDING INSTRUCTIONS 8 – Ride at a low engine speed instead of at a high engine speed with a slipping clutch. 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 (Option: Homologized) – Press and hold the stop button while the engine is idling until the engine stops. – Park the motorcycle on firm ground. Transporting Note Danger of damage The parked vehicle can roll away or fall over. –...
  • 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 After 3 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 Guideline Rebound damping (TXT RACING 125 EU) Standard 25 clicks Rebound damping (TXT RACING 250/280/300 EU) Standard 25 clicks Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. (All US RACING models) –...

  • Page 34: Measuring The Dimension Of The Rear Wheel Unloaded

    Check the static sag. Static sag (All US RACING mod- 10 … 15 mm (0.39 … 0.59 in) els) Static sag (TXT RACING 125 EU) 10 … 15 mm (0.39 … 0.59 in) Static sag 10 … 15 mm (0.39 … 0.59 in)

  • Page 35: Adjusting The Spring Preload Of The Shock Absorber

    TUNING THE CHASSIS 10 10.6 Adjusting the spring preload of the shock absorber Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. –...

  • Page 36: Checking The Riding Sag Of The Shock Absorber

    Guideline Riding sag (All US RACING mod- 70 … 75 mm (2.76 … 2.95 in) els) Riding sag (TXT RACING 125 70 … 75 mm (2.76 … 2.95 in) 402417-10 Riding sag 70 … 75 mm (2.76 … 2.95 in)

  • Page 37: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.8 Adjusting the riding sag Caution Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized GASGAS Motorcycles workshop will be glad to help.) Preparatory work –...
  • Page 38 (154 … 187 lb.) Weight of rider: 85 … 75 N/mm (428 lb/in) 100 kg (187 … 220 lb.) Spring rate (TXT RACING 125 EU) Weight of rider: 55 … 70 kg 65 N/mm (371 lb/in) (121 … 154 lb.) Weight of rider: 70 …...

  • Page 39: Basic Setting Of The Fork

    TUNING THE CHASSIS 10 – Check the riding sag of the shock absorber. ( p. 34) – Adjust the rebound damping of the shock absorber. ( p. 30) 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.

  • Page 40: Adjusting The Spring Preload Of The Fork

    10 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression. 10.12 Adjusting the spring preload of the fork – Turn adjusting screw counterclockwise all the way. Info Adjusting screw is located at the upper end of the left fork leg.
  • Page 41 TUNING THE CHASSIS 10 Info Turning it counterclockwise increases the damping of the fluid barrier: the end position damping and the puncture resistance of the fork increase. Turning it clockwise reduces the damping of the fluid bar- rier: the end position damping and the puncture resistance of the fork decrease.

  • Page 42: 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 43: 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 44: 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 45 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 46: 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. 119) – Insert the lower triple clamp with the steering stem. Mount upper steering head bearing –...

  • Page 47: 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 48 11 SERVICE WORK ON THE CHASSIS Main work – Remove handlebar cushion E01347-12 – Remove screws – Take off handlebar and place carefully to the front. Info Cover the components to protect them against damage. Do not kink the cables and lines. E01348-10 –...
  • Page 49 SERVICE WORK ON THE CHASSIS 11 – Tighten the steering head screw Guideline Nut, steering head 50 Nm (36.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. – Tighten screw Guideline Screw, steering stem 12 Nm (8.9 lbf ft) E01846-10...

  • Page 50: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS 11.10 Lubricating the steering head bearing – Remove the lower triple clamp. p. 42) – Install the lower triple clamp. p. 44) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp. H02387-01 11.11 Removing the headlight mask...

  • Page 51: Installing The Headlight Mask

    SERVICE WORK ON THE CHASSIS 11 11.12 Installing the headlight mask (Option: Not homologized) – Hook in the headlight mask in area E01352-10 – Secure the headlight mask to the fork legs with cable ties E01344-12 (Option: Homologized) Info Plug in connector according to the noted cable colors. –...

  • Page 52: Installing The Front Fender

    11 SERVICE WORK ON THE CHASSIS 11.14 Installing the front fender – Position the front fender. Mount and tighten screws Guideline Front fender 10 Nm (7.4 lbf ft) E01345-10 11.15 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 53: Removing The Air Filter Box

    SERVICE WORK ON THE CHASSIS 11 11.17 Removing the air filter box – Release hose clamp E01355-10 – 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. –...

  • Page 54: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS – Position and tighten hose clamp E01355-11 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 –...

  • Page 55: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove the screw and remove the air filter cover from the air filter box. E01358-10 – Remove screw – Remove air filter with air filter support from the air filter box. –...

  • Page 56: Cleaning The Air Filter And Air Filter Box

    11 SERVICE WORK ON THE CHASSIS 11.23 Cleaning the air filter and air filter box 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.

  • Page 57: Installing The Manifold

    SERVICE WORK ON THE CHASSIS 11 – Remove screws – Take off the manifold in a forward direction. E01786-10 – Remove gasket E01787-10 (Option: Not homologized) – Remove screws – Take off the manifold in a forward direction. E01379-10 – Remove gasket E01787-11 11.25...
  • Page 58 11 SERVICE WORK ON THE CHASSIS (Option: Homologized) – Mount gasket E01787-12 – Position the manifold. – Mount and tighten screws Guideline Screw, manifold 12 Nm (8.9 lbf ft) E01786-10 – Mount hose E01785-11 (Option: Not homologized) – Mount gasket E01787-12 –...

  • Page 59: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.26 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Preparatory work –...

  • Page 60: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    11 SERVICE WORK ON THE CHASSIS 11.28 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. Info Over time, the fibers of the glass fiber yarn filling escape and the damper "burns"...

  • Page 61: Removing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 11 – Mount and tighten screws E01757-11 Finishing work – Install the main silencer. ( p. 57) – Install the air filter box. p. 51) – Install the fuel tank. ( p. 60) 11.29 Removing the fuel tank Danger Fire hazard Fuel is highly flammable.

  • Page 62: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS – Pull off vent hose – Remove screw – Lift the fuel tank at the front and remove it from the frame. E01361-10 11.30 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.

  • Page 63: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS 11 11.31 Checking the chain for dirt – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 61) 400678-01 11.32 Cleaning the chain Warning Danger of accidents Lubricants on the tires reduces the road grip.

  • Page 64: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS 11.33 Checking 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 65: Checking The Frame

    SERVICE WORK ON THE CHASSIS 11 Main work – Loosen screw E01384-12 – Adjust the chain tension by turning eccentrics left and right. Guideline Chain tension 10 … 20 mm (0.39 … 0.79 in) Turn eccentrics left and right so that the eccentrics are on the same detent.

  • Page 66: Checking The Link Fork

    11 SERVICE WORK ON THE CHASSIS 11.36 Checking the link fork – Check the link fork for damage, cracking, and deformation. » If the link fork shows signs of damage, cracking, or deformation: – Change the link fork. Info Always replace a damaged link fork. GASGAS Motor- cycles does not permit repairing link forks.

  • Page 67: Adjusting The Basic Position Of The Clutch Lever

    SERVICE WORK ON THE CHASSIS 11 11.40 Adjusting the basic position of the clutch lever Main work – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

  • Page 68: Changing The Hydraulic Clutch Fluid

    11 SERVICE WORK ON THE CHASSIS 11.42 Changing the hydraulic clutch fluid 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 Do not use brake fluid.

  • Page 69: 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 70: 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...

  • Page 71: 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. 68) 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 72 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 73: 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 74 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 75: 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. 117) – 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 76: 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 77: 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 78 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 79: 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 25 Nm (18.4 lbf ft)
  • Page 80 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 81 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 82 12 BRAKE SYSTEM – Position foot brake lever; insert push rod into foot brake cylinder. – Mount and tighten screw with nut Guideline Screw, foot brake 25 Nm (18.4 lbf ft) Loctite ® 243™ lever E01398-10...

  • Page 83: Wheels, Tires 13

    WHEELS, TIRES 13 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 40) 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 84: 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. 40) Main work – Remove screw with spacer E01384-10 – Turn eccentrics so that the greatest possible chain play is present.

  • Page 85: 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 86: 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. 62) – Tighten screw Guideline Screw, rear wheel spin- 50 Nm (36.9 lbf ft) E01388-10 Finishing work –...

  • Page 87: 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 88 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 89: 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 14.2 Changing the headlight bulb (Option: Homologized) Note Damage to reflector Grease on the reflector reduces the light intensity. Grease on the bulb will evaporate due to the heat and be deposited on the reflector. –...

  • Page 90: Changing The Position Light Lamp (Option: Homologized)

    14 ELECTRICAL SYSTEM – Insert the bulb socket and headlight bulb in the reflector. – Fold retainer spring upward. E01777-10 – Mount protection cap E01775-10 Finishing work – Install the headlight mask. ( p. 49) 14.3 Changing the position light lamp (Option: Homologized) Note Damage to reflector Grease on the reflector reduces the light intensity.

  • Page 91: Changing The Turn Signal Bulb (Option: Homologized)

    ELECTRICAL SYSTEM 14 Main work – Carefully pull position light socket out of the housing. – Remove bulb – Position a new bulb in the socket. Position light (T4W / socket BA9s) ( p. 112) – Carefully position position light socket in the housing.
  • Page 92 14 ELECTRICAL SYSTEM Finishing work – Check that the turn signal system is functioning properly.

  • Page 93: Cooling System 15

    COOLING SYSTEM 15 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 94: Draining The Coolant

    15 COOLING SYSTEM – 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 95: Refilling With Coolant

    COOLING SYSTEM 15 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 96 15 COOLING SYSTEM 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 97: Tuning The Engine 16

    TUNING THE ENGINE 16 16.1 Checking the play in the throttle cable – 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 Play in throttle cable 2 …...

  • Page 98: Carburetor Tuning

    16 TUNING THE ENGINE 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 99 TUNING THE ENGINE 16 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 100: Carburettor - Idle Speed

    16 TUNING THE ENGINE 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 101: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16 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 102: 17 Service Work On The Engine

    17 SERVICE WORK ON THE ENGINE 17.1 Emptying the carburetor float chamber (Option: Not homologized) 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 103: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 17 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 104 17 SERVICE WORK ON THE ENGINE 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 105: Cleaning, Care 18

    CLEANING, CARE 18 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 106 18 CLEANING, CARE – Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor. Preserving materials for paints, metal and rubber ( p. 119) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 107: Storage 19

    STORAGE 19 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 108: Preparing For Use After Storage

    19 STORAGE 19.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 40) – Perform checks and maintenance measures when preparing for use. p. 23) – Take a test ride. 401059-01...

  • Page 109: Troubleshooting 20

    TROUBLESHOOTING 20 Faults Possible cause Action – Engine does not start Operating error Carry out start procedure. ( p. 23) The motorcycle has been in disuse (Option: Not homologized) – Empty the carburetor float cham- for an extended period and old ber.
  • Page 110 20 TROUBLESHOOTING 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. 91) – Too little air stream Switch off the engine when standing. –...

  • Page 111: Technical Data 21

    TECHNICAL DATA 21 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 112: Carburetor

    21 TECHNICAL DATA Screw, stator 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, water pump impeller 8 Nm (5.9 lbf ft) Coolant drain plug 10 Nm (7.4 lbf ft) Screw, cylinder head 15 Nm (11.1 lbf ft) Screw, kick starter lever 12 Nm (8.9 lbf ft) Loctite ®...

  • Page 113: Capacities

    174 mm (6.85 in) Suspension travel (All RACING models) front 167 mm (6.57 in) rear 174 mm (6.85 in) Shock absorber (TXT RACING 125 EU) Reiger 2V Shock absorber (TXT RACING 250/280/300 EU) Reiger 2V Shock absorber (All US RACING models) Öhlins 2V...

  • Page 114: Electrical System

    67.9 kg (149.7 lb.) 250/280/300) Homologated weight without fuel approx. 69.8 kg (153.9 lb.) (TXT RACING 125 EU) Homologated weight without fuel approx. 72.4 kg (159.6 lb.) (TXT RACING 250/280/300 EU) Homologated weight without fuel approx. (TXT GP 125 EU) 68.3 kg (150.6 lb.)

  • Page 115: Fork

    5.5 turns Air chamber length Air chamber length, left 130 mm Air chamber length, right 75 mm 21.9 Shock absorber 21.9.1 TXT RACING 125 EU Shock absorber article number BT30000GG-DBZ-1 Shock absorber Reiger 2V Rebound damping Standard 25 clicks Spring preload 7 mm (0.28 in)

  • Page 116: Txt Racing 250/280/300 Eu

    21 TECHNICAL DATA 21.9.2 TXT RACING 250/280/300 EU Shock absorber article number BT30000GG-DBV-1 Shock absorber Reiger 2V Rebound damping Standard 25 clicks Spring preload 7 mm (0.28 in) Spring rate Weight of rider: 55 … 70 kg (121 … 154 lb.) 67.5 N/mm (385.4 lb/in) Weight of rider: 70 …...

  • Page 117: All Us Racing Models

    TECHNICAL DATA 21 21.9.5 All US RACING models Shock absorber article number BT30000GG-CSV-1 Shock absorber Öhlins 2V Rebound damping Standard 20 clicks Spring preload 7.5 mm (0.295 in) Spring rate Weight of rider: 55 … 70 kg (121 … 154 lb.) 65 N/mm (371 lb/in) Weight of rider: 70 …...
  • Page 118 21 TECHNICAL DATA Screw, steering stem 12 Nm (8.9 lbf ft) Screw, top triple clamp 12 Nm (8.9 lbf ft) Remaining nuts, chassis 25 Nm (18.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) Screw, axle clamp 23 Nm (17 lbf ft) Screw, brake cable guiding 25 Nm (18.4 lbf ft) Loctite...

  • Page 119: Substances 22

    SUBSTANCES 22 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 120 22 SUBSTANCES Recommended supplier MOTOREX ® – Trial Gear Oil 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 ®...

  • Page 121: Auxiliary Substances 23

    AUXILIARY SUBSTANCES 23 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 122 23 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 123: Standards 24

    STANDARDS 24 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 124: 25 List Of Abbreviations

    25 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 125: Index

    INDEX fluid, changing ..... . . 66 INDEX Clutch lever ......Accessories .
  • Page 126 INDEX Front wheel Map switch ......15 installing ......81 Misuse .
  • Page 127 INDEX Spring preload fork, adjusting ..... . . 38 Starting ......23 Steering locking .
  • Page 128 *3215017en* 3215017en 11/2020 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

This manual is also suitable for:

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