GAS GAS TXT GP 250 2024 Owner's Manual
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GAS GAS TXT GP 250 2024 Owner's Manual

GAS GAS TXT GP 250 2024 Owner's Manual

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OWNER'S MANUAL
2024
TXT RACING 125
TXT RACING 250
TXT RACING 280
TXT RACING 300
TXT GP 250
TXT GP 300
Art. no. 3215159en

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  • Page 1 OWNER'S MANUAL 2024 TXT RACING 125 TXT RACING 250 TXT RACING 280 TXT RACING 300 TXT GP 250 TXT GP 300 Art. no. 3215159en...
  • 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 6.19 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 11.7 Checking the riding sag of the shock 12.41 Adjusting the free travel of the clutch absorber ............38 lever ............70 11.8 Adjusting the riding sag ......38 12.42 Adjusting the basic position of the clutch lever ............
  • Page 6 TABLE OF CONTENTS 16.4 Draining the coolant ........ 99 INDEX OF SPECIAL TERMS ........129 16.5 Refilling with coolant........ 100 LIST OF ABBREVIATIONS......... 130 16.6 Changing the coolant ......101 LIST OF SYMBOLS............ 131 TUNING THE ENGINE..........103 28.1 Yellow and orange symbols...... 131 17.1 Checking the play in the throttle cable..

  • 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). Indicates work that requires expert 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 transpon- der key) or the motor must be at a standstill (models without ignition lock or transponder 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) I00160-10 Hand brake lever ( p. 13) Clutch lever ( p. 13) Fuel tank filler cap 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) I00161-10 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. I00086-10 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 If the red magnetic switch on the handlebar is disconnected from the holder, e.g., in the event of a fall, the vehicle is switched off. By removing the magnetic switch from the handlebar, the vehicle can be quickly switched off in any operating state. Stop button (Option: Homologized) The stop button is located on the right side of the handlebar.

  • 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) Steering lock is located below the upper triple clamp. The steering lock is used to lock the steering. Steering, and therefore riding, is no longer possible. I00142-10 6.13 Fuel tap The fuel tap is on the left side of the fuel tank. Open or close the fuel supply to the carburetor using tap handle the fuel tap.

  • Page 19: Shift Lever

    CONTROLS 6 Choke function deactivated – Choke lever in basic position. • 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...

  • 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)

    7 COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED) Overview Overview of indicator lights ( p. 15) Left button Display Right button 402819-10 Activation Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor. 402819-01 Messages on the combination instrument Possible states...

  • Page 23: Setting Kilometers Or Miles

    COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED) 7 – Wait for 5 seconds. The combination instrument changes to the next menu item. symbol flashes. – Press one of the buttons to select the 24 h display or 12 h display for the clock. 401911-01 –...

  • Page 24: Setting The Clock

    7 COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED) – Press both buttons for 3–5 seconds. The Setup menu is displayed. The UNIT display flashes. – Press one of the buttons to select UNIT for the speed in kilometers KM/H or miles M/H. 401909-01 Setting the clock Condition The motorcycle is stationary.

  • Page 25: Speed, Time, And Dst Distance 1

    COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED) 7 Switching off the service interval display – Press and hold the left button. off appears in the display. 401914-01 Speed, time, and DST distance 1 – Press one of the buttons until DST appears on the combination instrument.

  • Page 26: Avg Average Speed, Art Operating Hours, And Odo Total Distance Covered

    7 COMBINATION INSTRUMENT (OPTION: HOMOLOGIZED) Press the right DST2 is reset to 0.0. button for 3 – 5 seconds. 7.10 AVG average speed, ART operating hours, and ODO total distance covered – Press one of the buttons until AVG, ART and ODO appear on the combination instrument.

  • Page 27: Preparing For Use 8

    PREPARING FOR USE 8 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 28: Running In The Engine

    8 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 29: Riding Instructions 9

    RIDING INSTRUCTIONS 9 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 30: Starting Off

    9 RIDING INSTRUCTIONS – Turn the tap handle of the fuel tap to the position ON facing down- ward. 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 31: Braking

    RIDING INSTRUCTIONS 9 – 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 32: Transporting

    9 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 33 RIDING INSTRUCTIONS 9 – Fill the fuel tank with fuel up to a maximum of level Guideline 35 mm (1.38 in) Dimension Total fuel tank capac- 2.2 l (2.3 qt.) Super unleaded (98 ity, approx. octane) mixed with 2-stroke engine oil (1:67) ( p.

  • Page 34: 10 Service Schedule

    10 SERVICE SCHEDULE 10.1 Additional information Any further work that results from the service 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. The most up-to-date service schedule can always be found on GASGAS Motorcycles Dealer.net.
  • Page 35 SERVICE SCHEDULE 10 every 24 months after every race Every 120 operating hours Every 60 operating hours Every 20 operating hours After 3 operating hours ● ● ● Check the headlight setting. (Option: Homologized) ( p. 52) ● ● ● ●...

  • Page 36: 11 Tuning The Chassis

    11 TUNING THE CHASSIS 11.1 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 37: Adjusting The Compression Damping Of The Shock Absorber (All Gp Models)

    TUNING THE CHASSIS 11 – Install the rear fender. ( p. 54) 11.3 Adjusting the compression damping of the shock absorber (All GP models) 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 38: Checking The Static Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.5 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 35) – 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 39 TUNING THE CHASSIS 11 Info Turn counterclockwise to increase the spring preload. Turning clockwise reduces the spring preload. – Tighten grub screws Guideline Grub screw, shock 2 Nm (1.5 lbf ft) absorber (All GP models) – Loosen grub screws but do not remove. –...

  • Page 40: Checking The Riding Sag Of The Shock Absorber

    11 TUNING THE CHASSIS 11.7 Checking the riding sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 35) – With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal riding position (feet on footrests) and bounces up and down a few times.

  • Page 41: Basic Setting Of The Fork

    TUNING THE CHASSIS 11 – Check the riding sag of the shock absorber. ( p. 38) – Adjust the rebound damping of the shock absorber. ( p. 34) – Install the air filter box. p. 56) – Install the rear fender. ( p.

  • Page 42: Adjusting The Spring Preload Of The Fork

    11 TUNING THE CHASSIS Guideline Compression damping Standard 1.75 turns Info Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression. 11.12 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 43 TUNING THE CHASSIS 11 Guideline Fluid barrier (All RACING models) Standard 2.5 turns Fluid barrier (All GP models) Standard 2.5 turns 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 44: 12 Service Work On The Chassis

    12 SERVICE WORK ON THE CHASSIS 12.1 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 45: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12 Main work – Push dust boots of both fork legs upwards. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

  • Page 46: Installing The Fork Legs

    12 SERVICE WORK ON THE CHASSIS 12.5 Installing the fork legs Main work – Position the left fork leg while carefully pushing the brake line guide onto the fork leg. – Tighten screw Guideline Screw, top triple clamp 12 Nm (8.9 lbf ft) –...
  • Page 47 SERVICE WORK ON THE CHASSIS 12 Main work – Remove handlebar cushion Z03063-10 – 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 or lines. Z03064-10 –...

  • Page 48: Installing The Lower Triple Clamp

    12 SERVICE WORK ON THE CHASSIS 12.7 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. Long-life grease ( p. 126) – Insert the lower triple clamp with steering stem –...

  • Page 49: Checking The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 12 – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses. – Tighten screw Guideline Screw, top triple clamp 12 Nm (8.9 lbf ft) – Position the handlebar. – Position the handlebar clamps. Mount screws and tighten evenly.

  • Page 50: Adjusting The Steering Head Bearing Play

    12 SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...
  • Page 51 SERVICE WORK ON THE CHASSIS 12 – Loosen screws I00154-10 – Tighten steering head screw Guideline Nut, steering head 20 Nm (14.8 lbf ft) – Tighten screw Guideline Screw, steering stem 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

  • Page 52: Lubricating The Steering Head Bearing

    12 SERVICE WORK ON THE CHASSIS – Remove the motorcycle from the lift stand. ( p. 42) 12.10 Lubricating the steering head bearing – Remove the lower triple clamp. p. 44) – Install the lower triple clamp. p. 46) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 53: Installing The Headlight Mask

    SERVICE WORK ON THE CHASSIS 12 Info Note the assignment of the cable colors. – Disconnect the connector of the horn. – Unplug connector of the headlight bulb and the parking light. – Unplug connector of the turn signal lamps. –...

  • Page 54: Checking The Headlight Setting (Option: Homologized)

    12 SERVICE WORK ON THE CHASSIS (Option: Homologized) Info Plug in connector according to the noted cable colors. – Plug in connector of the turn signal indicator lamp. – Plug in connector of the horn. – Plug in connector of the speedometer. –...

  • Page 55: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS 12 12.14 Removing the front fender – Remove screws and take off the fender. I00105-10 12.15 Installing the front fender – Position the front fender. Mount and tighten screws Guideline Front fender 12 Nm (8.9 lbf ft) Loctite ®...

  • Page 56: Installing The Rear Fender

    12 SERVICE WORK ON THE CHASSIS 12.17 Installing the rear fender – Insert the rear fender in area and engage it in area I00093-11 – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis I00092-10 12.18 Removing the shock absorber Preparatory work –...

  • Page 57: Removing The Air Filter Box

    SERVICE WORK ON THE CHASSIS 12 – Install the rear fender. ( p. 54) – Remove the motorcycle from the lift stand. ( p. 42) 12.20 Removing the air filter box Preparatory work – Remove the rear fender. ( p. 53) Main work –...

  • Page 58: Installing The Air Filter Box

    12 SERVICE WORK ON THE CHASSIS 12.21 Installing the air filter box Main work – Carefully position the air filter box on the frame, sliding the inlet sleeve onto the carburetor. – Mount and tighten screws Guideline Screw, air filter box 6 Nm (4.4 lbf ft) I00094-11 –...

  • Page 59: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 12 Main work – Remove quick release and take out the splash protector from the air filter box. I00109-10 – Remove air filter holding bracket – Remove the air filter with air filter support from the air filter box. –...

  • Page 60: Cleaning The Air Filter And Air Filter Box

    12 SERVICE WORK ON THE CHASSIS 12.24 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 61: Removing The Manifold

    SERVICE WORK ON THE CHASSIS 12 12.25 Removing the manifold Warning Danger of burns The exhaust system gets hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. (Option: Homologized) –...

  • Page 62: Installing The Manifold

    12 SERVICE WORK ON THE CHASSIS – Remove gasket Z03095-10 12.26 Installing the manifold Warning Danger of burns The exhaust system gets hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. (Option: Homologized) –...

  • Page 63: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12 (Option: Not homologized) – Mount gasket I00145-11 – Position the manifold. – Mount and tighten screws Guideline Screw, manifold 12 Nm (8.9 lbf ft) Loctite ® 243™ Z03094-11 12.27 Removing the main silencer Warning Danger of burns The exhaust system gets hot when the vehicle is driven.

  • Page 64: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    12 SERVICE WORK ON THE CHASSIS – Tighten screw Guideline Screw, top shock 50 Nm (36.9 lbf ft) absorber Finishing work – Install the air filter box. p. 56) – Install the rear fender. ( p. 54) 12.29 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets hot when the vehicle is driven.
  • Page 65 SERVICE WORK ON THE CHASSIS 12 – Prepare glass fiber yarn fillings from the repair kit. I00172-10 – Fold glass fiber yarn filling in half and stuff it into the upper part of the main silencer using the tool from the repair kit. –...

  • Page 66: Removing The Fuel Tank

    12 SERVICE WORK ON THE CHASSIS – Position glass fiber yarn filling over inner tube in silencer – Position glass fiber yarn filling under the inner tube in the silencer cap. I00171-10 – Position silencer cap holder – Mount and tighten screws I00166-10 Finishing work –...

  • Page 67: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS 12 – Turn the tap handle of the fuel tap to the position OFF toward the rear. – Push hose clamp toward the rear and pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. I01037-11 –...

  • Page 68: Checking The Chain For Dirt

    12 SERVICE WORK ON THE CHASSIS Guideline Route vent hose free of kinks. – Attach fuel hose and secure with hose clamp I01037-10 Finishing work – Check the throttle cable routing. 12.32 Checking the chain for dirt – Check the chain for coarse dirt accumulation. »...

  • Page 69: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS 12 Main work – Rinse off the loose dirt with a gentle jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 126) – After drying, apply chain spray. Off-road chain spray ( p.

  • Page 70: Adjusting The Chain Tension

    12 SERVICE WORK ON THE CHASSIS 12.35 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 71: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12 12.36 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Shift the transmission into neutral. – Check the chain, rear sprocket, and engine sprocket for wear. »...

  • Page 72: Checking The Free Travel Of The Clutch Lever

    12 SERVICE WORK ON THE CHASSIS 12.40 Checking the free travel of the clutch lever – Pull the clutch lever and check free travel ≥ 3 mm (≥ 0.12 in) Free travel of clutch lever » If the free travel does not match the specification: –...

  • Page 73: Checking/Correcting The Fluid Level Of Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12 12.43 Checking/correcting the fluid level of hydraulic clutch 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 74 12 SERVICE WORK ON THE CHASSIS – Fill the bleeding syringe with the appropriate hydraulic fluid. Hydraulic fluid (15) ( p. 125) – On the clutch slave cylinder, remove the protection cap, release bleeder screw and mount the bleeding syringe. Z03087-12 –...

  • Page 75: Brake System 13

    BRAKE SYSTEM 13 13.1 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 76: Removing Front Brake Disc Guard

    13 BRAKE SYSTEM 13.4 Removing front brake disc guard – Remove screws and take off the brake disc guard to the rear. I00103-10 13.5 Installing the front brake disc guard – Position the brake disc guard at the front. – Mount and tighten screws Guideline Screw, front brake...

  • Page 77: Checking The Front Brake Fluid Level

    BRAKE SYSTEM 13 Main work – Position the brake caliper on the brake disc carefully. I00104-10 Finishing work – Install the brake disc guard at the front. p. 74) 13.8 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 78 13 BRAKE SYSTEM Warning Skin irritation Brake fluid is a harmful substance. – 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 79: Checking That The Brake Linings Of The Front Brake Are Secured

    BRAKE SYSTEM 13 13.10 Checking that the brake linings of the front brake are secured 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.) –...
  • Page 80 13 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 81: Checking Brake Discs

    BRAKE SYSTEM 13 Brake fluid DOT 4 / DOT 5.1 ( p. 124) – Position cover with the membrane. Mount and tighten screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled. Finishing work –...

  • Page 82: Checking The Free Travel Of The Foot Brake Lever

    13 BRAKE SYSTEM 13.13 Checking the free travel of the foot brake lever Warning Danger of accidents The brake system will fail if it overheats or is adjusted incorrectly. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake. –...

  • Page 83: Checking The Rear Brake Fluid Level

    BRAKE SYSTEM 13 13.15 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 84 13 BRAKE SYSTEM Warning Danger of accidents Brake fluid which is too old or of the wrong type impairs the function of the brake system. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized GASGAS Motorcycles workshop will be glad to help.) –...

  • Page 85: Checking That The Brake Linings Of The Rear Brake Are Secured

    BRAKE SYSTEM 13 – Add brake fluid up to the marking Brake fluid DOT 4 / DOT 5.1 ( p. 124) – Position cover with membrane and mount and tighten screws Info Use water to immediately clean up any brake fluid that has overflowed or spilled.

  • Page 86: Changing The Rear Brake Linings

    13 BRAKE SYSTEM 13.18 Changing the rear brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized GASGAS Motorcy- cles workshop will be glad to help.) Warning Skin irritation Brake fluid is a harmful substance.
  • Page 87 BRAKE SYSTEM 13 – Remove screws I00132-10 – Remove screws – Remove cover with membrane – Secure the compensating tank in a vertical position. I00133-10 – Remove screw – Carefully remove the brake caliper from the link fork. I01012-10 – Remove latch to the right.
  • Page 88 13 BRAKE SYSTEM – Position the brake caliper on the link fork and mount and tighten screw Guideline Screw, rear brake 12 Nm (8.9 lbf ft) caliper Loctite ® 243™ I01012-10 – Correct brake fluid level to marking Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 89: Wheels, Tires 14

    WHEELS, TIRES 14 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove front brake disc guard. p. 74) – Remove front brake caliper. p. 74) Main work – Loosen screw by several rotations.

  • Page 90: Removing The Rear Wheel

    14 WHEELS, TIRES – Tighten wheel spindle Guideline Wheel spindle, front 50 Nm (36.9 lbf ft) – Install the front brake caliper. p. 74) The brake linings are correctly positioned. – Install the brake disc guard at the front. p. 74) –...

  • Page 91: Installing The Rear Wheel

    WHEELS, TIRES 14 – Remove eccentrics and spacers E01387-12 14.4 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.

  • Page 92: Checking The Tire Condition

    14 WHEELS, TIRES – Make sure that eccentrics are fitted correctly to the screws of link fork – Adjust the chain tension. ( p. 68) – Tighten screw Guideline Screw, rear wheel spin- 50 Nm (36.9 lbf ft) I00156-10 Finishing work –...

  • Page 93: Checking Tire Pressure

    WHEELS, TIRES 14 – 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 94 14 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 95: Electrical System 15

    ELECTRICAL SYSTEM 15 15.1 Diagnostics connector Diagnostics connector is located on the right-hand side below the fuel tank in the voltage regulator retaining bracket. I00157-10 15.2 Changing the headlight bulb (Option: Homologized) Note Impairments to reflectors and lamps Grease on the reflector reduces the emitted light. Grease on the bulb will evaporate due to the heat and be deposited on the reflector.

  • Page 96: Changing The Position Light Lamp (Option: Homologized)

    15 ELECTRICAL SYSTEM – Carefully push down headlight bulb and turn counterclockwise until it is released. – Remove the headlight bulb. – Insert the new headlight bulb. Low beam/high beam (BILUX bulb / socket BA20D) ( p. 120) – Carefully push down headlight bulb and turn clockwise until it engages.

  • Page 97: Changing The Turn Signal Bulb (Option: Homologized)

    ELECTRICAL SYSTEM 15 Main work – Carefully pull position light socket out of the housing. – Remove bulb – Position a new bulb in the socket. Position light (T5W/socket BA9s) ( p. 120) – Carefully position position light socket in the housing. I01010-10 Finishing work –...
  • Page 98 15 ELECTRICAL SYSTEM Finishing work – Check that the turn signal system is functioning properly.

  • Page 99: Cooling System 16

    COOLING SYSTEM 16 16.1 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. I00147-10 16.2 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure.

  • Page 100: Checking The Antifreeze And Coolant Level

    16 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 16.3 Checking the antifreeze and coolant level...

  • Page 101: Draining The Coolant

    COOLING SYSTEM 16 16.4 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 102: Refilling With Coolant

    16 COOLING SYSTEM 16.5 Refilling with coolant Warning Danger of poisoning Coolant is harmful to health. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. –...

  • Page 103: Changing The Coolant

    COOLING SYSTEM 16 16.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 104 16 COOLING SYSTEM Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use effective exhaust extraction when starting or run- ning the engine in an enclosed space.

  • Page 105: Tuning The Engine 17

    TUNING THE ENGINE 17 17.1 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 106: Carburetor Tuning

    17 TUNING THE ENGINE 17.3 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 107 TUNING THE ENGINE 17 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 108: Carburettor - Idle Speed

    17 TUNING THE ENGINE Carburettor – idle speed 17.4 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 109: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17 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 110: 18 Service Work On The Engine

    18 SERVICE WORK ON THE ENGINE 18.1 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 111: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 18 18.2 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 112 18 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 113: Cleaning, Care

    CLEANING, CARE 19 19.1 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 114 19 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. 126) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 115: Storage 20

    STORAGE 20 20.1 Storage Warning Danger of poisoning Fuel is harmful to health. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – Rinse the affected area immediately with plenty of water in the event of contact with the skin. –...

  • Page 116: Preparing For Use After Storage

    20 STORAGE 20.2 Preparing for use after storage – Remove the motorcycle from the lift stand. ( p. 42) – Perform checks and maintenance measures when preparing for use. p. 27) – Take a test ride. 401059-01...

  • Page 117: Troubleshooting 21

    TROUBLESHOOTING 21 Faults Possible cause Action – Engine does not start Operating error Carry out start procedure. ( p. 27) The motorcycle has been in disuse (Option: Not homologized) – for an extended period and old Empty the carburetor float cham- fuel is in the float chamber ber.
  • Page 118 21 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Too little air stream Switch off the engine when standing. – Radiator fins very dirty Clean the radiator fins. – Foam formation in the cooling Drain the coolant. p. 99) system –...

  • Page 119: Technical Specifications

    TECHNICAL SPECIFICATIONS 22 22.1 Engine Design 1-cylinder 2-stroke gasoline engine, water-cooled, with membrane inlet Displacement (TXT RACING 125 EU) 125 cm³ (7.63 cu in) Displacement (All 250 models) 247.7 cm³ (15.116 cu in) Displacement (TXT RACING 280 EU) 272.2 cm³ (16.611 cu in) Displacement (All 300 models) 294.1 cm³...

  • Page 120: Carburetor

    22 TECHNICAL SPECIFICATIONS Screw, water pump impeller 8 Nm (5.9 lbf ft) Coolant drain plug 15 Nm (11.1 lbf ft) Screw, cylinder head 15 Nm (11.1 lbf ft) Screw, kick starter lever 10 Nm (7.4 lbf ft) Loctite ® 243™ Bleeder screw, cylinder head 15 Nm (11.1 lbf ft) Nut, cylinder base...

  • Page 121: Capacities

    TECHNICAL SPECIFICATIONS 22 Idle air adjusting screw (TXT RACING 280 EU) open 1 turn Idle air adjusting screw (All 125/250/300 models) open 1.25 turns 22.4 Capacities 22.4.1 Gear oil Gear oil 0.37 l (0.39 qt.) Gear oil (API GL‑4, SAE 75W) p.

  • Page 122: Electrical System

    22 TECHNICAL SPECIFICATIONS Secondary drive ratio (TXT RACING 125 EU) 09:48 Secondary drive ratio (All 250/280/300 models) 10:39 Chain 5/8 x 1/4" Wheelbase 1,320 ± 10 mm (51.97 ± 0.39 in) Seat height unloaded 630 mm (24.8 in) Ground clearance unloaded 325 mm (12.8 in) Weight when ready for racing without fuel approx.

  • Page 123: All Gp Models

    TECHNICAL SPECIFICATIONS 22 22.8.2 All GP models Fork article number A53501100044 Fork Tech 39 mm Rebound damping Standard 19 clicks Compression damping Standard 1.75 turns Fluid barrier Standard 2.5 turns Spring preload Standard 5.5 turns Air chamber length Air chamber length, left 125 mm Air chamber length, right 70 mm...

  • Page 124: Chassis Tightening Torques

    22 TECHNICAL SPECIFICATIONS 22.10 Chassis tightening torques Remaining EJOT screws EJOT DELTA PT ® 1 Nm (0.7 lbf ft) Remaining EJOT screws EJOT DELTA PT ® 2 Nm (1.5 lbf ft) Screw, brake hose guide clamp EJOT DELTA PT ® K40x12 0.5 Nm (0.37 lbf ft) Screw, combination instrument...
  • Page 125 TECHNICAL SPECIFICATIONS 22 Screw, rear brake caliper 12 Nm (8.9 lbf ft) Loctite ® 243™ Screw, rear fender 6 Nm (4.4 lbf ft) Screw, sensor magnet (Option: 12 Nm (8.9 lbf ft) Homologized) Screw, side stand fixing on link fork 12 Nm (8.9 lbf ft) Screw, steering stem 12 Nm (8.9 lbf ft)

  • Page 126: 23 Substances

    23 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 127 SUBSTANCES 23 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 128: Auxiliary Substances

    24 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 129 AUXILIARY SUBSTANCES 24 Universal oil spray Recommended supplier MOTOREX ® – Joker 440 Synthetic...

  • Page 130: 25 Standards

    25 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 131: Index Of Special Terms

    INDEX OF SPECIAL TERMS 26 On-board diagnosis Vehicle system, which monitors the specified parameters of the vehicle electronics...

  • Page 132: List Of Abbreviations

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

  • Page 133: List Of Symbols

    LIST OF SYMBOLS 28 28.1 Yellow and orange symbols Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also repre- sented by yellow or orange symbols. Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics.

  • Page 134: Index

    INDEX Choke lever ......16 INDEX Clutch Accessories ......9 fluid level, checking/correcting .
  • Page 135 INDEX Frame removing ......44 checking ......69 Front brake caliper Magnetic switch .
  • Page 136 INDEX Type label ......12 Safe operation ......7 Service .
  • Page 137 *3215159en* 3215159en 10.10.2023 Stallhofnerstraße 3 / 5230 Mattighofen / Austria / http://www.gasgas.com...

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