TXT PRO ´07
MANUAL DEL USUARIO
USER MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
BETRIEBSANLEITUNG
ENGLISH
TXT PRO ´07
USER MANUAL
GAS GAS thank you for the trust you have placed in us.
By choosing the new GAS GAS TXT Pro 2007 you have become part of the great GAS GAS family and, as a user of the number one manufacturer of off-road motorbike, you deserve the distinguished treatment that we wish to offer to you both in our after-sale relationship and in the explanations that we provide in this manual.
Our Pro 2007 is a bike conceived for the practice of highcompetition trial. It is actually the fruit of many years of competition and experimentation in this demanding discipline, as well as the many great successes achieved thanks to great trial riders who have contributed with their expertise to the basic data that have allowed us to create a high-level motorbike, a GAS GAS which counts on its low weight as a significant key factor.
Congratulations for making the right choice. With your skills at the commands of this motorbike, an adequate preparation and the indispensable servicing for this to be highly reliable, you will be able to enjoy the most comfortable and rewarding trial practice.
Thank you for your trust in us, and welcome to GAS GAS Motorbikes.
GAS GAS MOTOS, S.A.
July - 2006
-3-
Important notice
Read this Manual carefully. You will find it contains all the necessary information for your safety, and that of third persons, as well as guaranteeing the correct conservation and maintenance of the GAS GAS motorbike you have just bought.
You will find all the necessary instructions for the correct riding and control of this vehicle are set out below. Each message is proceeded by a sign whose meaning is the following:
Be careful! This sign introduces all those rules and precautionary measures necessary to avoid slight or severe injuries, or even the death of the user should these instructions not be correctly followed.
Look out! This sign introduces special warnings to avoid damaging your motorbike. Should these warnings not be heeded, the guarantee may be automatically invalidated.
Various notes. These are the indications necessary for the optimal control and adjustment 
operations, together with those tasks of conservation and maintenance of the motorbike in
order that you may obtain the greatest possible satisfaction from your vehicle.
The aim of this Manual is to help the user to minimise or avoid possible damage to people, property, the environment, and naturally to his/her new motorbike. For this reason, all the information presented here is based on data obtained from the latest models put on the market just before the publication of this Manual. However, GAS GAS Motos, S.A. reserves the right to make modifications without any prior warning being given to consumers and without incurring any additional obligations in so doing. Your local dealer will also provide you with any information as might be deemed necessary.
-4-
Contents
Thanks to consumer |
3 |
Important notice |
4 |
Warranty regulations |
6 to 8 |
Recommendations |
9 |
Technical specifications |
10 & 11 |
Component location |
12 & 13 |
Maintenance guide |
14 & 15 |
Serial number |
16 |
Combination switch |
17 |
Steering lock |
18 |
Combustible |
18 |
Fuel tank cap |
19 |
Fuel tap |
20 |
Starter |
20 |
Carburation |
20 |
Kick-start engine pedal position |
21 |
Lever regulation |
21 |
Oil level checking |
22 |
Crankcase fill-in |
22 |
Crankcase draining |
22 |
Air filter box cleaning |
23 |
Fuel tank dismantle |
24 |
Radiator fill-in |
24 |
Spark dismantle |
25 |
Spark check |
25 |
Air filter box dismantle |
26 |
Carburettor dismantle |
27 |
Carburettor capacity check |
27 |
Carburettor cleaning |
27 |
Inlet valves dismantle |
28 |
Inlet valves |
28 |
Clutch operations |
29 |
Discs and clutch spring |
29 |
Air bleed |
29 |
Water pump draining |
29 |
Front suspension |
30 & 31 |
Rear suspension |
31 |
Swing-arm articulations |
32 |
Articulation lubrication |
33 to 35 |
Chain fixing link position |
36 |
Chain and wheel tension |
36 |
Tyres and tyre pression |
37 |
Brakes |
38 |
Rear brake fluid tank |
39 |
Torques |
40 |
Storage |
41 |
Multifunction |
42 to 47 |
Finally recommendations |
48 |
Homologation |
49 & 50 |
-5-
WARRANTY TERMS AND CONDITIONS
(According to Law decree 23/2003 on the 10th of July, covering Warranties on Consumer Item Sales)
Warranty terms of the manufacturer GASGAS Motos, S.A.
The company GAS GAS MOTOS, S.A. (hereafter referred to as “GG”), with this present document guarantees the consumer, the purchaser of a vehicle manufactured by GG, that both the materials and the manufacturing are free of defects in accordance with the highest standards of quality. Consequently, GG with this document guarantees the consumer (hereafter referred to as the “purchaser”), in accordance with the conditions set out below, the repair, free of charge, of any defect in materials or that might result from faulty manufacture that is detected in a new motorcycle within the period covered by this Warranty and with no limit on the number of kilometres covered or hours of use.
Warranty Period
The period covered by this Warranty will begin on the day of delivery of the vehicle to the purchaser by a GG authorised dealer, or in the case of demonstration models, on the date in which the vehicle is used for the first time. The seller will be responsible for any unwarranted faults that become apparent within the period established in the Law decree 23/2003 on the 10th of July covering Warranties on Consumer Goods Sold from the time of delivery and in accordance with the Directive 1999/44/EC for other members of the European Community. For countries outside the European Community, the Warranty Period will be determined by the existing regulations in those countries. Nevertheless, should the fault appear during the first six months after the delivery of the motorcycle, it will be presumed that the said fault existed at the time of delivery; from the end of the sixth month onwards, the purchaser must demonstrate that the unwarranted fault existed at the moment of delivery. During the first six months subsequent to the delivery of the repaired vehicle, the seller will be responsible for any unwarranted faults arising out of the repair.
Any defects detected in the product must be brought to the attention of a GG authorised dealer within the Warranty Period. If the last day of this period is a Sunday or an official holiday, the Warranty period will be extended such that the last day of the period covered will be the first working day after the Sunday or official holiday.
Those claims under Warranty for defects not brought to the attention of a GG authorised dealer before the end of the Warranty Period will be excluded.
-6-
Obligation of the purchaser
GG will have the right to reject any claims under Warranty in the event that:
a)The purchaser has failed to submit the vehicle to any of the inspections and/or maintenance work required in the Users’ Manual, or has exceeded the date set for such inspections or maintenance work. Also excluded from guarantee are those faults that appeared prior to the dates established for an inspection or maintenance work where the latter was not carried out, or was carried out later than the date established.
b)An inspection, maintenance or repair has been performed on the vehicle by third parties not recognised or authorised by GG.
c)Any maintenance or repair has been carried out on the vehicle that violates the technical requirements, specifications and/or instructions indicated by the manufacturer.
d)Spare parts whose use has not been authorised by GG have been used during the course of maintenance work or repairs to the vehicle, or in the event that the vehicle has been used with fuels, lubricants or other liquids (including, amongst others, cleaning products) that have not been expressly mentioned in the specifications set out in the User’s Manual.
e)The vehicle has been altered or modified in any way or fitted with components other than those expressly authorised by GG as accepted components of the vehicle.
f)The vehicle has been stored or transported in a way that is not in accordance to the corresponding technical requirements.
g)The vehicle has been used for special purposes other than ordinary use, such as competition, races or record breaking attempts.
h)The vehicle has been directly or indirectly damaged as a result of a fall or an accident.
Warranty exclusions
The following items are not covered by this Warranty:
a)Worn parts, including, without any limitation, spark plugs, batteries, petrol filters, oil filter elements, (secondary) chains, engine output pinions, rear sprockets, air filters, brake discs, brake pads, clutch plates and discs, bulbs, fuses, carbon brushes, footrest rubbers, tyres, inner tubes, cables and other rubber components
b)Lubricants (for example, oil, grease, etc.) and working fluids (for example, battery liquid, coolant, etc.)
c)Inspection, adjustments and other maintenance tasks, as well as all kinds of cleaning work
d)Damage to the paint-work and consequent corrosion due to external causes, such as stones, salt, industrial fumes and other environmental impact, or inadequate cleaning with inappropriate products
-7-
e)Any damages caused as a result of the defects, as well as any expenses incurred either directly or indirectly as a consequence of the defects (for example, communication costs, accommodation expenses, car hire costs, public transport costs, breakdown truck fees,, courier costs, etc.), as well as other financial losses (for example, those caused by the loss of the use of the vehicle, loss of income, time lost, etc.)
f)Any acoustic or aesthetic phenomenon that does not significantly affect the condition or use of the motorcycle (for example, small or hidden imperfections, noise or vibrations that are normal in use, etc.)
g)Phenomena that are the result of the ageing of the vehicle (for example, discolouring of painted or metallic coated surfaces).
Various
1.- GG shall have the prerogative to decide, at its own discretion, whether to repair or replace defective parts. Where parts are replaced, ownership of the parts removed shall pass to GG without any other consideration. The GG authorised dealer, to whom the making good of the defects has been entrusted, is not authorised to make any declarations that are binding on GG.
2.- In case of doubt regarding the existence of a defect, or a visual or material inspection is required, GG reserves the right to demand the return of the parts which are the object of a claim under Warranty, or to arrange an inspection of the defect by an expert from GG. Any additional obligations arising out of guarantees on parts replaced free of charge, or any other service rendered free of charge, are excluded from the effects of this present warranty. The Warranty on parts replaced within the Warranty Period will end at the expiry date for the Warranty Period of the product concerned. 3.- Should it prove to be the case that a defect can not be repaired, the purchaser guaranteed shall have the right to the cancellation of the contract (payment of compensation) or a partial refund of the purchase price (discount), instead of repairing the motorcycle.
4.- Any claims against Warranty by the purchaser under the terms of the sale contract with the corresponding authorised dealer shall not be affected by the terms of this present Warranty. Neither will this present Warranty affect those additional contractual rights acquired by the purchaser under the general commercial terms and conditions of the authorised dealer. However, such additional rights may only be exercised through claims against the authorised dealer. 5.- Should the purchaser resell the product within the Warranty Period, the duration and conditions of the present Warranty will remain unaltered, in such a way as that the rights to make claims under the present Warranty in accordance with the terms and conditions set out in this present document shall be transferred to the new owner of the motorcycle.
-8-
Recommendations for the good working of your GAS GAS.
•Eight hours of running-in are recommended in order to guarantee the correct working of the engine.
•It is important to warm the engine to the optimum working temperature every time the motorbike is used.
•Synthetic or semi-synthetic 2-stroke oil should be used at 2% in the oil/petrol mix.
RECOMMENDS THE USE OF OIL:
-9-
TECHNICAL SPECIFICATIONS
ENGINE |
2 stroke, single cylinder, direct reed valve crankcase induction. Liquid cooled. |
125 cc. engine |
124,8 cc. |
Cylinder size |
|
Bore and stroke |
54 x 54.5 mm. |
200 cc. engine |
175,3 cc. |
Cylinder size |
|
Bore and stroke |
64 x 54,5 mm. |
250 cc. engine |
247,7 cc. |
Cylinder size |
|
Bore and stroke |
72,5 x 60 mm. |
280 cc. engine |
272,2 cc. |
Cylinder size |
|
Bore and stroke |
76 x 60 mm. |
300 cc. engine |
294,1 cc. |
Cylinder size |
|
Bore and stroke |
79 x 60 mm. |
Carburettor, diameter of the diffusor |
26 |
Lubrication system |
Mixture (50:1)(2%) |
Ignition system |
Digital magnetic flywheel CDI |
|
|
|
|
TRANSMISSION |
6 gears, Four / Six system by GAS GAS* (Patented). |
Transmission type |
|
Clutch type |
Hydraulic command, 1/3 discs, variable progressive with diaphragm system by GAS GAS* (Patented). |
Driving system |
By chain |
Gear ratio |
1st. 2,996 (35x27x28/16x24x23) |
|
2nd. 2,571 (36/14) |
|
3th. 2,187 (35/16) |
4st. 2,112 (36x23x24/14x28x24) 5st. 1,125 (27/24)
6th. 0,821 (23/28)
-10-
Primary reduction ratio |
|
2,777 (75/27) |
Final reduction ratio |
|
3,818 (42/11) |
Overall drive ratio |
Capacity |
8,704 (6th. gear) |
Transmission oil |
550 cc. |
|
|
Type |
10W40 API SF o SG. |
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FRAME |
|
Eliptic profile made with Cr-Mo. |
Type |
Front |
|
Tyres |
2,75 x 21” Trial |
|
Suspension |
Rear |
4,00 x 18” Trial tubeless. |
Front |
Adjustable tele-hydraulic fork ø 40 mm. (125 / 200). |
|
|
Rear |
Adjustable tele-hydraulic fork ø 40 mm with aluminium bars (250 / 280 / 300) |
Suspension stroke |
Variable progressive system with mono-shock multiadjustable. |
|
Front |
177 mm. |
|
Front fork oil |
Rear |
164 mm. |
ø 40 mm.(125 / 200) |
SAE 5. |
|
Front fork oil level |
160 mm. air chamber |
|
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ø 40 mm. (250 / 280 / 300) |
180 mm. air chamber |
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BRAKES |
|
Disc brake. |
Type |
Front |
|
Disc diameter |
ø185 mm. 4 piston calipers. |
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Rear |
ø150 mm. 2 piston calipers. |
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DIMENSIONS |
|
1180 mm. |
Overall height |
|
|
Overall lenght |
|
2015 mm. |
Overall width |
|
820 mm. |
Seat height |
|
650 mm. |
Ground clearance |
|
315 mm. |
Wheelbase |
|
1315 mm. |
Fuel tank capacity |
|
3,1 liters. |
|
|
|
(Specifications subject to change wothout notice, which may not be applicable in every country).
-11-
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
12 |
28 |
29 |
30 |
31 |
32 |
33 |
34 |
13 |
14 |
15 |
16 |
17 |
18 |
19 |
20 21 22 23 |
24 |
25 26 |
35 |
36 |
37 |
38 |
39 40 |
41 |
42 |
43 |
44 |
1 |
Front fender |
12 |
Rear headlight |
24 |
Rear sprocket |
37 |
Swingarm |
2 |
Front brake caliper |
13 |
Front tyre |
25 |
Rear rim |
38 |
Right foot peg |
3 |
Front suspension left |
14 |
Front brake disc cover |
26 |
Rear tyre |
39 |
Rear brake pedal |
|
bottle |
15 |
Front brake disc |
28 |
Exhaust protection |
40 |
Kickstart pedal |
4 |
Front suspension bar |
16 |
Cylinder |
29 |
Frame |
41 |
Water pump |
5 |
Front brake lever |
17 |
Gear pedal |
30 |
Exhaust |
42 |
Exhaust pipe elbow |
6 |
Breather hose |
18 |
Carburettor |
31 |
Radiator |
43 |
Front suspension right |
7 |
Spark plug |
19 |
Left foot peg |
32 |
Handlebar |
|
bottle |
8 |
Fuel tank |
20 |
Chain guide |
33 |
Headlight |
44 |
Front wheel axle |
9 |
Filter box |
21 |
Chain slide |
34 |
Front tyre air valve |
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10 Silencer |
22 |
Chain |
35 |
Front brake disc |
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|
11 |
Rear fender |
23 |
Rear sprocket cover |
36 |
Sidestand lever |
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53 |
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54 |
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45 |
46 |
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47 |
48 |
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49 50 |
51 |
52 |
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55 |
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56 |
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57 |
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58 |
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60 |
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61 |
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70 |
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62 |
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63 |
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64 |
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66 |
67 |
68 |
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69 |
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65 |
|
45 |
Rear fender |
54 |
Clutch lever |
63 |
Throttle cover |
46 |
Axis nut rear wheel |
55 |
Light controls |
64 |
Front brake lever |
47 |
Left foot peg |
56 |
Clutch pump |
65 |
Throttle grip |
48 |
Air filter box cover |
57 |
Handlebar |
66 |
Silencer |
49 |
Shift pedal |
58 |
Left bottle regulation |
67 |
Right foot peg |
50 |
Ignition cover |
59 |
Multifunction |
68 |
Rear brake pedal |
51 |
Fuel tank |
60 |
Warning indicators |
69 |
Exhaust pipe elbow |
52 |
Fuel tank cap |
61 |
Right bottle regulation |
70 CDI Switch |
|
53 |
Left hanle grip |
62 |
Front brake pump |
|
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-13-
The maintenance table and adjustments are easy to carry out and must be done to insure the motorcycle is in good running condition.
MAINTENANCE TABLE
Part |
Check / |
Adjust |
Replace / |
Clean |
Grease / |
|
Inspect |
|
Change |
|
Lubricate |
|
|
|
|
|
|
Rear shock absorver |
Every year |
- |
Every 2 years |
- |
- |
Transmission oil |
30 hours |
- |
60 hours |
- |
- |
Front fork oil |
- |
- |
60 hours |
- |
- |
Brake adjust |
Every race |
If is necessary |
- |
- |
- |
Swingarm and connecting rod |
Every race |
- |
If is damaged |
Every race |
Every cleaning |
Spark plug |
Every race |
30 hours |
60 hours |
15 hours |
- |
Throttle cable |
Every race |
If is necessary |
If is damaged |
If is necessary |
Every cleaning |
Chain |
Every race |
If is necessary |
If is damaged |
Every race |
Every cleaning |
Reed valve box |
30 hours |
- |
If is damaged |
Every race |
- |
Carburettor |
Every race |
If is necessary |
If is damaged |
Every race |
- |
Frame |
Every race |
- |
If is damaged |
Every race |
. |
Carburettor jet |
- |
If is necessary |
If is damaged |
- |
- |
Steering bearing |
Every race |
- |
If is damaged |
- |
- |
Piston bearing |
- |
- |
If is damaged |
- |
- |
Wheel bearing |
- |
- |
If is damaged |
- |
- |
Engine bearing |
- |
- |
If is damaged |
- |
- |
Rear sprocket |
30 hours |
First 5 hours |
If is damaged |
- |
Every cleaning |
Cylinder and cylinder head |
60 hours |
- |
Every year |
- |
- |
Brake |
Every race |
If is necessary |
If is damaged |
- |
- |
Brake disc |
Every race |
First 5 hours |
If is damaged |
Every 2 races |
- |
Clutch discs |
- |
- |
If is damaged |
- |
- |
Clutch |
Every race |
- |
If is damaged |
- |
- |
NOTE: (*) Inspect or do this operations only it’s necessary.
-14-
MAINTENANCE TABLE
Part |
Check / |
Adjust |
Replace / |
Clean |
Grease / |
|
Inspect |
|
Change |
|
Lubricate |
|
|
|
|
|
|
Exhaust |
Every race |
- |
500 hours |
- |
- |
Exhaust silencer fiber |
- |
- |
200 hours |
- |
- |
Air filter |
Every race |
- |
If is damaged |
Every race |
Every cleaning |
Steering assembly |
Every race |
If is necessary |
- |
- |
- |
Brake hose |
Every race |
If is necessary |
Every 2 years |
- |
Every cleaning |
Cooling fliud |
Every race |
If is necessary |
Every year |
- |
- |
General lubrication |
Every race |
- |
- |
Every race |
Every cleaning |
Front and rear rims |
Every race |
- |
If is damaged |
Every race |
- |
Tyres |
Every race |
- |
If is damaged |
Every race |
- |
Brake oil level |
Every race |
If is necessary |
- |
- |
- |
Chain guide slide |
Every race |
- |
If is damaged |
- |
- |
Kickstart ang shift pedal |
Every race |
- |
If is damaged |
- |
Every cleaning |
Brake piston pump amb his dustcover |
- |
- |
If is damaged |
- |
- |
Brake piston amb his dust-cover |
- |
- |
If is damaged |
- |
- |
Piston and piston rings |
60 hours |
- |
Every year |
- |
- |
Front and rear spokes |
Every race |
5 hours |
If is damaged |
Every race |
- |
Fuel system |
Every race |
- |
If is damaged |
- |
- |
Front suspension |
Every race |
If is necessary |
If is damaged |
- |
- |
Exhaust o’ring |
- |
- |
If is damaged |
- |
- |
Bolts, nuts & fasteners |
Every race |
If is necessary |
If is damaged |
- |
- |
Fuel hose |
Every race |
If is necessary |
If is damaged |
- |
- |
Radiator hose set and connections |
Every race |
If is necessary |
If is damaged |
- |
- |
NOTE: (*) Inspect or do this operations only it’s necessary.
-15-
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