GasGas TXT Replica Factory 2013 Owner's manual

TXT REPLICA FACTORY 2013

GAS GAS thank you for the trust you have placed in us.

By choosing the new GAS GAS TXT REPLICA FACTORY 2013 you have become part of the great GAS GAS family and, as a user of the number one manufacturer of offroad 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 TXT REPLICA FACTORY 2013 is a bike conceived for the practice of high-competition 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.

April - 2013

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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.

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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	29
Clutch operations	30
Discs and clutch spring	31
Air bleed	31
Water pump draining	32
Front suspension	33
Rear suspension	34
Swing-arm articulations	32
Articulation lubrication	35 to 37
Chain fixing link position	38
Chain and wheel tension	38
Tyres and tyre pression	39
Brakes	40
Rear brake fluid tank	41
Torques	42
Storage	43
Multifunction	44 to 51
Troubleshooting	52 to 56
Finally recommendations	57
Homologation	57 to 59

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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.

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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

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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.

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Recommendations for the reliable operartion of your GAS GAS.

•Eight hours of running-in are recommended in order to guarantee the correct operation of the engine.

•It is important to warm the engine to the optimum operation temperature every time the motorbike is used.

•Synthetic or semi-synthetic 2-stroke oil should be used at 2% in the oil/petrol mix.

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TECHNICAL SPECIFICATIONS

ENGINE	2 stroke, single cylinder, direct reed valve crankcase induction. Liquid cooled.
125cc. engine
Cylinder size	124,8cc
Bore and stroke	54 x 54,5 mm.
250 cc. engine
Cylinder size	247,7 cc.
Bore and stroke	72,5 x 60 mm.
280 cc. engine
Cylinder size	272,2 cc.
Bore and stroke	76 x 60 mm.
300 cc. engine
Cylinder size	294,1 cc.
Bore and stroke	79 x 60 mm.
Carburetor, diameter of the diffuser	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).
Final drive 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)

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Primary reduction ratio		2,777 (75/27)
Final reduction ratio		3,818 (42/11)
Overall drive ratio	Capacity	8,704 (6th. gear)
Transmission oil		400 cc.
	Type	75W GRO GEAR EXTREME
FRAME
Type	Front	Tubular profile made with Cr-Mo.
Tyres		2,75 x 21” Trial
Suspension	Rear	4,00 x 18” Trial tubeless.
	Front	Adjustable tele-hydraulic fork ø 39 mm. Aluminium bars hard anodized.
Suspension stroke	Rear	Variable progressive system with mono-shock multiadjustable.
	Front	180 mm.
Front fork oil	Rear	164 mm.
	ø 39 mm.	SAE 5
Front fork oil level		LEFT 130 mm. air chamber
		RIGHT 75 mm. air chamber
BRAKES		Disc brake.
Type	Front
Disc diameter		ø185 mm. 4 piston calipers.
	Rear	ø150 mm. 2 piston calipers.
DIMENSIONS		1180 mm.
Overall height
Overall width		820 mm.
Seat height		650 mm.
Ground clearance		315 mm.
Wheelbase		1330 mm.
Fuel tank capacity		2,4 liters.

(Specifications subject to change wothout notice, which may not be applicable in every country).

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1	Front fender	12	Front brake disc	24	Middle silencier
2	Front brake caliper	13	Cylinder	25	Radiator
3	Front suspension left	14	Carburetor	26	Headlight
	leg	15	Chain guide	27	Front tyre air valve
4	Front suspension bar	16	Chain tensioner	28	Rear brake disc
5	Breather hose	17	Chain	29	Sidestand arm
6	Spark plug	18	Rear sprocket cover	30	Swingarm
7	Filter box	19	Rear sprocket	31	Rear brake pedal
8	Rear fender	20	Rear rim	32	Kickstart pedal
9	Tail lamp	21	Rear tyre	33	Water pump
10	Front tyre	22	Exhaust protection	34	Exhaust pipe elbow
11	Front brake disc cover	23	Frame	35	Front wheel axle

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					44
						45
36	38	39	40	41
	37					47
					46	48
						49
				43		50	51

										52
							61
	57					42	60		53
					58	59			54
									55
									56
36	Rear fender			45	Clutch lever
									54	Throttle cover
37	Axle nut rear wheel			46	Light controls
38	Left foot peg			47	Clutch pump				55	Front brake lever
39	Air filter box cover			48	Handlebar				56	Throttle grip
40	Shift pedal			49	Left suspension regulation				57	Silencer
41	Ignition cover			50	Multifunction				58	Right foot peg
42	Fuel tank			51	Warning indicators				59	Rear brake pedal
43	Fuel tank cap			52	Right suspension regulation				60	Exhaust pipe elbow
44	Left handle grip			53 Front brake pump					61 CDI Switch

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The maintenance table and adjustments are easy to carry out and must be done to insure the motorcycle is in good running condition.

MAINTENANCE TABLE

Part	Check /	Adjust	Replace /	Clean	Grease /
	Inspect		Change		Lubricate
Rear shock absorber	Every year	-	Every 2 years	-	-
Transmission oil	30 hours	-	60 hours	-	-
Front fork oil	-	-	60 hours	-	-
Brake adjust	Every race	If is necessary	-	-	-
Swingarm and connecting rods	Every race	-	If is damaged	Every race	Every cleaning
Spark plug	Every race	30 hours	60 hours	15 hours	-
Throttle cable and twist grip	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	-
Carburetor	Every race	If is necessary	If is damaged	Every race	-
Frame	Every race	-	If is damaged	Every race	.
Carburetor 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	-	-
Engine protector plate	Every race	im a fall	if is damaged	-	-

NOTE: (*) Inspect or do this operations only it’s necessary.

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MAINTENANCE TABLE

Part	Check /	Adjust	Replace /	Clean	Grease /
	Inspect		Change		Lubricate
Exhaust	Every race	-	500 hours	-	-
Packing	-	-	100 hours	-	-
Air filter	Every race	-	If is damaged	Every race	Every cleaning
Steering assembly	Every race	If is necessary	-	-	-
Brake hose	Every race	If is necessary	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 slider	Every race	-	If is damaged	-	-
Kickstart and shift pedal	Every race	-	If is damaged	-	Every cleaning
Brake piston pump anb the dustcover	-	-	If is damaged	-	-
Brake piston and the 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	-	-
Frame protect sickers	Every race	-	if is damaged	-	-
Tire-silencer space (clearance)	Every race	Im a fall	if is damaged	-	-
NOTE: (*) Inspect or do this operations only it’s necessary.		-15-

HOMOLOGATION P.

8	The new GAS GAS
	T X T R E P L I C A
	F A C T O R Y 2 0 1 3
	carries the appropriate
	certification		plate
	whose details should
	coincide with those on
	the accompanying
	documentation and
	the frame	number
	stamped	on	the

steering arm.

Homologation conditions are detailed on sheets 58 to 59.

Serial number.

Enter the vehicle identification number (serial

I number), the particulars shown on the model

label, and the ignition-key identification number in the spaces provided, in order to simplify your future orders for spare parts or as a useful reference

in the event of your vehicle being stolen.

Serial number (A)

This has been printed on the steering tube. It shows the frame number used for registering this machine.

SERIAL N.

Homologation plate (B)

The motorcycle carries a certification plate showing a serial number that has also been printed on the front, and this information must coincide with that contained in the vehicle documents. We recommend that this information be entered in the box below.

Key identification numbers

The motorcycle carries one key set. The identification number appears right on the key joints. This number may be quoted when ordering a spare to replace a lost key. (except some racing models)

KEY NUMBER

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C	The control panel includes
	lighting, turn signal, horn and
	engine stop switches.
	8

C T h e i n d i c a t o r control has been located on the underside of the left-hand grip. This is an orange-colour button. To start the right-hand indicator, move this switch to the right; and likewise, to start the left-hand indicator, move

this switch to the left.

All light controls have been located
on the left-hand grip; the various
C positions available are reached by
sliding the main switch, which is on	8
the left end of the grip.

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Located under the C suspension lower right side bracket. For correct

operation, it is necessary to turn the handlebar completely towards the right until it stops, insert the key in the slot, turn it in counterclockwise direction, press and to turn it again in clockwise direction. The key can now be removed and the steering will remain locked.

I Never leave the key in the

lock. If the steering is turned with the key in the lock it may be damaged and the

locking system could be damaged.

8

C	Fuel tank capacity : 2,4 liters

Use premium gasoline with an octane rating equal to or higher than that shown in the table.

OCTANE RATING METHOD	MINIMUM RATING
Antiknock Index (RON + MON)/2	90
Research Octane No. (RON)	98

Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

I

Never mix vegetal and mineral oils together. Too much oil may be cause an excessive amount of fumes and spark-plug dirt. Too little oil may cause engine damage or early wear.

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C	This engine	is
	designed to burn
	a mixture	of

combustible fuels, lead free petrol and oil.

C The fuel tank cap is of the quick release type. To open the

cap, lift the tab and turn it 1/4 turn in counterclockwise direction. To close it, place cap with the words GAS GAS in the upper position, and turn the tab in clockwise direction. It is important to check periodically the condition of the cap sealing O’ring to insure proper sealing.

RECOMMENDS SYNTHETIC 2 CYCLE ENGINE OIL:

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