GAS GAS TXT 2018 Series Instruction manual
Trial 80 125 250 280 300cc
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-- -
txt SERIES
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2018
Workshop Manual
2017 GAS GAS
All rights reserved
Workshop manual
-3-
GENERAL INFORMATION
INTRODUCTION5
LEGAL NOTICES5
NOTICES AND WARNINGS5
SAFETY RULES6
MAINTENANCE6
RECOMMENDED “WORK METHOD”7
TIGHTENING TORQUE
SPECIAL TOOLS10
MAINTENANCE 12
MAINTENANCE PROGRAMME13
PERIODIC INSPECTION
CARBURETTOR DISASSEMBLY AND INSPECTION
REED BLOCK DISASSEMBLY AND INSPECTION
EXHAUST SYSTEM DISASSEMBLY AND INSPECTION25
CYLINDER HEAD DISASSEMBLY AND INSPECTION30
CYLINDER AND PISTON DISASSEMBLY AND INSPECTION32
STARTER SYSTEM DISASSEMBLY AND INSPECTION37
CLUTCH ASSEMBLY DISASSEMBLY AND INSPECTION
CRANKCASE DISASSEMBLY AND INSPECTION
MAINTENANCE OF THE FRAME 50
ELECTRICAL DIAGRAMS
Contents
Workshop manual
GENERAL INFORMATION
Workshop manual
-5-
Introduction
DANGER
WARNING
Legal notices
Notices and warnings
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Safety rules
DANGER
SAFETY
death by inhalaon
Maintenance
Workshop manual
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Recommended “work method”
Workshop manual
Vehicle / engine identication
GENERAL TIGHTENING TORQUES
A
B
1
Tightening torque
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TYPE ASSEMBLY PHASE MEASUREMENT RATED TORQUE (Nm)
SCREW 20
SCREW 25
SCREW M5 6
SCREW 50
SCREW M6 12
SCREW M6 10
SCREW M6 12
NUT 50
SCREW M10 50
SCREW M10 50
SCREW M10
M10
M10
30
SCREW 50
SCREW 5
SCREW 20
SCREW M5 6
SCREW M5 6
SCREW 25
SCREW M6 12
SCREW 25
SCREW 25
SCREW M6 12
SCREW M5 6
SCREW 25
SCREW 25
SCREW M6 10
SCREW M6 12
25
M10 50
SCREW 25
SCREW M6 12
SCREW M6 12
SCREW M6 10
M6 6
SCREW M6 12
SCREW M5 6
SCREW M6
SCREW M6
SCREW M6 10
SCREW 5
SCREW 12
SCREW M6 12
SCREW M6 12
RACORD CLUTCH PUMP M10
RACORD CLUTCH COVER RACORD M10 20
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SPECIAL TOOLS
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Special tools
MT280234045
MT280250006
865207
MT95005GG-CHA-1
MT95010GG-CHA-1
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MAINTENANCE
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Maintenance programme
Element Check / Inspect Adjust Replace/Change Clean Grease /
Lubricate
Throle operaon Every race If is necessary - - Every race
Carbureor / Jet Every race If is necessary - 30 hours -
Air lter Every race - If is necessary Every race Every wash
Reed block 30 hours - If is necessary 30 hours -
Spark plug Every race 30 hours 60 hours 15 hours -
Transmission oil 30 hours -60 hours - -
Radiator coolant Every race - 1 year - -
Cooling system - - If is necessary - -
Decarbonisaon of the cylinder
head / Exhaust port 60 hours - - 60 hours -
Piston 60 hours - 1 year (180 h) - -
Piston rings 60 hours -Every six months - -
Cylinder 60 hours - If is necessary - -
Cranksha and bearings assembly 60 hours - If is necessary - -
Kick-starter and gear shi pedal - - - - 15 hours
Clutch system - - If is necessary - -
Clutch discs 60 hours - If is necessary - -
Exhaust system - - If is necessary - -
Muer bre - - 100 hours - -
Fuel line/tap Every race - If is necessary - -
General lubricaon Every race - - - Every wash
Chain / secondary transmission Every race 15 hours If is necessary Every race Every wash
Workshop manual
Periodic inspection
ATTENTION:
Before removing the spark plug, blow compressed air around it to remove any
dirt, making sure that it does not fall into the engine.
Remove:
Check:
Inspect:
Clean:
Measure:
Fit:
NOTE:
- Before ng the spark plug, clean the surface of its seang and gasket.
- If you do not have a torque wrench, a good guide for the correct torque is to
ghten the spark plug by hand to posion (1) and then ghten with a ¼ to ½
turn to posion (2).
- Always use a new gasket.
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Periodic inspection
AIR FILTER
Cleaning the lter
- It is important to periodically check the air lter.
- Inspect the lter and replace it if damaged to prevent dirt from entering the
carbureor.
- To clean it, use water and detergent, dry it and lubricate it with special lter
oil.
- Make sure that it is correctly ed once clean.
ATTENTION:
- A clogged air lter will allow dirt to enter the engine causing excessive wear
and damage.
- Inspect it periodically. Clean if necessary.
- Clean the lter in a venlated area and make sure that there are no sparks
or ames near the work place (including strong sources of light). Do not use
petrol to clean the lter as this may cause an explosion.
ATTENTION:
- At the boom of the lter box, there is a ap that funcons as a valve for
draining liquids and/or elements that accumulate inside the lter box.
- Make sure that this valve is operang correctly.
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Periodic inspection
2
1
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Periodic inspection
TRANSMISSION OIL LEVEL
NOTE
MAKE SURE THAT THE MOTORCYCLE IS PARALLEL TO THE GROUND TO ENSURE
CORRECT CHECKING OF THE OIL LEVEL.
1
2
3
Workshop manual
Carburettor disassembly and inspection
CARBURETTOR
1
2
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Carburettor disassembly and inspection
- Before removing the air volume adjustment screw (compensator)
from the low speed (idle) circuit (2), check its posion by counng the
necessary turns to screw it to the stop (without forcing it). Note down
this measurement and remove it by unscrewing it (If in doubt, consult
the vehicle characteriscs table to determine the standard posion of
this screw).
* For models with Keihin PWK28 carburettor
Workshop manual
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- Check the condion of the fuel ow system piston valve. Replace it if
there is any damage to the vulcanised sealing seang or on the metal
body of the piston itself (scratches and/or corrosion exceeding 25% of
its total surface area).
- Thoroughly clean all of the components of the carbureor with solvent (take
care not to damage the carbureor oat chamber gasket or the cold start
piston valve O-ring).
- With compressed air, thoroughly blow clean all air and fuel ow holes.
- With a set of scales, check the weight of the oat against what is marked on
it. Replace if that weight is exceeded.
- Check the sizing of the jets against the numbering marked on them, t
appropriate ones (see sengs table), otherwise the performance of the
engine will be aected.
Carburettor disassembly and inspection
This manual suits for next models
5
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