GAS GAS TXT BOY - 2009 User manual

TXT BOY
TXT BOY
ENGLISH
USER MANUAL
USER MANUAL

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GAS GAS thank you for the trust you have placed in us.
By choosing a new GAS GAS TXT Boy you have become part of the great GAS GAS family and,
as a user of the number one manufacturer of off-road motorbikes, you deserve to receive the best
treatment we can offer you both in our post-sales relations and in the explanations we offer in this
manual.
Our TXT Boy is designed for high-level trial competitions. In fact, it is the result of many years of
competition and experience in this highly demanding discipline and of the many excellent results
obtained by the great riders who have supplied the basic data to enable us to develop this excellent
motorbike, a GAS GAS that has one key advantage: its remarkably light weight.
Congratulations, because your choice has been, without doubt, the correct one. With your riding
skills, appropriate preparation and the relevant essential checks to maintain its highly reliable
performance, you will be able to enjoy your trial riding to the utmost.
Thank you for your trust in us, and welcome to GAS GAS motorbikes.
GAS GAS MOTOS, S.A.

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Important warning
Read this Manual carefully. You will find it contains all the necessary information for your safety,
and that of others, as well as guaranteeing the correct conservation and maintenance of the GAS
GAS motorbike you have just bought.
All of the necessary instructions for the correct riding and control of this vehicle are set out below.
Each message is preceded by a symbol whose meaning is as follows:
Caution! This symbol identifies all the safety measures and regulations which should help
avoid physical injury, serious or otherwise, or even loss of life, should the instructions not
be followed carefully.
Warning! This symbol introduces special warnings to avoid damaging your motorbike.
Should these warnings not be heeded, the guarantee may be automatically invalidated.
Miscellaneous. These are the instructions necessary to ensure good use of the control
and adjustment mechanisms, in addition to the correct conservation and maintenance of
the motorbike, to guarantee maximum satisfaction when riding.
The aim of this Manual is to help the user minimise or avoid possible damage to people, property,
the environment, and naturally to his/her new motorbike. Therefore, all the information presented
here is based on data obtained from the latest models put on the market just before publication.
However, GAS GAS Motos, S.A. reserves the right to make modifications without any prior warning
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.

Contens
Acknowledgements to the purchaser 5
Important warning 6
Quick Guide to Maitenance 8
Fuel-Petrol/oil mixture 9
Fuel tank 9
Fuel tap 10
Gear shift 10
Before starting the engine 11
Starting the engine 11
Stopping the engine 12
Riding your motorcicle 12
Stopping the motorcycle 12
Running-in period 13
Transmission oil
- Checking oil level 13
-Topping up 14
-Changing oil 14
Clutch system- Checking 15
Clutch system- Bleeding 15
Coolant system – Checking/topping up 16
Carburettor
- Adjusting throttle cable 17
- Adjusting idle speed 17
Spark plugs - Inspecting 18
Air Filter - Cleaning 18
Front brake fluid - Checking 19
Rear brake fluid - Checking 19
Clutch lever - Adjusting 20
Front brake lever - Adjusting 20
Rear wheel – Centre alignment 21
Chain slack - Checking 21
Master link - Checking 21
Tyre pressures - Checking 22
Brake pads - Checking 22
Brake circuit - Bleeding 23
Front fork – Oil level 23
Lubrication 24
Identification 26
Warranty terms and conditions 27
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Quick Guide to Maintenance
Coolant liquid Coolant liquid -30ºC
Crankcase oil (10w40) 500 cc.
Electrode separation 0.6 mm.
Forks suspension oil SAE 5 (Summer)
SAE 2.5 (Winter)
Fork suspension oil quantity 200 cm3
Shock absorber spring length 96 mm
Front wheel pressure Standard 0.400 bar
Competition 0.370 bar
Rear wheel pressure Standard 0.350 bar
Competition 0.300 bar

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1Fuel – Petrol/oil mixture
The motorcycle is fitted with a two-stroke internal
combustion engine. This type of engine requires a
mixture of petrol and oil.
To ensure the correct working of the engine, the following are
recommended:
- Use high quality petrol, with an octane rating equal to or
above 90 (RON + MON)/2 or 98 (RON).
- Use 2T synthetic oil.
Warning:
- If the recommended oil is not available, use semi-synthetic oil.
- Do not mix different oil-types.
Mixture ratio: oil, 1.5% of petrol volume (50 parts petrol to every
0.75 part oil).
Note: we recommend first preparing the mixture in a suitable
container and then filling the fuel tank.
Fuel tank
This has a rapid access cap Aand a vent hose Bto allow gases
produced in the tank to escape.
- To open the cap, lift the clip in the direction shown by the arrow
and turn to the left.
Warning! Regularly check the cap seal and vent hose to ensure
they are leak proof. Risk of spillage.
I
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3
2
Reserve Open Closed
Fuel tap
This has three positions:
open, closed and reserve.
The diagrams below show the
position of tap Afor each case.
8
C
A
Gear shift
The motorcycle has a two-
speed gearbox, which
may be selected manually
when the motorcycle is stationary, by
moving the lever Ain a horizontal
direction, as shown by the arrow.
Note:
Select the gear according to the cha-
racteristics of the track.
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8

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5
4
Starting the engine
Kick the start-pedal Ain the di-
rection shown by the arrow until
the engine starts.
Warning: Once the engine is running,
fold the kick-start pedal up against the
engine.
C
Before starting the engine
Warning: Before starting the engine, check that the
gear lever is in neutral (see instructions in the section
Gear lever, page 10)
- Open the fuel tap.
Note:
- If the engine is cold, move choke Aupwards, as shown by
the arrow, until it clicks into place (vertical). Once the engine
is turning over regularly at idle speed, return the choke to the
rest position (horizontal).
- Do not use the choke on hot days or when the engine is hot.
In this case, hold the throttle lever partially open until the
engine starts.
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Riding your motorcycle
- Select the gear according to the
characteristics of the track.
- To change gear, the motorcycle should
be stationary.
Stopping the motorcycle
- Release the throttle lever.
- Use the front Aand rear Bbrakes.
Warning: Depending on circumstances and
ground surface, it may be better to use the
front or rear brakes independently.
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A
B
A
CStopping the engine
- With the throttle lever in rest
position (engine idling), move the
gear lever to neutral.
- Press stop button Auntil the engine
stops.
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Running-in period
Care of the engine during the first
hours of use is vital for obtaining
the best from your motorcycle.
Therefore, we recommend:
- Strictly observe the oil and petrol ratios
shown, and use the recommended 2T oil
– see section “Fuel – petrol/oil mixture”,
page 9.
- In the first hour of use, keep the engine
at a moderate turnover speed (never go
to maximum turnover).
- Constantly change the speed, by
opening and closing the throttle
alternately.
CTransmission oil –
Checking the level
If the motorcycle has been
used recently, wait a few minutes before
checking the level.
Note: the motorcycle should be
perpendicular to the ground.
The level is correct if it falls within the
upper half of the transparent window A.
If the level falls below the upper half of
the transparent window A the oil should
be topped up.
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9
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11
10
Transmission oil – Topping up
If necessary, top up with oil:
- Remove vent hose A.
- Remove filler cap Band add oil until the
correct level is reached.
Warning: Use the recommended oil.
- See Quick Guide to Maintenance, page 8.
Warning: Do not exceed maximum level!
Risk of damage to engine.
- Replace filler cap and tighten.
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Transmission oil – Changing
- Start the engine and keep it running until
it warms up, then stop the engine.
- Drain off the used oil. To do so, remove the drain
plug Alocated on the lower part of the engine (visible
through the opening of the oil sump casing).
- Replace the drain plug using a new seal washer.
Tighten to 20 Nm.
- Remove the filler cap and fill with oil (450 cc).
Warning: Use the recommended oil.
- See Quick Guide to Maintenance, page 8.
- Tighten the filler cap.
Warning: Do not pour used oil down the drain.
C
A
B
A
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13
12
Clutch system- Checking
The clutch system is hydraulic.
Regularly check the level of fluid
through the transparent window Aon the tank.
- Position the lever so that the tank cover is
horizontal.
- The level is correct if it falls within the upper
half of the transparent window.
Warning: Use the recommended oil.
See Quick Guide to Maintenance, page 8.
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Clutch system - Bleeding
If the system has been dismounted
for repair, or if faults are detected
in the clutch system, the air in the hydraulic
circuit can be removed using the bleeder A.
Once the air has been removed from the
system, replace the rubber cap on the bleeder
to prevent dirt from entering the system.
Warning: Do not pour used oil down the drain.
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A
A
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14
Coolant system –
Checking/topping up
To reach the radiator cap, proceed
as follows:
- Undo the bolts shown by the arrow and
remove the fuel tank cover and the rear seat
unit.
- Carefully lift and remove the fuel tank.
Warning: If the motorcycle has just been used,
wait a few minutes before opening the radiator
cap. Risk of burns!
- Turn cap Ain an anti-clockwise direction until
it is loosened.
- Wait a few seconds, then push the cap
downwards, finish the turn in the same direction
and remove the cap.
- The level of coolant should be at the lower
edge of the filler neck of the radiator, below
the position of the cap seal. If this is not the
case, top up with coolant.
Warning: Only use coolant suited to light-alloy
engines, with antifreeze protection of up to -
30 ºC.
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15
Carburettor - Adjusting throttle cable
The throttle lever cable should have a
free play of between 2 to 3 mm.
If necessary, adjust as described.
- Raise the dust guard Aon the throttle lever cable.
- Turning the threaded terminal Bto the right
increases the play of the cable, and turning it to the
left reduces the play.
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7
Carburettor – Adjusting the idle
speed
The carburettor has an idle adjusting
screw A, which acts on the opening of the
carburettor throttle curtain, and an air adjusting
screw for the low system B, which controls the
proportion of air in the air/fuel mixture.
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18
17
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Spark plugs - Inspecting
The electrode separation is from a:
0.6 to 0.7 mm.
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7
Air Filter - Cleaning
A clean air filter not only improves
engine performance but also prolongs
its useful life. It should therefore be cleaned
regularly.
To reach the air filter, proceed as follows:
- Undo the bolts shown by the arrows, and remove
the rear seat unit.
- Using a screwdriver or similar, remove the elastic
band Afrom the bolt holding it.
- Remove cover Bfrom the filter box.
- Remove filter.
Wash the filter in warm water and soap and, once
dry, grease with special filter oil.
- Remount the parts in reverse order.
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a

19 20
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Front brake fluid - Checking
The level is correct if it falls within
the upper half of the transparent
window A. If not, top up with a recommended
brake fluid.
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7
Rear brake fluid - Checking
The level is correct if it falls within the
min and max marks on the tank.
If the level is below the min. mark, top up with the
recommended brake fluid.
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7
MAX
MIN
A

21
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Clutch lever - Adjusting
The clutch lever should have a
maximum play of 3 mm.
To adjust, proceed as follows:
- Adjust the maximum turn of the lever using
bolt A, to suit the driver.
- Adjust the play of the lever using bolt B.
Warning:
Maintain the clutch lever with the play shown,
otherwise the performance and useful life of
the clutch may be adversely affected.
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3 mm max
7
Front brake lever - Adjusting
The front brake lever should have
a maximum play of 3 mm.
To adjust, proceed as follows:
- Adjust the maximum turn of the lever using
bolt A, to suit the driver.
- Adjust the play of the lever using bolt B.
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3 mm max
22
A
B
A
B

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24
25
Rear wheel – Centre alignment
The rear axle has easily
graduated eccentrics for this
operation.
To ensure perfect wheel alignment, make
sure that the marks of both eccentrics are in
the same position on both sides.
C
Chain slack - Checking
Adjust chain tension with the
eccentrics so that the slack in the
tensed zone is 1.5 cm.
C
Master link - Checking
The master link of the chain has
an elastic locking clip.
As shown in the photo, place the closed
part of the clip in the direction of the chain
rotation.
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23
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26
27
Tyre pressures - Check
Check tyre pressures
order to obtain the holding possible.
Front tyre pressure:
0.450 bar - standard
0.420 bar - competition
Rear tyre pressure:
0.350 bar - standard
0.300 bar - competition
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Brake pads - Checking
The brake pads, both front and rear,
should be checked for wear
periodically,
in order to enable you to brake effectively
in any situation.
Replace if the thickness of the friction material
of the pads reaches 1 mm.
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