GAS GAS TXT CADETE - 2007 User manual

TXT ROOKIE /
CADETE ´07
TXT ROOKIE /
CADETE ´07
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 Rookie / Cadete 2007 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 Rookie / Cadete 2007 is designed for high-level trial competitions. In fact, it is the result of
many years of competing and experimenting 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 for you will doubtless have no reason to regret your choice. With your riding skills,
appropriate preparation and the relevant essential checks to maintain its highly reliable performance,
you will be able to enjoy to the utmost your trial riding.
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 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
Acknowledgements to the purchaser 3
Important warning 4
Recommendations for the best working 6
Quick Guide to Maintenance 7
Serial Number 8
Draining the Sump 8
Position of Fuel Tap 8
Filling of the Crankcase 9
Position of the Kick-start Pedal 9
Filling of the Radiator 9
Greasing the Joints 10 to 12
Tolerance of Throttle Cable 13
Spark Plug Control 13
Carburetion 13
Hand Control Settings 14
Cleaning of Air Filter 14
Position of Chain Fixing Link 15
Chain tensor setting 15
Cleaning the carburettor 16
Checking the Carburettor capacity 16
Inlet Valves 17
Discs and Clutch Springs 17
Draining the Water Pump 18
Checking Oil Levels 18
Air Bleed 18
Clutch Fluid Circuit 19
Front and Rear Suspension 19 to 20
Checking of Bearings and Rocker Arm 20 to 21
Shock Absorber Spring Pressure 21
Rear Brake Fluid Tank 21
Brakes 22
Controls 23
Tyre Pressures 23
Guarantee manual 25 to 27

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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 1.5% in the oil/petrol mix.
RECOMMENDS THE USE OF OIL

Quick Guide to Maintenance
Cooling liquid type Cooling fluid -30ºC.
Crankcase oil (10w40) 500 cc.
Spark plug CHAMPION RN11YCC / NGK BPR5ES.
Electrode separation 0,6 mm.
Forks suspension oil SAE 5 (Summer).
SAE 2,5 (Winter).
Fork suspension oil quantity -ROOKIE: 140 cm3
-CADETE: 135 cm3
Length of Shock Absorber Spring -ROOKIE: 310 cm3
-CADETE: 210 cm3
Front Wheel Pressure Standard 0,450 bar.
Competition 0,420 bar.
Rear Wheel Pressure Standard 0,350 bar.
Competition 0,300 bar.
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3
1
2
Reserve Open Closed
The fuel tap should
be in a vertical
position for normal
working. Forwards,
reserve; downwards, the supply
valve is open; and towards the
rear, the valve is closed.
I
The engine
crankcase drain
cap is situated on
the lower left-hand
side. The drainage hole in the
crankcase allows its easy
emptying.
I
7
8
The new GAS GAS
TXT Rookie / Cadete
2007 bears the
relevant qualification
approval plate *, the details of
which must match that in the
documentation and of the chassis
number on the steering tube.
* in the approved Rookie 50 version.
I
8

6
5
4
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A
When filling the
radiator, use cooling
fluid designed for
lightweight alloy
motors.
I
8
When topping up
the oil, open the
cap (A).
8
This is the position the
kick-start should be in
when not being used.
I
8
Engine Oil
capacity 500 cc
(10W40).
Cooling fluid
-30ºC

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8
With special oil it is
necessary to lubricate:
1) The joints of the clutch and
brake levers.
C
8
7
2) The joint of the gear
change pedal.
C
8
9
C3) Also the rear brake pedal
(bearings).
8

C5) Grease the joint of the kick-
start pedal of the engine.
11
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C
8
8
4) Grease the
fixings and
springs of the
footrests.
6) The secondary chain
should be cleaned and
lubricated regularly given
its constant friction and
exposure to the elements.
8
10
12
C

13
15
7
7
14
7
7) Grease the
handlebar with a fine
coating of oil to
guarantee the smooth
working of the throttle grip.
C
8) We also recommend the regula
greasing of the spring of the chain
tensor since it works under great
pressure.
C
9) The throttle should be
cleaned and oiled regularly
especially after washing the
motorbike with water at highpressure.
C
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17
16
7
0,6 ~0,7 mm
_
7
7
18 Regulation
mix-air
Regulation
idling
speed
It is necessary to
periodically check the
state of the spark
plug. The sparking plug
distance should be between
0.6 and 0.7mm.
C
Controlling the
tolerance on the
throttle cable is done
using the mechanism
indicated with the hand in the
photo.
C
Adjusting the idling
speed of the engine,
and the flow of fuel
into motor, can be done using
the screws marked in the
photograph.
C
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19 20
21
7
7
a
a
The front
brake le-
ver, just
like the
clutch, should be
at the ideal distan-
ce from the action.
In this case, the
play must never
exceed a maxi-
mum of 3 mm
(height a).
C
It is important to periodically
check the air filter. Open the
door set on the side of the
motorbike as shown in the photo. Clean
with water and detergent, then dry and
lubricate with oil designed for filters.
Ensure its correct collocation once clean.
In the lower part of the filter chamber
there is a leaf that acts as the escape
valve for the liquids and/or other
materials that may build up in the filter
chamber. Check this valve is working
properly.
C
7
The clutch operating lever
must be adjusted to the re-
quired distance and the play
of the lever must never ex-
ceed more than 3mm (height a).
Never override this play.
C
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23
7
7
7
24
22
To tense and centre
the rear wheel, the
hub is fitted with
easily adjustable eccentrics.
C
The tension on the
chain should allow an
oscillation of 1.5 cm
where it passes
through the tensor.
C
The chain
fixing link
should be
fitted so it faces against
the direction of
movement.
C
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7
25
7
C
7
26
a
27
Dismantle and clean periodically
the main nozzle after washing
the bike, as well as cleaning the
inside of the carburettor housing.
C
It is important to check the level of
petrol within the carburettor. The
height of the float is = 15 mm.
C
It is necessary to clean the
carburettor very thoroughly. To
do so use compressed air.
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29 30
7
C
28
a
After many hours of
use the clutch discs
should be checked for
possible wear. The minimum
size for their correct working is
15 mm.
CThe springs that exert
pressure on the clutch
should have a length
of between 28 and 29 mm.
C
The distance
between the plates
and the limits
should be = 8 mm.
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A
32
31
7
C
7
7
B
C
After any operation
involving the dismantling
or putting back together
of the clutch operating
circuit, any remaining air can be
eliminated using the air bleed (A).
C
To check the oil level,
first make sure the
motorbike is in a stable
position on a horizontal
surface. If the bike has been in
use, wait a few minutes. To check
the oil level, unscrew the cap (C)
and examine the level of oil using
the dip-stick. The level should be
between the marked maximum and
minimum levels. If it is too high,
drain the excess. If it is too low, add
the necessary quantity by opening
the oil cap. Use the same type and
make of lubricant as that which is
already in the engine.
C
The circle indicates
where the radiator
should be drained (B).
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7
7
33
34
Check the level of
clutch fluid periodica-
lly by looking through
the transparent spy-
hole mounted in the tank.
C
Each of the suspen-
sion bars is filled with
SAE 5 oil.
TXT Rookie: 310 cm3
TXT Cadete: 210 cm3
C
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35
C
C
7
8
36
35
The front suspension is
manually adjustable. To the
right (extension), to the left
(hydraulic compression).
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It is important to periodically
dismantle and check the
state of the bearings and the
rocker spports.
C
7
9.5 mm
The front suspen-
sion cap should
not exceed the fo-
llowing measure-
ments:
Rookie a = 3 mm
Cadete a = 0 mm
The front suspension of
the TXT Cadete model is
not fitted with adjustment.
a
C
7
a