GAS GAS TXT PRO - 2004 User manual

MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE
MANUAL DEL USUARIO
SERVICE MANUAL
MANUEL D’ENTRETIEN
LIBRETTO USO E MANUTENZIONE

TXT Pro 2004 -3-
GAS GAS thanks you for your confidence
By choosing the new GAS GAS Pro 2004 you have just entered the
great GAS GAS family and, as a user of the number one off-road
motorbike manufacturer, 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 2004 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 GAS GAS to be highly reliable, you
will be able to enjoy the most comfortable and rewarding trial
practice.
Thanks for your confidence and welcome to GAS GAS Motos.
GAS GAS MOTOS, S.A.
July - 2003

TXT Pro 2004 -4-
Important notice
Read this manual carefully. It contains all the aspects that must contribute to your and other people's safety,
apart from guaranteeing the perfect conservation and maintenance or the GAS GAS motorbike that you have
just purchased.
All the instructions to ride and handle it correctly are detailed below. Each message is preceded by the signs
below and their corresponding meanings:
Beware! With this symbol we detail all the precautions that must be taken to avoid minor or severe
injuries and even the user’s death in case they are not followed correctly.
Attention! This symbol indicates the special recommendations to avoid damaging the motorbike. If they
are not followed the guarantee may be automatically extinguished.
Notes. They are the necessary indications for a better use of the control and adjustment operations, as
well as the conservation and maintenance works to be performed on the motorbike, so that you get the
biggest satisfaction when riding it.
The aim of this manual is to help the user to minimise or avoid injuries to other people or damage properties
or the environment, as well as to your new motorbike. That is why all the information presented is based on
data obtained from the most recent range available from the manufacturer right before this document was
printed. However, GAS GAS has the right to alter it with no previous notice to the consumer without incurring
in obligations of any kind. Your closest dealer will also help you by providing any information you may require.

Contents
Thanks to the costumer 3
Important notice 4
Recommendations to get the best performance out of your bike 6
Summary of the manual 7
Serial number 8
Draining the oil sump 8
Position of the fuel tap 8
Filling the oil sump 9
Position of the kickstart lever 9
Filling radiator 9
Greasing the links 10 to 12
Throttle cable play 13
Spark plug control 13
Carburettor 13
Regulation of levers 14
Cleaning the air filter 14
Position of chain link 15
Índice
Regulation of chain tension 15
Cleaning the carburettor 16
Intake reed valve 16
Clutch plates and springs 17
Water punp draining 18
Checking the oil level 18
Air drain valve 18
Clutch liquid circuit 19
Front and rear suspension 20
Verifying the bearings and swing arm 20
Shock absorber spring tension 21
Brakes 22
Commands 23
Tyre Pressure 24
Watch 25 to 27
Warranty regulation 28 to 30
TXT Pro 2004 -5-

TXT Pro 2004 -6-
Recommendations to get the best performance out of your GAS GAS
We recommend an eight-hour running-in for the
best engine operation.
It is important to get the engine to its optimum
working temperature every time that the motorbike
is used.
Use 1.5% mixture of petrol and synthetic or
semi-synthetic 2-Stroke oil.

TXT Pro 2004 -7-
Maintenance summary
Cooling liquid -30ºC cooling liquid
Sump oil (10w40) 550 c.c.
Spark plug NGK BPR5ES
Electrode gap 0.6 mm
Amount of oil in the fork 310 cm3
Length of shock-absorbing spring 140 mm
Suspension fork oil SAE 5
Front wheel pressure Normal 0.450 bar
Competition 0.420 bar
Rear wheel pressure Normal 0.350 bar
Competition 0.300 bar

TXT Pro 2004 -8-
3
1
2

The position of the fuel
tap must be forward
rearward for normal
operation. When
turned upwards, it opens the
reserve, downwards it turns off the
fuel.
Reserve Open Close
The oil drain plug is
underneath the left
side of the engine. A
hole in the skid plate
makes it easier to drain the oil.
,
,

The new GAS GAS
Pro 2004 has its
corresponding
homologation plate,
which must correspond to the
documents and frame number,
printed in the steering axle.
,

4
A
B
6
5


TXT Pro 2004 -9-
This is the position of the
kickstart lever when not in
use.
To fill the radiator, use
special cooling liquid for
light alloy engines.
The system holds
between 550 cc of
oil (10W40)
-30ºC cooling
liquid
To refill oil, pour it
through the filler plug
and check the level in
the window.
,
,
,

9
TXT Pro 2004 -10-
&
&

&

7

8
2) The gear lever pivot
You must use special oil
for:
1) The clutch and brake lever pivots
3) The rear brake pedal pivot (bearings)

TXT Pro 2004 -11-
&


4) The foot peg
springs and pivots.
6) The chain must be
cleaned and oiled
regularly, due to its
constant friction and exposure to all
types of weather conditions.
&
&5) The kick start lever.
11
10
12


15
TXT Pro 2004 -12-
&&
14


8) The chain tensioner spring must also
be greased as it takes a lot of strain.
9) The throttle grip must be oiled
and cleaned frequently as well,
specially after using high pressure
water washing equipment.
7) Apply a thin oil film
over the handlebar on
the throttle side for
smooth operation.
&


18
16
TXT Pro 2004 -13-


17
Adjust the throttle cable
free play as shown in the
illustration.
&
The state of the spark
plug must be regularly
checked. The gap of the
electrode must be
&

The idle and petrol-air
mixture can be adjusted
as shown in the
illustration.
&


&
Like the clutch,
the front brake
lever must be in
the ideal posi-
tion. Again, the
play must not
exceed 3mm,
and must never
be eliminated.
TXT Pro 2004 -14-
19 20
21 

3 mm.
The clutch lever must be
adjusted to your liking, but
the free play should not
exceed 3mm. This play
must never be eliminated.
&

3 mm. máx.
&
21 
The air filter must regularly be cleaned.
To remove it, open the lid under the seat
cover. To clean it, use water and detergent,
leave it to dry and use special foam filter oil
to soak it. Make sure it is properly re-installed
once it has been cleaned. The rubber stopper
under the filter cartridge must be hand-
tightened to let out the water accumulated
inside.

23
TXT Pro 2004 -15-



24
The split link
clip should be
placed with
the open end facing away
from the direction of the
drive (see photo).
&
To tension and centre the
rear wheel, there are two
easy-to-use snail cam
adjusters.
&
The chain tension should
allow it a movement of
1.5 cm at the chain
tensioner.
&
22

TXT Pro 2004 -16-
&

25


26
18,50 mm
27
Periodically dismantle and clean the
main jet after each wash, as well as the
inside of the carburettor fuel bowl.
Compressed air should be used to
clean jets and passageways in the
carburettor body.
&
It is important to control the float level
inside the carburettor. The buoy height
should be 18.50 mm.
&

The clutch pressure plate
must be 4.4-4.5 mm
thick.
The gap between the
reeds and the bumpers
must be 3.5 mm for all
cylinder sizes.
After a long time of use
the clutch plate wear
must be checked. The
minimum thickness for correct
operation must be 9.75-9.85 mm.
29
TXT Pro 2004 -17-


&
&&
28
17±1
9,75+0.1
0
30

A
B31
After dismantling and
assembling the clutch drive
circuit, the remaining air
can be removed through the bleed
nipple.
TXT Pro 2004 -18-
&


(B) To check the oil level, set the
motorbike upright. If the bike has just
been used, leave it steady for some
minutes. Check the oil level in the window situated
low on the right side of the engine. The oil level must
be between the minimum and maximum indicators.
If it is too high, remove the excess; if it is too low, add
the necessary oil through the oil filler plug. Use the
same type and make of oil as the one already inside
the engine.
&
(A) The circle indicates
where the water pump
draining plug is.
&

32

Each suspension bar
must hold 310 cm3 of
SAE5 oil.
Regularly verify the
clutch fluid level through
the window.
TXT Pro 2004 -19-

&
&

33
34

The front suspension
stopper must not reach
higher than 9.5 mm
above the upper platen.
If your motorcycle
features a short bar, this
distance should be 0
mm.
It is important to dismantle
and verify regularly the state
of the swing arm and rear
suspension bearings and seals.
&


The front suspension is
manually regulated. The
right bar contains the
damping regulation, the left one the
hydraulic compression.
&
36
35
&
TXT Pro 2004 -20-


9,5 mm

37
38
TXT Pro 2004 -21-
B
A
The linkage in the
lower rear part of the
bike should be
regularly cleaned, verified and
lubricated.
&
The pressure of the shock
absorber spring is regulated
using the geared rings with
the help of a special key. The spring
length must be 140 mm.
&

The rear brake
fluid reservoir is
in the centre of
the frame.
&

