GAS GAS TXT PRO - 2006 User manual

MANUAL DEL USUARIO
USER MANUAL
MANUEL D’ENTRETIEN
LIBRETTO D´USO
BETRIEBSANLEITUNG

ENGLISH
USER MANUAL
USER MANUAL

-3-
GAS GAS thank you for the trust you have
placed in us.
By choosing the new GAS GAS TXT Pro 2006 you have
become part of the great GAS GAS family and, as a user
of the number one manufacturer of off-road 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 Pro 2006 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.
Mayo - 2005
-3-

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.
-4-

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 28
Clutch operations 29
Discs and clutch spring 29
Air bleed 29
Water pump draining 29
Front suspension 30 & 31
Rear suspension 31
Swing-arm articulations 32
Articulation lubrication 33 to 35
Chain fixing link position 36
Chain and wheel tension 36
Tyres and tyre pression 37
Brakes 38
Rear brake fluid tank 39
Torques 40
Storage 41
Multifunction 42 to 47
Finally recommendations 48
Homologation 49 & 50
-5-

-6-
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.

-7-
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

-8-
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.

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 2% in the oil/petrol mix.
-9-
RECOMMENDS THE USE OF OIL:

-10-
TECHNICAL SPECIFICATIONS
ENGINE 2 stroke, single cylinder, direct reed valve crankcase induction. Liquid cooled.
125 cc. engine
Cylinder size 124,8 cc.
Bore and stroke 54 x 54.5 mm.
200 cc. engine
Cylinder size 175,3 cc.
Bore and stroke 64 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.
Carburettor Dell'Orto* PHBL26BS.
Lubrication system Mixture (50:1)(2%)
Ignition system Digital magnetic flywheel CDI Kokusan* (125-200-250-280-300).
Spark plug NGK* BPR5ES
TRANSMISSION
Transmission type 6 gears, Four / Six system by GAS GAS* (Patented).
Clutch type Hydraulic command, 1/3 discs, variable progressive with diaphragm system by GAS GAS* (Patented).
Driving 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)

-11-
Primary reduction ratio 2,777 (75/27)
Final reduction ratio 3,818 (42/11)
Overall drive ratio 8,704 (6th. gear)
Transmission oil Capacity 550 cc.
Type 10W40 API SF o SG.
FRAME
Type Eliptic profile made with Cr-Mo.
Tyres Front 2,75 x 21” MICHELIN* Trial
Rear 4,00 x 18” MICHELIN* Trial tubeless.
Suspension Front Marzocchi* adjustable tele-hydraulic fork ø 40 mm. (125 / 200).
Marzocchi* adjustable tele-hydraulic fork ø 40 mm with aluminium bars (250 / 280 / 300)
Rear Variable progressive system with mono-shock multiadjustable SACHS*.
Suspension stroke Front 177 mm.
Rear 164 mm.
Front fork oil SAE 5.
Front fork oil level ø 40 mm.(125 / 200) 160 mm.
ø 40 mm. (250 / 280 / 300) 180 mm.
BRAKES
Type Disc brake.
Disc diameter Front ø185 mm. 4 piston calipers AJP*.
Rear ø150 mm. 2 piston calipers AJP*.
DIMENSIONS
Overall height 1180 mm.
Overall lenght 2015 mm.
Overall width 820 mm.
Seat height 650 mm.
Ground clearance 315 mm.
Wheelbase 1315 mm.
Fuel tank capacity 3,1 liters.
* REGISTERED TRADEMARK (Specifications subject to change wothout notice, which may not be applicable in every country).

-12-
13 14 15 16 17 18 19 20 21 22 23 24 25 26
1 3 4 6 7 8 9 10 11 1252
35 36 37 38 39 40 41 42 4443
28 29 30 31 3332 34
1 Front fender
2 Front brake caliper
3 Front suspension left
bottle
4 Front suspension bar
5 Front brake lever
6 Breather hose
7 Spark plug
8 Fuel tank
9 Filter box
10 Silencer
11 Rear fender
12 Rear headlight
13 Front tyre
14 Front brake disc cover
15 Front brake disc
16 Cylinder
17 Gear pedal
18 Carburettor
19 Left foot peg
20 Chain guide
21 Chain slide
22 Chain
23 Rear sprocket cover
24 Rear sprocket
25 Rear rim
26 Rear tyre
28 Exhaust protection
29 Frame
30 Exhaust
31 Radiator
32 Handlebar
33 Headlight
34 Front tyre air valve
35 Front brake disc
36 Sidestand lever
37 Swingarm
38 Right foot peg
39 Rear brake pedal
40 Kickstart pedal
41 Water pump
42 Exhaust pipe elbow
43 Front suspension right
bottle
44 Front wheel axle

66
45 46 47 48 49 50 5251
53
54
55
56
57
58
61
62
63
64
65
67 68 69
59
60
-13-
45 Rear fender
46 Axis nut rear wheel
47 Left foot peg
48 Air filter box cover
49 Shift pedal
50 Ignition cover
51 Fuel tank
52 Fuel tank cap
53 Left hanle grip
54 Clutch lever
55 Light controls
56 Clutch pump
57 Handlebar
58 Left bottle regulation
59 Multifunction
60 Warning indicators
61 Right bottle regulation
62 Front brake pump
63 Throttle cover
64 Front brake lever
65 Throttle grip
66 Silencer
67 Right foot peg
68 Rear brake pedal
69 Exhaust pipe elbow
70 CDI Switch
70

Rear shock absorver
Transmission oil
Front fork oil
Brake adjust
Swingarm and connecting rod
Spark plug
Throttle cable
Chain
Reed valve box
Carburettor
Frame
Carburettor jet
Steering bearing
Piston bearing
Wheel bearing
Engine bearing
Rear sprocket
Cylinder and cylinder head
Brake
Brake disc
Clutch discs
Clutch
-14-
The maintenance table and adjustments are easy to carry out and must be done to insure the motorcycle is in good running condition.
NOTE: (*) Inspect or do this operations only it’s necessary.
MAINTENANCE TABLE
Check /
Inspect Replace / Change Grease / Lubricate
Adjust
Every year
30 hours
-
Every race
Every race
Every race
Every race
Every race
30 hours
Every race
Every race
-
Every race
-
-
-
30 hours
60 hours
Every race
Every race
-
Every race
-
-
-
If is necessary
-
30 hours
If is necessary
If is necessary
-
If is necessary
-
If is necessary
-
-
-
-
First 5 hours
-
If is necessary
First 5 hours
-
-
-
-
-
-
Every cleaning
-
Every cleaning
Every cleaning
-
-
.
-
-
-
-
-
Every cleaning
-
-
-
-
-
Clean
Every 2 years
60 hours
60 hours
-
If is damaged
60 hours
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
Every year
If is damaged
If is damaged
If is damaged
If is damaged
-
-
-
-
Every race
15 hours
If is necessary
Every race
Every race
Every race
Every race
-
-
-
-
-
-
-
-
Every 2 races
-
-
Part

Exhaust
Exhaust silencer fiber
Air filter
Steering assembly
Brake hose
Cooling fliud
General lubrication
Front and rear rims
Tyres
Brake oil level
Chain guide slide
Kickstart ang shift pedal
Brake piston pump amb his dustcover
Brake piston amb his dust-cover
Piston and piston rings
Front and rear spokes
Fuel system
Front suspension
Exhaust o’ring
Bolts, nuts & fasteners
Fuel hose
Radiator hose set and connections
-15-
MAINTENANCE TABLE
Every race
-
Every race
Every race
Every race
Every race
Every race
Every race
Every race
Every race
Every race
Every race
-
-
60 hours
Every race
Every race
Every race
-
Every race
Every race
Every race
-
-
-
If is necessary
If is necessary
If is necessary
-
-
-
If is necessary
-
-
-
-
-
5 hours
-
If is necessary
-
If is necessary
If is necessary
If is necessary
-
-
Every cleaning
-
Every cleaning
-
Every cleaning
-
-
-
-
Every cleaning
-
-
-
-
-
-
-
-
-
-
500 hours
200 hours
If is damaged
-
Every 2 years
Every year
-
If is damaged
If is damaged
-
If is damaged
If is damaged
If is damaged
If is damaged
Every year
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
If is damaged
-
-
Every race
-
-
-
Every race
Every race
Every race
-
-
-
-
-
-
Every race
-
-
-
-
-
-
NOTE: (*) Inspect or do this operations only it’s necessary.
Check /
Inspect Replace / Change Grease / Lubricate
Adjust CleanPart

Enter the vehicle identification number (serial
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 arm. It shows
the frame number used for registering this moped.
Homologation plate (B)
The moped 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 moped 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.
-16-
The new GAS GAS
TXT Pro 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 49 to 50.
8
Serial number.
The model shown is the TXT PRO 200
A
B
SERIAL N.
HOMOLOGATION P.
KEY NUMBER
I

-17-
The control panel includes
lighting, turn signal, horn and
engine stop switches.
8
Long lights
Normal lights
Lights turn off
Light controls diagram.
8
8
The indicator
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
positions available are reached by
sliding the main switch, which is on
the left end of the grip.
CC
C

-18-
8
Located under the
suspension lower right side
bracket. For correct
operation, it is necessary
to turn the handlebar completamente
towards the right until it stops, insert
the key in the groove, 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.
C
Never leave the key in the
locked latch. If the steering
is turned with the key in
the latch it may be damaged and the
locking system could be damaged.
I
Use premium gasoline with an octane rating equal to or higher
than that shown in the table.
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.
C
OCTANE RATING METHOD
Antiknock Index (RON + MON)/2
Research Octane No. (RON)
MINIMUM RATING
90
98
Fuel tank capacity : 3,1 liters
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.
I