Gas gas Txt racing 2015 User manual

TXT RACING 2015

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GAS GAS thank you for the trust you have

placed in us.

By choosing the new GAS GAS TXT RACING 2015 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 RACING 2015 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.

July - 2014

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.

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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

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 32

Swing-arm articulations 33

Articulation lubrication 34 to 36

Chain fixing link position 37

Chain and wheel tension 37

Tyres and tyre pression 38

Brakes 39

Rear brake fluid tank 40

Installation 41-43

Torques 44

Storage 45

Multifunction 46 to 48

Troubleshooting 49 to 53

Finally recommendations 54

Homologation 55 & 56

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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.

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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

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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 reliable operartion of your GAS GAS.

•Eight hours of running-in are recommended in order

to guarantee the correct operation of the engine.

•It is important to warm the engine to the optimum

operation temperature every time the motorbike is used.

•Synthetic or semi-synthetic 2-stroke oil should be

used at 2% in the oil/petrol mix.

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RECOMMENDS THE USE OF OIL:

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TECHNICAL SPECIFICATIONS

ENGINE 2 stroke, single cylinder, direct reed valve crankcase induction. Liquid cooled.

80 cc. engine Cylinder size 79,14 cc.

Bore and stroke 43 x 54.5 mm

125 cc. engine Cylinder size 124,8 cc.

Bore and stroke 54 x 54.5 mm

250cc. 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

Carburetor, diameter of the diffuser

28 (125cc - 300cc) - 21 (80cc)

Lubrication system Mixture (50:1)(2%)

Ignition system

Digital magnetic flywheel CDI

TRANSMISSION

Transmission type 6 gears, Four / Six system by

GAS GAS* (Patented).

Clutch type

Hydraulic command, 1/3 discs, variable progres. with diaphragm system by GAS GAS* (Patented).

Final drive 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)

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Primary reduction ratio 2,777 (75/27)

Final reduction ratio 3,818 (42/11). 125cc - 300cc 6,667 (60/9). 80cc

Overall drive ratio 8,704 (6th. gear). 125cc - 300cc 15,2 (6th gear). 80cc

Transmission oil Capacity 400 cc.

Type 75W GRO GEAR EXTREME

FRAME

Type Tubular profile made with Cr-Mo.

Tyres Front 2,75 x 21” Trial(125cc - 300cc) 2,50 x 19" Trial(80cc)

Rear 4,00 x 18” Trial tubeless (125cc - 300cc) 3,50 x 17" Trial (80cc)

Suspension Front Adjustable tele-hydraulic fork ø 40 mm (Ø33mm para la 80cc)

Rear Variable progressive system with mono-shock multiadjustable.

Suspension stroke Front 177 mm (125cc - 300cc) 180mm (80cc)

Rear 164 mm

Front fork oil SAE 5 W GRO FORK FLUID.

Front fork oil level Ø40 mm 160 mm air chamber aluminium bar

Ø33 mm (80cc) 155 mm air chamber

BRAKES

Type Disc brake.

Disc diameter Front Ø185mm (125cc - 300cc) Ø175mm (80cc)// 4 piston calipers

Rear ø150mm 2 piston calipers

DIMENSIONS 125cc to 300cc 80cc

Overall height 1180 mm 1040 mm

Overall width 820 mm 745 mm

Seat height 630 mm 590 mm

Ground clearance 315 mm 265 mm

Wheelbase 1330 mm 1290 mm

Fuel tank capacity 2,4 liters 2,4 liters

(Specifications subject to change wothout notice, which may not be applicable in every country).

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1 Front fender

2 Front brake caliper

3 Front suspension left

leg

4 Front suspension bar

5 Breather hose

6 Spark plug

7 Filter box

8 Rear fender

9 Tail lamp

10 Front tyre

11 Front brake disc cover

24 Middle silencier

25 Radiator

26 Headlight

27 Front tyre air valve

28 Rear brake disc

29 Sidestand arm

30 Swingarm

31 Rear brake pedal

32 Kickstart pedal

33 Water pump

34 Exhaust pipe elbow

35 Front wheel axle

10 11 12 13

17 18 19 20

5678

22 23 25

21 28 29 30 31 34 35

32 33

24 26

12 Front brake disc

13 Cylinder

14 Carburetor

15 Chain guide

16 Chain tensioner

17 Chain

18 Rear sprocket cover

19 Rear sprocket

20 Rear rim

21 Rear tyre

22 Exhaust protection

23 Frame

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36 Rear fender

37 Axle nut rear wheel

38 Left foot peg

39 Air filter box cover

40 Shift pedal

41 Ignition cover

42 Fuel tank

43 Fuel tank cap

44 Left handle grip

45 Clutch lever

46 Light controls

47 Clutch pump

48 Handlebar

49 Left suspension regulation

50 Multifunction

51 Warning indicators

52 Right suspension regulation

53 Front brake pump

54 Throttle cover

55 Front brake lever

Throttle grip

57 Silencer

58 Right foot peg

59 Rear brake pedal

Exhaust pipe elbow

61 CDI Switch

49 50 51

38 39 40 42

57 58 59

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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 CleanPart

Rear shock absorber

Transmission oil

Front fork oil

Brake adjust

Swingarm and connecting rods

Spark plug

Throttle cable and twist grip

Chain

Reed valve box

Carburetor

Frame

Carburetor jet

Steering bearing

Piston bearing

Wheel bearing

Engine bearing

Rear sprocket

Cylinder and cylinder head

Brake

Brake disc

Clutch discs

Clutch

Engine protector plate

Every year

30 hours

Every race

30 hours

Every race

30 hours

60 hours

Every race

If is necessary

30 hours

If is necessary

First 5 hours

If is necessary

First 5 hours

im a fall

Every cleaning

Every 2 years

60 hours

If is damaged

60 hours

If is damaged

Every year

If is damaged

if is damaged

Every race

15 hours

If is necessary

Every race

Every 2 races

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MAINTENANCE TABLE

NOTE: (*) Inspect or do this operations only it’s necessary.

Exhaust

Packing

Air filter

Steering assembly

Brake hose

Cooling fliud

General lubrication

Front and rear rims

Tyres

Brake oil level

Chain guide slider

Kickstart and shift pedal

Brake piston pump anb the dustcover

Brake piston and the 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

Frame protect sickers

Tire-silencer space (clearance)

Every race

60 hours

Every race

If is necessary

5 hours

If is necessary

Im a fall

Every cleaning

500 hours

100 hours

If is damaged

Every 2 years

Every year

If is damaged

Every year

If is damaged

if is damaged

Every race

Check /

Inspect Replace /

Change Grease /

Lubricate

Adjust CleanPart

Enter the vehicle identification number (serial

number), the particulars shown on the model

label,andtheignition-keyidentificationnumber

in the spaces provided, in order to simplify

yourfutureordersforsparepartsorasausefulreference

in the event of your vehicle being stolen.

Serial number (A)

This has been printed on the steering tube. It shows

the frame number used for registering this machine.

Homologation plate (B)

The motorcycle 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 motorcycle 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. (except some racing models)

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The new GAS GAS

TXT RACING 2015

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 56 to 57.

Serial number.

SERIAL N.

HOMOLOGATION P.

KEY NUMBER

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.

The control panel includes

lighting, turn signal, horn and

engine stop switches.

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Located under the

suspension lower right side

bracket. For correct

operation, it is necessary

to turn the handlebar completely

towards the right until it stops, insert

the key in the slot, 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.

Never leave the key in the

lock. If the steering is

turned with the key in the

lock it may be damaged and the

locking system could be damaged.

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.

OCTANE RATING METHOD

Antiknock Index (RON + MON)/2

Research Octane No. (RON)

MINIMUM RATING

Fuel tank capacity : 2,4 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.

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RECOMMENDS SYNTHETIC

2 CYCLE ENGINE OIL:

The fuel tank cap is of the quick release type. To open the

cap, lift the tab and turn it 1/4 turn in counterclockwise

direction. To close it, place cap with the words GAS GAS in

the upper position, and turn the tab in clockwise direction.

It is important to check periodically the condition of the cap

sealing O’ring to insure proper sealing.

This engine is

designed to burn

a mixture of

combustible fuels,

lead free petrol and oil.

The idle and petrol-air

mixture can be adjusted

by the screw as shown

in the illustration.

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(A)

(B)

The position of the fuel tap (A)

must be pointing down for

normaloperation. When turned

forwards, it opens the reserve,

to the rear turns off the fuel.

CReserve Open Closed

The choke (B) is a device

for aiding the starting

when cold. The enigne will

reach a normal

temperature in a short

time and it won’t damage

anything.

80cc carburetor model

GAS GAS TXT RACING 2015 User manual