TXT PRO´09
Contents
1. The multifunction display shows all the information on three different screens While in motion screens 1 and 2 are on display Screen 3 is displayed for 3 seconds and then returns to screen 1 To change from one screen to another press button 2 Mode in succession To edit the distance travelled DST keep button 3 pressed down Screen 1 Screen 1 shows the following information Speed distance travelled time ambient temperature tachometer bar Screen 2 Screen 2 shows the following information Speed digital tachometer time in motion time in operation engine temperature tachometer bar Screen 3 Screen 3 shows the following information Maximum speed danger rpm accumulated time in operation odometer maximum temperature Optional Lighting The display is powered by an internal 3 V battery type CR2032 To change the battery open the cover behind the display and use a coin to unscrew it counter clockwise Make sure that the positive terminal on the battery is facing upward When the display is powered by the internal battery only the screen lights up partially for 3 seconds when the button is pressed If the lighting is connected to the 12V system on the vehicle it will be brighter and stay on for up to 20 minutes after the vehicle has come to a full halt Sleep Mode If the multifunction display does not receive any information for 20 minutes signal from wheels turning or a2. Patented By chain Gear ratio 1st 2 996 35x27x28 16x24x23 2nd 2 571 36 14 3th 2 187 35 16 Ast 2 112 36x23x24 14x28x24 5st 1 125 27 24 6th 0 821 23 28 10 Primary reduction ratio Final reduction ratio Overall drive ratio Transmission oil FRAME Type Tyres Suspension Suspension stroke Front fork oil Front fork oil level BRAKES Type Disc diameter DIMENSIONS Overall height Overall width Seat height Ground clearance Wheelbase Fuel tank capacity Capacity Type Front Rear Front Rear Front Rear 40 mm 125 200 40 mm 250 280 300 2 177 75 27 3 818 42 11 8 704 6th gear 550 cc 10W40 API SF 0 SG Tubular profile made with Cr Mo 2 75 x 21 Trial 4 00 x 18 Trial tubeless Adjustable tele hydraulic fork 40 mm 125 200 Adjustable tele hydraulic fork 40 mm with aluminium bars 250 280 300 Variable progressive system with mono shock multiadjustable 177 mm 164 mm SAE 5 180 mm air chamber steel bar 160 mm air chamber aluminium bar Disc brake 185 mm 4 piston calipers 150 mm 2 piston calipers 1180 mm 820 mm 650 mm 315 mm 1330 mm 3 1 liters Specifications subject to change wothout notice which may not be applicable in every country 11 Front fender Front brake caliper Front suspension left bottle Front suspension bar Breather hose Spark plug Filter box Rear fender Rear h
3. Trial rear pilot Rear left turn signal M6 Bolt ULS screw 6x16 Phillips screw M6 x 25 Philips screw 6 3x16 Front left turn signal 10 Turn signal box 11 Trial license holder homologated 12 Stand spring 13 ULS screw 8x12 8 8 14 Self locking M6 nut with galvanized washer 15 Mirrors 16 Carburettor kit A SOON DAA WD 250 280 300 BT280634018 16 125 200 250 280 300 BT280520003
4. button pressed the screen goes off showing only the time When the vehicle starts or a button is pressed it will start up again Measuring the wheel circumference Method 1 Measures the diameter of the front wheel Multiply the diameter by 3 14 and if necessary convert the measurement into mm by multiplying the figure obtained by 25 4 The measurement obtained is the size of the wheel circumference Method 2 On a smooth flat surface make a mark on the side of the tyre where it touches the ground Move the vehicle forward until the tyre has made a complete turn and the mark is back at the lowest point Make a new mark on the ground at this point Measure the distance between the marks on the ground and if necessary convert the measurement into mm by multiplying the figure obtained by 25 4 The measurement obtained is the size of the wheel circumference To obtain a more precise measurement the driver must remain on the vehicle while taking measurements CP KTP KT TROUBLESHOOTING NOTE This is not an exhaustive list of malfunctions it only shows the most common problems MALFUNCTION POSSIBLE CAUSE REMEDY Engine does not crank Seized crankshaft Go to a specialized workshop Seized cylinder piston jornal bearing Go to a specialized workshop Seized transmission assembly Go to a specialized workshop Motorcycle inactive too long Drain old fuel out of the tank With the fuel tank filled with
5. lever must be in the ideal position Again the play must not The clutch lever must be exceed 3mm adjusted to your liking but the free play should not exceed 3mm This play must never be This play must never be eliminated eliminated 21 COP IICT IEI This is the position the kick start should be in when not being used CP KC KT When topping up the oil open the cap A Engine Oil Kd capacity 550 cc To check the oil level first make sure the motorbike is perpendicular to the ground If the bike has been in use wait a few minutes To check the oil level unscrew the cap B 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 f 10w10 The engine crankcase drain cap is situated on the lower left hand side The drainage hole in the crankcase allows its easy emptying 9 CP KC KT oma _ 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 filt
6. of the EU and complies with all the homologation requirements demanded Compulsory homologation elements required among others when travelling on a public road and to meet periodical vehicle inspection approval at state controlled plants are listed below Among other requirements all homologation components are identified with a determined and registered mark List of elements required Illustration Qty bike Manufacture identification plate Catalyzed with with secondary air Available Muffler Available Carburettor jets Available Front and rear turn signals Available License plate holder Available Speedometer Available Electrical installation homologated lights Available Engine output pinnion and sprocket for a correct transmission gear ratio Horn Available Rearview mirror Available Antitheft system Antimanipulation plate 125 cc version Air filter restriction carburettor hood limit according to model ok ok ok Ak kk A ON EK Sk a Each one of the homologation components must form part of the vehicle and in case of loss breakage or malfunction it is recommended that the owner contact his official dealer to correct this problema o Besides the homologated vehicle you have received a complementary kit for a racing version of this same vehicle Be advised that this version is not homologated o o 56 CP KC KT HOMOLOGATION Front right turn signal Rear right turn signal
7. that these items must be washed carefully If the washer applies water at high pressure and or temperature w take the precaution of maintaining the washer outlet gun at a distance of 30 centimeters minimum this will insure the correct gloss of the plastics and adherence of the self adhesive labels that decorate the motorcycle oO SAFE RIDING OF THIS MOTORCYCLE Safe riding of a motorcycle does not only depend on the vehicle The driver s intelligence and common sense are key factors to be taken into consideration It is recommended that you practice your favorite sport wearing all the necessary safety equipment helmet protection gear boots etc LEGAL ADVICE In the interest of technical development we reserve the right to modify the construction the equipment and accesories of the motorcycle It is understood that all measurements weights and power data must include their respective tolerances The photographs included in this manual may not match the model you have purchased The descriptions and the illustrations may vary depending on the volume of equipment and accesories of your motorcycle and also of the versions exported Because of this there can be no liability except in case of errors misprint or omission GAS GAS MOTOS S A reserves the right to make changes and or modifications at any time without notice 55 CP KTP KT HOMOLOGATION The vehicle you have just acquired has been homologated under the directives
8. the linkage of a f the engine starting lever a thouroughly and frequently since it is exposed to inclemency and constant rubbing p N 6 The secondary chain must Pa amp 7 Lubricate the handlebar D with a fine coat of oil to i allow smooth operation of the gasoline control 3A AR RAN D N S S a a amp 8 It is also recommended to S 9 Oil and clean the gas control frequently it is frequently lubricate the chain tensor especially recommended to do so after the bike f spring because ii is under great f has been cleaned with water under high pressure stress 35 To regulate the chain slack and center the rear wheel use the shaft excentrics which can be easily graduated The chain tension must allow a slack near the tensor of about 2 cm 36 The chain linkage must be placed in opposite direction of the wheel travel PON AIL sotyres 7 conditions r must checked to insure optimum road adherence possible Fig 1 Bad condition Fig 2 Good condition Tyre pressure should be checked periodically to insure the best road adherence possible CP KC KT Fig 1 Fig 2 ay Front tyre 2 75 x 21 TRIAL Rear tyre 4 00 x 18 TRIAL tubeless l Front wheel pressure 0 450 bar normal 0 420 bar competition Rear wheel pressure 0 350 bar normal 0
9. 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 8 CP KC KT Recommendations for the good working of your GAS GAS eEight hours of running in are recommended in order to guarantee the correct working of the engine elt 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 CP IEICE RECOMMENDS THE USE OF OIL Global Racing Oil CP KC KT TECHNICAL SPECIFICATIONS 2 stroke single cylinder direct reed valve crankcase induction Liquid cooled 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 00 cc engine Cylinder size 294 1 cc Bore and stroke 79 x 60 mm Carburettor diameter of the diffusor 26 Lubrication system Mixture 50 1 2 iti Digital magnetic flywheel CDI 6 gears Four Six system by GAS GAS Patented Hydraulic command 1 3 discs variable progressive with diaphragm system by GAS GAS
10. 300 bar competition 37 CP KP KS Pad brakes wear front and rear must be checked from time to time to bp insure an efficient braking power under all circumstances The brake calipers have been 44 furnished with bleeder valves to eliminate the air trapped in the brake circuit The front brake fluid level can be verified watching through the transparent inspection window 39 CP KC KT e o The rear brake fluid N y reservoir is located at the ee cylinder support 44 Verify fluid level periodically and refill if necessary pr To verify the reservoir D level you must remove i the fuel tank and place de oil reservoir in horizontal position to check the real fluid level Must be filled between the marks MIN amp MAX MAX MIN Upper shock absorber fastener ipper shock absorber tasienoe 40250 1 Lower shock absorber fastener 40 50 _ Connecting rods caps 40 50 Handlebars a Muffler fasteners 18 25 Rear wheel axle axle Eea ee Engine fasteners Engine fasteners Rear brake pump fastener 7 10 Ignition fasteners 7 8 Ciuth fasteners 7 8 Cylinder stud bolt fasteners 25 Reeds fasteners 7 8 Clutch ground fastener 3 4 Crankcases fasteners 7 8 Water pump cap fastener 7 8 Clutch cap fastener 7 8 Flywheel fastener 4 Water fastener 10 Engine drain plug 12 Kickstart pedal screw 12 13 Cylin
11. ATION TIME ART 0 9999 hours 59 minutes 1 minute 0 1 ACCUMULATED CLOCK 00 00 00 12 59 59 or 23 59 59 ee 0 1 BATTERY LOW Approximately 1 year life S 0 1 Initial voltage 9 400 V AC DC Speed sensor Non contact magnetic sensor Tachometer input Electrical pulse sensor Wheel circumference adjustment 1 mm 3 999 mm 1 mm increments Operating storage temperature from 0 C to 60 C from 32 F to 140 F from 20 C to 80 C from 4 F to 176 F Battery life 3V CR2032 Approx 1 year 43 Functions RPM Bar Tachometer with bar graph The bar graph of the tachometer displays up to 12 000 rpm RPM Digital Tachometer The rpm are shown on the right side second row The digital tachometer displays up to 12 000 rpm The tachometer signal can be captured from the sparkplug cable Gear change indicator according to rpm This function permits setting an indicator for changing gears at a specific rom level The red LED warning light flashes when the rpm reaches the specific level and stops flashing when the gear is changed SPD Speedometer The speedometer information appears in the centre of the screen It shows up to 399 9 kmph or mph MS Maximum speed gauge It shows the highest speed reached since the last resetting of the data DST Distance travelled This appears on the right side in the second line of the screen The TRIP function contains the vehicle s accumulated mileage
12. 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 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 18 CP KC KT ra amp This engine is 4 Im a The fuel tank cap is of the quick release type To open the S designed tu burn cap lift the tab and turn it 1 4 turn in counterclockwise a mixture of direction To close it place cap with the words GAS GAS in combustible fuels the upper position and turn the tab in clockwise direction lead free petrol and oil It is important to check periodically the condition of the cap sealing O ring to insure proper sealing 7v v COP KICI I RECOMMENDS SYNTHETIC 2 CYCLE ENGINE OIL GO Global Racing Oil 19 CP KC KS The choke B is a device for aiding the engine start if this is cold The enigne will get a good temperature in a short time and it won t damage a a oe POX The idle and petrol air y Reserve Open Closed S mixture can be adjusted a 7 by the screw as shown The position of the fuel tap A D Ce in the illustration must be forward rearward for normal operation When turned upwards it opens the reserve downwards it turns off the fuel 290 Like the clutch lever the front brake
13. T FORK 40 mm aluminium bars 250 280 300 575 mm FRONT FORK 40 mm 125 200 For a medium weight of 75 Kg we should preload the spring to 2 5 mm 30 CP KC KT TE The front suspension S is adjusted manually Right hydraulic extension Left hydraulic compression Q T The regulation is done S by turning one screw T A located in the axis of the suspension tube cap The bleeder B is used to purge air that may be trapped inside the slider 31 mn The preloading of the damper spring A is measured by the rotation of the toothed rings C with the aid of a special wrench The hidraulic brake compression can be adjusted by turning the screw D located in the lowest area of the shock absorber it should be at the mid point of his career v v CP KC KT D 44 The link adjustments at the lower part of rear ni suspension must be A e go Do s periodically cleaned verified a tee ld and lubricated with grease li is very importante to 4 periodically remove and verify the condition of the swingarm bearings and holders 39 3 Also the rear brake pedal bearings 1 All Use special oil to lubricate the following inkages of the brake and clutch levers 4 Apply grease to the footrests springs and fixtures 33 CP KOC KT 2 The linkage of the gear shift lever SX 5 Apply grease to
14. ace the clutch friction plate Go to a specialized workshop Worn clutch center hub Replace the clutch center hub Broken or weak clutch spring Adjust or replace the clutch spring Unevenly worn clutch discs Replace the clutch discs Go to a specialized workshop The motorcycle is unstable Cable interferes with the handlebar turns Move or loosen the cable just a little Steering stem locknut too tight Loosen the steering stem locknut Damaged or worn steering bearings Replace the steering bearings Bent steering stem Replace the steering stem Go to a specialized workshop MALFUNCTION POSSIBLE CAUSE REMEDY Shock absorber set too hard Excessive front fork oil Pour excess oil until reaching the correct oil level Front fork oil viscosity too high Drain fork oil and fill with correct fork oil viscosity Bent front fork Replace the front fork Go to a specialized workshop Tire air pressure set too high Check tire air pressure Incorrect rear shock absorber adjustment Adjust rear shock absorber Shock absorber set too soft Insufficient front fork oil Fill with fork oil until reaching the correct oil level Front fork oil viscosity too low Drain fork oil and fill with correct fork oil viscosity Bent front fork Replace the front fork Go to a specialized workshop Incorrect rear shock absorber adjustment Adjust the rear shock absorber Abnormal motorcycle noi
15. brake adjustment Excessive steering axles tolerances Tighten steering bracket and steering stem locknut to the correct torque values Tighten steering bracket and steering stem locknut to the correct torque values Replace the chassis Go to a specialized workshop Adjust the steering Go to a specialized workshop Replace the steering stem Go to a specialized workshop Replace the front fork Align the wheels Replace the discs Verify the brake circuits Replace the damaged or broken parts Drain the brake fluid and fill with the new fluid recommended by the manufacturer Replace the pump piston Adjust brakes CP KC KT FINAL RECOMMENDATIONS PREVENTIVE ADVICE Before you ride the vehicle take all the time you may require to check your motorcycle carry out the periodical upkeep and check all functions In different sections of this manual you will find data and work specifications that must be done at an autorized GAS GAS dealer because of this and to extend the useful life of the motorcycle all periodical inspections must be carried out by specially trained professionals at a GAS GAS Post Sale Service Shop Poor maintenance work of the motorcycle or not taking proper care of any problem even if its is a small concern can cause severe personal injury and may lead to death To avoid excessive ageing of the plastic parts and other washable pieces of the motorcycle it is suggested f
16. d 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 faul
17. der head screws 11 5 13 Cylndernt 3 40 CP KC KT STORAGE For extended storage of the motorcycle you must do the following Clean the motorcycle thoroughly Start the engine for about 5 minutes to warm up the transmission oil and then drain it see crankcase drain cap page 22 Fill with new transmission oil Empty the fuel tank gasoline will deteriorate if left too long Lubricate the chain and all cables Cover all unpainted metal surfaces with a coat of oil to prevent rust do not apply oil to the brakes and rubber parts Cover the exhaust pipe with a plastic bag to prevent corrosion Place the motorcycle in such a position so that the wheels do not touch the ground if possible place cardboards under the wheels Cover the motorcycle to protect it from dust and dirt When starting off after an extended storage Remove the plastic bag from the exhaust pipe Tighten the spark plug Fill the fuel tank General lubrication Inspect tyre pressure and inflate to the specified pressure if necessary To avoid excessive ageing of the plastic parts and other washable pieces of the motorcycle it is suggested n that these items must be washed carefully If the washer applies water at high pressure and or temperature w take the precaution of maintaining the washer outlet gun at a distance of 30 centimeters minimum this 5 will insure the correct gloss of the plastics and adherence of
18. e Every race 30hours Ifisdamaged Everyrace Every race Every race Ifisdamaged Everyrace Ifisnecessary lfisdamaged o o Every race Ifisdamaged o o o po Hfisdamaged po Hfisdamaged po Hfisdamaged 30 hours 60hours Everyyear o o O Everyrace Ifisnecessary Ifisdamaged Z o Z Every race Every year Clutch discs If is damaged Engine protector plate Every race ifisdamaged NOTE Inspect or do this operations only it s necessary 14 CP KP KT MAINTENANCE TABLE as ee Exhaust 500hours o o Exhaust silencer fiber EE 100hours o o Air filter Steering assembly If is necessary Oooo o e ae s O Brake hose If is necessary Every2yeas Every cleaning Cooling fliud Ifisnecessary Every year General lubrication Fe Everyrace Every cleaning Front and rear rims Tyres Brake oil level If is necessary ee ae l Chain guide slide lfisdamaged Kickstart ang shift pedal Ifis damaged Every cleaning Brake piston pump amb his dustcover Ifis damaged a ae a Brake piston amb his dust cover Ooo a If is damaged Piston and piston rings Front and rear spokes 5hours lfisdamaged_ _Everyrace Fuel system Ifisdamaged o Front suspension fis necessary Ifisdamaged o o Exhaust o ring Pe Ifisdamaged o o Bolts nuts amp fasteners fis necessary Ifisdamaged S o o o Fuel hose
19. eadlight 10 Front tyre 11 Front brake disc cover oo N CO COND OF 12 Front brake disc 13 Cylinder 14 Carburettor 15 Chain guide 16 Chain slide 17 Chain 18 Rear sprocket cover 19 Rear sprocket 20 Rear rim 21 Rear tyre 22 Exhaust protection 23 Frame 24 Middle silencier 25 Radiator 26 Headlight 2 Front tyre air valve 28 Rear brake disc 29 Sidestand lever 30 Swingarm 31 Rear brake lever 32 Kickstart pedal 33 Water pump 34 Exhaust pipe elbow 35 Front wheel axle 36 Rear fender 37 Axis 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 hanle grip 45 Clutch lever 46 Light controls 47 Clutch pump 48 Handlebar 49 Left bottle regulation 50 Multifunction 51 Warning indicators 52 Right bottle regulation 53 Front brake pump A3 50 51 54 Throttle cover 55 Front brake lever 56 Throttle grip 57 Silencer 58 Right foot peg 59 Rear brake pedal 60 Exhaust pipe elbow 61 CDI Switch CP KC KT The maintenance table and adjustments are easy to carry out and must be done to insure the motorcycle is in good running condition MAINTENANCE TABLE Rear shock absorver Everyyear Every 2 years Transmissionol 30hours Ors Frontforkoil ors a o Brake adjust Everyrace Ifisnecessay gt o Swingarm andconnectingrod Every race lfisdamaged Everyrace Every cleaning Every rac
20. econds Activating adjustment mode Selecting the speed unit To start setting mode for the To change between kmph and multifunction display press mph press button 1 buttons 1 2 and 3 Confirm the selection by pressing eo simultaneously for 3 seconds button 2 and then release Selecting the values for the Selecting the time format wheel circumference To change between the 12 and Enter the value for the wheel 24 hour clock press button 1 circumference by pressing button 7 aa m Confirm by pressing button 2 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Note If you do not know the value of the wheel circumference see the section on Measuring the wheel circumference Setting the time Enter the value for the time by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Setting the pulse per revolution PPR Note This step is only to be taken on vehicles that change the type of PPR pulse at a specific number of rpm If you do not know this value press button 2 to go on to the next screen Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 CP KTP KT Setting the pulse per revolution PPR The gauge receives one electrical pulse for each revolution on the engine PPR Default value for 2 and 4 stroke eng
21. er 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 03 CP KC KT Remove the fuel tank located in the upper area of the chassis before servicing the motor or any other internal part of the motorcycle To do this first check that the gasoline cap and fuel cock are closed properly Next pull out the fuel tube end A which is inserted in the fuel cock The third step is to unscrew the Allen screw M6 B fastening the front upper part of the tank Once the fuel tank is released lift it at the front section and remove the tank completely out the inside of the chassis C Coolin 30 uid When filling the radiator V use cooling fluid gt gt designed for lightweight alloy motors The engine must be cool before removing the radiator cap or when replacing radiator coolant or severe scalding may result 24 yam it is necesassary to periodically check the spark plug condition S This must be done removing the spark plug from its housing in the upper part of the cylinder head First disconnect the spark plug cap and remove the spark plug using an adequate wrench Clean the spark plug with compressed air to remove dirt and prevent foreign material to enter inside the engine compartment o e v v 25 COP IICT IEI It is necessary to z periodically c
22. fis necessary Ifisdamaged o o o Radiator hose set and connections If is necessa Ifisdamaged Frame protect sickers ifisdamaged Tire silencer space Every race Im a fall if is damaged NOTE Inspect or do this operations only it s necessary 15 CP KC KT Serial number The model shown is the TXT PRO 200 44 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 o n Enter the vehicle identification number serial Q 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 Oo O 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 join
23. hanks to consumer Important notice Warranty regulations Recommendations Technical specifications Component location Maintenance guide Serial number Combination switch Steering lock Combustible Fuel tank cap Fuel tap Starter Carburation Kick start engine pedal position Lever regulation Oil level checking Crankcase fill in Crankcase draining Air filter box cleaning Fuel tank dismantle Radiator fill in Spark dismantle Spark check Air filter box dismantle 6 to 8 10 amp 11 12 amp 13 14 amp 15 16 17 18 18 19 20 20 20 21 21 22 22 22 23 24 24 25 25 26 Carburettor dismantle Carburettor capacity check Carburettor cleaning Inlet valves dismantle Inlet valves Clutch operations Discs and clutch spring Air bleed Water pump draining Front suspension Rear suspension Swing arm articulations Articulation lubrication Chain fixing link position Chain and wheel tension Tyres and tyre pression Brakes Rear brake fluid tank Torques Storage Multifunction Troubleshooting Finally recommendations Homologation COP KC II 27 27 27 28 28 29 29 29 29 30 amp 31 31 32 33 to 35 36 36 37 38 39 40 41 42 to 49 50 55 56 amp 57 CP KC KT 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 referre
24. he rpm for a gear change When the set rpm is reached the left hand warning LED flashes to show that the gear must be changed Default value 6000 rpm Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Selecting the danger rpm When the set rpm is reached the right hand warning LED flashes to show that the rom on the engine are too high Default value 10000 rpm Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Resetting the display functions after each use of the vehicle After each use of the vehicle the following functions can be reset simultaneously Maximum speed Distance Chronometer Maximum temperature Maximum rpm Confirm the reset by pressing buttons 1 and 2 simultaneously CP KTP KT Total reset of the display Press the RESET button using a suitable object The display will start from zero except for the data for total accumulated distance and time Internal battery The display is powered by an internal 3 V battery type CR2032 When the voltage in the internal battery drops below 2 45V the screen displays LO To change the battery open the cover behind the display and use a coin to unscrew it counter clockwise Make sure that the positive terminal on the battery is facing upward CP KC KT Screen options
25. heck the w state of the spark plug The sparking plug distance should be between 0 6 and 0 7mm 0 6 0 7 mm CP KC KT o To carry out any type of operations on and improve access to the carburettor it is recommended S to remove the filter box You must follow these steps J 1 Loosen the admission port clamp 2 Unscrew 4 tapered Allen screws M6 which are used to anchor the filter box to the chassis 3 Pull the filter box straight up just enough until the rear intallation connecting fixture is visible 4 Disconnect the fixture Fig 1 5 Remove the filter box completely Fig 2 The carburettor is now exposed and can be separated from the motor assembly by loosening the reed box port clamp Loosen the two screws of the carburettor upper cover to allow the carburettor body being ready for cleaning Fig 3 v Ad Fig 1 Fig 2 26 Extreme precautions must be taken to dry the inside of the carburettor thoroughly Water droplets dirt or other forign material may enter and damage the reed box and consequently cause damages to the piston and cylinder assembly 75 CP KTP KT It is important to check the level of petrol within the carburettor The float should be at 18 5mm It is necessary to clean the carburettor very thoroughly To do so use compressed air Dismantle and clean periodically the main nozzle after washing the bike as well as cleaning the ins
26. i PAIERO USER MANUAL GAS GAS thank you for the trust you have placed in us By choosing the new GAS GAS TXT Pro 2009 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 2009 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 August 2008 CP KC IEI 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 m
27. ide of the carburettor housing CP KC KT pam The reed box assembly is composed of only one body the reeds and reed keepers To inspect the assembly remove it by removing the 4 screws A attaching it to the rear of the left and right crankcases The distance between reeds and the reed keeper should be 6 5 mm for all types of displacement models Reeds must be kept in perfect ey conditions with no signs of nicks scratches broken or folded sections Otherwise the reed assembly must be replaced with a new one 28 gt gt a Since this is the last w door of access to the inside of the cylinder special precautions must be taken to keep it in good condition and to monitor its performance periodically Cover the cylinder bore with a clean shop towel to prevent foreing material to enter the compartment when handling these parts fe Sy Check clutch discs for i i y ible wear after wm oping height of the Ez possI clutch stack should gt gt many hours of use For measure between 4 3 correct operation the minimum and 4 4 mm measure should be between 9 75 to 9 85 mm A After any removal or assembly y operations on the clutch lifter w7 circuit air trapped inside must be purged by connecting an air bleeder A The circle indicates where the engine oil should be poured in 29 CP KC KT Level of air chamber Level of air chamber 180 mm 160 mm FRON
28. ines 1 PPR Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Setting the pulse per revolution PPR Note This step is only to be taken if a value of 0 was entered in the previous step Default value 1 0 If you do not know this value press button 2 to go on to the next screen Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 CP KC KT Selecting the temperature unit To change the temperature display between C and F press button 1 Confirm by pressing button 2 Selecting the danger temperature Note This step can only be taken on vehicles fitted with the optional temperature sensor When the engine temperature exceeds the set value the warning LED on the right lights up Default value 110 C 230 F Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Selecting the warning temperature Note This step can only be taken on vehicles fitted with the optional temperature sensor When the engine temperature exceeds the set value the warning LED on the left lights up Default value 90 C 190 F Enter the value by pressing button 1 in succession To go on to the next digit press button 3 Confirm by pressing button 2 Selecting t
29. ized exhaust pipe workshop Main jet set too high Verify main jet operation Go to a specialized workshop MALFUNCTION POSSIBLE CAUSE REMEDY Gears do not engage correctly Clutch does not disengage Go to a specialized workshop Bent or seized shift fork Replace the shift fork Gear seized at the transmission Go to a specialized workshop Damaged gearshift lever Replace the gearshift lever Broken or loose selector position spring Adjust or replace the selector position spring Broken spring in the reverse selector Replace the spring in the reverse selector mechanism mechanism Broken spring in the reverse selector Replace the spring in the reverse selector mechanism mechanism Broken gear drum Replace the gear drum Broken spring in the gear selector ratchet Replace the spring in the gear selector ratchet Jumps out of gear Shift fork worn at the gears Replace the shift fork Worn gear grooves Replace Go to a specialized workshop Worn gear dogs Replace Go to a specialized workshop Worn shift drum groove Replace Go to a specialized workshop Worn shift fork shaft Replace shaft Go to a specialized workshop Broken selector drum position spring Replace the spring Go to a specialized workshop Broken gears Go to a specialized workshop Clutch slips No clutch lever free play Go to a specialized workshop Worn clutch friction plate Repl
30. mponents 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 sfo CP KC KT 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 go
31. new fuel the engine will start immediately Wet or fouled spark plug Clean and dry or replace the spark plug Flooded engine In order to relieve the engine accelerate to max speed press the starter pedal 5 or 10 times Then start the engine as described above If the engine fails to start remove the spark plug and dry it Incorrect air fuel mixture Clean the fuel tank air vent Adjust the air cleaner duct Exhaust valve stuck open Verify the exhaust valve and repair as necessary Engine cranks but then stops Incorrect air supply Close the starter Clean fuel tank air vent Adjust the air cleaner duct No fuel Fill up the fuel tank Engine overheating Insufficient cooling liquid in the circuit Fill up cooling liquid verify the refrigeration system watertightness Radiator is dirty or partially restricted Clean radiator fins or replace it The engine operates irregularly Spark plug dirty or misadjusted Verify the spark plug condition and clean it accordingly Poor contact with the spark plug cap or tighten or replace it cable loose in cap Verify the spark plug cap condition Replace if deteriorated MALFU MALFUNCTION POSSIBLECAUSE CAUSE REMEDY The engine operates irregularly Ignition rotor damaged Replace the rotor Water in fuel Drain the fuel tank and fill up with new fuel Engine lacks power or poor Fuel supply defective Clean the fuel system and
32. nised 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 co
33. od 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
34. otorbike 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 aw 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 T
35. ses Incorrect drive chain adjustment Adjust the drive chain Worn drive chain Replace the drive chain rear sprocket and the secondary transmission pinion Worn rear sprocket teeth Replace the rear sprocket Insufficient drive chain lubrication Lubricate with appropriate chain oil Incorrect rear wheel alignment Align the rear wheel Go to a specialized workshop Insufficient front fork oil Add front fork oil until reaching the correct level Weak or broken front fork spring Replace the front fork spring Worn disc brake Change the disc brake Pad installed incorrectly or surface glazed Reinstall or replace pad Damaged cylinder Replace the damaged cylinder Improperly tightened brackets nuts bolts Verify and adjust to the correct torque values Handlebar vibration Worn tire and worn swingarm or its Replace worn parts with new ones needle bearings Wheel rim off centre Centre rim Incorrect wheel alignment Verify wheel spokes tension Readjust if necessary MALFUNCTION POSSIBLE CAUSE REMEDY Handlebar vibration Loose handlebar bracket and loose handlebar stem locknut Bent chassis Incorrect steering adjustment Bent steering stem Bent front fork Incorrect wheel alignment Motorcycle pull to one side Brakes do not operate correctly Worn discs Leaking brake fluid Deteriorated brake fluid Broken pump piston Incorrect
36. since the last RESET operation CP KTP KT ODO Odometer It shows the total mileage accumulated by the vehicle The data is stored in the memory even when the device is not running ART Time of use controller Calculates the total time in operation It starts counting from the moment the motor is turned on RT Total time of use controller It calculates the vehicle s operation time since the last RESET operation It starts counting from the moment that movement begins The data is stored in the memory even when the device is not running 12 24 hour clock It shows the time in either 12 or 24 hour formats Ambient temperature engine temperature gauge The ambient temperature is displayed on the upper left hand part of the screen The screen can display the engine temperature from an optional temperature sensor If this is too high a warning LED lights up in yellow High rpm gauge Gear change warning according to rpm If the rpm are too high the second warning LED lights up in red This function permits setting an indicator for changing gear ata specific rom level The red LED warning light flashes when the rpm reaches the specific level and stops flashing when the gear is changed CP KC KT Setting the multifunction display parameters After confirming each value the display goes from one screen to the next until all have been displayed If no button is pressed the display returns to the home screen after 15 s
37. t 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 6 CP KC KT 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 recog
38. the self adhesive labels that decorate the motorcycle 41 GAS GAS MULTIFUNCTION INSTRUCTIONS The multifunction apparatus which is waterproof has 2 LED indicators on a central indicator screen This central indicator screen made of liquid crystal and with illumination gives information about the rpm speed distance travelled total kilometres travelled time average speed maximum speed ambient temperature length of time with motor running and total time The odometer and the control for the total time with motor running save the data to the memory even when the device is switched off When the multifunction apparatus is not activated it displays a clock The value of the wheel circumference can be altered as well as the system of measurement metric or British The ambient temperature is displayed on the upper left hand part of the screen The screen can display the engine temperature from an optional temperature sensor If this is too high a warning LED lights up in yellow If the rom are too high the second warning LED lights up in red wi g z Yellow warning LED Red warning LED Right hand button MODE button Left hand button Central display screen PN ERN S CP KC KT Technical characteristics FUNCTIONS SYMBOL TECHNICAL INCREMENTS PRECISION CHARACTERISTICS TIME RUNNING 0 9999 hours 59 minutes 0 1 ODOMETER opo 0 0 999999 0 1 OPERATION TIME 0 999 hours 59 minutes 0 1 OPER
39. ts This number may be quoted when ordering a spare to replace a lost key O o The control panel includes lighting turn signal horn and engine stop switches the left end of the grip 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 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 gt gt 17 CP KTP KT mn Located under the S suspension lower right side bracket For correct i 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 f Never leave the key in the i y locked latch If the steering 3 is turned with the key in the latch 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 OCTANE RATING METHOD MINIMUM RATING Antiknock Index RON MON 2 Research Octane No RON Gasoline is extremely flammable and can be explosive under certain conditions
40. verify its operation acceleration Dirty air cleaner Clean or replace the air cleaner Verify its operation Leaking or deteriorated exhaust system Verify if the exhaust system is damaged Replace the muffler fiberglass packing if necessary Dirty carburetor jets Disassembly the carburetor and clean all jets Worn or damaged crankshaft bearings Replace the crankshaft bearings Clutch slips Verify the clutch operation Go to a specialized workshop Abnormal engine noise Ignition problem Go to a specialized workshop Overheating Refer to section 5 Detonations from the exhaust Carbon build up in combustion chamber Clean the combustion chamber pipe Incorrect octane or poor quality gasoline Drain all gasoline and fill up with a higher octane fuel Damaged spark plug or incorrect Replace the spark plug with a new one of the correct type specifications Deteriorated exhaust system gaskets Verify if the exhaust system is damaged All gaskets must be in perfect conditions otherwise replace them with new ones if necessary White smoke coming out of the Deteriorated cylinder head gasket water Replace the cylinder head gasket Go to a exhaust pipe leakage into the cylinder specialized workshop Incorrect throttle valve cable adjustment Readjust the throttle valve cable Brown smoke coming out of the Restricted air cleaner Clean or replace the air cleaner Go to a special
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