TXT RACING 2015

GAS GAS thank you for the trust you have

placed in us.
Thank you for your trust in us, and welcome to GAS GAS
Motorbikes.
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 July - 2014
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.

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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 Carburettor dismantle 27
Important notice 4 Carburettor capacity check 27
Warranty regulations 6 to 8 Carburettor cleaning 27
Recommendations 9 Inlet valves dismantle 28
Technical specifications 10 & 11 Inlet valves 28
Component location 12 & 13 Clutch operations 29
Maintenance guide 14 & 15 Discs and clutch spring 29
Serial number 16 Air bleed 29
Combination switch 17 Water pump draining 29
Steering lock 18 Front suspension 30 & 31
Combustible 18 Rear suspension 32
Fuel tank cap 19 Swing-arm articulations 33
Fuel tap 20 Articulation lubrication 34 to 36
Starter 20 Chain fixing link position 37
Carburation 20 Chain and wheel tension 37
Kick-start engine pedal position 21 Tyres and tyre pression 38
Lever regulation 21 Brakes 39
Oil level checking 22 Rear brake fluid tank 40
Crankcase fill-in 22 Installation 41-43
Crankcase draining 22 Torques 44
Air filter box cleaning 23 Storage 45
Fuel tank dismantle 24 Multifunction 46 to 48
Radiator fill-in 24 Troubleshooting 49 to 53
Spark dismantle 25 Finally recommendations 54
Spark check 25 Homologation 55 & 56
Air filter box dismantle 26

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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.
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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.

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, w

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 5 9
6 7
8 24 26
22 23 25

27

14 16

10 13 15
17 20 21
11 12 18 19 28 29 30 31 32 33 34 35

1 Front fender 12 Front brake disc 24 Middle silencier

2 Front brake caliper 13 Cylinder 25 Radiator
3 Front suspension left 14 Carburetor 26 Headlight
leg 15 Chain guide 27 Front tyre air valve
4 Front suspension bar 16 Chain tensioner 28 Rear brake disc
5 Breather hose 17 Chain 29 Sidestand arm
6 Spark plug 18 Rear sprocket cover 30 Swingarm
7 Filter box 19 Rear sprocket 31 Rear brake pedal
8 Rear fender 20 Rear rim 32 Kickstart pedal
9 Tail lamp 21 Rear tyre 33 Water pump
10 Front tyre 22 Exhaust protection 34 Exhaust pipe elbow
11 Front brake disc cover 23 Frame 35 Front wheel axle
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 44

45

42 46
38 39 40
37
47

41 48
36

49
43 50
51

52

61
60 53
57 58 59
54

36 Rear fender 47 Clutch pump 55

37 Axle nut rear wheel 48 Handlebar 56

38 Left foot peg 49 Left suspension regulation
39 Air filter box cover 50 Multifunction
40 Shift pedal 51 Warning indicators
41 Ignition cover 52 Right suspension regulation
42 Fuel tank 53 Front brake pump
43 Fuel tank cap 54 Throttle cover 58 Right foot peg
44 Left handle grip 55 Front brake lever 59 Rear brake pedal
45 Clutch lever 56 Throttle grip 60 Exhaust pipe elbow
46 Light controls 57 Silencer 61 CDI Switch
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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.

MAINTENANCE TABLE
Part Check / Adjust Replace / Clean Grease /
Inspect Change Lubricate
Rear shock absorber Every year - Every 2 years - -
Transmission oil 30 hours - 60 hours - -
Front fork oil - - 60 hours - -
Brake adjust Every race If is necessary - - -
Swingarm and connecting rods Every race - If is damaged Every race Every cleaning
Spark plug Every race 30 hours 60 hours 15 hours -
Throttle cable and twist grip Every race If is necessary If is damaged If is necessary Every cleaning
Chain Every race If is necessary If is damaged Every race Every cleaning
Reed valve box 30 hours - If is damaged Every race -
Carburetor Every race If is necessary If is damaged Every race -
Frame Every race - If is damaged Every race .
Carburetor jet - If is necessary If is damaged - -
Steering bearing Every race - If is damaged - -
Piston bearing - - If is damaged - -
Wheel bearing - - If is damaged - -
Engine bearing - - If is damaged - -
Rear sprocket 30 hours First 5 hours If is damaged - Every cleaning
Cylinder and cylinder head 60 hours - Every year - -
Brake Every race If is necessary If is damaged - -
Brake disc Every race First 5 hours If is damaged Every 2 races -
Clutch discs - - If is damaged - -
Clutch Every race - If is damaged - -
Engine protector plate Every race im a fall if is damaged - -
NOTE: (*) Inspect or do this operations only it’s necessary.
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 MAINTENANCE TABLE

Part Check / Adjust Replace / Clean Grease /

Inspect Change Lubricate
Exhaust Every race - 500 hours - -
Packing - - 100 hours - -
Air filter Every race - If is damaged Every race Every cleaning
Steering assembly Every race If is necessary - - -
Brake hose Every race If is necessary Every 2 years - Every cleaning
Cooling fliud Every race If is necessary Every year - -
General lubrication Every race - - Every race Every cleaning
Front and rear rims Every race - If is damaged Every race -
Tyres Every race - If is damaged Every race -
Brake oil level Every race If is necessary - - -
Chain guide slider Every race - If is damaged - -
Kickstart and shift pedal Every race - If is damaged - Every cleaning
Brake piston pump anb the dustcover - - If is damaged - -
Brake piston and the dust-cover - - If is damaged - -
Piston and piston rings 60 hours - Every year - -
Front and rear spokes Every race 5 hours If is damaged Every race -
Fuel system Every race - If is damaged - -
Front suspension Every race If is necessary If is damaged - -
Exhaust o’ring - - If is damaged - -
Bolts, nuts & fasteners Every race If is necessary If is damaged - -
Fuel hose Every race If is necessary If is damaged - -
Radiator hose set and connections Every race If is necessary If is damaged - -
Frame protect sickers Every race - if is damaged - -
Tire-silencer space (clearance) Every race Im a fall if is damaged - -
NOTE: (*) Inspect or do this operations only it’s necessary.

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 8
Enter the vehicle identification number (serial
I
The new GAS GAS
TXT RACING 2015 number), the particulars shown on the model
carries the appropriate label, and the ignition-key identification number
certification plate in the spaces provided, in order to simplify
whose details should your future orders for spare parts or as a useful reference
coincide with those on in the event of your vehicle being stolen.
the accompanying
documentation and Serial number (A)
the frame number This has been printed on the steering tube. It shows
stamped on the the frame number used for registering this machine.
steering arm.

Homologation
SERIAL N.
conditions are detailed
on sheets 56 to 57. Homologation plate (B)
The motorcycle carries a certification plate showing a
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
B information be entered in the box below.
Serial number.

HOMOLOGATION P.
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)

KEY NUMBER

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 All light controls have been

C C
The indicator control
located on the left-hand grip; the has been located on
various positions available are the underside of the
reached by sliding the main left-hand grip. This is an orange-
switch, which is on the left end colour button. To start the right-
of the grip.
8 hand indicator, move this switch
to the right; and likewise, to start
the left-hand indicator, move this
switch to the left.

The control panel includes

C lighting, turn signal, horn and

engine stop switches. 8

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 Located under the

C suspension lower right side

bracket. For correct
operation, it is necessary
C Fuel tank capacity : 2,4 liters

to turn the handlebar completely Use premium gasoline with an octane rating equal to or higher
towards the right until it stops, insert than that shown in the table.
the key in the slot, turn it in
OCTANE RATING METHOD MINIMUM RATING
counterclockwise direction, press and
to turn it again in clockwise direction. Antiknock Index (RON + MON)/2 90
The key can now be removed and Research Octane No. (RON) 98
the steering will remain locked.
Never leave the key in the
I lock. If the steering is
turned with the key in the
lock it may be damaged and the
locking system could be damaged.
Gasoline is extremely flammable and can be explosive under
certain conditions. Always stop the engine and do not smoke.
8

Make sure the area is well ventilated and free from any source
of flame or sparks; this includes any appliance with a pilot light.

I
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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 C
This engine is The fuel tank cap is of the quick release type. To open the

C designed to burn
a mixture of
combustible fuels,
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.
lead free petrol and oil. It is important to check periodically the condition of the cap
sealing O’ring to insure proper sealing.

RECOMMENDS SYNTHETIC
2 CYCLE ENGINE OIL:

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80cc carburetor model

(A) 8
C
The choke (B) is a device
for aiding the starting
when cold. The enigne will
reach a normal
temperature in a short
(B) time and it won’t damage
anything.

7
8

C
The idle and petrol-air

C
The position of the fuel tap (A)
mixture can be adjusted
by the screw as shown
in the illustration.
Reserve Open Closed
must be pointing down for
normal operation. When turned
forwards, it opens the reserve,
to the rear turns off the fuel.

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125 - 300cc carburetor model

8
C
The choke (B) is a device
A for aiding the starting
B when cold. The enigne will
reach a normal
temperature in a short
time and it won’t damage
anything.
8

7
The position of the fuel tap (A)

C
must be pointing down for The idle and petrol-air
normal operation. When turned Reserve Open Closed mixture can be adjusted
by the screw as shown
forwards, it opens the reserve, in the illustration.
to the rear turns off the fuel.

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 Mínimo 3 mm

Like the

C c l u t c h
lever, the
front brake
lever must be in the
ideal position. Again,
7
the play must not
The clutch lever must be exceed 3mm,

C adjusted to your liking, but

the free play should not
exceed 3mm. This play must
never be
This play must never be eliminated. eliminated.

This is the position

I
8 the kick-start should
be in when not being
used.

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 When topping up

C
8 the oil, open the
cap (A).

Engine Oil The engine crankcase

A capacity
400cc. C drain cap is situated on
the lower left-hand side.
The drainage hole in the
B crankcase allows emptying.

8
8

To check the oil level, first make sure

C the motorbike is perpendicular to the

ground. If the bike has been in use,
wait a few minutes. To check the oil level, (B)
and examine the level of oil using the window.
The level should be in the middle of the window.
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.

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 It is important to periodic
lly check the air filter. Open
the door on the motorbike as
shown in the photo. Clean
with water and detergent, then dry and
lubricate with oil designed for filters.
Ensure its correct installation once clean.
In the lower part of the filter chamber
there is a leaf that acts as the escape
valve for the liquids and/or other mate-
rials that may build up in the filter cham-
ber. Check that this valve is working
properly.

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 B) C)
I
Remove the fuel tank,
out
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.
Coolin
Next pull out the fuel tube g fl
end (A) which is inserted -30ºC uid
in the fuel cock. The third
When filling the radiator,
step is to unscrew the
screw (B) fastening the
front upper part of the
I use cooling fluid
designed for lightweight
alloy motors.
8
tank . Once the fuel tank
is released, lift it at the The engine must be
front section and remove cool before removing
the tank completely out the radiator cap or
the of the chassis (C). when replacing radiator
coolant, or severe scalding may
result.

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 It is necesassary to periodically check the spark plug condition.

C This must be done removing the spark plug from the upper
part of the cylinder head.
First disconnect the spark plug cap and remove area first.
Clean the spark plug with compressed air to remove dirt and prevent
foreign material from entering inside the engine compartment.

7
It is necessary to
periodically check the
I state of the spark
plug. The sparking
plug distance should
be between 0.6 and
0.7mm.

0,6 _
~ 0,7 mm.

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 To carry out any type of operations on and improve access to the carburetor, it is recommended
C to remove the filter box. You must follow these steps:
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 wiring connector is visible (Fig. 2).
4.- Disconnect the connector (Fig. 1).
5.- Remove the filter box completely.
The carburetor is now exposed and can be separated from the motor assembly by loosening the reed port
clamp.

Loosen the two screws of the carburetor cap to allow the removal of the body to prepare it for cleaning.

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 18,5mm

C
7 It is important to check the
level of petrol within the
carburetor. The float should
be at 18.5mm.

Fig. 3 C
7

It is necessary to clean the

7 carburetor very thoroughly.
To do so use compressed air.

I
C
Extreme precautions must be
taken to dry the inside of the
carburetor thoroughly. Water
Dismantle and clean
droplets, dirt, or other forign
material may enter and damage
7 periodically the main nozzle
the reed box and consequently after washing the bike, as well
cause damages to the piston as cleaning the inside of the
and cylinder assembly. carburetor housing.

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80cc model

The reed box assembly is composed of only one body, the

C stops. To inspect the assembly remove it by removing the

4 screws (A) wich attach it to the rear of the left and right
crankcases.
I Since this is the last
point 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
foreign material from entering
the compartment when
(A) handling these parts.

The distance between

reeds and the reed
keeper should be 6,5 mm
for all types of
displacement models. 7
Reeds must be kept in perfect
conditions with no signs of nicks,
scratches, broken or folded sections.
Otherwise, the reed assembly must
be replaced with a new one.
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125 - 300cc model

The reed box assembly is composed of only one body, the

C stops. To inspect the assembly remove it by removing the

4 screws wich attach it to the rear of the left and right
crankcases.
I Since this is the last
point 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
foreign material from entering
the compartment when
handling these parts.

The distance between

reeds and the reed keeper
should be 6,5 mm
for all types of displacement models. 7
Reeds must be kept in perfect
conditions with no signs of nicks,
scratches, broken or folded sections.
Otherwise, the reed assembly must
be replaced with a new one.

-28a-
 9,88 +-0.05

C After any removal or assembly

operations on the clutch air
trapped inside must be purged by C
Check clutch discs for
possible wear after
many hours of use. For
connecting wrench (spanner) and correct operation the minimum
bleeding the system. measurement should be 9,83 mm.

17,5 +1
+0

7 C
(A) The circle indicates
where the engine oil
should be poured in

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80cc model

*Level of air chamber

155 mm.

FRONT FORK
ø 33 mm
575 mm.

*Measure without the spring and the hydraulic rod extended

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125 - 300cc model

*Level of air chamber

160 mm.

FRONT FORK
ø 40 mm. aluminium bars
575 mm.

For a medium weight of 75 Kg.

we should preload the spring to 2.5 mm

*Measure without the spring and the hydraulic rod extended

-30a-
 The front suspension The preload on the shock absorber

C is adjusted manually
is adjusted by turning the toothed
rings (C) with the aid of two special
spanners.
Right (hydraulic extension). Starting from the standard preload of 8.5mm,
Left (hydraulic compression). tighten it up or loosen it off depending on the
weight of the rider, up to a maximum of 9mm
preload (see springs and preloads table).
Preload refers to the difference in length in
mm between the spring when compressed
and at rest.

The regulation is done

C by turning one screw
(B) located in the
center of the suspension tube
cap.The bleeder (A) is used to
purge air that may be trapped
inside the slider.

-31-
Adjust the rebound or extension
by means of screw.
The standard position is 30 clicks
from closed. From this starting REIGER SHOCK ABSORBER
position, open up clicks to get a
IDEAL PRELOADS AND SPRINGS DEPENDING ON RIDER WEIGHT
faster extension or rebound, and Rider weight without equip.(Kg) k (daN/mm) spring Spring preload (mm)
close up clicks to get a slower
Up to 70 67,5 8 125cc
extension or rebound.
It is advisable to work with a 70 - 80 70 8 250-280-300cc

maximum of 10 clicks on either 80 - 85 72,5 7,5

side of the standard position. Over 85 75 7,5

-32-
 The linkage at the lower part of rear
suspension must be periodically cleaned,
inspected and lubricated with grease.

It is very important to

C periodically remove and verify

the condition of the swingarm
bearings and pieces.

-33-
 Use special oil to

C lubricate the
following: C 2) The pivot of the
gear shift lever.

8
1) All pivot points of the brake
and clutch levers.

4) Apply grease to

C 3) Also the rear brake

pedal (bearings).
C the footrest springs
and fixtures.

8
8

-34-
 8

8
C 5) Apply grease to the linkage of
the engine starting pedal.
C
6) The drive chain must be cleaned and
lubricated thouroughly and frequently
since it is exposed to the elements and
constant abrassion.

7) Lubricate the handlebar

7 C with a fine coat of oil to
allow smooth operation of
the throttle control.

-35-
 7

8) It is also recommended to

C frequently lubricate the chain

tensioner spring because it is under

7
great stress.

C
9) Oil and clean the throttle control frequently; it is
especially recommended to do so after the bike has
been cleaned with water under high pressure.

-36-
 7

7
To regulate the chain slack The chain master link clip
C and center the rear wheel
use the shaft excentrics
which can be easily
C must be placed in
opposite direction of the
wheel travel.
adjusted.

-37-
 C
All tyre
conditions Front tyre:
must checked 2,75 x 21” TRIAL
to insure optimum. 7 2,50 x 19" TRIAL (80cc)
Rear tyre:
Fig. 1 - Bad condition 4,00 x 18” TRIAL (tubeless)
Fig. 2 - Good condition 3,50 x 17" TRIAL (80cc)

C 7
Tyre pressure should be
checked periodically to
insure the best.

Front wheel pressure:

0,450 bar - normal
0,420 bar - competition
0,500 bar - 80cc
Rear wheel pressure:
0,350 bar - normal
0,300 bar - competition
0,500 bar - 80cc

-38-
 Brake pad wear,

C front and rear, must

be checked from
time to time to insure 8
an efficient braking power under
all circumstances.

7
The brake

7
C calipers
have been
7

furnished with bleeder

valves to eliminate the
The front brake fluid level air trapped in the brake
system.
C can be verified through the
transparent inspection
window.

-39-
 C
The rear brake fluid
reservoir is located at the
cylinder support.
7 Verify fluid level periodically and refill
if necessary.

Put the bike in vertical

C position to be able to see

the liquid real level in
order to check the tank level.

It must be between MIN and MAX

MAX

MIN

-40-
 ELECTRICAL INSTALLATION.
COMTETITION.

-41-
 ELECTRICAL INSTALLATION.
HOMOLOGATION.

-42-
 ELECTRICAL INSTALLATION
(IGNITION)

-43-
Torques

PART NAME N-m PART NAME N-m

Front wheel axle 40 - 50 Spark plug 11

C E
Chassis to swingarm fastener 60 - 70 Ignition fasteners 7-8
H Upper shock absorber fastener 40 - 50 N Cluth fasteners 7-8
A Lower shock absorber fastener 40 - 50 G Cylinder stud bolt fasteners 25
S Connecting rods caps 40 - 50 Reeds fasteners 7-8
Handlebars 18 - 25 I Clutch ground fastener 3-4
S
Hand levers 7 - 10 N Crankcases fasteners 7-8
I
Radiator fasteners 7 - 10 E Water pump cap fastener 7-8
S Front bridge wing 7 - 10 Clutch cap fastener 7-8
Brake pedal 27 - 32 Flywheel fastener 40
Muffler fasteners 18 - 25 Water fastener 10
Rear wheel axle 40 - 50 Ignition cap 7-8
Rear brake caliper fastener 27 - 32 Engine drain plug 12
Front brake caliper fastener 27 - 32 Kickstart pedal screw 12 - 13
Exhaust pipe elbow fastener 27 - 32 Shift pedal screw 7-8
Engine fasteners 18 - 25 Cylinder head screws 11,5 - 13
Rear brake pump fastener 7 - 10 Cylinder nut 25
-44-
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 cardboard
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
that these items must be washed carefully. If the washer applies water at high pressure and/or temperature,
I 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.
-45-
Multifunction gauge (Only on certain models and markets) QUICK GUIDE: SETUP MENU

The multifunction device is water resistant, has 3 buttons To enter into the setup menu Endurance II, hold buttons 1,
with a brightly lit LCD. 2 and 3 for three seconds. Be sure to hold the 3 buttons at
the same time.
• Current speed
• Backlight Full time
• Average speed
• Maximum speed
• Two independent tripmeters
• Odómeter(total kms)
• Time on motorcycle
• Chronometer
• Tracking total hours
• Clock
• Maintenance Reminder
• Travel Distance

WARNING
The multifunction device is water resistant BUTTONS SUMMARY:
but not waterproof. Do not wash with pressure
washer. Do not leave the device in direct Button 1: Increase (above)
sunlight when the motorcycle is stopped. Avoid contact Button 2: Decrease (below)
Button 3: Next configuration
with gasoline, degreasers or other cleaning chemical
products that could be cause damages in the device.
Always remember to pay attention to the road when
you’re driving.
-46-
ADJUSTING the distance units:

Select the units (kilometers or miles) with 1 or 2 buttons.

SET the front tire size:

Select the size with button 1 or 2 (2300m).

ADJUST the clock format:

Select the desired format using the buttons 1 or 2 (12H or 24H).

SETTING the time:

Set the clock to the desired time by pressing 1 to 2.

SETTING the maintenance reminder method:

Select the desired maintenance reminder method using the buttons 1 or 2.

ODO: Odometer. kilometers based.
ART: Accumulated driving time, hours based.

SETTING the maintenance reminder:

Select the value until the next maintenance.

This value is based on time or mileage, depending on the method chosen
on the previous menu (ODO/ART).

-47-
SCREENS IN NORMAL MODE: Screen 1: DST

DST (Distance Traveled). DST function accumulates the

distance data since the last reset while you’re riding a
motorcycle.
Press and hold buttons 1 and 2 for three seconds to reset
DST (Distance 1 ).
Hold the button 3 to set the DST. Use buttons 1 and 2 to
increase and decrease the DST.
Press the 3 button to return to main menu.

Screeb 2: DST2

DST2 (Distance Traveled 2). The multifunction ENDURANCE

II, can accumulate data from two different travel distances.
Press and hold buttons 1 and 2 for three seconds to reset
DST2, driving time and average speed.
Hold the button 3 to set the DST.
Use buttons 1 and 2 to increase and decrease the DST.
Press the 3 button to return to main menu.

-48-
 TROUBLESHOOTING

NOTE
This is not an exhaustive list of malfunctions, it only shows the most common problems.

MALFUNCTION POSSIBLE CAUSE REMEDY

1 Engine does not start - 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
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.

2 Engine start 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.

3 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.

4 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.

-49-
 MALFUNCTION POSSIBLE CAUSE REMEDY

4 The engine operates irregularly - Ignition rotor damaged. - Replace the rotor.
- Water in fuel. - Drain the fuel tank and fill up with new fuel.

5 Engine lacks power or poor - Fuel supply defective. - Clean the fuel system and 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.

6 Abnormal engine noise - Ignition problem. - Go to a specialized workshop.

- Overheating. - Refer to section 5.

7 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.

8 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 cable adjustment. - Readjust the throttle valve cable.

9 Brown smoke coming out of the - Restricted air cleaner. - Clean or replace the air cleaner. Go to a specialized
exhaust pipe workshop.
- Main jet set too high. - Verify main jet operation. Go to a specialized workshop.

-50-
 MALFUNCTION POSSIBLE CAUSE REMEDY

10 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.

11 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.

12 Clutch slips - No clutch lever free play. - Go to a specialized workshop.

- Worn clutch friction plate. - Replace 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.

13 The motorcycle is unstable - Cable interferes with the handlebar. - 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.

-51-
 MALFUNCTION POSSIBLE CAUSE REMEDY

14 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.

15 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.

16 Abnormal motorcycle noises - 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.

17 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.

-52-
 MALFUNCTION POSSIBLE CAUSE REMEDY

17 Handlebar vibration - Excessive steering axles tolerances. - Tighten steering bracket and steering stem locknut to the
correct torque values.
- Loose handlebar bracket, and loose - Tighten steering bracket and steering stem locknut to the
handlebar stem locknut. correct torque values.

18 Motorcycle pull to one side - Bent chassis. - Replace the chassis. Go to a specialized workshop.
- Incorrect steering adjustment. - Adjust the steering. Go to a specialized workshop.
- Bent steering stem. - Replace the steering stem. Go to a specialized workshop.
- Bent front fork. - Replace the front fork.
- Incorrect wheel alignment. - Align the wheels.

19 Brakes do not operate correctly - Worn discs. - Replace the discs.

- Leaking brake fluid. - Verify the brake circuits. Replace the damaged or broken
parts.
- Deteriorated brake fluid. - Drain the brake fluid and fill with the new fluid recommended
by the manufacturer.
- Broken pump piston. - Replace the pump piston.
- Incorrect brake adjustment. - Adjust brakes.

-53-
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
that these items must be washed carefully. If the washer applies water at high pressure and/or temperature,
I 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.

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 accessories
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 accessories of your motorcycle and also
of the versions exported. Because of this, there can be no liability 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.
-54-
HOMOLOGATION (Only for homologated version)
The vehicle you have just acquired has been homologated under the directives 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 1
- Catalyzed with with secondary air Available 1
- Muffler Available 1
- Carburettor jets Available 1
- Front and rear turn signals Available 1
- License plate holder Available 1
- Speedometer Available 1
- Electrical installation, homologated lights Available 1
- Engine output pinnion and sprocket for a correct transmission gear ratio 1
- Horn Available 1
- Rearview mirror Available 2
- Antitheft system 1
- Antimanipulation plate (125 cc version) 1
- Air filter restriction; carburettor hood limit (according to model) 1

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 problem.

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.

-55-
 HOMOLOGATION
1- Front right turn signal
2- Rear right turn signal
3- Trial rear pilot
4- Rear left turn signal
5- M6 Bolt
6- ULS screw 6x16
7- Phillips screw M6 x 25
8- Philips screw 6.3x16
9- Front left turn signal
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

BT93900RA3010
Note: N/A USA also some “competition only” models

T0803020

-56-