MANUAL DEL USUARIO USER MANUAL MANUEL D'ENTRETIEN LIBRETTO D´USO BETRIEBSANLEITUNG USER MANUAL USERMANUAL ENGLISH GAS GAS thank you for the trust you have placed in us. By choosing a new GAS GAS TXT Boy 2006 you have become part of the great GAS GAS family and, as a user of the number one manufacturer of off-road motorbikes, you deserve to receive the best treatment we can offer you both in our post-sales relations and in the explanations we offer in this manual. Our TXT Boy 2006 is designed for high-level trial competitions. In fact, it is the result of many years of competition and experience in this highly demanding discipline and of the many excellent results obtained by the great riders who have supplied the basic data to enable us to develop this excellent motorbike, a GAS GAS that has one key advantage: its remarkably light weight. Congratulations, because your choice has been, without doubt, the correct one. With your riding skills, appropriate preparation and the relevant essential checks to maintain its highly reliable performance, you will be able to enjoy your trial riding to the utmost. Thank you for your trust in us, and welcome to GAS GAS motorbikes. GAS GAS MOTOS, S.A. -5- Important warning Read this Manual carefully. You will find it contains all the necessary information for your safety, and that of others, as well as guaranteeing the correct conservation and maintenance of the GAS GAS motorbike you have just bought. All of the necessary instructions for the correct riding and control of this vehicle are set out below. Each message is preceded by a symbol whose meaning is as follows: Caution! This symbol identifies all the safety measures and regulations which should help avoid physical injury, serious or otherwise, or even loss of life, should the instructions not be followed carefully. Warning! This symbol introduces special warnings to avoid damaging your motorbike. Should these warnings not be heeded, the guarantee may be automatically invalidated. Miscellaneous. These are the instructions necessary to ensure good use of the control and adjustment mechanisms, in addition to the correct conservation and maintenance of the motorbike, to guarantee maximum satisfaction when riding. The aim of this Manual is to help the user minimise or avoid possible damage to people, property, the environment, and naturally to his/her new motorbike. Therefore, all the information presented here is based on data obtained from the latest models put on the market just before publication. However, GAS GAS Motos, S.A. reserves the right to make modifications without any prior warning 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. -6- Contens Acknowledgements to the purchaser Important warning Quick Guide to Maitenance Fuel-Petrol/oil mixture Fuel tank Fuel tap Gear shift Before starting the engine Starting the engine Stopping the engine Riding your motorcicle Stopping the motorcycle Running-in period Transmission oil - Checking oil level -Topping up -Changing oil Clutch system- Checking Clutch system- Bleeding Coolant system ­ Checking/topping up 5 6 8 9 9 10 10 11 11 12 12 12 13 13 14 14 15 15 16 Carburettor - Adjusting throttle cable - Adjusting idle speed Spark plugs - Inspecting Air Filter - Cleaning Front brake fluid - Checking Rear brake fluid - Checking Clutch lever - Adjusting Front brake lever - Adjusting Rear wheel ­ Centre alignment Chain slack - Checking Master link - Checking Tyre pressures - Checking Brake pads - Checking Brake circuit - Bleeding Front fork ­ Oil level Lubrication Identification Warranty terms and conditions 17 17 18 18 19 19 20 20 21 21 21 22 22 23 23 24 26 27 -7- Quick Guide to Maintenance Coolant liquid Crankcase oil Spark plug Electrode separation Forks suspension oil Fork suspension oil quantity Coolant liquid -30ºC (10w40) 500 cc. CHAMPION RN11YCC / NGK BPR5ES. 0.6 mm. SAE 5 (Summer) SAE 2.5 (Winter) 200 cm3 Shock absorber spring length 96 mm Front wheel pressure Rear wheel pressure Standard 0.400 bar Competition 0.370 bar Standard 0.350 bar Competition 0.300 bar -8- 1 Fuel ­ Petrol/oil mixture The motorcycle is fitted with a two-stroke internal combustion engine. This type of engine requires a mixture of petrol and oil. To ensure the correct working of the engine, the following are recommended: - Use high quality petrol, with an octane rating equal to or above 90 (RON + MON)/2 or 98 (RON). - Use 2T synthetic oil. Warning: - If the recommended oil is not available, use semi-synthetic oil. - Do not mix different oil-types. Mixture ratio: oil, 1.5% of petrol volume (50 parts petrol to every 0.75 part oil). Note: we recommend first preparing the mixture in a suitable container and then filling the fuel tank. I B A Fuel tank This has a rapid access cap A and a vent hose B to allow gases produced in the tank to escape. - To open the cap, lift the clip in the direction shown by the arrow and turn to the left. Warning! Regularly check the cap seal and vent hose to ensure they are leak proof. Risk of spillage. -9- 7 2 A Gear shift The motorcycle has a twospeed gearbox, which may be selected manually when the motorcycle is stationary, by moving the lever A in a horizontal direction, as shown by the arrow. Note: Select the gear according to the characteristics of the track. C 8 3 8 Fuel tap This has three positions: open, closed and reserve. The diagrams below show the position of tap A for each case. C Reserve Open Closed N 2ª -10- 1ª A Before starting the engine Warning: Before starting the engine, check that the gear lever is in neutral (see instructions in the section Gear lever page 10) , - Open the fuel tap. Note: - If the engine is cold, move choke A upwards, as shown by the arrow, until it clicks into place (vertical). Once the engine is turning over regularly at idle speed, return the choke to the rest position (horizontal). - Do not use the choke on hot days or when the engine is hot. In this case, hold the throttle lever partially open until the engine starts. C 4 8 A 5 A C Starting the engine Kick the start-pedal A in the direction shown by the arrow until the engine starts. Warning: Once the engine is running, fold the kick-start pedal up against the engine. -11- 8 6 A C Stopping the engine - With the throttle lever in rest position (engine idling), move the gear lever to neutral. - Press stop button A until the engine stops. 8 C Riding your motorcycle - Select the gear according to the characteristics of the track. - To change gear, the motorcycle should be stationary. Stopping the motorcycle - Release the throttle lever. - Use the front A and rear B brakes. Warning: Depending on circumstances and ground surface, it may be better to use the front or rear brakes independently. 8 7 A B -12- 8 Running-in period Care of the engine during the first hours of use is vital for obtaining the best from your motorcycle. Therefore, we recommend: - Strictly observe the oil and petrol ratios shown, and use the recommended 2T oil ­ see section "Fuel ­ petrol/oil mixture", page 9. - In the first hour of use, keep the engine at a moderate turnover speed (never go to maximum turnover). - Constantly change the speed, by opening and closing the throttle alternately. C C Transmission oil ­ Checking the level If the motorcycle has been used recently, wait a few minutes before checking the level. Note: the motorcycle should be perpendicular to the ground. The level is correct if it falls within the upper half of the transparent window A. If the level falls below the upper half of the transparent window A the oil should be topped up. 9 -13- 10 B A Transmission oil ­ Topping up If necessary, top up with oil: - Remove vent hose A. - Remove filler cap B and add oil until the correct level is reached. C Tr a n s m i s s i o n o i l ­ C h a n g i n g - Start the engine and keep it running until it warms up, then stop the engine. - Drain off the used oil. To do so, remove the drain plug A located on the lower part of the engine (visible through the opening of the oil sump casing). - Replace the drain plug using a new seal washer. Tighten to 20 Nm. - Remove the filler cap and fill with oil (450 cc). Warning: Use the recommended oil. - See Quick Guide to Maintenance, page 8. - Tighten the filler cap. Warning: Do not pour used oil down the drain. C 11 A Warning: Use the recommended oil. - See Quick Guide to Maintenance, page 8. Warning: Do not exceed maximum level! Risk of damage to engine. - Replace filler cap and tighten. -14- 7 7 Clutch system- Checking The clutch system is hydraulic. Regularly check the level of fluid through the transparent window A on the tank. - Position the lever so that the tank cover is horizontal. - The level is correct if it falls within the upper half of the transparent window. Warning: Use the recommended oil. See Quick Guide to Maintenance, page 8. C 13 7 A 12 A Clutch system - Bleeding If the system has been dismounted for repair, or if faults are detected in the clutch system, the air in the hydraulic circuit can be removed using the bleeder A. Once the air has been removed from the system, replace the rubber cap on the bleeder to prevent dirt from entering the system. Warning: Do not pour used oil down the drain. C 7 -15- as follows: - Undo the bolts shown by the arrow and remove the fuel tank cover and the rear seat unit. - Carefully lift and remove the fuel tank. Warning: If the motorcycle has just been used, wait a few minutes before opening the radiator cap. Risk of burns! - Turn cap A in an anti-clockwise direction until it is loosened. - Wait a few seconds, then push the cap downwards, finish the turn in the same direction and remove the cap. - The level of coolant should be at the lower edge of the filler neck of the radiator, below the position of the cap seal. If this is not the case, top up with coolant. Warning: Only use coolant suited to light-alloy engines, with antifreeze protection of up to 30 ºC. -16- 7 A C Coolant system ­ Checking/topping up To reach the radiator cap, proceed 14 7 Carburettor - Adjusting throttle cable The throttle lever cable should have a free play of between 2 to 3 mm. If necessary, adjust as described. - Raise the dust guard A on the throttle lever cable. - Turning the threaded terminal B to the right increases the play of the cable, and turning it to the left reduces the play. C A A B 15 16 B A Carburettor ­ Adjusting the idle speed The carburettor has an idle adjusting screw A, which acts on the opening of the carburettor throttle curtain, and an air adjusting screw for the low system B, which controls the proportion of air in the air/fuel mixture. 7 C -17- 17 _ 0.6 ~ 0.7 mm 7 C Spark plugs - Inspecting The electrode separation is from 0.6 to 0.7 mm. Air Filter - Cleaning A clean air filter not only improves engine performance but also prolongs its useful life. It should therefore be cleaned regularly. To reach the air filter, proceed as follows: - Undo the bolts shown by the arrows, and remove the rear seat unit. - Using a screwdriver or similar, remove the elastic band A from the bolt holding it. - Remove cover B from the filter box. - Remove filter. C Wash the filter in warm water and soap and, once dry, grease with special filter oil. - Remount the parts in reverse order. 7 A B 18 -18- 7 Front brake fluid - Checking The level is correct if it falls within the upper half of the transparent window A. If not, top up with a recommended brake fluid. C 19 20 MAX A MIN Rear brake fluid - Checking The level is correct if it falls within the min and max marks on the tank. If the level is below the min. mark, top up with the recommended brake fluid. C 7 -19- Clutch lever - Adjusting The clutch lever should have a maximum play of 3 mm. To adjust, proceed as follows: - Adjust the maximum turn of the lever using bolt A, to suit the driver. - Adjust the play of the lever using bolt B. C A B 3 mm max Warning: Maintain the clutch lever with the play shown, otherwise the performance and useful life of the clutch may be adversely affected. 7 22 21 3 mm max B A Front brake lever - Adjusting The front brake lever should have a maximum play of 3 mm. To adjust, proceed as follows: - Adjust the maximum turn of the lever using bolt A, to suit the driver. - Adjust the play of the lever using bolt B. C 7 -20- operation. To ensure perfect wheel alignment, make sure that the marks of both eccentrics are in the same position on both sides. C Rear wheel ­ Centre alignment The rear axle has easily graduated eccentrics for this 25 7 23 Master link - Checking The master link of the chain has an elastic locking clip. As shown in the photo, place the closed part of the clip in the direction of the chain rotation. C 7 7 -21- Chain s ...