Workshop Manual 2018

txt SERIES

Trial 80 - 125 - 250- 280 - 300cc

2017 GAS GAS
All rights reserved
Reprinting and reproduction of any kind, either in whole or in part, is prohibited without the written permission
of the copyright holder.
The company has the right, without prior notice, to change the technical content of the products.
The models in the images may appear with special equipment that does not come with the standard model.

Edition 24/07/2018
Workshop manual

Contents

General information.....................................................................................................................................................4

Introduction.................................................................................................................................................................... 5

Legal notices.................................................................................................................................................................... 5

Notices and warnings...................................................................................................................................................5

Safety rules....................................................................................................................................................................... 6

Maintenance..................................................................................................................................................................... 6

Recommended “work method”....................................................................................................................................7

Vehicle / engine identification...................................................................................................................................8

Tightening torque.......................................................................................................................................................... 8

SPECIAL TOOLS................................................................................................................................................................... 10

maintenance................................................................................................................................................................... 12

Maintenance programme........................................................................................................................................... 13

Periodic inspection....................................................................................................................................................... 14

Carburettor disassembly and inspection ............................................................................................................18

Reed block disassembly and inspection..................................................................................................................24

Exhaust system disassembly and inspection........................................................................................................25

Cylinder head disassembly and inspection...........................................................................................................30

Cylinder and piston disassembly and inspection................................................................................................32

Starter system disassembly and inspection..........................................................................................................37

Clutch assembly disassembly and inspection.......................................................................................................41

Crankcase disassembly and inspection..................................................................................................................44

Maintenance of the frame......................................................................................................................................... 50

Electrical diagrams..................................................................................................................................................... 78

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General information
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Introduction

TORROT ELECTRIC EUROPA S.A. thanks you for your confidence.

This manual was created by TORROT ELECTRIC EUROPA S.A. to be used by official services of the GAS GAS (GG) brand. It is assumed that
whoever reads this publication for enjoyment or for the repair of GG vehicles has a basic knowledge of the principles of mechanics and the
methods used in the repair of these vehicles.
Any major changes in the characteristics of the vehicles or in specific repair operations will be communicated through updates of this
manual.

It is important to note that a completely satisfactory job cannot be carried out if appropriate facilities and tools are not available, which is
why we invite you to consult the pages of this manual that refer to specific tools and equipment.

In it, you will find precise instructions for carrying out all repairs, as well as the necessary technical data to perform maintenance on the
motorcycles.

It also has extensive information about special GG tools that will be of great help to optimise each repair process.

By choosing the new GG, you have just joined the great GG team and, as a user of the number one brand of off-road motorcycles, you
deserve the special care that we would like to offer you, both after purchasing your GG and in the explanations that we set out in this
manual.

Legal notices

In the interests of technical development, GG reserves the right to change the construction, equipment and accessories of the motorcycle
without prior notice. Measurements, weight and power data are understood to include the respective tolerances. Depending on the
volume of equipment and accessories of your GG, as well as in the approved versions in accordance with the different laws of each state,
there may be variations with respect to the descriptions and illustrations. Therefore, the photographs contained in this manual may not
correspond to the model purchased. For this reason no liability shall be derived for error, printing error or omission.

Notices and warnings

Please read this manual thoroughly, paying particular attention to the following warnings:

DANGER
Warning about a hazard that could lead to serious injury or even death.

WARNING

Notices regarding danger that could result in personal injury and/or damage to the vehicle.

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Safety rules

DANGER
It is necessary to follow certain safety and maintenance rules when doing repair work on vehicles.
Here are some of the most important:

SAFETY
- If it is necessary to carry out work on the engine while it is still running, make sure that the premises have adequate ventilation and, if
necessary, use smoke extractors. Never leave the engine running in closed premises. Exhaust gases contain CO (carbon monoxide), which
can cause loss of consciousness and death by inhalation.
- The electrolyte in batteries contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; if it comes
into contact with your eyes or skin, flush the area with plenty of water and seek medical advice immediately. If you have accidentally
swallowed electrolyte, drink large amounts of water or milk and seek medical advice immediately.
- Batteries produce hydrogen, a gas that can be highly explosive. Do not smoke and ensure that no flames or sparks come near the battery,
especially during recharging operations.
- Petrol is extremely flammable and can be explosive under certain conditions. Do not smoke in the work area and make sure that no naked
flames or sparks are produced.
- Avoid prolonged contact of used engine oil on your skin; use gloves or wash your hands immediately after use to remove any oil.
- Carry out the cleaning of the brake pads in a ventilated location; DO NOT USE compressed air to clean the pads or brake caliper. Although
the powder does not contain asbestos, its inhalation can cause respiratory diseases.
- Brake fluid is extremely aggressive; avoid contact with painted surfaces. Protect painted elements with a clean cloth when performing
operations with brake fluid. Use gloves if possible, as contact of brake fluid with the skin is not recommended.
- Make sure that coolant does not spill onto hot parts, as this produces an invisible flame that cannot be seen and can cause burning.
- Do not remove the radiator cap when the engine is still hot, as the coolant is under pressure and at high temperature, which can cause
severe burns.
- If coolant comes into contact with your eyes, flush them immediately with fresh water and seek medical advice.
- During normal operation, the exhaust system and engine are at high temperature. If you have to perform operations on them, wait until
they have cooled down or use suitable gloves to avoid burns.
- Avoid wearing loose clothing that could get caught on parts of the vehicle or surroundings. Although total safety is impossible, the use of
adequate equipment reduces the possibility and/or severity of injuries.

Maintenance
- Always use original GG spare parts and lubricants recommended by the manufacturer. Non-original spare parts can damage the engine.
- Only use tools specifically designed for this vehicle.
- Always replace gaskets, seals and O-rings during servicing and assembly.
- After disassembly, clean the components with non-flammable solvents.
- Lubricate all work surfaces prior to assembly, excluding conical couplings.
- Apply oil to all pairs of parts and bearings during assembly.
- Only use tools with metric measurements during disassembling, servicing and assembling operations. Metric screws, nuts and bolts are
not interchangeable with connecting elements with imperial measurements.
- All surfaces that receive gaskets, seals and O-rings must be cleaned with special care.
- Carefully examine all retaining rings prior to assembly and replace any deformed ones. Always replace piston pin retaining rings after each
use.
- After assembly, check that all components have been properly fitted and that all mechanisms work correctly.

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Workshop manual

Recommended “work method”

- Remove all dirt, mud, dust and other foreign material before disassembly. Use appropriate tools and cleaning equipment.

- When removing parts, always keep them together in their pairs. This includes gears, cylinders, pistons and other parts subjected to
natural wear in their pairs. Pairs of parts should always be replaced together.

- While removing parts, clean them and place them in trays in their order of removal. This will speed up reassembly and ensure that all
parts are properly fitted.

- Use original GG spare parts and GG recommended lubricants. Non-original or non-compliant spare parts can damage the vehicle. Other
brands may look similar in function and appearance, but are inferior in quality.

- Carefully check all circlips before assembly. Always replace the pin circlips after each use.
Replace any deformed circlips. When installing a circlip, make sure that the sharp edge is on the side opposite to where force is applied.

- Replace all gaskets, seals and O-rings when servicing the engine. All surfaces that support gaskets, seals and O-rings should be cleaned.

- After removing them, replace all sealing/spacer washers and external tooth lock washers.

- Fit bearings and seals in such a way that the manufacturers’ brands are visible. When fitting seals, apply a thin layer of light grease with a
lithium soap base on their lips. If necessary, apply plenty of oil when fitting bearings.

- When fitting bearings and seals, ensure that uniform pressure is exerted on both tracks in order not to damage them.

- During assembly, always use new gaskets, seals, compression rings and pins.

- After disassembly, clean the components with non-flammable or non-high flash point solvents. Grease all work surfaces prior to assembly,
excluding conical fittings.

- After assembly, check that all components have been properly fitted and that they work correctly.

- Only use metric tools during disassembly, servicing and assembly operations. Metric screws, nuts and bolts are not interchangeable with
connecting elements that have imperial measurements. Using inappropriate tools and connecting elements may damage the vehicle.

- If working on the vehicle’s electrical system, check that the electrical connections are correct, especially earth connections.

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Vehicle / engine identification

Make a note of the vehicle’s identification number (serial no.), information on

the model label and key identification details in the spaces provided for this
purpose for ease of ordering spare parts or as a reference in the event of theft of
A the motorcycle.

B - All GG motorcycles have an official authorisation plate. (B) where the following
information is detailed: Manufacturer, frame number, authorisation number
and sound emission level, all of which must match the documentation.

- The frame number is also stamped on the right-hand side of the steering
column (A).

You can identify your specific engine model by means of a code located on the
front of the engine below the exhaust elbow, as shown in the image (1).

- Always quote the engine serial number when ordering an original GG spare
part for the engine.

Tightening torque
GENERAL TIGHTENING TORQUES

The following table specifies tightening torques for nuts or screws with ISO
threads.
Tightening torques for special components or assemblies are indicated in the
respective repair processes of this manual.
To prevent deformation, tighten the assemblies with several nuts or screws
progressively and in a diagonal or alternating sequence until the specified torque
is reached. Threads have to be clean and dry to apply the tightening torques
described below. Components should be at room temperature.

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Workshop manual

TYPE ASSEMBLY PHASE MEASUREMENT RATED TORQUE (Nm)

SCREW Rear lower handlebar clamp M8 20
SCREW Front upper handlebar clamp M8 25
SCREW Clutch pump clamp M5 6
SCREW Front wheel axle M18x1.5 50
SCREW Suspension mudguard support M6 12
SCREW Bottom suspension clamp M6 10
SCREW Top suspension clamp M6 12
NUT Top steering cap nut M20x1 50
SCREW Rear wheel axle M10 50
SCREW Shock absorber top fixing M10 50
SCREW Shock absorber bottom fixing M10 45
SCREW/NUT Rocker arm to swinging arm fixing M10 45
SCREW/NUT Tie rod-rocker arm coupling M10 45
SCREW/NUT Tie rod to frame fixing M8 30
SCREW Swinging arm shaft M14x1.5 50
SCREW Rear brake hose guide fixing M4 5
SCREW Chain tensioner M8 20
SCREW Swinging arm to chain guard fixing M5 6
SCREW Sprocket protector fixing M5 6
SCREW Rear brake caliper guide M8 25
SCREW Rear brake caliper retainer M6 12
SCREW Stand guide bushing M8 25
SCREW Stand (bottom) M8 25
SCREW Stand (int. swinging arm) M6 12
SCREW Front brake pump clamp M5 6
SCREW Front brake caliper fixing M8 25
SCREW Rear brake pedal shaft fixing M8 25
SCREW Rear brake pump fixing M6 10
SCREW CDI support fixing M6 12
SCREW/NUT Cylinder to frame tie rod fixing M8 25
SCREW/NUT Engine to frame fixing M10 50
SCREW Crankcase guard fixing M8 25
SCREW Frame-chain protector fixing M6 12
SCREW Steering stop M6 12
SCREW Rear mudguard (central) M6 10
SCREW/NUT Rear mudguard (sides) M6 6
SCREW Rear disc protector (front) M6 12
SCREW Rear disc protector (rear) M5 6
SCREW Filter box to frame fixing M6 8
SCREW Fuel tank vent hose M6 8
SCREW Radiator to frame fixing M6 10
SCREW Radiator safety valve M8 5
SCREW Exhaust elbow to cylinder fixing M8 12
SCREW Exhaust to frame fixing M6 12
SCREW Brake discs M6 12
RACORD CLUTCH PUMP M10 18
RACORD CLUTCH COVER RACORD M10 20

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SPECIAL TOOLS
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Special tools

- Magneto flywheel puller.

Ref: MT280234045

- Primary transmission sprocket puller.

Ref: MT280250006

- Tool set for 250cc-280cc-300cc engines.

Ref. 865207

- Primary sprocket puller.

Ref. MT95005GG-CHA-1

- Primary nut removal tool.

Ref. MT95010GG-CHA-1

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Workshop manual

maintenance
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Maintenance programme

Grease /
Element Check / Inspect Adjust Replace/Change Clean
Lubricate
Throttle operation Every race If is necessary - - Every race
Carburettor / Jet Every race If is necessary - 30 hours -
Air filter Every race - If is necessary Every race Every wash
Reed block 30 hours - If is necessary 30 hours -
Spark plug Every race 30 hours 60 hours 15 hours -
Transmission oil 30 hours - 60 hours - -
Radiator coolant Every race - 1 year - -
Cooling system - - If is necessary - -

Decarbonisation of the cylinder

60 hours - - 60 hours -
head / Exhaust port

Piston 60 hours - 1 year (180 h) - -

Piston rings 60 hours - Every six months - -
Cylinder 60 hours - If is necessary - -
Crankshaft and bearings assembly 60 hours - If is necessary - -
Kick-starter and gear shift pedal - - - - 15 hours
Clutch system - - If is necessary - -
Clutch discs 60 hours - If is necessary - -
Exhaust system - - If is necessary - -
Muffler fibre - - 100 hours - -
Fuel line/tap Every race - If is necessary - -
General lubrication Every race - - - Every wash
Chain / secondary transmission Every race 15 hours If is necessary Every race Every wash

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Periodic inspection

ATTENTION:
Before removing the spark plug, blow compressed air around it to remove any
dirt, making sure that it does not fall into the engine.

Remove:
- Spark plug cap.
- Spark plug.

Check:
- Spark plug type
Incorrect => Replace

Inspect:
- Electrode (1)
Damage/wear => Replace
- Insulator (2)
Abnormal colour => Replace
Normal colour is light brown

Clean:
- Spark plug
(Clean spark plug with spark plug cleaner or steel brush)

Measure:
- Play between electrodes (A). (with feeler gauge)
Out of specification => Adjust play.
Play between electrodes: 0.7 mm - 0.8 mm

Fit:
- Spark plug
1.2 - 1.4 kgf·m (12-14 Nm)

NOTE:
- Before fitting the spark plug, clean the surface of its seating and gasket.
- If you do not have a torque wrench, a good guide for the correct torque is to
tighten the spark plug by hand to position (1) and then tighten with a ¼ to ½
turn to position (2).
- Always use a new gasket.

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Workshop manual

Periodic inspection

AIR FILTER

Cleaning the filter

- It is important to periodically check the air filter.
- Inspect the filter and replace it if damaged to prevent dirt from entering the
carburettor.
- To clean it, use water and detergent, dry it and lubricate it with special filter
oil.
- Make sure that it is correctly fitted once clean.

ATTENTION:
- A clogged air filter will allow dirt to enter the engine causing excessive wear
and damage.
- Inspect it periodically. Clean if necessary.
- Clean the filter in a ventilated area and make sure that there are no sparks
or flames near the work place (including strong sources of light). Do not use
petrol to clean the filter as this may cause an explosion.

ATTENTION:
- At the bottom of the filter box, there is a flap that functions as a valve for
draining liquids and/or elements that accumulate inside the filter box.
- Make sure that this valve is operating correctly.

- Unscrew the cover located on the tail fairing of the motorcycle as shown in the
photograph.

- Remove the cover

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Periodic inspection

- Remove the filter rod (arrow) completely.

- Remove the inner visor to access the filter.

- Clean inside the filter box with a damp cloth.

Remove the filter by unscrewing the bar (1)

- Remove the cage from the air filter. (2)

Clean the filter in a filter cleaning bath using a soft brush.

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Workshop manual

Periodic inspection

- View of the filter components once clean.

- For reassembly, follow the same steps in reverse.

TRANSMISSION OIL LEVEL

For the transmission and clutch to work properly, keep the transmission oil at
the optimum level and replace it periodically.
A motorcycle with insufficient, deteriorated or contaminated transmission oil
1 can accelerate wear and damage transmission.

Place the motorcycle on a flat surface.

NOTE

2 MAKE SURE THAT THE MOTORCYCLE IS PARALLEL TO THE GROUND TO ENSURE

CORRECT CHECKING OF THE OIL LEVEL.

Checking the oil level

1. If the motorcycle has just been used, wait a few minutes.
2. Check the oil level using the level indicator on the lower right-hand side of the
engine (1).
3. The oil level must be between the maximum and minimum.
4. If the level is too high, remove the excess through the drain plug (2)
5. If the level is low, open the cap to add the required amount (3).
Use the same type and brand of oil as you already had in the engine.
3
Transmission oil
Recommended oil: NILS FOR TX CLUTCH
Capacity: 375 cc

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Workshop manual

Carburettor disassembly and inspection

CARBURETTOR

- Disconnect the fuel line and fuel tap, and remove the carburettor.

- Loosen securing clamps (1) and (2) of the carburettor from the inlet and air
filter nozzles.

- Remove the carburettor.

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Workshop manual

Carburettor disassembly and inspection

* For models with Keihin PWK28 carburettor

- Compress the gas valve return spring against the cover and remove the throttle
cable terminal through the channel in the gas valve.

- Remove the securing clamp from the piston valve of the cold start system.
(starter) and remove the assembly (1).

- Before removing the air volume adjustment screw (compensator)

from the low speed (idle) circuit (2), check its position by counting the
necessary turns to screw it to the stop (without forcing it). Note down
this measurement and remove it by unscrewing it (If in doubt, consult
the vehicle characteristics table to determine the standard position of
this screw).

- Loosen the screws of the carburettor float chamber and remove to access the
jets: maximum (1), minimum (2) and cold start (2), as well as the float and its
shut-off valve.

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Workshop manual

Carburettor disassembly and inspection

- Check that the cone at the end of the fuel flow control pin and the float
connector stud spring are in good condition, if not, replace with new ones.

- Check the condition of the fuel flow system piston valve. Replace it if
there is any damage to the vulcanised sealing seating or on the metal
body of the piston itself (scratches and/or corrosion exceeding 25% of
its total surface area).

- T horoughly clean all of the components of the carburettor with solvent (take
care not to damage the carburettor float chamber gasket or the cold start
piston valve O-ring).

- With compressed air, thoroughly blow clean all air and fuel flow holes.

-W
 ith a set of scales, check the weight of the float against what is marked on
it. Replace if that weight is exceeded.

-C
 heck the sizing of the jets against the numbering marked on them, fit
appropriate ones (see settings table), otherwise the performance of the
engine will be affected.

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Carburettor disassembly and inspection

- Check the position of the circlip on the conical dosing needle.

-B
 y moving the circlip upwards on the needle, a weaker mixture will be
produced and, by moving it downwards on the needle, a richer mixture will be
obtained; this allows adjustments for very extreme weather conditions.

- Replace the conical dosing needle if there is any damage to its

circumference.
- Check that there are no scratches on the conical tip of the minimum
circuit air adjustment screw, as this would affect its performance.

- Also check for scratches on the slide valve. Replace if the scratches
cover more than 25% of its total surface area.

-M
 ake sure that one with the same characteristics is fitted (see marking on its
base).

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Workshop manual

Carburettor disassembly and inspection

-R
 eassemble the carburettor completely. Re-mount the carburettor onto
the engine, making sure that the fuel lines and tap depressor activation are
properly connected.

- Check that the air volume adjustment screw (compensator) on the low speed
(idle) circuit is in the same position as before it was removed (if in doubt,
consult the vehicle characteristics table to determine the standard position).

- Check that the travel of the throttle cable is correct and that it does not
become caught or stiff at any point.

- Adjust the play on the throttle grip by tightening or slackening the throttle
cable cover tensioner located beside the throttle control until a play of 3 to 5
mm is obtained.

-R
 emove the foam from the air filter, wash in a mixture of soap and water, drain
and dry completely, then soak with special filter oil and reinsert it.

- Adjust the idle speed following the procedure below:

1. Start the engine.

2. Turn the slide valve rest position screw until the engine does not stall (screw in).

3. Turn the slide valve rest position screw again, slowly screwing in and out,
until a stable idle speed of 1,600 +- 200 rpm is obtained (use an external rev
counter).

4. Quickly perform the engine firmly using the throttle control and check that
the engine accelerates and decelerates smoothly and quickly with no gaps,
otherwise, change the position of the minimum circuit air adjustment screw
(TA) by a ¼ turn to point 3.
By screwing in the TA, a richer mixture will be obtained (with more fuel), while
unscrewing it will weaken the mixture (less fuel).

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Workshop manual

Carburation table

125 cc
Type of carburettor KEIHIN PWK28
Competition

Main jet 125

Idle jet 52
Needle JJH
Needle position 3rd from above
Throttle valve 3.5
Air screw 1v+1/4v , 1v+1/2v
Float level

250 cc
Type of carburettor Dell’Orto PHBL26BS KEHIN PWK28
Main jet 120 125
Competition

Idle jet 35 45
Needle D36 JJH
Needle position 3rd from above 3rd from above
Emulsion tube 270K
Throttle valve 60 3.5
Air screw 1v+1/4v from closed
Float level

280 cc
Type of carburettor Keihin PWK 28
Main jet 125
Competition

Idle jet 45
Needle JJH
Needle position 3rd from above
Emulsion tube
Throttle valve 3.5
Air screw 1 v from closed
Float level

300 cc
Type of carburettor Keihin PWK 28
Main jet 125
Competition

Idle jet 48
Needle JJH
Needle position 4th above
Emulsion tube
Throttle valve 3.5
Air screw 1v+1/4v from closed
Float level

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Reed block disassembly and inspection

REED BLOCK

- Remove the carburettor from the engine.

- Remove the inlet nozzle securing screws, after which you can release the reed
valve.

- Check that the reed petals are not cracked, deformed or broken. If they
are, replace them.

- Remove the fixing screws of the opening limiter and the petals of the inlet
reed, and check that there are no cracks in the mounting base of the petals; if
there are, replace the reeds.

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Exhaust system disassembly and inspection

EXHAUST SYSTEM

- Remove the rear structure of the motorcycle by unscrewing the bolts that hold
it.

- Disconnect the clamp that secures the air filter to the carburettor.

- Remove the filter box structure by disconnecting the electrical wiring.

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Exhaust system disassembly and inspection

- Unscrew the bolts that hold the exhaust elbow to the cylinder.

- Once the previous step has been carried out, release the exhaust elbow from
the muffler by pulling it, as shown in the photograph.

- Then remove the muffler.

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Exhaust system disassembly and inspection

- Release the muffler from the screw that holds it at the top, as shown in the
image.

- Continue unscrewing the upper bolt from the rear brake pump to release the
muffler from the bottom.

- Then extract the screw from the shock absorber that secures the muffler to the
frame.

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Exhaust system disassembly and inspection

- Once the bolts have been removed, extract the muffler from the rear part of
the motorcycle frame.

- Once the exhaust assembly has been removed from the motorcycle,
check that the system’s gaskets and couplings are in good condition to
prevent leaks.

- Also check the exhaust system for any deformations, dents or cracks which
could affect its proper functioning.

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Exhaust system disassembly and inspection

- To change the exhaust fibre, remove the screws that secure the rear plastic
part of the muffler to the metal part (see photograph).

- Then, with a nylon hammer, carefully tap the metal part downwards, as shown
in the photograph.

- Once the back part of the muffler has been removed from the exhaust system,
the fibre can be extracted.

- Replace the fibre with another one in good condition. To assemble the exhaust,
repeat the process described above in reverse.

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Cylinder head disassembly and inspection

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Cylinder head disassembly and inspection

CYLINDER HEAD

- Empty the coolant by removing the hose located in the water pump.

- Place a tray underneath to collect it.

- Remove the hose between the cylinder head and radiator.

- Disconnect the high-voltage cable from the spark plug (cap), and remove it.

- First loosen and then diagonally remove the 6 M6 screws and remove the
cylinder head cover.

Remove the cylinder head and its O-ring.

- Clean the carbon deposits without scratching or scouring the surfaces.

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Cylinder head disassembly and inspection

- Using a feeler gauge and straight edge ruler, check for warping on the bearing
planes, both on the cylinder head and on the cylinder.
Maximum warpage 0.05 mm.

Cylinder and piston disassembly and inspection

CYLINDER AND PISTON

- Drain the coolant from the engine.

- Remove the cylinder head cover from the cylinder head.

- Release the cylinder by unscrewing the 4 nuts that secure it (as shown in the
images).

- Remove the cylinder by pulling it upwards.

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Cylinder and piston disassembly and inspection

- Check the cylinder on the inside and make sure it is not scratched. If
there are any scratches or signs of wear, replace it.

- Place a clean cloth in the opening of the crankcase to prevent objects

from accidentally falling inside.

- Remove the circlips from the pin, and then continue with the pin, piston and
connecting rod end bearing.

- If it is necessary to push the pin out to remove it, hold the connecting rod
firmly and in the opposite direction to the pushing in order to avoid damaging
or deforming it.

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Cylinder and piston disassembly and inspection

- Remove the gasket from the base of the cylinder.

- Gently clean and remove any gasket debris and carbon deposits (avoid scratch-
ing the circumference of the piston).

-V
 isually check the condition of the connecting rod end. If there is damage to
the surface from contact with the needle roller bearing, replace it.

-V
 isually check the condition of the needle roller bearing of the connecting rod
end; if there is damage to the needles or cracks in the cage, replace it.

-R
 emove the rings by opening them from their tips and lifting them by the part
opposite them.

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Cylinder and piston disassembly and inspection

- Verify the distance between the tips of the rings (0.15mm/0.35mm),

inserting them in an aligned manner inside the cylinder and checking
the distance with a feeler gauge.

- Check the cylinder’s degree of wear with an alesometer. Calibrate it

beforehand using the dimensions contained in the cylinder-piston
families table.
- Carry out the check on two axes and at three heights.

- Check the diameter of the piston on the axis transverse to the pin at a
distance of 15 mm from the lower end of the piston skirt.

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Cylinder and piston disassembly and inspection

80cc MODEL FAMILY

CLEARANCE
Tolerance category CYLINDER PISTON
ASSEMBLY MAXIMUM
A 42.970 +0.01 42.940 0.030 0.080
B 42.980 +0.01 42.950 0.030 0.080
C 42.990 +0.01 42.960 0.030 0.080
D 43.000 +0.01 42.970 0.030 0.080

125cc MODEL FAMILY

CLEARANCE
CYLINDER PISTON CLEARANCE
ASSEMBLY MAXIMUM
53.970 ±0.005 53.950 ±0.005 0.020 0.080 0.080
53.980 ±0.005 53.960 ±0.005 0.020 0.080 0.080
53.990 ±0.005 53.970 ±0.005 0.020 0.080 0.080
54.000 ±0.005 53.980 ±0.005 0.020 0.080 0.080

250cc MODEL FAMILY

CLEARANCE
CYLINDER PISTON CLEARANCE
ASSEMBLY MAXIMUM
72.510 ±0.005 72.460 ±0.005 0.050 0.100 0.080
72.520 ±0.005 72.470 ±0.005 0.050 0.100 0.080
72.530 ±0.005 72.480 ±0.005 0.050 0.100 0.080
72.540 ±0.005 72.490 ±0.005 0.050 0.100 0.080

280cc MODEL FAMILY

CLEARANCE
CYLINDER PISTON CLEARANCE
ASSEMBLY MAXIMUM
76.005 ±0.005 75.950 ±0.005 0.055 0.100 0.080
76.015 ±0.005 75.950 ±0.005 0.055 0.100 0.080
76.025 ±0.005 75.950 ±0.005 0.055 0.100 0.080
76.035 ±0.005 75.950 ±0.005 0.055 0.100 0.080

300cc MODEL FAMILY

CLEARANCE
PISTON CLEARANCE CLEARANCE
ASSEMBLY MAXIMUM
78.950 ±0.006 0.056 0.100 0.100 0.080
78.960 ±0.006 0.058 0.100 0.100 0.080
78.970 ±0.006 0.060 0.100 0.100 0.080
78.980 ±0.006 0.060 0.100 0.100 0.080

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Workshop manual

Starter system disassembly and inspection

* For models with electric starter

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Workshop manual

Starter system disassembly and inspection

* For models with electric starter

STARTER SYSTEM

-R
 emove the gear shift pedal and the magneto flywheel alternator cover on the
left-hand side of the engine.

- T o release the magneto flywheel cover, remove the screws marked with arrows
in the photograph.

- Unscrew the bolt located in the centre of the flywheel.

- Once the bolt is removed, you can access the nut that secures the flywheel.

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Workshop manual

Starter system disassembly and inspection

- To unscrew the central nut, you will need puller Ref: MT280234045

- Using the extractor, a spanner and a ratchet, unscrew the central nut and
release the starter sprocket and ignition rotor.

- To remove the stator coil assembly, loosen and remove the screws (marked
with arrows in the photograph) that secure it to its support.

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Workshop manual

Starter system disassembly and inspection

- Release the ignition pick-up.

- Loosening and extracting the two bolts that secure it to the semi-crankcase.

- Once all of the fixing bolts are released, you can remove the stator assembly
and ignition pick-up.
Check for proper operation and, in the event of a fault, replace altogether the
component where the problem is located.

- Reassemble the assembly, paying special attention to the condition of the cot-
ter pin on the end of the crankshaft. Replace if it shows damage.

- To reassemble the components, follow the same steps in reverse.

Generator Coil 0.7 +- 0.07

Capacitor Charging Coil 15.8 +- 1.6
Pick Up Coil 101 +- 20%

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Workshop manual

Clutch assembly disassembly and inspection

CLUTCH ASSEMBLY

- Drain the coolant from the engine.

2
2
2
- Drain the transmission oil by removing the two plugs (clutch semi-crankcase
1
and crankcase base).

- Remove the water pump assembly. (1)

1

2 2 1
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Workshop manual

Clutch assembly disassembly and inspection

- Remove the screws from the clutch cover (2), cover and gasket.
This will provide access to the assembly of primary transmission elements, and
clutch.

-R
 emove the clutch assembly by removing the central nut that secures the
clutch. (3)

- Remove the driven clutch plate.

3

- Pay attention to the central bushing and set of washers (4).

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Workshop manual

Clutch assembly disassembly and inspection

- Extract the driving clutch plate, and remove all of the screws to access the
discs.

- Replace the disc if it has lost some of its lining, has thermal fatigue
(coloured) or is deformed, or its external crenellation is damaged.

- Check the clutch discs for warpage, max. 0.05mm using a gauge on a flat sur-
face.

- Visually check the teeth. If there are any signs of thermal fatigue
(coloured), loss of surface hardness coating or irregular wear of the
teeth (sharpening), replace the damaged components.

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Workshop manual

Crankcase disassembly and inspection

CRANKCASES

- Remove the thermodynamic assembly (cylinder head, cylinder and piston).

- Remove the magneto flywheel alternator.
- E xtract the bearing from the clutch sprocket, remove the circlip and then the
needle bearing.

- Once the needle bearings have been extracted, we will remove the kick-start
sprocket assembly.

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Workshop manual

Crankcase disassembly and inspection

- To remove the intermediate kick-start sprocket assembly (1), release the seeger
(2) and, once the washer has been removed, extract the kick-start sprocket
assembly.
1

- Once the above operation has been carried out, you can remove the bearing
and the corresponding washer.

- You can then remove the kick-start shaft.

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Workshop manual

Crankcase disassembly and inspection

- To be able to remove the sprocket (2), you must first extract the seeger (1)

- Once the above operation has been carried out, you can remove the sprocket,
using puller (1) Ref: MT280250006
1

- This is how it should be left after the sprocket has been removed.

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Workshop manual

Crankcase disassembly and inspection

- Remove the positioner and the selector shaft secured by means of a seeger
and washer (2).

- Once the above operation has been carried out, you can remove the selector
spring.

- Once all of the above disassembly steps have been carried out, this is what the
crankcase will look like.

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Workshop manual

Crankcase disassembly and inspection

- Remove the 9 screws that secure the left-hand crankcase.

9
8
1

7
2
4
6
3

- Pay special attention to screw (5). It incorporates a copper washer.

- This is how it should appear after the left-hand crankcase has been removed.
You can now extract the gear shift assembly.

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Workshop manual

Crankcase disassembly and inspection

- Remove the desmodromic.

- Pay special attention to possible wear of the fork.

If it shows wear, replace it.

- To reassemble, repeat the same steps in reverse.

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Workshop manual

Maintenance of the frame

BRAKE PADS
1
3
(1) Pad pin
2
(2) Screws
(3) Disc cover
(4) Front brake caliper
2
Changing the front brake pads
- Clean the brake disc with a high-quality degreasing compound if it is fouled
with oil or grease.
Change the pads if they are dirty.
- Loosen the pad pins.
4 - Remove the brake caliper mounting screws, disc cover, flange bushings and
caliper.

1 - Push the pistons completely inwards to enable the new brake pads to be fitted.
- Check the brake fluid level in the reservoir, as this operation causes the level to
rise.
- Remove pad pins (1) and brake pads (5).
- Clean the inside of the brake caliper, especially around the caliper pistons.

- Fit the new pads and secure them with two pad pins.

- Fit the caliper to the fork so that the disc is positioned between the pads, taking
care not to damage the pads.
- Apply a locking agent to the threads of the caliper mounting screws.
- Fit the disc cover and then fix and tighten the mounting screws. Tightening
torque: 25 +-2 Nm.
- Engage the brake lever to seat the caliper pistons against the pads.

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Workshop manual

Maintenance of the frame

1 BRAKE PADS

Changing the rear brake pads

(1) Brake caliper

2 (2) Adjustment tab/slot
3 (3) Pad pin
(4) Caliper piston

- Remove the rear wheel. (see pp. 54-55)

- Push piston (4) completely inwards to enable the new brake pads to be fitted.
- Check the brake fluid level in the reservoir, as this operation causes the level to
rise.
- Remove pad pins (3) and brake pad.
4 - Clean the inside of the brake caliper, especially around the caliper pistons.

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Workshop manual

Maintenance of the frame

(1) Brake pads

(2) Pad pin

- Fit the new pads and secure them with the pad pins.
- Fit the brake caliper bracket, aligning its slot with the swinging arm tab.
- Fit the rear wheel (see pp. 54-55).
2 - Engage the brake pedal to seat the caliper pistons against the pads.

15
7

6 14

5
4
14
5
13
7 12

3 11

10
9

22 23 24

16

2 1
21

20

18
17

19

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Workshop manual

Maintenance of the frame

REMOVING THE FRONT WHEEL

1
- Remove the fixing screws of brake caliper (1) and (2), and the disc cover.

- Loosen axle fixing screws (3) and (4).

Place the motorcycle on its stand and keep the front wheel off the ground.
Remove the axle and brake caliper to release the front wheel.

Do not engage the brake lever after removing the front wheel.
The caliper pistons would move, making fitting difficult.

3
WARNING
4
Dirt on the brake disc or pad reduces braking ability, which could lead
to serious injury or death.
Throw away the dirty pads and clean the dirty discs with a high-quality brake
degreaser.

FITTING THE FRONT WHEEL

- Clean the contact surfaces between axle (5) and axle clamps (6) then place the
front wheel between the fork tubes.

- Apply a thin layer of grease to the surface of the axle.

- Apply grease to the axle threads.
- Fit the axle from the right-hand side through the wheel and left-hand bushing.
- Tighten the axle to the specified torque.
6 Tightening torque 50 Nm +/- 5

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Workshop manual

Maintenance of the frame

- Fit front brake caliper (7) and the disc cover (8).
- Tighten mounting screws (9) to the specified torque.
7
Tightening torque 25 Nm. +/-2
9

9 With the front brake engaged, move the fork up and down several
times to seat the axle and check the operation of the front brake.

- Keeping the fork in parallel, tighten the axle clamping screw to the specified
torque.
Tightening torque 23Nm. +/-2

10

REMOVING THE REAR WHEEL

1
- Lift the rear wheel off the ground and rest it on a block or maintenance stand
positioned under the engine
3

Remove the following components:

- Axle nut (2) and transmission chain adjuster (1).
2
- Transmission chain (3).
- Axle (4), transmission chain adjuster and rear wheel.

Do not engage the brake pedal after removing the front wheel. The
2
caliper pistons would move, making fitting difficult.

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Workshop manual

Maintenance of the frame

WARNING
Dirt on the brake disc or pad reduces braking ability, which could lead
to serious injury or death.
Throw away the dirty pads and clean the dirty discs with a high-quality brake

4 degreaser.

FITTING THE REAR WHEEL

- Fit the rear brake caliper, aligning it with the caliper slide guide.
- Apply a thin layer of grease to the axle.
- Carefully position the rear wheel between the swinging arm so as not to dam-
age the disc.
- Insert the rear axle into the chain’s left-hand adjuster, side bushing and wheel.
- Apply grease to the axle nut thread and seating surfaces.
- Fit the chain’s right-hand adjuster and axle nut.
- Fit the transmission chain.
- If the master link retaining circlip has been removed, fit the transmission chain
with the closed end of the circlip in the direction of wheel rotation.
- Check and adjust the tension of the transmission chain.
- Tighten the axle nut to the specified torque.
Tightening torque 50 Nm +/- 5

REMOVING THE FORK

1. Front Mudguard Bridge

2. Left-hand suspension bar
3. Front mudguard
4. Right-hand suspension bar
1
2 4
- This is how it should appear after the left-hand crankcase has been removed.
You can now extract the gear shift assembly.

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Workshop manual

Maintenance of the frame

5. Top suspension clamp

6. Headlight holder
5 7. Bottom suspension clamp
6

7 - Remove the front wheel (see p. 53).

- Remove the front headlight holder, bridge and front mudguard.
- Loosen the top and bottom clamp fixing screws.
- Remove the fork tube by pulling downwards.

MAINTENANCE OF THE FORK

Dust covers

- The table below shows the cleaning intervals for the fork dust covers.

Failure to regularly clean the dust covers will result in dirt entering the
fork. This dirt can compromise the smoothness of the fork and cause
serious oil losses from the joints.

Intervals
Description of the After every three races After every race with the
operation with the presence of dirt presence of mud

√ √
Cleaning the fork dust
covers

Lift the edge of the dust cover and remove it from the seating of the outer tube.

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Workshop manual

Maintenance of the frame

- Use a cloth to clean away any traces of mud from the dust cover seating and
upper edge of the oil seal.

- Move the dust cover to one side and insert the cloth. Turn the dust cover until
all traces of dirt inside the sealing lips are removed.

- Lubricate the tube with a seal grease.

- Fit the dust cover spreading the grease by tuning it from right to left.

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Workshop manual

Maintenance of the frame

- Insert the dust cover into place, using the flat side of a screwdriver to help
position it.

MAINTENANCE OF THE FORK

Oil and seal change, right-hand side

- The table below shows the recommended oil change intervals.

Leaving the oil for too long without changing it leads to reduced fork
performance and oil thickening, which can cause leaks.

Intervals
Description of the
After the first 50 hours After 6 months
operation

√ √
Oil change

Proceed as follows:
- Perform a general cleaning of the suspension.
- Protect the surface of the pipe before closing it in a vice, as shown in the figure.

Lightly squeeze the clamp, making sure not to distort the tube.

- Use a 17 mm spanner to disengage the cover and fully unscrew it.

-58-
Workshop manual

Maintenance of the frame

- Remove cover (A) enough to disengage lock nut (B).

- Insert a 14 mm spanner into lock nut (B) and a 17 mm spanner into cover (A).
- Place the two components in the same clean place.

- Hold rod (E) to prevent it from falling, as shown in the figure.

- Pour the oil into a tray at the same time, move rod (E) back and forth, as shown
in the figure.

- Insert a tube into hole in the wheel (1) and unscrew the cover of the cartridge
with a 12 mm socket wrench. (2)

2
1

- Remove the pump locking screw together with the seal.

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Workshop manual

Maintenance of the frame

- Remove the cartridge from the tube.

- Turn the fork and remove the hydraulic end of stroke cone.

- Push the compression unit inwards and remove the seeger from its housing.

- Remove the compression assembly.

- Place the cartridge in an oil collection device and have the rod inserted in the
cartridge tube for complete drainage of the oil.
- Reinsert the hydraulic unit into the cartridge.
- Reinsert the seeger into its housing (see figure), making sure it is correctly
positioned.

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Workshop manual

Maintenance of the frame

- Insert the end of the cone into the bottom of the cartridge.

- Lift the edge of the dust cover and remove it from the seating of the bar.

- Remove the seeger from its housing.

- Secure the tube at the top to protect it (as shown in the figure), while deliver-
ing firm blows to the bar.
- Remove the oil seal and outer tube bushing

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Workshop manual

Maintenance of the frame

- Remove all insulating parts of the tube (A-B-C-D-E).

Replace part (A) with a new one.

- Grease the bushing seatings and oil seal.

- Squeeze the pipe in a vice, casing (X) checking that the non-discharge side is
against bushings (B).
- With firm blows of the outer tube, insert bushing (B) into its place. Check that
it is completely inserted.

- Secure the tube at the top to protect it (as shown in the figure), while deliver-
ing firm blows to the bar.
- Remove the oil seal and outer tube bushing

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Workshop manual

Maintenance of the frame

- Insert ring nut (C) against bushing (B), making sure that the edge of the ring nut
is facing upwards.

- Insert the oil seal into the tube (with the spring facing up) and close the tube in
a vice with the help of casing (X), with the drainage towards the seal.
- With moderate movements of the outer tube, insert oil seal (D) into its place.
This operation does not require much force. Avoid hitting the oil seal once it is
in place.

- Insert the seeger into its housing

-63-
Workshop manual

Maintenance of the frame

- Grease the tube with grease suitable for seals.

- Fit the dust cover spreading the grease by tuning it from right to left.

- Insert the dust cover into place, using the flat side of a screwdriver to help
position it.

- Insert the cartridge into the tube until it is seated at the bottom of the outer
tube.

-64-
Workshop manual

-P
 ress the cartridge axle against the bottom of the outer tube to fix the car-
tridge screw.

- Lightly squeeze the outer tube in a vice, making sure not to distort it and pro-
tecting it with a cloth.
- Insert an axle into the wheel pin hole and fix it with a tightening torque of 23.5
÷ 25.5 Nm.

- Place the suspension bar in a vertical position and add approximately 280 cc of
oil.
Use OJ 01 (SAE 5) oil.

- Pump the rod up and down until gentle braking can be felt during the return
stroke.

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Workshop manual

Maintenance of the frame

- Complete the filling of the oil and proceed as indicated below

- Holding the suspension in a vertical position, compress tube (F) and rod (E)
until the end of the stroke.

- Bring the oil up to the proper level (see table below) from the top edge of the
pipe (keep the tube and rod at the end of the stroke).

Motorcycle model Year Oil level Type of oil

GasGas 2012 55 OJ 01
GasGas (aluminium) 2013 75 OJ 01

- Screw the cover completely by hand (after having the lock nut in the fully un-
screwed position) on rod (E), as shown in the figure.

- Hold cover (A) and screw it against lock nut (B) with a tightening torque of 14.7
Nm, as shown in the figure.

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Workshop manual

Maintenance of the frame

- Completely tighten the tube cover with a 17 mm spanner at a torque of 11.7 ÷

13.7 Nm.

MAINTENANCE OF THE FORK

Oil and seal change, left-hand side

- The table below shows the recommended oil change intervals.

Leaving the oil for too long without changing it leads to reduced fork
performance and oil thickening, which can cause leaks.

Intervals
Description of the
After the first 50 hours After 6 months
operation

√ √
Oil change

Proceed as follows:
- Perform a general cleaning of the suspension.
- Protect the surface of the pipe before closing it in a vice, as shown in the figure.

Lightly squeeze the clamp, making sure not to distort the tube.

- Use a 17 mm spanner to disengage the cover and fully unscrew it.

-67-
Workshop manual

Maintenance of the frame

- Completely remove cover (A) and put it in a clean place.

- Remove tapered spacer (B) and put it in a clean place.

- Remove spacer (C) and put it in a clean place.

- Remove washer (D) and put it in a clean place.

-68-
Workshop manual

Maintenance of the frame

- Slowly extract spring (E).

- Wipe off oil from the spring with a cloth.

- Put all parts in a clean place.

- Pour the oil into a container as shown in the figure.

To prevent damage to the environment, collect the used oil and send it
to a waste treatment centre.

-69-
Workshop manual

Maintenance of the frame

- Squeeze the two clamps in a vice, protecting them with a cloth.

- Unscrew the pump nut with a 12 mm spanner.

- Remove the screw and oil seal.

- Remove the complete pump unit.

- Turn the fork the opposite way and remove the end of the stroke cone.

-70-
Workshop manual

Maintenance of the frame

- Lift the edge of the dust cover and remove it from the seating of the bar.

- Remove the seeger from its housing.

- Secure the tube at the top to protect it (as shown in the figure), while deliver-
ing firm blows to the bar.
- Remove the oil seal and outer tube bushing

- Remove all insulating parts of the tube (A-B-C-D-E).

Replace part (A) with a new one.

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Workshop manual

Maintenance of the frame

- Grease the bushing seatings and oil seal.

- Squeeze the pipe in a vice, casing (X) checking that the non-discharge side is
against bushings (B).
- With firm blows of the outer tube, insert bushing (B) into its place.
Check that it is completely inserted.

- Insert ring nut (C) against bushing (B), making sure that the edge of the ring nut
is facing upwards.

Insert the seeger into its housing

-72-
Workshop manual

Maintenance of the frame

- Insert the oil seal into the tube (with the spring facing up) and close the tube in
a vice with the help of casing (X), with the drainage towards the seal.
- With moderate movements of the outer tube, insert oil seal (D) into its place.
This operation does not require much force. Avoid hitting the oil seal once it is
in place.

- Insert the seeger into its housing

- Grease the tube with grease suitable for seals.

-73-
Workshop manual

Maintenance of the frame

- Fit the dust cover spreading the grease by tuning it from right to left.

- Insert the dust cover into place, using the flat side of a screwdriver to help
position it.

- Insert the end of the cone and then the cartridge into the outer tube.

- Squeeze the outer tube in a vice, protecting it with a cloth.

Hold the tube at the end of the stroke and, using the fork spring, fix the pump
screw.

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Workshop manual

Maintenance of the frame

- Screw the plug with a tightening torque of 23.5 ÷ 25.5 Nm.

 lace the suspension in a vertical position and add some new oil. Use OJ 01
-P
(SAE 5) oil.

Motorcycle model Year Oil level Type of oil

GasGas 2012 110 OJ 01
GasGas (aluminium) 2013 130 OJ 01

- Pump the tube several times and position it at the end of the stop.
Bring the oil up to the proper level (see table below) from the edge to the top
of the tube.

- Following the sequence shown in the photographs below, insert spring (E),
washer (D), spacer (C) and finally tapered spacer (B).

-75-
Workshop manual

Maintenance of the frame

- Completely tighten the tube cover using a 17 mm spanner with a tightening

torque of 11.7 ÷ 13.7 Nm.

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Workshop manual

Maintenance of the frame

REAR SHOCK ABSORBER

Settings and configuration

- The preloading of the shock absorber is adjusted by rotating toothed rings (C)
with two special spanners.
- Starting from the standard preloading of 7.5 mm for 300-280-250 and 7 mm
for 125, tighten or loosen, depending on the weight of the rider, reaching a
maximum of 9 mm of preloading. (see spring and preloading table).
- Preloading is the difference in length in mm between a spring when it is ten-
sioned and when it is at rest.

ÖHLINS SHOCK ABSORBER

Rider weight without Spring preloading
K (N/mm) spring
equipment (Kg) (mm)
Up to 70 65 7
From 70 to 85 70 7.5
Over 85 75 From 7 to 8.5

- The rebound or extension is adjusted with the screw. Its standard position is 20
clicks from closed. From this starting position, open clicks if faster extension or
rebound is sought and close clicks if slower extension or rebound is desired.

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Workshop manual

Electrical diagrams
-78-
Workshop manual

TXT approved electrical system

-79-
Workshop manual

TXT ignition electrical system

-80-
Workshop manual

CONTACT approved electrical system

-81-
Workshop manual

CONTACT ignition electrical system

-82-
Workshop manual

TXT - 80 - School electrical system

-83-