2009 GAS GAS TXT PRO TECHNICAL SPECIFICATIONS AND OWNER'S MANUAL

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Filed Under (Gas Gas) by admin on 28-11-2010

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ENGINE 2 stroke, single cylinder, direct reed valve crankcase induction. Liquid cooled. 125 cc. engine Cylinder size 124,8 cc. Bore and stroke 54 x 54.5 mm. 200 cc. engine Cylinder size 175,3 cc. Bore and stroke 64 x 54,5 mm. 250 cc. engine Cylinder size 247,7 cc. Bore and stroke 72,5 x 60 mm. 280 cc. engine Cylinder size 272,2 cc. Bore and stroke 76 x 60 mm. 300 cc. engine Cylinder size 294,1 cc. Bore and stroke 79 x 60 mm. Carburettor, diameter of the diffusor 26 Lubrication system Mixture (50:1)(2%) 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 progressive with diaphragm system by GAS GAS* (Patented). Driving 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)
-11- Primary reduction ratio 2,777 (75/27) Final reduction ratio 3,818 (42/11) Overall drive ratio 8,704 (6th. gear) Transmission oil Capacity 550 cc. Type 10W40 API SF o SG. FRAME Type Tubular profile made with Cr-Mo. Tyres Front 2,75 x 21″ Trial Rear 4,00 x 18″ Trial tubeless. Suspension Front Adjustable tele-hydraulic fork ø 40 mm. (125 / 200). Adjustable tele-hydraulic fork ø 40 mm with aluminium bars (250 / 280 / 300) Rear Variable progressive system with mono-shock multiadjustable. Suspension stroke Front 177 mm. Rear 164 mm. Front fork oil SAE 5. Front fork oil level ø 40 mm.(125 / 200) 180 mm. air chamber steel bar ø 40 mm. (250 / 280 / 300) 160 mm. air chamber aluminium bar BRAKES Type Disc brake. Disc diameter Front ø185 mm. 4 piston calipers. Rear ø150 mm. 2 piston calipers. DIMENSIONS Overall height 1180 mm. Overall width 820 mm. Seat height 650 mm. Ground clearance 315 mm. Wheelbase 1330 mm. Fuel tank capacity 3,1 liters.

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HARLEY-DAVIDSON 5 Speed Transmissions 1984 – 1999 EVO / 5 Speed & 1999 – 2006 Twin Cam Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-11-2010

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Remove Original Parts From Vehicle. 2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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Harley-Davidson Motorcycle Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 Figure 2. Exposed Shoulders Mark shifter fork rod flush with case Remove Spacers Vehicle Transmission Counter Shaft Main Shaft Front of Motorcycle Figure 1
Reverse Gear Installation Instructions For EVO / 5 Speed and Twin Cam Harley-Davidson® Motorcycle Page 3 of 6 Revision 7 © 2007 Champion Motorcycle Accessories International, Inc. dba Champion Sidecars 11841 Monarch Street Garden Grove, CA 92841 (800) 875-0949 (714) 847-0949 www.championsidecars.com www.championtrikes.com Figure 6 CAUTION: Do not pull the shifter fork rod out of the transmission more than 1/4″. If you pull the shifter fork rod out too far, it will be difficult to realign it with the internal shifter fork. 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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