Gas Gas 2004 Motorcycles

GAS GAS Motos, S.A. has already completed its range of motorcycles and quadricycles
for the 2004 season. The main developments apply mostly to Trial, two- and four-stroke
Enduro (FSE) models, together with cross-country motorcycles and the new family of
quads; whilst all Pampera, Supermotard, Rookie and Boy models have just been
redecorated, a number of technical improvements having already been carried out during
the season.
Once again, competitions have proved an unbeatable test bed for such evolution of the
GAS GAS products. Adam Raga’s victory in the Indoor-Trial World Championship, with
relevant expert advice from Jordi Tarrés, the holder of seven World Championship titles;
or the crown achieved by Petri Pohjarno in the Enduro World Championship, among many
other things, have helped to improve these models through the implementation of a great
many small changes which now result in an extremely reliable, high-quality range. Having
joined a number of competitions, both the Wild HP quad and the cross-country motorcycles,
ridden by true experts in the various European championships, have led to the achievement
of an exclusive, most competitive product.
Within the TXT Pro range, the aim has been to achieve a highly robust product that would
prevent deflections, especially at the front, by means of a new Marzocchi fork and a 25mmdiameter
wheel axle, together with the implementation of a new rating to the Sachs rearsuspension
shock absorber, always keeping weight at minimum levels. In the Enducross
(EC) range we have continued to improve the rider’s position and have modified our (fourstroke)
FSE model, fitted with an electronic-injection system that makes it a revolutionary
unit. The development of the EC units has resulted in technical benefits for the MC (crosscountry
motorcycles) range, which has also been given an extremely aggressive, attractive
look. The expanded quad family has been fitted with a number of elements that turn these
units into the ideal sports machines for “devouring” the hills.
When the August 2002-July 2003 financial year is about to close, the quality of its products
has allowed this Gerona province-based company to once again increase its production
figures beyond the 14,000-unit mark, all models included, with an expected turnover of
EUR 59.50 million and shipments amounting to 75% of its yearly output to 45 countries all
over the world. The 2004 output of new-range motorcycles is expected to reach the 16,000-
unit mark, with a total turnover in the region of EUR 70 million.
Applying the best from racing to production machines

Trials: TXT Pro range

Production units fitted with the features of the motorcycle
that won the World Championship
The trial speciality being one of the mainstays of the
company, the new 2004 TXT Pro have been redesigned
to give them a stronger racing-unit appearance that
provides production machines with the best from the
trial motorcycles.
One of the great novelties is the fitting of a new Marzocchi
front fork with a larger diameter of 40 mm in the larger
displacement models and 38 mm in the 125cc and 200cc units. This
larger bar diameter provides a proportional increase in the rigidity of the
whole unit and prevents every possible frame deflection.
The 2004 TXT Pro units have also been fitted with a new rear-suspension shock
absorber and consequently a new rating resulting from the experience drawn over a number
of years by the pilots of the company’s official World-Championship team. The clutch discs
are new, too, and their better quality ensures a constantly smooth disc surface. The original
mouldings have been modified to provide both the clutch and the new crankcase covers
with a better finishing.
The starting pedal is also brand new and has been re-styled in an interesting manner. For
this series, the rocker shaft has been made in aluminium. This change in material provides
lighter components (one of the distinguishing features of the TXT Pro, when compared
with other brands, is its much lower weight) without ever losing any of its mechanical
properties. Also, the front-wheel axle has now an increased diameter. The new arrangement
provides the long sought-after rigidity while highlighting the prevention of deflections in the
whole of the front structure.
Aluminium is also the component used for the chain tensioner and the new intermediate
exhaust (with the resulting lower weight for the whole assembly), while the end silencer
has been given a new look.
Yet another great novelty offered by the 2004 TXT Pro range is a new sheet housing fitted
with a nozzle. This item has evolved towards a more compact design of its components, in
an effort to improve any possible assembly, disassembly or repair operations.
The modifications also include a new crankshaft (and bearing) retainer that makes
assembling easier, and a new thermocontact that has been made smaller by integrating it
into the radiator and which provides a better performance without restricting any features
of the whole unit. The new radiator improves the cooling capacity available; and other new
items are the rectifier, the cylinder head and the fuel tank, the latter having been given a
better finishing and redesigned to dispense with the devaporizer hole. More specifically,
the devaporizer has been added to the fuel-tank cap and is now made of polyamide. This
Production units fitted with the features of the
motorcycle that won the World
Championship
also means that the cap cannot be easily lost, as it will remain joined to the devaporizer
tube in case of an incorrect closing procedure. The brake-fluid reservoir has been relocated
in order to improve the assembling of the filter housing.
With a view to offering a competitive, reliable product with an attractive appearance, apart
from the new decoration a clear evolution towards a better design has also been achieved
by means of a more attractive-looking chain- and front-disc guard. Finally, access has
also been improved through the fitting of a new brake tip.
All of the above changes involve the five TXT Pro engine specifications available (125,
200, 250, 280 and 300), but some of them only apply to the lower displacements.

Summary of changes to the TXT Pro 2004

- Marzocchi forks, 40 mm diameter in Titanium Nitride,
with wheel hub of 25 mm diameter to increase the
rigidity of the assembly. Models 250 / 280 / 300.
- Marzocchi forks, 38 mm diameter. Models 125 / 200
- New settings of the Sachs shock absorbers based on
experience gathered during the previous season by
our official World Championship riders.
- New clutch discs.
- Aluminum intermediate silencer.
- New end silencer in line with the overall aesthetic
styling. Models 125 / 200.
- New forged kick-start pedal.
- Aluminium rocker arm.
- New reed valve assembly with inbuilt nozzle.
- New rectifier, with improved performance.
- New polyamide cover and fuel tank.
- New chain guard, in line with the overall aesthetic
styling.
- New front disc protector, in line with the overall
aesthetic styling.
- New Ducati starter.
- New brake fluid tank, easing filter box assembly.
- New decoration. Overall aesthetic restyling. Using
new materials, we combine matt and high-gloss
finishes.
- Aluminium chain tensor.
- New reed valve filters, to ensure removal of water.

TXT Pro Raga, E.L.
Besides developing its 2004 Trial range,
GAS GAS has produced a limited
edition (E.L.) of 300 replicas of the
motorcycle used by Adam Raga to win
the 2003 Indoors Trial World
Championship. The specification items
distinguishing this more racing-like
model from standard production
machines are given below.
- Mg – T6 (T6 magnesium) crankcase
- Mg – T6 Rocker
- Mg – T6 clutch covers
- Öhlins shock absorbers
- ’04 disc guard
- ’04 chain guard
- 38-diameter Marzocchi suspension
- Aluminium chain tensioner
- Fully racing-like brake pump
- Limited-series exclusive decorations
(numbered chassis and rocker signed
by Adam Raga)
- ’04 clutch disc
- ’04 tank cap
- ’04 starting lever
- Rocker axle inaluminium
- Aluminiumdesmodromic device
- Ducati ignition
 

Enduro: EC 125/200/250/300

All GAS GAS  Enducross (EC) motorcycles are
meant for demanding users
interested in highperformance units, as shown by the results achieved
through sports competitions. Due to a number of unique
modifications, basically involving the chassis, the improvement of this range goes on to
achieve a motorcycle that is both powerful and light, with good suspension systems and
top-class brakes, plus a high level of riding comfort.
Further to the small chassis modifications of the previous edition, consisting in the slight
closure of the steering and a fractional relocation of the engine at the front –which gave it
the status of best Enduro chassis as far as performance was concerned, according to the
most respected specialised magazines–, one of the achievements of the 2004 models is
the improved driving position of the rider through the fitting of an upper flange with two
alternative handlebar positions and a slightly different tank location, all of which is very
much in line with the company’s style, even if it has become less conventional than in the
past. Thus, the new range combines a very efficient driving position with such qualities as
stability at high speeds and excellent manoeuvrability under any working conditions. All of
this highlights a performance further improved by the use of a perimetric-type chassis.
Still on the cyclo area, all GAS GAS EC units feature a Marzocchi suspension on the front
assembly and an Öhlins one on the rear. For 2004, new adjustments have been applied to
the front suspension to improve the response of the assembly and for a higher performance,
whilst increasing the accuracy of the whole motorcycle. GAS GAS prefers rather soft
ratings giving top priority to comfort considerations, a suspension type that provides
substantial advantages in rocky, uneven, slow areas.
As in the case of the Trial units, here a more rigid structure has also been achieved whereby
deflections within the whole of the front assembly are successfully prevented through a
front wheel with a larger axle diameter.
In spite of the fact that GAS GAS always provides plenty of braking power, the brakes,
especially the rear one, have also been modified. The 2004 models feature brake shoes
made of a different compound that improves their performance at high temperatures. Added
to the brake-disc improvement, this provides higher heat resistance and a more accurate
response to braking actions. An improved touch of the front-brake whip has also been
achieved.
As in the case of the TXT Pro units, all GAS GAS Enduro motorcycles now include a new
fuel-tank cap with an integrated devaporizer that has been further developed through the
use of polyamide as its core material and a much more compact design.
Yet another development of the updated EC range is a new steel centrifugal pinion. This
change in the material used extends the duration of the adjustments and makes things
much easier for the rider. The timing has also been improved for a better overall performance.
Within the realm of aesthetic considerations, three features become immediately
obvious: the new rear mudguard, the number-plate holder, and the 2004 decoration that is
standard for the whole range.
These changes affect all of the two-stroke EC units. The details of every engine specification,
including major drive modifications as per the various displacements available, especially
for the Enducross 250cc and 125cc versions, are as follows:
 

Chassis                                              125 200 250 300
- Superior grip with two positions on handlebars      X   X   X   X
- New settings on front-wheel suspension              X   X   X   X
- Improved touch control of front brake               X   X   X   X
- Larger diameter axle on front wheel                 X   X   X   X
- New fuel tank allowing an improved riding position  X   X   X   X
- New seat allowing an improved riding position       X   X   X   X
- Shock-absorber with double compression settings     X   X   X   X
- Different composition of rear brake pads            X   X   X   X
- Improved heat resistance of rear disc               X   X   X   X
- New rear mudguard                                   X   X   X   X
- New registration plate support                      X   X   X   X
Engine                                                    125 200 250 300
- New exhaust valves with improved performance at low revs X
- New, lighter piston                                      X       X   X
- Reinforced primary and secondary pinions                 X
- Improved lubrication of secondary shaft                  X
- New distribution                                             X   X   X
- New reed valve assembly                                          X
- New exhaust                                                      X
- New steel centrifugal pinion                                 X   X   X
 

Four-stroke: Blue blood for the majestic FSE 450

As in the case of their two-stroke
counterparts, the FSE (Four-Stroke
Enducross) feature all of the innovations
affecting the EC range, but these
modifications reach further afield, both in the
cyclo and engine areas.
Stemming from 100% Enduro origins,
this motorcycle is best described as
one that is extremely easy to ride
(relaxed, comfortable position for the pilot)
and fitted with rather soft suspension
systems and new adjustments at the
front (Marzocchi). Its new blue
decoration points in the direction
of the numerous small
modifications carried out in this
unit, which make it majestically
elegant.
Having fitted it with a computercontrolled
electronic-injection
system and the appropriate diagnosis
software for checking out its
various components, GAS GAS took
one great step towards perfection by definitely getting rid of the carburettor. The injection
system provides better, quicker responses from a drive placed in a position slightly closer
to the front end than in previous versions. The starting engine is more powerful and includes
a clutch system on the pinion cascade.
Magnesium is the material used for making the new disc and ignition cover, together with
the lower register cover, which affects the overall weight. The alternator and regulator
(Ducati Energia) also cut down the weight and improve the overall inertia. The gearbox
has been fitted with needle bearings.
Within the cyclo area, the motorcycle features a petrol tank fitted with a returnless device
and a single fuel line reaching from the wing-nut body to the automatic-valve petrol pump,
plus a quick connector in between. Under the wing-nut body an expansion vessel has
been fitted, to further both the overall simplicity of the assembly and its reliability.
The inner chassis includes a shorter oil-return line, whilst the longer accelerator cable has
been protected from contact with the cylinder head. Another decorative, more convenient
item is the new digital odometer with larger, easier-to-handle buttons, designed to be used
by the rider with his/her gloves on. The handlebars, fitted with the same grips as the EC
models, are higher and position-adjustable. Due to the policy of carrying out modifications
that take into account the users’ needs, the new FSE has been fitted with a more powerful
radiator. The new radiator features a fan that prevents the engine from heating up when
the motorcycle is used in slow areas; its activation is immediate whenever the temperature
rises above a preset level.
 

FSE450 2004
Cross
Chassis
Superior grip with two positions on handlebars
New settings on front-wheel suspension
Improved touch control of front brake
Larger diameter axle on front wheel
Shock-absorber with double compression settings
Different composition of rear brake pads
Improved heat resistance of rear disc
New rear mudguard
New registration plate support
New blue decoration
Fuel tank with return-less system (a single pipe connecting the butterfly housing to the
fuel pump) with 1 quick connector in the middle
Throttle grip like that used on the EC model
Longer fuel pipe protected against possible contact with the cylinder head
Radiator with increased cooling capacity
Expansion chamber located under the butterfly housing
Chassis with internal oil return feed
Shorter oil return feed
Mileometer with larger buttons for ease of use when wearing gloves
Engine
Multiple geared starter motor with clutch
New fuel injection programme
More powerful starter motor
Cast magnesium disc cover
Cast magnesium ignition cover
Lower inspection cover in magnesium
Cylinder head cover with exhaust to air filter
Gear shift with needle bearings
Lighter and more responsive Ducati Energia alternator and regulator

Motocross: units inherit the best from the Enduro range

The experience gathered in the Spanish Championship has brought about the logical
evolution within the GAS GAS range of cross-country motorcycles; which, added to the
fact that these units stem directly from the Enduro range, means that many of the small
changes implemented in the EC units have also been applied to the 125cc and 250cc MC
versions.
Thus, the rider’s position has been one of the aspects for improvement, by means of a
two-position upper flange on the Hebo handlebars; simultaneously, this aspect has also
been improved through a new saddle (filled with slightly softer foam) and a new tank.
An analysis of the cyclo area based on assessments made by users has resulted in new
ratings for the front suspension system, with softer springs and a better hydraulic hold,
plus a dual compression-adjustment shock absorber. As for the brakes, a new compound
material for the rear-brake shoes provides an improved touch, whilst the disc features
higher heat-resistance levels.
One aspect that warrants highlighting is the aggressive, powerful look acquired by this
unit through a redesigned decoration that gives it the appearance of an extremely
demanding motorcycle, as far as riding it is concerned; but also one that is extremely
comfortable and simple to handle.
The 125cc MC engine has been fitted with new exhaust valves providing a better performance
at low rpm rates, whilst the 250cc one features new timing and a new sheet housing.
The following summary of the above innovations provides a more detailed picture of the
main changes carried out in both engine specifications:
 

Cross 125- 250 of 2004 (modifications)                     125 250
- Superior grip with two positions on handlebars             X X
- New Marzocchi forks diameter 50 with double casing         X X
- Improved touch control of front brake                      X X
- Larger diameter axle on front wheel                        X X
- New fuel tank allowing an improved riding position         X X
- New seat allowing an improved riding position              X X
- Shock-absorber with double compression settings            X X
- Different composition of rear brake pads                   X X
- Improved heat resistance of rear disc                      X X
- New rear mudguard                                          X X
Engine
- New exhaust valves with improved performance at low revs   X
- New, lighter piston                                        X X
- Reinforced primary and secondary pinions                   X
- Reinforced primary and secondary pinions                   X
- New distribution                                             X
- New steel centrifugal pinion                                 X
 

A list of the modifications made to the remaining
models in the 2004 GAS GAS range
BOY TRIAL 50
- Red colour replaces previous blue.
- New decorations.
BOY ENDURO 50
- New decorations similar to those on more
powerful units, 2004 EC model.

ROOKIE TRIAL 80
- New plastics.
- New rear mudguard.
- Filter housing.
- Swivel-mounted shaft.
- New wheels.
- Noiseless medium.
- New end silencer.
- Everything like the pro model.

ROOKIE ENDURO 50
- New plastics, similar to those on more powerful units, 2004 EC model.
- Introduction of number side plates.
- New rear mudguard.
- New decorations (totally new).
- Plastic oil reservoir, for mixture, independent from chassis.

PAMPERA
- Improved chassis manufacture for higher quality.

EC 125 SUPERMOTARD
CHASSIS
- Top flange with two positions on handlebars.
- Improved touch of the front-brake whip.
- New tank, allowing a better riding position.
- New saddle, allowing a better riding position.
- A different compound used for the rear brake shoes.
- New rear mudguard.
- New number-plate holder.
- Odometer fitted with larger keypads for improved use, even when wearing gloves.
ENGINE
- New exhaust valves for better performance at low revolutions.
- New, lighter piston.
- Strengthened first and second pinions.
- Better lubrication for output shaft.

EC 250 SUPERMOTARD
CHASSIS
- Top flange with two positions on handlebars.
- Improved touch of the front-brake whip.
- New tank, allowing a better riding position.
- New saddle, allowing a better riding position.
- A different compound used for the rear brake shoes.
- New rear mudguard.
- New number-plate holder.
- Odometer fitted with larger keypads for improved use, even when wearing gloves.
ENGINE
- New, lighter piston.
- New timing.
- New sheet housing.
- New steel centrifugal pinion.

FSE 450 SUPERMOTARD
CHASSIS
- Top flange with two positions on handlebars.
- Improved touch of the front-brake whip.
- A different compound used for the rear brake shoes.
- New rear mudguard.
- New number-plate holder.
- New blue decorations.
- Returnless-fitted petrol tank (one single pipe from the wing-nut body to the petrol
pump) and one quick connector in between.
- Accelerator grip like the one fitted on the EC model.
- Longer accelerator cable, protected from contact with the cylinder head.
- Radiators providing higher cooling power.
- Expansion vessel fitted under the wing-nut body.
- Odometer fitted with larger keypads for improved use, even when wearing gloves.
- Better location for battery resulting in a more comfortable saddle.
- Chrome-plated chassis.
ENGINE
- Starting-motor pinion cascade with returnless clutch.
- New injection program for low-rpm torque improvement and fitting of warm-up strategy
for a better cold start.
- Increased power of starting motor for improved motorcycle start.
- Injected-magnesium disc cover.
- Injected-magnesium ignition cover.
- Magnesium lower register cover.
- Cylinder-head cover with exhaust towards air filter.
- Gearbox fitted with needle bearings.
- Lighter, lower-inertia Ducati Energia alternator and regulator.
- New crankshaft rebalancing for fewer vibrations at low rpm.
- Cylinder head fitted with oil-pressure sensor.

Information kindly provided by:

For GAS GAS written or graphical press releases
JAS Info Service
Raimon d’Abadal, 29 2°
08500 Vic (Barcelona)
Tel. 93.885.22.56 – Fax 93.885.64.98
jas@jas.es - www.jas.es/gasgas

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