um DSR EX 125 Workshop Manual
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um DSR EX 125 Workshop Manual

Engine 125 4t / 4v 6m euro 4
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ENGINE 125 4T / 4V 6M EURO 4

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  • Page 1 WORKSHOP MANUAL ENGINE 125 4T / 4V 6M EURO 4...
  • Page 2 This manual has been produced by UM Motorcycles for use by UM dealer and sub-agency workshops. It is assumed that those using this publication for training purposes and for repairing UM vehicles, have a basic knowledge of mechanics and of the methods inherent in the technique of vehicle repair. Significant variations in the characteristics of the machines or in the specific repair operations will be communicated by means of updates to this manual.
  • Page 4 INDEX GENERAL INFORMATION Pag. 4 ENGINE SPECIF ICATIONS Pag. 12 TIGHTENING TORQUES Pag. 13 IDENTIFICATION OF SETS Pag. 15 ELECTRICAL SYSTEM SPECIFICATIONS Pag. 19 LUBRICATION CIRCUIT Pag. 21 COOLANT CIRCUIT Pag. 23 PERIODICAL INSPECTIONS AND ADJUSTMENTS Pag. 34 DISMANTLING THE ENGINE Pag.
  • Page 5 - Petrol is extremely inflammable and in certain conditions may explode. Smoking must not be allowed in the work area, nor should there be naked flames or sparks. MAINTENANCE REGULATIONS Use genuine UM spare parts and lubricants recommended by UM. Non-genuine or unauthorised parts may damage the machine. Only use the specific tools intended for this machine.
  • Page 6 GENERAL INFORMATION IDENTIFICATION MODEL CHASSIS CODE ENGINE CODE DSR EX 125 M6FDS0001Hxxxxxxx DSR SM 125 UXPI 125 RENEGADE SCRAMBLER CLASSIC 125 M6FSC0001Hxxxxxxx RENEGADE SCRAMBLER SPORT 125 xxxxxxx DSR ADVENTURE 125 M6FDA0001Hxxxxxxx DSR ADVENTURE TT 125 ENGINE CODE The engine code can be found at the back of the engine, in front of the rear wheel.
  • Page 7 GENERAL INFORMATION P REPARATION FOR REMOVAL AND DISMANTLING Remove all the dirt, grime, dust and other foreign material before removing and dismantling. Use properly cleaned tools and equipment. See “ SPECIAL TOOLS ”. On dismantling parts, always keep related items together. This includes gears, cylinders, pistons and other parts sub- mitted to natural wear together.
  • Page 8 GENERAL INFORMATION SPARE PARTS Use only genuine UMspare parts. For all lubrication tasks, use oils and greases recommended by UM. Other makes make seem similar in their function and appearance, but are inferior in quality. SEALS, RETAINING RINGS AND O...
  • Page 9 GENERAL INFORMATION TDC measuring tool. LOCKING RINGS Examine all the locking rings carefully before fitting. Always replace the gudgeon pin circlips after every use. Replace dis- torted locking rings. On fitting a locking ring (1), ensure that the sharp edge (2) is on the opposite side to the force (3) to be applied to it.
  • Page 10 GENERAL INFORMATION Ref. 864592 Ref. T01010045 TDC measuring tool. Ref. 00H05300041 Ref. T01010042 Clutch bell housing fitting tool. Ref. 864486 Ref. T01010043 Balance shaft locking tool. Ref. 864567 Ref. T01010044 Set of camshaft locking keys. WORKSHOP MANUAL...
  • Page 11 GENERAL INFORMATION Ref. 864487 Ref. T01010050 Crankshaft sprocket locking tool. Ref. 864868 Ref. T01010051 Magneto flywheel extractor tool. Ref. 865261 Ref. T01010049 Piston fitting clamp. Ref. 865207 Ref. xxxxxxxx Set of tools for 125cc 4-stroke 4 valve engine. WORKSHOP MANUAL...
  • Page 12 GENERAL INFORMATION Engine EURO 4 single cylinder 4-stroke Diameter x stroke 58x47 mm 124.2 cm 3 Cubic capacity Cooling Water Electric Starter 12:1 Compression ratio Cv: 15,5 Kw:11,4 a 9250 at the crankshaft Maximum nominal power Cv: 14,0 Kw:10,3 a 9250 at the rear wheel Fuel Lead-free petrol Lubrication system...
  • Page 13 ENGINE SPECIFICATIONS TRANSMISSION 2,38 Primary transmission ratio First gear ratio Second gear ratio Third gear ratio Fourth gear ratio 1,08 Fifth gear ratio 0,96 Sixth gear ratio 14/51 = 3,64 Secondary transmission ratio WORKSHOP MANUAL...
  • Page 14 TIGHTENING TORQUES THREAD TIGHTENING TORQUE PARTS TO BE TIGHTENED QTY. Obs. DESCRIPTION Kgf.m N·m MEASUREMENT 1,2-1,4 12-14 Spark plug Bolt 1-1,2 10-12 Rocker cover 10-12 Bolt 1-1,2 Camshaft bridge 2,5-2,7 25-27 Bolt Timing crown wheel 1 2,5-2,7 25-27 Bolt Timing crown wheel 2 2,7+90°...
  • Page 15 TIGHTENING TORQUES TORQUE DE APRIETE MEDIDA DE PIEZAS A APRETAR CANT. Obs. DESCRIPCIÓN LA ROSCA Kgf.m N·m Magneto cover Bolt 1,1-1,3 11-13 Oil sensor cable securing device Bolt 0,3-0,5 Neutral sensor indicator M10x1,25 0,8-1,0 8-10 Oil dipstick M12x1,5 0,4-0,6 Magneto stator 0,5-0,7 Bolt Pick-up.
  • Page 16 SETS IDENTIFICATION CRANKCASE LOCATION ½ CRANKSHAFT DIAMETER S/T BALANCE SHAFT GEARINGENGRANAJES PRIMARY SHAFT GEARING CRANKSHAFT DIAMETER REFERENCE CLASS 1 32.480 32.485 8711475001 Go to spare parts catalogs CLASS 2 32.485 32.490 8711475002 Go to spare parts catalogs BALANCE SHAFT – GEAR SET CRANKSHAFT GEAR BALANCE GEAR REFERENCE...
  • Page 17 SETS IDENTIFICATION PRIMARY SHAFT- GEAR SET CRANKSHAFT GEAR BALANCE GEAR REFERENCE REFERENCE X CLASS 8714475001 8714605001 Y CLASS 8714475002 8714605002 N.B.: The crankcases available as spare parts are always of the X kind. X CLASS 86.00 86.04 Y CLASS 85.96 86.00 N.B.: the distances between the primary shaft and the crankshaft are the following.
  • Page 18 SETS IDENTIFICATION VALVE GUIDES REFERENCE THICKNESS CM222701 2,20 CM222702 2,25 CM222703 2,30 CM222704 2,35 CM222705 2,40 CM222706 2,45 CM222707 2,50 CM222708 2,55 THICKNESS CM222709 2,60 CM222710 2,65 CM222711 2,70 CM222712 2,75 N.B.: In the markings on the inside of the valve, you will find for example: 20, corresponding to 2.20 in the table.
  • Page 19 SETS IDENTIFICATION CRANKSHAFT RANKCASE HALF-BEARING HALF-BEARING CRANKCASE MACHINED DIAMETER (D1) 36.500 36.508 CLASS A CLASS B 36.508 36.516 CRANKSHAFT DIAMETER REFERENCE CLASS 1 32.480 32.485 8711475001 Go to spare parts catalogs CLASS 2 32.485 32.490 8711475002 Go to spare parts catalogs HALF-BEARING THICKNESS Lower Ref.
  • Page 20 ELECTRICAL SYSTEM SPECIFICATIONS IGNITION DESCRIPTION OF THE SYSTEM System logic - The fundamental parameter is the rpm reading from the pick-up - Based on the information from this sensor the ECU calcula tes the moment in which the spark plug should fire. Components - Engine rpm sensor (pick-up) Sensor resistance: 105 -124 _ at 20º...
  • Page 21 ELECTRICAL SYSTEM SPECIFICATIONS CHARGING SYSTEM COMPONENTS - Three-phase system with a power rating of 200w. - Voltage produced at regulator output: 13 – 15 v at 8000 rpm - Current produced at regulator output: around 14A at 8000 rpm Resistance of stator between phases: +/- 10%.
  • Page 22 LUBRICATION CIRCUIT - (1) Crankshaft breather. - (2) To the gearbox. - (3) To the gearbox. - (4) To the filter, lubrication of technical part. N.B. THE OIL PUMP IS A DOUBLE ROTOR PUMP THAT PUMPS SEPARATELY. - The lubrication is the semi-wet crankcase type. - The gearbox is used as an oil tank.
  • Page 23 LUBRICATION CIRCUIT To bottom of cylinder To bottom of cylinder Oil input to filter Oil to supports Rises for Oil to filter By-pass camshafts Oil input Oil input Rises for camshafts Oil to supports Rises for camshafts WORKSHOP MANUAL...
  • Page 24 LUBRICATION CIRCUIT To bottom of cylinder GEAR BOX CIRCUIT LUBRICATION Gear Box lubrication circuit THIS PIPE HAVE SEVEN HOLE 7 holes pipe ALWAYS REPLACE PIPE OR Lubricate the gear shaft before assembly CHECK IF THE CONDITION OF PIPE IS GOOD Always replace pipe OR BEFORE ASSEMBLY THE ENGINE LUBRICATE SHAFT AND GEAR VERY WELL To bottom of cylinder...
  • Page 25 COOLANT CIRCUIT - There is a small by-pass to heat up the carburettor. - The pump oil seal is the metal type. - The thermostat opens at between 80ºC and 85ºC. - The radiator is fitted with an electric fan. - Resistance value of the temperature sensor (NTC): - At 60ºC = 600-470 - At 90ºC = 215-175...
  • Page 26 REGULAR INSPECTION AND ADJUSTMENTS I NTRODUCTION This chapter contains all the necessary information for carrying out recommended inspections and adjust- ments. If followed correctly, these preventative maintenance procedures will ensure a reliable operation of the machine and a longer operating life. The need for costly servicing will be significantly reduced. This information applies not only to machines already in service but also new machines being prepared for sale.
  • Page 27 REGULAR INSPECTION AND ADJUSTMENTS SYSTEM 1ST SERVICE/RUNNING IN NOTE ENGINE OIL: Change (warm up the engine before draining) Engine/trans. OIL FILTER: Change Cycle WHEELS: Check the correct tension of the spokes Electrical FINAL CHECK: Carry out an on-road test drive, paying attention to the general operation of the brakes, steering, clutch, suspensions, engine, lights and instru- ment panel indicator lights.
  • Page 28 REGULAR INSPECTION AND ADJUSTMENTS SYSTEM INSPECTION TYPE 2 NOTA Engine/trans. SPARK PLUG: Change EXHAUST SYSTEM: Check the correct tightness of the bolts and clamps ENGINE SUPPORT BOLTS: Check nominal torque tightness SECONDARY TRANSMISSION: Check the condition of the chain, sprocket and Note 2 plate - Renew if they have reached the end of their useful life AIR FILTER: Renew...
  • Page 29 REGULAR INSPECTION AND ADJUSTMENTS ADJUSTING THE THROTTLE CABLE N.B: BEFORE ADJUSTING THE THROTTLE CABLE, THE IDLE SPEED MUST BE ADJUSTED. 1. Check: - Throttle cable play (1). Outside that specified => Adjust . Clearance: 2÷6 mm. In the throttle twist-grip plate. 2.
  • Page 30 REGULAR INSPECTION AND ADJUSTMENTS INSPECTING THE SPARK PLUG 1. Extract: - Spark plug connector. - Spark plug. ATTENTION BEFORE REMOVING THE SPARK PLUG, BLOW AROUND IT WITH COMPRESSED AIR TO REMOVE ANY DIRT, THEREBY PREVENTING THIS FROM FALLING INTO THE ENGINE. 2.
  • Page 31 REGULAR INSPECTION AND ADJUSTMENTS ADJUSTING THE COMPRESSION PRESSURE N.B.: INSUFFICIENT COMPRESSION PRESSURE LEADS TO A LOSS OF POWER. Check: - Valve clearance. Outside that specified => Adjust . See “ VALVE CLEARANCE ADJUSTMENT ” section. Start the engine and leave to warm up for a few minutes. Stop the engine.
  • Page 32 REGULAR INSPECTION AND ADJUSTMENTS Compression pressure (at sea level): Standard: 1200 kPa (12 kg/cm 2 ) Minimum: 1040 kPa (10,4 kg/cm 2 ) Steps for removal: - Start the engine with the throttle completely open, until the comprerssion reading stabilises. WARNING: BEFORE STARTING THE ENGINE CONNECT THE SPARK PLUG WITH HANDLE TO PREVENT SPARKS.
  • Page 33 REGULAR INSPECTION AND ADJUSTMENTS I NSPECT THE ENGINE OIL LEVEL Position the motorcycle on a flat surface. N.B.: ENSURE THAT THE MOTORCYCLE IS PARALLEL TO THE GROUND IN ORDER TO BE ABLE TO CHECK THE OIL LEVEL CORRECTLY. Start the engine and leave to warm up for a few minutes. Stop the engine.
  • Page 34 REGULAR INSPECTION AND ADJUSTMENTS CHANGING THE ENGINE OIL Start the engine and leave to warm up for a few minutes. Stop the engine and place a container under the engine. Extract: - Dipstick. - Drain plug (1). - The prefilter. Drain the oil from the crankcase.
  • Page 35 DISMANTLING THE ENGINE CAMSHAFT Extract: - The spark plug (1). - The four bolts (2) from the cylinder head. - The cylinder head (3). Extract: - Bolts (timing chain tensioner): Fit: - The camshaft sprocket locking tool (5). The camshaft sprocket locking tool: Ref.
  • Page 36 DISMANTLING THE ENGINE AMSHAFT TIMING CHAIN Extract: - The spark plug (1). - The 4 bolts(2) from the cylinder head cover. - The cylinder head cover (3). Extract: - The 4 bolts (4) from the bridge of the camshafts. - The bridge (5) of the camshafts. Extract: - The 2 bolts (6) securing the starter motor.
  • Page 37 DISMANTLING THE ENGINE Extract: - The 10 bolts (13) from the clutch cover. - The clutch cover (14). - The clutch cover gasket. (Renew when refitting). Remove the clutch assembly (see the chapter). Extract: - The fixed timing chain roller (15). Fit: - The crankshaft sprocket locking tool (16).
  • Page 38 DISMANTLING THE ENGINE C YLINDER HEAD, CYLINDER AND PISTON Extract: - The inlet manifold, by removing the 3 bolts (1). Remove: - The TDC (top dead centre) checking plug (2). - The central plug (3). Align: Use an Allen key (b) to turn the crankshaft in an anti-cloc- kwise direction until the mark (a) is aligned with the statio- nary point.
  • Page 39 DISMANTLING THE ENGINE Extract: - The 2 bolts (6) securing the timing chain tensioner. - Bolts (timing chain tensioner): - The tensioner seal. Extract: - The 2 bolts and the thermostat cover (8). Extract: -The thermostat (9). Extract: - The spark plug (10). - The 4 cylinder head cover bolts(11).
  • Page 40 DISMANTLING THE ENGINE Extract: - The two cylinder head cover gaskets(13). - The 8 bolts (14) from the camshafts cover. - The bridge (15) from the camshafts. N.B.: TIE A PIECE OF WIRE TO THE TIMING CHAIN TO STOP IT FROM FALLING INTO THE ENGINE.
  • Page 41 DISMANTLING THE ENGINE Fit: - The fork tool for fitting the piston (22). Piston fitting clamp. Ref. 865261 Ref. T01010049 N.B.: BEFORE REMOVING THE CIRCLIP FROM THE GUDGEON PIN, COVER THE BASE OF THE CYLINDER WITH A CLOTH TO PREVENT OBJECTS FROM FALLING INTO THE ENGINE. Extract: - The 2 circlips (23), one on each side, securing the piston gudgeon pin.
  • Page 42 DISMANTLING THE ENGINE Fit: F LYWEEL MAGNETO N.B.: PLACE A CONTAINER UNDER THE ENGINE AND DRAIN THE OIL FROM THE CRANKCASE. Extract: - The engine oil pre-filter cap (1). - The engine oil pre-filter. - The 10 bolts (2) from the magneto flywheel cover. - Cylinder head side cover (3).
  • Page 43 DISMANTLING THE ENGINE C LUTCH Extract: - The coolant pipe (1). - The 3 bolts (2) from the water pump cover (3). Extract: - The water pump turbine (4). N.B.: PLACE A CONTAINER UNDER THE ENGINE AND DRAIN THE OIL FROM THE CRANKCASE. Extract: - The engine oil plug (5).
  • Page 44 DISMANTLING THE ENGINE Extract: - The 5 bolts (10) with washer and spring from the clutch closing cover. - The clutch closing cover (11). Extract: - The clutch disks and separators (12). Abrir: - The seal tab (13). Extract: - The nut(15). - The seal (13).
  • Page 45 DISMANTLING THE ENGINE OIL PUMP Remove the clutch assembly (see the chapter). Extract: - The intermediate starter gear clip and washer(1). - The intermediate starter gear (2). Extract: - The oil pump gear clip (3). - The oil pump gear (4). Extract: - The 3 oil pump bolts (5).
  • Page 46 DISMANTLING THE ENGINE CRANKSHAFT Removing the cylinder head, piston and clutch (see chapter). Fit: - The balance shaft locking tool (1). Balance shaft locking tool: Ref. 864486 Ref. xxxxxxxx Extract: - The nut balance shaft nut (2). - The balance gear (3). Fit: - Fit the crankshaft sprocket using the locking tool (4).
  • Page 47 DISMANTLING THE ENGINE CRANKCASES Remove the cylinder head, cylinder and piston (see the chapter). Remove the clutch assembly (see the chapter). Remove the magneto (see the chapter). Remove the crankshaft (see the chapter). Extract: - The balance shaft (1). Extract: - The 6 outer bolts (2) from the left-hand crankcase.
  • Page 48 DISMANTLING THE ENGINE T RANSMISSION, GEAR SELECTOR, GEARCHANGE SHAFT AND SELECTOR DISTRIBUTOR Remove the cylinder head, cylinder and piston (see the chapter). Remove the clutch assembly (see the chapter). Remove the magneto (see the chapter). Remove the crankshaft (see the chapter). Remove the crankcases (see the chapter).
  • Page 49 DISMANTLING THE ENGINE Extract: - The gear selector (9) by pulling it upwards. Extract: - The main shaft (10). - The intermediate shaft (11). N.B. LENGTH OF SECONDARY SHAFT 92’2mm (+010 -0,18mm). WORKSHOP MANUAL...
  • Page 50 INSPECTION AND REPAIR CYLINDER HEAD 1. Eliminate: - Carbon sediments (from the combustion chamber) Use a rounded spatula. N.B.: AVOID USING ANY SHARP EDGED INSTRUMENT THAT CAN CAUSE DAMAGE AND SCRATCHING. - IN THE SPARK PLUG THREADS - ON THE VALVE SEATS. 2.
  • Page 51 INSPECTION AND REPAIR ADJUSTING THE VALVES Remove the camshaft (see chapter) Valve clearance: Inlet: 0,10 – 0,15mm para 0,15 – 0,20mm Outlet: cambiar de 0,15 – 0,20 para 0,20 – 0,25mm Extract: Remove the tappet and check the numbering of the pad fitted (1). In the event of the clearance being incorrect, continue by calculating the appropriate pad(s) in accordance with the fo- llowing calculation:...
  • Page 52 INSPECTION AND REPAIR VALVE SEATS 1. Eliminate: - Carbon sediments. (from the valve face and seat). 2. Inspect: - Valve seats. Grooves/wear => Grind the valve. Steps for removal: - Apply blue mechanical dye (Dykem) (b) to the valve face. - Fit the valve into the cylinder head.
  • Page 53 INSPECTION AND REPAIR Steps for seating valves: - Apply a coarse abrasive paste to the valve face. ATTENTION DO NOT ALLOW THE PASTE TO PENETRATE IN THE SPACE BETWEEN THE VALVE STEM AND THE VALVE GUIDE. - Apply acid with molybdenum disulphate to the valve stem. - Fit the valve into the cylinder head.
  • Page 54 INSPECTION AND REPAIR V ALVES AND VALVE SPRINGS 1. Measurement: - Free length (a) of spring. Outside that specified => Renew . Valve spring free length: 44,90 mm 2. Measurement: - Spring contact face. Wear/damage/scratches => Renew. I NSPECTING THE CAMSHAFT 1.
  • Page 55 INSPECTION AND REPAIR TIMING CHAIN, SPROCKET AND GUIDES 1. Inspect: - Timing chain. Rigidity/damage => Renew chain and sprockets. 2. Inspect: - Drive sprockets Damage/wear => Renew the sprockets and the timing chain. (1) 1/4 of the tooth (2) Correct (3) Roller (4) Sprocket 3.
  • Page 56 INSPECTION AND REPAIR C YLINDER AND PISTON 1. Inspect: - Cylinder and piston walls. Vertical scratches => Rectify or replace the cylinder and the piston. 2. Measurement: - Cylinder-Piston clearance. Steps for removal: Step 1: - Measure cylinder diameter “C” with an internal calliper. N.B.: MEASURE THE DIAMETER “C”...
  • Page 57 INSPECTION AND REPAIR I NSPECTING THE CLUTCH BELL HOUSING 1. Inspect: - Primary sprocket teeth (1) . - Bell housing sprocket teeth (2) . Wear/damage => Renew both sprockets. Excessive noise when functioning => Renew both spro- ckets. I NSPECTING THE CLUTCH 1.
  • Page 58 INSPECTION AND REPAIR I NSPECTION OF THE FORKS AND GEAR SELECTOR 1. Inspect: - Fork follower (1). - Ends of the gear change forks (2). Scoring/warping/wear/damage => Renew. 2. Inspect: Wear/damage/scratches => Renew. - Gear change selector follower. Wear/damage => Renew.
  • Page 59 INSPECTION AND REPAIR 6. Inspect: - Gear teeth Blue colouring/grooves/wear => Renew. - Gear claws Rounded edges/cracks/pieces missing => Renew. 7. Inspect: - Gear change shaft (1). Damage/warping/wear => Renew. - Return spring (gear change shaft) (2). - Return spring (limiter rod) (3). Wear/damage =>...
  • Page 60 INSPECTION AND REPAIR I NSPECTING THE OIL PASSAGES ( RIGHT HAND SIDE CASING COVER) 1. Inspect: - Oil passage Obstructions => Blow through with compressed air. C ASING 1. Wash the casings well with petrol. 2. Clean the seal-bearing surfaces and the casing contact surfaces well.
  • Page 61 ASSEMBLING THE ENGINE AND ADJUSTMENTS T RANSMISSION, GEAR SELECTOR, GEAR CHANGE SHAFT AND SELECTOR DISTRIBUTOR Fit: - The main shaft (1). - The intermediate shaft (2). Fit: - Gear change shaft assembly (3). Fit: - Gear change shaft assembly (4). - The gear change selector bolt (5) situated on the other side of the right-hand crankcase.
  • Page 62 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The gear selector lever (9) and the spring, using the bolt (10). Fit: - The gear change selector shaft (11). N.B.: FIT THE GEAR CHANGE SELECTOR SHAFT, BY ALIGNING THE ENDS OF THE RETURN SPRING WITH THE POSITIO- NING BRACKET (12) ON THE CRANKCASE.
  • Page 63 ASSEMBLING THE ENGINE AND ADJUSTMENTS T RANSMISSION PARTS Distributor drum Gear change greasing tube Roller O-ring Washer Z14 gear change output gear Primary fork shaft Output gear seal Cat. 1 gear change fork. 5M80x10 Allen bolt Secondary fork shaft Int. star washer Cat.
  • Page 64 ASSEMBLING THE ENGINE AND ADJUSTMENTS G EAR CHANGE SELECTOR PARTS Clutch push rod Selector spring stud Clutch lever Bolt Clutch cable securing plate Gear selection lever Selector shaft assembly Spring D12 safety ring Washer Bolt Washer Drum control head Gear selection spring Special bolt Gear lever assy.
  • Page 65 ASSEMBLING THE ENGINE AND ADJUSTMENTS C RANKSHAFT Fit: - Crankshaft (1). Fit crankcases (see chapter) ATTENTION TO PREVENT SCRATCHES TO THE CRANKSHAFT AND TO HELP ITS FITTING, APPLY GREASE TO THE RETAINING RING EDGES AND ENGINE OIL TO THE BEARINGS. GREASE THE CRANKSHAFT USING THE GREASING HOLES (A).
  • Page 66 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The timing chain (7). N.B.: FIT IT ON THE CENTRAL TEETH. Fit: - The crankshaft gear (8). - The fitting tool (9). Crankshaft sprocket locking tool: Ref. 864487 Ref. T01010050 Fit: -The crankshaft gear nut (10). Crankshaft gear nut: 7,5-8,3 kgf.m (75-83 N.m) N.B.:...
  • Page 67 ASSEMBLING THE ENGINE AND ADJUSTMENTS CRANKSHAFT PARTS Crankshaft-connecting rod assy. Counterweight shaft Intermediate gear counterweight Counterweight gear WORKSHOP MANUAL...
  • Page 68 ASSEMBLING THE ENGINE AND ADJUSTMENTS CRANKCASES Fit: - The engine crankcase gasket (1) (new gasket). Fit: - The left-hand crankcase (2) onto the right-hand crankcase (3), being guided by the centring studs (4). ATTENTION MAKE SURE THAT THE GASKET REMAINS IN THE CORRECT POSITION.
  • Page 69 ASSEMBLING THE ENGINE AND ADJUSTMENTS C RANKCASE PARTS Crankcases assy. M5x14 bolt Counterweight bearing Top mounting blue semi-bearing Crankcase gasket Bottom mounting blue semi-bearing Crankshaft oil seal Secondary shaft bearing Primary shaft needle bearing assy. Neutral switch Gasket Counterweight shaft needle bearing assy. Bolt M6x75 hex.
  • Page 70 ASSEMBLING THE ENGINE AND ADJUSTMENTS O IL PUMP - (1) Crankshaft breather. - (2) To the gearbox. - (3) To the gearbox. - (4) To the filter, lubrication technical part. N.B.: THE OIL PUMP IS A DOUBLE ROTOR PUMP WHICH PUMPS SEPARATELY.
  • Page 71 ASSEMBLING THE ENGINE AND ADJUSTMENTS O IL PUMP ASSEMBLY PARTS Rubber ring. Flat washer Intermediate oil pump gear Bolt Circlip Oil pump gear Oil pump gear Crankcase / oil pump gasket Oil pressure valve spring Oil by-pass valve Oil filter Oil filter gasket Plug gasket Oil filter plug...
  • Page 72 ASSEMBLING THE ENGINE AND ADJUSTMENTS I NSTALLING THE CLUTCH Fit: - The clutch bell housing (1). - The washer (2). Fit: - The clutch bell housing (3). - The seal (4). - The nut (5). The clutch housing nut: 3,5-4,5 kgf.m (35-45 N.m) Closing: - The seal tab (4).
  • Page 73 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The clutch disks and separators (8). N.B.: - FIT THE DISKS (BLADES TO THE RIGHT) AND THE SEPARA- TORS (ROUNDED PROFILE INWARDS) ALTERNATELY ONTO THE CLUTCH HUB, BEGINNING WITH A FRICTION DISK AND ENDING WITH A FRICTION DISK. - LUBRICATE ALL THE DISKS AND SEPARATORS WITH ENGI- NE OIL BEFORE FITTING.
  • Page 74 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The oil filter (15). - The spring (16). - The oil filter plug (17) The oil filter plug: 2,4-2,6 kgf.m (24-26 N.m) Fit: - The water pump turbine (18). The water pump turbine: 0,4-0,6 kgf.m (4-6 N.m) Fit: - The water pump cover (19) and the 3 bolts (20).
  • Page 75 ASSEMBLING THE ENGINE AND ADJUSTMENTS C LUTCH BELL HOUSING PARTS Clutch bell housing Clutch casing HZ driving disk HZ driven disk Clutch closing cover Clutch spring Bolt with washer Washer M6 hexagonal nut Clutch bolt Separator Washer Nut with tapered spring Engine gear Seeger ring Washer...
  • Page 76 ASSEMBLING THE ENGINE AND ADJUSTMENTS C LUTCH COVER PARTS Clutch cover assy. Clutch cover – crankcase gasket Oil filter cover O-ring Oil filter cartridge spring Oil filter cartridge M5x14 bolt Water pump cover O-ring Complete drive shaft Water pump oil seal Clamp M6x35 bolt Oil seal...
  • Page 77 ASSEMBLING THE ENGINE AND ADJUSTMENTS M AGNETO Fit: - The 2 starter system gears (1). - The key (2). - The safety roller (3). Fit: - The rotor (4) - The washer (5). Fit: - The rotor nut (6). Fifar: - The rotor onto the magneto flywheel, using the magne- to fl ywheel locking tool (7).
  • Page 78 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The cover gasket (8) (new gasket). Fit: - Cylinder head side cover (9). - The 10 bolts (10) on the left-hand crankcase cover. The crankcase cover bolts: 1,1-1,3 kgf.m (11-13 N.m) IMPORTANT TIGHTEN THE BOLTS ON THE BLOCK IN SUCCESSION CROSSWISE, GOING FROM ONE TO ANOTHER TWO OR THREE TIMES.
  • Page 79 ASSEMBLING THE ENGINE AND ADJUSTMENTS M AGNETO PARTS Magneto side cover Starter crown wheel retaining plate Magneto cover-crankcase gasket M6x14 bolt O-ring Ignition cover 6M100 hexagonal nut with clamp M6x35 bolt O-ring Oil dipstick Flat washer Stator M 5x25 bolt M 5x16 bolt Bolt Washer...
  • Page 80 ASSEMBLING THE ENGINE AND ADJUSTMENTS C AMSHAFT Remove: - The TDC (top dead centre) checking plug. - The central plug. Align: Turn the crankshaft in an anticlockwise direction with an Allen key (b) until the mark (a) is lined up with the point on the nut, as shown in the photograph.
  • Page 81 ASSEMBLING THE ENGINE AND ADJUSTMENTS Position: - Set of camshaft locking keys (6). Set of camshaft locking keys: Ref. 864567 Fit: - The camshaft crown wheels (7). - The timing chain (8). - Apply Loctite before fitting the 2 volts. - The camshaft crown wheels washer (9) and bolts (10).
  • Page 82 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The 2 bolts (15) securing the starter motor. - The starter motor (16). - The 2 bolts (apply Loctite before fitting ). The starter motor bolts: 1,1-1,3 kgf.m (11-13 N.m) Fit: - The camshaft sprocket locking tool (17). The camshaft sprocket locking tool.
  • Page 83 ASSEMBLING THE ENGINE AND ADJUSTMENTS T IMING CHAIN N.B.: FIT THE TIMING CHAIN SPROCKET WITH THE GUIDE POINT FACING FORWARDS. Fit: - The timing chain sprocket (1). N.B. See chapter (identification of sets). N.B.: TIE A PIECE OF WIRE TO THE TIMING CHAIN TO PREVENT IT FROM DETACHING FROM THE SPROCKET.
  • Page 84 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The clutch cover (7). - The clutch cable support (8). - The 10 clutch cover bolts (9). The clutch cover bolts: 1,1-1,3 kgf.m (11-13 N.m) N.B.: TO HELP THE COVER TO FIT, THE WATER PUMP SHOULD BE TURNED UNTIL THE 2 GEARS COINCIDE.
  • Page 85 ASSEMBLING THE ENGINE AND ADJUSTMENTS V ALVES AND CAMSHAFT PARTS Cylinder head assy. Gasket 12x13 centring bush Chain guide fixed roller M8x20x1 bolt Chain tensioner mobile roller 8x13 centring bush M6 bolt M8x166 bolt Timing chain 8.5x16x1.5 washer Crown wheel M6x130 bolt 8.25x23x4 washer Distribution gear...
  • Page 86 ASSEMBLING THE ENGINE AND ADJUSTMENTS I NSTALLING THE PISTON RINGS N.B.: COVER THE BASE OF THE CYLINDER WITH A CLOTH TO PRE- VENT OBJECT FROM FALLING INTO THE ENGINE. Fit in accordance with the following sequence: - Expansion ring (oil ring) (1). - Secondary ring (scraper) (2).
  • Page 87 ASSEMBLING THE ENGINE AND ADJUSTMENTS C YLINDER HEAD, CYLINDER AND PISTON Fit: - The piston fitting clamp (1). Piston fitting clamp: Ref. 865261 Ref. T01010049 N.B.: BEFORE REMOVING THE CIRCLIP FROM THE GUDGEON PIN, COVER THE BASE OF THE CYLINDER WITH A CLOTH TO PREVENT OBJECTS FROM FALLING INTO THE ENGINE.
  • Page 88 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The comparer (6) onto the TDC measuring tool (7). N.B.: PLACE THE COMPARER ON A FLAT SURFACE AND ADJUST CORRECTLY (0). Fit: - The TDC measuring tool (7), using 2 cylinder head bolts. TDC measuring tool: Ref.
  • Page 89 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The front timing chain roller (8). - The top gasket (9) (new gasket). - The coolant pipe (10). Fit: - The cylinder head. N.B.: APPLY OIL TO THE WASHERS OF THE 4 BOLTS JOINING THE CYLINDER HEAD TO THE CRANKCASE.
  • Page 90 ASSEMBLING THE ENGINE AND ADJUSTMENTS Fit: - The thermostat (14). Fit: - The 2 thermostat cover bolts. - The thermostat cover (15). The thermostat cover bolts: 1-1,2 kfg.m (10-12 N.m) WORKSHOP MANUAL...
  • Page 91 ASSEMBLING THE ENGINE AND ADJUSTMENTS C YLINDER HEAD AND CYLINDER PARTS Piston-cylinder assy. 1st cat. piston assy. Cylinder – cylinder head gasket Cylinder - crankshaft gasket First piston ring Scraper ring Piston gudgeon pin Piston gudgeon pin circlip Chain tensioner Gasket M6x16 bolt WORKSHOP MANUAL...
  • Page 92 ASSEMBLING THE ENGINE AND ADJUSTMENTS THERMOSTAT PARTS Hose joining the EFI to the inlet manifold Bolt Intake connector O-ring Thermistor Thermostat Thermostat cover 6.3x8x6.8 bush M6x20 bolt Studs Carburettor clamp WORKSHOP MANUAL...
  • Page 93 IGNITION COIL SPEED NEUTRAL GEAR/DUMPING SWITCH ENGINE STOP SWITCH STARTING IGNITION (+) BATTERY (+) START RELAY (-) O2 SIGNAL (+) O2 SIGNAL (-) TEMPERATURE SENSOR FAST ACTING SHIFTING DEVICE SIDE STAND IN K-LINE NEUTRAL GEAR LIGHT/ALARM LIGHT CLUTH SIDE STAND OUT MAGNETO (-) SPEED SENSOR (+) INJECTOR RELAY...
  • Page 94 IGNITION COILS SPEED NEUTRAL / DUMPING SWITCH TURN OFF SWITCH START UP IGNITION (+) BATT (+) START RELAY (-) O2 SIGNAL (+) O2 SIGNAL (-) TEMPERATURE SENSOR FAST ACTING SHIFTING DEVICE OUTPUT LOW DIAGNOSYS NEUTRAL LIGHT ANTI-TEFTH LIGHT CLUTCH LOW POWER START MAGNETO (-) SPEED SENSOR (+) INJECTION RELAY...
  • Page 95 IGNITION COIL SPEED NEUTRAL GEAR/DUMPING SWITCH ENGINE STOP SWITCH STARTING IGNITION (+) BATTERY (+) START RELAY (-) O2 SIGNAL (+) O2 SIGNAL (-) TEMPERATURE SENSOR FAST ACTING SHIFTING DEVICE SIDE STAND ENGINE STOP (-) K-LINE NEUTRAL GEAR LIGHT/ALARM LIGHT CLUTH SIDE STAND ENGINE STOP SWITCH SIGNAL MAGNETO (-) SPEED SENSOR (+)
  • Page 96 EMS Link EMS Link—Installation and Comm. Line CAN1L CAN Bus low User Manual Power BAT+ KL30 permanent power EMS Link This file is in Glasscubes or ask through e-mail, download in your computer and via USB cable put the file in your android phone , If the App doesn't open, go to settings and unlock it.
  • Page 97 Download instruction Comm. Line CAN1L CAN Bus low Power BAT+ KL30 permanent power Only for Android Phone Comm. Line CAN1L CAN Bus low Power BAT+ KL30 permanent power EXEC EMS Link EMSLinkMIU This file is in Glasscubes or ask through e-mail, download in your computer and via USB cable put the file in your android phone , If the App doesn't open, go to settings and unlock it.
  • Page 98 1 Requirement of your smart phone .................... 03 2 Connector information ......................03 3 Installation and step of use ....................... 05 3.1 Installation ........................... 05 3.2 Step of use ........................... 05 3.2.1 Connection between the smart phone and vehicle ............05 3.2.2 Operation of vehicle .....................
  • Page 99 1 Requirement of your smart phone For android system, the OS of smart phone must be 4.2 and above; for IOS, the OS of ANDROID PHONE smart phone must be 7.0 and above 2 Connector information Figure 1 is Dongle OBDII connector (male). figure 1 Table 1 is pinout of OBDII connector.
  • Page 100 Comm. Line CAN1L CAN Bus low Power BAT+ KL30 permanent power...
  • Page 101 3 Installation and step of use 3.1 Installation Download the APK to your smart phone and click “install” 3.2 Step of use 3.2.1 Connection between the smart phone and vehicle Please insert the Dongle to the vehicle‟s OBD connector, as shown in figure 2 figure 2 3.2.2 Operation of vehicle Insert the key to the vehicle, and make sure the vehicle‟s status is “key on”.
  • Page 102 (1) Click the icon “EMS Link” to use the APP, as shown in figure 3 figure 3 (2) After clicking „‟EMS Link”, you will enter the “Take A Look” page, as shown in figure 4. In this page, you can slip picture to learn how to use APP. Click the “Skip” button, you will enter the “welcome”...
  • Page 103 (3) The “welcome” page is shown in figure 5. Click the “Introduction” button, you will open the user manual; click “Take A Look” button, you will learn how to use app briefly; click the “Go” button, you will enter the “Main” page. figure 5 (4) When you are in main interface, the APP will scan the available devices automatically, as shown in figure 6...
  • Page 104 (5) when scanning finished, the APP will list all available devices to user, and the user can click the name of device to connect, as shown in figure 7 figure 7 (6) If the dongle is connected successfully, the “Connect” will become “Disconnect”, as shown in figure 8 figure 8...
  • Page 105 (7) Click the “Settings” button to enter the “Settings” page, as shown in figure 9 figure 9 (8) In “Settings” page you can select the language, click “Language” button, you will see the “Chinese” and “English”, you can select either one, as shown in figure 10 figure 10...
  • Page 106 (9) In “Settings” page, click the “Bluetooth Device” to clear the paired device, as shown in figure 11 figure 11 (10) In “Setting” page, you can select the “important parameters” which will be shown in “Dashboard”. Click the “Important Parameters” to select. The “Engine RPM” and “Vehicle Speed”...
  • Page 107 (11) In “Setting” page, you can select the “other parameters” which will be shown in “Dashboard”. Click the “Other Parameters” to select, as shown in figure 13 figure 13 (12) Click the “Back” button on Smart Phone or Tablet, you will go back to the “Main” page, as shown in figure 14 figure 14 Note: to perform diagnostic features, you have to establish the connection by pushing the...
  • Page 108 3.3 Note 1 One dongle only can be connected with one smart phone at the same time 2 If you want to use other smart phone to connect dongle, please kill the running EMS Link APP in the running smart phone, as shown in figure 15 figure 15...
  • Page 109 4 Feature description The EMS Link APP includes “Dashboard” function, “Trip meter” function, “Service Tool” function, “Reflashing” function and “Scan Tool” function, as shown in figure 16 figure 16 4.1 DashBoard The “DashBoard” function can display real-time parameters such as “RPM”, “SPEED”, “Manifold Pressure”, “Battery Voltage”, “Gear Position”, “Water Temperature”, “Air Temperature”...
  • Page 110 The “other parameters” which is selected in “Other Parameters” page will be shown in “Information” page, as shown in figure 18 figure 18 4.2 Trip Meter The “Trip Meter” function through the GPS to display the “Max Speed”, “Acceleration”, “Altitude” and the “Speed” on your trip. The “Trip Meter” function need to enable the GPS function, as shown in figure 19 figure 19...
  • Page 111 4.3 Service Tool “Service Tool” can do the diagnostic function for your vehicle, it includes several modules, as shown in figure 20 figure 20 （ 1 ） Read Data The “Read Data” function is used to read the system parameter, as shown in figure 21. Click “Start”...
  • Page 112 The test result of “Read Data” function is shown in figure 22 figure 22 （ 2 ） Configure Data The “Configure Data” function is used to read the configuration information, such as ECU version. Click “Start” button and “Search” icon to read data, as shown in figure 23 figure 23...
  • Page 113 （ 3 ） Actuator Control The “Actuator Control” function sends the command to test the actuator of the vehicle, as shown in figure 24 figure 24 The test result of “Actuator Control” is shown in figure 25 figure 25...
  • Page 114 （ 4 ） Monitor Mode The “Monitor Mode” allow the users to edit the command to test the vehicle, as shown in figure 26 figure 26 You can edit the command in edit box, and click the “Send” button to send the command, the test result of “Monitor Mode”...
  • Page 115 （ 5 ） DTC Management The “DTC Management” function is used to read the DTC, and you can clear the DTC by it, as shown in figure 28. Click the “Start” button to scan DTC, click the “Clear” button to clear DTC.
  • Page 116 The .bin file and .cks file which will be downloaded into ECU should be stored in the same folder on the smart phone. Click “Select” button to select the .bin file, as shown in figure figure 30 After selecting the correct .bin file, click the “Reflash” button to start, as shown in figure figure 31...
  • Page 117 Figure 32 shows the “Reflashing” is successful. figure 32 4.5 Scan Tool The “Scan Tool” function read data and perform diagnostic function for OBD II protocol 4.6 Log In/Upload Data/Download In “Main” page, click the “Log in” button to sign in (if you have registered before) or sign up (if have not registered before), as shown in figure 33 and figure 34 By this function you can send/upload diagnostic data to the server or receive/download new engine control software code for the ECU (need to get the access authorization on the...
  • Page 118 figure 33 figure 34...
  • Page 119 when you log in successfully, you can upload ECU data in “Settings” page, as shown in figure 35 figure 35 Contact us Please contact the following email address if you meet any question Email: ems-link.support@magnetimarelli.com...
  • Page 120 ummotorcycles.eu umglobal.com...

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Dsr sm 125Renegade scrambler classic 125Renegade scrambler sport 125Dsr adventure 125Dsr adventure tt 125

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