TM RACING 250 MX Workshop Manual
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TM RACING 250 MX Workshop Manual

2 stroke engine
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Workshop Manual
2 STrOKE EnGInE
250-300
Mx - En - SMx
SMr - 2019
www.tmracing.it

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  • Page 1 Workshop Manual 2 STrOKE EnGInE 250-300 Mx - En - SMx SMr - 2019 www.tmracing.it...
  • Page 3 TM racing SPA, declines all liability for any errors in the compilation of this manual, and reserves the right to make any modifications required for the development of its products. Illustrations shown are approximate and, in some cases, may not precisely correspond with the part...
  • Page 4 SMX = COMPETITION SUPERMOTO The displacement, type of power source and type of use define the motorcycle model and engine of each TM Racing motorcycle. The combination of codes 1 and 3 identifies the standard engine type. The combination of the three codes fully identifies the motorcycle model.

  • Page 5: Table Of Contents

    INDEX ADJUSTMENTS/REPLACEMENTS ............9 EnginE Oil And FiltEr ChAngE ............10 StAndArd ClUtCh rEPlACEMEnt ............11 ENGINE DISASSEMBLY................ 15 ENGINE COMPONENTS LAYOUT (MX-SMX) ..........16 ENGINE COMPONENTS LAYOUT (EN-SMR) ..........17 rEMOving thE PiniOn COvEr ..............18 PiniOn rEMOvAl ..................18 tEMPErAtUrE SEnSOr rEMOvAl ............19 hEAd rEMOvAl ..................19 INjECTORS DISASSEMBLY (EN-SMR) ............20 2.7.1 disassembly .................
  • Page 6 INDEX 2.17 trAnSMiSSiOn gUArd ................46 2.17.1 transmission cover re-assembly ..........47 2.18 idlE kiCk StArtEr rEMOvAl (OnlY k.S.) ..........48 2.18.1 Starter dismantling ..............48 2.18.2 Re-mounting ................48 2.19 drUM And ClUtCh BEll .................49 2.19.1 disassembly ................. 49 2.19.2 Re-mounting ................50 2.20 trAnSMiSSiOn SidE COUntEr gEArS.............52 2.20.1 gears removal ................
  • Page 7 TECHNICAL SPECIFICATIONS ENGINE TECHNICAL DATA 250-300 mx smx ENGINE Type Single cylinder 2-stroke, liquid-cooled Displacement 249,3 cm 293,1 cm Bore/stroke 66.4x72 72x72 Compression 14.5:1 11.5:1 Fuel (E5) / (E10) super unleaded fuel mixed with oil at 3% Squish height 1.6 / 1.7 mm Piston height from the cylinder surface to the PMS 0.75 ÷...
  • Page 8 Cooling fluid, 40% antifreeze, 60% water (up to -25°C), circulation forced with pump Fluid amount 1 liter (see page 4-97) CArBUrETTOrs sETTING mx-smx kEIHIN 250 mx 300 mx 300 smx 300 mx BrAsILE Type PWK 38 PWK 38 PWK 38...
  • Page 9 ENGINE TIGHTENING TOrQUEs Carter Allen screw, transmission torque, clutch torque, ignition torque 12 Nm Oil drain screw cap M14x1.5 20 Nm Oil load screw cap M14x1.5 20 Nm Valve adjustment grub screws 8 Nm Valve adjustment locknuts 8 Nm Laminated body Allen screw 12 Nm Cylinder-head tightening flange screw 27 Nm...
  • Page 10 MAINTENANCE MAINTENANCE TABLE Clean exhaust screw magnet • • Check tightness of engine fixing screws • • Replace spark plug and check cap • Check exhaust valves • Check cylinder and piston wear • Fully change piston • Check exhaust valve actuator play •...
  • Page 11 TROUBLESHOOTING Problem Cause Solution The engine does not start or Insufficient compression struggles to start replace 1. Piston seizing replace 2. Rod head or foot seizing replace 3. Worn piston segments replace 4. Worn cylinder tighten 5. Insufficient cylinder head tightening replace 6.
  • Page 12 TROUBLESHOOTING Problem Cause Solution The shift control pedal 1. Selector switch recall spring weakened or broken replace does not go back into position 2. gear forks worn replace The gears disengage 1. Sliding gears couplings consumed replace 2. Brake grooves worn replace 3.

  • Page 13: Adjustments/Replacements

    1. ADJUSTMENTS/REPLACEMENTS...

  • Page 14: Engine Oil And Filter Change

    ADJUSTMENTS/REPLACEMENTS ENGINE OIL AND FILTER CHANGE The oil must be changed with the engine off but still warm enough to allow the waste oil to flow out easily. Position the motorcycle on a flat surface and prepare a suitable recipient under the same.

  • Page 15: Standard Clutch Replacement

    ADJUSTMENTS/REPLACEMENTS STANDARD CLUTCH REPLACEMENT Drain the engine oil as described in the relative paragraph. Unscrew the M5-l75 (1) and M5-l25 (2) screws, then remove the clutch cover (3). remove the gasket (4). Unscrew the screws (5) of the clutch pack. remove the spring (6) and the pressure plate (7).
  • Page 16 ADJUSTMENTS/REPLACEMENTS Check that the pressure plate (8) is present and remove it. Use two sticks to pry up and remove the discs (9). NOTE: On re-mounting the new discs (9), lubricate them with engine oil and make sure that the first disc mounted is lined. Remount the pressure plate (7) with the relative springs (6).
  • Page 17 ADJUSTMENTS/REPLACEMENTS Re-mount the screws (5) and tighten them crosswise and gradually with a torque of 8 Nm (0.8 kgm/ 5.9 ft/lb). Check that the gasket (4) is not ruined, otherwise replace it, and mount it on the guard. Mount the clutch guard (3) and tighten the screws (1) and (2) gradually with a torque of 8 Nm (0.8 kgm/ 5.9 ft/lb) Introduce oil into the engine oil as described in the relative paragraph.
  • Page 18 ADJUSTMENTS/REPLACEMENTS...

  • Page 19: Engine Disassembly

    2. ENGINE DISASSEMBLY...

  • Page 20: Engine Components Layout (Mx-Smx)

    ENGINE DISASSEMBLY ENGINE COMPONENTS LAYOUT (MX- SMX) Cylinder head Cylinder Starter motor Reed valve pack Pinion Transmission cover Water pump Ignition cover Gear sensor Clutch actuator Drain valve...

  • Page 21: Engine Components Layout (En-Smr)

    ENGINE DISASSEMBLY ENGINE COMPONENTS LAYOUT (EN-SMR) Cylinder head Cylinder Starter motor Reed valve pack Water temperature sensor Transmission cover Injector Water pump Ignition cover Gear sensor Clutch actuator Pinion Drain valve...

  • Page 22: Removing The Pinion Cover

    ENGINE DISASSEMBLY REMOvING THE PINION COvER Unscrew the two screws (1). Remove the pinion cover (2) and the protection bracket (3). NOTE: Upon reassembly, make sure that the two bushes (4) are present on the pinion cover (2). Tighten the two screws (1) with a torque of 15 Nm (1,5 kgm, 11,6 ft/lb) PINION REMOvAL Remove the pinion cover casing, as described in the relative paragraph.

  • Page 23: Temperature Sensor Removal

    ENGINE DISASSEMBLY TEMPERATURE SENSOR REMOvAL Unscrew the sensor (1) and remove it from the head. Check that the Or gasket (2) is not damaged. When refitting, smear the thread (3) with lithium grease and screw with a torque of 30 Nm (3,0 Kgm, 22,12ft/lb) HEAD REMOvAL remove the spark plug and the temperature sensor as described in the relative paragraph.

  • Page 24: Injectors Disassembly (En-Smr)

    ENGINE DISASSEMBLY INjECTORS DISASSEMBLY (EN-SMR) NOTE: Before disassembling the injector, the area around the injector must be clean. 2.7.1 Disassembly Unscrew the two screws (1). Collect the two Teflon washers (2) for each screw. remove the injector (3). Remove the injector (3) from the duct (4), clean it and put it in a plastic bag so that it does not get dirty.

  • Page 25: Reassembly

    ENGINE DISASSEMBLY 2.7.2 Reassembly Check the condition of the “OR” gasket (5) if damaged or dry replace the injector. grease the part (6) and (7) of the injector with lithium grease. reassemble the injector (3) in the duct (4). Mount the injector (3) in the seat (8) of the cylinder. Put abundant loctite 243 on the threads of the two screws (1) then reas- semble them making sure that the Teflon washers (2) are positioned as shown in the figure.
  • Page 26 ENGINE DISASSEMBLY remove the cylinder (3) by sliding it from the stud bolts. remove the gasket (4). remove the lock ring (5) of the piston (6) Extract the pin (7) and remove the piston (6).

  • Page 27: Ring Replacement And Assembly

    ENGINE DISASSEMBLY remove the roller cage (8). 2.8.2 Ring replacement and assembly Before fitting the new rings on the piston, it is necessary, by means of a file, to “Break the corner” by chamfering on both sides (1) and (2) the upper open part of the ring.

  • Page 28: Strap Mounting

    ENGINE DISASSEMBLY Insert the piston (5) on the cylinder (4) so that the ring (3) is positioned level. With a thickness gauge (6) check the “Thermal GAP” ring opening distance (3) which must be 0,60 ÷ 0,65 mm (0,0236 ÷ 0,0255 in). If necessary, using a file, restore the measurement and repeat the check procedure.

  • Page 29: Piston Replacement With Cylinder To Be Machined

    ENGINE DISASSEMBLY 2.8.6 Piston replacement with cylinder to be machined if the barrel of the cylinder is scratched, it is necessary to lap the barrel itself. After processing it is necessary to measure, with an micrometer (1) for insides, the diameter of the barrel crosswise at 90° first at a distance of 10 mm (0,393 in) from the top of the cylinder and then at a distance of 20 mm (0,787 in) from the top of the cylinder.

  • Page 30: Checking The Squish

    ENGINE DISASSEMBLY Fit a new gasket (6). insert the cylinder (7) onto the studs (8). Screw without tightening the nuts (9) then tighten crosswise with a torque of 26 Nm (2,6 Kgm, 19,18 ft/lb). NOTE: If the cylinder has been replaced, it is necessary to check the squish as described in the paragraph “Checking the squish”.
  • Page 31 ENGINE DISASSEMBLY Fit the new gaskets (2) on the upper part of the cylinder (3). Mount the head (4) on the cylinder (3) and screw the screws (5) without tightening then tighten them crosswise with a torque of 20 Nm (2,0 kgm, 14,75 ft/lb).

  • Page 32: Drain Valve Removal / Revision

    ENGINE DISASSEMBLY 2.10 DRAIN vALvE REMOvAL / REvISION Remove the cylinder as described in the relative paragraph. Place the cylinder in a vice and unscrew the screws (1) of the cover (2). remove the cover (2) and check the gasket (3); if dam- aged, replace.
  • Page 33 ENGINE DISASSEMBLY Check the condition of the bearing (9), if damaged, replace by removing the seeger (10). With an aluminum punch (11) and a hammer extract the pin (12) from the opposite side. remove the pin (12). remove the two valves (13).

  • Page 34: Dismantling The Lever (5)

    ENGINE DISASSEMBLY remove the socket (14). remove the seal (15) and the roller bearing (16) located behind. 2.10.1 Dismantling the lever (5) Withdraw the spring (17) from the pin (18) of the lever (5). Undo the screw (19) to disassemble the lever.

  • Page 35: Refitting The Lever (5)

    ENGINE DISASSEMBLY 2.10.2 Refitting the lever (5) Put graphite grease around the pin (20) and on the screw (19) without dirt- ying the thread. Put loctite 243 on the thread (21) Recompose the lever and tighten the screw (19). insert the spring (17) in the pin (18) and on the screw (19). 2.10.3 Reassembly of the valve (13) reassemble the roller bearing (16) and the seal (15) with the printed side facing out.
  • Page 36 ENGINE DISASSEMBLY Insert the two valves (13) in the cylinder seat, taking care to position the part of the valve cutting edge (chamfered part) towards the inside of the cylinder. grease the pin (12) with graphite grease and reassemble it in the cylinder. to insert the pin (12) completely use an aluminum punch and lightly tap on the head of the pin.

  • Page 37: Valve Height Adjustment In Closed Position

    ENGINE DISASSEMBLY insert the lever (5) into the pin (12). With two fingers hold the valve (13) in the fully open position, insert an Allen key (22) on the screw (6) and screw the nut (4). 2.10.4 Valve height adjustment in closed position With the valve completely closed, the distance between the upper surface of the cylinder (23) and the chamfered part of the valve (24) (Cutting edge) must be 56 mm;...

  • Page 38: Reed Valve Pack

    ENGINE DISASSEMBLY 2.11 REED vALvE PACk Check and/or replace the blades. Unscrew the screws (1) that fix the external frame (2) of the reed valve pack. Check the rubber fitting (3) on the carburettor/throttle body, if damaged, cracked, etc. replace. Check the Or gasket (4);...
  • Page 39 ENGINE DISASSEMBLY remove the internal frame (7). remove the external blades (8). With a screwdriver, slide out the two internal stops (9). remove the internal blades (10). Check the state of the blades, if chipped or deformed, they must be re- placed.

  • Page 40: Clutch

    ENGINE DISASSEMBLY 2.12 CLUTCH 2.12.1 Clutch actuator removal Remove the sprocket cover as described in the relative paragraph. Unscrew the screw (1) and remove the actuator (2). 2.12.2 Actuator dismantling remove the piston (3). Check the conditions of the OR gaskets (4 and 5); replace them if ruined. NOTE: On re-mounting, lubricate the gaskets with clutch oil.

  • Page 41: Flywheel Removal

    ENGINE DISASSEMBLY 2.14 FLYWHEEL REMOvAL 2.14.1 Flywheel cover Unscrew the M5-l25 screws (1). Remove the flywheel cover (2). remove the gasket (3). retrieve the two centring bushes (4). NOTE: On re-mounting, check that the two centring bushes (4) are positioned correctly. Clean the surface of the cover and the split crankcase of any residues and check that the gasket (3) is not damaged, otherwise replace.

  • Page 42: Stator

    ENGINE DISASSEMBLY 2.14.2 Stator Disassembly Remove the flywheel cover as described in the relative section. Unscrew the screws (1) that secure the stator (2). Unscrew the screws (3) and remove the stop plate (4). Remove the stator (2) with the relative cabling. Mounting Re-mount the stator (2), tightening the screws (1) to a torque value of 8 Nm (0.8 Kgm - 5.9 ft/lb + Loxeal 82-33).
  • Page 43 ENGINE DISASSEMBLY remove the complete rotor (1). retrieve the key (6). Re-mounting Make sure the key (6) is properly positioned in its housing. Re-mount the fly wheel (1). Tighten the nut (2) with relative curve washer with a torque of 60 Nm (6 kgm/ 44.2 ft/lb).

  • Page 44: Starter Motor

    ENGINE DISASSEMBLY 2.15 STARTER MOTOR 2.15.1 Disassembly Remove the flywheel cover, as described in the relevant paragraphs. remove the Bendix starter (1). Unscrew the two starter motor fastening screws (2). remove the starter motor (3). 2.15.2 Re-mounting Check the status of the “OR” gasket (4) positioned on the starter motor (3); replace it if ruined.
  • Page 45 ENGINE DISASSEMBLY Tighten the screws (2) with a torque of 10 Nm (1,0 kgm, 7,38 ft/lb). Grease the bronze bush (5) with graphite grease. Grease the gears (6) of the Bendix (1) and reassemble it in the bronze bush (5).

  • Page 46: Water Pump

    ENGINE DISASSEMBLY 2.16 WATER PUMP 2.16.1 Replacing the sealing gasket it is possible to replace the water pump seal without removing the trans- mission card. Unscrew the screws (1) on the pump cover (3); the screw (1a) is the system drain screw and is equipped with an alu- minum washer (2).

  • Page 47: Water Pump Removal

    ENGINE DISASSEMBLY Check the condition of the gasket (4) if damaged, replace. Refit the pump cover (3) by tightening the screws (1) with a torque of 8Nm (0,8 kgm, 5,9 ft/lb) by replacing the aluminum washer (2) of the screw (1a). Refit the cap (4).
  • Page 48 ENGINE DISASSEMBLY Put aluminum jaws (6) in a vice and lock the shaft (7) of the water pump. Unscrew the impeller (8). Remove the shaft (7) from the crankcase (5). Check the condition of the seal (9) if damaged, replace. Check the correct functioning of the bearing (10), if it does not slide freely replace;...

  • Page 49: Reassembling The Water Pump

    ENGINE DISASSEMBLY 2.16.3 Reassembling the water pump grease the bearing (10) with graphite grease and lubricate the sealing gas- ket (9) with engine oil. Insert the pump shaft (7) in the bearing (10) and in the seal (9). Place the shaft (7) in a vice and screw the impeller (8) with a torque of 6 Nm (0,6 kgm, 4,42 ft/lb), greasing the thread.

  • Page 50: Transmission Guard

    ENGINE DISASSEMBLY 2.17 TRANSMISSION GUARD Unscrew the screws (1): M5-L25 screw M5-L30 screw M5-L70 screw remove the guard (2), with the aid of a rubber hammer. remove the gasket (3). recover the three centring bushes (4).

  • Page 51: Transmission Cover Re-Assembly

    ENGINE DISASSEMBLY 2.17.1 Transmission cover re-assembly Clean the surface of the lid and the semicase from any residues. Check that the three centring bushes (4) are in their respective housing. replace and re-mount the gasket (3). Mount the cover (2), centring it on the bushes (4), paying attention not to ruin the seals.

  • Page 52: Idle Kick Starter Removal (Only K.s.)

    ENGINE DISASSEMBLY 2.18 IDLE KICK STARTER REMOVAL (ONLY K.S.) remove the transmission cover and the clutch bell as described in the relative paragraphs. Release the spring (1) from the relative housing, turn the starter (2) anti- clockwise by 1/4 of a turn. remove the starter (2) complete with spring (3) and washer (4).

  • Page 53: Drum And Clutch Bell

    ENGINE DISASSEMBLY 2.19 DRUM AND CLUTCH BELL 2.19.1 Disassembly Remove the transmission cover as described in the relative paragraph. Remove the clutch discs as described in the relative paragraph. Open the lock washer (1) with a chisel. Use a spanner to block rotation of the clutch drum (2) and tighten the nut (3).

  • Page 54: Re-Mounting

    ENGINE DISASSEMBLY remove the washer (4). remove the bell (5). remove the two roller bearing (6) and the spacer (7). remove the washer (8). 2.19.2 Re-mounting insert the washer (8). re-mount everything, proceeding in the reverse order to disassembly. Make sure that the spacer (7) and ball bearing cage (6) are re-mounted correctly and lubricate them with engine oil.
  • Page 55 ENGINE DISASSEMBLY re-mount the bell (5). insert the washer (4). After having re-mounted the bell (5) and the drum (2), make sure the safety washer (1) has been positioned correctly. Screw the nut (3), blocking drum rotation with a spanner, with torque of 100 Nm 10.0 kgm 73.75 ft/lb + strong threadlocker (green).

  • Page 56: Transmission Side Counter Gears

    ENGINE DISASSEMBLY 2.20 TRANSMISSION SIDE COUNTER GEARS Components layout: Countershaft gear Idle gear kick starter removal Kick starter Gearbox primary shaft Gearbox command shaft Crankshaft gear 2.20.1 Gears removal remove the pedal start gear (3) as described in the relevant paragraph. Unscrew the fixing screw (7) of the pedal start retaining gear (2) .

  • Page 57: Reassembly Of Gears

    ENGINE DISASSEMBLY Unscrew the screw (9) of the countershaft (1). remove the gear (1). Collect the key (10). Remove the seeger (11) of the crankshaft gear (6). Remove the crankshaft gear (6). 2.20.2 Reassembly of gears Reassemble the gear (6) of the crankshaft by matching the arrow (12) stamped on the crankshaft with the reference dot (13) of the gear.
  • Page 58 ENGINE DISASSEMBLY Reassemble the countershaft gear (1) by matching the timing point (14) of the countershaft gear with the timing point (15) of the crankshaft gear and put Loctite 243 on the oven (16) and not on the screw. Tighten the screw (9) with a torque of 22 Nm (2,2 kgm, 16,22 ft/lb) + loctite 243.

  • Page 59: Gearbox Control Shaft And Ratchets Holder Removal

    ENGINE DISASSEMBLY 2.21 GEARBOX CONTROL SHAFT AND RATCHETS HOLDER REMOvAL Disassembly Turn the gearbox putting the 5th or 6th gear according to the type of en- gine. Remove the transmission casing and the countershaft gear as described in the relevant paragraph. Remove the gearbox control shaft (1) and recover the shim (2).
  • Page 60 ENGINE DISASSEMBLY Dismantle the ratchets (7) and (8) with the relative tips (9) and the springs (10). Unscrew the pin (11) securing the desmodromic shaft head (12). remove the pin (11). With a screwdriver (13) move the rod (14) and with a screwdriver (15) lever to remove the ring nut (12).
  • Page 61 ENGINE DISASSEMBLY to remove the rod (14) unscrew the screw (16). Reassembly Reassemble the rod (14) by correctly positioning the spring (17) and tight- ening the screw (16) with a torque of 10 Nm (1 kgm, 7,37 ft/lb) Use a screwdriver (13) to move the rod (14) and fit the gear selection ring (12) by inserting the hole (18) in the pin (19) of the drum (20).
  • Page 62 ENGINE DISASSEMBLY Reassemble the rod making sure that the ratchets (7) and (8) fit correctly into their seats; the two ratchets cannot be reversed. Fit the ratchet support (6) on the plate (5). Fit the plate (5) on the pin (11) by inserting the ratchet support (6) in the ring nut (12), tighten the screws (4) with a torque of 10 Nm, (1 kgm, 7,37 ft/lb).

  • Page 63: Semicase

    ENGINE DISASSEMBLY 2.22 SEMICASE Remove the heating unit as described in the relevant paragraph. Remove all parts on the flywheel side and transmission side as described in the relative paragraphs. 2.22.1 Opening On the transmission side, remove the gearbox secondary shaft locking see- ger (1).

  • Page 64: Re-Assembly

    ENGINE DISASSEMBLY 2.22.2 Re-assembly Check that all components are correctly positioned in their housing and that the centring bushes (8) and (9) are mounted. Clean, first with an iron spatula and then with scotch-brite, the contact surface from any residual sealant paste and then spread a treebond type sealing paste.
  • Page 65 ENGINE DISASSEMBLY Re-position the screws (1) in the relative housing depending on their length and tighten them with torque of 12 Nm (1.2 kgm, 8.68 ft/lb): 5a = M6 x 50 5b = M6 x 35 5c = M6 x 60 Refit the countershaft (4).

  • Page 66: Crankshaft, Gearbox, Gears Drum

    ENGINE DISASSEMBLY 2.23 CRANKSHAFT, GEARBOX, GEARS DRUM Open the guards as indicated in the relative section. 2.23.1 Components position Crankshaft Gearbox primary shaft Gearbox secondary shaft Gears selector drum (desmo) 2.23.2 Crankshaft removal Using a rubber hammer, slide the complete crankshaft (1) from the semicase.

  • Page 67: Primary Shaft, Gear Sequence

    ENGINE DISASSEMBLY Spread the forks and remove the gear selector drum (4) (desmo). Remove the fork (5) of the primary shaft. remove the complete gear assy (6) with the fork inserted. 2.23.4 Primary shaft, gear sequence Primary shaft First Fifth Third Fourth Second...

  • Page 68: Secondary Shaft, Gear Sequence

    ENGINE DISASSEMBLY 2.23.5 Secondary shaft, gear sequence Secondary shaft First Fifth Third Fourth Second 2.23.6 Bearings replacement Unscrew the screws (1) that block the bearing and remove the plates (2). Unscrew the screw (3) with relative bearing safety washer. remove all seals. heat the guards and remove the bearings (4).

  • Page 69: Components Re-Mounting

    ENGINE DISASSEMBLY 2.23.7 Components re-mounting Check the condition of the OR gasket (9); if damaged, replace. NOTE: Check that the pin (8) of the fork (2) is not worn, if worn replace. Check that the fork rollers are correctly inserted in the relative hollows on the drum (6).
  • Page 70 ENGINE DISASSEMBLY re-mount the components, proceeding in reverse order to disassembly, lubricating with engine oil and, when re-mounting the gearbox unit, paying attention to correctly position the forks (2, 5 and 7) in the relevant positions: Fork (2) cod.33024 between the 5th and 3rd gear. Fork (7) cod.33023 between the 4th and 6th gear.
  • Page 72 www.tmracing.it...

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