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Manuals
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TM RACING Manuals
Engine
250 EN
Workshop manual
TM RACING 250 EN Workshop Manual
2 stroke engine
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Contents
Table of Contents
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Table of Contents
Table of Contents
1 Adjustments/Replacements
Engine Oil and Filter Change
Standard Clutch Replacement
2 Engine Disassembly
Engine Components Layout (MX-Smx)
Engine Components Layout (En-Smr)
Removing the Pinion Cover
Pinion Removal
Temperature Sensor Removal
Head Removal
Injectors DISASSEMBLY (EN-SMR)
Disassembly
Reassembly
Cylinder and Piston
Cylinder and Piston Removal
Ring Replacement and Assembly
Strap Mounting
Piston Replacement
Piston Replacement with Intact Cylinder
Piston Replacement with Cylinder to be Machined
Cylinder Replacement
Cylinder and Piston Re-Mounting
Checking the Squish
Drain Valve Removal / Revision
Dismantling the Lever (5)
Refitting the Lever (5)
Reassembly of the Valve (13)
Valve Height Adjustment in Closed Position
Reed Valve Pack
Clutch
Clutch Actuator Removal
Actuator Dismantling
Gear Sensor
Flywheel Removal
Flywheel Cover
Stator
Pick-Up
Rotor
Starter Motor
Disassembly
Re-Mounting
Water PUMP
Replacing the Sealing Gasket
Water Pump Removal
Reassembling the Water Pump
Transmission Guard
Transmission Cover Re-Assembly
Idle Kick Starter Removal (Only K.s.)
Starter Dismantling
Re-Mounting
Drum and Clutch Bell
Disassembly
Re-Mounting
Transmission Side Counter Gears
Gears Removal
Reassembly of Gears
Gearbox Control Shaft and Ratchets Holder Removal
Semicase
Opening
Re-Assembly
Crankshaft, Gearbox, Gears Drum
Components Position
Crankshaft Removal
Gear Shafts Removal
Primary Shaft, Gear Sequence
Secondary Shaft, Gear Sequence
Bearings Replacement
Components Re-Mounting
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Table of Contents
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Engine Oil and Filter Change
3
Cylinder and Piston
Download this manual
Workshop Manual
2 STrOKE EnGInE
250-300
Mx - En - SMx
SMr - 2019
www.tmracing.it
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Summarization of Contents
Foreword
Coolant Liquid Safety
Safety precautions for handling coolant liquid.
Used Oil Handling
Safety precautions for handling used engine and gearbox oil.
Repair Advice
General recommendations for achieving excellent repair results.
General Repair Regulations
Essential regulations for performing motorcycle repairs.
Motorcycle Recognition
Identifying TM Models
Guide to identifying TM Racing motorcycle models based on codes.
Engine Serial Number
Locating and noting the engine serial number for identification.
Technical Specifications
Engine Technical Data 250-300 MX SMX
Technical specifications for 250-300 MX SMX engines.
Engine Data and Carburettor Settings
Engine Technical Data 250-300 EN-SMR
Technical specifications for 250-300 EN-SMR engines.
Carburettors Setting MX-SMX
Carburettor settings for MX-SMX models.
Torques and Lubrication
Engine Tightening Torques
Specifications for tightening engine component screws and nuts.
Lubrication
Recommended lubricants for various engine parts.
Maintenance
Maintenance Table
Scheduled maintenance tasks and intervals.
Troubleshooting
Engine Start/Stop Issues
Diagnosing and resolving engine starting or stopping problems.
Engine Noise Issues
Identifying and fixing sources of engine noise.
Clutch and Gearbox Issues
Troubleshooting problems related to gears and clutch engagement.
Troubleshooting (Continued)
Shift Control and Gear Disengagement
Resolving issues with gear shifting and disengagement.
Insufficient Power and Overheating
Diagnosing insufficient power and engine overheating.
Electric Part Issues
Troubleshooting problems with spark plug and starter motor.
Adjustments and Replacements
Engine Oil and Filter Change
Procedure for changing engine oil and filter.
Standard Clutch Replacement
Procedure for replacing the standard clutch.
Engine Disassembly
2.1 Engine Components Layout (MX-SMX)
Layout and identification of engine components for MX-SMX models.
2.8 Cylinder and Piston
Procedure for removing and replacing cylinder and piston.
2.10 Drain Valve Removal / Revision
Procedure for removing and revising the drain valve.
2.14 Flywheel Removal
Procedure for removing the flywheel and its components.
2.16 Water Pump
Procedure for water pump seal replacement and removal.
2.20 Transmission Side Counter Gears
Procedure for removing and reassembling transmission side counter gears.
2.23 Crankshaft, Gearbox, Gears Drum
Procedure for removing and reassembling crankshaft, gearbox, and gears.
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