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TM RACING TM 2 stroke 85 User And Maintenance Manual

Tm 2 stroke 85-100-125-144 cc
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Summary of Contents for TM RACING TM 2 stroke 85

  • Page 2 ENGLISH ENGLISH...
  • Page 3 IMPORTANT YOU ARE ADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM. IT CONTAINS A LOT OF INFORMATION AND ADVICE THAT WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE MUCH EASIER AND SAFER. IT IS IN YOUR SPECIFIC INTEREST TO PAY PARTICULAR ATTENTION TO THE WARNINGS INDICATED IN THE FOLLOWING WAY: DANGER FAILURE TO COMPLY WITH THESE WARNINGS RISKS LIVES!
  • Page 4 Always remember to respect the environment and other people. Always use the motorcycle with caution, it is in everybodys interest to safeguard the future of our sport. Enjoy yourself with your TM motorcycle! TM RACING S.p.A. Via Fano 6 - 61122 PESARO ITALY...
  • Page 5 IMPORTANT ADVICE REGARDING THE LEGAL WARRANTY AND THE COMMERCIAL WARRANTY TM sport motorcycles are designed and constructed in a manner to support the stress that may be verified in normal road and competition use. Competition motorcycles are in compliance with the regulations of the categories actually in force at the most important international motorcycling federations.

  • Page 6: Table Of Contents

    INDEX INDEX Page Page POSITION OF SERIAL NUMBER ........... 7 Chain maintenance ................44 Frame number ................... 8 Chain wear ..................45 Engine number ................... 8 Basic indications for TM disc brakes ..........45 OPERATING CONTROLS ..............9 Front brake NISSIN pump (END/MX) ..........46 Clutch lever BREMBO pump ..............

  • Page 7: Position Of Serial Number

    POSITION POSITION OF SERIAL OF SERIAL NUMBER NUMBER ENGLISH ENGLISH...

  • Page 8: Frame Number

    POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER FRAME NUMBER The frame number is embossed on the right side of the steering metal tube. Make note of this number in the appropriate space on page 3. In the END, SMR, SMM models, the serial number is also stated on a plate positioned on the left hand side.

  • Page 9: Operating Controls

    OPERATING OPERATING CONTROLS CONTROLS ENGLISH ENGLISH...

  • Page 10: Clutch Lever Brembo Pump

    OPERATING CONTROLS OPERATING CONTROLS CLUTCH LEVER BREMBO PUMP The Brembo clutch pump is visibile in the picture with n. 1 The clutch lever (2) is located on the left side of the handlebar. With this option, to adjust the clutch lever distance from the handlebar grip (see maintenance operation), you have to turn the adjustment knob (3).

  • Page 11: Electronic Digital Tachometer (End)

    OPERATING CONTROLS OPERATING CONTROLS ELECTRONIC DIGITAL TACHOMETER (END) See n.1 in the picture. It has a large backlit display and four pilot lights. On the LH side, in the top there is the high beam pilot light (2), in the centre there is the neutral pilot light (3) not used, in the bottom there is the ADJUST button (4).

  • Page 12: Engine Stop Switch (Mx/Smx)

    OPERATING CONTROLS OPERATING CONTROLS ENGINE STOP SWITCH (MX) The engine stop switch is found near the clutch pump. The engine is shutdown using the engine stop switch (20): when it is activated a shortcircuit is caused in the ignition, which no longer supplies voltage to the spark plug.

  • Page 13: Handlebar Switch (Smr/Smm)

    OPERATING CONTROLS OPERATING CONTROLS HANDLEBAR SWITCH (END) This command is located near the the handlebar left grip. See n. 1 in the picture. The use of the handlebar switch is normal and simple. The button (2) activates the horn, the button (3) if pressed towards left, activates the LH indicator, if pressed towards right, activates the RH indicator.

  • Page 14: Ignition Switch

    OPERATING CONTROLS OPERATING CONTROLS IGNITION SWITCH In the SMR and SMM models a lock (1) for the ignition key is added on the left side of the dashboard. By turning the key clockwise, the electric circuit is closed and you can press the kickstart pedal up the engine.

  • Page 15: Idle Speed Adjustment Command

    OPERATING CONTROLS OPERATING CONTROLS IDLE SPEED ADJUSTMENT COMMAND This control is on the left-hand side of the carburettor for both models. Turning the idle screw (2) increases or decreases the engine’s idling speed. Turn it clockwise to increase the idling speed or anticlockwise to de- crease it.

  • Page 16: Side Stand

    OPERATING CONTROLS OPERATING CONTROLS SIDE STAND Push the side stand to the floor using the foot and rest the motorcycle on it. Pay attention that the ground is solid and the position stable. SIDE STAND FIXING FOR OFF-ROAD ROUTES If you drive the motorcycle off-road, the closed side stand can be ad- ditionally fixed using a rubber band (1).

  • Page 17: Fork Rebound Adjustment

    OPERATING CONTROLS OPERATING CONTROLS FORK REBOUND ADJUSTMENT The hydraulic dampening in extension determines the behaviour of the fork in the rebound stroke. The degree of dampening in rebound can be adjusted on the basis of rider preferences and/or hardness of the spring installed. MARZOCCHI USD FORK The adjustment screw (1) is located in the lower part of the fork leg.

  • Page 18: Shock Absorber Rebound Adjustment

    OPERATING CONTROLS OPERATING CONTROLS OHLINS SHOCK ABSORBER (OPTIONAL) Low speed- The adjustment screw (1) is on the top of the damper gas tank. Use a screwdriver. By turning the screw clockwise, dampening increases, anticlockwise dampening decreases. A total of 25 clicks are available.

  • Page 19: Steering Lock

    OPERATING CONTROLS OPERATING CONTROLS OHLINS SHOCK ABSORBER (OPTIONAL) The adjustment knob (1) is located low at the end of the damper rod. Operate manually. By turning clockwise (looking from the bottom up- wards) braking increases, anticlockwise, it decreases. A total of 40 clicks are available.
  • Page 20 ENGLISH ENGLISH...

  • Page 21: Advice And General Recommendations For Commissioning The Motorcycle

    ADVICE AND ADVICE AND GENERAL GENERAL RECOMMENDATIONS RECOMMENDATIONS FOR COMMISSIONING FOR COMMISSIONING THE MOTORCYCLE THE MOTORCYCLE ENGLISH ENGLISH...

  • Page 22: Indications For First Start-Up

    ADVICE AND GENERAL RECCOMANDATIONS FOR ADVICE AND GENERAL RECCOMANDATIONS FOR COMMISSIONING THE MOTORCYCLE COMMISSIONING THE MOTORCYCLE DANGER INDICATIONS FOR FIRST START-UP - ALWAYS WEAR SUITABLE CLOTHING WHEN USING THE MOTOR- CYCLE. ASTUTE MOTORCYCLISTS THAT DRIVE A TM ALWAYS - Ensure that the “PRE-DELIVERY OPERATIONS” of your mo- WEAR THE TYPE-APPROVED HELMET, BOOTS, GLOVES AND torcycle have been carried out by your TM dealer.

  • Page 23: Instructions For Use

    INSTRUCTIONS INSTRUCTIONS FOR USE FOR USE ENGLISH ENGLISH...

  • Page 24: Check Before Every Start-Up

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE CHECK BEFORE EVERY START-UP To use the motorcycle safely, it must be in a good shape. It is a good idea to carry out a general check-up of the motorcycle before every start-up. This check must include the following operations: 1 LEVEL OF TRANSMISSION OIL To ensure adequate lubrication, the level of the oil in the engine must be kept within the envisioned limits.

  • Page 25: Cold Engine Start

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE COLD ENGINE START 1 Open the fuel tap (1). 2 Remove the motorcycle from the stand. 3 Put the gears in neutral. 4 Activate the choke command (2), which is located on the left side of the carburetor.

  • Page 26: If The Engine Is "Flooded

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE IF THE ENGINE IS “FLOODED” In the event of a fall, a certain amount of fuel can flow out the carburetor and enter the cylinder, “flooding” the engine. To start the engine, pull out the plug cap assy , unscrew the spark plug and extract it, then press the kick start pedal several times firmly DOWN TO THE BOTTOM.
  • Page 27 INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INDICATION: All TM models do not have a radiator cooling fan and the radiator di- mensions have been studied to optimise compactness and weight. The cooling system is sufficient for touristic or sports use. If you want to use an additional cooling fan contact a TM authorised dealer.

  • Page 28: Braking

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE BRAKING Close the throttle and brake at the same time progressively with the front and rear brakes. Insert a lower gear depending on speed. On dusty, wet or slippery surfaces, operate the brakes and change down the gears gently without locking the wheels.

  • Page 29: Fuel

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INDICATIONS REGARDING THE SIDE STAND: Push the stand forward until it stops and lean the motorcycle on it. Ensure that the ground is solid and the parking position is stable. For greater safety insert the 1st gear. WARNING THE SIDE STAND IS DESIGNED ONLY FOR THE WEIGHT OF THE MO- TORCYCLE.
  • Page 30 ENGLISH ENGLISH...

  • Page 31: Maintenance And Lubrication Table

    MAINTENANCE MAINTENANCE LUBRICATION LUBRICATION TABLE TABLE ENGLISH ENGLISH...
  • Page 32 MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE 85/100/125/144 END/MX HOBBY USE 85/100/125/144 END/MX HOBBY USE SERVICE A CLEAN VEHICLE ALLOWS qUICKER AND THEREFORE CHEAPER INSPECTIONS EVERY 30 HOURS AFTER 3 HOURS •...
  • Page 33 MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE 85/100/125/144 END/MX COMPETITION USE 85/100/125/144 END/MX COMPETITION USE SERVICE A CLEAN VEHICLE ALLOWS qUICKER AND THEREFORE CHEAPER INSPECTIONS EVERY AFTER 2 HOURS RACE • •...
  • Page 34 MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE BRIEF CHECK AND MAINTENANCE OPERATIONS TO BE PERFORMED BY THE RIDER/PILOT BRIEF CHECK AND MAINTENANCE OPERATIONS TO BE PERFORMED BY THE RIDER/PILOT BEFORE EVERY AFTER EVERY AFTER START UP WASH OFF-ROAD USE •...
  • Page 35 MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE CHECKS TO BE CARRIED OUT ON ENGINE 85/100 MX CHECKS TO BE CARRIED OUT ON ENGINE 85/100 MX COMPETITION USE COMPETITION USE 15 HOURS 30 HOURS 45 HOURS 60 HOURS 75 HOURS 90 HOURS •...
  • Page 36 MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE CHECKS TO BE CARRIED OUT ON ENGINE 85/100 MX CHECKS TO BE CARRIED OUT ON ENGINE 85/100 MX HOBBY USE HOBBY USE HOURS HOURS HOURS HOURS HOURS HOURS • • • • •...

  • Page 37: Frame And Engine Maintenance

    FRAME AND FRAME AND ENGINE ENGINE MAINTENANCE MAINTENANCE ENGLISH ENGLISH...

  • Page 38: Check Steering Bearings And Play Adjustment

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE DANGER ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH (A) REQUIRE TECHNICAL MASTERY. FOR THIS REASON IT IS IN THE INTEREST OF YOUR SAFETY TO HAVE THESE OPERATIONS CARRIED OUT EXCLUSIVELEY BY A SPECIALISED TM WORKSHOP WHERE YOUR MOTORCYCLE WILL BE MAINTAINED IN AN OPTIMAL MANNER BY SPECIFICALLY TRAINED STAFF.

  • Page 39: Telescopic Fork Vent Screws

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE TELESCOPIC FORK VENT SCREWS Every 5 hours of use in competition it is necessary to release the the air-pressure from inside the fork. The Marzocchi fork features a tyre valve (1) protected by a rubber cap (2).

  • Page 40: Basic Calibration Of The Chassis On The Basis Of Pilot Weight

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE BASIC CALIBRATION OF THE CYCLE PART ON THE BASIS OF THE PILOT’S WEIGHT To obtain optimal driving features of the motorcycle and to prevent dam- age to the fork, rear shock, rear swing arm and frame, it is necessary that the basic calibration of the suspension is adapted to your body weight.

  • Page 41: Establishing Rear Shock Lowering In Running Order

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE ESTABLISHING REAR SHOCK LOWERING IN RIDING CONDITIONS - Now, with the help of a person who holds the motorcycle, sit on the motorcycle wearing all protective clothing (with feet on the footrests) and rock up and down a few times to normalise the set-up of the rear suspension.

  • Page 42: Replacement Of Fork Springs

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE REPLACEMENT OF FORK SPRINGS If your body weight is less than 70 kg or exceeds 80 kg, adequate fork springs must be used. If you are in doubt or have any questions, please contact your authorised TM dealer.

  • Page 43: Rear Suspension Mechanical Linkage

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE REAR SUSPENSION MECHANICAL LINKAGE The rear suspension of all TM motorcycles has a link-rod and rocker mechanism that progressively changes the lever ratio between the wheel and the rear shock. This mechanism works on bearings, which must be cleaned and greased at the envisioned intervals to maintain the working of the suspension efficient.

  • Page 44: Adjustment Of Chain Tension (Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE ADJUSTMENT OF CHAIN TENSION (SMM) Loosen both the locking screws (1) of the rear eccentric hub in a way that the hub itself can turn around its axis. Using the relevant TM tool, code F50806 (2), turn the hub until correct chain tension is reached.

  • Page 45: Chain Wear

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CHAIN WEAR To check chain wear follow carefully the instructions given below : put the gear into neutral, pull the upper part of the chain in an upward direction with a force of 10 - 15 kilograms (see figure). Now, measure the distance of 18 links on the lower part of the chain.

  • Page 46: Front Brake Nissin Pump (End/Mx)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE BRAKE FLUID RESERVOIRS: The front and rear brake liquid reservoirs are dimensioned in a way that topping-up is not necessary even if the brake pads are worn. In fact, when the pads are worn, the fluid in the hoses tends to occupy the space left by the small pistons, which have moved so that the pads always lay on the disc.

  • Page 47: Front Brake Brembo Radial Pump (Smr/Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE WARNING - DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS, THE BRAKE FLUID CORRODES PAINT. - USE ONLY CLEAN BRAKE FLUID OUT OF A HERMETICALLY SEALED CONTAINER. FRONT BRAKE BREMBO RADIAL PUMP (SMR/SMM) FRONT BRAKE LEVER ADJUSTMENT The distance of the front brake lever from the handlebar grip can be ad-...

  • Page 48: Replacement Of Front Brake Pads

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE REPLACEMENT OF FRONT BRAKE PADS (A) FOR ALL MODELS WITH FLOATING CALIPER (END/MX) Push the brake caliper towards the disc, in a way that the brake pistons reach their base position. Remove the safety devices (1), extract the pin (2) and remove the pads from the caliper.

  • Page 49: Modification Of Rear Brake Pedal Base Position

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE MODIFICATION OF REAR BRAKE PEDAL BASE POSITION (A) The base position of the rear brake pedal can be modified in the following way: loosen counter-nut M6 (1) fork side, turn the adjustment screws by acting on the hexagonal head (2).

  • Page 50: Check Rear Brake Pads

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CHECK REAR BRAKE PADS The brake pads must be controlled from the rear side. The thickness of the pad friction material must not be less than 1 mm. DANGER AT THE THINNEST POINT, THE THICKNESS OF THE BRAKE PAD FRICTION MATERIAL MUST NOT BE LESS THAN 1 MM, OTHERWISE A FAULT COULD OCCUR IN THE BRAKES.

  • Page 51: Disassembly And Assembly Of The Rear Wheel (All Except Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE WARNING - NEVER ACTIVATE THE BRAKE LEVER WHEN THE FRONT WHEEL IS DISASSEMBLED - ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO PREVENT DAMAGE. To re-assemble the front wheel, insert it carefully into the fork, taking care to insert the disc correctly between the brake pads without damaging them.

  • Page 52: Disassembly And Assembly Of Rear Wheel (Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE DISASSEMBLY AND ASSEMBLY OF REAR WHEEL (SMM) Rest the motorcycle with the frame cradle on a stand, in a way that the rear wheel does not touch the ground. Cut the safety binding (1), slide out the clasp (2) and unscrew the wheel nut M50x1.5 (3).

  • Page 53: Tyres, Tyre Pressure

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE TYRES, TYRE PRESSURE TYRE PRESSURE TYRE PRESSURE The type, the state and the pressure of the tyres condition the motor- FRONT REAR cycle’s behaviour on the road and they must be checked before every journey.

  • Page 54: Battery

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE BATTERY (SMR E SMM) The saddle must be removed to access the battery. The battery does not require maintenance. It is not necessary to check the level of the electrolyte or top-up with water.

  • Page 55: Halogen Light (End)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE HALOGEN LIGHT (END) LIGHT HEIGHT ADJUSTMENT The front light height can be adjusted. First you need to move the rubber stripes on the fork leg so as the light body sits horizontally, then you can turn the front screw (1) the adjust the light height.

  • Page 56: Halogen Light (Smr)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE HALOGEN LIGHT (SMR) LIGHT HEIGHT ADJUSTMENT The front light height can be adjusted. First you need to move the rubber stripes on the fork leg so as the light body sits horizontally, then you can turn the front screw (1) the adjust the light height.

  • Page 57: Ciclops Headlight (Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CICLOPS HEADLIGHT (SMM) REPLACEMENT OF HEADLIGHT/POSITION LIGHT BULB Release both of the elastic stripes and move the light-holder mask forward. HEADLIGHT BULB Disconnect the terminal, remove the cover (4) and the seal (5). Unscrew the screws (6) and remove the retainer (7).

  • Page 58: Led Rear Light (End)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE LED REAR LIGHT (END) REPLACEMENT POSITION LED/ STOP LED / NUMBER PLATE Unscrew the screws (1) and remove the rear light body after discon- necting the wires from the bike harness. Since the led light is a single part, you have to change it completely.

  • Page 59: Cooling

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE COOLING The water pump (1) housed in the engine induces forced circulation of the coolant liquid. There is no thermostat in the system, therefore, when the engine is cold, it is important to moderate the number of revs. of the engine and speed. Proceed for at least 5 minutes at half throttle and at reduced pace to allow the engine to reach an adequate working temperature.

  • Page 60: Check Coolant Level

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CHECK COOLANT LEVEL When the engine is cold, the liquid must cover the radiator channels by at least 10 mm. If the circuit is emptied, fill it immediately and bleed. WARNING WHEN THE COOLANT LIQUID HAS BEEN EMPTIED, WHEN RE-FILLING IT IS NECESSARY TO BLEED THE COOLING SYSTEM (SEE BELOW).

  • Page 61: Cleaning The Air Filter

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE WARNING REPLACE THE FIBREGLASS CARTRIDGE WITH A NEW ONE OF THE SAME BASIC WEIGHT OR BOUGHT AT A TM AUTHORIZED DEALER. FIBREGLASS LENGTH: 85cc / 100cc MX L=255mm 125cc / 144cc MX L=320mm 125cc / 144cc END L=435mm 125cc / 144cc SMR/SMM L=435mm CLEANING THE AIR FILTER...

  • Page 62: Hydraulic Clutch Brembo Pump

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE HYDRAULIC CLUTCH BREMBO PUMP ADJUSTMENT OF CLUTCH LEVER BASIC POSITION With this option, to adjust the clutch lever distance from the handlebar grip (see maintenance operation), you have to turn the adjustment knob (1).

  • Page 63: Notes On The Carburettor

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE NOTES ON THE CARBURETTOR The carburetor is calibrated at sea level and at a temperature of 20° using premium-grade fuel (RON95, unleaded) mixed with 1:30 specific 2T oil. The only changes that you might need to make are to the main jet, idle jet and jet needle;...

  • Page 64: Check Fuel Level (Float Height)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CARBURETOR ADJUSTMENTS OPERATION AT IDLING SPEED Turn the idle adjustment screw to gently adjust engine range – clockwise to increase, anticlockwise to decrease. Make sure the engine speed is as smooth and constant as possible. OPERATION WITH THROTTLE VALVE OPENING If you have properly regulated the idling speed and partial capacity but the engine rumbles, emits excessive fumes and reaches full speed...

  • Page 65: Emptying The Carburetor Float Bowl

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE EMPTYING THE CARBURETOR FLOAT BOWL After washing or driving in wet environments (watercourses, etc.) the carburetor float bowl should be emptied to remove any water that may have entered. Water in the float bowl causes working problems.

  • Page 66: Transmission Oil

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE TRANSMISSION OIL TM use and recommended Bel-Ray Gear Saver SAE 80W. WARNING LOW OIL LEVEL, LOW QUALITY OIL MAINTENANCE INTERVALS LONGER THAN THOSE ESTABLISHED, CAUSE SERIOUS DAMAGE TO THE EN- GINE. CHANGE TRANSMISSION OIL (A) WARNING WHEN CHANGING THE OIL, CLEAN THE MAGNET OF THE OIL DRAIN BOLT The oil must be changed with the engine at working temperature.

  • Page 67: Tmees Electronic Exhaust Valve (125 End/Mx)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE TMEES ELECTRONIC EXHAUST VALVE (125 END/MX) Starting from 2012, on the 125 engines in END and MX versions, a new digitally controlled valve has been introduced to shut the exhaust port. The main components are shown in the picture. Servomotor (1), control cables (2), cylinder with valve (3).
  • Page 68 FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE Lock the cylinder pulley (10) by mean of another 4mm dia. pin (the straight shank of a drill is enough in both cases). Now it is possible to check the correct cables tension by extracting them from their seat one at a time and measuring the preload between the sheath and the seat, it must be around 1.5-2.0 mm If necessary operate on the registers (12) to restore the correct...

  • Page 69: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING If you have the envisioned maintenance operations carried out on your motorcycle, you will have very few problems. If, however, a problem does occur, please look for it in the following table and try to solve it. Please note that a lot of the operations cannot be carried out without the help of technicians .
  • Page 70 TROUBLESHOOTING TROUBLESHOOTING PROBLEM CAUSE SOLUTION Clogged idle speed jet Disassemble the carburetor and clean the jet THE ENGINE WILL NOT Altered idle speed adjustment screws Adjust the idle speed screws RUN AT IDLE SPEED Damaged spark plug Replace the spark plug Faulty Ignition system Have the ignition system checked The fuel overflows because the level is adjusted too...

  • Page 71: Cleaning

    CLEANING CLEANING Clean the motorcycle regularly in a way to maintain the surface of the plastic parts in good condition. To do this, it is advised to use hot water with a detergent and sponge. Most of the dirt can be removed using weak water jets. WARNING NEVER CLEAN THE MOTORCYCLE WITH HIGH PRESSURE CLEANING DEVICES OR WITH STRONG JETS OF WATER! BECAUSE OF THE HIGH PRESSURE THE WATER COULD REACH THE ELECTRICAL PARTS, CONNECTORS, FLEXIBLE CABLE COMMANDS, BEARINGS, THE...

  • Page 72: Technical Data - Engine

    TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE 85/100 MX 2012 TECHNICAL DATA - ENGINE 85/100 MX 2012 ENGINE 85 MX 100 MX Type 2 stroke single-cylinder , liquid cooled Displacement 85 cm 100 cm Cylinder bore and stroke 47.95x47 51.97x47 Compression...
  • Page 73 TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE 125/144 END/MX/SMR/SMM 2012 TECHNICAL DATA - ENGINE 125/144 END/MX/SMR/SMM 2012 ENGINE SMR/SMM Type 2 stroke single-cylinder , liquid cooled Displacement 124.8 cm 143.3 cm Cylinder bore and stroke 54 x 54.5 mm 56 x 58.2 mm Compression...

  • Page 74: Carburetor Settings

    CARBURETOR SETTINGS 2012 CARBURETOR SETTINGS 2012 85-100 MIKUNI TM 28-91 Type Main Jet Slow Jet Jet needle 5DP-39 Clip position 4^ from top Throttle valve Slow air screw 1.5 turns Float height 16.30 mm. 125-144 125 END 125 MX 144 END KEIHIN 144 MX SMM/SMR...

  • Page 75: Engine Tightening Torques

    ENGINE TIGHTENING TORqUES ENGINE TIGHTENING TORqUES 85-100 cc 85/100/125/144 ENGINE TIGHTENING TORqUES 2012 Crankase Allen screws, transmission cover, clutch cover, ignition cover 8 Nm Oil drain screw cap M14x1.5 20 Nm Oil filler screw cap M14x1.5 20 Nm Oil net filter screw cap 8 Nm Oil cartridge filter cover Allen screws Engine oil pump body screws...

  • Page 76: Technical Data-Cycle Part

    TECHNICAL DATA - CYCLE PART TECHNICAL DATA - CYCLE PART TECHNICAL DATA - CYCLE PART 85/100 JUNIOR MX 2012 TECHNICAL DATA - CYCLE PART 85/100 JUNIOR MX 2012 85 JUNIOR 100 JUNIOR Frame Perimeter in CrMo tubes Front suspension Paioli USD fork Rear/front suspension travel Rear suspension , Ohlins...
  • Page 77 TECHNICAL DATA - CYCLE PART TECHNICAL DATA - CYCLE PART TECHNICAL DATA - CYCLE PART 85/100 SENIOR MX - 125/144 MX/END/SMR/SMM 2012 TECHNICAL DATA - CYCLE PART 85/100 SENIOR MX - 125/144 MX/END/SMR/SMM 2012 85/100 SENIOR 125/144 END 125 SMR/SMM 125/144 MX Frame Twin-spar high resistance aluminium alloy frame...

  • Page 78: Alphabetic Index

    ALPHABETIC INDEX ALPHABETIC INDEX Page Page Front brake lever BREMBO radial pump (SMR/SMM) ...... 10 Adjustment of chain tension (all models except SMM) ....43 Adjustment of chain tension (SMM) ..........44 Front brake lever NISSIN pump ............10 Front brake NISSIN pump (END/MX) ..........46 ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE .........

  • Page 79: Wiring Diagram

    WIRING DIAGRAMS 2012 WIRING DIAGRAMS 2012 ENGLISH ENGLISH...
  • Page 80 TMEES TMEES (TM Electronic Exhaust System) (TM Electronic Exhaust System) ENGLISH ENGLISH...
  • Page 81 TMEES (TM Electronic Exhaust System) TMEES (TM Electronic Exhaust System) ENGLISH ENGLISH...
  • Page 82 TMEES (TM Electronic Exhaust System) TMEES (TM Electronic Exhaust System) ENGLISH ENGLISH...
  • Page 83 TMEES (TM Electronic Exhaust System) TMEES (TM Electronic Exhaust System) ENGLISH ENGLISH...

This manual is also suitable for:

Tm 2 stroke 100Tm 2 stroke 144Tm 2 stroke 125Tm 2 stroke 250 2012Tm 2 stroke 300 20122012 tm 85 mx ... Show all
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