TM RACING TM 2 stroke 85 Istruzioni operative
ENGLISH
ENGLISH
2
ENGLISH
ENGLISH
3
ENGINE NUMBER
KEY NUMBER
STAMP OF THE AUTHORISED DEALER
TM reserves the right to carry out changes without forewarning. The specications can change from country to country.
All indications are valid subject to spelling and printing errors.
FRAME NUMBER
Please make note of your motorcycle’s serial numbers in the boxes below.
When you must contact TM for spare parts, updating requests or to signal problems, indicate the model, cylinder capacity, year of
manufacture and most of all the frame number and the engine serial number.
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!
WARNING
FAILURE TO COMPLY WITH THESE WARNINGS COULD CAUSE DAMAGE TO PARTS OF THE MOTORCYCLE
OR MAKE IT UNSAFE FOR USE.
ENGLISH
ENGLISH
4
Dear TM customer,
We would like to congratulate you for having chosen a TM motorcycle.
Your TM is a competitive and modern motorcycle that will surely give you a lot of satisfaction if you treat it ac-
cording to the provisions contained in this manual. Before starting up your TM motorcycle for the rst time,
you must read this manual carefully so as to understand the regulations for use and the features of
your new motorcycle.
Only in this way will you know how to adjust the motor cycle, and to adapt it in the best way possible
to your personal characteristics and how to protect yourself from injury. This manual also contains
important information regarding the maintenance of your new motorcycle.
This manual is based on the most recent information concerning the product that was available on going to print.
Further variations owing to succesive constructive developments of the motorcycle are however possible.
This manual is an integral part of the motorcycle, it must be given to the customer at the time of purchase and
must remain with the motor cycle whenever it is re-sold.
Please note that the operations marked with (A) in the “Frame and Engine Maintenance” chapter must be carried
out by a TM.specialised workshop. If these maintenance operations should be necessary during competitions,
they must be carried out by a qualied mechanic.
For your safety, only use TM original spare parts and accessories.
TM does not assume any responsibility for the use of other products and for damage deriving from
them.
We advise you to respect the running in period, inspection periods and established maintenance periods scru-
pulously. Only full compliance with these regulations will lengthen the life of your motorcycle. Overhauls and
repairs must only be carried out by a specialised TM workshop.
For any information or requests contact a specialised TM workshop, which is backed by the TM importer.
Please remember that a lot of technical data and information regarding TM motorcycles is available at: www.
tmracing.it.
Motorcycling is a marvellous sport that you will be able to enjoy with your TM motorcycle.
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
TM RESERVES THE RIGHT TO CHANGE OR TO EXECUTE MODIFICATIONS AS IT DEEMS NECESSARY
.
ENGLISH
ENGLISH
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
veried 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.
The scrupulous compliance with the established inspections, maintenance and tuning of the engine
and chassis part of the motorcycle, indicated in the user manual, is indispensable for correct func-
tioning and to prevent premature wear of the parts of the motorcycle itself.
Incorrect tuning of the engine or of the chassis can also jeopardise one’s own safety and that of
others.
The maintenance operations established in the “Maintenance and Lubrication” table must be car-
ried out by a specialised TM workshop at the envisioned dates, otherwise any warranty rights will
be forfeited.
When you must contact your TM Dealer for spare parts, updating requests or to signal problems, indicate
the model, cylinder capacity, year of manufacture and most of all the frame number and the engine serial
number.
Fuels and lubricants must be those established in the user and maintenance manual and must be
used as per maintenance programme. Products of other brands can be used as long as they have
the equivalent specications.
In cases of direct and consequent damage caused by tampering or modications to the motorcycle,
no legal warranty claim can be asserted.
The use of the motorcycle in extreme conditions, for example on muddy and very wet ground, may
lead to greater than average wear of components, such as transmission components or the brakes.
It is therefore possible that maintenance or replacement of some parts is necessary before the limit
normally envisioned by the maintenance programme.
MX AND SMX MODELS CANNOT BE USED ON PUBLIC ROADS.
The 125 and 144 models in the END, SMR and SMM versions can be used on roads only in the
unvaried type-approved version (reduced). Without this power limitation (i.e. reduced) these
models can only be used off-the-road, but not on public roads.
The END models have been designed for off-the-road resistance competitions (Enduro) and are
not suitable for Motocross.
The 85 and 100 models cannot be used on roads.
ENGLISH
ENGLISH
6
INDEX
INDEX
Page
POSITION OF SERIAL NUMBER ................................................... 7
Frame number ................................................................................... 8
Engine number ................................................................................... 8
OPERATING CONTROLS ................................................................ 9
Clutch lever BREMBO pump .............................................................. 10
Front brake lever NISSIN pump ...................................................... 10
Front brake lever BREMBO radial pump (SMR/SMM)......................... 10
Electronic digital tachometer (END)..................................................... 11
Electronic digital tachometer (SMR/SMM)........................................... 11
Engine stop switch (MX/SMX) ........................................................... 12
Combination switch (END)................................................................... 12
Handlebar switch (SMR/SMM).............................................................13
Maps selection switch ......................................................................... 13
Ignition switch ..................................................................................... 14
Fuel ller cap .................................................................................... 14
Fuel tap ............................................................................................. 14
Choke command (cold starter) .......................................................... 14
Idle speed adjustment command ..................................................... 15
Gear shift pedal ................................................................................. 15
Kickstart pedal .................................................................................... 15
Brake pedal ........................................................................................ 15
Side stand .......................................................................................... 16
Side stand xing for off-road routes .................................................... 16
Fork adjustment in compression ........................................................ 16
Fork rebound adjustment ................................................................... 17
Shock absorber compression adjustment .......................................... 17
Shock absorber rebound adjustment ................................................. 18
Steering lock .................................................................................. 19
ADVICE AND GENERAL RECOMMENDATIONS FOR
COMMISSIONING THE MOTORCYCLE ......................................... 21
Indications for rst start-up .......................................................... 22
Running in instructions ................................................................... 22
INSTRUCTIONS FOR USE .............................................................. 23
Check before every start-up ........................................................ 24
Cold engine start ........................................................................... 25
If the engine is “ooded” ................................................................ 26
Bike starting ..................................................................................... 26
Shifting gear, accelerating, slowing down .......................................... 26
Braking ........................................................................................... 28
Stopping and parking ..................................................................... 28
Fuel ................................................................................................... 29
MAINTENANCE AND LUBRICATION TABLE ................................. 31
FRAME AND ENGINE MAINTENANCE ........................................... 37
Check steering bearings and play adjustment .............................. 38
Telescopic fork vent screws ......................................................... 39
Cleaning telescopic fork dust scraper ............................................. 39
Basic calibration of the chassis on the basis of pilot weight ........... 40
Shock absorber calibration and spring check ................................ 40
Establishing rear shock static lowering ........................................ 40
Establishing rear shock lowering in running order ........................ 41
Check telescopic fork basic calibration ......................................... 41
Variation of telescopic fork preload .............................................. 41
Replacement of fork springs .......................................................... 42
Variation of rear shock spring preload .......................................... 42
Rear suspension mechanical linkage ............................................. 43
Check chain tension ......................................................................... 43
Adjustment of chain tension (all models except SMM) ..................... 43
Adjustment of chain tension (SMM) .................................................. 44
Page
Chain maintenance ............................................................................ 44
Chain wear ........................................................................................ 45
Basic indications for TM disc brakes ................................................ 45
Front brake NISSIN pump (END/MX) ................................................ 46
Front brake BREMBO radial pump (SMR/SMM)........... ...................... 47
Check front brake pads ..................................................................... 47
Replacement of front brake pads ..................................................... 48
Modication of rear brake pedal base position .................................. 49
Check rear brake uid level .............................................................. 49
Top-up rear brake uid ...................................................................... 49
Check rear brake pads ...................................................................... 50
Replacement of rear brake pads ....................................................... 50
Disassembly and assembly of the front wheel .................................. 50
Disassembly and assembly of the rear wheel (all except SMM) ....... 51
Disassembly and assembly of rear wheel (SMM) ............................. 52
Check spoke tension ......................................................................... 52
Tyres, tyre pressure .......................................................................... 53
Check adjustment of magnetic sensor for tachometer ..................... 53
Battery ............................................................................................... 54
Battery charge .................................................................................... 54
Halogen light (END) ........................................................................... 55
Halogen light (SMR) ........................................................................... 56
Ciclops headlight (SMM) ..................................................................... 57
LED rear light (END)............................................................................ 58
Rear light (SMR/SMM)......................................................................... 58
Direction indicator lamp (END/SMR/SMM) ....................................... 58
Cooling ............................................................................................. 59
Check coolant level .......................................................................... 60
Emptying, lling and bleeding of the cooling system ........................ 60
Replacement of exhaust silencer packing material ........................... 60
Cleaning the air lter ......................................................................... 61
Hydraulic clutch BREMBO pump ....................................................... 62
Bleeding hydraulic clutch ................................................................... 62
Throttle cable command adjustment .................................................. 62
Notes on the carburettor ................................................................... 63
Denition and use of carburetor for a 2 stroke engine ....................... 63
Check fuel level (oat height) ........................................................... 64
Basic indications regarding carburetor wear .................................... 64
Emptying the carburetor oat bowl .................................................... 65
Check transmission oil level ................................................................. 65
Transmission oil ................................................................................... 66
Change transmission oil ...................................................................... 66
Inspection of the reed valve ............................................................... 66
TMEES electronic exhaust valve (125 END/MX) ............................... 67
Valve control cables tension check .................................................... 67
TROUBLESHOOTING ...................................................................... 69
CLEANING ........................................................................................ 71
PRECAUTIONS FOR WINTER USE ................................................ 71
STORAGE ......................................................................................... 71
Start-up after seasonal pause ........................................................... 71
TECHNICAL DATA - ENGINE ......................................................... 72
CARBURETOR SETTINGS .............................................................. 74
ENGINE TIGHTENING TORQUES .................................................. 75
TECHNICAL DATA-CYCLE PART .................................................... 76
ALPHABETIC INDEX ....................................................................... 78
WIRING DIAGRAM .............................................................. appendix
TMEES Assembling and adjustment .................................. appendix
ENGLISH
ENGLISH
7
POSITION
OF SERIAL
NUMBER
POSITION
OF SERIAL
NUMBER
ENGLISH
ENGLISH
8
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. See photo.
The frame number for models 85/100 Junior is on the right-hand side
of the head tube.
ENGINE NUMBER
The engine number is engraved on the back side of the engine. Make
note of this number in the appropriate space on page 3.
POSITION OF SERIAL NUMBER
ENGLISH
ENGLISH
9
OPERATING
CONTROLS
OPERATING
CONTROLS
ENGLISH
ENGLISH
10
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).
Rotate clockwise to increase the distance or counterclockwise to de-
crease the distance.
FRONT BRAKE LEVER NISSIN PUMP (END/MX)
The front brake pump lever (4) is located on the right side of the handlebar
and activates the front wheel brake.
The distance of the front brak lever from the handlebar grip can be
adjusted through the adjustment screw (5) (see “Frame and Engine
Maintenance” chapter”).
FRONT BRAKE LEVER BREMBO RADIAL PUMP
(SMR/SMM)
The front brake pump lever (6) is located on the right side of the handle-
bar and activates the front wheel brake. The distance of the brake lever
from the handlebar grip can be adjusted through the adjustment knob
(7) (see “Frame and Engine Maintenance” chapter)
Questo manuale è adatto per i seguenti modelli
13
Indice
Altri manuali TM RACING Motociclo
TM RACING
TM RACING TM 4 STROKE 2007 Manuale utente
TM RACING
TM RACING 4 Stroke 2009 Istruzioni operative
TM RACING
TM RACING 250Fi EN Manuale di istruzioni
TM RACING
TM RACING 2010 STROKE 250 Istruzioni operative
TM RACING
TM RACING 250Fi EN Manuale utente
TM RACING
TM RACING 4 STROKE 2006 Istruzioni operative
TM RACING
TM RACING 125 SMR 2022 Manuale utente
