um DSR EX 125 Manuale di istruzioni
ENGINE 125 4T / 4V 6M EURO 4
WORKSHOP MANUAL
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.
Completely satisfactory work cannot however be carried out without the availability of suitable facilities
and tools, which is why we ask you to consult the pages of this manual referring to special tools and imple-
ments.
Particularly important items of information in this manual are distinguished by the following an N.B.:tions:
N.B.
KEY INFORMATION FOR PERFORMING THE PROCEDURE IN AN EASIER AND CLEARER WAY, OR ANY
ESSENTIAL OPERATION.
UM MOTORCYCLES
The UM logo is the registered trademark and property of UM.
The total or partial reproduction of any photograph, graphical image or text inserted in this ma-
nual is prohibited.© 2017 UM
1
INTRODUCTION
WORKSHOP MANUAL
GENERAL INFORMATION
ENGINE SPECIF ICATIONS
TIGHTENING TORQUES
IDENTIFICATION OF SETS
ELECTRICAL SYSTEM SPECIFICATIONS
LUBRICATION CIRCUIT
COOLANT CIRCUIT
PERIODICAL INSPECTIONS AND ADJUSTMENTS
DISMANTLING THE ENGINE
Camshaft
Timing chain
Cylinder head, cylinder and piston
Flyweel magneto
Clutch
Oil pump
Crankshaft
Crankcases
Transmission, gear selector, gearchange shaft and selector distributor
INSPECTION AND REPAIR
ASSEMBLING AND ADJUSTING THE ENGINE
Transmission, gear selector, gearchange shaft and selector distributor
Crankshaft
Crankcases
Oil pump
Clutch
Flyweel magneto
Camshaft
Timing chain
Installing the piston rings
Cylinder head, cylinder and piston
FUEL SUPPLY
Pag. 4
Pag. 12
Pag. 13
Pag. 15
Pag. 19
Pag. 21
Pag. 23
Pag. 34
Pag. 33
Pag. 33
Pag. 34
Pag. 36
Pag. 40
Pag. 41
Pag. 43
Pag. 44
Pag. 45
Pag. 46
Pag. 48
Pag. 58
Pag. 59
Pag. 63
Pag. 66
Pag. 68
Pag. 70
Pag. 75
Pag. 78
Pag. 81
Pag. 84
Pag. 85
Pag. 91
3
INDEX
WORKSHOP MANUAL
Diagram wiring
APPENDIX :
MAGNETI MARELLI DONGLE INSRUCTION
REGULATIONS
This section describes the machine’s general safety and maintenance work rules.
SAFETY REGULATIONS
- In the event of having to carry out work on the engine while this is running, ensure that the area is well
ventilated, where possible using extractor fans. Never leave engines running in closed spaces. Exhaust gases
are poisonous.
- 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.
During assembly, always use new gaskets, oil seals, piston rings and keys.
After dismantling, clean the components with solvents that are non-inflammable or with a high flammability
point. Grease all working surfaces before assembling, excluding tapered joints.
After assembly, check that all components have been correctly fitted and that they are functioning perfectly.
For dismantling, checking and assembly operations use only tools with metric measurements. Metric screws,
nuts and bolts are not interchangeable with imperial measurement joining devices. Using unsuitable tools
and joining devices may damage the machine.
In the case of work on the machine’s electrical circuitry, check that electrical connections have been correctly
fitted, especially the earth connections.
4
GENERAL INFORMATION
WORKSHOP MANUAL
IDENTIFICATION
MODEL CHASSIS CODE ENGINE CODE
DSR EX 125
DSR SM 125
RENEGADE SCRAMBLER CLASSIC 125
RENEGADE SCRAMBLER SPORT 125
DSR ADVENTURE 125
DSR ADVENTURE TT 125
M6FSC0001Hxxxxxxx
M6FDA0001Hxxxxxxx
M6FDS0001Hxxxxxxx
ENGINE CODE
The engine code can be found at the back of the engine,
in front of the rear wheel.
5
GENERAL INFORMATION
WORKSHOP MANUAL
UXPI 125
xxxxxxx
PREPARATION 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. Related parts must always
be reassembled or replaced together.
While dismantling the motorcycle, clean all the parts and lay
them out on trays in the order dismantled. This speeds up re-
assembly and ensures the correct fitting of all the parts.
Keep all parts away from any contact with fire.
P
6
GENERAL INFORMATION
WORKSHOP MANUAL
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-RINGS
Renew all seals, retaining rings and O-rings when servicing
the engine.
All surfaces receiving seals, retaining ring edges and O-rings
must be cleaned.
Apply oil to all paired parts and bearing during reassembly.
Apply grease to the retaining ring edges.
TAB/SPACER WASHERS AND SPLIT PINS
After removing them, renew all tab/spacer washers (1) and
split pins. Bend the tabs to fit the flat surfaces of the bolt or
nut once they have been tightened to the specified torque.
BEARINGS AND RETAINING RINGS
Fit bearings and retaining rings in such a way that the ma-
nufacturers marks remain visible. On fitting retaining rings,
applying a thin film of light lithium soap based grease to
their edges. Where required, apply oil generously when fit-
ting bearings.
WARNING
DO NOT USE COMPRESSED AIR TO DRY BEARINGS. THIS
DAMAGES THE BEARING SURFACES.
T
7
GENERAL INFORMATION
WORKSHOP MANUAL
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.
See the figure on the side, (4) Shaft.
SPECIAL TOOLS
The following special tools are needed for assembly and for
complete and exact adjustments. Only use the proper special
tools; thereby avoiding damage caused by the use of unsui-
table tools or improvised techniques.
Ref. 865260
The camshaft sprocket locking tool.
Ref. 865259
Magneto flywheel locking tool.
8
GENERAL INFORMATION
WORKSHOP MANUAL
TDC measuring tool.
Ref. T01010047
Ref. T01010046
9
Ref. 864592
TDC measuring tool.
Ref. 00H05300041
Clutch bell housing fitting tool.
Ref. 864486
Balance shaft locking tool.
Ref. 864567
Set of camshaft locking keys.
GENERAL INFORMATION
WORKSHOP MANUAL
Ref. T01010045
Ref. T01010042
Ref. T01010043
Ref. T01010044
Questo manuale è adatto per i seguenti modelli
5
Indice
Altri manuali um Motore
