TM RACING 125 EN 2022 Use And Maintenance Manual Download Page 14

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2-STROKE - EN

Summary of Contents for 125 EN 2022

Page 1: ...www tmracing it 125 SMR EN TSI 125 MX SMK 144 SMR EN MX SMK 2 STROKE USE AND MAINTENANCE MANUAL...

Page 3: ...with the standard engine regardless of the type of use Code 2 Type of Use used on its own means that the information refers to all motorcycles with that type of use regardless of displacement and pow...

Page 4: ...MAY LEAD TO SERIOUS INJURY OR DEATH DANGER ALL MAINTENANCE WORK OR ADJUSTMENTS MARKED WITH THE ABOVE SYMBOL REQUIRE TECHNICAL KNOWLEDGE THEREFORE FOR YOUR SAFETY HAVE SUCH OPERATIONS CARRIED OUT ONLY...

Page 5: ...hol If it does determine the type and percentage of alcohol used If during operation no negative effects are detected while using petrol containing alcohol or which you think may contain it replace it...

Page 6: ...ion centers in compliance with regulations in force in the country in which the motorcycle is used LITHIUM IRON PHOSPHATE BATTERY SMR EN The motorcycles do not have electric start up and are fitted wi...

Page 7: ...orting your TM motorcycle make sure that it is secured in an upright position using straps or other mechanical fixing devices to be fixed on sturdy parts of the motorcycle such as the handlebar forks...

Page 8: ...8 2 STROKE EN...

Page 9: ...issues always quote the model displacement year of manufacture and above all the frame serial number and engine serial number Use the fuels and lubricants indicated in the use and maintenance manual...

Page 10: ...10 2 STROKE EN...

Page 11: ...ding on the weight of the rider 4 61 Adapting fork basic calibration 4 61 Adapting shock absorber basic calibration 4 61 Checking shock absorber static sag 4 62 Checking shock absorber rider sag 4 62...

Page 12: ...EN Chassis technical data 6 122 Tightening torques 6 122 7 WIRING DIAGRAMS 7 123 Carburettor wiring diagram 1285 144 MX 7 124 Engine wiring diagram SMR 125 144 EN 7 125 Engine wiring diagram EN 125 S...

Page 13: ...13 CONTENTS EN 2 STROKE 1 VEHICLE IDENTIFICATION 2 CONTROL COMPONENTS 3 INSTRUCTIONS FOR USE 4 MAINTENANCE 5 DIAGNOSIS 6 TECHNICAL DATA 7 WIRING DIAGRAMS...

Page 14: ...14 2 STROKE EN...

Page 15: ...1 VEHICLE IDENTIFICATION...

Page 16: ...1 16 1 VEHICLE IDENTIFICATION 2 STROKE EN...

Page 17: ...NUMBER 2T 125 EN TM RACING S p A L3e A1E e24 168 2013 00064 ZEX125AKSTMMP0000 85 dB A 3250 min 1 5 4 kW max 250 kg 2T 125 SM TM RACING S p A L3e A1E e24 168 2013 00064 ZEX125AMSTMMP0000 82 dB A 3250 m...

Page 18: ...1 18 1 VEHICLE IDENTIFICATION 2 STROKE EN...

Page 19: ...2 CONTROL COMPONENTS...

Page 20: ...R 4 Front wheel 5 Front suspensions 6 Exhaust manifold 7 Rear brake lever 8 Engine 9 Kick start lever 10 Pump with rear brake oil tank 11 Rear damper 12 Exhaust silencer 13 Rear wheel 14 Rear brake di...

Page 21: ...uel tank 6 Capacitor 7 Engine control unit 8 Battery fuse 9 Left switch EN SMR Engine switching off button MX SMK 10 Clutch lever with oil tank 11 Fuel tap MX SMK 12 Carburettor MX SMK Throttle body E...

Page 22: ...on BREMBO PUMP FRONT BRAKE LEVER The Brembo front brake pump 1 is located on the right hand side of the handlebar The front brake lever 2 applies the front wheel brake The position of the front brake...

Page 23: ...plies the front wheel brake The position of the front brake lever relative to the grip can be altered to suit the rider See the Maintenance section THROTTLE The throttle control 1 is located on the ri...

Page 24: ...right to activate the right direction indicator The lever 4 returns to central position Press the lever 4 to deactivate the direction indicator Press the button 5 to switch off the engine DIMMER SWITC...

Page 25: ...nally the knob remains in extracted position After the vehicle start wait a few seconds until the engine speed stabi lizes depending on ambient temperature then disable the cold start device by moving...

Page 26: ...GREEN left turn signal indicator 2b GREEN right turn signal indicator 3 BLUE high beam ON indicator 4 GREEN low beam ON indicator 5 Not used 6 Select button Press the button to select the following fu...

Page 27: ...counters Two partial counters Trip A and Trip B can be set Indicates the partial km miles travelled Maximum value is 9999 9 km miles When that maximum has been reached the counter is reset and starts...

Page 28: ...rip A press the Adjust button to go to the Trip B partial km miles travelled function A A B B To reset the km miles travelled both in Trip A and in Trip B with the function active press the Adjust but...

Page 29: ...f engine operation value cannot be reset B B Press the Adjust button to switch from the total hours of engine operation to the partial hours of operation A A A From A press the Adjust button to switch...

Page 30: ...atch starts when the wheel begins turning and stops when the motorcycle comes to a stop or you can press the Select button to start it To stop the stopwatch press the Select button again To reset the...

Page 31: ...NOTE To move from one setting to another press the Select button Setting the wheel circumference and sensor setup Depending on the models the following values must be set MODEL CIRCUMFERENCE SENSOR S...

Page 32: ...to 3 press the Adjust button to move to the fourth editable number In this case do not press the Setup button as the number to be set is 0 press the Adjust button to set the sensor setup and the foll...

Page 33: ...example 14 press the Setup button as many times as needed to reach the desired hours number NOTE Set the time according to the 12 or 24 hour format selected Press the Adjust button to move to the minu...

Page 34: ...page Stopwatch The stopwatch has been set to work automatically It starts when the motorcycle begins moving and stops when the motorcycle comes to a stop NOTE The default setting must not be changed I...

Page 35: ...ion push the starter all the way down with fast continuous movements Once the engine has started fold the pedal in again COMBINED BRAKING PEDAL SMR The brake pedal 1 is located in front of the right h...

Page 36: ...NAKED FLAME OR LIT CIGARETTES ALWAYS TURN OFF THE ENGINE BEFORE FILLING UP WITH PETROL TAKE CARE NOT TO GET PETROL ON THE ENGINE OR ON THE EXHAUST PIPE IMMEDIATELY REMOVE ANY SPILT PETROL WITH A CLOT...

Page 37: ...ALWAYS TURN OFF THE ENGINE BEFORE FILLING UP WITH PETROL TAKE CARE NOT TO GET PETROL ON THE ENGINE OR ON THE EXHAUST PIPE IMMEDIATELY REMOVE ANY SPILT PETROL WITH A CLOTH IF PETROL IS SWALLOWED OR GET...

Page 38: ...ee positions OFF tap closed there s no insertion of mix in the carburettor It s a normal position when the motorcycle is stationary and switched off ON tap open there s insertion of mix in the carbure...

Page 39: ...3 INSTRUCTIONS FOR USE...

Page 40: ...3 40 3 INSTRUCTIONS FOR USE 2 STROKE EN...

Page 41: ...WEAR SUITABLE CLOTHES WHEN USING THE MOTORCYCLE WISE BIKERS WHO RIDE A TM ALWAYS WEAR APPROVED HELMET BOOTS GLOVES AND JACKET BOTH FOR LONG JOURNEYS AND SHORT DISTANCES PROTECTIVE GEAR SHOULD BE HIGH...

Page 42: ...engine life It is essential that you carry out the operations described in the Maintenance Schedule during the running in period Be particularly careful when replacing oil as metal particles that can...

Page 43: ...hile the passengers mounts and dismounts Do not get off the vehicle by jumping or extending your legs and always dismount by following the instructions given in the relevant section MOUNTING OF RIDER...

Page 44: ...h mirrors 1 so that you can clearly see the road behind you when seated START OF THE MOTORCYCLE 1 Get on the motorcycle from the left hand side 2 Raise the motorcycle the kickstand 1 will raise automa...

Page 45: ...AYS MAKE SURE SUFFICIENT VENTILATION IS PRESENT ALWAYS CHECK THAT GEARBOX IS IN NEUTRAL BEFORE STARTING THE MOTORCYCLE IF A GEAR IS ENGAGED WHEN STARTING THE MOTOR CYCLE THE LATTER WILL JUMP FORWARD A...

Page 46: ...of the start switch is set to OFF 3 When the throttle 3 is completely open EN Press and keep pressed the button 4 Activate the start pedal 5 approximately 5 times from top to bottom at normal speed 4...

Page 47: ...he front and rear brakes Engage a lower gear if necessary On dusty wet or slippery surfaces use the brakes and down shift as gently as possible without locking the wheels Locking of the wheels leads t...

Page 48: ...ews on the motorcycle are fully tightened If you hear strange noises while riding your motorcycle stop immediately turn off the engine and contact a TM dealer STOPPING AND PARKING With the throttle fu...

Page 49: ...wn oil or grease all sliding parts and bearings Apply a specific spray to the chain Apply a specific spray for contacts to all the electrical controls on the handlebar and electrical system connectors...

Page 50: ...be dry and not subject to drastic temperature changes Cover the motorcycle preferably with a breathable sheet or cover Do not use airtight materials as moisture would be trapped and could cause corro...

Page 51: ...4 MAINTENANCE...

Page 52: ...uid Check brake fluid level pad thickness front and rear brake discs Change front and rear brake fluid Check condition and seal of brake pipes Check operation adjustment smoothness and play of front b...

Page 53: ...ace spark plug and check cap Check exhaust valves Check cylinder and piston wear Fully change piston Exhaust valve actuator clearance check Exhaust valves replacement Fully change conrod Check clutch...

Page 54: ...hock absorber Check wear on chain junction mesh pinion sprocket and guides chain tension Lubricate chain Check fluid level in hydraulic clutch control tank Change hydraulic clutch fluid Check brake fl...

Page 55: ...rication of control cables Gearbox oil replacement Clean exhaust screw magnet Check tightness of engine fixing screws Replace spark plug and check cap Check exhaust valves Check cylinder and piston we...

Page 56: ...4 56 4 MAINTENANCE 2 STROKE EN...

Page 57: ...se a screwdriver Turn it clockwise to increase braking or anti clockwise to reduce it There are a total of 19 clicks available WARNING Do not touch the bleeder screw 2 WARNING Before starting tighten...

Page 58: ...ounting the clicks Write down the number of clicks counted so that you can restore the standard adjustment if necessary The clicks are normally indicated from the fully closed position Both tubes must...

Page 59: ...to leak from the fork If your fork leaks oil try bleeding the air before replacing the sealing elements CLEANING TELESCOPIC FORK DUST SEAL NOTE You must contact a TM dealer to carry out this operatio...

Page 60: ...lly closed WARNING Before starting tighten the adjuster from the standard position to fully closed while counting the clicks Write down the number of clicks counted so that you can restore the standar...

Page 61: ...nvolves mounting a certain type of spring and a set of adjust ments of the compression and rebound braking TM motorcycles come calibrated for a rider weight with full protective gear of 70 80 kg Adjus...

Page 62: ...pre load See the Varying pre load and replacing shock absorber spring section CHECKING SHOCK ABSORBER RIDER SAG Correct shock absorber rider sag should correspond to a lowering of the motorcycle of 9...

Page 63: ...adjust loosen the four M8 screws 1 and nut 2 of the fork head and tighten or loosen ring nut 3 as necessary Do not tighten ring nut 3 beyond the play elimination point to avoid damaging the bearings...

Page 64: ...heck chain tension put the motorcycle up on the center stand Push the chain upwards at the end of the chain guide The upper branch of the chain must be taut The distance between the swing arm and the...

Page 65: ...correctly the marks 4 on the right and left chain tensioner must be in the same position relative to the reference marks 5 Tighten the lock nuts 2 of the adjusting screws 3 Before locking the wheel p...

Page 66: ...MOTORCYCLE WARNING When assembling the chain joint 1 the closed part must always be in the direction of travel Always check for wear on the pinions sprocket and guides Replace these parts if necessar...

Page 67: ...osition the fluid level must be 5 mm below the edge Top up if necessary Use DOT4 brake hydraulic fluid Re fit the membrane cover and screws and tighten them Use water to wash away any hydraulic fluid...

Page 68: ...hydraulic fluid for the clutch hydraulic control Never use DOT5 or other fluids Prevent contact between brake fluid and painted parts Brake fluid corrodes paint Only use clean brake fluid from a herm...

Page 69: ...that topping up is not necessary even if the brake pads are worn In fact as the pads wear the fluid in the pipes takes up the space left by the pistons which have shifted to allow the pad to always r...

Page 70: ...at the front wheel can turn freely with the lever at rest If this play is missing pressure builds in the braking system and the front wheel brake may fail due to overheating or the wheel locking CHECK...

Page 71: ...cover and screws and tighten them Use water to wash away any brake fluid that overflowed or was spilled DANGER STORE BRAKE FLUID OUT OF THE REACH OF CHILDREN BRAKE FLUID MAY IRRITATE SKIN AVOID CONTA...

Page 72: ...the reservoir in an upright position the fluid level must always be between the MAX and MIN indications DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE THIS MEANS THERE IS A LEAK IN THE...

Page 73: ...he reservoir in an upright position the fluid level must always be between the MAX and MIN indications DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE THIS MEANS THERE IS A LEAK IN THE B...

Page 74: ...r line of the indicator 1 on the pump body DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE THIS MEANS THERE IS A LEAK IN THE BRAKING SYSTEM OR THAT THE BRAKE PADS ARE COMPLETELY WORN AWA...

Page 75: ...imit DANGER THE THICKNESS OF THE BRAKE PAD FRICTION MATERIAL MUST NOT BE LESS THAN 1 MM OTHERWISE THE BRAKES MAY FAIL REPLACE BRAKE PADS PROMPTLY TO ENSURE YOUR SAFETY WARNING If the brake pads are no...

Page 76: ...limit DANGER AT THE THINNEST POINT THE THICKNESS OF THE BRAKE PAD FRICTION MATERIAL MUST NOT BE LESS THAN 1 MM OTHERWISE THE BRAKES MAY FAIL REPLACE BRAKE PADS PROMPTLY TO ENSURE YOUR SAFETY WARNING I...

Page 77: ...ate the brake lever while removing the pads Check that the pump reservoir oil level is correct If necessary top up as indicated in the relevant paragraph FOR MODELS WITH FUSA FIXED CALIPER SMR SMK Rad...

Page 78: ...ycleanthebrakecaliperwithcompressed air and check that the surface of the guide pins is intact Fit the new pads paying attention to the position of the fins Insert the pin and tighten it Re fit the ca...

Page 79: ...brake pads without damaging them With the wheel correctly positioned insert the wheel pin 4 positioning the spacer 5 on the left hand part of the wheel Screw in and temporarily tighten the flanged sc...

Page 80: ...A A B SMK 16 7 mm 13 7 mm MX EN SMR 13 7 mm 13 7 mm To re fit the rear wheel insert the shim sprocket side in the hub insert the wheel in the swing arm and supporting the wheel fit the chain on the sp...

Page 81: ...data and in the registration document Check the condition of the tires before every ride Ensure that the tires have no cuts nails or other sharp objects pushed into them In terms of the minimum tread...

Page 82: ...The distance between the screw heads 2 and the sensor 1 must be 2 4 mm Otherwise speedometer operation may be irregular The bushing 3 adjusts the sensor distance Do not remove it otherwise the sensor...

Page 83: ...r the quick coupling 1 to absorb possibly leaking petrol Disconnect the quick coupling 1 of the hose 2 which connects the tank to the injectors by working on the tabs Disconnect the electrical connect...

Page 84: ...bed in the relative paragraph Place a container to collect petrol possibly leaking from the hose Close the fuel tap 1 OFF Open the clamp 2 and disconnect the hose 3 from the carburettor Unscrew the co...

Page 85: ...ised to connect the battery to a charger or alterna tively remember to recharge it every 15 days to protect it from possible damages Always recharge the battery before it discharges completely in orde...

Page 86: ...ting sparks switch off the battery charger before disconnecting its terminals from the battery DANGER DO NOT CHARGE THE BATTERY BEYOND THE MAXIMUM VOLTAGE VALUE INDICATED NOTE We recommend the followi...

Page 87: ...he side panels unscrewing the screws 1 On the left hand side of the motorcycle EN SMR there are Condenser 2 ECU control unit 3 EN SMK On the right hand side of the motorcycle there are Ignition relay...

Page 88: ...the dark zone and the lit zone must be at a height not greater than 9 10ths of the height of the center of the bulb from the ground LED HEADLIGHT FOR MODELS EN SMR ADJUSTING THE HEADLIGHT HEIGHT The...

Page 89: ...om the bike lighting system Then remove the taillight unit Since this is all one unit the whole thing must be replaced Ask a TM dealer for the original spare part TURN SIGNAL EN SMR Led turn signals T...

Page 90: ...reme weather or in stop and go traffic To solve this problem an electric fan kit is available as an optional accessory for models with electric start ask your TM dealer for details CHECKING COOLANT LE...

Page 91: ...he level Add more fluid if necessary Go for a short ride then check the coolant level again DANGER DRAIN THE COOLANT IF POSSIBLE WITH THE ENGINE COLD IF YOU NEED TO DRAIN THE COOLANT WHILE THE ENGINE...

Page 92: ...nal pipe 3 remove the cap Remove the sound absorbing material to be replaced Insert TM s fiberglass cartridge 4 in the external hose Re fit the front cap 2 and secure it with the new rivets Mount the...

Page 93: ...ase is intact and positioned correctly Oil the cage with filter oil then put the sponge and cage back together Re fit the air filter positioning it correctly on the supporting surface Ensure that the...

Page 94: ...o obtain the required play Tightening the adjusting screw increases play Loosening the adjusting screw reduces play Tighten the lock nut and check that the grip rotates smoothly Put the protective cap...

Page 95: ...warm enough and without touching the throttle grip turn the knob 1 or the screw 2 located on the left hand side of the bike Models EN SMR Rotating the knob 1 clockwise decreases rpm while rotating it...

Page 96: ...inage holes Then clean the seal surfaces check the gaskets clean any debris from the drainage cap magnets 3 and screw on the cap again tightening them to 20 Nm Prepare a measuring cup with the necessa...

Page 97: ...external cover 1 Extract the spring 2 and the valve 3 Unscrew the needle screw 4 Extract the needle 5 Move the Seeger 6 following the indications below Standard factory adjustment is on the third not...

Page 98: ...ed clean the hole using the relevant tips without deforming the shape of the jet Unscrew the pilot jet 4 and clean it using compressed air if clogged clean the hole using the relevant tips without def...

Page 99: ...If the rod 8 must be replaced adjust the distance of the new rod between the two heads and try it on the two measuring rods 11 positioned on the cover 6 Reassemble all the components working in rever...

Page 100: ...MORISING SYSTEM LIMIT SWITCH POINTS MX SMK Before starting the engine it is necessary to store in the exhaust valve con trol unit the end stroke points This must be always done after each service oper...

Page 101: ...ition Connect the connector 3 to the diagnostics socket 4 Within two seconds from the connector 3 connection press the shutting off button 5 and keep it pressed for at least five seconds Release the t...

Page 102: ...raph Connect the cable 1 to the battery terminals Remove the cap 2 from the wiring connector located in the front left part of the motorcycle Mount the connector 3 using the supplied bridge Bleed the...

Page 103: ...5 DIAGNOSIS...

Page 104: ...5 104 5 DIAGNOSIS 2 STROKE EN...

Page 105: ...ignition key and turn it clockwise Petrol cock closed MX SMK Open the petrol cock No fuel supply to the engine Refuel Check tank carburettor connections Incorrect idle speed adjustment Correctly adjus...

Page 106: ...ds replacing Check the faulty parts on the exhaust system replace the fiberglass in the exhaust silencer E x h a u s t v a l v e n o t adjusted correctly Check the valves wires Replace the control uni...

Page 107: ...The radiator fins are very dirty Clean the radiator fins with water not under pressure Formation of foam in the cooling system Replace the coolant using a good brand of anti freeze LIGHTS SPEEDOMETER...

Page 108: ...OL The socket for connecting this tool is on the left side of the motorcycle under the tank Take out the socket 1 remove the protective cap 2 and connect the tool WARNING After making the required adj...

Page 109: ...table to start the installation process Select I agree to the License terms and conditions Proceed to installation Once the app is installed open it CALTOOL MANUAL Open the installation executable to...

Page 110: ...he first time you open the app and choose the file which is provided with the software to upload In order to change template you must return to the previous window To do so select and choose the file...

Page 111: ...ap files and set up files currently uploaded The name of the uploaded template in use The names of the currently open set up files and map files are visible on the title bar On the left vertical toolb...

Page 112: ...t To communicate with the ECU it is necessary to use the CAN USB EM008 adapter to be connect to the PC after installation of the driver After this operation it will be possible to connect it to the re...

Page 113: ...rrently loaded in the ECU It is possible to see extra information regarding the current map and configuration with the The diagnostic files must be compatible with the configuration cu It is possible...

Page 114: ...to imagine by a maximum of 3 degrees 3 0 and delay by a maximum of 8 degrees 8 0 The modified values will always remain highlighted with a different colour Injection auxiliary correction the value 10...

Page 115: ...e small changes to the injection offset In the left vertical menu you find the general monitor and analog inputs which you can access commands that allow you to verify the general status of the manual...

Page 116: ...eset them With the OBD names widget you can check the name which is transmitted from the ECU to the BUS OBD to do so it s necessary to select update ECU UPDATE If you need to update the ECU s firmware...

Page 117: ...6 TECHNICAL DATA...

Page 118: ......

Page 119: ...roller bearings Small end bearing Silver coated shims roller bearings cage Big end bearing needle roller cage Piston cast in light alloy Segments 2 segments GAP 0 40 0 45 Gearbox oil quantity 650 cc P...

Page 120: ...0 05 0 06 Small end bearing Silver coated shims roller bearings cage Big end bearing needle roller cage Piston cast light alloy Segments 2 segments GAP 0 40 0 45 Gearbox oil quantity 650 cc Primary tr...

Page 121: ...se cylinder tightening flange nuts M 10 35 Nm Water pump cover Allen screw M 6 12 Nm Water pump rotor M 6 Loctite 243 15 Nm Clutch hub nut M14x1 5 Loctite 243 70 Nm Clutch springs Allen screw M 6 10 N...

Page 122: ...r stop licence plate position light EN Led 12V 0 9W 0 006W SMR P21 5W 12V 21 5W BAY15d Indicator bulb R10W 12V 10W BA15S TIGHTENING TORQUES 125 144 MX EN SMK 125 144 SMR Front wheel pin flange nut M20...

Page 123: ...7 WIRING DIAGRAMS...

Page 124: ...7 124 7 WIRING DIAGRAMS 2 STROKE EN CARBURETTOR WIRING DIAGRAM 125 144 MX...

Page 125: ...7 125 7 WIRING DIAGRAMS EN 2 STROKE ENGINE WIRING DIAGRAM SMR 125 144 EN...

Page 126: ...7 126 7 WIRING DIAGRAMS 2 STROKE EN ENGINE WIRING DIAGRAM EN 125 SMR...

Page 127: ...Checking speedometer magnetic sensor distance en smr 4 82 Checking spoke tension 4 81 Checking steering bearings and play adjustment 4 63 Cleaning air filter 4 93 Cleaning telescopic fork dust seal 4...

Page 128: ...lve 4 101 Right hand side main components topography 2 20 Running in instructions 3 42 S Safety regulations 3 41 Setting off 3 47 Shock absorber compression adjustment 4 60 Shock absorber rebound adju...

Page 129: ......

Page 130: ...TM RACING S p A Via Fano 6 61122 Pesaro Italy Tel 39 0721 25113 Fax 39 0721 401808 www tmracing it R ENGLISH 1st Ed 03 2022...

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TM RACING 125 EN 2022, Use And Maintenance Manual

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