TM RACING 2012 TM 100 MX User And Maintenance Manual Download Page 68

Page: 68 / 84

ENGLISH

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

preload.

Remove the locking pins, close the servomotor cover hole, reassemble

the cylinder cover tightening the screws and slide the rubber nipples into

their normal position.

SHOULD ONE CABLE SHOW SOME DAMAGE OF ANY TYPE, IT IS NEC

ESSARY TO CHANGE THE ENTIRE CABLE ASSEMBLY, FOLLOWING THE

INSTRUCTIONS ATTACHED TO THIS MANUAL. ALLEGATO.

FRAME AND ENGINE MAINTENANCE

Summary of Contents for 2012 TM 100 MX

Page 1: ......

Page 2: ...ENGLISH ENGLISH 2...

Page 3: ...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 YOU...

Page 4: ...erations 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...

Page 5: ...ms 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 man...

Page 6: ...al 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 brake...

Page 7: ...ENGLISH ENGLISH 7 POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER...

Page 8: ...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...

Page 9: ...ENGLISH ENGLISH 9 OPERATING CONTROLS OPERATING CONTROLS...

Page 10: ...rease 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 le...

Page 11: ...the new setting and come back to the initial screen The trip odometer can be reset by holding pressed the SET button once for 5 seconds The total kilometres odometer resets automatically when reaching...

Page 12: ...ip See n 1 in the picture The use of the switch is very easy When the symbol 4 on the rotating ring 3 is aligned with the symbol 5 on the switch body lights are switched off To switch the lights on tu...

Page 13: ...straight in the middle it deactivates the indicator The slider 4 allows you to select between lights off position lights on low beam on The red button 5 switches between low beam and high beam By pres...

Page 14: ...on the fuel tap is closed ON On the ON position the fuel tap is open When the motorcycle is used turn the tap to the ON position In this way the fuel flows to the carburetor and the tank empties up to...

Page 15: ...ar shift pedal The gear shift pedal is positioned on the engine left side The position of the gears is indicated in the illustration The neutral is between the first and second gears To select the fir...

Page 16: ...urning the screw clockwise the dampening increases turning it anticlockwise the dampening decreases A total of 28 clicks Never turn the side screw 3 WARNING Do not operate on the red hexagonal nut 4 b...

Page 17: ...SITION BOTH LEGS MUST HAVE THE SAME ADJUSTMENT WARNING FOR FURTHER AND MORE DETAILED INFORMATION REGARDING THE FORK BOTH STANDARD AND OPTIONAL REFER TO THE OWNERS MANUAL SUPPLIED BY THE MANUFACTURER O...

Page 18: ...speeds adjustment screw Use a 14mm hexagonal wrench By turning the nut clockwise dampening increases anticlockwise dampen ing decreases A total of 28 clicks are available The Ohlins shock absorber fo...

Page 19: ...LOSED POSITION AND COUNT THE CLICKS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NUMBER OF CLICKS IS INDICATED FROM THE TOTALLY CLOSED POSITION THE DAMPER GAS TANK IS FILL...

Page 20: ...ENGLISH ENGLISH 20...

Page 21: ...ENGLISH ENGLISH 21 ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE...

Page 22: ...throttle By following these regulations you will obtain maximum perform ance and longer duration of the motorcycle through time warning THE 85 100 MX and 125 and 144 END MX MODELS HAVE BEEN DE VELOPE...

Page 23: ...ENGLISH ENGLISH 23 INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE...

Page 24: ...check the air pressure and take it to the values envi sioned in the table if necessary Worn tread and unsuitable air pressure worsen driving of the motorcycle and may cause loss of control and seriou...

Page 25: ...RESS THE KICKSTARTER DOWN HARD WITHOUT ACCELER ATING KICKSTARTING WITH LITTLE FORCE OR WITH OPENED THROT TLE INCREASES THE RISK OF ENGINE KICK BACK DO NOT START THE ENGINE IN A CLOSED SPACE AND NEVER...

Page 26: ...accelERATING SLOWING DOWN 1st gear which should be selected is the pulling away and ascent gear If the circumstances permit speed limits traffic slopes to increase speed insert higher gears To do thi...

Page 27: ...S STRENGTH WARNING USE OF THE ENGINE AT A HIGH NUMBER OF REVS WHEN IT IS COLD NEGATIVELY AFFECTS THE DURATION OF THE ENGINE BEFORE US ING THE MOTORCYCLE AT FULL WORKING CONDITIONS IT IS BETTER TO WARM...

Page 28: ...OVERHEATING THE ENTIRE BRAKING SYSTEM MAY NOT WORK IF THE FORCE AT THE FRONT BRAKE LEVER OR BRAKE PEDAL IS MINIMAL THERE COULD BE A FAULT IN THE BRAKING SYSTEM IN THIS CASE IT IS A GOOD IDEA TO HAVE...

Page 29: ...of unleaded fuel Bel Ray H1 R is the only synthetic oil that TM approves uses and recommends warning FILLTHE TANK WITH UNLEADED FUEL WITHAMINIMUM OCTANE NUMBER OF 95 NEVER USE FUEL WITH AN OCTANE NUMB...

Page 30: ...ENGLISH ENGLISH 30...

Page 31: ...ENGLISH ENGLISH 31 MAINTENANCE AND LUBRICATION TABLE MAINTENANCE AND LUBRICATION TABLE...

Page 32: ...ght high beam stop indicators lights horn OFF button Check brake fluid level pad thickness brake discs Check conditions of brake hoses Check functionality adjustment smoothness and free play of front...

Page 33: ...carburetor to engine and filter case Check idle speed adjustment Check conditions and unbent positioning of vent pipes Check for leaks of the cooling system and coolant level Check for leaks and screw...

Page 34: ...e for leaks Cleaning of caburetor and jets for dirt and water removal Check smoothness of all command elements Check braking effect Treatment of bright metal parts apart from brake and exhaust system...

Page 35: ...ge to plating Replace conrod axle and roller cage Replacement of main bearings Check complete gearbox including drum and forks Check clutch plate wear Check length of clutch springs WARNING IF AFTER C...

Page 36: ...nd roller cage Replacement of main bearings Check complete gearbox including drum and forks Check clutch plate wear Check length of clutch springs WARNING IF AFTER CHECKING IT IS DETECTED THAT THE WEA...

Page 37: ...ENGLISH ENGLISH 37 FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE...

Page 38: ...O PARTS OF THE FRAME AND LOOSEN CONTINUALLY USE SELF LOCKING NUTS LEAVE THE MOTORCYCLE TO COOL BEFORE STARTING ANY MAINTENANCE THIS WILL PREVENT BURNS DISPOSE OF OILS grEASES filtERS FUELS detergentS...

Page 39: ...ent only to carry out this operation during periodical maintenance WARNING VERY HIGH PRESSURE INSIDE THE forK CAN CAUSE THE FORK TO LEAK IF YOUR forK presentS a LEAK LOOSEN THE VENT SCREWS BEFORE HAVI...

Page 40: ...C LOWERING The static lowering should be35 mm Variations of more than 2 mm can notably influence driving of the motorcycle Procedure Position the motorcycle on a stand so that the rear wheel does not...

Page 41: ...indicated on the outside of the spring wire After mounting a different spring static lowering must be adjusted again to 35 mm 2 mm According to our experience the dampening grade in compression can re...

Page 42: ...take note of te basic adjustment e g how many thread turns are visible above the lock ring nut 6 By 1 turn of the adjustment ring nut 1 4 6 the spring pre load varies by 1 5 mm SACHS Loosen the lock r...

Page 43: ...IVEN SHAFT MAY BREAK IF HOWEVER CHAIN TENSION IS INSUFFICIENT IT CAN EXIT FROM THE SPROCKET AND LOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN BOTH CASES IT IS EASY TO LOOSE CONTROL OF THE MOTORCY CLE AD...

Page 44: ...th two M8 screws and two nuts to turn the hub inserting the two screws into the two holes in the hub itself ATTENTION IF YOU DO NOT HAVE SUITABLE EXPERIENCE IT IS ADVISED TO HAVE THE OPERATION CARRIED...

Page 45: ...are not rigidly joined to their support The lateral compensation always allows the pads to work in the best way on the discs The brake caliper fastening screws must be assembled using Loctite 243 and...

Page 46: ...wise to reduce the distance Re tighten the lock nut 2 warning AT THE END OF THE OPERATION VERIFY THAT THE FRONT BRAKE LEVER HAS A FREE STROKE BEFORE THE BRAKE STARTS TO LOCK THE WHEEL AND THAT THE FRO...

Page 47: ...OVERHEATING OR BLOCKING OF THE WHEEL ITSELF CHECK FLUID LEVEL The reservoir 7 is transparent and allows you to check for the fluid level with the reservoir standing up the fluid level must be always...

Page 48: ...5 out Lever on each pair of pads to allow the pistons to go back to their seat Extract the worn pads and insert the new ones Repeat the operation for the other pair of pads Press the two hooks down a...

Page 49: ...ALEAK IN THE BRAKING SYSTEM OR COMPLETE CONSUMP TION OF THE BRAKE PADS TOP UP REAR BRAKE FLUID A ALL THE MODELS EXCLUDING JUNIOR As soon as the level of rear brake fluid reaches the centreline on the...

Page 50: ...emount the tap using a screw driver Tighten well FOR ALL MODELS WITH FIXED CALIPER SMM Remove the safety ring 5 and slide the pin out 6 hitting with a pin puller with 4mm diameter on the same side whe...

Page 51: ...emove the chain tensioning slide 11 remove the chain from the sprocket remove the caliper with its support and carefully extract the rear wheel from the swing arm Pay attention to the thin wheel shim...

Page 52: ...CAN CAUSE UNSTABLE DRIVING THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER HAVING RE ASSEMBLED THE REAR WHEEL ALWAYS...

Page 53: ...UR OF THE MOTORCYCLE ON THE ROAD AND be the cause of fines ENVISIONED BY THE REGULATIONS IN FORCE IN YOUR COUNTRY TO GUARANTEE YOUR SAFETY AND THAT OF OTHERS DAMAGED TYRES MUST BE REPLACED IMMEDIATELY...

Page 54: ...IS POSSIBLE THAT EXPLOSIVE GASES MAY COME OUT KEEP THE BATTERY AWAY FROM SPARKS OR FLAMES KEEP FAULTY BATTERIES AWAY FROM CHILDREN AND DISPOSE OF THEM IN THE CORRECT MANNER WARNING THE CLOSURE STRIP...

Page 55: ...TWO LIGHT BULB Disconnect the cable connector and remove the rubber protection 2 Release the retainer and carefully extract the halogen bulb 3 Reassemble the new bulb the rubber protection and the co...

Page 56: ...HEADLIGHT TWO LIGHT BULB Disconnect the cables connector and remove the rubber protection 2 Release the retainer and carefully extract the halogen bulb 3 Reassemble the new bulb the rubber protection...

Page 57: ...al under the head of the screw Remount the cover with the seal and connect the terminal HIGH BEAM BULB Remove the rubber protection 10 unscrew the screw 11 and carefully extract the bulb 12 Replace th...

Page 58: ...ompletely Ask for the original spare part to an official TM Dealer REAR LIGHT smr smm REPLACEMENT posiTion stop NUMBER PLATE LIGHT BULB Unscrew the screws 2 and remove the cover 3 Replace the bulb wit...

Page 59: ...T DISCONNECT THE RADIATOR HOSES WHEN THE ENGINE IS HOT THE COOLANT LIQUID AND THE HOT STEAM THAT ESCAPE MAY CAUSE SERIOUS BURNS IF YOU ARE BURNED PUT THE INTERESTED PART UNDER COLD RUN NING WATER THE...

Page 60: ...s are filled with acoustic insulating material fibre glass to limit motorcycle noise Because of high temperatures reached by the exhaust gases the fibreglass tends to burn leading to a decrease in the...

Page 61: ...er screw positioned at the centre of the filter and carefully slide it the filter out of its case WARNING DO NOT CLEAN THE FOAM FILTER WITH FUEL OR KEROSENE WHICH CAN CORRODE IT FOR CORRECT MAINTENANC...

Page 62: ...the bleeding nipple 5 of the clutch cylinder on the engine Switch on the suction machine and loosen the nipple Continue until no more air escapes from the nipple only oil Tighten the nipple Disconnec...

Page 63: ...IN EXTREME CASES RESULT IN IRREPARABLE DAMAGE AN EXCESSIVE AMOUNT OF OIL INSTEAD CAN CAUSE MORE FUMES THAN NORMAL AND FOUL THE SPARK PLUG AND EXHAUST VALVE DEFINITION AND USE OF A CARBURETOR FOR A 2 S...

Page 64: ...e at full gas the insulating part of a new plug the ceramic part around the electrodes appears particularly bright or white you will need to replace the main jet with a richer one If instead the insul...

Page 65: ...MPREGNATED WITH FUELARE ALSO HIGHLY INFLAMMABLE IF YOU SWALLOW FUEL OR IT COMES INTO CONTACT WITH THE EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF FUEL ACCORDING TO THE REGULATIONS ENVISIONED IN YOUR...

Page 66: ...ion the motorcycle on a flat surface loosen and unscrew the cap 1 positioned on the lower face of the engine and allow the oil to flow into a container BEWARE OF HOT OIL Clean the cap and incorporated...

Page 67: ...he control cables tension To do this move the rubber nipples 6 which protect the cables on both servomotor and cylinder sides Remove the cylinder cover 7 lock the servomotor pulley 8 by insert ing a 4...

Page 68: ...e seat it must be around 1 5 2 0 mm If necessary operate on the registers 12 to restore the correct preload Remove the locking pins close the servomotor cover hole reassemble the cylinder cover tighte...

Page 69: ...connect the fuel hose from the carburetor place it in a con tainer and open the fuel tap if fuel escapes clean the carburetor if fuel does not escape control the tank vent pipe or clean the fuel tap U...

Page 70: ...ng checked ENGINE MISFIRINGS OR BACKFIRES FROM THE CARBURETOR Fuel missing Air leaks in the intake manifold Clean and check the fuel circuit and the carburetor Checktherubbermanifoldsbetweenthefilterc...

Page 71: ...e stops Successively open the carburetor bowl empty screw to empty the remaining fuel Disassemble the spark plug and pour into the plug hole 5 cc of oil Activate the kickstart pedal 10 times to distri...

Page 72: ...ectrode gap Cooling Coolant fluid capacity 85 MX 100 MX 2 stroke single cylinder liquid cooled 85 cm3 100 cm3 47 95x47 51 97x47 16 5 1 15 3 1 unleaded fuel RON 95 mixed ratio 1 30 with oil 0 9 mm 0 9...

Page 73: ...ded fuel RON 95 mixed ratio 1 30 with oil 1 1 mm 1 3 mm 1 1 mm 1 65 mm SMR SMM 1 85 mm 2 ball bearings needle cage silver plated needle cage chilled light alloy 1 ring mixture 1 30 of unleaded fuel RO...

Page 74: ...ns 16 mm PWK 38 188 50 N1EI 3 from top 7 1 0 urns 16 mm 125 END 125 MX 144 END 125 144 SMM SMR mikuni Type Main Jet Slow Jet Jet needle Clip position Throttle valve Slow air screw Float height TM 28 9...

Page 75: ...ap Oil filler screw cap Oil net filter screw cap Oil cartridge filter cover Allen screws Engine oil pump body screws Head cylinder nuts Head cylinder flanged nuts Water pump cover Allen screws Water p...

Page 76: ...r 90 100 14 or 90 100 16 90 100 16 1 1 bar 6 5 liters including reserve 1 lt 16 54 16 56 1 2 x 5 16 25 Nm 25 Nm 15 Nm 15 Nm 20 Nm 20 Nm 12 Nm 60 Nm 50 Nm 20 Nm 40 Nm 35 Nm 35 Nm 15 Nm 45 Nm 10 Nm 25 N...

Page 77: ...5 M16x1 5 M8 M10 M10x1 25 M10x1 25 M8 M6 M10 M50 M12x1 25 M6 M8 M10 M6 M8 M10 Frame Front suspension Rear front suspension travel Rear suspension Front disc brake Rear disc brake Brake disc wear limi...

Page 78: ...ng in running order 41 Establishing rear shock static lowering 40 Fork adjustment in compression 16 Fork rebound adjustment 17 FRAME AND ENGINE MAINTENANCE 37 Frame number 8 Front brake BREMBO radial...

Page 79: ...ENGLISH ENGLISH 79 WIRING DIAGRAMS 2012 WIRING DIAGRAMS 2012...

Page 80: ...ENGLISH ENGLISH 80 TMEES TM Electronic Exhaust System TMEES TM Electronic Exhaust System...

Page 81: ...ENGLISH ENGLISH 81 TMEES TM Electronic Exhaust System TMEES TM Electronic Exhaust System...

Page 82: ...ENGLISH ENGLISH 82 TMEES TM Electronic Exhaust System TMEES TM Electronic Exhaust System...

Page 83: ...ENGLISH ENGLISH 83 TMEES TM Electronic Exhaust System TMEES TM Electronic Exhaust System...

Page 84: ......

Search results

Summary of Contents for 2012 TM 100 MX

Reviews:

Related manuals for 2012 TM 100 MX

Brands by name

Popular brands

TM RACING 2012 TM 100 MX, User And Maintenance Manual

Search results

Summary of Contents for 2012 TM 100 MX

Reviews:

Related manuals for 2012 TM 100 MX

Brands by name

Popular brands