TM RACING 2012 TM 100 MX Скачать руководство пользователя страница 50

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ENGLISH

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.

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. IN THE INTEREST OF YOUR SAFETY HAVE THE

PADS REPLACED IN TIME.

WARNING

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE FRICTION

MATERIAL IS COMPLETELY CONSUMED, THE STEEL PARTS OF THE PADS

RUB ON THE DISC. THIS LEADS TO A NOTEWORTHY DECREASE OF THE

BRAKING EFFECT AND DAMAGE OF THE BRAKE DISC.

REPLACEMENT OF REAR BRAKE PADS (A)

FOR ALL MODELS WITH FLOATING CALIPER (END/MX/SMR)

Push the brake caliper (1) towards the disc, until the piston reaches its

base position. Remove the cap (2) using a screwdriver, unscrew the pin

(3) and slide the brake pad out. Pay attention to the plates (4) placed

between the pads: these must be remounted accurately. Clean the

brake caliper with compressed air and check that the drive pin sheaths

are not damaged.

Remount the new pads, paying attention to the positioning of the plates,

insert the pin, re-screw it and tighten. Remount 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 where the safety ring

is found.

- THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND

GREASE. OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY

REDUCED.

- AFTER MOUNTING, CHECK THAT THE SAFETY DEVICES ARE POSI-

TIONED CORRECTLY.

- AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM, ACTIVATE

THE FRONT BRAKE LEVER AND THE REAR BRAKE PEDAL TO MAKE

THE PADS ADHERE TO THE DISC AND TO RESTORE THE CORRECT

ADJUSTMENT OF PLAY.

DISASSEMBLY AND ASSEMBLY OF THE

FRONT WHEEL

Position the motorcycle with the frame cradle on a stand in a way that

the front wheel does not touch the ground.

Loosen the flanged nut (7), loosen the fastening screws (8) on the left

and right fork shoes, finish unscrewing the flanged nut.

Holding the front wheel still, slide the wheel axle out.

If necessary, to help the wheel axle to exit, strike lightly with a mallet

(hammer with plastic ends) on the threaded end of the axle itself.

Alternatively, use a normal hammer and place a piece of wood be

tween.

NEVER USE THE HAMMER DIRECTLY ON THE AXLE, YOU RISK TO

DAMAGE THE AXLE IRREVERSIBLY.

Slide the front wheel carefully out of the fork.

DANGER

FRAME AND ENGINE MAINTENANCE

Содержание 2012 TM 100 MX

Страница 1: ......

Страница 2: ...ENGLISH ENGLISH 2...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 9: ...ENGLISH ENGLISH 9 OPERATING CONTROLS OPERATING CONTROLS...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 20: ...ENGLISH ENGLISH 20...

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

Страница 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...

Страница 23: ...ENGLISH ENGLISH 23 INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 30: ...ENGLISH ENGLISH 30...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 79: ...ENGLISH ENGLISH 79 WIRING DIAGRAMS 2012 WIRING DIAGRAMS 2012...

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

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

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

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

Страница 84: ......

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