TM RACING 2010 STROKE 250 Instruction manual
www.tmracing.it
Ed.01 - 02/2020
250-300
- 2020
Workshop Manual
, declines all liability for any errors in the compilation of this manual, and reserves the right to make any modifications required
for the development of its products. Illustrations shown are approximate and, in some cases, may not precisely correspond with the part
referred to. Reproduction of this publication, even partial, without written authorisation is prohibited.
Foreword
This publication, to be used by TM Racing workshops, has been drawn-up to assist authorised personnel in the maintenance and repair of
motorcycles handled. Perfect knowledge of the technical data stated herein is decisive for the most complete professional training of the
operator.
In order to make it easier to understand, the paragraphs have been distinguished by schematic illustrations, which highlight the topic in
question.
Always operate in compliance with the accident-prevention regulations in force, using suitable PPE.
In order to prevent problems on reaching an excellent final result, srl recommends that the following generic regulations are
complied with:
– in the event of any repair, assess the impressions of the Customer reporting the operating anomalies of the motorcycle and formulate
appropriate questions in order to clarify the symptoms of the problem;
– clearly diagnose the cause of the anomaly. From this manual it is possible to assimilate the essential theoretical bases, which, moreover,
must be integrated by personal experience:
– plan the repair rationally, in order to prevent downtimes, receiving spare parts, preparation of tools etc.;
– reach the item to repair, limiting to the essential operations.
In this regard, consulting the disassembly sequence shown in this manual, will be of great help.
1 Always replace the gaskets, sealing rings and the cotter pins with new parts.
2 When loosening/tightening nuts or screws, always start with the largest ones or from the centre. Lock at the coupling torque prescribed.
following a crosswise pathway.
3 Always mark all parts or positions that could be exchanged on re-mounting.
4 Use original spare parts and recommended lubricants.
5 Use special tools, where specified.
6 Consult official Technical Memos, since they could contain more updated state adjustment data and methods of intervention, with respect
to this manual.
1
The displacement, type of power source and type of use dene the motorcycle model and engine of each TM Racing motorcycle.
The combinaon of codes 1 and 3 idenes the standard engine type. The combinaon of the three codes fully idenes the motorcycle model.
All 3 codes are usually used in this Manual, to specify the motorcycle model to which certain informaon refers.
If only codes 1 and 3 are indicated, followed by the word “ALL”, it means that the informaon relates to all motorcycles with standard engine,
regardless of the type of use.
Code 2 (Type of Use) used alone means that the informaon refers to all motorcycles with that type of use, regardless of displacement and
power source.
All EN/SMR models are equipped as standard with electric start (E.S.) as well as kick start ( K.S.). MX/SMX models have K.S. as standard and
may be equipped with E.S. as an opon.
Please make a note of your motorcycle’s serial numbers in the boxes below.
When it is necessary to contact TM for spare parts, updates or to report any issues, always quote the model, displacement, year of manufacture
and, above all, the frame serial number and engine serial number.
250 = 250cc
300 = 300cc
Fi = INJECTION
EN = ENDURO
MX = MOTOCROSS
FT = FLAT TRACK
SMR = ROAD SUPERMOTO
SMX = COMPETITION SUPERMOTO
(ONLY WHEN INCLUDED AS AN OPTIONAL)
E.S. = ELECTRIC START
K.S. = KICK START
2
13
The engine serial number (1) is embossed into the rear part of the engine,
near to the shock absorber.
Make a note of this number in the relevant space at the beginning of the
manual.
1
1. ADJUSTMENTS/REPLACEMENTS ..........................................................7
....................................8
.................................................... 11
..................................................................12
.........................................................15
......................................................17
...........................................................19
........................................................................ 19
............................. 21
2. ENGINE DISASSEMBLY........................................................................27
............................................................28
...................................................................................29
..................................................................................30
.............................................................. 30
................................................. 32
........................................................................................................34
............................................................................... 34
......................................................................... 37
........................................................................ 40
....................................................................... 42
...........................................................................45
........................................................ 45
........................ 46
....................................................... 46
................................................. 46
...................................................................... 48
...............................................48
.......................................................48
.........................................49
.............................................49
....................................................................................................50
.................. 50
................................................................... 51
..........................................................................................51
..............................................................................52
............................................................................. 52
........................................................................................... 53
......................................................................................... 53
............................................................................................ 54
.....................................................................................56
................................................................................. 56
................................................................................ 58
..........................................................................................59
...........................................................................61
................................... 62
...................................... 62
................................................................. 62
.................................................. 63
INDEX
2
............................................64
...................................................................... 64
................................................................................ 65
.......................................................................65
................................................................................. 65
................................................................................ 67
................................................69
..............................................................70
...............................................................................71
..............................................73
.......................................................74
.................................................................. 75
................................................................................................76
....................................................................................... 76
............................................................................... 77
...............................................77
................................................................... 77
.......................................................................... 77
...................................................................... 77
..................................................................... 78
...................................................... 79
.................................................. 79
........................................................................... 79
.................................................................. 80
............................................................ 80
INDEX
3
ENGINE TECHNICAL DATA 250FiiEN EU4 250FFi
ENGINE MODEL 250
33
14: 1 13.7: 1
18 / 59 20 / 59
1
2
3
4
5
6
14:30
16:28
20:29
22:27
24:25
20:19
13:31
15:27
16:23
20:24
20:21
22:20
Key:
E.S. =
K.S. =
WARNING
TECHNICAL SPECIFICATIONS
4
MAINTENANCE TABLE
Every 15
every ride)
Every 45
Every year
•••
•
• •
•••
•
•
••
••
••
••
••
•
•
•
••
•
•
•
•
•
WARNING
TM
MAINTENANCE
5
ENGINE
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5.
1.
2.
3.
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
4.
1.
2.
1.
2.
1.
2.
1.
2.
3.
TROUBLESHOOTING
6
INSUFFICIENT ENGINE POWER
ELECTRIC PART
overheat
The starter motor
TROUBLESHOOTING
7
1. ADJUSTMENTS/REPLACEMENTS
8
1
1
2
2
5
4
6
ADJUSTMENTS/REPLACEMENTS
9
7
9
8
8
10
14
11
7
12
12
ADJUSTMENTS/REPLACEMENTS
10
15
18
14
17
19
19
16
20
21
20
21
ADJUSTMENTS/REPLACEMENTS
11
14
22
1
2
4
5
ADJUSTMENTS/REPLACEMENTS
12
1
2
5
4
6
6
ADJUSTMENTS/REPLACEMENTS
13
9
9
1
8
7
ADJUSTMENTS/REPLACEMENTS
14
12
11
17
17
16
10
14
14
15
ADJUSTMENTS/REPLACEMENTS
15
2
1
1
5
4
7
6
ADJUSTMENTS/REPLACEMENTS
16
8
8
9
610
11
54
ADJUSTMENTS/REPLACEMENTS
DANGER
- PAY ATTENTION TO THE HOT OIL AND PARTS OF THE ENGINE; THERE
IS A BURNS HAZARD.
WARNING
ENGINE OIL QUANTITY TABLE
......................................................................... 1.25 l
............................................................. 1.25 l
................................................................................ 1.35 l
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