TM RACING 250 EN User Manual

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1. ADJUSTMENTS/REPLACEMENTS ..........................................................9
1.1 ENGINE OIL AND FILTER CHANGE ............................................................10
1.2 STANDARD CLUTCH REPLACEMENT .......................................................... 11
2. ENGINE DISASSEMBLY........................................................................15
  ..............................................16
  ...............................................17
2.3 REMOVING THE PINION COVER ................................................................18
2.4 PINION REMOVAL .....................................................................................18
2.5 TEMPERATURE SENSOR REMOVAL ...........................................................19
2.6 HEAD REMOVAL ........................................................................................19
  .........................................................20
2.7.1 Disassembly ................................................................................. 20
2.7.2 Reassembly .................................................................................. 21
2.8 CYLINDER AND PISTON .............................................................................21
2.8.1 Cylinder and piston removal ........................................................ 21
2.8.2 Ring replacement and assembly .................................................. 23
  ............................................................................ 24
2.8.4 Piston replacement ...................................................................... 24
2.8.5 Piston replacement with intact cylinder ...................................... 24
2.8.6 Piston replacement with cylinder to be machined ...................... 25
2.8.7 Cylinder replacement ................................................................... 25
  ................................................. 25
2.9 CHECKING THE SQUISH .............................................................................26
2.10 DRAIN VALVE REMOVAL / REVISION ......................................................... 28
2.10.1 Dismantling the lever (5) .............................................................. 30
  ................................................................... 31
2.10.3 Reassembly of the valve (13) ....................................................... 31
  ................................. 33
2.11 REED VALVE PACK .....................................................................................34
2.12 CLUTCH .....................................................................................................36
2.12.1 Clutch actuator removal .............................................................. 36
2.12.2 Actuator dismantling ................................................................... 36
2.13 Gear sensor...............................................................................................36
2.14 FLYWHEEL REMOVAL ................................................................................37
2.14.1 Flywheel cover ............................................................................. 37
2.14.2 Stator ........................................................................................... 38
2.14.3 Pick-up ......................................................................................... 38
2.14.4 Rotor ............................................................................................ 38
2.15 STARTER MOTOR .......................................................................................40
2.15.1 Disassembly ................................................................................. 40
  ................................................................................ 40
2.16 WATER PUMP............................................................................................42
2.16.1 Replacing the sealing gasket ........................................................ 42
2.16.2 Water pump removal ................................................................... 43
2.16.3 Reassembling the water pump .................................................... 45
INDEX

TM RACING 250 EN Specifications

General

Brand	TM RACING
Model	250 EN
Category	Engine
Language	English