125cc / 144cc / 250cc / 300cc
Maintaining Your Electronic Exhaust-valve System.
It is advised that the following procedure relating to the set-up and maintenance of your TMEES Engine is used as per instruction on a regular basis to ensure both the performance and reliability of your TM Racing machine is maximised, it should be noted that TM UK recommend the procedure be applied to your machine at 4 hours intervals for MX and prior to each event for Enduro machines.
Please Click On The Link Below To Download The TMEES Set-Up Guide.
TMEES Set-Up Instructions
The above instruction manual has been translated by the TM Racing Staff into English, therefore some of the wording will seem unfamiliar, please see below for an altered translation of the numbered procedures.
NOTE: The servo unit only needs to be removed from the machine to replace the cables, for simple maintenance and cable adjustment the servo unit can stay attached to the cylinder brace but with it’s two fastenings bolts loosened slightly to allow some movement whilst performing the cable adjustment operation. The domed Allen Key headed bolt in the black moulded plastic cover on the servo unit can be removed to give access to the 4mm positioning hole for locking the servo arm ‘pulley reference’ hole into place prior to cable adjustment. If the 4mm ‘pulley reference’ hole in the servo arm is not inline with the 4mm hole in the servo unit’s black moulded plastic cover the servo can be moved by gently rotating the cable arm on the cylinder, this will allow the cables to pull on the servo arm rotating the 4mm ‘pulley reference’ hole into the correct position for a 4mm locking pin to be inserted. It is advised that the 4mm ‘tool’ used to lock the servo arms ‘pulley reference’ hole to the covers 4mm positioning hole be slightly tapered to ease insertion. Do not loosen the 10mm nut fixing the cable pulley to the power-valve mechanism in the cylinder. Releasing the nut, and therefore the pressure on the shaft the power-valve blades are fixed to, with allow the blades to move independently and out of correct alignment and ‘timing’ of operation. Please see below for the settings of the power-valve blades and the measurements of.
1: Cables fitted in the correct position.
2: Cable with red sheath (2012/2013) / blue sheath (2014) / red+blue or clear sheath on 250cc/300cc models (2015) fitted into the lower position.
3: Cable tensioner locking nuts wound back fully allowing the tensioner adjuster to be screwed fully into the servo unit allowing maximum cable movement (fully ‘slack’).
A: 4mm hole in the servo arm used to lock the servo into place for correct cable adjustment.
4: Black moulded protection cover in place and secured using the 6 screws.
5: Servo Unit installed onto the cylinder brace with the cable tensioner adjuster locking nuts wound back fully with the tensioner adjuster wound fully into the servo unit allowing maximum cable movement (fully ‘slack’).
6: Pulley reference 4mm positioning hole in the black moulded plastic cover inline with 4mm ‘pulley reference’ hole in the servo arm, please see ‘NOTE’ above for instructions on aligning the two holes with the servo unit fitted in place on the cylinder brace.
7: 4mm ‘tool’ inserted into black moulded plastic cover positioning hole and into 4mm ‘pulley reference’ hole in servo arm, this locks the servo into the correct position for cable adjustments to be set.
8: fixing the two cables to the cylinders exhaust valve pulley arm.
9: Remove the cylinder’s black moulded plastic cover to expose the cylinder exhaust valve pulley arm and cable housings. Lock the cylinder exhaust valve pulley into place using another 4mm ‘tool’ allowing it to pass through the exhaust valve pulley arm and into the 4mm positioning hole located in the cylinder, this secures the cylinder exhaust valve pulley into the correct position prior to cable adjustment (cylinder exhaust valve pulley 4mm locking hole shown in ‘Figure 4’)
NOTE: both the cylinder exhaust valve pulley arm and the servo units pulley arm must both be locked into position to adjust the cables correctly.
10: Adjusting the tension of the pulley cables by means of winding the tensioner adjusters screwed into the servo unit outwards (anti clockwise) removing the ‘slack’ from the cables.
NOTE: The correct tension of the two pulley cables is set thus, remove the upper cable from it’s machined recessed housing in the cylinder and hold it over its housing, whilst pushing the black sheath of the cable gently rearward to ensure the cable is pushed fully home into the cable tensioner adjusters on the servo unit simultaneously wind the tensioner adjuster outwards increasing the tension until the cable sheath’s silver cap at the cylinder end is 1.0mm over the fitting face (2012>2013 machines), this ensures the correct cable pre-loading is set. The cable sheath can then be pulled gently backwards and pushed into the machined recessed housing that secures it. Repeat this procedure with the lower cable. Please try to ensure the cables are running from the servo to the cylinder in as straight a line as can be achieved, this can be assisted by moving the servo on it’s elongated mounting holes. Do not over-tighten as this will cause premature wear of the cables.
IMPORTANT NOTE: On the 2014 125cc/144cc machines (cable with the blue sheath and the new pulleys) and 2015 125cc / 144cc / 250cc / 300cc machines (red/blue cables and clear sheathed cables) is it advised that the tensioning procedure above is applied but the amount of tension itself should be reduced, the cables themselves once fitted should move relatively easily if squeezed between the thumb and finger, giving a more visible ‘loose’ setting ( of around 3mm of cable movement up/down) than that compared to the 2012>2013 system. The electronic system on the 2015 onward machines also automatically tests the system once the engine is started or it can be manually tested using the PDA plugged into the OBD port or with the TM Racing battery cable into the condenser port using a 12v motorcycles battery.
11: Once the correct tension has been set on the pulley cables the locking nuts on the cable tensioner adjusters of both the upper and lower cables can be wound clockwise against the servo unit body and tightened locking the cable tensioner adjusters into place, please ensure the the cable tensioner adjusters are held securely in position whilst tightening the locking nuts to avoid accidental cable adjustments.
12: Remove the two 4mm ‘tools’ used to lock both the servo pulley arm and the cylinder exhaust valve pulley arm into place during cable tension setting.
13: Refit the domed Allen Key headed bolt into the pulley reference positioning hole in the servo’s black moulded plastic cover.
14: Refit the cylinder pulley black moulded plastic cover and replace the 3 fastenings Allen bolt securing it into place.
15: Re-tighten the servo units two fastenings.
16: Reinstall the 4 rubber protection ‘boots’ on the two pulley cables into their correct positions to minimise water and dirt ingress into the cables and operating system.
NOTE: For the 2015 models there is also a built in program in the electronics that will allow a ‘setting operation’ to be performed on the TMEES system after adjusting or fitting new cables. This ‘test’ will require the use of a cable (TM Part No’ 68193) and the purchase of a 12v motorcycle low-amperage battery which can then be connected into the motorcycles electrical system, via the condenser/capacitor connection port. To connect into the system remove the green connector on the cable from the condenser/capacitor from the port it is fitted to, plug the ‘setting operation’ cable (connected to a 12v motorcycle battery only – low amp) into the port, the electronics will now automatically perform a procedure that will move the servo and powervalve system between fully open to fully closed and come to rest in its neutral pre’ engine starting position, it is advised to leave the cylinder TMEES cover off whilst this is being performed to watch the operation cycle and ensure it has been completed. This setting operation will only take around 30 seconds to perform and once the operation has terminated, and the servo has stopped moving the cable system, remove the cable/battery and re-fit the condenser/capacitor connector. All other components can now be re-fitted to the machine prior to starting / riding.
VIDEO: A Video Demonstration of Powering the TMEES System by Battery Can Be Found In The Video Section Below. NOTE: Only on 2015> models and using the condenser/capacitor port or the correct cable/fitting for the PDA (‘Palm’) connection into the main wiring harness.
Please ensure the power-valve cables are treated as per any other cable, ensure frequent lubrication of the cables by either a penetrating spray or a designated light cable oil. Also periodic changing of the cables is advised, as with any cable under load, and whilst in a harsh environment, it will eventually fail, if the cable shows any sign of corrosion or fraying of the cable wire strands please replace the cable immediately.
TMEES Cable Pulley Positioning and Setting.
During any removal and / or re-fitting of the TMEES cable pulley on the cylinder there are several ‘set-up’ and positioning requirements for the limitation of movement allowed for the actual power-valve blades within the cylinder. With the nut loose and with the power-valve blades moving loosely on the shaft you can now begin to set the positioning of the blades. To set the maximum opening position of the power-valve blades you must first insert the 4mm holding tool into the cable pulley and into the locating hole behind (as per setting cable tension) to lock the pulley into its ‘maximum’ position. using two fingers (one on each power-valve blade) push the blades as far as possible into the roof of the exhaust port (wide open), now tighten the nut on the end of the cable pulley shaft, the maximum opening position is now set. To set the minimum position firstly remove the 4mm holding tool to allow the cable pulley / power-valve blades to move up and down freely. Using a vernier measure form the top of the cylinder (with the cylinder head removed, directly down the side of the exhaust bridge) to the leading edge of one of the pulleys, this needs to be set to the measurement given below for each model. If you need to adjust the power-valve blades to achieve the given measurement you must use the adjuster on the cable pulley to set this. Loosen the locking nut and adjust the screw in either direction required to achieve the correct measurement, once achieved the locking nut can be re tightened, you can then double check your measurement is correct. The cylinder can now be re-fitted to the engine.
Measurements for the TMEES Power-Valve Blades in the ‘Closed’ Position.
125cc MX Models – 38.50mm
125cc Enduro Models – 39.50mm
144cc MX/Enduro Models – 41.50mm
250cc MX/Enduro Models – 57.30mm
300: MX/Enduro Models – 57.30mm
VIDEO DEMONSTRATIONS: Video demonstration of the pulley positioning setting (fully open) and the measurement setting (fully closed) can be found in the video section below.
PLEASE NOTE: On models equipped with a gear position sensor (mapping altered in the lower gears) that the TMEES system will not operate to 100 percent of its travel whilst in ‘neutral’ or the lower gears whilst the engine is running. When testing the TMEES system / or if running the machine on a stand and ‘watching’ the functionality of the TMEES system under engine power you must remove the drive chain from the engine to the rear wheel, select 3rd gear and then test. This will allow the electronics to give full operational travel to the servo system that would not normally be permitted whilst in Neutral/lower gears.
IMPORTANT INFORMATION: The new TM Racing TMEES engine is a high performance competition motor and it is recommended that the larger carburetor main jet sizes are fitted immediately during running-in and for initial ‘hard runs’ to give yourself a base setting. As there are so many variables with carburetion settings it is advisable that the possibility of being too ‘rich’ on fueling is better than being too ‘lean’. This latest generation of TM Racing 125cc engine with the electronic exhaust-valve operation is ‘all new’ and needs to be treated as such, therefore all known carburetion settings that were employed in the previous engine design are to be discarded, it is advised that a new program of education in fueling this new engine is devised as it’s required fuel quantities at various rpm stages have altered, this shows in the differing needle designation and position and jet sizes. Please be advised to start with larger main jet sizes and decrease as required, not the other way round. Correct fueling of any 2-Stroke engine is of the uppermost importance to ensure correct performance and reliability, please ensure that conditions, temperature, elevation and rider ability is taken into consideration when carbureting your machine. Remember that an engine running on a harder surfaced circuit on a warm day will require different fueling to the same engine on a loose surface circuit on a colder day.
Please be advised that is up to you to ensure that you machines engine is running correctly, checking the spark plug during every ride will soon inform you of any changes that may need to be made to your machines carburetion for the conditions. It is advised that you carry a selection of carburetor jets suitable for you machine which will allow you to make any changes should the need arise. NOTE: Incorrect carburetion will lead to poor performance, bad running and even engine failure.
PLEASE NOTE: All advisories are for assistance only, you must test and set your machine to the given conditions, Super-unleaded fuel must be used at all times pre-mixed to the correct oil ratio of 33:1 – 40:1 (600ml / 500 ml of quality synthetic oil to 20 Litres of fuel), please be advised that conventional ‘regular’ unleaded does not meet the higher octane requirements of competition engines and it’s use will lead to poor running and even engine failure.
NOTE: Please ensure correct fueling at all times, regularly check the engines spark plug colour to ensure your engine is running within the correct parameters, please also take notice of the spark plug advisory relating too temperature. If the machine appears to be running incorrectly please rectify the carburetion or if you cannot do this please stop using the machine immediately and seek advice from your TM Racing dealer.
This video shows, using a cut-away cylinder, how the pulley must be locked in place using the pin holes used for cable adjustment, the powervalve blades pushed and held fully to the roof of the cylinder, and then, the nut tightened. This ensures that when the pulley is fully open the powervalve blades are open fully also.
This video shows how to measure the travel of the powervalve blades using a vernier caliper. Each model has a specific measurement that the powervalves blades must ‘close’ from the fully open position, these measurements can be found in the text above. Measuring just off-centre from the exhaust bridge the ‘closing’ measurement can be found, this can be adjusted using the threaded adjuster bolt on the pulley, once set correctly the locking nut on the adjuster bolt can be tightened. Re-measure after locking to ensure the measurement is still correct.
This video shows how to power the TMEES system, on 2015 onward models, for operational check and system set after fitting new cables. This can be done using the OBD port and the TM Racing PDA or by using the TM Racing cable plugged into the Condeser port and powering using a 12 volt motorcycle specific battery. Once connected the system will take a few seconds to respond upon which it will then cycle the powervalve opening and closing procedure and then return to the ‘closed’ position, at which time you unplug the PDA / Battery.
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