TMEES 2015-2019 125/144, 2015-2018 250/300

 

TM Racing TMEES (TM Electronic Exhaust System)

Maintenance procedure for the TMEES Electronic Exhaust Valve System

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 maximized, 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 molded 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 no 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 molded 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 molded 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 molded 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 molded 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,  this ensures the correct cable preloading 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 (around 3mm of cable movement up/down) than  on the 2012/2013 red sheathed cable system.

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  tensioning.

13: Refit the domed Allen Key headed bolt into the pulley reference positioning hole in the servo’s black molded plastic cover.

14: Refit the cylinder pulley black molded 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 minimize 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 power valve 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 Demonstration of Powering the TMEES System by Battery. NOTE:  Only on 2015> models and using the condenser/capacitor port or the  correct cable/fitting for the ‘Palm’ connection into the main wiring  harness.

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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.

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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 maximun 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 first 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 Demonstration – Maximum Setting.

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Video Demonstration – Minimum Setting.

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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. 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.

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TMEES 2019 250/300

Resetting the valve for models 250/300 MX EN)

WARNING

Make sure the engine has switched off.

- Remove the seat as described in the relevant paragraph.

- Connect the cable (TM68193) to the battery terminals.

- Press the mapping button and select “MAP 1”

- Engage the 5^ gear by means of the shift lever 

- Connect the connector to the diagnostics socket (Left side below tank).

- Within two seconds from the connector connection, press the

kill button  and keep it pressed for at least five seconds.

- At this point, the actuator slowly searches for 0% and 100% points of

opening by first moving to 100% and then to 0%.

- Once the two extremes have been memorized, the valve sets to 100%

of opening.

- Disconnect the cable (1) and move the gear back to neutral position

“N”.

- Remove the cap (Left Side Exhaust Valve Cap).

- Reconnect the cable (TM68193) as previously described.

- Work on the gearbox (3) lever by engaging gears from 1^ to 5^ and

check that, by means of the hole , the control rod positions in the

following manner:

1^ = 100%

N = 0%

2^ = 25%

3^ = 50%

4^ = 75%

5^ = 100%

- Once finished, re-fit the cap , disconnect the cable and re-fit the seat

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