TMEES Set-Up Instructions
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.
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.
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.
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
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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