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USER AND MAINTENANCE MANUAL

1. 48 Running in instructions Rex bREE 20 Shifting gear accelerating slowing down _ 24 Shock absorber adjustment in compression 16 Shock absorber adjustment in rebound _ 17 Shock absorber calibration and spring check 38 Side stand BERNER ERR EROR 14 Side stand fixing for off road 2 2020222 15 Standard headlightd END SMR SMM 53 Standard rear 54 Start up after seasonal pause 67 sua gag 18 Stopping and parking 2 26 STORAGE E P r o 67 TECHNICAL DATA ENGINE 1 1 rotten trn etae 68 TECHNICAL DATA CYCLE PARI 72 Telescopic fork vent SCTEWS 37 Throttle cable command adjustment 60 Topsup rear Drake fluid perna eda arie Peer Ea ues 47 TROUBLESHOOTING 65 Tyres tyre pressure d ep 51 Variation of rear shock spring preload 40 Variation of telescopic fork preload 39 WIRING DIAGRAM uscite ret gin t
2. 46 Modification of rear brake pedal base position 47 Check rear brake fluid level 2 47 Top Up rear brake fluid 47 Check rear brake pads 48 Replacement of rear brake pads 48 Disassembly and assembly of the front wheel 48 Disassembly and assembly of the rear wheel all except SMM 49 Disassembly and assembly of rear wheel SMM 50 Check spoke tension 2 50 Tyres tyre pressure tub rdi oii 51 Check adjustment of magnetic sensor for tachometer 51 zl M 52 Battery Charge 52 Standard headlightd END SMR SMM 53 Halogen light END SMR SMM _ 53 Halogen light END SMR SMM 53 Ciclops optional headlight END SMR SMM 54 Standard rear light 54 MT 55 Direction indicator lamp END SMR SMM 55 N 56 Check coolant level nt apta siat e E 57 Emptying filling and bleeding of the cooling system
3. 37 Cleaning telescopic fork dust scraper _ 37 Basic calibration of the chassis on the basis of pilot weight 38 Shock absorber calibration and spring check 38 Establishing rear shock static lowering 38 Establishing rear shock lowering in running order 39 Check telescopic fork basic calibration _ 39 Variation of telescopic fork preload 39 Replacement of fork springs 40 Variation of rear shock spring preload __ 40 Rear suspension mechanical linkage 40 Check chain tension 2 00000880 41 Adjustment of chain tension all models except SMM 41 LIV DIES Page Adjustment of chain tension 42 Chain EDaeliu ral 6B Lucae abet hund 42 AAU iu 43 Basic indications for disc brakes 43 Front brake NISSIN pump END MX 44 Front brake BREMBO radial pump SMR SMM SMX 45 Check front brake pads 45 Replacement of front brake pads
4. 40 LEP ERAMEANDIENGINEIVAINTENANG LLANE CHECK CHAIN TENSION Put the motorcycle onto the central stand to control chain tension Push the chain upwards to the end of the drive chain slider The upper part of the chain A must be taught see photo The distance between the chain and rear fork must be about 10 15 mm Adjust the tension if necessary A DANGER IF THE CHAIN IS TOO TIGHT THE FINAL TANSMISSION COMPONENTS CHAIN GEARBOX AND REAR WHEEL BEARINGS ARE GREATLY STRESSED AS WELL AS A PREMATURE WEAR IN EXTREME SITUA TIONS THE CHAIN OR GEARBOX DRIVEN SHAFT MAY BREAK IF HOWEVER CHAIN TENSION IS INSUFFICIENT IT CAN EXIT FROM THE SPROCKET AND LOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN BOTH CASES IT IS EASY TO LOOSE CONTROL OF THE MOTOR CYCLE ila 2 ADJUSTMENT OF CHAIN TENSION ALL MODELS EXCEPT SMM Loosen the wheel axle nut 1 loosen the counter nuts 2 and turn the adjustment bolts 3 to the left and to the right by the same amount To increase chain tension unscrew the adjustment bolts To decrease chain tension screw the adjustment bolts Reach correct chain tension For correct alignment of the rear wheel the marks 4 on the right and left chain tensioner must aligned with respect to the reference markings 5 Tighten the adjustment screw counter nuts Before locking the wheel axle nut check that the chain tensioners 6 are laying on the heads of
5. Check functionality adjustment smoothness and free play of front brake lever and brake pedal e Check brake hoses screws tightness d Check for leaks and working of shock absorber and forks Clean dust screen lt Bleed fork leg W Check rear suspension mechanical linkage screw tightness o Check and adjustment of steering bearings 9 2 Check tightness of chassis screws fork clamps fork legs wheels axles nuts and screws rear fork 9 9 axle shock absorber Check spoke tension and trueness of rims H Check tyre conditions and pressure Y Y T Check chain wear chain link sprockets chain tension gt Chain lubrication M Check wheel bearing play bhusoitrulraublirzbulczopzzizxlioi iizcecouhl zlgzozV zisf EVERY YEAR Complete fork maintenance e Complete shock absorber maintenance e Cleaning and greasing of steering bearings and related sealing elements e Cleaning and tuning of the carburetor e Replacement of silencer packing material e Treatment of electric contacts and switches with contact spray e Replacement of hydraulic clutch fluid e Replacement of brake fluid e The distance between maintenance intervals should not be exceeded by more than 2hours or 15 litres THE MAINTENANCE CARRIED OUT BY THE AUTHORISED TM DEALER DOES NOT REPLACE THE CHECKS AND MAINTE NANCE CARRIED OUT BY THE RIDER Sine 30 WALTER ANCE AND TABELLA M
6. Rider only air pressure 1 1 bar Tank capacity 9 5 litri Final transmission 13 51 144 MX 13 50 13 52 13 40 Chain 5 8 x 1 4 Optional rear sprockets 48 49 50 51 52 38 39 40 41 42 43 44 45 46 Bulbs only END SMR SMM Halogen light HS1 12V 35 35W Opt Cyclops H3 12V 55W PK22s 12V 5W W5W Led 12V 0 9W 0 006W R10W 12V 10W 155 Front position light Opt Cyclops T10 12V 5W Position stop number plate light Indicator TIGHTENING TORQUES 85 100 125 144 MX END 125 SMR SMM Front wheel axle flanged nut M20x1 5 M20x1 5 40 Nm Front brake caliper fastening screws M8 M10 30Nm 40 Nm Rear brake caliper fastening screws SMM M8 25 Nm Front brake disc fastening screws M6 cl 10 9 M6 cl 10 9 15 Nm Rear brake disc fastening screw M6 cl 10 9 M6 cl 10 9 15 Nm Rear brake disc fastening nut SMM M8 25 Nm Upper fork head fastening screws M8 M8 20 Nm Lower fork head fastening screws M8 M8 20 Nm Marzocchi fork leg fastening screws M6 M6 12 Nm Rear wheel axle flanged nut M22x1 5 M22x1 5 80 Nm Swing arm axle flanged nut M16x1 5 M16x1 5 80 Nm Handlebar caps fastening screws M8 M8 20 Nm Handlebar elastic support nut M10 M10 35 Nm Upper end shock nut M10x1 25 M10x1 25 40 Nm Lower end shock screws M10x1 25 M10x1 25 35 Nm Rear sprocket nuts M8 M8 35 Nm Rear brake pedal adjustment nut M6 M6 15 Nm Engine fastening screws M10 M10 45 Nm Rear wheel nut SMM M50 185 Nm Rear hub locking screws SMM M12x1 25 M12x1 25 31 Nm General frame
7. ENGINSEH 18 AVAICE ANP COIS SIChIhE ThE 1 INDICATIONS FOR FIRST START UP Ensure that the PRE DELIVERY OPERATIONS of your mo torcycle have been carried out by your TM dealer Carefully read all user instructions before making the first journey Become familiar with all operating controls Adjust the clutch lever the front brake lever and the brake pedal so that they are in the most comfortable position Get used to driving in an empty carpark or on land where it is easy to handle the motorcycle before making a long journey Also try to move at a slow pace on foot to get used to the mo torcycle Do not take routes that are too difficult for your driving ability and experience On the road hold the handlebar with both hands and leave your feet on the footrests Be careful not to push the brake pedal if you do not wish to brake If the brake pedal is not released the brake pads rub continuously and the brake overheats Do not modify the motorcycle and always use ORIGINAL TM SPARE PARTS Spare parts made by other manufacturers can jeopardise the safety of the motorcycle Motorcycles are sensitive to the movement of weight When carrying luggage fix it as near as possible to the centre of the motorcycle and distribute the weight equally between the front and rear wheel Follow running in instructions RUNNING IN INSTRUCTIONS The surfaces of compone
8. 38 AAD VWAINTENANG 774 BRAM LLANE ESTABLISHING REAR SHOCK LOWERING IN RUNNING ORDER Now with the help of a person who holds the motorcycle sit on the motorcycle wearing all protective clothing with feet on the footrests and rock up and down a few times to normalise the set up of the rear suspension A third person must then measure the distance between the same points with the motorcycle loaded and note this measurement as C Lowering in running order is the difference between measurements A and C EXAMPLE Motorcycle on stand measurement A 600 mm Motorcycle on the ground loaded with the pilot s weight Unc ee 510 mm Lowering in running 2 90 mm Lowering in running order should be 90 105 mm If lowering in running order is less than 90 mm the spring is too hard spring rate too high If the lowering exceeds 105 mm the spring is too soft spring rate too low The spring rate is indicated on the outside of the spring wire After mounting a different spring static lowering must be adjusted again to 35 mm 2 mm According to our experience the dampening grade in compression can remain unvaried With a softer spring the dampening grade in rebound can be reduced by some clicks with an harder spring increased by some clicks CHECK TELESCOPIC FORK BASIC CALIBRATION For several reas
9. AUDAX A WARNING DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES PAINT USE ONLY CLEAN BRAKE FLUID OUT OF A HERMETICALLY SEALED CONTAINER FRONT BRAKE BREMBO RADIAL PUMP SMR SMM SMX FRONT BRAKE LEVER ADJUSTMENT The distance of the front brake lever from the handlebar grip can be adju sted through the adjustment knob 1 Turning it clockwise the distance increases turning it anticlockwise the distance decreases A WARNING AT THE END OF THE OPERATION VERIFY THAT THE FRONT BRAKE LEVER HAS A FREE STROKE BEFORE THE BRAKE STARTS LOCK THE WHEEL AND THAT THE FRONT WHEEL CAN ROTATE FREELY WITH THE BRAKE LEVER AT REST IF THE FREE STROKE IS MISSING PRESSURE IS FOR MED IN THE BRAKING SYSTEM AND THE CONSEQUENCE CAN BE LACK OF FUNCTIONING OF THE FRONT WHEEL BRAKE DUE TO OVERHEATING OR BLOCKING OF THE WHEEL ITSELF CHECK FLUID LEVEL The reservoir 2 is transparent and allows you to check for the fluid level with the reservoir standing up the fluid level must be always between MAX and MIN remarks IF THE BRAKE FLUID LEVEL FALLS BELOW THE MINIMUM VALUE IT IN DICATES A LEAKING IN THE BREAKING SYSTEM OR CONSUMPTION OF BRAKE PADS BEYOND THE ACCEPTABLE LIMIT CHECK FRONT BRAKE PADS The brake pads can be checked from below The thickness of the pad friction material must not be less than1 mm THE THICKNESS OF THE BRAKE PAD THICKNESS MATERIAL MUST NOT BE LESS THAN 1 MM
10. LLANE IF THE ENGINE IS FLOODED In the event of a fall a certain amount of fuel can flow out the carburetor and enter the cylinder flooding the engine To start the engine pull out the plug cap assy unscrew the spark plug and extract it then press the kick start pedal several times firmly DOWN TO THE BOTTOM Check that the electrodes on the spark plug are not wet with fuel and dry if they are Put the spark plug back in screwing it back down carefully Try the kick start pedal again BIKE STARTING Pull the clutch lever insert the first gear release the clutch lever slowly accelerating at the same time BEFORE STARTING ALWAYS CHECK THAT THE SIDE STAND HAS BEEN LIFTED IF THE STAND SLIDES ALONG THE GROUND YOU COULD LOOSE THE CONTROL OF THE MOTORCYCLE SHIFTING GEAR ACCELERATING SLOWING DOWN 1 gear which should be selected is the pulling away and ascent gear If the circumstances permit speed limits traffic slopes to increase speed insert higher gears To do this close the throttle pull the clutch lever at the same time insert the successive gear release the clutch and accelerate up to 1 2 turn of the throttle Then insert the following gear and repeat this operation until the desired speed is reached and however permitted by the limits in force Gradual opening of the accelerator favours careful driving and limits consumption Learn the correct opening of the throttle on the basis of the pace a
11. 57 Replacement of exhaust silencer packing material 57 Cleaning the air filter 58 Hydraulic clutch AJP 59 Hydraulic clutch BREMBO pump sese 59 Bleeding hydraulic clutch 4 60 Throttle cable command adjustment 60 Notes on the carburettor 4 60 Basic indications regarding carburetor wear 61 Check fuel level float height 2 24 2 2 62 Emptying the carburetor float 63 Check engine oil level etn enn tran 63 ge pfo e ee nr me etre 64 Change engine oil M M 64 Inspection of the reed valve 64 TROUBLESHOOTING word ada cdd ura Qu cunc 65 CLEANING d adco dada unn RR 67 PRECAUTIONS FOR WINTER USE 67 STORAGE itinerant 67 Start up after seasonal pause 67 TECHNICAL DATA ENGINE 1 68 CARBURETOR SETTINGS patiar ina rena ah daB Edd au VE aao 70 ENGINE TIGHTENING TORQUES 71 TECHNICAL DATA CYCLE PART 2 111 72 ALPHABETIC INDEX si
12. Adjust the gap between the electrodes as shown in the tables Slide off the spark plug cover unscrew the spark plug put the cover back onto the spark plug and gripping the cover keep the threaded part of the spark plug in contact with the head of the engine Turn the engine with the electric starter or pedal a spark should appear between the electrodes of the spark plug if the spark plug does not produce a spark it must be repla ced if there is still no spark remove the spark plug cover from the H T cable coming from the coil hold it at a distance of about 5 mm from the head and operate the starting system if there is a spark replace the spark plug cover if there is still no spark check the ignition system Remove the saddle the left side panel and the fuel tank clean the connectors and treat them with a contact spray Disassemble and clean the carburetor 7 LLANE PROBLEM CAUSE Clogged idle speed jet THE ENGINE WILL NOT Altered idle speed adjustment screws RUN AT IDLE SPEED Damaged spark plug Faulty Ignition system The fuel overflows because the level is adjusted too THE ENGINE DOES NOT high or the float needle valve is dirty or worn REACH FULL SPEED The carburetor jets are loose The ignition timing is not correct Fuel supply partially interrupted or dirty carburetor Float not leakproof Air filter very dirty POOR ENGINE POWER Exhaust system not leakproof deformed or fibreglass in
13. Fuel expands when heated Therefore never fill the tank completely with high environmental temperatures 27 Poly UK ier ENGIISEH 28 AND LUBRICATION 44277 MAINTENANCE AND LUBRICATION TABLE VRAIN TABELLA MANUIENZIONE LUBRIFICAZIONE 85 100 425 144 USO HOBBY 1ST SERVICE EVERY 30 HOURS A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS AFTER HOURS OR a5Lt OfpueL 150 LT OF FUEL Replacement of engine oil 2 Z Clean of drain bolt 2 5 Check conditions and and unbent positioning of rubber pipes B Check tightness of engine fastening screws 5 Check fixing for carburetor to engine and filter case 2 Check idle speed adjustment Z Check conditions and unbent positioning of vent pipes s s Check for leaks of the cooling system and coolant level Check for leaks and tightness of all oil drain screws Check conditions smoothness unbent positioning of all pipes and cables i adjustment and lubrication of throttle and decompressor cables 2 x o Check fluid level in the hydraulic brake and clutch reservoirs 2 2 Clean filter case and air filter Check conditions and unbent positioning of cables i Check headlamp orientation Check electric system head light high beam stop indicators 9 2 lights horn OFF button Check brake fluid level pad thickness brake discs id Check conditions of brake hoses
14. Gear pedal Allen screw General screws nuts General screws nuts General screws nuts ENGINE OIL Only use premium quality fully synthetic oils SAE 80W that correspond to or exceed the quality standards of the API SG or SH classes indi cation on container A WARNING ALEVEL THAT IS TOO LOW LOW QUALITY OIL OR MAINTENANCE INTER VALS LONGER THAN ESTABLISHED CAUSE SERIOUS DAMAGE TO THE ENGINE 71 5 14 1 14 1 5 5 M6 M6 M8 5 6 12 6 M6 M6 M6 M6 M6 M5 M6 M8 125 144 CC 8 Nm 20 Nm 20 Nm 8 Nm 8Nm 12Nm 15Nm 28 Nm 8 Nm Loctite 243 15 Nm Loctite 270 80 Nm 8 Nm Loctite 243 8 Nm 12 Nm Loctite 243 10 Nm Loctite 243 25 Nm Loctite 243 10 Nm 8 Nm 10 Nm 20 Nm 5 DATA CYCLE TECHNICAL DATA CYCLE PART 69 100 JUNIOR MA 2010 85 JUNIOR Frame Perimeter in CrMo tubes Front suspension Paioli USD fork Rear front suspension travel Rear suspension Aluminium swing arm Progressive mechanical linkage Ohlins shock Front disc brake 260 mm floating caliper Rear disc brake 220 mm floating caliper Brake disc wear limit mm 0 4 below original thickness Front tyre 70 100 17 Rider only air pressure 1 1 bar Rear tyre 90 100 14 Rider only air pressure 1 1 bar Tank capacity 6 5 litri Final transmission 16 54 Chain 1 2 x 5 16 TIGHTENING TORQUES 85 100 JUNIOR MX 2010 Front wheel axle flanged nut M12x1 5 Front
15. THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED DISASSEMBLY AND ASSEMBLY OF THE REAR WHEEL ALL EXCEPT SMM Rest the motor cycle with the frame cradle on a stand in a way that the rear wheel does not touch the ground Unscrew the flanged nut 1 and supporting the wheel extract the wheel axle 2 remove the chain tensioning slide 3 remove the chain from the sprocket remove the caliper with its support and carefully extract the rear wheel from the swing arm Pay attention to the thin wheel shim sprocket side and thick shim brake side WARNING DO NOT ACTIVATE THE BRAKE PEDAL WHEN THE REAR WHEEL HAS BEEN DISASSEMBLED ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO PREVENT DAMAGE WHEN THE WHEELAXLE IS DISASSEMBLED THE WHEEL AXLE THREADS AND THE THREADS OF THE FLANGED NUT MUST BE WELL CLEANED RE GREASE THEM TO PREVENT SEIZING OF THE THREADS To assemble insert the thin shim sprocket into the hub position the chain tensioners insert the wheel into the swing arm and supporting the wheel position the caliper with its support and mount the chain onto the sprocket Insert the axle from the sprocket side into half the wheel to permit positioning of the thick shim brake side Finish inserting the axle insert the chain tensioner slide screw the nut and tighten it at 80 Nm Before tightening the flanged nut push the rear whe
16. exceeds 272 mm it is advised to replace the chain The chains are not always worn in a even way For this reason the measurement must be taken in different points on the chain INDICATION When a new chain is mounted also replace the sprockets A new chain wears more quickly on old and worn sprockets A WARNING WHEN THE CHAIN SPROCKETS ARE REPLACED IT IS ADVISED TO MOUNT NEW SELF LOCKING NUTS AND TO TIGHTEN WITH CROSS SEQUENCE TIGHTENING TORQUE AT NUTS 35 NM BASIC INDICATIONS FOR TM DISC BRAKES CALIPERS The mounting system of the calipers of these models is floating i e they are not rigidly joined to their support The lateral compensation always allows the pads to work in the best way on the discs The brake caliper fastening screws must be assembled using Loctite 243 and tightened at 25 Nm The front calipers of the SMR SMM SMX models are an exception as they are fixed type PADS The minimum thickness of the friction material cannot go under the limit of 1mm In case of replacement it is advised always to use TM original spare parts for your motorcycle BRAKE DISCS With wear the thickness of the brake disc is reduced in the contact area of the pads 1 In the thinnest point A the brake disc may present max wear of 0 4 mm with respect to original thickness The original thickness can be measured in point B outside of the contact area Check wear in different points BRAKE DISCS WITH WEAR EXCEEDING 0 4
17. MM ARE ARISK FOR SAFETY WHEN THE LIMIT OF WEAR HAS BEEN REACHED HAVE THE BRAKE DISCS REPLACED IMMEDIATELY IT IS COMPULSORY TO HAVE THE BRAKE UNIT REPAIRED BY A TM AUTHORISED WORKSHOP 43 LEE AND LENE BRAKE FLUID RESERVOIRS The front and rear brake liquid reservoirs are dimensioned in a way that topping up is not necessary even if the brake pads are worn fact when the pads are worn the fluid in the hoses tends to occupy the space left by the small pistons which have moved so that the pads always lay on the disc If the level of brake fluid falls below the minimum value it indicates that there is a leak in the braking system or brake pad wear is beyond accepted limits BRAKE FLUID The braking system is filled by TM with top quality DOT 4 brake fluid We recommend that top ups and complete replacement are carried out using the same type of fluid DOT 4 HAVE THE BRAKE FLUID REPLACED AT LEAST ONCE A YEAR IF YOU WASH THE MOTORCYCLE FREQUENTLY IT SHOULD BE REPLACED MORE OFTEN THE BRAKE FLUID SOAKS WATER IN OLD FLUID THEREFORE IT IS POSSIBLE THAT STEAM BUBBLES FORM EVEN AT LOW TEMPERATURES AND THE BRAKING SYSTEM DOES NOT WORK CORRECTLY FRONT BRAKE NISSIN PUMP END MX FRONT BRAKE LEVER ADJUSTMENT The distance of the front brak lever from the handlebar grip can be adju sted through the adjustment screw 1 Loosen the lock nut 2 and turn the screw clockwise to
18. OTHERWISE THERE COULD BE A FAULT IN THE BRAKES IN THE INTEREST OF YOUR SAFETY HAVE THE THE PADS RE PLACED IN TIME A WARNING IF THE BRAKE PADS ARE REPLACED TOO LATE AND ARE COMPLETELY WORN THE STEELPARTS OF THE PADS RUB ON THE DISC THIS LEADS TO A NOTABLE DECREASE IN THE BRAKING EFFECT AND DAMAGE OF THE BRAKE DISC 45 p 7774 ERAMEANDIENGINEIVAINTENANG LLANE REPLACEMENT OF FRONT BRAKE PADS A FOR ALL MODELS WITH FLOATING CALIPER END MX Push the brake caliper towards the disc in a way that the brake pistons reach their base position Remove the safety devices 1 extract the pin 2 and remove the pads from the caliper Use compressed air to clean the brake caliper and the caliper support check that the driving pin seals are not damaged and if necessary grease them Mount the right brake pad and fix it with the pin Mount the left brake pad and insert the pin until it stops Mount the safety devices During mounting of the pads ensure that the protection sheet steel in the caliper support and the leaf spring are correctly positioned FOR ALL MODELS WITH FIXED CALIPER SMR SMM SMX RADIAL COUPLING Unscrew the two screws M10 3 and remove the caliper from the fork shoe Press the two hooks 4 one at a time to release and slide the retainer pins 5 out Lever on each pair of pads to allow the pistons to go back to their seat Extract the worn pads and insert the new ones Repeat the
19. S p A Via Fano 6 61100 PESARO ITALY www tmracing it Published and printed by 5 Fabriano www seriart com ENGLISH 97045 10 06 ed 03 10
20. THROTTLE CABLE COMMAND ADJUSTMENT The throttle command should always have a free play of 3 5 mm Mo reover when the engine is idling the revs must not vary when steering as far as possible to the left and to the right To adjust the play push the protection hood backwards 6 Loosen the counter nut 7 and unscrew or screw the adjustment device 8 By screwing the free play increases By unscrewing the free play decreases Tighten the counter nut and control the smoothness of the the throttle command handlebar grip NOTES ON THE CARBURETTOR The carburetor is calibrated at an altitude of O meters above the level of the sea and at a temperature of 20 using premium grade fuel 95 unleaded mixed with 1 30 specific 2T oil The only changes that you might need to make are to the main jet idle jet and jet needle changes to other parts of the carburetor are usually pretty minor ATTENTION High altitude or high temperature conditions require a leaner carburetor setting Low altitude or low temperature conditions require a richer carburetor setting A WARNING 2 STROKE ENGINES REQUIRE A MIXING RAIO OF 1 30 WITH OIL SO YOU SHOULD ADD 33 CC OR ML OF OIL FOR EACH LITRE OF FUEL DO NOT USE FUEL WITH OCTANE RATING UNDER 95AS THIS COULD DAMAGE THE ENGINE USE HIGH QUALITY 2T ENGINE OIL THE BEL RAY SYNTHETIC 2 STROKE RACING OIL IS THE ONLY ONE TM APPROVES USES AND RECOMMEN DS YOU MUST PUT IN THE CORRECT AMOUNT OF OI
21. You are advised to use the same type of engine oil already in the en gine A WARNING LOW OIL LEVEL LOW QUALITY OIL MAINTENANCE INTERVALS LONGER THAN THOSE ESTABLISHED CAUSE SERIOUS DAMAGE TO THE ENGINE 63 ENGLISH p 7774 LEE AND PINGING MAINED ANGI LARI ENGINE OIL TM use and recommended motor oil Bel Ray Gear Saver Motorcycle Transmission oil SAE 80W WARNING LOW OIL LEVEL LOW QUALITY OIL MAINTENANCE INTERVALS LONGER THAN THOSE ESTABLISHED CAUSE SERIOUS DAMAGE TO THE ENGI NE CHANGE ENGINE OIL A A WARNING WHEN CHANGING THE OIL CLEAN THE MAGNET OF THE OIL DRAIN BOLT The oil must be changed with the engine at working temperature THE ENGINE AT WORKING TEMPERATURE AND THE OIL INSIDE ARE VERY HOT PAY ATTENTION BURNS HAZARD Position the motorcycle on a flat surface loosen and unscrew the cap 1 positioned on the lower face of the engine and allow the oil to flow into a container BEWARE OF HOT OIL Clean the cap and incorporated magnet well After the oil has flowed out completely clean the sealing face remount the cap together with the seal and tighten at 20 Nm Replace the seal if it is damaged Quantity of oil after replacement 500 550 cc w A NN d Quantity of oil after a complete engine overhaul 600 cc INSPECTION OF THE REED VALVE The reed valve situated between the cylinder and the manifold should be inspected whenever the engine is serviced Remove the carburettor and man
22. dampening increases turning it anticlockwise the dampening decreases A total of 20 clicks are available A WARNING BEFORE STARTING IT IS ADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITION TO THE TOTALLY CLOSED POSITION AND COUNT THE NOTCHES DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NOTCHES ARE INDICATED FROM THE TOTALLY CLOSED POSITION BOTH RODS MUST HAVE THE SAME ADJUSTMENT 15 OPERATING CONTROLS ier UGE LECLE FORK ADJUSTMENT IN REBOUND The hydraulic dampening in extension determines the behaviour of the fork in the rebound stroke The degree of dampening in rebound can be adjusted on the basis of pilot preferences and or hardness of the spring installed MARZOCCHI USD FORK The adjustment screw is located in the lower part of the fork leg 8 For this operation use a screwdriver By turning the screw clockwise dampening increases while turning it anticlockwise dampening decreases A total of 28 clicks are available PAIOLI USD FORK The adjustment screw is located in the top side of the fork cap 4 Tur ning the screw clockwise dampening increases turning it anticlockwise dampening decreases A total of 28 clicks are available OHLINS USD FORK The adjustment knob 5 is located in the top side of the fork cap Operate by hand Turning the knob clockwise dampening increases turning it anticlockwise dampening decreases A total of 20 clicks are availa
23. needle cage silver plated needle cage forged light alloy 1 ring direct with mixture fully synthetic premium quality oil 600 cc straight toothing gears 15 66 multiple discs in oil bath 6 speed 12 14 32 2 17 29 19 27 42 23 28 5 22 24 6 23 23 Kokusan digital CDI with variable timing 12V 60W Ducati Energia NGK BR 8EG 0 6 0 7 mm liquid cooled 40 9o antifreeze 60 9o water up to 25 forced circulation with pump 0 8 litres LLANE TEGCANICAL DAIA ENGINE TECHNICAL DATA ENGINE 129 144 ENDIMA 2010 ENGINE PES END XE ns END Type 2 stroke single cylinder liquid cooled Displacement 124 8 cm 143 3 cm Cylinder bore and stroke 54 54 5 mm 56x 58 2 mm Compression 14 2 1 12 5 1 14 1 Fuel unleaded fuel mixed ratio 1 30 with oil Squish height 1 1 1 2 mm 1 6 1 8 mm 1 1 1 2 mm Piston heigth from cylinder upper that to the TDC 1 65 1 75 mm Crank shast supports 2 ball bearings Connecting rod big end needle cage Connecting rod small end silver plated needle cage Piston forged light alloy Rings 1 ring Lubrication direct with mixture Engine oil fully synthetic premium quality oil Oil capacity 600 cc Primary transmission straight toothing gears 19 63 Clutch multiple discs in oil bath Gearbox with front engagement 5 speed 6 speed 6 speed 5 speed 6 speed 12 14 32 1713 32 1713 32 12 14 32 1713 32 2 16 29 2 16 29 2 16 29 2 16 29 2 16 29 Gear ratios 3 18 27 18 2
24. operation for the other pair of pads Press the two hooks down and re insert the pins be sure that they are fully inserted have their play and are correctly attached Reassemble the caliper and tighten the M10 screws at 40Nm AXIAL COUPLING Unscrew the two M8 screws 6 and remove the caliper Lever the pads to allow the pistons to go back into their seat then remove the safety pin 7 slide the pin 8 out and then extract the pads paying attention to the laminated spring 9 Remount the new pads the laminate the pin and the safety retainer then reassemble the caliper and tighten the M8 screws at 25 Nm A WARNING FORALL MODELS WHEN THE CALIPER PISTONS ARE PUSHED BACK TO THEIR SEAT TO PROVIDE ROOM FOR THE NEW PADS PAY ATTENTION THAT THE FLUID CONTAINED IN THE RESERVOIR HAS THE SPACE TO EXPAND DO NOT WORK WITHOUT THE CAP MOUNTED OTHERWISE THE FLUID COULD OVERFLOW AND DAMAGE PARTS OF THE MOTOR CYCLE THE BRAKE DISC MUST ALWAYS BE KEPT FREE FROM OIL AND GRE ASE OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY REDU CED AFTER MOUNTING CHECK THAT THE SAFETY DEVICES ARE COR RECTLY POSITIONED AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM ACTIVATE THE FRONT BRAKE LEVER AND THE REAR BRAKE PEDAL TO MAKE THE PADS ADHERE TO THE DISC AND TO RESTORE THE CORRECT ADJUSTMENT OF PLAY ENGINSEH 46 774 ERAMEANDIENGINEIVAINTENANG AIAX MODIFICATION OF REAR BRAKE PEDAL BASE POSITION A The base position of the rear br
25. tachometer may not work proper ly The distance of the sensor is adjusted by the shim 3 Do not remove it otherwise the sensor may hit the screws and get damaged SMM The distance between the brake disc side face 4 and the sensor 1 must be 2 4mm If not the tachometer may not work properly The distance is adjusted by the shim 3 Do not remove it otherwise the sensor may hit the disc side face 4 and get damaged 51 UGE LLANE BATTERY SMR E SMM The saddle must be removed to access the battery The battery does not require maintenance It is not necessary to check the level of the electrolyte or top up with water The battery poles must be cleaned and if necessary slightly greased using grease that does not contain acids Battery disassembly First remove the negative pole and then the positive pole from the battery Disconnect the elastic stripes 1 Remove the battery When assembling the battery place it with the poles pointing external part see figure first connect the positive pole and then the negative pole to the battery IF FOR SOME REASON THE ELECTROLYTE SULPHURIC ACID SHOULD ESCAPE FROM THE BATTERY BE VERY CAREFUL THE ELECTROLYTE CAN CAUSE SERIOUS BURNS ON CONTACT WITH THE SKIN RINSE WELL WITH WATER IF DROPS OF THE ELECTROLYTE ENTER INTO THE EYES RINSE FOR AT LEAST 15 MINUTES WITH WATER AND CONSULT A DOCTOR IMME DIATELY EVEN IF THE BATTERY IS SEALED I
26. the adjustment bolts and that the rear wheel is aligned with the front wheel Tighten the wheel axle nut to 80 Nm A ATTENTION IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH FOR ASSEMBLING HAVE THE TIGHTENING TORQUE CHECKED BY A SPECIALISED TM WORKSHOP AS SOON AS POSSIBLE A LOOSE WHEEL AXLE MAY CAUSE UNSTABLE DRIVING OF THE MO TORCYCLE 41 5 p 7774 LLANE ADJUSTMENT OF CHAIN TENSION SMM Loosen both the locking screws 7 of the rear eccentric hub in a way that the hub itself can turn around its axis Using the relevant TM tool code F50806 8 turn the hub until correct chain tension is reached Tighten the two locking screws to 30 Nm Since the movement is an eccentric system alignment of the rear wheel is unvaried and no further adjustment is required At the same time by turning the hub a slight variation in the height of the rear wheel axle may be verified and consequently of the rear part of the motorcycle It is possible to compensate this by varying the projection of the fork legs from the upper clamp For example if the motorcycle by effect of chain adjustment has lifted by 5mm at the rear it is advised to decrease the projection of the fork rods by about 5mm to also raise the front and restore the original level ling of the motorcycle It is advised to use the TM tool code F50806 pairing with two M8 screws and two nuts to turn the hub insertin
27. the silencer packing damaged The ignition timing is not correct ENGINE MISFIRINGS OR Fuel missing BACKFIRES FROM THE CARBURETOR Air leaks in the intake manifold Non vi sufficiente liquido nel sistema di raffred damento Ventilazi insufficient THE ENGINE OVERHEATS entilazione insufficiente EXCESSIVELY Aria nel sistema di raffreddamento Le lamelle dei radiatore sono molto sporche Formazione di schiuma nel sistema di raffreddamento Tubo del radiatore piegato EXCESSIVE OIL The vent hose is bent CONSUMPTION Engine oil level too high Engine oil too thin viscosity ALL OF THE BULBS BLOW The regulator is damaged UNEXPECTEDLY LIGHTS HORN AND INDI CATORS DO NOT WORK The lights cable fuse is burned out 66 TROUBLESHOOTING SOLUTION Disassemble the carburetor and clean the jet Adjust the idle speed screws Replace the spark plug Have the ignition system checked Disassemble the carburetor and check the height of the float and the state of the needle valve as described in the Frame and Engine Maintenance chapter Tighten the jets Have the ignition timing checked Clean and check the fuel circuit and the carburetor Replace the float Clean or replace the air filter contact a specialised workshop Check the faulty parts on the exhaust system replace the fibre glass in the silencer Have the ignition timing checked Clean and check the fuel circuit and the carburetor Check the rubber man
28. 7 3 18 27 3 18 27 3 18 27 4 20 25 4 20 25 4 20 25 4 20 25 4 20 25 5 22 24 5 22 24 5 22 24 5 22 24 5 22 24 6 27 24 6 27 24 6 27 24 Ignition Kokusan digital CDI with variable timing and 2 selectable maps Generator 12V 60W Regulator Ducati Energia Spark plug NGK BR 9EG Electrodes gap 0 6 0 7 mm Cooling liquid cooled 40 antifreeze 60 water up to 25 C forced circulation with pump Coolant fluid capacity 1 litre 69 9 9 1uBieu 32014 suJni Z S suJn 2 86 M9J9S MO S 2 2 9 oJu p do do ye uonisod dijo OALN 3MfN 9 peeu jer 0 8 CV Jof MOIS 061 881 08 jor 8 8 od 06791 1e0 J4 suJni M9J9S MO S v 9 oJu p do yp uonisod dijo 6 dds 9 peeu jor O jer MOIS oLz jor UIEN L6 82 INL od ENGINE TORQUES ENGINE TIGHTENING TORQUES Crankase Allen screws transmission cover clutch cover ignition cover Oil drain screw cap Oil filler screw cap Oil net filter screw cap Oil cartridge filter cover Allen screws Engine oil pump body screws Head cylinder nuts Head cylinder flanged nuts Water pump cover Allen screws Water pump rotor Clutch hub nut Clutch springs Allen screws Mobile chain guide fastening flanged screws Ignition stator Allen screws Ignition pickup fastening Allen screws Kickstart pedal screw
29. AINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH A REQUIRE TECHNICAL MASTERY FOR THIS REASON IT IS INTHE INTEREST OF YOUR SAFETY TO HAVE THESE OPERATIONS CARRIED OUT EXCLUSIVELEY BY A SPECIALISED TM WORKSHOP WHERE YOUR MOTORCYCLE WILL BE MAINTAINED IN AN OPTIMAL MANNER BY SPECIFICALLY TRAINED STAFF WARNING Periodically check the play of the steering bearings For the check lift the front wheel and shake the fork forward and backwards For adjustment loosen the four 8 screws 1 and nut 2 of the head of the fork and act on the ring nut 3 tightening it until there is no more play Do not tighten the ring nut further to prevent damage to the bearings Tighten the fork head nut and successively the four M8 screws to20 Nm Check for a smooth steering IF THE STEERING BEARINGS DO NOT HAVE THE CORRECT CLEARANCE THE BEHAVIOUR ON THE ROAD WILL BE IRREGULAR AND YOU COULD IF POSSIBLE DO NOT USE HIGH PRESSURE JETS WHEN WASHING THE MOTORCYCLE BECAUSE THE WATER COULD PENETRATE INTO THE BEARINGS THE CARBURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR TM ENSURE THAT 15 WELL HELD IN A VERTICAL POSITION USING BELTS OR OTHER MECHANICAL FIXING DEVICES AND ENSURE THAT THE FUEL TAP IS SWITCHED OFF IF THE MOTORCYCLE SHOULD FALL FUEL COULD ESCAPE FROM THE CABURETOR OR TANK TO FIX THE SHROUDS TO THE TANK ONLY USE THE SPECIAL SCREWS WITH THE CORRECT LENGTH OF THREAD FOR TM BIKES IF YOU USE DIFFERENT SCREWS OR LONGER SCREWS TH
30. AND THEREFORE THE STEAM CREATED DURING THE COMBUSTION PROCESS WOULD CONDENSE CAUSING THE OXIDATION OF THE EXHAUST VALVES START UP AFTER SEASONAL PAUSE Mount the charged battery pay attention to polarity Fill the tank with new fuel Control the motorcycle as before any start up see Instructions for use chapter Make a short inspection trip WARNING Before storing the motorcycle for the season check functioning and wear of all components If maintenance operations repairs or modifications are necessary it is a good idea to have them carried out during the winter time less busy workshops In this way it is possible to avoid long waits in the workshop at the beginning of the spring season 67 p 56 6111672 DATA ENGINE TECHNICAL DATA ENGINE 69 100 MA 2010 ENGINE Type Displacement Cylinder bore and stroke Compression Fuel Squish height Piston heigth from cylinder upper that to the TDC Crank shast supports Connecting rod big end Connecting rod small end Piston Rings Lubrication Engine oil Oil capacity Primary transmission Clutch Gearbox with front engagement Gear ratios Ignition Generator Regulator Spark plug Electrode gap Cooling Coolant fluid capacity ENGINSEH 68 85 MX 100 MX 2 stroke single cylinder liquid cooled 85 cm 100 cm 47 95 47 51 97 47 18 1 16 3 1 unleaded fuel mixed ratio 1 30 with oil 0 9mm 0 9mm 0 75 mm 0 75 mm 2 ball bearings
31. ANUIENZIONE E LUBRIFICAZIONE 85 100 125 144 END MX SMX USO COMPETIZIONE A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS AFTER 2 HOURS EVERY 42 LT FUEL COMPETITION Replacement of engine oil 2 Z Clean of drain bolt 2 Check condition and unbent positioning of rubber pipes a Check tightness of engine fastening screws 2 Check fasteners for carburetor to engine and filter case 2 Check idle speed adjustment Check conditions and unbent positioning of vent pipes d 2 Check for leaks of the cooling system and coolant level Check for leaks and screws tightness of the all exhaust system Check conditions smoothness and unbent positioning adjustment and lub of command cables i Replacement of silencer packing material x Check fluid level in the hydraulic clutch reservoir 8 gt Cleaning of filter case and air filter 9 T Check conditions and unbent positioning of cables 2 Check head light orientation END Check electric system head light high beam stop indicators lights horn END version 2 OFF button Check brake fluid level pad thickness brake discs S 2 Check conditions of brake hoses Check functionality adjustment smoothness and free play of front brake lever and brake pedal Check brake hoses screws tightness 5 Check for leaks and working of shock absorber and forks Clean dust screen 2 Bleed fork legs W Check rear suspensi
32. E TANK COULD BE DAMAGED WITH CONSEQUENT FUEL LEAK DO NOT USE NOTCHED WASHERS OR SPRING WASHERS FOR THE ENGINE FASTENING SCREWS BECAUSE THEY COULD PENETRATE INTO PARTS OF THE FRAME AND LOOSEN CONTINUALLY USE SELF LOCKING NUTS LEAVE THE MOTORCYCLE TO COOL BEFORE STARTING ANY MAINTENANCE THIS WILL PREVENT BURNS DISPOSE OF OILS GREASES FILTERS FUELS DETERGENTS ETC INA REGULAR MANNER COMPLY WITH THE RESPECTIVE REGU LATIONS OF YOUR COUNTRY DISPOSE OF WASTE OIL INA REGULAR MANNER NEVER POUR OLD OIL INTO DRAINS OR RIVERS CHECK OF STEERING BEARINGS AND PLAY ADJUSTMENT A LOOSE CONTROL OF THE MOTORCYCLE A WARNING MAKING LONG JOURNEYS WITH INCORRECT STEERING BEARINGS ADJUSTMENT YOU RISK TO DAMAGE THE BEARINGS AND THEIR SEATS IN THE FRAME The steering bearings should be re greased at least once a year ENGLISH 36 LEP BRAVEVANDI ENGINE VAIN TENANG LLANE TELESCOPIC FORK VENT SCREWS Every 5 hours of use in competitions loosen the vent screws 1 by a few turns so allowing the release of any air pressure from inside the fork Instead of a screw Marzocchi fork features a tyre valve 3 which is protected by a rubber bulb 4 Remove the rubber bulb and press gently the valve stem Before operating on the screws or on the valve lift the motorcycle onto the stand in a way that the front wheel does not touch the ground If the motorcycle is used mainly on roads it is sufficient only to carry out this operation
33. L LESS OR OUT OF DATE OIL COULD CAUSE THE ENGINE TO WEAR OUT QUICKLY AND IN EXTREME CASES RESULT IN IRREPARABLE DAMAGE AN EXCESSIVE AMOUNT OF OIL INSTEAD CAN CAUSE MORE FUMES THAN NORMAL AND FOUL THE SPARK PLUG AND EXHAUST VALVE ENGLISH 60 LEP LEE AND ENGINE MW ATISTERZIN GI LLANE BASIC INDICATIONS REGARDING CARBURETOR WEAR The throttle valve jet needle and the float needle valve are subject to great wear caused by engine vibration As a consequence the carbure tor may malfunction e g enrichening of the mixture These parts must therefore be controlled after 200 hours THE DEFINITION AND USE OF A CARBURETOR FOR A 2 STROKE ENGINE RICH MIXTURE the amount of fuel is too high in relation to the amount of air LEAN MIXTURE there is not enough fuel in relation to the amount of air OPERATION AT IDLING phase 1 The carburetor is running with the throttle valve closed The mixture is regulated by the air adjustment screw 1 and idle adjustment screw 2 You should make the necessary adjustments with the engine hot OPERATION WITH THROTTLE VALVE OPENING phase 2 The throttle valve is open mixture is controlled by the idle jet and shape of the throttle valve OPERATION WITH THROTTLE VALVE PARTIALLY OPEN PARTIAL CAPACITY phase 3 The throttle valve is partially open In this case the mixture is regulated simply by the position notch and the shape of the jet needle It is de termined at low speed by the idle
34. MAPS SELECTION SWITCH Some models are equipped with a central control unit with double map ping that can be selected using the button positioned on the left side of the handlebar Map 1 corresponds to an aggressive map Map 2 to a soft map ENGLISH 12 OPERATING CONTROLS FUEL FILLER CAP The fuel fill cap is found on top of the tank Open turn the cap in an anti clockwise direction Close place the cap on the inlet well and tighten it in a clockwise di rection Position the tank s open vent pipe 1 preventing bends or crushing and making sure that it is inserted correctly FUEL TAP The tap is located on the left hand side of the tank base OFF On the OFF position the fuel tap is closed ON Onthe ON position the fuel tap is open When the motorcycle is used turn the tap to the ON position In this way the fuel flows to the carburetor and the tank empties up to reserve RES On the RES position the reserve is used After having filled up the tank do not forget to move the tap back to the ON position Tank capacity all models 8 5 Lt reserve 1 Lt CHOKE COMMAND COLD STARTER This command is located on the carburetor For MIKUNI carburetors 85cc 100cc and KEIHIN carburetors 125cc 144cc By extracting the choke knob 1 as far as possible a passage is opened in the carburetor through which the engine can suck additional fuel In this way a rich air fuel mix is obtain
35. ND SMR SMM _ 4 53 Halogen light END SMR SMM 53 Hydraulic clutch AJP 59 Hydraulic clutch BREMBO pump 59 Idle speed adjustment command 13 If the engine is 2 24 ine ciim FU 15 Indications for first 20 Inspection of the reed valve 64 INSTRUCTIONS FOR USB 21 een mane oe ios 14 Ezio 55 MAINTENANCE AND LUBRICATION TABLE 29 maps selection switch 12 Modification of rear brake pedal base position 47 Notes on the carburettor _ 60 OPERATING CONTROLS 2 9 POSITION OF SERIAL NUMBER sese 7 PRECAUTIONS FOR WINTER USE 67 Rear suspension mechanicallinkage 40 Replacement of exhaust silencer packing material 57 Replacement of fork springs 40 Replacement of front brake pads _ 46 Replacement of rear brake pads
36. NG PRELOAD The preload of the spring can be varied by turning the adjustment ring nut 5 With this aim it is advised to disassemble the rear shock and clean it well before operating INDICATION Before varying the spring preload you should take note of te basic adjustment e g how many thread turns are visible above the lock ring nut 6 By 1 turn of the adjustment ring nut 5 the spring pre load varies by 1 5 mm SACHS Loosen the lock ring nut 6 and turn the adjustment ring nut 5 Turning it anticlockwise the preload decreases turning it clockwise the preload increases After the adjustment tighten the lock ring nut 6 OHLINS Loosen the clamp 7 using a 4mm Allen wrench and turn the adjustment ring nut 5 Turning it anticlockwise the preload decreases turning it clockwise the preload increases Tighten the clamp closure 7 after adjustment The Junior model has an Ohlins shock absorber with double nut adjustment REAR SUSPENSION MECHANICAL LINKAGE The rear suspension of all TM motorcycles has a link rod and rocker mechanism that progressively changes the lever relationship between the wheel and the rear shock This mechanism works on bearings which must be cleaned and greased at the envisioned intervals to maintain the working of the suspension efficient When cleaning the motorcycle with high pressure cleaning devices do not aim the jet completely onto the suspension mechanical linkage
37. OMETRIC WRENCH WHEN MOUNTING HAVE THE TIGHTENING TORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP A LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER HAVING RE ASSEMBLED THE REAR WHEEL ALWAYS ACTI VATE THE BRAKE PEDAL SO THAT THE PADS ADHERE TO THE DISC AGAIN CHECK SPOKE TENSION Correct tension of the spokes is very important for the stability of the wheel and therefore safety on the road An insufficiently taught spoke leads to unbalancing of the wheel and in brief time loosening of other spokes Regularly check the tension of the spokes particularly on new motorcycles Briefly hit every spoke with the end of a screwdriver see photo the spoke should produce a clear sound Hollow sounds mean loose spokes In this case you must have the spokes adjusted in a spe cialised workshop The wheel must also be centred IF YOU CONTINUE TRAVELLING WITH INSUFFICIENTLY TIGHT SPOKES THEY MAY TEAR CAUSING PROBLEMS OF INSTABILITY EXCESSIVELY TIGHT SPOKES MAY TEAR DUE TO LOCAL OVERLOA DING ENGINSEH 50 LEP PAE AND ERGERE MATS ARENG LLANE TYRES TYRE PRESSURE Pisa UIs The type the state and the pressure of the tyres condition the motor cycle s behaviour on the road and they must be checked before every journey The dimension of the tyres is in
38. OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP 15 HOURS OF SERVICE EQUAL ABOUT 150 LT ice E P m MET OF FUEL CONSUMPTION 150LT 30011 45017 60011 750LT 900LT Check cylinder and piston wear e e e Check piston pin visual check e e e e Check the exhaust valve e e e e e e Check reed valve block e e e e e Check head and cylinder surfaces e e e e Check small end for marking damage to plating e e e Replace conrod axle and roller cage e e Replacement of main bearings Check complete gearbox including drum and forks e e Check clutch plate wear 8 e e e e Check length of clutch springs e e e e e WARNING IF AFTER CHECKING IT IS DETECTED THAT THE WEAR LIMITS OF A SINGLE COMPONENT HAVE BEEN EXCEEDED THE COMPONENT MUST BE REPLACED THE INSTALLATION OF AN HOUR COUNTER INSTRUMENT IS ADVISED THE ABOVE MENTIONED OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP 33 ENGLISH UGE PHECKS TO RE CARRIED OUT 1 ly ZORRY put E 30 60 90 120 150 180 t9 HOURS SF FUEL CONSUMPTION dale rb rers Check cylinder and piston wear e e e e e e Check piston pin visual check e e e e e Check the discharge valve 9 e e Check lamellar body e e e e e e Check head and cylinder surfaces e e e e e Check small end for marking damage to plating e e e e Replace conrod axle and roller cage e e Replacemen
39. OR IN STOP AND GO TRAFFIC OVERHEATING MAY OCCUR TO SOLVE THIS PROBLEM AN ELEC TROVENTILATOR KIT IS AVAILABLE FOR ALL MODELS WITH ELECTRIC STARTER ASK AT YOUR TM AUTHORISED DEALER ENGINSEH 56 7 72225 Y S 2 CHECK COOLANT LEVEL When the engine is cold the liquid must cover the radiator channels by at least 10 mm If the circuit is emptied fill it immediately and bleed A WARNING WHEN THE COOLANT LIQUID HAS BEEN EMPTIED WHEN RE FILLING IT IS NECESSARY TO BLEED THE COOLING SYSTEM SEE BELOW EMPTYING FILLING AND BLEEDING OF THE COOLING SYSTEM The coolant liquid may be emptied by removing the screw 5 from the guard on the right side of the engine Prepare an adequate container to collect the liquid when it comes out To empty the liquid the filling cap must be opened At the end screw the emptying screw and tighten to 12 Nm To fill the cooling system pour the amount of coolant liquid indicated in the Engine Technical Data Table through the inlet Close the radiator cap and start up the engine for a few seconds Re open the cap and check the level add more liquid if necessary After a brief journey check the level of coolant liquid again REPLACEMENT OF EXHAUST SILENCER PACKING MATERIAL The aluminium silencers are filled with acoustic insulating material fibre glass to limit motorcycle noise Because of high temperatures reached by the exhaust gases the fibreglass tends to burn leading to
40. OR PARK THE MOTORCYLE IN PLACES WHERE THERE IS THE RISK OF FIRE DUE TO DRY GRASS OR OTHER EASILY INFLAMMABLE MATERIALS ENGLISH 26 H SIUC ONS E01 UK 2 INDICATIONS REGARDING THE SIDE STAND Push the stand forward until it stops and lean the motorcycle on it Ensure that the ground is solid and the parking position is stable For greater safety insert the 1st gear A WARNING THE SIDE STAND IS DESIGNED ONLY FOR THE WEIGHT OF THE MO TORCYCLE NEVER SIT ON THE MOTORCYCLE WHEN IT IS RESTING ON THE SIDE STAND OTHERWISE THE STAND MAY BE DAMAGED AND THE MOTORCYCLE CAN FALL FUEL The 2 stroke engines require a mixture of fuel and oil TM s 2 stroke engines require a mixing ratio 1 30 so you need to add 33 cc or ml of oil for each liter of super fuel Bel Ray Synthetic 2 Stroke Racing Oil is the only synthetic oil that TM approves uses and recommends A WARNING FILL THE TANK WITH UNLEADED FUEL WITHAMINIMUM OCTANE NUMBER OF 95 NEVER USE FUEL WITH AN OCTANE NUMBER LOWER THAN 95 BECAUSE THIS WOULD DAMAGE THE ENGINE FUEL IS HIGHLY INFLAMMABLE AND TOXIC HANDLE FUEL WITH GREAT CARE DO NOT FILL UP WITH FUEL NEAR TO FLAMES OR CIGARETTES ALWAYS SWITCH THE ENGINE OFF WHEN FILLING UP WITH FUEL NEVER POUR FUEL ONTO THE ENGINE OR ONTO THE EXHAUST PIPE IF ANY FUEL IS ACCIDENTLY POURED ONTO THESE PARTS DRY IT IMMEDIATELY USING A CLOTH IF FUEL IS SWALLOWED OR SPRAYED INTO THE EYES SEEK MEDICAL HELP IMMEDIATELY
41. PE APPROVED FOR USE ON PUBLIC ROADS OR MOTORWAYS WHENUSING YOUR MOTORCYCLE ALWAYS KEEP IN MIND THAT EXCESSIVE NOISE DISTURBS OTHERS ISDS URS USE UGE LLANE CHECK BEFORE EVERY START UP To use the motorcycle safely it must be in a good shape It is a good idea to carry out a general check up of the motorcycle before every start up This check must include the following operations 1 LEVEL OF ENGINE OIL To ensure adequate lubrication the level of the oil in the engine must be kept within the envisioned limits Using the engine with the oil level below minimum leads to premature wear and successively to damage and risks to the driver 2 FUEL If the motorcycle does not have a transparent tank open the tank cap and visually check the quantity of fuel contained in the tank Re close the tank making sure that the open vent pipe is not bent and so impeding the flow of air 3 CHAIN The drive chain must always be tensioned corretly and well lubrica ted A loose chain knocks and may escape from the sprockets A too tight chain wears early and may cause wear and breakage of some important transmission components 4 TYRES Check for any damage Tyres with cuts or swellings must be replaced immediately Check the depth of the tread which must correspond to the law Finally check the air pressure and take it to the values envi sioned in the table if necessary Worn tread and unsuitable air pressure worsen driving of th
42. S AND THE VALVES AND OTHER ENGINE COMPONENTS WOULD BE DA MAGED THE REAR WHEEL COULD ALSO LOCK LEADING TO LOSS OF CONTROL OF THE VEHICLE IF THERE ARE ABNORMAL VIBRATIONS DURING FUNCTIONING CHECK THAT THE SCREW FASTENERS ARE TIGHTENED WELL IF STRANGE NOISES ARE HEARD DURING DRIVING STOP IMMEDIATELY SWITCH THE ENGINE OFF AND CONTACT A TM AUTHORISED DEALER 25 KSU ONS UK 5 7 LZA BRAKING Close the throttle and brake at the same time progressively with the front and rear brakes Insert a lower gear depending on speed On dusty wet or slippery surfaces operate the brakes and change down the gears gently without locking the wheels Locking the wheels leads to swerving or a fall When following long descending roads make use of the engine s braking effect To do this insert the 1st or 2nd gear without however increasing the revs excessively In this way you will have to brake much less and the brakes will not overheat IN CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER IMMER SION IN WATER OR TRAVELLING OVER WET GROUND THE BRAKING ACTION COULD BE DELAYED BECAUSE OF WET OR DIRTY BRAKE DISCS THE BRAKES MUST THEREFORE BE OPERATED REPEATEDLY UNTIL THE DISCS ARE DRY AND CLEAN THE BRAKING ACTION CAN ALSO BE DELAYED WHEN TRAVELLING ON DIRTY ROADS OR ROADS COVERED WITH SALT THE BRAKES MUST BE OPERATED UNTIL THE DISCS ARE CLEAN WHEN THE BRAKE DISCS ARE DIRTY THERE IS GREATER WEAR OF
43. SE TO BE SURE OF INSERTING THE ESTABLISHED BULBS CONSULT THE CYCLE PART TECHNICAL TABLE STANDARD REAR LIGHT REPLACEMENT OF REAR POSITION 5 NUMBER PLATE LIGHT BULB END SMR SMM Unscrew the screws 3 and remove the cover 4 Replace the bulb with an equivalent one Remount the cover and tighten the screws The bulb is two light and carries out all above mentioned functions ENGINSEH 54 LEP ERAMEANDIENGINEIVAINTENANG LLANE LED REAR LIGHT REPLACEMENT LED POSITION STOP NUMBER PLATE END SMR SMM Unscrew the screws 5 and remove the rear light body after disconnec ting the wires from the bike harness Since the led light is a single part you have to change it completely Ask for the original spare part to an official TM Dealer DIRECTION INDICATOR LAMP END SMR SMM REPLACEMENT OF BULB Unscrew the screws 6 and remove the cover 7 Replace the bulb with an equivalent one Remount the cover and tighten the screws 55 ENGLISH UGE LLANE COOLING The water pump 1 housed in the engine induces forced circulation of the coolant liquid There is no thermostat in the system therefore when the engine is cold itis important to moderate the number of revs of the engine and speed Proceed for at least 5 minutes at half throttle and at reduced pace to allow the engine to reach an adequate working temperature Cooling takes place thanks to the passage of air through t
44. T HAS BEEN SPREAD WASH THE MOTORCYCLE WELL WITH COLD WATER AND LEAVE IT TO DRY u FORAGE If the motorcycle is not to be used for a long time take the following measures Clean the motorcycle well see CLEANING chapter Change the engine oil and oil filter cartridge clean the net filter old oil contains dangerous impurities Check the antifreeze and the quantity of the coolant Warm the engine up again close the fuel tap and wait until the engine stops Successively open the carburetor bowl empty screw to empty the remaining fuel Disassemble the spark plug and pour into the plug hole 5 cc of oil Activate the kickstart pedal 10 times to distribute the engine oil onto the walls of the cylinder and then remount the spark plug Bring the piston in compression to induce valve closure Empty the fuel tank collecting the fuel in an appropriate container Adjust tyre pressure Grease bearings or command lever supports footrests etc and also the chain Disassemble the battery and charge it see BAT TERY chapter Store it disassembled from the motorcycle The place of storage should be dry and not subject to large temperature changes Cover the motorcycle with a sheet or cover that allows air to pass Do not use materials that do not allow the passage of air as humidity would not be able to escape and could cause oxidation A WARNING IT IS NOT ADVISED TO START THE ENGINE FOR SHORT TIMES THE ENGINE WOULD NOT HEAT UP SUFFICIENTLY
45. T IS POSSIBLE THAT EXPLOSIVE GASES MAY COME OUT KEEP THE BATTERY AWAY FROM SPARKS OR FLAMES KEEP FAULTY BATTERIES AWAY FROM CHILDREN AND DISPOSE OF THEM IN THE CORRECT MANNER A WARNING THE CLOSURE STRIP 2 MUST NOT BE REMOVED PRESERVATION If the motorcycle is kept at a standstill for a long time remove the bat tery and charge it Keep it at at temperature of 0 35 C away from direct sunlight BATTERY CHARGE Install the battery in a low power electronic buffer battery charger A battery charge keeper is also suitable The instructions for charging are also given on the side of the battery A WARNING THE CLOSURE STRIP MUST NOT BE REMOVED AS IT WOULD BE DA MAGED TORECHARGE FIRST CONNECT THE BATTERY TO THE BATTERY CHAR GER THEN SWITCH THE BATTERY CHARGER ON WHEN RECHARGING IN CLOSED SPACES ENSURE GOOD VENTILATION THE BATTERY PRODUCES EXPLOSIVE GASES DURING CHARGING IF THE BATTERY IS CHARGED TOO LONG AT A TOO HIGH VOLTAGE THE ELECTROLYTE WILL COME OUT THROUGH THE SAFETY VALVES THE BATTERY THEREFORE LOOSES CAPACITY ENGLISH 52 13 5 13 8 0 32 A 14 4 15 LLANE STANDARD HEADLIGHTD END SMR SMM REPLACEMENT OF HEADLIGHT POSITION LIGHT BULB Release both elastic stripes and move the light holder mask forward HEADLIGHT TWO LIGHT BULB Disconnect the blue black and white cables and remove the rubber protection 7 Release the retainer and carefully extract the bulb hol
46. THE PADS AND THE BRAKE DISCS THEMSELVES AFTER USING THE BRAKES THE DISC THE PADS THE CALIPERS AND THE BRAKE FLUID HEAT UP THE HOTTER THESE PARTS THE LESS THE BRAKING EFFECT IN CASE OF OVERHEATING THE ENTIRE BRAKING SYSTEM MAY NOT WORK IF THE FORCE AT THE FRONT BRAKE LEVER OR BRAKE PEDAL IS MI NIMAL THERE COULD BE A FAULT IN THE BRAKING SYSTEM IN THIS CASE IT IS A GOOD IDEA TO HAVE THE MOTORCYCLE CHECKED BY AN AUTHORISED TM DEALER STOPPING AND PARKING Stop the motorcycle and shift into neutral To switch the motorcycle off press at normal minimum revs the engine stop switch until the engine has stopped or the red emergency shutdown button In this case it is advised to leave the red button in this way until the engine is started again Close the fuel tap park on solid ground and lock the motorcycle using the steering lock In the case of the SMR SMM models turn the key to switch off the engine MOTORCYCLES PRODUCE ALOT OF HEAT DURING WORKING THE ENGI NE RADIATORS EXHAUST SYSTEM BRAKE DISCS AS WELL AS SHOCK ABSORBERS CAN ALL BECOME VERY HOT NEVER TOUCH THESE PARTS WHEN DRIVING AND AFTER HAVING SWITCHED THE ENGINE OFF PARK THE MOTORCYCLE IN A WAY THAT PEDESTRIANS CANNOT TOUCH THEM AND BE BURNED A WARNING THE FUEL TAP MUST ALWAYS BE CLOSED WHEN THE MOTORCYCLE IS PARKED IF IT IS NOT CLOSED THE FUEL COULD RUN OUT INTO THE CARBURETOR AND PENETRATE THE ENGINE FLOODING IT NEVER PARK WITH THE ENGINE RUNNING
47. THING SHOULD BE BRIGHT SO THAT THE MO TORCYCLIST CAN BE EASILY SEEN BY OTHER ROAD USERS ALWAYS SWITCH THE HEADLIGHT ON DURING THE JOURNEY SO THAT OTHER ROAD USERS CAN SEE YOU IN TIME DO NOT DRINK AND DRIVE ONLY USE ORIGINAL TM ACCESSORIES FRONT COVERINGS FOR EXAMPLE CAN NEGATIVELY AFFETCT THE BEHAVIOUR OF THE MOTORCYCLE ON THE ROAD AT HIGH SPEEDS OR HAVE NEGATIVE INFLUENCE OF THE BEHAVIOUR OF THE MO TORCYCLE DUE TO DIFFERENT WEIGHT DISTRIBUTION THE FRONT AND REAR TYRES MUST HAVE THE SAME TYPE OF PROFILE AFTER THE FIRST 30 MINS OF DRIVING THE WHEEL SPOKE TENSION MUST BE CHECKED SPOKE TENSION DECREASES QUICKLY ON NEW WHEELS IF YOU DRIVE WITH LOOSE SPO KES THE SPOKES MAY BREAK CAUSING UNSTABLE DRIVING CONDITIONS SEE CHECK SPOKE TENSION THE RACING MODELS HAVE BEEN DESIGNED AND PREPARED ONLY FOR ONE PERSON IT IS PROHIBITED TO TAKE ON PAS SENGERS FOLLOW THE HIGHWAY CODE DRIVE CAREFULLY SO AS TO RECOGNISE DANGERS AS SOON AS POSSIBLE ADAPT SPEED TO THE CONDITIONS OF THE ROAD AND YOUR DRIVING CAPABILITY DRIVE CAREFULLY ON UNKNOWN ROADS OR LAND WHEN OFF ROAD YOU SHOULD ALWAYS BE ACCOMPANIED BY A FRIEND WITH A SECOND MOTORCYCLE SO THAT YOU CAN HELP EACH OTHER IF DIFFICULTIES OCCUR IN DUE TIME REPLACE THE VISOR OR LENSES OF THE GOG GLES YOU WILL BE BLINDED AGAINST SUNLIGHT IF THE VISOR OR GOGGLES ARE SCRATCHED DO NOT LEAVE THE MOTORCYCLE UNSUPERVISED IF THE EN GINE IS RUNNING MX AND SMX MODELS ARE NOT TY
48. TRACES OF GREASE TO BE SURE OF INSERTING THE ESTABLISHED BULBS CONSULT THE CYCLE PART TECHNICAL TABLEs 53 er p 7774 LEE LLANE CICLOPS OPTIONAL HEADLIGHT END SMR SMM REPLACEMENT OF HEADLIGHT POSITION LIGHT BULB ATA x Release both of the elastic stripes and move the light holder mask forward HEADLIGHT BULB Disconnect the terminal remove the cover 4 and the seal 5 Unscrew the screws 6 and remove the retainer 7 Loosen the Allen screw 8 and carefully extract the bulb 9 Replace with an equivalent one tighten the Allen screw again re mount the retainer in the correct position and lock with the screw taking care to insert the engine stop eyelet terminal under the head of the screw Remount the cover with the seal and connect the terminal HIGH BEAM BULB Remove the rubber protection 10 unscrew the screw 11 and carefully extract the bulb 12 Replace the bulb with an equivalent one Remount the retainer in the correct position and lock with the screw taking care to insert the engine stop eyelet terminal under the head of the screw Reposition the rubber protection POSITION LIGHT BULB Extract the bulb holder 1 from the parabola replace the bulb 2 Re mount the bulb holder Repositon the light holder mask and fix it with the elastic stripes A WARNING NEVER TOUCH THE GLASS BULB TO PREVENT LEAVING TRACES OF GREA
49. USER AND MAINTENANCE MANUAL TM 2 STROKE 2010 85 100 125 144 cc IMPORTANT YOU ARE ADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM IT CONTAINS ALOT OF INFORMATION AND ADVICE THAT WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE MUCH EASIER AND SAFER IT IS IN YOUR SPECIFIC INTEREST TO PAY PARTICULAR ATTENTION TO THE WARNINGS INDICATED IN THE FOLLOWING WAY N DANGER FAILURE TO COMPLY WITH THESE WARNINGS RISKS LIVES WARNING URE TO COMPLY WITH THESE WARNINGS COULD CAUSE DAMAGE TO PARTS OF THE MOTORCYCLE OR MAKE IT UNSAFE FOR USE Please make note of your motorcycle s serial numbers in the boxes below When you must contact TM for spare parts updating requests or to signal problems indicate the model cylinder capacity year of manufacture and most of all the frame number and the engine serial number FRAME NUMBER KEY NUMBER STAMP OF THE AUTHORISED DEALER TM reserves the right to carry out changes without forewarning The specifications can change from country to country All indications are valid subject to spelling and printing errors 3 Dear TM customer We would like to congratulate you for having chosen a TM motorcycle Your TM is a competitive and modern motorcycle that will surely give you a lot of satisfaction if you treat it according to the provisions contained in this manual Before starting up your TM motorcycle for the first time you must r
50. a decrease in the effect of noise absorbtion and also causing a decrease in power To replace the fibreglass disassemble the silencer from the motorcycle frame remove the rivets that support the front cap and slide the cap and the wool to be replaced out Before dismantling you are advised to mark with a pen the points between the slotted tube and silencer so that you ll be able to put them together again properly later on Slide the fiberglass cartridge on the punched pipe and push it all into the silencer Hold the clamp and fasten with rivets WHEN THE ENGINE IS RUNNING THE EXHAUST SYSTEM BECOMES VERY HOT ONLY START TO WORK ON THE EXHAUST SYSTEM WHEN IT HAS COOLED DOWN TO PREVENT BURNS To ease mounting of the silencer grease the ends of the pipes Also fix the retaining spring between the pipe and the silencer When the engine is started up it might generate some smoke from the previously greased parts This is caused by the high temperature that melts the grease 57 xe I p 7774 ERAMEANDIENGINEIVAINTENANG LLANE A WARNING REPLACE THE FIBREGLASS CARTRIDGE WITH ANEW ONE OF THE SAME WEIGHT OR BOUGHT AT A TM AUTHORISED DEALER ROCK WOOL LENGTH 85cc 100cc MX L 255mm 125cc 144cc MX L 320mm 125 144 END L 435mm 125cc 144cc SMR SMM SMX L 435mm CLEANING THE AIR FILTER A dirty air filter jeopardises the filtering of air reducing engine power and increasing fuel consumption In some cases the dust can
51. adjustment screw and at high speed by the main jet OPERATION WITH GAS THROTTLE VALVE FULLY OPEN MAX CAPACITY phase 4 MAIN JET In this case the mixture is regulated simply by the main jet and the jet JET NEEDLE needle PHASE 3 JET NEEDLE IDLE JET CARBURETOR ADJUSTMENTS PHASE 2 THROTTLE VALVE OPERATION AT IDLING SPEED rnm AIR ADJUSTMENT SCREW Turn the idle adjustment screw to gently adjust engine range clockwise IDLE ADJUSTMENT SCREW to increase anticlockwise to decrease Make sure the engine speed is as smooth and constant as possible OPERATION WITH THROTTLE VALVE OPENS If you have properly regulated the idling speed and partial capacity but the engine rumbles emits excessive fumes and reaches full speed brusquely revving faster than expected it could be a too rich mixture or a too high fuel level in the float bowl 61 7 LENE OPERATION WITH THROTTLE VALVE PARTIALLY OPEN PARTIAL CAPACITY If the engine runs on a four stroke cycle or with decreased power during acceleration with the throttle valve partially open then you will need to lower the jet needle raising the clip by 1 groove If instead the engine rattles especially during acceleration and at high speeds then you will need to raise the jet needle Alternatively if you encounter similar problems while travelling at low speed and at partial capacity you need to check whether the engine has flooded and set a leaner mixt
52. ake pedal can be modified in the following way loosen counter nut M6 1 fork side turn the adjustment screws by acting on the hexagonal head 2 Once the ideal position has been found tighten the counter nut The pedal free play is given by the stroke of the pump piston check that the pedal has a free play of about 1 5cm before starting to brake A WARNING IF THERE IS NO FREE PLAY PRESSURE DEVELOPS IN THE BRAKING SY STEM AND CONSEQUENTLY THE REAR WHEEL IS BRAKED THE BRAKING SYSTEM OVERHEATS AND IN EXTREME CASE IT WILL NOT WORK CHECK REAR BRAKE FLUID LEVEL ALL THE MODELS The reservoir for the rear disc brake fluid is incorporated into the rear brake pump When the motorcycle is in a vertical position the level must always be over half way on the window 3 positioned on the body of the pump IF THE LEVEL OF THE BRAKE FLUID FALLS BELOW THE MINIMUM LEVEL IT INDICATESALEAK IN THE BRAKING SYSTEM OR COMPLETE CONSUM PTION OF THE BRAKE PADS TOP UP REAR BRAKE FLUID A ALL THE MODELS EXCLUDING JUNIOR As soon as the level of rear brake fluid reaches the centreline on the window situated on the pump it must be topped up Unscrew the two screws 4 and remove the lid Top up with DOT4 brake fluid to the top of the window Remount the lid and tighten the screws Wash any spilled brake fluid away with water JUNIOR MODEL The Junior model has a pump without inspection hole The oil is in an outer tank Take off the cap top up
53. ashing close the exhaust pipe rear end to prevent water from entering Normal soaps found on the market should be used to clean the motorcycle Particularly dirty parts should be cleaned using a brush After having rinsed the motorcycle well using a weak jet of water dry using compressed air and a cloth Empty the carburetor bowl Immediately after make a brief journey until the engine has reached the normal working temperature and at this point activate the brakes Because of the heat the water that is left in the unreachable points and on the brakes will evaporate After the motorcycle has cooled down oil and grease all motion parts and bearings Treat the chain with an appropriate spray Also oil the fuel tap To prevent faults in the electric system treat the emergency shutdown button the engine stop button the light switch and the connectors with contact spray ZIEGAUTION FOR VINIER USE OW FOL LOL US If the motorcycle is also used in winter it is necessary to consider the salt on the roads and appropriate countermeasures must be taken against the salt aggressiveness The motorcycle must be cleaned well after use and left to dry Treat engine carburetor swing arm and all other bright or galvanised components except brake disc with wax based anti corro Sives PREVENT CONTACT OF THE ANTICORROSIVE WITH BRAKE DISCS THIS CAUSES GREAT REDUCTION IN THE BRAKING EFFECT A WARNING AFTER TRAVELLING ON ROADS WHERE SAL
54. at eap eu bo Re erue rene appendix 74 6 0 089 31N3I TO IdN3L OOIWLLITS OLNVIDWI VNSHOS 709 3A4 N333H0D 340415 c QIYGNNVA OALLISOd SIZ HILIMS NOILYNIGWOD 05504 TOAN ov18 ae fer AA MES aene meu LLLLLLLLISSLESE MOLVOIQNI NOLLOSYIG LNO3MJ 1331 WOLVOIONI 0112340 102 430 3NIDN3 3ALLISOd LESE TETTE Torte E TIVE lt om j lt c ee S IEE 840102 5 B z 30 m PI gt gt lt T n 5 5 5 8 a m 8 E EXISTE IEEE T 2 2 lt 5 gt 5 50 ONY 4015 N San b NMOUd EUN LH9l1l LNOM Lune 189 2 d INOIZISOd 47 7 NOILISOd B R dOLS 30011000 21 4015 1 083 V19 18 0113 0 8 Dv 18 038 Ovx Dv 18 038 Voll SIO INOIZINO Vall SIO INOIZINO FHOUSOd BAUM 3401 4015 MOLVOIQNI NOLLOSYIO LNOYS JYOLINYIYILNI Jdol V MOLVOIQNI NOLLO3MIQ 9015 8 ONW TIL VSSVW 1 SISSVH2 75 TM Racing
55. be used SHOCK CALIBRATION AND SPRING CHECK If the rear shock spring is suitable for your weight it can be seen by lowering in running order However before establishing the lowering in running order static lowerlng must be adjusted correctly ESTABLISHING REAR SHOCK STATIC LOWERING The static lowering should be35 mm Variations of more than 2 mm can notably influence driving of the motorcycle Procedure Position the motorcycle on a stand so that the rear wheel does not touch the ground Measure the distance between the rear wheel axle and a fixed point e g a mark on the side panel paying attention that the straight line that joins the axle and the fixed point is as perpendicular as possible to the ground and make note of the value as A Rest the motorcycle back on the ground Ask a helper to hold the motorcycle in a vertical position Measure the distance between the rear wheel axle and the fixed point again Make note of this measurement as B The static lowering is the difference between measurement A and B EXAMPLE Motorcycle on stand measurement 600 mm Motorcycle on the ground not loaded measurement B 565 mm Static lowering eee OO MM If thestatic lowering is smaller the rear shock spring pre load must be decreased If the static lowering is greater the spring pre load must be increased See variation of rear shock spring pre load chapter
56. ble A WARNING BEFORE STARTING IT IS ADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITION TO THE TOTALLY CLOSED POSITION AND COUNT THE CLICKS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NUMBER OF CLICKS IS INDICATED FROM THE TOTALLY CLOSED POSITION BOTH LEGS MUST HAVE THE SAME ADJUSTMENT A WARNING FOR FURTHER AND MORE DETAILED INFORMATION REGARDING THE FORK BOTH STANDARD AND OPTIONAL REFER TO THE OWNERS MA NUAL SUPPLIED BY THE MANUFACTURER OF THE FORK SUPPLIED BY TM ACCOMPANYING THE MOTORCYCLE SHOCK ABSORBER ADJUST IN COMPRESSION The hydraulic dampening in compression determines the behaviour of the shock absorber in the compression stroke The degree of dampening in compression can be adjusted on the basis of pilot preferences and or hardness of the spring installed Both standard and optional shock absorbers mounted on the TM offer the possibility of double adjustment in compression for low and high speeds Low and high speeds mean the movement speed of the damper in compression and not the speed of the motorcycle SACHS SHOCK ABSORBER STANDARD Low speeds The adjustment screw 6 is located on the top of the damper gas tank Use a screwdriver By turning the screw clockwise dampening increases anticlockwise dampening decreases A total of 24 clicks are available High speeds The adjuster is a knob 7 and is concentric to the low speed adjustment screw Ope
57. brake caliper fastening screws END MX M8 Front brake disc fastening screws M6 Rear brake disc fastening screw M6 Upper fork head fastening screws M8 Lower fork head fastening screws M8 Paioli fork leg fastening screws M6 Rear wheel axle flanged nut M16x1 5 Swing arm axle flanged nut M14x1 5 Handlebar caps fastening screws M8 Upper end shock nut M10x1 25 Lower end shock screws M10x1 25 Rear sprocket nuts M8 Rear brake pedal adjustment nut M6 Engine fastening screws M10 M6 General frame screw M8 M10 M6 General frame nuts M8 M10 ENGINSEH 72 25 Nm 25 Nm 15 Nm 15 Nm 20 Nm 20 Nm 12 Nm 60 Nm 50 Nm 20 Nm 40 Nm 35 Nm 35 Nm 15 Nm 45 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm LEP TEGHNICAL DATA CYCLE PART LLANE WSC rhe C O BNI SOOO SATs 3 17441442 UO USS 85 100 SENIOR 125 144 MX 125 144 END 125 SMR SMM Frame Twin spar high resistance aluminium alloy frame Front suspension Marzocchi USD fork Rear front suspension travel 300 315 mm Rear suspension Aluminium swing arm Single arm on SMM Progressive mechanical linkage Sachs shock Ohlins optional Front disc brake 320 mm 4 pistons caliper 2 240 mm SMR 0 220mm SMM mm 0 4 below original thickness 270 mm floating caliper Rear disc brake 240 mm floating caliper Brake disc wear limit Front tyre 80 100 21 90 90 21 120 70 17 Rider only air pressure 1 1 bar Rear tyre 100 90 19 120 90 18 150 60 17
58. crew the pin 3 and slide the brake pad out Pay attention to the plates 4 placed between the pads these must be remounted accurately Clean the brake caliper with compressed air and check that the drive pin sheaths are not damaged Remount the new pads paying attention to the positioning of the plates insert the pin re screw it and tighten Remount the tap using a screwdri ver Tighten well FOR ALL MODELS WITH FIXED CALIPER SMM Remove the safety ring 5 and slide the pin out 6 hitting with a pin puller with 4mm diameter on the same side where the safety ring is found THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER MOUNTING CHECK THAT THE SAFETY DEVICES ARE POSITIO NED CORRECTLY AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM ACTIVATE THE FRONT BRAKE LEVER AND THE REAR BRAKE PEDAL TO MAKE THE PADS ADHERE TO THE DISC AND TO RESTORE THE CORRECT ADJUSTMENT OF PLAY DISASSEMBLY AND ASSEMBLY OF THE FRONT WHEEL Position the motorcycle with the frame cradle on a stand in a way that the front wheel does not touch the ground Loosen the flanged nut 7 loosen the fastening screws 8 on the left and right fork shoes finish unscrewing the flanged nut Holding the front wheel still slide the wheel axle out If necessary to help the wheel axle to exit strike lightly with a mallet hammer with plastic ends on the threaded end of the axle it
59. der 8 Replace the bulb 9 Remount the bulb holder the rubber protection and the cables respecting the position indicated POSITION BULB Extract the bulb holder 10 from the parabola replace the bulb Remount the bulb holder Reposition the light holder mask and fix it using the elastic stripes A WARNING NEVER TOUCH THE GLASS BULB TO PREVENT LEAVING TRACES OF GREASE TO BE SURE OF INSERTING THE ESTABLISHED BULBS CONSULT THE CYCLE PART TECHNICAL TABLE HALOGEN LIGHT END SMR SMM LIGHT HEIGHT ADJUSTMENT The front light height can be adjusted First you need to move the rubber stripes on the fork legs so as the light body sits horizontally then you can rotate the front screw 11 to adjust the light height Turn the screw clockiwise to lift the light anticlockwise to lower it HALOGEN LIGHT END SMR SMM REPLACEMENT OF HEADLIGHT POSITION LIGHT BULB Release both rubber stripes and move the light holder mask forward HEADLIGHT TWO LIGHT BULB Disconnect the cables connector and remove the rubber protection 1 Release the retainer and carefully extract the halogen bulb 2 Reassemble the new bulb the rubber protection and the connector POSITION BULB Disconnect the side connector extract the bulb holder 3 from the light body and change the bulb Reassemble the bulb holder Reposi tion the light holder mask and secure it with rubber stripes A WARNING NEVER TOUCH THE GLASS BULB TO PREVENT LEAVING
60. dicated in the technical data and in the registration paper Off road 1 1 bar 1 1 bar The state of the tyres must be controlled before every journey Check the tyres by verifying that they are not cut have nails or other sharp objects pushed into them Regarding the minimum depth of the profile respect the regulations in force in your country We recommend that the tyres are changed at Road rider only 1 7 bar 1 7 bar the latest when the profile has reached a depth of 2 mm The tyre air pressure must be checked regularly when the tyres are cold Correct adjustment of the pressure guarantees optimal comfort when travelling and maximum duration of the tyre HAVE EXCLUSIVELY TYRES OF APPROVED TYPE AND DIMENSIONS MOUNTED ON YOUR VEHICLE AND HOWEVER ESTABLISHED BY TM DIFFERENT TYRES CAN NEGATIVELY CONDITION THE BEHAVIOUR OF THE MOTORCYCLE ON THE ROAD AND BE THE CAUSE OF FINES ENVISIONED BY THE REGULATIONS IN FORCE IN YOUR COUNTRY TO GUARANTEE YOUR SAFETY AND THAT OF OTHERS DAMAGED TYRES MUST BE REPLACED IMMEDIATELY EXCESSIVELY WORN TYRES NEGATIVELY CONDITION THE BEHAVIOUR OF THE MOTORCYCLE MOST OF ALL ON WET SURFACES INCORRECT PRESSURE LEADS TO ANOMALOUS WEAR AND OVERHE ATING OF THE TYRE CHECK ADJUSTMENT OF MAGNETIC SENSOR FOR TACHOMETER A In all the versions the magnetic sensor is located on the rear wheel END SMR The distance between the head of the screws 2 and the sensor 1 must be 2 4mm If not the
61. during periodical maintenance A WARNING VERY HIGH PRESSURE INSIDE THE FORK CAN CAUSE THE FORK TO LEAK IF YOUR FORK PRESENTS ALEAK LOOSEN THE VENT SCREWS BEFORE HAVING THE SEALING ELEMENTS REPLACED CLEANING OF TELESCOPIC FORK DUST SCRAPER The dust scraper 2 must scrape the dust and dirt from the fork rods However after some time dirt may also reach behind the dust scrapers If the dirt is not removed the oil seal units which are found behind may leak Use a screwdriver to lever the dust scraper from the outside legs and push it downwards Clean the dust scraper the outside legs and the rods carefully Oil them well with silicone spray or with engine oil Finally push the dust scraper manually into the outside legs 37 p 7774 BRAM BASIC CALIBRATION THE CYCLE PART THE BASIS OF THE PILOT S WEIGHT To obtain optimal driving features of the motorcycle and to prevent dama ge to the fork rear shock rear swing arm and frame it is necessary that the basic calibration of the suspension is adapted to your body weight In the delivery status the off road TM motorcycles are calibrated on a pilot weight with complete protective clothing of 70 80 kg If your weight is not within these values you must adequately adapt the basic calibra tion of the suspensions Minor weight changes can be compensated by varying the spring pre load For greater variations suitable springs rates must
62. e motorcycle and may cause loss of control and serious accidents 5 BRAKES Verify correct working Check the level of brake fluid The reservoir on the pumps are dimen sioned in a way that in case of normally worn brake pads the fluid does not need to be topped up If the level of brake fluid falls below the minimum level this indicates a leak in the brake system or complete consumption of the brake pads Have the brake system checked by a specialised TM workshop given that in this case the brakes could fail The state of the brake s flexible pipes and the thickness of the pads must also be checked Check the free play and the smoothness of the front brake lever and the rear brake pedal 6 FLEXIBLE CABLE COMMANDS Check the adjustment and correct working of all flexible cable com mands 7 COOLANT Check the level of coolant with cold engine Top up with the liquid stated in the table if necessary 8 ELECTRICAL PLANT With the engine running check for the front headlight the front and rear position lights the rear stopping light the direction indicator lights the control lights and the horn 9 LUGGAGE Check that any luggage is well fixed 22 INS TE UCHOI STO US CEE INSTRUGTIONS FORLUSE LLANE COLD ENGINE START 1 Open the fuel tap 1 2 Remove the motorcycle from the stand 3 Put the gears in neutral 4 Activate the choke command 2 which is located on the left side of the carburet
63. ead this manual carefully so as to understand the regulations for use and the features of your new motorcycle Only in this way will you know how to adjust the motor cycle and to adapt it in the best way possible to your personal characteristics and how to protect yourself from injury This manual also contains important information regarding the maintenance of your new motorcycle This manual is based on the most recent information concerning the product that was available on going to print Further variations owing to succesive constructive developments of the motorcycle are however possible This manual is an integral part of the motorcycle it must be given to the customer at the time of purchase and must remain with the motor cycle whenever it is re sold Please note that the operations marked with A in the Frame and Engine Maintenance chapter must be carried out by a TM specialised workshop If these maintenance operations should be necessary during competitions they must be carried out by a qualified mechanic For your safety only use TM original spare parts and accessories TM does not assume any responsibility for the use of other products and for damage deriving from them We advise you to respect the running in period inspection periods and established maintenance periods scru pulously Only full compliance with these regulations will lengthen the life of your motorcycle Overhauls and repairs must only be carried out by a specia
64. ed This is necessary for starting the engine when it is cold To disconnect the command push the choke knob inwards to its original position IDLE SPEED ADJUSTMENT COMMAND This control is on the left hand side of the carburettor for both models Turning the idle needle screw increases or decreases the engine s idling speed Turn it clockwise to increase the idling speed or anticlockwise to de crease it The idling speed with the engine warm must be between 1 400 and 1 600 rpm The idling control for the MIKUNI carburettor models 85 100 features a lock nut You need to undo this lock nut 1 before turning the screw 2 Remember to tighten the lock nut when you have made the adjustment 13 OPERATING CONTROLS SNOEISK 7 LLANE GEAR SHIFT PEDAL The gear shift pedal is positioned on the engine left side The position of the gears is indicated in the illustration The neutral is between the first and second gears KICKSTART PEDAL The kickstart pedal is positioned on the right side of the engine The upper part is turned outwards to start up the engine and replaced inside as soon as the engine is running BRAKE PEDAL The brake pedal is positioned in front of the right foot rest The basic position can be adjusted on the basis of the position of the saddle see maintenance operations SIDE STAND Push the side stand to the floor using the foot and rest the motorcycle on it Pay attention that the ground
65. el forward until the chain tensioners are in contatct with the heads of the adjusting screws IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH WHEN MOUNTING HAVE THE TIGHTENING TORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP A LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER HAVING RE ASSEMBLED THE REAR WHEEL ALWAYS ACTIVATE THE BRAKE PEDAL SO THAT THE PADS ADHERE TO THE DISC AGAIN TIGHTEN THE FLANGED NUT WITH THE ESTABLISHED TIGHTENNGTOR QUE ALOOSE WHEEL AXLE CAN LEAD TO UNSTABLE DRIVING 49 ENGLISH ERAMEANDIENGINEIVAINTENANG LLANE DISASSEMBLY AND ASSEMBLY OF REAR WHEEL SMM Rest the motorcycle with the frame cradle on a stand in a way that the rear wheel does not touch the ground Cut the safety binding 6 slide out the clasp 7 and unscrew the wheel nut M50x1 5 8 Pay attention to the conical shim 9 placed between the nut and ring Extract the wheel carefully A WARNING WHEN THE WHEEL NUT IS DISASSEMBLED THE SHAFT AND NUT THRE ADS MUST BE CLEANED CAREFULLY RE GREASE THEM TO PREVENT SEIZING OF THE THREADS To assemble proceed in the opposite direction tightening the M50x1 5 wheel nut at 185 Nm Remount the clasp and re make the safety bin ding DO NOT FORGET TO CARRY OUT THE SAFETY BINDING AT THE ENDS OF THE CLASP IF YOU DO NOT HAVE A DYNAM
66. even reach the engine causing derious damage For this reason maintenance of the filter should be carried out regularly Remove the seat to access the filter and lift the control unit support To remove the filter unscrew the finger screw positioned at the centre of the filter and carefully slide it the filter out of its case A WARNING DO NOT CLEAN THE FOAM FILTER WITH FUEL OR KEROSENE WHICH CAN CORRODE IT FOR CORRECT MAINTENANCE OF THE FOAM FILTER USE THE RELEVANT PRODUCTS ON THE MARKET FOR CLEANING AND LUBRICATION NEVER START UP THE MOTORCYCLE WITHOUT THE AIR FILTER THE INFILTRATION OF DUST AND DIRT CAN CAUSE DAMAGE AND INCREASE WEAR Wash the filter carefully using a special liquid detergent and dry well squeeze the filter slightly but do not wring it Also clean the filter case and check that the rubber manifold that connects the carburetor to the filter case is integral and positioned correctly Remount the air filter positioning it correctly on the rest surface taking care that edges of the filter are not raised or not adherent with the rest surface Rescrew the finger screw and tighten it adequately ENGINSEH 58 LLANE HYDRAULIC CLUTCH AJP PUMP ADJUSTMENT OF CLUTCH LEVER BASIC POSITION Use the adjustment screw 4 to adjust the basic position of the clutch lever In this way the optimal position for the clutch lever can be found for any hand size If the adjustment screw is turned clockwise the c
67. g the two screws into the two holes in the hub itself A ATTENTION F YOU DO NOT HAVE SUITABLE EXPERIENCE IT IS ADVISED TO HAVE THE OPERATION CARRIED OUT BY A SPECIALISED TM WORKSHOP CHAIN MAINTENANCE Chain duration depends most of all on maintenance Chains without O rings must be regularly cleaned with petroleum and then immersed in warm chain oil or treated with chain spray Maintenance of chains with O rings is reduced to a minimum The best cleaning method is using lots of water Never use brushes or solvents to clean the chain When the chain is dry use a chain spray that is especially suitable for chains with O rings A DANGER DO NOT ALLOW THE LUBRICANT TO REACH THE REAR TYRE OR THE BRAKE DISC OTHERWISE ADHERENCE TO THE GROUND OF THE REAR WHEEL AND REAR BRAKE ACTION COULD BE NOTABLY REDUCED AND IT COULD BE EASY TO LOOSE CONTROL OF THE MOTORCYCLE A WARNING ON MOUNTING THE CHAIN SPLIT LINK THE CLOSED PART MUST BE IN THE DIRECTION OF MOVEMENT Always check both engine and rear wheel sprockets and drive slider for wear If necessary replace these parts ENGINSEH 42 LEP LANL LLANE CHAIN WEAR To check chain wear follow carefully the instructions given below put the gear into neutral pull the upper part of the chain in an upward direction with a force of 10 15 kilogrammes see figure Now measure the distance of 18 links on the lower part of the chain If the distance
68. he fins of the radiator the lower the speed the less the cooling effect Dirty radiator fins also decrease the cooling effect The pressure caused by the high liquid temperature is adjusted by a valve on the radiator cap 2 it is possible to reach temperatures of 120 C without problems CHECK THE LEVEL OF THE COOLANT LIQUID WHEN THE ENGINE IS COLD IF YOU MUST REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT COVER IT WITH A CLOTH AND OPEN SLOWLY TO RELEASE THE PRESSURE ATTENTION BURNS HAZARD DO NOT DISCONNECT THE RADIATOR HOSES WHEN THE ENGINE IS HOT THE COOLANT LIQUID AND THE HOT STEAM THAT ESCAPE MAY CAUSE SERIOUS BURNS IF YOU ARE BURNED PUT THE INTERESTED PART UNDER COLD RUN NING WATER THE COOLANT IS TOXIC THEREFORE PRESERVE IT OUT OF THE REACH OF CHILDREN IF YOU SWALLOW COOLANT SEEK MEDICAL ADVICE IMMEDIATELY IF THE COOLANT HITS THE EYES RINSE IMMEDITAELY WITH COLD WATER AND SEEK MEDICAL ADVICE The coolant liquid is a mixture of antifreeze at 40 and water at 60 The antifreeze protection limit must however be at least 25 C This mixture offers protection against freezing as well as a good protection against corrosion and therefore should not be replaced by pure water A WARNING AFTER THE COOLANT LIQUID HAS BEEN EMPTIED WHEN RE FILLING IT IS NECEESARY TO BLEED THE COOLING SYSTEM SEE NEXT PAGE ALWAYS USE GOOD QUALITY PRODUCTS TO PREVENT CORROSION OR FOAM IN EXTREME WEATHER CONDITIONS
69. ifold and take out the reed valve check the carbon parts are not damaged ENGINSEH 64 PROUBLESHOOTING If you have the envisioned maintenance operations carried out on your motorcycle you will have very few problems If however a problem does occur please look for it in the following table and try to solve it Please note that a lot of the operations cannot be carried out without the help of technicians If in doubt please contact an authorised TM dealer PROBLEM CAUSE The motorcycle hasn t been used for a while therefo re the old fuel has remained in thecarburetor bowl Fuel supply interrupted Engine flooded Spark plug blackened or wet Incorrect spark plug electrodes gap THE ENGINE DOES NOT START Spark plug cover or spark plug damaged Oxidised CDI unit pickup orcoil connectors Water in the carburetor or clogged jets 65 SOLUTION The volatile fuel components evaporate easily If the motorcycle has not been used for more than 1 week the old fuel should be emptied from the carburetor bowl When the bowl has been filled with fresh fuel the engine will start immediately Disconnect the fuel hose from the carburetor place it in a con tainer and open the fuel tap if fuel escapes clean the carburetor if fuel does not escape control the tank vent pipe or clean the fuel tap Use the by pass command as explained in the Operating controls chapter Clean and dry the spark plug or replace it
70. ifolds between the filter case and the carburetor and between the carburetor and head and tighten the clamps Riempire con il liquido di raffreddamento vedere capitolo Ma nutenzione Telaio e Motore controllare la tenuta del sistema di raffreddamento Proseguire a velocit sostenuta possibile montare un elettro ventilatore opzionale Spurgare il sistema di raffreddamento Pulire le lamelle dei radiatore con getto d acqua Sostituire il liquido di raffreddamento utilizzare anticongelanti di buona marca Accorciare il tubo del radiatore o sostituirlo Position the vent hose or replace it Check and correct the engine oil level if necessary Use more viscous oil see Engine oil chapter Remove the saddle and tank and check the connections of the voltage regulator Have the regulator checked in a specialised TM workshop Remove the left side panel and replace the lights cable 7 5A fuse CL Izd LG Clean the motorcycle regularly in a way to maintain the surface of the plastic parts in good condition To do this it is advised to use hot water with a detergent and sponge Most of the dirt can be removed using weak water jets A WARNING NEVER CLEAN THE MOTORCYCLE WITH HIGH PRESSURE CLEANING DEVICES OR WITH STRONG JETS OF WATER BECAUSE OF THE HIGH PRESSURE THE WATER COULD REACH THE ELECTRICAL PARTS CONNECTORS FLEXIBLE CABLE COMMANDS BEARINGS THE CARBURETOR ETC AND CAUSE FAULTS OR PREMATURE BREAKAGE OF THESE PARTS Before w
71. increase the distance anticlockwise to reduce the distance Re tighten the lock nut 2 A WARNING AT THE END OF THE OPERATION VERIFY THAT THE FRONT BRAKE LEVER HAS AFREE STROKE BEFORE THE BRAKE STARTS TO LOCK THE WHEEL AND THAT THE FRONT WHEEL CAN ROTATE FREELY WITH THE BRAKE LEVER AT REST IF THE FREE STROKE IS MISSING PRESSURE IS FOR MED IN THE BRAKING SYSTEM AND THE CONSEQUENCE CAN BE LACK OF FUNCTIONING OF THE FRONT WHEEL BRAKE DUE TO OVERHEATING OR BLOCKING OF THE WHEEL ITSELF CHECK FLUID LEVEL The reservoir is part of the front brake pump positioned on the handlebar and has an inspection window 3 with the tank in the horizontal posi tion the fluid level must never fall below the centreline on the inspection window IF THE LEVEL OF BRAKE LIQUID FALLS BELOW THE MINIMUM VALUE IT INDICATES A LEAK IN THE BRAKING SYSTEM OR CONSUMPTION OF BRAKE PADS BEYOND THE ACCEPTED LIMITS TOP UP FRONT BRAKE FLUID A Unscrew and remove the cap 3 and the membrane 4 Keep the reservoir standing up and top up the brake fluid to the MAX remark on the reservoir Reassemble the membrane the cap and tighten Wash spilled brake fluid away with water KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN BRAKE FLUID MAY IRRITATE THE SKIN DO NOT ALLOW IT TO TOUCH SKIN OR EYES IF THE BRAKE FLUID SHOULD ACCIDENTLY SPRAY INTO THE EYES RINSE WELL WITH WATER AND SEEK MEDICAL ASSISTAN CE ENGLISH 44 ERAMEANDIENGINEIVAINTENANG
72. ir is part of the clutch pump positioned on the handlebar To check the fluid level remove the screws 2 and the cap 3 together with the rubber seal 4 With the reservoir in a horizontal position the fluid should not be below the centreline or above the top threshold A WARNING FOR THE HYDRAULIC COMMAND OF THE CLUTCH TM USES DOT4 BRAKE FLUID NEVER USE DOT5 OR OTHER DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES THE PAINT ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY SEALED CON TAINERS 59 ier p 7774 ERAMEANDIENGINEIVAINTENANG LLANE BLEEDING THE HYDRAULIC CLUTCH For bleeding the hydraulic clutch remove the cap of the pump both AJP and Brembo on the handlebar Connect the suction machine to the bleeding nipple 5 of the clutch cylinder on the engine Switch on the suction machine and loosen the nipple Continue until no more air escapes from the nipple only oil Tighten the nipple Disconnect the suction device During the operation control that the level in the clutch pump reservoir is always sufficient and prevent the pump from taking up air If necessary top up with DOT4 brake fluid A WARNING FOR THE HYDRAULIC COMMAND OF THE CLUTCH TM USES DOT4 BRAKE FLUID NEVER USE DOT5 OR OTHER DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES THE PAINT ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY SEALED CON TAINERS
73. is solid and the position stable 14 OPERATING CONTROLS SIDE STAND FIXING FOR OFFROAD ROUTES If you drive the motorcycle off road the closed side stand can be addi tionally fixed using a rubber band 2 IGNITION SWITCH In the SMR and SMM models an ignition key is added on the left side of the dashboard By turning the key clockwise the electric circuit is closed and you can press the kickstart pedal up the engine Turn the key anticlockwise to turn off the engine FORK ADJUSTMENT IN COMPRESSION The hydraulic brake system determines the behaviour of the fork in the in compression stroke The degree of hydraulic dampening in compres sion can be adjusted on the basis of pilot preferences and or hardness of the spring installed MARZOCCHI USD FORK There is an adjusting screw 4 on the fork cover Operate using a screwdriver Turning the screw clockwise the dampening increases turning it anticlockwise the dampening decreases A total of 28 clicks Never turn the side screw 5 PAIOLI USD FORK Remove the rubber hood 1 situated in the lower part of the fork leg and turn the adjustment screw 2 using a screwdriver By turning the screw clockwise dampening increases turning it anticlockwise the dampening decreases A total of 26 clicks are available OHLINS USD FORK There is an adjusting screw 3 at the base of the fork foot Operate using a screwdriver Turning the screw clockwise the
74. k of the shock absorber side of mechanical linkage Use a screwdriver By turning clockwise braking increases anticlockwise it decreases A total of 40 clicks are available OHLINS SHOCK ABSORBER OPTIONAL The adjustment knob 4 is situated low at the end of the damper rod Act manually By turning clockwise looking from the bottom upwards braking increases anticlockwise it decreases A total of 40 clicks are available A WARNING BEFORE STARTING IT IS ADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITION TO THE TOTALLY CLOSED POSITION AND COUNT THE CLICKS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NUMBER OF CLICKS IS INDICATED FROM THE TOTALLY CLOSED POSITION A PERICOLO THE DAMPER GAS TANK IS FILLED WITH PRESSURISED NITROGEN VER TRY TO DISASSEMBLE THE DAMPER OR CARRY OUT MAINTENANCE OPERATIONS WITHOUT THE HELP OF TECHNICIANS OTHERWISE PARTS COULD BE DAMAGED AND PERSONS INJURED 17 OPERATING CONTROLS p 7774 OPERATINGICONTROLS LLANE STEERING LOCK This lock is situated on the left side of the frame steering tube This lock stops rotation of the handlebar preventing the motorcycle being driven To lock the steering turn the handlebar completely to the right insert the key turn it to the left press turn to the right and extract A WARNING NEVER LEAVE THE KEY IN THE LOCK BY TURNING THE HANDLEBAR TO THE LEFT THE KEY COULD BE DAMAGED
75. lised TM workshop For any information or requests contact a specialised TM workshop which is backed by the TM importer Please remember that a lot of technical data and information regarding TM motorcycles is available at www tmracing it Motorcycling is a marvellous sport that you will be able to enjoy with your TM motorcycle Always remember to respect the environment and other people Always use the motorcycle with caution it is in everybodys interest to safeguard the future of our sport Enjoy yourself with your TM motorcycle TM RACING S p A Via Fano 6 61100 PESARO ITALY TM RESERVES THE RIGHT TO CHANGE OR TO EXECUTE MODIFICATIONS AS IT DEEMS NECESSARY 4 IMPORTANT ADVICE REGARDING THE LEGAL WARRANTY AND THE COMMERCIAL WARRANTY TM sport motorcycles are designed and constructed in a manner to support the stress that may be verified in normal road and competition use Competition motorcycles are in compliance with the regulations of the categories actually in force at the most important international motorcycling federations The scrupulous compliance with the established inspections maintenance and tuning of the engine and chassis part of the motorcycle indicated in the user manual is indispensable for correct fun ctioning and to prevent premature wear of the parts of the motorcycle itself Incorrect tuning of the engine or of the chassis can also jeopardise one s own safety and that of others The mai
76. ll except SMM 49 Electronic digital tachometer 2 2 11 Emptying the carburetor float bowl 63 Emptying filling and bleeding of the cooling system 57 8 H 64 Engine stop switch MX SMX 11 ENGINE TIGHTENING TORQUES 71 Establishing rear shock lowering running order 39 Establishing rear shock static lowering 38 Fork adjustment in compression 15 Fork adjustment in rebound 2 16 FRAME AND ENGINE MAINTENANCE 02 35 ENGLISH TIC INDEX Page Frame number ETT 8 Front brake BREMBO radial pump SMR SMM SMX 45 Front brake lever BREMBO radial pump 10 Front brake lever NISSIN pump _ 10 Front brake NISSIN pump END MX 44 au MT 9 O 27 13 E e e O 13 Gear shin pedal 14 Halogen light E
77. lutch lever approaches the handlebar If the adjustment screw is turned anti clockwise the clutch lever moves away form the handle bar The adjustment screw 5 is used to adjust the pump run after having adjusted the position of the lever A WARNING THE RANGE OF ADJUSTMENT IS LIMITED ONLY TURN THE ADJUSTMENT SCREW MANUALLY WITHOUT FORCE CHECK HYDRAULIC CLUTCH FLUID LEVEL The reservoir is part of the clutch pump positioned on the handlebar and has an inspection window with the reservoir in a horizontal position the level of the fluid must never fall below the centreline of the window nor be above the upper margin If it is necessary to top up the oil remove the screws 6 and then the cover 7 together with the rubber seal 8 Keeping the reservoir in a horizontal position top up with DOT4 brake fluid WARNING FOR THE HYDRAULIC COMMAND OF THE CLUTCH TM USES DOT4 BRAKE FLUID NEVER USE DOT5 OR OTHER DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES THE PAINT ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY SEALED CON TAINERS HYDRAULIC CLUTCH BREMBO PUMP ADJUSTMENT OF CLUTCH LEVER BASIC POSITION With this option to adjust the clutch lever distance from the handlebar grip see maintenance operation you have to turn the adjustment knob 1 Rotate clockwise to increase the distance or counterclockwise to de crease the distance CHECK HYDRAULIC CLUTCH FLUID LEVEL The reservo
78. n 15 Fork adjustment in rebound 16 Shock absorber adjustment in compression 16 Shock absorber adjustment in rebound _ 17 Steering lock 18 ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE 19 Indications for first start up 0442022 20 Running in instructions iret eet er et dee 20 INSTRUCTIONS FOR USE 21 Check before every start up _ 22 Cold engine start 23 If the engine is 2 24 BIK 24 Shifting gear accelerating slowing down 24 sod M 26 Stopping 2 50 2 26 a 27 MAINTENANCE AND LUBRICATION TABLE 29 FRAME AND ENGINE MAINTENANCE 35 Check steering bearings and play adjustment 36 Telescopic fork vent SCTEWS
79. ntenance operations established in the Maintenance and Lubrication table must be carried out by a specialised TM workshop at the envisioned dates otherwise any warranty rights will be forfeited When you must contact your TM Dealer for spare parts updating requests or to signal problems indicate the model cylinder capacity year of manufacture and most of all the frame number and the engine serial number Fuels and lubricants must be those established in the user and maintenance manual and must be used as per maintenance programme Products of other brands can be used as long as they have the equivalent specifications In cases of direct and consequent damage caused by tampering or modifications to the motorcycle no legal warranty claim can be asserted The use of the motorcycle in extreme conditions for example on muddy and very wet ground may lead to greater than average wear of components such as transmission components or the brakes It is therefore possible that maintenance or replacement of some parts is necessary before the limit normally envisioned by the maintenance programme MX AND SMX MODELS CANNOT BE USED ON PUBLIC ROADS The 125 and 144 models in the END SMR and SMM versions can be used on roads only in the unvaried type approved version reduced Without this power limitation i e reduced these models can only be used off the road but not on public roads The END models have been designed for off the road resis
80. nts of a new motorcycle even if they undergo precision workings are however less smooth than the same components a motorcycle that have been driven for a time this explains the necessity for running in the new engine To obtain an optimal bedding of the moving parts of a new engine it must be taken to produce maximum performance gradually For this reason during the first 3 hours of use 1 hour for com petition use the engine must only be used up to max 50 of its power Moreover the number of revs must not exceed 7000 min In the following 5 hours of use 1 hour for competition use the engine can be used up to max 75 of its power Drive the mo torcycle in different conditions road easy off road tracts Do not make long journeys without ever closing the throttle By following these regulations you will obtain maximum perfor mance and longer duration of the motorcycle through time A WARNING THE 125 and 144 END MX SMX MODELS HAVE BEEN DEVELOPED WITH NO COMPROMISE FOR OFF ROAD COMPETITIONS EVEN IF THE ENDURO MODELS ARE TYPE APPROVED PAY ATTENTION WHEN USING ON THE ROAD MOST OF ALL AVOID SUSTAINED ACCELERATION CONSTANT THROTTLE ON LONG ROADS ROLL THE THROTTLE ON AND BACK SLIGHTLY ENGINSEH 20 ALWAYS WEAR SUITABLE CLOTHING WHEN USING THE MOTOR CYCLE ASTUTE MOTORCYCLISTS THAT DRIVE A TM ALWAYS WEAR THE TYPE APPROVED HELMET BOOTS GLOVES AND A JACKET WHETHER IT IS A LONG OR SHORT JOURNEY THE PROTECTIVE CLO
81. oe 57 Check engine oil level 63 Check front brake pads 45 Check fuel level float height 62 Check rear brake fluid level 2 4T Check rear brake pads 3 52 modii o de Queue E debidas 48 Check spoke tension 50 Check steering bearings and play adjustment 36 Check telescopic fork basic calibration __ 39 Choke command cold starter 13 Ciclops optional headlight END SMR SMM 54 eEZOULDUCHMMC e 67 Cleaning telescopic fork dust scraper _ 37 Cleaning the air filter 2 58 Clutch lever AJP PUMP 10 Clutch lever BREMBO pump 10 Cold engine 23 Combination switch END SMR SMM 12 Ges 56 Direction indicator lamp END SMR SMM 55 Disassembly and assembly of rear wheel SMM 50 Disassembly and assembly of the front wheel 48 Disassembly and assembly of the rear wheel a
82. on mechanical linkage screw tightness 2 o Check and adjustment of steering bearings z 2 Check tightness of chassis screws and bolts fork clamps fork legs wheel axles nuts and screws M rear fork axle shock absorber Check spoke tension and trueness of rims A Check tyre condition and pressure n Check chain wear chain link sprockets and guides chain tension 2 z Chain lubrication e Check wheel bearing play OTHER IMPORTANT MAINTENANCE OPERATIONS RECOMMENDED EVERY 3 RACES EVERY 3 RACES Complete fork maintenance Complete shock absorber maintenance Cleaning and greasing of steering bearings and related sealing elements Cleaning and tuning of the carburetor Treatment of electric contacts switches with contact spray Replacement of hydraulic clutch fluid Replacement of brake fluid The distance between maintenance intervals should not be exceeded by more than 2 or 15 litres THE MAINTENANCE CARRIED OUT BY THE AUTHORISED TM DEALER DOES NOT REPLACE THE CHECKS AND MAINTE NANCE CARRIED OUT BY THE RIDER 31 ENGLPISEH BRIEF CHECK AND NAINTENANCE OPERATIONS Check engine oil level Check brake fluid level Check brake pad wear Check light system if present Check horn if present Lubrication and adjustment of command cables Bleed fork legs Disassembly and cleaning of the dust shields Cleaning lubrication and tension check of final transmission chain Cleaning filte
83. ons the exact lowering in running order of the tele scopic fork can not be established Small variations in body weight can be compensated as for the rear shock through the spring pre load If your telescopic fork however lowers completely it is necessary to use an higher rate fork spring to prevent damage to the telescopic fork and frame VARIATION OF TELESCOPIC FORK PRE LOAD To vary the spring pre load on these telescopic forks it is necessary to disassemble them partially see specific manual of the fork mounted on the motorcycle It is possible to add pre load spacers The fork springs however can be pre loaded to a max of 20 mm 39 AAD 5 p 7774 ERAMEANDIENGINEIVAINTENANG LLANE REPLACEMENT OF FORK SPRINGS If your body weight is less than 70 kg or exceeds 80 kg adequate fork springs must be used If you are in doubt or have any questions please contact your authorised TM dealer 29090 7 According to our experience the dampening grade in compression can remain unvaried With a softer spring the dampening grade in rebound can be reduced by some clicks with a harder spring increased by some clicks A WARNING FOR FURTHER AND MORE DETAILED INFORMATION REGARDING THE STANDARD AND OPTIONAL FORK REFER TO THE INSTRUCTION BOOK SUPPLIED BY THE MANUFACTURER OF THE FORK AND GIVEN BY TM ACCOMPANYING THE MOTORCYCLE 5 v VARIATION OF REAR SHOCK SPRI
84. or 5 WITHOUT opening the throttle press hardly the kickstarter DOWN TO THE BOTTOM once or twice or operate the electric starter 6 Start to warm the engine by accelerating slightly for about 30 secs Disconnect the choke 2 which is situated on the left side of the carburetor ALWAYS WEAR STRONG MOTORCYCLE BOOTS WHEN STARTING UP THE MOTORCYCLE TO PREVENT INJURY YOU COULD SLIP OFF OF THE PEDAL OR THE ENGINE COULD KICKBACK AND MAKE YOU KNOCK YOUR FOOT VIOLENTLY ALWAYS PRESS THE KICKSTARTER DOWN HARD WITHOUT ACCE LERATING KICKSTARTING WITH LITTLE FORCE OR WITH OPENED THROTTLE INCREASES THE RISK OF ENGINE KICK BACK DONOT START THE ENGINE IN A CLOSED SPACE AND NEVER LEAVE IT RUNNING IN CLOSED SPACES THE EXHAUST FUMES ARE POISONOUS AND MAY LEAD TO RISK OF UNCONSCIOUSNESS AND DEATH WHEN THE ENGINE IS RUNNING ALWAYS ENSURE THERE IS SUFFICIENT VENTILATION ALWAYS CHECK THAT THE GEAR IS IN NEUTRAL BEFORE OPERATING THE KICKSTARTER PEDAL IF A GEAR IS INSERTED WHEN STARTING THE ENGINE THE MOTORCYCLE WILL JUMP FORWARDS A WARNING OPERATE THE STARTER FOR MAX 5 SECONDSAT A TIME WAIT ANO THER 5 SECONDS BEFORE TRYING AGAIN DO NOT ALLOW THE ENGINE REVS TO INCREASE TOO MUCH WHILE THE ENGINE IS COLD THIS COULD DAMAGE THE ENGINE BECAUSE THE PISTON HEATS UP AND CONSEQUENTLY IT EXPANDS QUICKER THAN THE CYLINDER WHICH IS WATER COOLED ALWAYS WARM THE ENGINE AT A STANDSTILL OR MOVE AT LOW REVS 23 5 UGE
85. p odometer can be reset by holding pressed the SET button once for 4 seconds The total kilometres odometer resets automatically when reaching the limit of 99999 Km or Miles The SMR and SMM models only are supplied with a separate battery for using the speedometer while the engine is OFF This is under the saddle ENGINE STOP SWITCH MX SMX The engine stop switch is found near the clutch piston The engine is shutdown using the engine stop switch 1 when it is ac tivated a shortcircuit is caused in the ignition which no longer supplies voltage to the spark plug Press the button until the engine switches off and then release 11 OPERATING CONTROLS 7 LLANE COMBINATION SWITCH WITH BACKLIT DIGITAL ELECTRONIC SPEEDOMETER END SMR SMM This command 1 is located near the handlebar left grip The use of the switch is very easy When the symbol 3 on the rotating ring is aligned with the symbol 4 on the switch body lights are switched off To switch the lights on turn the ring 2 counterclockwise until the symbol 5 is aligned with the symbol 4 Operate in the same way to switch on the low beam 7 and the high beam 6 Press the button 8 to activate the horn Press the rocker switch 9 on the left to activate the left hand indicator and on the right to activate the right hand indicator Press button 10 to switch off The OFF button 10 on the SMR and SMM models is disabled
86. r case and air filter Check tyre pressure and wear Check coolant level Check fuel pipe for leaks Cleaning of caburetor and jets for dirt and water removal Check smoothness of all command elements Check braking effect Treatment of bright metal parts apart from brake and exhaust system with anti corrosives Treatment of ignition switch steering lock with contact spray Check correct tightness of all screws nuts and clamps ENGINSEH 32 MAINTENANCE AND LUBRICATION TABLE ERFORMED BY RIDER PILOT BEFORE EVERY START UP AFTER EVERY WASH AFTER OFF THE ROAD USE MAINTENANCE AND LUBRICATION TABLE SCHECKS TO BE CARRIED OUT ENG E 85 100 MX 15 30 45 60 75 90 t9 HOURS OF FUEL CONSUMPTION eae Check cylinder and piston wear e e e Check piston pin visual check e e e e e Check the exhaust valve e e e e Check reed valve block e e e e e e Check head and cylinder surfaces e e e e e Check small end for marking damage to plating e e e Replace conrod axle and roller cage Replacement of main bearings e Check complete gearbox including drum and forks e e e Check clutch plate wear e e e e e Check length of clutch springs e e e e e e WARNING IF AFTER CHECKING IT IS DETECTED THAT THE WEAR LIMITS OF A SINGLE COMPONENT HAVE BEEN EXCEEDED THE COMPONENT MUST BE REPLACED THE INSTALLATION OF AN HOUR COUNTER INSTRUMENT IS ADVISED THE ABOVE MENTIONED
87. rate manually By turning the knob clockwi se dampening increases anticlockwise dampening decreases A total of 20 clicks are available ENGINSEH 16 OPERATING CONTROLS LLANE OHLINS SHOCK ABSORBER OPTIONAL Low speeds The adjustment screw 1 is on the top of the damper gas tank Use a screwdriver By turning the screw clockwise dampening increases anticlockwise dampening decreases A total of 25 clicks are available High speeds The adjuster is a hexagonal ring nut 2 and is concentric to the low speeds adjustment screw Use a 17mm hexagonal spanner By turning the nut clockwise dampening increases anticlockwise dam pening decreases A total of 4 clicks are available The Ohlins shock absorber for the Junior model can only be adjusted in terms of compression A WARNING BEFORE STARTING IT ISADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITION TO THE TOTALLY CLOSED POSITION AND COUNT THE CLICKS TURNS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NUMBER OF CLICKS TURNS ARE INDICATED FROM THE TOTALLY CLOSED POSITION SHOCK ABSORBER ADJUSTMENT IN REBOUND The hydraulic brake system in rebound determines the behaviour of the shock absorber in rebound stroke The degree of hydraulic braking in rebound can be adjusted on the basis of pilot preferences and or hardness of the spring installed SACHS SHOCK ABSORBER STANDARD The adjustment screw 3 is situated on the for
88. rses etc the carburetor float bowl should be emptied to remove any water that may have entered Water in the float bowl causes working problems Carry this operation out when the engine is cold Close the fuel tap and place a container underneath the carburetor to collect the fuel coming out Now open the screw 1 to empty the fuel and water Re close the screw open the fuel tap and control tightness of the system THE FUEL IS HIGHLY INFLAMMABLE AND TOXIC HANDLE THE FUEL WITH CARE NEVER CARRY OUT OPERATIONS ON THE FUEL SYSTEM NEAR TO FLAMES OR CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL USE A CLOTH TO REMOVE ANY OVERFLOWING FUEL MATERIALS IMPREGNATED WITH FUEL ARE ALSO HIGHLY INFLAMMABLE IF YOU SWALLOW FUEL OR IT COMES INTO CONTACT WITH THE EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF FUEL ACCORDING TO THE REGULATIONS ENVISIONED IN YOUR COUNTRY CHECK ENGINE OIL LEVEL You should check the level of the engine oil with the engine at standstill but while it is still warm Park the vehicle on level ground and keep it vertical not on its side stand Remove the cap at the top 1 and the screw on the right hand side 2 The correct level is determined by the screw 2 If no engine oil drips out of the latter then you will need to top up the level through the cap 1 If instead some oil does drip out this means there is plenty of oil inside and you should wait until the oil stops dripping out and reaches the level of the hole
89. screw M6 M6 10 Nm M8 M8 25 Nm M10 M10 45 Nm General frame nuts M6 M6 15 Nm M8 M8 30 Nm M10 M10 50 Nm 73 5 d ALPHABE Page Adjustment of chain tension all models except SMM 41 Adjustment of chain tension 42 ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE _ 19 ALPHABETIC INDEX I Eben qu umts KS mh pau 74 Basic calibration of the chassis on the basis of pilot weight 38 Basic indications for TM disc brakes 43 Basic indications regarding carburetor wear 61 ilg d 52 Battery Charge 52 BIKE SIINO 24 Bleeding hydraulic clutch 60 Brake 14 BEARINGS 26 CARBURETOR SETTINGS 70 Chain maintenance 2 42 CHAM WEAN 43 Change engine Oil ERE 64 Check adjustment of magnetic sensor for tachometer 51 Check before every start up 2 22 001 22 CHECK chain 41 Check coolant level Geren trea k
90. self Alternatively use a normal hammer and place a piece of wood betwe en NEVER USE THE HAMMER DIRECTLY ON THE AXLE YOU RISK TO DAMAGE THE AXLE IRREVERSIBLY Slide the front wheel carefully out of the fork ENGINSEH 48 ERAMEANDIENGINEIVAINTENANG LLANE A WARNING NEVER ACTIVATE THE BRAKE LEVER WHEN THE FRONT WHEEL IS DISASSEMBLED ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO PREVENT DAMAGE To re assemble the front wheel insert it carefully into the fork taking care to insert the disc correctly between the brake pads without damaging them Position it correctly and mount the wheel axle Screw and temporarily tighten the flanged nut 7 until the wheel shim is locked tighten the locking screws 8 on the right fork shoe to pre vent the wheel axle from turning and tighten the flanged nut at 40 Nm Tighten the locking screws on the left fork leg at 12Nm Loosen the locking screws on the right shoe again remove the motrcycle from the stand activate the front brake and force the fork down several times to align the rods End by definitively tightening the locking screws on the right fork shoe at 12Nm IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH WHEN MOUNTING HAVE THE TIGHTENING TORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP A LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING AFTERHAVING MOUNTED THE FRONT WHEEL REPEATEDLY ACTIVATE THE BRAKE LEVER UNTIL THE PAD ADHERES TO THE DISC AGAIN
91. sts ciicniiisssissaiveuntsacnauiveveasiustsicevndunteviaciusautaisesinnst 74 WIRING DIAGRAM 2 22 2 1 1 1 appendix POST eo NUNBER 7 LLANE FRAME NUMBER The frame number is embossed on the right side of the steering metal tube Make note of this number in the appropriate space on page 3 In the END SMR SMM models the serial number is also stated on a plate positioned on the left hand side See photo The frame number for models 85 100 Junior is on the right hand side of the head tube ENGINE NUMBER The engine number is engraved on the back side of the engine Make note of this number in the appropriate space on page 3 8 OPERATING CO PAO LS UGE LLNS CLUTCH LEVER AJP PUMP The clutch lever 1 is mounted on the left of the handlebar The position of the clutch lever with respect to the handlebar grip can be varied using the adjustment screws A see maintenace operation The adjusting screws B are used to adjust the pump after having adju sted the lever position and to ensure the correct freeplay CLUTCH LEVER BREMBO PUMP The Brembo clutch pump is fit on request The clutch lever 2 is located on the left side of the handlebar With this option to adjust the clutch lever distance from the handlebar grip See maintenance operation you have to turn the adjustment knob 3 Rotate clockwise to increase the distance or counterclockwise
92. t of main bearings e Check complete gearbox including drum and forks e e 5 Check clutch plate wear e e e e e Check length of clutch springs e e e e e e WARNING IF AFTER CHECKING IT IS DETECTED THAT THE WEAR LIMITS OF A SINGLE COMPONENT HAVE BEEN EXCEEDED THE COMPONENT MUST BE REPLACED THE INSTALLATION OF AN HOUR COUNTER INSTRUMENT IS ADVISED THE ABOVE MENTIONED OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP 2OAD HORRBY USE 15 HOURS OF SERVICE EQUAL ABOUT 300 LT Pa AE ae ed OF FUEL CONSUMPTION 60017 12001 1800LT 24001 30001 3600LT Check cylinder and piston wear e e Check piston pin visual check e e e e e Check the discharge valve e e e e e Check lamellar body e e e Check head and cylinder surfaces e e e e Check small end for marking damage to plating e e e Replace conrod axle and roller cage e e Replacement of main bearings o Check complete gearbox including drum and forks e 5 Check clutch plate wear 8 e e e e Check length of clutch springs e e e e e e WARNING IF AFTER CHECKING IT IS DETECTED THAT THE WEAR LIMITS OF A SINGLE COMPONENT HAVE BEEN EXCEEDED THE COMPONENT MUST BE REPLACED THE INSTALLATION OF AN HOUR COUNTER INSTRUMENT IS ADVISED THE ABOVE MENTIONED OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP ENGINSEH 34 p 7774 ERAMEANDIENGINEIVAINTENANG LLANE ALL M
93. t which you want the motorcycle to move To reduce speed the throttle must be closed Brake and shift down the gears pulling the clutch lever and inserting a lower gear Release the clutch slowly and accelerate or change gear again Always increase or change down the gears one at a time ENGINSEH 24 Poly LLANE INDICATION All TM models do not have a radiator cooling fan and the radiator di mensions have been studied to optimise compactness and weight The cooling system is sufficient for touristic or sports use If you want to use an additional cooling fan contact a TM authorised dealer TM MODELS CAN BE RE STARTED AT ANY TIME BY KICK STARTER SWITCH THE ENGINE OFF WHEN YOU INTEND TO KEEP THE MOTORCYCLE AT A STANDSTILL FOR MORE THAN 2 MINUTES AFTER EVERY FALL THE MOTORCYCLE MUST BE CONTROLLED IN THE SAME WAY AS BEFORE EVERY START UP A DEFORMED HANDLEBAR MUST ALWAYS BE REPLACED NEVER STRAIGHTEN THE HANDLEBAR AS IT COULD LOOSE ITS STRENGTH A WARNING USE OF THE ENGINE AT A HIGH NUMBER OF REVS WHEN IT IS COLD NEGATIVELY AFFECTS THE DURATION OF THE ENGINE BEFORE USING THE MOTORCYCLE AT FULL WORKING CONDITIONS IT IS BETTER TO WARM IT ADEQUATELY BY DRIVING AT AN AVERAGE SPEED THE EN GINE HAS REACHED ITS WORKING TEMPERATURE AS SOON AS THE RADIATORS BECOME HOT NEVER SHIFT DOWN A GEAR WITHOUT HAVING FIRST SLOWED DOWN THE ENGINE WOULD BE TAKEN TO AN EXCESSIVE NUMBER OF REV
94. tance competitions Enduro and are not suitable for Motocross The 85 and 100 models cannot be used on roads 5 ENGLPISEH 7 2 2 POSITION OF SERIAL NUMBER _ 7 D 8 ENGINE o 8 OPERATING CONTROLS aux d d ok ooo 9 Clutch lever AJP pump reat hint eerta br ERE 10 Clutch lever BREMBO pump 10 Front brake lever NISSIN pump __ 10 Front brake lever BREMBO radial pump 10 Electronic digital tachometer 11 Engine stop switch MX SMX 11 Combination switch END SMR SMM 12 Maps selection switch 12 PTT P 13 mio 13 Choke command cold starter 13 Idle speed adjustment command 13 Gear shift pedal RI EROR 14 le pedal NM TT 14 Brake pedal 14 RUNS SUING M s 14 Side stand fixing for off road 15 iie 15 Fork adjustment in compressio
95. to de crease the distance FRONT BRAKE LEVER NISSIN PUMP END MX The distance of the front brak lever 5 from the handlebar grip can be adjusted through the adjustment screw C Loosen the lock nut 6 and turn the screw clockwise to increase the distance anticlockwise to re duce the distance Re tighten the lock nut 6 See Frame and Engine Maintenance chapter FRONT BRAKE LEVER BREMBO RADIAL PUMP SMR SMM SMX The front brake pump lever 5 is located on the right side of the handle bar and activates the front wheel brake The distance of the brake lever from the handlebar grip can be adjusted through the adjustment knob D see Frame and Engine Maintenance chapter 10 UFPENATING CONTROLS ELECTRONIC DIGITAL TACHOMETER See picture 1 It is used on the END SMR SMM models t has a wide backlit display and four pilot lights In the top there are the left indicator pilot light 2 the low beam pilot light 3 the high beam pilot light 4 and the right indicator pilot light 5 Inside the display you find the tachometer 6 the trip odometer 7 and the total kilometers odometer 8 In the bottom there are two buttons SET 9 and MODE 10 The instrument unit is the Kmh but it can be easily changed in Mph in the following way press and hold the SET button while holding it press once the MODE button Repeat the same operation to switch back to Kmh The tri
96. ure or set a richer one if the engine is rattling OPERATION WITH THROTTLE FULLY OPEN MAX CAPACITY If after a while at full gas the insulating part of a new plug the ceramic part around the electrodes appears particularly bright or white you will need to replace the main jet with a richer one If instead the insulating part of the plug appears dark or blackened you will need to replace the main jet with a leaner one Contact your TM agent for selecting needles main and idle jets or any other part of the carburetor CHECK FUEL LEVEL FLOAT HEIGHT A Disassemble the carburetor and remove the float bowl Turn the carbure tor upside down and keep it inclined so that the float rests on the needle valve but does not compress the spring with its weight In this position use a gauge to measure the distance between the apex of the float body and the float bowl surface on the carburetor body see image Refer to the technical data for the correct value for your motorcycle If necessary adjust the height by slightly bending the float adjustment plate 4 If possible also check the tightness and the state of wear of the needle valve cone if in doubt replace the valve and brass seat Mount the float bowl mount the carburetor and adjust the idle speed ENGLISH 62 EMPTYING THE CARBURETOR FLOAT BOWL After washing or driving wet environments watercou
97. with oil and then re seal the cap NEVER USE DOT5 BRAKE FLUID IT IS A PURPLE SILICONE OIL BASED BRAKE FLUID IT REQUIRES THE USE OF SPECIAL SEALS AND HO SES KEEP THE BRAKE FLUID OUT OF CHIDREN S REACH THE BRAKE FLUID CAN IRRITATE THE SKIN DO NOT ALLOW IT TO TOUCH THE SKIN OR EYES IF THE BRAKE FLUID SHOULD SPRAY INTO THE EYES RINSE WELL WITH WATER AND SEEK MEDICAL ATTEN TION A WARNING DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS BRAKE FLUID CORRODES PAINT USE ONLY CLEAN BRAKE FLUID FROM A HERMETICALLY SEALED CON TAINER 47 ERAMEANDIENGINEIVAINTENANG LENE CHECK REAR BRAKE PADS The brake pads must be controlled from the rear side The thickness of the pad friction material must not be less than 1 mm AT THE THINNEST POINT THE THICKNESS OF THE BRAKE PAD FRICTION MATERIAL MUST NOT BE LESS THAN 1 MM OTHERWISE A FAULT COULD OCCUR IN THE BRAKES IN THE INTEREST OF YOUR SAFETY HAVE THE PADS REPLACED IN TIME A WARNING IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE FRICTION MATERIAL IS COMPLETELY CONSUMED THE STEEL PARTS OF THE PADS RUB ON THE DISC THIS LEADS TO A NOTEWORTHY DECREASE OF THE BRAKING EFFECT AND DAMAGE OF THE BRAKE DISC REPLACEMENT OF REAR BRAKE PADS A FOR ALL MODELS WITH FLOATING CALIPER END MX SMR SMX Push the brake caliper 1 towards the disc until the piston reaches its base position Remove the cap 2 using a screwdriver uns

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