Home

2006 4 Stroke Owners Manual

1. POLE SOVHMHLNI 3 18V IIVAV LON JONVHO VLVG NOLLOSNNOO ON Td 8 wk 5 5 S m SHOLOZNNOO G3 IV3S NOLLIN9I WVeSOVIG NIYIM ILL3LO8 amp Md IMOLLANNOO ANOISNAIOV Send vokas vasisi 200 1907 ANI VOL 11815 1619894 NYOH SLHOIT OL 3078 ANS E LON IMOTBAMOYI7H 915 3SVHd 9 _ 915 8 7109 E N3dO ISN ON bh i 4 1 58104 9 3mgAXS ZL ISN ON m 6 9 2 gxu 4 MOTISASIOV T8 MS 9 ISN ON 9 NSSUOODVIS N34O 380 ON y ISN ON
2. IR ALL OF THE BULBS BLOW Remove the saddle and tank and check the connections of the UNEXPECTEDLY The regulator is damaged voltage adjuster Have the regulator checked in a specialised TM workshop LIGHTS HORN AND The light cable fuse is burned out Remove the left side piece and replace the light cable 5A fuse INDICATORS DO NOT WORK Remove the saddle and control the regulator contacts Have 15 FLAT The battery is not charged by the generator the regulator and generator checked in a specialised TM workshop 67 5 CLEANING 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 ERALY BREAKAGE OF THESE PARTS Before washing block the exhaust pipe to prevent water from entering Normal soaps found on the market should be used to clean the motorcycel Particularly dirty points should be cleaned using a brush After having rinsed the motorcycle
3. 16 N VA 1805 1805 VNIHOOVIN xoa SHOLOSNNOO 6410 8 AVE AO SF 6 4 2 4350 LON 8 1 MOTTA 9 3LIHM 0JY 4 6 D 2 N3349 IAN SL G3erx2v 18 9 MOVIE 841 HOLIMS 9 5 5 SdL EL 2 4351 LON 14 AG 541 21 LON MOVIE 2 3LIHM 0L AYYWIYd NOLLINSI 4 JYIM SIWVN TVNIAMSIL TVNIASISLL 3HIM SWVN ON TWNINYSL T 9 O SIHM G3N SIHAPXOVTS MOTE FTV IVAW LON SdL HOA NOLLOSNNOO 35 umm 68104 2 ONOLINNS 1 JVE 5 MOTTA 521025 58104 t ONOLINNS OWOLIWNS OWOLINNS 59709 Z ONOLINNS fal m 5 HOLIMS SHOW TE ee Sages Erivw 6104 ONOLINNS 99V LINN IAO Smm a 2 5 9 54104 OWOLINNS 54104 2 ONOLINNS bragez amg ana MOTA MOTA N3dO 2 4 ATVW 531044 9 OWOLINNS 581049 ONOLINNS
4. Modification of rear brake pedal base position Oil OPERATIONAL PRECAUTIONS FOR WINTER USE PRESERVATION Programming the Programming the electronic tachometer Rear suspension mechanical Recharge fuse all models 5 56 Replacement of direction indicator bulb Replacement of exhaust silencer filling material Replacement of fork Springs Replacement of front brake pads Replacement of headlight position light bulb with cyclops 58 Replacement of headlight position light bulb 55 Replacement of rear brake 50 Replacement of rear position stop numberplate bulb END SMB SMM oci irr eee rti eee ci rev ehe veu ped Services fuse all models with lights Setting the distance travelled Start command and emergency stop 5 5 5 Start up with cold engine Start up with warm engine Start up after seasonal pause Steering
5. 14 Idle speed adjustment 14 Gear shift pedal Kickstart 219 Brake pedal eot 15 iioc M O 15 Fixing for off the road 16 Ignition switch 16 Fork adjustment in compression 16 Fork adjustment in 17 Damper adjustment in compression wei 17 Damper adjustment in extension esee 18 Era See 19 ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE 21 Indications for the first 22 Running In IRSEFUCLIOTIS is ieu cuenten teint nnus 22 INSTRUCTIONS FOR 06 11 ener nnn 23 Prestid COMMON 24 Engine ignition when cold eere eene nnne nnne Engine ignition when warm 2 engine is flooded neenon ettet etnies BIrusce Changing gear accelerating slowing 26 Braking 28 Stoping and parking 28 29 LUBRICATION AND MAINTENANCE PROGRAMME
6. 3 18V IIVAV LON 39NVHO VIVA NOILOANNOOD 78 axe LLL TM Racing S p A Via Fano 6 61100 PESARO ITALY www tmracing it Published and printed by SERIART Fabriano AN www seriart com
7. FRAME AND ENGINE MAINTENANCE 37 Control of steering bearings and play adjustment 38 Telescopic fork vent 99 Cleaning of telescopic fork dust 39 Basic calibration of the chassis on the basis of pilot weight 39 Damper calibration and spring 40 Establishment of damper static lowering 40 Establishment of damper lowering in running 40 Control of telescopic fork basic 41 Variation of telescopic fork pre load Replacement of fork springs Variation of damper spring pre load Rear suspension mechanical linkage axe Control chain teMSiON etae 43 Correction of chain tension all except SMM 43 Correction of chain tension SMM 44 2 iot etta ecc cete dator certe ode duse sh ct 44 ISI HH HET 45 Basic indications for TM disc brakes 45 Free play adjustment of the front brake lever 46 Control front brake fluidi
8. Stopping and parking TECHNICAL DATA eene Telescopic fork vent Throttle cable command adjustment Topping up front brake fluid Topping up rear brake fluid TROUBLESHOOTING E Tyres tyre pressure eene Unload filling and bleeding of the cooling system 58 Variation of damper spring pre load Variation of telescopic fork pre load WIRING DIAGRAM eene 5 O1VHOSV 3 31N3S3Hd OLNNALNOO 1 12531 V 1 5 3 3993110 SNINYAL V 01 15 86189 4 vivo 5 OLSIA S 15504 d sid 7 9002 GOW S3 OOIM LLITA VISHOS ouvsad S 3 WvsOVIG SNIMIM 100 viva VOISIGOW 31 t 3MOMIS v oN 1505 Noung LYVLS ANIDNA HOLIMS m ES BRE dOLS NNY 5443 SNION3
9. 36104 NMONE 3S Td 100 1 1 0 123M 93M 2 8 AWN 88104 ONOLINNS 1 E 0 6 NC FIV 63104 OWOLINNS 6 3178 ANS MOTIN 69 6 e N3SWHO9IOV 18 B 3 2 OKO c 2 3LIHM 5 WW 88104 Z ONOLINNS 3 IVW3 88104 Z ONOLINNS 76 axe A h WIRING O1VHO8V 3 31N3S3Hd OLNNALNOO 1I 12531 V 31N3AVSOSOOIS 3993110 V O1V1S V S 72189 4 80
10. 90mm axe 40 y 774 AND ENGINE LLANO Lowering in running order should be 90 105 mm If lowering in running order is less than 90 mm the spring is too hard stiffness index too high If the lowering exceeds 105 mm the spring is too soft stiffness index too low The stiffness index is indicated on the outside of the spring After mounting of another spring static lowering must be adjusted again to 35 mm 2 mm According to our experience the damper level in compression can remain unvaried With a softer spring the level of dampening in extension can be reduced by some clicks with a hrder spring increased by some clicks CONTROL BASIC CALIBRATION OF TELESCOPIC FORK For several reasons the exact lowering in running order on the telescopic fork can not be established Small variations in body weight can be compensated as in the damper through the spring pre load If your telescopic fork however lowers completely it is indispensable to mount a harder 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 Paioli or Ohlins manual It is possible to add pre load bushes The fork springs however can be pre loaded to a max of 20 mm REPLACEMENT OF FORK SPRINGS If your body weight is less than 70 kg or exceeds 80 kg adequate fork spring
11. y 774 GEERATING CONTROLS START COMMAND AND EMERGENCY STOP END MXE S SMXE S SMR SMM In the models with battery and electric ignition a two button command is found at the side of the throttle command one button is red the other black The red button 1 has two positions Positioned inwards it interrupts contact with the battery removing the current from all services consumers ancilleries The engine will not start even with the pedal On these models position it like this to switch the engine off It is advised to leave it like this until the engine is started up again otherwise the battery will go flat Positioned outwards it closes the contact with the battery C enables the use of all services including elecctric starter For this reason never leave it like this with the engine switched off otherwise the ignition control unit which absorbs current even when the engine is switched off can make the battery flat The black button 2 activates the starter Press to start up the engine and release once running Activate this command for a maximum of 8 10 sec at a time and wait a few seconds before re trying Do not insist for more than 3 4 times look for the probable fault Never press this button when the engine is running 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 in
12. 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 TOANOTEWORTHY DECREASE OF THE BRAKING EFFECTAND DETERIORATION OF THE BRAKE DISC REPLACEMENT OF REAR BRAKE PADS E A FOR ALL MODELS WITH FLOATING CALIPER END MX SMR SMX Push the brake caliper 1 towards the disc until the small piston reaches its base position Remove the cap 2 using a screwdriver unscrew 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 screwdriver Tighten well FOR ALL MODELS WITH FIXED CALIPER SMM Remove the safety ring and slide the pin out hitting with a pin puller with 4mm diameter on the same side where the safety ring is found THEBRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER MOUNTING CHECK THAT THE SAFETY DEVICES ARE POSITIONED 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
13. Brake Braking T Carburetor Idle speed adjustment CARBURETOR SETTINGS Chain maintenance Chain wear i Change engine Changing gear accelerating slowing down Choke command cold CLEANING 5 renes Cleaning telescopic fork oil Cleaning the air filter a Combination switch END SMR SMM p Control before every Controlchain tension s cese cesse eo eri arare here Control engine oil level Control front brake fluid level Control front brake Control fuel level float height Control hand decompressor adjustment Control hydraulic clutch oil level Control level of coolant Control rear brake fluid level E Control reat brake pads nir ine ener te Controlspoke 1 1 Control steering bearings and play adjustment Control telescopic fork basic calibration Control adjustment magnet sensor distance visi Correction of chain tension all except SMM E Correction of chain tension CYCLE PART TECHNICAL DATA Damper adjustment in compression Damper adjustment in extension
14. Check brake fluid level pad thickness brake discs 5 S Check conditions and brake pipe for leaks 2 Check functionality adjustment smoothness and front brake lever and brake pedal free play M Check brake plant screw tightness Check for leaks and functioning of damper and fork Q m Clean dust screen a Bleed fork rods 2 E Check rear suspension mechanical linkage screw tightness 2 Check adjust steering bearings 9 9 Check tightness of chassis screw and bolts fork plates fork legs wheel pin nuts and screws rear fork pin damper Check spoke tension and centring of wheel rings 2 e Check tyre condition and pressure Check chain wear chain link sprockets and guides chain tension 9 s Chain lubrication c Check wheel bearing play 9 MAINTENANCE OPERATIONS EVERY COMPETITIONS 3 COMPETITIONS Complete fork maintenance Complete damper maintenance Cleaning and greasing of steering bearings and relative sealing elements 5 Cleaning and tuning of the carburetor 2 Treatment of electric contacts and switches with spray for contacts Treatment of battery connections with grease for contacts Replacement of hydraulic clutch fluid Replacement of brake fluid The distance between maintenance intervals should not be exceeded more than 2hours or 15 litres THE MAINTENANCE CARRIED OUT BY THE AUTHORISED TM D
15. Five zeroes appear in the display of which the first is flashing along with DST which is also flashing Press the right hand button blue to make the first of the four numbers to be set flash and press the left hand button yellow to set the desired value Repeat the operation until all of the numbers have been set as desired End by pressing the grey button on the rear of the instrument for 1 sec ENGINE STOP SWITCH MX SMX The engine stop switch is found near to the handlebar s left handlebar grip The engine is shutdown using the engine stop switch 1 when it is activated 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 COMBINATION SWITCH END SMR SMM This command is found on the handlebar near to the left handlebar grip The light selector switch has 4 positions lights off B position lights on C position lights and headlights on D position lights and headlights on Key 1 activates the horn Use cursor 2 to activate the direction indicators move it to the left when turning to the left and towards the right when turning tot he right Place it back in the central position when the manouevre has been carried out Use button 3 to switch the engine off only if the motorcycle does not have a battery This button is deactivtaed when there is a battery ENGLISH 12 OPERATING CONTROLS
16. lt 01 28 1301 281301 28 1301 28 1301 28 1301 C 8 4 Gd Gd Gd Gd 8d Gd 9 4 Gd Joinquisiq 64 99 99 99 0S 64 99 Or 814 002 902 902 902 021 081 021 991 xe 1 YWOL HINQ L 8 510 54 34 9004 S 01 267 S MI 71 ENGINE GCOUFLING TORQUES ENGINE COUPLING TORQUES Sump Allen screw transmission torque clutch torque ignition torque Oil empty screw cap Oil load screw cap Oil net filter screw cap Oil filter cartridge cover Allen screws Engine oil pump body screws Head cylinder lock nuts Head cylinder tigyhtening flanged nuts Head cylinder tigyhtening flanged nuts Head cylinder screw fasteners Camshaft bearing cap Allen screw Camshaft flanged nut cap Distribution chain tensioner Allen screws Water pump cover Allen screws Water pump rotor Head cover Allen screws Primary pinion hexagon nut Clutch hub nut Clutch springs Allen nuts Starter motor bush head Allen screws Starter motor fixing Allen screws Mobile chain guide fixing flanged screws Ignition stator Allen screws Ignition pickup fixture Allen screws Allen screws for gear block Ignition flywheel flanged nut Kickstart pedal screws Gear lever Allen screws Empty collector flanged nuts General screws nuts General screws nuts General screws nuts ENGINE OIL Only u
17. MANUAL DECOMPRESSOR LEVER ALL530 AND 660CC The hand decompressor lever 2 is on the left side of the handlebar and is used when or after a fall or following overheating the engine finds it difficult to start up when warm To ventilate the engine pull the decompressor lever during ignition The lever must always have a play of about 10 mm measured between the lever and support before starting to open the valves The moment of opening is recognised by greater resistance of the lever see Fra me and Engine Maintenance chapter FRONT BRAKE LEVER The front brake lever 3 is located on the right of the handlebar and activates the front wheel brake The position of the brake lever with respect to the handlebar grip can be varied using the adjustment screw A see Frame and Engine Maintenance chapter CONTROL LIGHTS END SMR SMM The green control light 1 lights up when the indicator is switched on and flashes in time to the indicator The blue control light 2 illuminates when the full beam headlight is switched on axe 10 28727 ELECTRONIC END SMR SMM The electronic tachometer display is always activated The electronic tachometer is powered by 5844 1 5 Volt battery D357 11 6x5 4mm Replace the battery every 2 years or in case of blurring of the display To replace the battery open the cover positioned on the rear using a screwdriver and extract the battery Insert t
18. axe 62 27 AND ENGINI LLANO CONTROL OF ENGINE OIL LEVEL The engine oil level must be checked when the engine is running Start up the motorcycle on flat ground and keep it in a vertical position not on the side stand Start up the engine and keep it at a constant speed a little above the idle speed the oil level must be visible from 1 2 to 3 4 of the hatch glass positioned on the right side of the motorcycle If it is too low or cannot be seen at all top up immediately with engine oil Use the same type that has already been introduced into the engine WARNING LOW OIL LEVEL LOW QUALITY OIL MAINTENANCE INTERVALS LONGER THAN THOSE ESTABLISHED CAUSE SERIOUS DAMAGE TO THE ENGINE ENGINE OIL Only use top quality completely synthetic SAE10W 50 oils which correspond to or exceed the quality standards of theAPI SG or SH classes indications on container WARNING LOW OIL LEVEL LOW QUALITY OIL MAINTENANCE INTERVALS LONGER THAN THOSE ESTABLISHED CAUSE SERIOUS DAMAGE TO THE ENGINE CHANGE ENGINE OIL A WARNING WHEN CHANGING THE OIL CLEAN THE OIL SUMP NET FILTER AND REPLACE THE FILTER CARTRIDGE The oil must be changed with the engine at working temperature THE ENGINE AT WORKING TEMPERATURE AND THE OIL IT CONTAINS 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 flo
19. 9 co 0 51 ISNA V0L G31V3S 161894 DE vum diii I8 V3Wal3dMWi VOL 5 L61894 53108 OWOLINNS 88104 2 OWOLINNS 9 03 AOVAYALNI NOILONGOdd ATEVIIVAV LON NOLLOSNNOO 5 77 RAM DIA WIRING O1VHOSV 3 31N3S3Hd OLNNALNOO 1 12531 V 3snaosdid 1 31N3AVSOSOOIS 3 3993110 V 92189 4 sid 1916 VWS OLNAWYLLV YL 60 60 61 OLSIA 15504 4 sid Zd 9002 XWS XW 3NOISN3OOV 09181 1978 5 9002 VOIJIQON 5 LER
20. Close the radiator cap and start up the engine for a few seconds Re open the cap and control 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 antinoise material fibreglass to limit motorcycle noise Because of high temperatures reached by the exhaust gases the fibreglass tends to melt leading to a decrease in the effect of noise absorption and also causing a decrease in power To replace the fibreglass disassemble the silencer from the motorcycle frame remove the rivets that support the rear cap 1 and slide the wool to be replaced out In END SMM SMR models the fibreglass cartridge must be cut to a length of about 30 cm weight 300 grammes while in the other models it is inserted whole Push it down well close the cover and fix the rivets DURING FUNCTIONING OF THE MOTORCYCLE 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 spring of holding between the pipe and the silencer When the engine is started up it generates a white smoke from the previously greased parts This is caused by the hight temperatures that melt the grease ENGLISH 58 y 774 IAM ENGINE WARNING REPLACE THE FIBREGLASS CAR
21. ON CONTACT WITH THE SKIN RINSE WELL WITH WATER IF DROPS OF THE ELECTROLYTE ENTER INTO THE EYES RINSE FOR LEAST 15 MINUTES WITH WATER AND CONSULT A DOCTOR IMMEDIATELY EVENIF THE BATTERY IS SEALED IT IS POSSIBLE FOR EXPLOSIVE GASES TO ESCAPE 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 AS OTHERWISE THE ADJUSTER STRAIGHTENER WOULD BE DESTROYED THE BATTERY MUST BE MOUNTED WITH THE POLES IN FRONT AS IN THE FIGURE IF ITIS MOUNTED IN THE OPPOSITE DIRECTION THE ELECTROLYTE CAN ESCAPE PRESERVATION If the motorcycle is kept at a standstill for a long period of time remove the battery and charge it Keep it at at temperature of 0 35 away from direct sunlight BATTERY CHARGER Remove the battery and determine if it is charged or not To do this measure the voltage between the poles using a voltmetre rest voltage To obtain a correct measurement the battery must not be charged or discharged for at least 30 minutes before the measurement is taken If itis not possible to determine the charge the battery can be charged for a maximum of 10 hours with 0 5 ampere and max 14 4 volt A WARNING THECLOSURE STRIP MUST NOT BE REMOVED AS IT WOULD BE DAMAGED TORECHARGE FIRST CONNECT THE BATTERY TO THE BATTERY CHARGER THEN SWITCH THE BATTERY CHARGER ON WHEN RECHARGING IN
22. The maintenance 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 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 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 250 and 450 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 resistance c
23. activate the front brake and force the fork down several times to align the rods End by definitively tightening the blocking screws on the right fork leg to 12Nm IF YOU DO NOT HAVE A DYNOMOMETRIC WRENCH WHEN MOUNTING HAVE THE COUPLING TORQUE CONTROLLED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP A LOOSE WHEEL PIN CAN CAUSE UNSTABLE DRIVING AFTER HAVING MOUNTED THE FRONT WHEEL REPEATEDLY ACTIVATE THE BRAKE LEVER UNTIL THE PAD ADHERES TO THE DISC AGAIN 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 MODELS APART FROM 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 pin 2 remove the chain tensioning slide 3 remove the chain from the crown wheel remove the caliper with its support and carefully extract the rear wheel from the rear fork Pay attention to the low wheel shims crown wheel side and high shims 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 WHEEL PIN IS DISASSEMBLED THE WHEEL PIN THREADS AND THE THREADS OF THE COLLAR NUT MUST BE CLEANED WELL RE GREASE THEM TO PREVENT SEIZING OF THE THREADS To
24. apex of the float and the small tank 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 valve coning if in doubt replace the valve and brass seat Mount the float bowl mount the carburetor and adjust the idle speed EMPTYING THE CARBURETOR TANK After washing or driving in wet environments watercourses etc the carburetor tank should be emptied to remove any water that has entered Water in the carburetor tank causes functioning 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 that escapes 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 PLANT NEAR TO FLAMES OR CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL USE 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 OIL CIRCUIT The delivery pump 3 sucks the oil through the
25. dimensions a If the mix adjustment screw is screwed right down without variation of the number of revs of the idle speed a smaller idle speed jet must be installed b If the engine switches off with the mix adjustment screw still open by two turns a larger idle speed jet must be installed Obviously after the jet has been replaced adjustment must be carried out again from the beginning 5 Now adjust the number of revs of the idle speed desired using the adjustment knob 6 In the presence of large variations in the external temperature and the altitude the idle speed must be set again To adjust the mix screw idle speed a very short screwdriver may be required Notches may be useful on the handgrip BASIC INDICATIONS REGARDING WEAR OF THE CARBURETOR The throttle valve conical needle the power distributer where present and the float needle valve are subject to great wear caused by engine vibration As a consequence the carburetor may malfunction e g strengthening of the mix These pieces must therefore be controlled after 200 hours 61 5 CRAME AND ENGINE LA CONTROL OF FUEL LEVEL FLOAT HEIGHT A With this scope disassemble the carburetor and remove the float bowl Turn the carburetor over 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 gauge to measure the distance between the
26. 30 hours 5 e 5 9 M Check and adjust valve play clearances e e Check valve spring length Check upper and lower spring plate wear Check valve cotters and valve rods Check guide wear Check valve 5 Q Q Check automatic decompressor functionality 9 Check head surfaces and cylinder s s Check engine crankshaft for trueness Replace conrod axle and roller cage Check small end for marking damage to coating e 9 O Check oil pump and lubrication circuit Replacement of main bearings 5 9 9 Check complete change including the valve gear and forks 5 5 5 5 5 WARNING IFATTHE CHECKIT IS DETECTED THAT THE RELATIVE TOLERANCES HAVE BEEN EXCEEDED THE INTERESTED COMPONENTS MUST BE REPLACED THE MOUNTING OF AN HOUR COUNTER INSTRUMENT ISADVISED THE ABOVE MENTIONED OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP 35 5 LE MALNTENANGE AND EWE TARILE 1 ROAD HOBBY USE 60 90 120 180 240 270 20 HOURS OF FUEL CONSUMPTION C Bus ene Check cylinder and piston wear 2 e Check crank pin visual check 2 Check camshaft wear and spring cups visual check 5 5 Check camshaft supports 2 Check timing chain after checks at 3 hours and 30 hours 5 gt M Check and adjust valve play clearances 5 2 Check spring valve length gt Check upper and lower spring plate w
27. 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 5 loosen the screw fasteners on the left and right fork legs 6 finish unscrewing the flanged nut Holding the front wheel still slide the wheel pin out 7 If necessary to help the wheel pin to exit strike lightly with a mallet hammer with plastic head on the threaded end of the pin itself Alternatively use a normal mallet and place a piece of wood between NEVER USE THE MALLET DIRECTLY ON THE PIN YOU RISK DAMAGING THE PIN IRREVERSIBLY Slide the front wheel carefully out of the fork ENGLISH 50 2 7707 PRAME AND EGUNE LORE A WARNING NEVER ACTIVATE THE BRAKE LEVER WHEN THE FRONT WHEEL IS DISASSEMBLED ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TOPREVENT 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 pin Screw and temporarily tighten the flanged nut 5 until the wheel shim is blocked tighten the locking screws 6 on the right fork leg to prevent the wheel pin from turning and tighten the flanged nut to 40 Nm Tighten the locking screws on the left fork leg to 12Nm Loosen the blocking screws on the right leg again remove the motrcycle from the stand
28. Remount the caliper tighten the M8 screws to 25Nm and finish tightening the retainer pin to 12Nm SMX Unscrew the two M10 screws 10 and remove the caliper from the leg piece Press the two hooks one at a time 8 to release and slide the retainer pin out 9 Lever a couple of pads to allow the small pistons to return to their base position Extract the worn pads and insert the new ones Repeat the operation for the other couple of pads Press the two hooks down and re insert the pins make sure that they are inserted as far as possible have their play and are correctly attached Remount the caliper and tighten the M10 screws to 40Nm WARNING FORALLMODELS WHEN THE SMALL PISTONS ARE MADE TO RETURN TO THEIR BASE POSITION TO MAKE SPACE FOR THE NEW PADS PAY ATTENTION THAT THE OIL CONTAINED IN THE TANK HAS SPACE TO EXPAND DO NOT WORK WITHOUT THE CAP MOUNTED OTHERWISE ON EXPANSION THE OIL COULD OVERFLOW AND DAMAGE PARTS OF THE MOTORCYCLE THEBRAKE DISC MUST ALWAYS BE KEPT FREE FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER MOUNTING CHECK THAT THE SAFETY DEVICES ARE POSITIONED 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 axe 48 y 774 FRAME AND ENGINE MAINTENANG LLANO MODIFICATION OF THE REAR BRAKE PEDAL BASE POSITION A The
29. YOUR TM ENSURE THAT IT IS WELL HELD IN A VERTICAL POSITION USING BELTS OR OTHER MECHANICAL FIXING DEVICES AND ENSURE THAT THE PETROL TAP IS SWITCHED OFF IF THE MOTORCYCLE SHOULD FALL PETROL COULD ESCAPE FROM THE CABURETOR OR TANK TOFIXTHE PIPES TO THE TANK ONLY USE THE SPECIAL SCREWS WITH THE CORRECT LENGTH OF THE TM THREAD IF YOU USE DIFFERENT SCREWS OR LONGER SCREWS THE TANK COULD BE DAMAGED WITH CONSEQUENTFUEL LEAK DONOTUSE NOTCHED WASHERS OR SPRING WASHERS FOR THE ENGINE SCREW FASTENERS BECAUSE THEY COULD PENETRATE INTO PARTS OF THE FRAME AND LOOSEN CONTINUALLY USE SELF LOCKING NUTS LEAVETHE MOTORCYCLE TO COOLBEFORE STARTING ANY MAINTENANCE THIS WILL PREVENT BURNS DISPOSE OF OILS GREASES FILTERS FUELS DETERGENTS ETC INAREGULAR MANNERE COMPLY WITH THE RESPECTIVE REGULATIONS OF YOUR COMPANY DISPOSE OF WASTE OIL IN A REGULAR MANNER NEVER POUR OLD OIL INTO DRAINS OR RIVERS CONTROL OF STEERING BEARINGS AND PLAY ADJ USTMENT A 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 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 thefork head nut and successively the four M8 screws to20 Nm Control that steering is smooth IF THE STEERING BEARINGS ARE T
30. base position of the rear brake 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 empty stroke is given by the run of the pump small piston check that the pedal has an empty stroke of about 1 5cm before starting to brake WARNING IF THERE IS NO FREE PLAY PRESSURE DEVELOPS IN THE BRAKING SYSTEM AND CONSEQUENTLY THE REAR WHEEL IS MADE TO BRAKE THE BRAKING SYSTEM OVERHEATS AND IN EXTREME CASE IT WILL NOT FUNCTION CONTROL REAR BRAKE FLUID LEVEL FOR END MX SMX MODELS The container 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 inspection hatch 3 positioned on the body of the pump FOR SMR SMM MODELS The container 4 for the rear disc brake fluid is transparent and is situated in the right triangle of the frame The fluid must always be between the maximum Upper and the minimum Lower indicated the container itself IF THE LEVEL OF THE BRAKE FLUID FALLS BELOW THE MINIMUM LEVEL IT INDICATES A LEAK IN THE BRAKING SYSTEM OR COMPLETE CONSUMPTION OF THE BRAKE PADS TOP UP REAR BRAKE FLUID A FOR END MX SMX MODELS As soon as the level of rear brake fluid reaches the centreline on the inspection hatch situated on the pump it must be top
31. corresponds to the activation of the accelerator pump This could flood the engine ADJ USTMENT OF CLUTCH LEVER BASIC POSITION Use the adjustment screw 1 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 clutch lever approaches the handlebar If the adjustment screw is turned anticlockwise the clutch lever moves away form the handle bar The adjustment screw 2 is used to adjust the pump run after having adjusted the position of the lever WARNING THEFIELD OFADJUSTMENT IS LIMITED OBNLY TURN THEADJUSTMENT SCREW MANUALLY WITHOUT FORCE CONTROL HYDRAULIC CLUTCH OIL LEVEL The oil tank is part of the clutch pump positioned on the handlebar and has an inspection hatch with the tank in a horizontal position the level of the liquid 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 2 and then the cover 3 together with the rubber seal 4 Keeping the tank in a horizontal position top up with DOT4 brake fluid A WARNING FORTHE HYDRAULIC COMMAND OF THE CLUTCH TM USES DOT4 BRAKE FLUID NEVER USE DOT5 OR OTHER DONOTALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES THE PAINT ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY SEALED CONTAINERS BLEEDING THE HYDRAULIC CLUT
32. knob 1 forward as far as possible a hole is opened in the feeding pipe through which the engine can suck an additional amount of air not mixed with fuel The result is a lean air fuel mix This is required for ignition of the engine when it is flooded or particularly overheated As soon as the engine is running push the starter motor to return it to its normal position BY PASS COMMAND HOT START models with kickstart This command is found on the handlebar near to the right handlebar grip By turning the by pass lever 1 as far as possible a hole is opened in the feeding pipe through which the engine can suck an additional amount of air not mixed with fuel The result is a lean air fuel mix This is required for ignition of the engine when it is flooded or particularly overheated As soon as the engine is running push the starter motor to return it to its normal position IDLE SPEED ADJ USTMENT COMMAND This command is found on the left side of the motorcycle By turning the idle speed adjustment knob the normal running of the engine at idle speed is raised or lowered By turning it in a clockwise direction the idle speed is raised by turning it in an anti clockwise direction the idle speed is lowered The normal idle speed when the engine is warm must be between 1 600 and 1 800 revs min ENGLISH 14 OPERATING CONTROLS y 774 OPE RATINGECONTROIS LLANO GEAR SHIFT PEDAL The gear shift ped
33. 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 WARNING WHEN THE COOLANT LIQUID HAS BEEN EMPTIED WHEN RE FILLING IT IS NECEESARY TO BLEED THE COOLING SYSTEM SEE BELOW ALWAYS USE GOOD QUALITY PRODUCTS TO PREVENT CORROSION OR THE FORMATION OF FOAM IN EXTREME WEATHER CONDITIONS OR IN STOP AND GO TRAFFIC OVERHEATING MAY OCCUR TO SOLVE THIS PROBLEM AN ELECTROVENTILATOR KIT IS AVAILABLE FOR ALL MODELS WITH ELECTRIC STARTER ASK AT YOUR TM AUTHORISED DEALER 57 5 A 2 FRAME MATIN TEIN LLL CONTROL 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 water pump cover on the right side of the engine Prepare an adequate container to collect the liquid when it is unlaoded To empty the liquid the filling tap 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
34. net filter 4 from the sump The oil is delivered pressurised through a pipe 5 to the filter cartridge where it is purified from all particles and delivered partly to the engine shaft and partly to the distribution and gears The oil delivered to the crankshaft enters in a co axial pipe to the shaft and arrives lubricating the big end bearing 6 The oil delivered to the distribution and gears is made to ascend to the top of the crankcases and before entering the cylinder it divides again A part is channeled towards the gear which lubricates through a distributor 7 the teem in the gearbox Another part passes through a spray nozzle towards the small end 8 for lubrication of the piston pin Finally another part is channeld along the cylinder and through a relevant hole and arrives at the smooth bearings of the camshaft and to the point of contact between the cams and spring cups 9 10 All pressurised oil delivered to the main parts of the engine is returned by fall and depression to the point in which the drainage pump is found 11 which collects the oil and send it back to the oil sump Note that the oil sump is separate from the rotating parts of the engine dry sump but integrated in the casting of the crankcases For circulationof the oil channels were used that were contained inside the engine without using external pipes
35. out by a specialised 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 safe 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 axe 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 controls maintenance and tuning of the engine and chassis part of the motorcycle indicated in the user manual is indispensable for correct functioning 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
36. the behaviour of the fork in the in compression stroke The degree of hydraulic braking in compression can be adjusted on the basis of pilot preferences and or hardness of the spring installed PAIOLI USD FORK STANDARD 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 it in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 26 notches are available OHLINS USD FORK OPTIONAL The adjustment screw is found in the lower part of the fork leg 3 Turn with a screwdriver By turning it in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 20 notches are available 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 axe 16 OPERAIING CONIROL5 LAARO FORK ADJ USTMENT IN EXTENSION The hydraulic brake system in extension determines the behaviour of the fork in the return or rebound stroke The degree of hydraulic braking in extension can be adjusted on the basis of pilot preferences and or hardness of the spring installed PAIOLI USD FORK STANDARD The adjustment screw is fo
37. the external pipes BASIC CALIBRATION OF THE CYCLE PART ON THE BASIS OF THE PILOT S WEIGHT To obtain optimal driving features of the motorcycle and to prevent damage to the fork damper rear fork and frame it is necessary that the basic calibration of the suspension is adapted to your body weight In the delivery status the off the road TM motorcycles are calibratedon a pilot weight of with complete protective clothing 70 80 kg If your weight is not within these values you must adequately adapt the basic calibration of the suspensions Minor weight changes can be compensated by varying the spring pre load For greater variations suitable springs must be mounted 39 5 CE ANDY ENGINES LOMA DAMPER CALIBRATION AND SPRING CONTROL If the damper spring is suitable for your weight it can be seen by lowering in running order However before establishing the lowering in running order static lowerng must be adjusted correctly ESTABLISHING STARTIC LOWERING OF THE DAMPER The static lowering should be35 mm Variations of more than 2 mm can otably 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 pin and a fixed point e g a mark on the side piece paying attention that the straight line that joins the pin and the fixed point is as sperpendicular as possible to
38. thickness brake discs Check conditions of brake pipes 5 F Check functionality adjustment smoothness and front brake lever and brake pedal free play 5 4 Check brake hose screw tightness 5 e Check for leaks and functioning of shock absorber and forks H Clean dust screen e Bleed fork leg Check rear suspension mechanical linkage screw tightness 2 Check and adjustment of steering bearings 2 Check tightness of chassis screw tightness fork plates fork legs wheel pin nuts and screws 5 rear fork pin shock absorber Check spoke tension and centring of wheel rings Check tyre conditions and pressure gt 2 Check chain wear chain link sprockets chain tension 34 Chain lubrication 9 Check wheel bearing play 2 2 EVERY YEAR Complete fork maintenance Complete damper maintenance Cleaning and greasing of steering bearings and relative sealing elements Cleaning and tuning of the carburetor 5 Replacement of silencer antinoise material 4 Treatment of electric contacts and switches with spray for contacts Treatment of battery connections with grease for contacts Replacement of hydraulic clutch fluid Replacement of brake fluid 3 The distance between maintenance intervals should not be exceeded by more than 2hours or 15 litres THE MAINTENANCE CARRIED OUT BY T
39. 0 90 19 110 90 19 Off the road air pressure 1 1 bar Tank capacity 9 litres Final transmission 13 50 13 51 13 50 13 50 13 51 13 49 Chain O Ring 5 8 x 1 4 5 8 x 1 4 Notched crown wheels optional 48 49 50 51 52 58 Bulbs only END Headlight full beam 212V 45 40W BA20d Opt Cyclops H3 12V 55W PK22s Front position light T4W 12V 4W 95 Opt Cyclops T10 12V 5W Position stop number plate light P21 5W 12V 21 5W BAY15d Indicator R10W 12V 10W BA15S Battery 12V 6Ah 12V 6Ah only with E S opt COUPLING TORQUES 250 450 530 END 250 450 530 MX 2006 Front wheel pin flanged nut M20x1 5 40Nm Front brake caliper screw fasteners END MX 25 Front brake disc screw fasteners M6 cl 10 9 15Nm Rear brake disc screw fasteners M6 cl 10 9 15Nm Upper fork head screw fasteners 20 Lower fork head screw fasteners M8 20 Nm Paioli fork leg screw fasteners M6 12Nm Ohlins fork leg screw fasteners M8 12 Rear wheel pin flanged nut M22x1 5 80 Nm Rear fork pin flanged nut M16x1 5 80 Nm Handlebar tightener screw caps M8 20 Nm Handlebar elastic support nut M10 35 Nm Upper damper nut M10x1 25 40 Lower damper nut M10x1 25 35 Nm Crown wheel nuts M8 35 Rear brake pedal adjustment nut 15 Engine fixing screws M10 45Nm General frame screws 10 M8 25 Nm M10 45Nm General frame nuts M6 15Nm 30 10 50 Nm 73 5 LEG TECHNICAL DATA CYCLE PART TECHNICAL DATA CYCLE PART
40. 1 n4 9686 einsojo uni 0 UNI 9 10411 0 Buiuedo 86 e zzou jybiey yeo 4 M9J9S peeds 201 91 LA M L uonisod dij 4 NASOO NIN38O 561 S94 qef xen 4 2 x l i 11 Ci C Or Or Or Or Or Or Or e zzou ww o g WLU L WLU GZ LL WLU GZ WUG joefoud uni pug LL 0 28 ww 08 0 28 028 0 98 uu 098 sxeiejuipouxul coy ey 86 86 86 86 86 86 86 86 86 uu gor WLU rt WLU QL 4 021 0 0 0 021 02 021 021 01 19 peeds 8 9 4 Q SABI SABI 5 1 8 70 SAI SAI SAI M9JOS peeds sgjououg g sajoyoug g sajoyoug z sajoyoug g sajoyoug g sajoyoug z M do wos pig do wo pig do pig pig dojwoypig do pig uolAisod dijo p 28 1301 28 1301 28 1301
41. 250 450 530 SMR SMM 450 660 SMX 2006 250 450 530 SMR 250 450 530 SMM 450 SMX 660 SMX Frame Molybdenum chrome steel enclosure Front suspension Paioli USD fork optional Ohlins USD Rear front suspension run 270 280 mm Rear suspension Aluminium rear fork Single arm on SMM Progressive mechanical linkage Sachs damper Ohlins optional Front disc brake 320 calipers with 4 pistons 2420 caliper with 4 perimeter pistons 0 320 caliper with 4 radial pistons Rear disc brake 320 calipers with 4 pistons 2420 caliper with 4 perimeter pistons 0 320 caliper with 4 radial pistons Brake disc wear limit mm 0 4 below original thickness Front tyre 120 70 17 Only air pressure 1 7 bar Rear tyre 150 60 17 165 55 17 Only air pressure 1 7 bar Tank capacity 9 litres Final transmission 13 40 13 44 Chain 5 8 x 1 4 Notched crown wheels optional 39 41 42 43 44 45 42 39 40 41 42 43 45 Bulbs only SMR SMM Head high beam light 5212 45 40W BA20d Opt Ciclope 12V 55W 225 Front position light T4W 12V 4W 95 Opt Ciclope T10 12V 5W Rear position stop number plate light P21 5W 12V 21 5W BAY15d Indicator R10W 12V 10W 155 Battery 12V 6Ah 12V 6Ah only with E S opt COUPLING TORQUES 250 450 530 SMR SMM 450 660 SMX 2006 Front wheel pin flanged nut M20x1 5 40Nm Front brake caliper screw fastener SMR SMX M10 40Nm Front brake caliper screw fastener SMM M8 25 Rear brake caliper screw fastener SMM M8 25 F
42. 3 eaa esce 68 Start up after seasonal 68 TECHNICAL DATA ENGINE 69 70 CARBURETOR 5 5 71 ENGINE COUPLING TORQUES eere 72 CYCLE PART TECHNICAL DATA 73 74 ALPHABETICAL INDEX 2i aoc teta 75 WIRING DIAGRAM eene 144 appendix POS OF p 774 POSITION Or SERIAL MUMBER 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 ENGINE NUMBER The engine number is engraved on the left side of the engine underneath the chain pinion Make note of this number in the appropriate space on page 3 axe 8 OPS RATING Tao s 2727 OPERATING CONTROLS CLUTCH LEVER 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 and the ensure correct freeplay pump after having adjusted the lever position
43. 90 62 viva OLSIA S a OLN3AVLLVHL 15504 d sid Zd Oddnuo 9002 GOW VZN3S 54 3NOISN3OOV OOIMHLLSTI VIASHOS ouvsad O M ONIMIM Sarena 11 VOISIGOW IdWAL 4 15 1808 1808 VNIHOOVIN SHOLOSNNOO G3 IV4 S NIYIM IMOLLANNOOD ZINOISNHOOV Yad VNAHOS 916 9 ois 8 L 109 L y N3dO ISN bh L HOLIMS 3018 10279 5 ISN ON 458 10N 0L an9 6 e 5 8 3 1 4 9 QNS ON MOLO3NNOO 68104 9 N3dO ISN ON t 9 ISN ON 6 3LIHM 38104 2 43979 TVNIASS L N33U oOVIB woTEuoDVIS 5 FWA gt o o 1988 944 5 0 6 ITIN 58104 ONOLINNS 6 3018 aaro mL OWE ania al 4 MOTBAGOVIE 5 5 2 5 MOTISASIOV TE NMOUB 631042 4 3wW34syiodzdWv B 5
44. CH The cover of the clutch pump must be removed for bleeding Remove the screws 2 and remove the cover 3 together with the rubber seal 4 The clutch cylinder pump bleeding nipple on the engine 5 must be connected to the relevant suction device and this must be activated Loosen the bleeding nipple at the same time 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 tank is always sufficient and prevent the pump from taking up air If necessary top up with 4 brake fluid WARNING FORTHE HYDRAULIC COMMAND OF THE CLUTCH TM USES DOT4 BRAKE FLUID NEVER USE DOT5 OR OTHER DONOTALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES THE PAINT ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY SEALED CONTAINERS ENGLISH 60 y 274 FRAME AND ENGINE CARBURETOR ADJ USTMENT OF IDLE SPEED The adjustment of the idle speed greatly influences the ignition of the engine this means that an engine with the idle speed correctly adjusted will be easier to start up than an engine with an incorrect idle speed The idle speed is adjusted using the adjustment knob 1 and the mix adjustment screw 2 The adjustment knob is used to adjust the basic position of the throttle valve The mix adjustment screw is used to adjust the mix for the idle speed whic
45. CLOSED SPACES ENSURE GOOD VENTILATION THE BATTERY PRODUCES EXPLOSIVE GASES DURING CHARGING BATTERY IS CHEAGED FOR TOO LONG OR WITH A VOLTAGE THAT IS TOO HIGH THE ELECTROLYTE WILL ESCAPE THROUGH THE SAFETY VALVES THE BATTERY THEREFORE LOOSES CAPACITY AVOID FAST RECHARGING axe 54 AND ENGINI M E TEIN AICI REST STATE OF DUR OF CHARGING VOLATGE CHARGING VOLTAGE VOLT 96 AT 0 5 A 2127 100 Max 12 5 75 4 hours 14 4V 12 2 50 7 hours 12 0 25 11 hours 11 8 0 14 hours 247 AND ENGIN LANO RECHARGE FUSE ALL MODELS WITH E S The fuse 1 is found in the electric starter relay 2 under the right flank After having removed the right side piece and the protective hood it is possible to access the fuse The fuse has a capacity of 30 amperes This fuse protects the following recharging system battery A spare 10 ampere fuse is also found in the starter relay 3 SERVICES FUSE ALL MODELS WITH LIGHTS The fuse is found in the relevant rubber fuse holder 4 situated below the left side piece in SMR and SMM models it is under the right side piece After having removed the left side piece right for SMR and SMM and opened the fuse holder it is possible to access the fuse The fuse has a capcity of 10 ampere This fuse protects the following lighting plant direction indicator acoustic warning device A burn
46. D ENGINE MAITEAC 5 FOR ALL MODELS WITH FLOATING END MX Push the brake caliper towards the disc in a way that the small 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 Mountthe left brake pad and insert the pin until it stops Mount the safety devices During mounting of the pads ensure that the running sheet in the caliper support and the leaf spring are positioned correctly FOR ALL MODELS WITH FIXED CALIPER SMR SMM SMX SMR Unscrew the two screws 1 and remove the caliper Levert he small pistons into their seat then remove the safety pin 2 slide the pin out 3 and then extract the pads paying attention to the laminated spring 4 Remount the new pads the laminate the pin and the safety retainer then remount the caliper and tighten the M8 screws to 25Nm SMM Loosen the retainer pin b using an 8mm spanner unscrew the two M8 screws 6 and remove the caliper Lever in the middle of the pads to allow the small pistons to return to their base position Slide the pin out extract the worn pads insert the new pads and tighten the pin as far as possible
47. D YOUR DRIVING CAPABILITY DRIVE CAREFULLY ON UNKNOWN ROADS OR LAND WHEN OFF THE ROAD YOU SHOULD ALWAYS BE ACCOMPANIED AFRIEND WITH ASECOND MOTORCYCLE SO THAT YOU HELP EACH OTHER IF DIFFICULTIES OCCUR IN DUE TIME REPLACE THE VISOR OR LENSES OF THE GOGGLES YOU WILL BE BLINDED AGAINST SUNLIGHT IF THE VISOR OR GOGGLES ARE SCRATCHED DO NOT LEAVE THE MOTORCYCLE UNSUPERVISED IF THE ENGINE IS RUNNING MX AND SMX MODELS ARE NOT TYPE APPROVED FOR USE ON PUBLIC ROADS OR MOTORWAYS WHEN USING YOUR MOTORCYCLE ALWAYS KEEP IN MIND THAT EXCESSIVE NOISE DISTURBS OTHERS TONES USE LOMA PRE RIDE CONTROL To use the motorcycle safely it must be in a good state 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 controls 1LEVEL 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 thetank 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 pasage of air 3 CHAIN The drive chain must always be tensioned corretly and well lubricated A loose chain knocks and may escape fr
48. Damper calibration and spring control Departure nre terrere Disassembly and assembly of front wheel 88 Disassembly and assembly of rear wheel all except SMM 51 Disassembly and assembly of rear wheel SMM Electronic Emptying of carburetor tank ENGINE COUPLING TORQUES Engine number Engine Oll enne Engine stop switch MX SMX Establishment of damper lowering in running order 40 Establishment of damper static lowering E Fixing for off the road 16 Fork adjustment in Fork adjustment in extension FRAME AND ENGINE MAINTENANCE Frame numbet rper Free play adjustment of front brake 46 Front brake lever Fuel fill cap Fuel tap UC Function selection and reset Gear pedal Idle speed adjustment command If the engine is flooded eene 26 Ignition switch Indications for the first start up Inspection hatches Instructions for running in INSTRUCTIONS FOR USE m Kickstart LUBRICATION AND MAINTENANCE PROGRAMME 31 Manual decompressor
49. E NUMBER OF REVS AND THE VALVES AND OTHER ENGINE COMPONENTS WOULD BE DAMAGED 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 ATM AUTHORISED DEALER 27 INSTRUCTIONS FOR USE 5 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 activate the brakes and change down the gears delicately without locking the wheels locking of the wheels leads to swerving or a fall When following long descending routes 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 THE CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER IMMERSION 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 ACTIVATED REPEATEDLY UNTIL THEY ARE DRY AND CLEAN THE BRAKING ACTION CAN ALSO BE DELAYED WHEN TRAVELLING ON DIRTY ROADS OR ROADS COVERED IN SALT THE BRAKES MUST BE ACTIVATED UNTIL THEY ARE CLEAN WHEN THE BRAKE DISCS ARE DIRTY
50. EALER DOES NOT REPLACE THE CHECKS AND MAINTENANCE CARRIED OUT BY THE DRIVER 33 5 MAINTENANCE AND 1081 SSF AND MAINT SWANS OFS Check engine oil level Check brake fluid level Check brake pad wear 5 Check light system functioning if present 5 Check horn functioning if present 5 Lubrication and adjustment of command cables Bleed fork rods 9 Disassembly and cleaning of the dust shields 9 Cleaning lubrication and check of drive chain tension 9 Cleaning filter cas and air filter Check tyre pressure and wear 2 Check coolant level Check fuel pipe for leaks e Cleaning of caburetor and jets for dirt and water removal 9 Check smoothness of all command elements 5 Check braking effect Treatment of shiney metal parts apart from brake plant and exhaust with anti corrosives 5 Treatment of ignition switch steering lock with spray for contacts Check regular tightness of all screws nuts and bands ENGUSH 34 y 274 MAINTENANCE S Us 30 45 60 90 120 135 15 HOURS OF FUEL CONSUMPTION ie mee poete aene o Check cyclinder and piston wear 2 Check crank pin visual check e Check camshaft wear and spring cups visual check Q Check camshaft supports 9 Check timing chain after checks at 3 hours and
51. HE AUTHORISED TM DEALER DOES NOT REPLACE THE CHECKS AND MAINTENANCE CARRIED OUT BY THE DRIVER axe 32 y 774 AND ON TARILE AND ABLE 250 450 580 29 4 420899 SMX COMPETITION USE 15 SERVICE A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS EVERY 12 OF FUEL Replacement of engine oil cartridge oil filter 2 5 Cleaning of net oil filter and clean sump magnet drain screws 9 2 Check condition and unbent positioning of rubber pipes 2 2 Adjustment of timing chain Check and adjustment of play 5 Check tightness of engine screw fasteners y 5 Check fixing for carburetor to engine and filter case Check idle speed adjustment 5 5 Check conditions and unbent positioning of vent pipes Check for leaks of the cooling system and coolant level 6 9 Check for leaks and fixture of the all oil drain screws 9 Check conditions smoothness and unbent positioning adjustment and lub of command cables 9 2 Replacement of silencer antinoise material Q Check fluid level in the hydraulic clutch command tank 9 6 2 Cleaning of filter case and air filter Check conditions and unbent positioning of cables 5 Check head light orientation END Check functioning of the electric system head light high beam stop indicators lights horn END 9 e safety button switch
52. ING 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 alone Successively open the carburetor tank empty screw to empty the remaining fuel Disassemble the spark plug and pour about engine 5 cc of oil into the cylinder through the spark plug hole Activate the kickstart pedal 10 times to distribute the engine oil onto the walls of the cylinder and then remount the spark plug Compress the piston 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 BATTERY chapter Preserve 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 corrosion A WARNING ITIS NOTADVISED TO START UP THE ENGINE FOR BRIEF PERIODS OF TIME THE ENGINE WOULD NOT HEAT UP SUFFICIENTLY AND THEREFORE THE STEAM CREATED DURING THE COMBUSTION PROCESS WOULD CONDENSE CAUSING THE OXIDATION OF THE EXHAUST VALVES START UP AFTER SEASONAL PAUSE Mount t
53. JUMP FORWARDS WARNING ACTIVATE THE STARTER FOR A MAX OF 5 SECONDS AT A TIME WAIT ANOTHER 5 SECONDS BEFORE TRYING AGAIN DONOTALLOW THE ENGINE REVS TO INCREASE TOO MUCH WHILE THE ENGINE IS COLD THIS COULD DAMAGE THE ENGINEE BECAUSE THE PISTON HEATS UPAND CONSEQUENTLY IT DILATES QUICKER THAN THE CYCLINDER WHICH IS WATER COOLED aL WAYS WARM THE ENGINE AT A STANDSTILL OR MOVE AT LOW REVS ENGINE IGNITION WHEN WARM 1 Open the fuel tap 1 2 Remove the motorcycle from the stand 3 Insert the neutral gear 4 WITHOUT opening the throttle press the starter pedal hard AS FAS AS POSSIBLE or activate the electric starter WARNING ACTIVATE THE STARTER MOTOR OF 5 SECONDS ATATIME WAIT ANOTHER 5 SECONDS BEFORE TRYING AGAIN 25 INSTRUCTIONS USE IF THE ENGINE IS FLOODED In the event of a fall a certain amount of fuel can flow out of the caburetor and enter the head flooding the engine To start the engine pull the knob or turn the hot start lever 1 WITHOUT opening the throttle push the kickstart pedal hard AS FAR AS POSSIBLE or activate the electric starter On models with a manual decompressor to eliminate the excess fuel from the engine pull the manual decompressor lever and activate the kickstart pedal 5 10 times or the electric starter button respectively twice for 5 seconds Start the engine as previously described If necessary remove th
54. OF THE FRONT BRAKE LEVER The free play to the front brake lever can be varied using the adjustment screw 1 In this way the position of the pressure point the resistance that can be perceived at the front brake lever when the pads are pressed against the brake discs can be adjusted for any hand size A WARNING THE FREE PLAY OF THE FRONT BRAKE LEVER MUST BE AT LEAST 3 MM ONLY THEN THE LEVER MUST START TO MOVE THE PISTON IN THE FRONT BRAKE PUMP PERCEIVABLE FROM THE GREATER RESISTANCE OF THE LEVER IF THIS EMPTY STROKE IS MISSING PRESSURE IS FORMED IN THE BRAKING SYSTEMAND THE CONSEQUENCE CAN BE LACK OF FUNCTIONING OF THE FRONT WHEEL BRAKE DUE TO OVERHEATING OR BLOCKING OF THE WHEEL ITSELF axe 46 Ei FRAME AND ENGINE LLANO CONTROL OF FRONT BRAKE FLUID LEVEL The Reservoir is part of the front brake pump positioned on the handlebar and has an inspection window with the tank in the horizontal position the fluid level must never fall below the centreline on the inspection window The SMR SMM SMX models are an exceptiom as they have an independent transparent plastic tank Also in this case the fluid level must never fall below half of the tank 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 Remov
55. OO TIGHT OR HAVE PLAY BEHAVIOUR ONTHE ROAD WILL BE IRREGULAR AND YOU COULD LOOSE CONTROL OF THE MOTORCYCLE WARNING MAKING LONG JOURNEYS WITH INCORRECT STEERING BEARINGADJUSTMENT RISKS RUINING THE BEARINGS AND THEIR SEAT IN THE FRAME The steering bearings should be re greased at least once a year ENGLISH 38 RAME AND ENGINS MATANE 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 To do this 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 during periodical maintenance WARNING VERY HIGH PRESSURE INSIDE THE FORK CAN CAUSE THE FORK TO LEAK IF YOUR FORK PRESENTSALEAKS 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 with time dirt may also reach behind the dust scrapers If this is not removed the oil seal units which are found behind may leak Use a screwdriver to lever the dust scraper from the external pipes and push it downwards Clean the rdust scraper the external pipes and the rods carefully Oil them well with silicone spray or with engine oil Finally push the dust scraper manually into
56. OUT INTO THE CARBURETORAND PENETRATE THE ENGINE FLOODING IT NEVER PARK WITH THE ENGINE RUNNING OR PARK THE MOTORCYLE IN PLACES WHERE THEREIS THE RISK OF FIRE DUE TO DRY GRASS OR OTHER EASILY INFLAMMABLE MATERIALS axe 28 INSTRUCTIONS FOI UST 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 that the parking position is stable For greater safety insert the 1st gear WARNING THE SIDE STAND IS DESIGNED ONLY FOR THE WEIGHT OF THE MOTORCYCLE NEVER SIT ON THE MOTORCYCLE WHEN ITIS RESTING ON THE SIDE STAND OTHERWISE THE STAND MAY BE DAMAGED AND THE MOTORCYCLE CAN FALL PETROL TM engines require super unleaded fuel with at least 95 RON WARNING FILL THE TANK WITH UNLEADED FUEL WITH A MINIMUM OCTANE NUMBER 95 NEVER USE PETROLWITHAN OCTANE NUMBER LOWER THAN 95 BECAUSE THIS WOULD DAMAGE THE ENGINE PETROL IS HIGHLY INFLAMMABLE AND TOXIC HANDLE PETROL WITH GREAT CARE DO NOT FILL UP WITH PETROL NEAR TO FLAMES OR CIGARETTES ALWAYS SWITCH THE ENGINE OFF WHEN FILLING UP WITH PETROL NEVER POUR PETROL ONTO THE ENGINE OR ONTO THE EXHAUST PIPE IF ANY PETROLIS ACCIDENTLY POURED ONO THESE PARTS ELIMI NATE IT IMMEDIATELY USING A CLOTH IF PETROL IS SWALLOWED OR SPRAYED INTO THE EYES SEEK MEDICAL HELP IMMEDIATELY Fuel expands when heated Therefore never fill the tank completely with hi
57. PETITIONS EVEN IF THE ENDURO MODELS ARE TYPE APPROVED PAY ATTENTION WHEN USING ON THE ROAD MOST OF ALLAVOID SUSTAINED ACCELERATION CONSTANT THROTTLE ON LONG ROADS ROLL THE THROTTLE ON AND BACK SLIGHTLY axe 22 FOR MOTORCYCLE ALWAYS WEAR SUITABLE CLOTHING WHEN USING THE MOTORCYCLE ASTUTE MOTORCYCLISTS THAT DRIVE A TM ALWAYS WEAR THE TYPE APPROVED HELMET BOOTS GLOVES AND A JACKET WHETHER IT BE A LONG OR SHORT JOURNEY THE PROTECTIVE CLOTHING SHOULD BE BRIGHT SO THAT THE MOTORCYCLIST CAN BE EASILY SEEN BY OTHER ROAD USERS ALWAYS SWITCH THE HEADLIGHT ON DURING THE JOURNEY SO THAT OTHER ROAD USERS CAN SEE YOUIN 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 NEGA TIVEINFLUENCE OF THE BEHAVIOUR OF THE MOTORCYCLE DUE TO DIFFERENT WEIGHT DISTRIBUTION THE FRONT AND REAR TYRESMUST 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 SPOKES THE SPOKES MAY BREAK CAUSING UNSTABLE DRIVING CONDITIONS SEE CONTROL SPOKE TENSION THE RACING MODELS HAVE BEEN DESIGNED AND PREPARED ONLY FOR ONE PERSON IT IS PROHIBITED TO TAKE ON PASSENGERS FOLLOW THE HIGHWAY CODE DRIVE CAREFULLY SO AS TO RECOGNISE DANGERS AS SOON AS POSSIBLE ADAPT SPEED TO THE CONDITIONS OF THE ROAD AN
58. R ADJ USTMENT IN EXTENSION The hydraulic brake system in extension determines the behaviour of the shock absorber in the return or rebound stroke The degree of hydraulic braking in extension can be adjusted on the basis of pilot preferences and or hardness of the spring installed SACHS DAMPER STANDARD The adjustment screw 3 is situated on the attachment ot the fork of the shock absorber mechanical linkage Use a screwdriver By turning in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 40 notches are available OHLINS DAMPER OPTIONAL The adjustment knob 4 is situated low at the end of the damper rod Act manually By turning in a clockwise direction looking from the bottom upwards braking increases in an anticlockwise direction it decreases A total of 40 notches 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 THE DAMPER GAS TANK IS FILLED WITH PRESSURISED NITROGEN NEVER TRY TO DISASSEMBLE THE DAMPER OR CARRY OUT MAINTENANCE OPERATIONS WITHOUT THE HELP OF TECHNICIANS OTHERWISEOBJECTS COULD BE DAMAGED AND PERSONS INJURED axe 18 OPERATING CONTROLS y 774 STEERING LOCK This lo
59. R COUNTRY TOGURANTEE 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 OVERHEATING OF THE TYRE FRONT REAR CONTROL ADJ USTMENT OF MAGNET SENSOR DISTANCE A The distance between magnet 2 and sensor 1 must be 2 4mm On the contrary the tachometer may functon irregularly In the END versions the magnet is positioned in the rear wheel while in the SMR SMM versions in the front one BATTERY END MX SMR SMM SMX ALL MODELS WITH E S The saddle must be removed to access the battery The battery does not require maintenance It is not necessary to control the level of the electrolyte or top up with water Just the battery poles must be cleaned and if necessary grease them slightly using grease that does not contain acids Battery disassembly First remove the negative pole and then the positive pole from the battery Disconnect the elastics 1 Remove the battery When mounting the battery insert it with the poles in front see figure first connect the positive pole and then the negative pole to the battery 53 5 LLL IF FOR SOME REASON THE ELECTROLYTE SULPHURIC ACID SHOULD ESCAPE FROM THE BATTERY BE VERY CAREFUL THE ELECTROLYTE CAN CAUSE SERIOUS BURNS
60. THERE IS GREATER WEAR OF THE PADS AND THE BRAKE DISCS THEMSELVES FOLLOWING USE OF THE BRAKE THE DISC THE PADS THE CALIPER AND THE BRAKE FLUID HEAT UP THE HOTTER THESE PARTS THE LESS THE BRAKING EFFECT IN THE CASE OF OVERHEATING THE ENTIRE BRAKING SYSTEM MAY NOT WORK IFTHEFORCE ON THEFRONT BRAKE LEVER OR BRAKE PEDAL IS MINIMAL 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 put the gear 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 block the motorcycle using the steering lock MOTORCYCLES PRODUCE A LOT OF HEAT DURING FUNTIONING THE ENGINE RADIATORS EXHAUST PLANT 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 NEVER SWITCH THE ENGINE OFF USING THE DECOMPRESSOR LEVER BUT USE THE ENGINE STOP SWITCH OR THE EMERGENCY SHUTDOWN BUTTON FOR THIS SCOPE THE FUEL TAP MUST ALWAYS BE CLOSED WHEN THE MOTORCYCLE IS PARKED IF IT IS NOT CLOSED THE FUEL COULD RUN
61. TRIDGE WITHANEW ONE OF THE SAME WEIGHT OR BOUGHTATATM AUTHORISED DEALER 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 even reach the engine causing derious damage For this reason maintenance of the filter should be carried out regularly Remove the to access the filter 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 DONOTCLEAN THE SPONGE FILTER WITH PETROL OR KEROSENE WHICH CAN CORRODE IT FOR CORRECT MAINTENANCE OF THE SPONGE 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 control that the bunch 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 CONTROL OF HAND DECOMPRESSOR ADJUSTMENT A ALL 530 AND 660 CC MODELS Take the e
62. USER AND MAINTENANCE MANUAL TM 4 STROKE 2006 TM RACING USES and ADVICES 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 EASIERAND SAFER ITIS 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 FAILURE 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 ENGINE 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 5 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 fir
63. ace it if necessary Insert a new filter cartridge making sure that the open side is towards the outside of the engine The filter must insert into the sump as far as possible in its seat axe 64 MATIN TIEN ANCL y 774 FRANE AND ENGINI LAARO Remount the cover paying attention not to ruin the O Ring and insert the small pipe projecting from the cover correctly into the hole in the filter cartridge Greasing the O Ring with a small amount of grease helps to keep it in its seat during mounting Tighten the screws to 10Nm REMEMBER THAT THE FILTER CARTRIDGE CANNOT BE CLEANED IT MUST BE REPLACED AT THE ENVISIONED INTERVALS Prepare a measuring beaker with 1 4 Litres of completely synthetic engine oil of the established type see engine data Unscrew the oil load cap and fill with about 0 8 Litres Close the cap temporarily start up the engine and allow it to run for about 5 seconds DO NOT ALLOW IT TO RUN FOR LONGER TO PREVENT DAMAGE Re open the cap and finish filling with the oil remaining in the measuring beaker A total of 1 4 Litres of oil has been introduced Tighten the cap to 20Nm Start up the engine and check tightness of the filling and emptying caps the net filter cap and the filter cartridge cover Finally check the engine oil level and correct it if necessary 65 WA LINNAN CI ENONSH WROUBLESHOOTING If you have the envisioned maintenance operations carried out on your motorcycle you will hav
64. al is mounted on the engine on the left The position of the gears is indicated in the illustration The neutal position is found between the first and second gears KICKSTART PEDAL The kickstart pedal is mounted 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 Press the side stand to the floor using the foot and rest the motorcycle on it Pay attention that the ground is solid and the position stable 15 5 FIXING FOR OFF THE ROAD OURNEYS If you drive the motorcycle off the road the closed central stand can be additionally fixed using a rubber band 2 IGNITION SWITCH In the SMR and SMM models an key ignition is added on the left side of the dashboard By turning the key in a clockwise direction the electric circuit is closed and after the startter button has been pushed so as to close the contact with the battery it is possible to activate the electric starter To switch the engine off remember to position the red starter button to interrupt the battery connection circuit and turn the key in an anticlockwise direction FORK ADJ USTMENT IN COMPRESSION The hydraulic brake system determines
65. assemble insert the low shim sprocket into the hub position the chain tensioners insert the wheel into the rear fork and supporting the wheel position the caliper with its support and mount the chain onto the crown wheel Insert the pin from the crown wheel side up to half the wheel to permit positioning of the high shim brake side Finish inserting the pin insert the chain tensioner slide screw the nut and tighten it to 80 Nm Before tightening the flanged nut push the rear wheel forward until the chain tensioners are in contatct with the heads of the adjusting screws IF YOU DO NOT HAVE A DYNOMOMETRIC WRENCH WHEN MOUNTING HAVE THE COUPLING TORQUE CONTROLLED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP A LOOSE WHEEL PIN 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 COUPLING TORQUE A LOOSE WHEEL PIN CAN LEAD TO UNSTABLE DRIVING 51 5 1822 AND ENGINE MAINTENANGI LALO DISASSEMBLY AND ASSREMBLY OF THE 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 Pa
66. at least 95 NO Distribution two shaft 4 valve in head activated by silent chain A S camshafts N2 N3 F1 F1 N2 N3 N1 N2 Suction valve diameter 36mm 36 mm Ti 36mm 40mm Discharge valve diameter 31mm 31 mmTi 31mm 33mm Cold suction valve play mm 0 20 mm 0 30 mm 0 20 mm 0 20 Discharge valve play when cold mm 0 25 mm 0 35 mm 0 25 mm 0 25 Engine shaft supports 2 ball bearings Link rod bearing silver plated roller cage Small end cover coppering Piston forged in light alloy Segments 2 segments 1 oil scraper Lubrication 2 oil pumps 1 delivery 1 recovery Engine oil completely synthetic brand name oil SAE 10W 50 API SG SH Quantitative of oil 1 4 litres Primary transmission straight tooth gears 21 53 22 53 Friction with multiple discs in oil bath Gears with front engagement 5 gears 5 gears 5 gears 5 gears Gear ratio 1514 28 15 15 27 15 14 28 1515 27 2 917 25 274 17 25 21017 25 2091 5225 39 19 23 3 19 23 39 19 23 39 19 23 47 21 21 4 21 21 4 21 21 4 21 21 5 24 19 5 23 20 5 24 19 5th 23 20 Ignition Kokusan digital with variable advance Generator 12V 180W 12 V 180W 12V 180W 12V 180W Spark plug NGK CR 8E Electrodes distance 0 8 mm Cooling liquid cooled 40 antifreeze 60 water up to 25 C circulation forced with pump Quantitative liquid 1 3 litres 1 litre 1 3 litres Start up E S K S K S E S K S K S E S opt E S opt LEGEND E S Electric start K S Kickstart axe 70 uni 710J41 9600
67. ck is found on the left side of the metal steering tube This lock stops rotation of the handlebar preventing the motorcycle being driven To block 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 19 5 227 ADVISE AND y aS ANE 5 GOMMUSSIONING TE WOLTORGYGUS ADVICE AND GENERAL KRECCOWMANRDATIONS COMMISSIONING The INDICATIONS FOR FIRST START UP Ensure that the PRE DELIVERY OPERATIONS of your motorcycle 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 fromt 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 motorcycle 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 press the brake pedal if you do not wish to brake If the brake pedal is not released the brake pads rub continually and the brake overhea
68. d 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 Engine flooded controls chapter Clean and dry the spark plug or replace it Spark plug blackened or wet Adjust the distance between the elctrodes to 0 8 mm Distance between the electrodes incorrect Slide off the spark plug hood unscrew the spark plug put the THE ENGINE DOES NOT hood back onto the spark plug and gripping the hood keep the START UP threaded part of the spark plug in contact with the head of the MODELS WITH engine KICKSTARTER PEDAL Turn the engine with the electric starter or pedal a spark should appear between the elctrodes and the spark plug Spark plug cap or spark plug damaged ifthe spark plug does not produce a spark it must be replaced if there is still no spark remove the spark plug hood from the A T cable coming from the coil hold it at a distance of about 5 mm from the engine stop button and start up if there is a spark replace the spark plug hood if there is still no spark have the ignition plant controlled Remove the saddle and fuel tank disconnect the emergency Stop button cable or the engine stop button cable and check the spark If there is a spark look for the fault along the emergency Engine stop button cable damaged engine stop shutdown button cable or the bottone di massa cable button or emergency st
69. e marks 4 on the right and left chain tensioner must be in the same position with respect to the reference markings 5 Tighten the adjustment screw counter nuts Before blocking the wheel pin nut check that the chain tensioners 6 are resting at the heads of the adjustment screws and that the rear wheel is aligned with the front wheel Tighten the wheel pin nut to 80 Nm ATTENTION IF YOU DO NOT HAVEADYNAMOMETRIC WRENCH FOR MOUNTING HAVE THE COUPLING TORQUE CONTROLLED ATAA SPECIALISED TM WORKSHOP ALOOSE WHEEL PIN CAN CAUSE UNSTABLE DRIVING OF THE MOTORCYCLE 43 Lai FRAME AND ENGINE LARO CORRECTION OF CHAIN TENSION SMM Loosen the two blocking screws 7 of the rear eccentric hood in a way that the hub itself can tn its axis Using the relevant TM tool code F50806 8 turn the hub until correct chain tension is reached Tighten the two blocking screws to 31 Nm Given that the movement system is eccentric alignment of the rear wheel is unvaried and no 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 rods from the upper plate 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 abo
70. e spark plug and dry it WARNING The carburetor has an accelerator pump Every time that you open the throttle with the engine running or switched off a quantity of fuel is sprayed into the inlet tract If this operation is carried out with the engine switched off it causes flooding of the engine with the consequent starting difficulties and a dangerous distribution of fuel NEVER TURN THE THROTTLE WHEN THE ENGINE IS NOT RUNNING IF NOT STRICTLY NECESSARY IN ANY CASE ONLY DO IT ONCE AND NEVER REPEATEDLY DEPARTURE Pull the clutch lever insert the first gear release the clutch lever slowly accelerating at the same time BEFORE DEPARTING ALWAYS CHECK THAT THE SIDE STAND HAS BEEN LIFTED IF THE STAND SLIDES ALONG THE GROUND YOU COULD LOOSE CONTROL OF THE MOTORCYCLE CHANGING 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 at which
71. e the screws 2 and remove the lid 3 and the membrane 4 Place the front brake pump in a horizontal position and top up the brake fluid to 5 mm below the upper edge of the container Re mount membrane lid and screws Wash any spilled brake fluid away with water Where the tank is separate unscrew the cap and remove the membra ne Repeat the top up operation as mentioned above Wash any 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 ASSISTANCE WARNING DO NOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES PAINT ONLY USE CLEAN BRAKE FLUID OUT OF A HERMETICALLY SEALED CONTAINER CONTROL FRONT BRAKE PADS The brake pads are controlled from below The thickness of the pad friction material must not be less thani mm THE THICKNESS OF THE BRAKE PAD THICKNESS MATERIAL MUST NOT BE LESS THAN 1 MM OTHERWISE THERE COULD BE A FAULT IN THE BRAKES IN THE INTEREST OF YOUR SAFETY HAVE THE THE PADS REPLACED IN TIME 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 DETERIORATION OF THE BRAKE DISC 47 5 627 RAME AN
72. e upper part of the chain in an upward direction with a force of 10 15 kilogrammes see figure At this point measure the distance of 18 rollers on the lower part of the chain If the distance exceeds 272 mm it is advised to replace the chain The chains are not always worn in a uniform manner 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 pinions A WARNING WHEN THE CHAIN SPROCKETS ARE REPLACED IT ISADVISED TO MOUNT NEW SELF LOCKING NUTS AND TO TIGHTEN WITH CROSS SEQUENCE COUPLING TORQUE AT NUTS 35 NM BASIC INDICATIONS FOR TM DISC BRAKES CALIPERS The seat of the calipers of this series of models is floating i e they are not joined to their support The lateral compensation always allows the pads to rest optimally on the discs The brake caliper support screws are held using Loctite 243 and tightened with 25 Nm The front calipers of the SMR SMM SMX models are an exception as they are the fixed type PADS The minimum thickness of the friction material cannot descend 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 surface contact area of the pads 1 In the weakest point A the brake discs may present max wear of 0 4 mm
73. e 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 SOLUTION Incorrect command Position the emergency shutdown button and where present THESTARTERCANNOT 02000 TURN THE ENGINE urned fuse emove the left side piece and replace the use in the starter relay Key not inserted or not turned Insert the key and turn it in a clockwise direction Battery flat Charge the battery and identify the cause of discharging contact a specialised workshop Low external temperature Start the engine using the kickstarter pedal ___ THE STARTER TURNS THE Lack of fuel in the engine Open the fuel tap fill up with fuel ENGINE BUT THE ENGINE 5 i DOES NOT START observe the indications for start up see Instructions for use MODELS WITH ELECTRIC chapter STARTER O M The motorcycle hasn t been used for a while The volatile fuel components evaporate easily If the motorcycle therefore the old fuel has remained in thecarburetor has not been used for more than 1 week the old fuel should tank be emptied from the carburetor tank When the tank has been filled with fresh fuel the engine will start immediately Disconnect the fuel pipe from the carburetor place it in a Fuel supply interrupted container an
74. eadlight 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 fixed well ENGLISH 24 INSTRUCTIONS FOI LLANO ENGINE IGNITION WHEN COLD 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 found on the left side of the motorcycle 5 WITHOUT opening the throttle press the kickstarter hard AS FAR AS POSSIBLE or activate the electric starter 6 Start to warm the engine by accellerating slightly for about 30 secs Disconnect the choke 2 which is found on the left side of the motorcycle ALWAYS WEAR STRONG MOTORCYCLE BOOTS WHEN STARTING UP THE MOTORCYCLE TO PREVENT INJURY YOU COULD SLIP OFF OF THE PEDAL OR THE ENGINE COULD REBOUND AND MAKE YOU KNOCK YOUR FOOT VIOLENTLY ALWAYS PRESS THE KICKSTARTER DOWN HARD WITHOUT ACCELLERATING KICKSTARTING WITH LITTLE FORCE OR WITH THE THROTTLE KNOB OPEN INCREASES THE RISK OF ENGINE KICK BACK DO NOT START THE ENGINE IN A CLOSED SPACE AND NEVER LEAVE IT RUNNING IN CLOSED SPACES THE EXHAUST FUMES ARE POISONOUS AND MAY LEAD RISK OF UNCONSCIOUSNESS AND DEATH WHEN THE ENGINE IS RUNNING ASWAYS ENSURE THEIR IS SUFFICIENT VENTILATION ALWAYS CHECK THAT THE GEAR IS IN NEUTRAL BEFORE ACTIVATING THE STARTER BUTTON IF A GEAR IS INSERTED ON IGNITION THE MOTORCYCLE WILL
75. ear Check valve cotters and valve rods 5 Check valve guide wear Check valve 5 Check automatic decompressor functionality 2 9 2 2 Check head surfaces and cylinder Check engine cranshaft for trueness Replace conrod axle and roller cage 2 Check small end coppering 2 Check oil pump and lubrication circuit 6 Replacement of main bearings 5 s Check complete change including the valve gear and forks Check clutch plate wear Check length of clutch springs ____ WARNING IF AT THE CHECK IT IS DETECTED THAT THE RELATIVE TOLERANCES HAVE BEEN EXCEEDED THE INTERESTED COMPONENTS MUST BE REPLACED THE MOUNTING OF AN HOUR COUNTER INSTRUMENT IS ADVISED THE ABOVE MENTIONED OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP ENGLISH 36 PIAS AND SNGINE MAINS MASS LE FRANE AND ENGINE MATINTENANG LOMA A DANGER ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH A REQUIRE TECHNICAL MASTERY FOR THIS REASON IT IS IN THE 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 A WARNING IF POSSIBLE DO NOT USE HIGH PRESSURE JETS WHEN WASHING THE MOTORCYCLE BECAUSE THE WATER COULD PENETRATE INTO THE BEARINGS THE CARBURETORAND ELECTRIC CONNECTORS ETC WHEN TRANSPORTING
76. econd number flash and press the left hand yellow button in sequence to visualise the desired value Repeat the operation to change the value of the following number and so on until the exact development of the wheel expressed in mm tyre diam in mm x3 14 is visualised Finally with the 4th number still flashing to change the unit of measurement from Kmh to Mph press the right hand button blue and will start to flash now press the left hand button yellow to pass to Mph End programming by pressing the grey button on the rear of the instrument for 1 sec 11 OPERAITING ONTROLS axe LAXE PROGRAMMING THE CLOCK END SMR SMM Remove the connector positioned on the back of the instrument Select the CLK function on the display by pressing the right hand button blue Press the grey button on the rear of the instrument for 5 secs and CLK Clock will start to flash on the display together with the hours Press the left hand button yellow to set the hour on 24 hours Press the right hand button blue again to make the tens of minutes flash press the left hand button yellow to set the tens of minutes Repeat to set the minutes End by pressing the grey button on the rear of the instrument for 1 sec SETTING THE DISTANCE TRAVELLED END SMR SMM only after battery replacement The value of the distance travelled must only be re inserted if the battery has been replaced
77. ed out fuse must be replaced exclusively with an equivalent one If the new fuse should also burn out once mounted contact a specialised TM workshop A WARNING NEVER MOUNT FUSES WITH GREATER POWER OR TRY TO ADJUST THE SAME FUSE UNAPPROPRIATE TREATMENTS COULD CAUSE FAULTS TO THE ENTIRE ELECTRIC PLANT REPLACEMENT OF HEADLIGHT POSITION LIGHT BULB WITH STANDARD HEADLIGHTD END SMR SMM Release both eleastics 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 holder 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 elastics 55 P 2427 AND ENGINE MATNTENZANGI LAXE REPLACEMENT OF HEADLIGHT POSITION LIGHT BUL WITH CYCLOPS OPTIONAL HEADLIGHT END SMR SMM Disconnect both of the elastics and move the light holder mask forward HEADLIGHT BULB Disconnect the terminal remove the cover 13 and the seal 14 Unscrew the screws 15 and remove the retainer 16 Loosen the Allen screw 17 and carefully extract the bulb 18 Replace with an equivalent one tighten the Allen screw again remount the retainer in the co
78. gh environmental temperatures 29 INSTRUCTIONS FOR USE 227 MAINE NANG AND LE MALNTENANGCE ANID LLLP MAINT ENANG S AND EUSRIFICNTION TASES 229020539 115 501 528 ROND MOSS US 1ST SERVICE EVERY 30 HOURS A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS AFTER 3 HOURS OR OR SOR EYEE Replacement of engine oil cartridge oil filter 2 2 Cleaning of net oil filter and clean sump magnet drain screws 5 5 Check conditions and and unbent positioning of rubber pipes 2 s 2 Adjustment of the timing chain 5 5 Check tightness of engine screw fasteners 9 4 55 Check fixing for carburetor to engine and filter case gt Check idle speed adjustment o Check conditions and unbent positioning of vent pipes 5 gt Check for leaks of the cooling system and coolant level 5 Check for leaks and tightness of the of all oil drain screws 5 Check conditions smoothness and unbent positioning of all pipes and cables a adjustment and lubrication of throttle and decompressor cables Q Check fluid level in the hydraulic brake reservoirs and clutch Q 2 Clean filter case and air filter 5 T3 Check conditions and unbent positioning of cables 9 Check headlamp orientation Check electric system function head light high beam stop indicators 2 check lights horn safety button switch Check brake fluid level pad
79. h arrives through the system for the idle speed up to the engine By turning in a clockwise direction the quantity of fuel decreases weak mix by turning in an anticlockwise direction the quantity of fuel increases strong mix TO SET IDLE SPEED FUNCTIONING CORRECTLY PROCEED AS FOLLOWS 1 Screw the mix adjustment screw 2 until it stops without force then unscrew it untill you obtain the basic adjustment envisioned by TM see Engine Technical Data 2 Warm up the engine 3 Use the adjustment knob 1 to adjust the number of revs of the normal idle speed 1600 1800 min 4 Slowly turn the mix adjustment screw 2 in a clockwise direction until the number of revs of the idle speed starts to fall Keep this position in mind and now turn the mix adjustment screw slowly in an anticlockwise direction until the number of revs of the idle speed starts to fall again Set the point between these two positions in which the number of idle speed revs is highest If there is a notable increase in the number of revs reduce the number of revs to the normal level using the adjustment knob 1 and repeat the procedu re from point 4 Anyone using the motorcycle for sport will set a weaker mix of about 1 4 of a turn in a clockwise direction with respect to the ideal value because the engine will become hotter NOTE If the described methods are followed and satisfying results are not obtained the cause could be an idle speed jet with unsuitable
80. he 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 putting the motorcycle away 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 brake less work in the workshops In this way it is possible to avoid long waits in the workshop at the start of the spring season ENGLISH 68 TECHNICAL DATA ENGINE TECHNICAL ENGINE 250 EN N ZS EM A EASE 72006 ENGINE END SMMSMR END MX SMX SMM SMR Type 4 stroke single cylinder two shaft liquid cooled Oylinder capacity 250 cm 449 cm Oylinder bore x run 77x53 6 mm 95x63 4 mm Compression 13 5 1 ESEA 11 8 1 11 5 1 Fuel lead free fuel with at least 95 NO Distribution two shaft 4 valve in head activated by silent chain A S camshafts C2 N2 N2 N3 F1 F1 1 4 N2 NS8 Suction valve diameter 30mm 30mmTi 30mm 36m 36 36mm Discharge valve diameter 24 5mm 25 245mm 31mm 31 mmTi 31 Cold suction valve play mm 0 20 mm 0 20 mm 0 30 mm 0 25 mm 0 20 Empty valve play when cold mm 0 25 0 25 mm 0 35 mm 0 30 0 25 Engine shaft supports 2 ball bearings Link rod bearing silver plated roller cage Small end cover coppering Piston forged in light alloy Segme
81. he new battery inserting it in a way that the positive pole is visible from the outside and close the cover Before extracting the battery make note of the WS wheel development and DST total mileage values These values will be re programmed into the instrument after battery replacement FUNCTION SELECTION AND RESET END SMR SMM While the electronic tachometer always displays the speed of the vehicle expressed in Kmh or Mph on the basis of the selection made it also allows to visualise the following functions on selection TRP Daily mileage AVS Average speed after 10 hours or 1000Km press RESET STP Chronometre start and stop autom max time 10 hours MAX Max speed reached from the last RESET DST mileage up to 99999Km CLK Clock To reset the TRP AVS STP and MAX functions press the right button blue Select the function and press the left button for 5 sec yellow The values displayed are zeroed PROGRAMMING THE ELECTRONIC TACHOMETER ENDSMR SMM only after battery replacement Remove the connector positioned on the back of the instrument Press the grey button on the rear of the instrument for 5 seconds Four numbers appear on the display of which the first is flashing WS Wheel Size also flashing appears in the top right of the display Now press in sequence the left hand button yellow to change the value of the first flashing number Press the right hand button blue to make the s
82. his mechanism works on the bearings which must be cleaned and greased at the envisioned intervals to maintain the functioning of the suspension efficient When cleaning the motorcycle with high pressure cleaning devices do not aim the jet completely onto the suspension mechanical linkage ENGLISH 42 1227 FRANE AND ENGINE MAINTENANCE CONTROL 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 IS TOO TAUGHT THE FINAL TANSMISSION COMPONENTS CHAIN GEAR BEARINGS AND REAR WHEEL ARE GREATLY STRESSED AS WELL AS EARLY WEAR IN EXTREME CASES THE CHAIN OR GEAR SCONDARY SHAFT MAY BREAK IF HOWEVER CHAIN TENSION IS INSUFFICIENT IT CAN EXIT FROM THE SPROCKET WHEELAND LOCK THE REAR WHEEL OR DAMAGE THE ENGINE IIN BOTH CASESITIS EASY TO LOOSE CONTROL OF THE MOTORCYCLE CORRECTION OF CHAIN TENSION ALL MODELS EXCEPT SMM Loosen the wheel pin nut 1 loosen the counter nuts 2 and turn the adjustment screws 3 to the left and to the right by the same amount To increase chain tension unscrew the adjustment screws To decrease chain tension screw the adjustment screws Reach correct chain tension For correct alignment of the rear wheel th
83. ight bulb position light stop light number plate light END SMR SMM 56 Replacement of indicator bulb resi Control coolant level inerenti secun p Unloading filling and bleeding of cooling system 58 Replacement of exhaust silencer filling 58 Cleaning the air fill r decine 59 Control of hand decompressor 59 Adjustment of throttle cable 60 Adjustment of clutch lever basic 60 Control hydraulic clutch oil 60 Bleeding of hydraulic clutch Carburetor Adjustment of idle 61 Basic indications regarding wear of the carburetor 61 Control fuel level float 62 Emptying of carburetor tank 62 Oil ues 62 63 Engine oil 63 Change engine Oil aie iine tener td erhoben i 63 TROUBLESHOOTING eere eere nennen nn nnnnnnnn nnn nnn 66 edil ce 68 PRECAUTIONS FOR WINTER USE 68 PRESERVATION 22 222
84. ing damaged in the silencer Insufficient valve play Adjust the valve play There is a loss of compression because the hand Adjust the hand decompressor flexible cable command decompressor hasn t got enough play it remains Have the ignition plant checked taught The ignition timing is not correct THE ENGINE MISSES Fuel missing Clean and control the fuel circuit and the carburetor Dirt in the air boots Check the rubber sheaths between the filter case and the THE CARBURETOR carburetor and betweenthe carburetor and head and tightening SSS SSS SSS SSS SSS SSS SS SSS SS SSS Se There is not enough fluid in the cooling system Fill with coolant see Frame and Engine Maintenance chapter check the leaktightness of the cooling system Insufficient ventilation Continue at sustained speed it is possible to mount a fan optio nal THE ENGINE OVERHEATS in the cooling system Bleed the cooling system EXCESSIVELY The radiator plates are very dirty Clean the radiator plates with jets of water Formation of a foam in the cooling system Replace the coolant use good antifreeze Shorten the radiator pipe or replace it The radiator pipe is bent EXCESSIVE OIL The vent pipe is bent Position the vent pipe or replace it CONSUMPTION Engine oil level too high Check and correct the engine oill evel if necessary Engine oil too thin viscosity Use more viscous oil see Engine oil chapter E
85. let well and tighten it in a clockwise direction 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 found on the right hand side of the tank base OFF 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 Lt reserve 1 Lt 13 THROTTLE COMMAND COLD STARTER This command is found on the left side of the motorcycle For MIKUNI carburetors 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 obtained This is necessary for ignition when the engine is cold To disconnect the command push the choke knob inwards to its original position For KEIHIN carburetors Extract the knob and turn it in a clockwise direction to block it To disconnect it turn in an anticlockwise direction BY PASS COMMAND HOT START models with electric starter This command is found on the right side of the motor cycle By pulling the by pass
86. mper in compression and not the speed of the motorcycle SACHS DAMPER STANDARD Low speeds The adjustment screw 6 is found on the top of the damper gas tank Use a screwdriver By turning in a clockwise direction braking increase in an anticlockwise direction it decreases A total of 24 notches are available High speeds The adjuster is a knob 7 and is concentric to the low speed adjustment screw Act manually By turning in a clockwise direction braking increase in an anticlockwise direction it decreases A total of 20 notches are available 17 OPERATING CONTROLS LAXE OHLINS DAMPER OPTIONAL Low speeds The adjustment screw 1 is found on the top of the damper gas tank Use a screwdriver By turning in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 25 notches 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 in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 4 notches 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 TURNS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NOTCHE TURNSS ARE INDICATED FROM THE TOTALLY CLOSED POSITION SHOCK ABSORBE
87. nduces forced circulation of the coolant liquid There is no thermostat in the plant therefore when the engine is cold it is 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 functioning temperatu re Cooling takes place thanks to the passage of air through the gills of the radiator the lower the speed the less the cooling effect Dirty radiator gills 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 of120 C without problems CHECK THE LEVEL OF THE COOLANT LIQUID WHEN THE ENGINE IS COLD IF YOU MUST REMOVE THE RADIATOR CAP WHE THE ENGINE IS HOT COVER IT WITH A CLOTH AND OPEN SLOWLY TO RELEASE THE PRESSURE ATTENTION BURNS HAZARD DO NOT DISCONNECT THE RADIATOR SHEATHS 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 RUNNING 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 ENTERS 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 antifreeze protection limit must however be at
88. ngine shaft to the PMS with valves closed and activate the hand decompressor An free play of about 5mm must be perceived on the end of the lever The end of the empty stroke is recognised by the hardening of the lever that starts to open the right discharge valve Adjust the empty stroke if necessary To adjust push the protective hood backwards loosen the counter nut 1 and loosen or unscrew the adjustment screw 2 Tighten the counter nut and replace the protective hood A WARNING IF THERE IS NO FREE PLAY ON THE DECOMPRESSION LEVER THE ENGINE COULD BE DAMAGED INDICATION The automatic decompressor does not require adjustment 59 5 y 774 RAME AND ENGINE MANTENE USTMENT OF THROTTLE CABLE COMMAND The throttle command should always have a play of 3 5 mm Moreover when the engine is running the number of ticking over revs must not vary when steering as far as possible to the left and to the right To adjust the play remove the saddle and the tank with the conveyors Push the protection hood backwards 3 Loosen the counter nut 4 and unscrew or screw the adjustment device 5 By screwing the empty stroke increases By unscrewing the empty stroke decreases Tighten the counter nut and control the smoothness of the the throttle command handlebar grip Remount the tank and saddle When the engine is not running do not open and close the throttle grip more than 1 2 times every time it is opened it
89. nts 2 segments 1 oil scraper Lubrication 2 oil pumps 1 delivery 1 recovery Engine oil completely synthetic brand name oil SAE 10W 50 API SG SH Quantitative of oil 1 4 litres Primary transmission straight tooth gears18 67 straight tooth gears 20 57 Friction with multiple discs in oil bath Gears with front engagement 5gears 5gears 5gears 5 5 5 gears 5 gears Gearbox ratio 15 14 28 1515 27 1514 28 1 14 28 1 15 27 15 14 28 12 55 41 225225 225 2 17 25 2 917 25 39 19 23 39 19 23 3 19 23 3 19 23 39 19 23 39 19 23 4 21 21 4 21 21 4 21 21 4 21 21 4 21 21 4 21 21 5 24 19 5223 20 5 23 20 5 23 20 5h 24 19 5 23 20 Ignition Kokusan digital CDI with variable advance Generator 12V180W 12V180W 12V180W r 12V 180W Generator with E S optional 12V180W 12V180W Spark plug NGK CR8bE Electrode distance 0 8mm Cooling liquid cooled 40 antifreeze 60 water up to 25 circulation forced with pump Quantitative fluid 1 litre 1 3 litres 1 litre Start up ES4KS KS 54 5 5 5 KS ESAKS only KS opt E S opt solo K S opt E S opt LEGEND E S Electric start K S Kick start 69 5 TECHNICAL DATA ENGINE VACINA ENGINE 530 END 530 MX 530 SMM SMR 660 SMX Type 4 stroke single cylinder two shaft liquid cooled Cylinder capacity 528 cm 657 Cylinder bore x run 98x70 mm 104x77 4 mm Compression 11 9 1 lage 1 e Fuel lead free fuel with
90. om the notched wheel A tight chain wears early and may cause wear and brakage 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 envisioned in the table if necessary Worn tread and unsuitable air pressure worsen driving of the motorcycle and may cause loss of control of the means and serious accidents 5 BRAKES Verify correct functioning Check the level of brake fluid The reservoir on the pumps are dimensioned in a way that in the 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 Control the adjustment and correct function of all flexible cable commands 7 COOLANT Check the level of coolant with the engine cold Top up with the liquid stated in the table if necessary 8 ELECTRICAL PLANT With the engine running check the correct functioning of the front h
91. ompetitions Enduro and are not suitable for motor cross LLANE Page POSITION OF SERIAL 5 2 2 22 2241 7 ivi heed uana o 8 Engine sees 8 OPERATING 6 9 lO Ve M 10 Manual decompressor 10 Front brake lever 10 Control RP ae 10 Electronic tachometer ires iii cage irte zoe 11 Function selection and reset Programming the electronic 11 Programming the clock 1 onion 12 Setting the distance 12 Engine stop switch 0440404040 12 Combination switch END SMR SMM Start command and emergency stop 5 5 13 M 13 13 Throttle command cold starter 14 By Pass command warm
92. op button damaged Remove the saddle the left side piece and the fuel tank clean the connectors and treat them with a contact spray Disassemble and clean the carburetor CDI unit connectors of the pickup or starter coil Replace the spark plug oxidised Water in the carburetor or blocked jets ENGLISH 66 IQR Ja A T TROUBLESHOOTING VAATIVA PROBLEM CAUSE SOLUTION THE ENGINE WILL NOT Idle speed jet blocked the carburetor and clean the jets Idle speed adjustment screws altered Adjust the idle speed screws RUNATIDLE SPEED Spark plug damaged Replace the spark plug Ignition plant faulty Have the ignition plant checked The fuel overflows because the level is adjusted Disassemble the carburetor and check the height of the float THE ENGINE DOESNOT high or the float needle valve is dirty or consumed and the state of the needle valve as described in the Frame REACHFULLWORKING The carburetor jets are loose and Engine Maintenance chapter CONDITIONS The ignition phase is not correct Tighten the jets Have the ignition plant checked Fuel supply partially interrupted or carburetor dirty Clean and control the fuel circuit and the carburetor Float not leakproof Air filter very dirty Replace the float Clean or replace the oil filter contact a specialised workshop WEAKENGINEPOWER Exhaust system not leakproof deformed or Checkthe faulty parts on the empty plant replace the fibreglass fibreglass in the silencer pack
93. ped up With this Scope unscrew the two screws 5 and remove the lid Top up with DOT4 brake fluid to the top of the inspection hatch Remount the lid and tighten the screws FOR SMR SMM MODELS As soon as the level of the rear brake fluid reaches the Lower line on the container it must be topped up With this scope unscrew the lid 6 with the rubber seal Top up with DOT4 brake fluid up to the Upper line Remount the seal and the lid Tighten well Wash any overflowing brake fluid with water NEVER USE DOT5 BRAKE FLUID IT IS A PURPLE SILICONE OIL BASED BRAKE FLUID IT REQUIRES THE USE OF SPECIAL SEALS AND PIPES KEEP THE BRAKE FLUID OUT OF CHIDREN S REACH THEBRAKEFLUID CANIRRITATE 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 SEEL MEDICAL ATTENTION WARNING DONOTALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS BRAKE FLUID CORRODES PAINT ONLY USE CLEAN BRAKE FLUID FROM A HERMETICALLY SEALED CONTAINER 49 PRANE ENGINE LOCA 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 THINEST 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 GOOD TIME
94. ront brake disc screw fastener M6 cl 10 9 15Nm Rear brake disc screw fastener SMR SMX M6 cl 10 9 15Nm Rear brake disc fixing nut SMM M8 25 Upper fork head screw fasteners M8 20 Nm Lower fork head screw fasteners M8 20 Nm Paioli fork leg screw fasteners M6 12Nm Ohlins fork leg screw fasteners M8 12Nm Rear wheel pinflanged nut M22x1 5 80 Nm Rear fork pin flanged nut M16x1 5 80 Nm Handlebar tightener screw caps M8 20 Nm Handlebar elastic support nut M10 35 Upper damper nut M10x1 25 40Nm Lower damper screws M10x1 25 35Nm Notched crown wheel nuts 35 Rear brake pedal adjustment nut M6 15Nm Engine srew fasteners M10 45Nm Rear wheel nut SMM M50 185 Nm Rear hub blocking screws SMM M12x1 25 31 General frame screw M6 10Nm 25 10 45 General frame nuts M6 15Nm 30 10 50 ENGLISH 74 By Pass command warm Adjustment of clutch lever basic position ADVICE AND GENERAL RECOMMENDATIONS COMMISSIONING THE MOTORCYCLE 21 ALPHABETIG INDEX rire 75 Basic calibration of the chassis on the basis of pilot weight 39 Basic indications for TM disc brakes Basic indications regarding carburetor wear Battery all models with 5 Battery charger Bleeding nhydraulic clutch s
95. rrect position and block with the screw taking care to insert the engine stop support under the head of the screw Remount the cover with the seal and connect the terminal HIGH BEAM BULB Remove the rubber protection 19 unscrew the screw 20 and carefully extract the bulb 21 Replace the bulb with an equivalent one Remount the retainer in the correct position and block with the screw taking care to insert the engine stop support under the head of the screw Reposition the rubber protection POSITION LIGHT BULB Extract the bulb holder 22 from the parabola replace the bulb 23 Remount the bulb holder Repositon the light holder mask and fix it with the elastics WARNING NEVER TOUCH THE GLASS BULB TO PREVENT LEAVING TRACES OF GREASE TOBE SURE OF INSERTING THE ESTABLISHED BULBS CONSULT THE CYCLE PART TECHNICAL DATA TABLE REPLACEMENT OF REAR POSITION LIGHT BULB STOP LIGHT BULB NUMBER PLATE LIGHT BULB END SMR SMM Unscrew the screws 1 and remove the cover 2 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 REPLACEMENT OF INDICATOR 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 ENGLISH 56 y 774 AND ENGINE WAINTENANG LLANO COOLING The water pump 1 housed in the engine i
96. s must be mounted If you are in doubt or have any questions please contact your authorised TM dealer According to our experience the damper level in compression can remain unvaried With a softer spring the level of dampening in extension can be reduced by some clicks with a hrder spring increased by some clicks A WARNING FOR FURTHER NAD 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 41 p 774 AND ENGINE LATE VARIATION OF DAMPER SPRING PRE LOAD The pre loading of the spring can be varied by turning the adjustment ring 5 With this aim it is advised to disassemble the damper and clean it well INDICATION Before varying the spring pre load you should make note of te basic adjustment for example how many thread turns are visible above the adjustment ring At1 turn from the adjustment ring 5 the spring pre load varies by 1 5 mm Loosen the lock nut 6 and turn the adjustment nut By turning it in an anti clockwise direction the pre load decreases by turning it in a clockwise direction the pre load inceases After the adjustment tighten the lock nut 6 REAR SUSPENSION MECHANICAL LINKAGE The rear suspension of all TM moorcycles has a link rod and rocker mechanism that progressively modifies the lever relationship between the wheel and damper T
97. se top quality completely synthetic oils SAE10W 50 that correspond to or exceed the quality standards of the API SG or SH classes indication on container A WARNING ALEVEL THAT IS TOO LOW LOW QUALITY OIL OR MAINTENANCE INTERVALS LONGER THAN ESTABLISHED CAUSE SERIOUS DAMAGE TO THE ENGINE axe 72 M6 M16x1 5 M20x1 5 M28x1 5 855555855255 M20x1 25 M18x1 5 5 595999 M12x1 559558 10 20 20 15 10 10 40 20 12 20 12 10 10 10 Loctite 243 15 Nm 10Nm Loctite 270 100 Nm Loctite 270 80 Nm 8Nm Loctite 243 6 Nm 12Nm 12Nm Loctite 243 8 Nm 8Nm Loctite 243 10 Nm 60Nm Loctite 243 25 Nm Loctite 243 10 Nm Loctite 243 12 Nm 8Nm 10Nm 20Nm PARI 111 DATA CYCL 250 450 530 27 25412541550 2006 250 450 530 250 450 530 Frame Molybdenum chrome steel enclosure Front suspension Paioli USD fork optional Ohlins USD Rear front suspension run 300 315 mm Rear suspension Aluminium fork Progressive mechanical linkage Sachs damper optional Ohlins Front brake With steel disc 270 mm floating caliper Rear brake With steel disc 245 mm floating caliper Brake disc wear limit mm 0 4 below original thickness Fronttyre 90 90 21 Off the road air pressure 1 1 bar Rear tyre 120 90 18 140 80 18 10
98. st time you must read 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 press 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 scrupulously Only full compliance with these regulations will lengthen the life of your motorcycle Overhauls and repairs must only be carried
99. tereti rete front brake Control front brake pads Replacement of front brake 48 Modification of rear brake pedal basic position 49 Control rear brake fluid level 49 Top Up rear brake fl id rne 49 Control rear brake 50 Replacement of rear brake 50 Disassembly and assembly of front 50 Disassembly and assembly of rear wheel all except SMM 51 Disassembly and assembly of rear wheel 5 52 Control of 8 cipes tete tice eren 52 Tyres tyre 14 44 2 53 Control adjustment of magnetic sensor distance 53 Battery all models with E S su 53 Battery HT 54 Recharge fuse all models with E S 55 Services fuse all models with 2 2 2 2 1 55 Replacement of headlight position light bulb 22455 Replacement of headlight position light bulb with cyclops 56 Replacement of rear l
100. 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 pin 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 600mm Motorcycle on the ground not loaded measurement B 565 mm Staticlowerirng eo peto 35 If thestatic lowering is lower the damper spring pre load must decreased If the static lowering is greater the spring pre load must be inreased See variation of damper spring pre load chapter ESTABLISHMENT OF DAMPER LOWERING IN RUNNING ORDER Now with the help of a person who holds the motorcycle sit on the morcycle wearing allprotective 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 AandC EXAMPLE Motorcycle on stand measurement 600 mm Motorcycle on the ground loaded with the pilot s weight s measurement C oo 510 mm Lowering in running
101. ts 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 components of a new motorcycle even if they undergo precision workings are however less smooth than the same components in 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 producing maximum performance gradually For this reason during the first 3 hours of use 1 hour for competition 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 motorcycle in different conditions road easy off the 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 250 450 530 END MX SMX MODELS HAVE BEEN DEVELOPED WITHOUT HALF MEASURESFOROFF THE ROAD COM
102. und in the upper part of the fork cap 4 By turning it in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 28 notches are available OHLINS USD FORK OPTIONAL The adjustment knob is found in the upper part of the fork cap 5 Act manually By turning it in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 20 notches 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 WARNING FOR FURTHER NAD MORE DETAILED INFORMATION REGARDING THE FORK BOTH STANDARD AND OPTIONAL REFER TO THE OWNERS MANUAL SUPPLIED BY THE MANUFACTURER OF THE FORK SUPPLIED BY TM ACCOMPANYING THE MOTORCYCLE SHOCK ABSORBER ADJ USTMENT IN COMPRESSION The hydraulic brake system in compression determines the behaviour of the shock absorber in the compression stroke The degree of hydraulic braking in compression can be adjusted on the basis of pilot preferences and or hardness of the spring installed Both standard and optional shock absorber 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 da
103. ut 5mm to also raise the front and restore the original levelling of the motorcycle It is advised to use the TM tool code F50806 with two M8 screws and two nuts to turn the hob on the eccentric inserting the two screws into the two holes in the hub itself A ATTENTION IFYOUDONOT 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 petrol and then immersed in oil for hot chains 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 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 ACTIVATION 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 sprockets crown wheel drive slider wear If necessary replace these particulars ENGLISH 44 y 774 AND ENGINE WAINTENANG CHAIN WEAR To check chain wear follow the instructions given below carefully Put the gear into neutral pull th
104. w into a container BEWARE OF HOT OIL Clean the cap and incorporated magnet well After the oil has flowed out completely clean the raised face remount the cap together with the seal and tighten to 20 Nm Replace the seal if it is damaged 63 SAE 10W 50 OIL 5 2727 FRAME AND ENGINE CLEANING NET FILTER after having emptied oil from the engine The net oil filter is found in the lower part of the engine and is accessible through the cap 2 situated in the left side under the gear lever Unscrew the cap and remove the filter Wash with petrol or other solvent and blow Remount taking care to place the filter correctly in its seats on the base of the engine and in the cap Tighten to 20 Nm A WARNING THE NET OIL FILTER MUST BE MOUNTED CAREFULLY INCORRECT MOUNTING PREVENTS FILTERING OF THE OIL SUCKED BY THE DELIVERY PUMP WITH THE RISK OF DAMAGING BOTH THE PUMP AND OTHER ENGINE COMPONENTS REPLACEMENT OF OIL FILTER CARTRIDGE after having emptied the oil from the engine The cartridge oil filter is found on the right side of the motorcycle underneath the cover 1 Place a container under the engine to collect the oil that escapes from the filter compartment Loosen the two screws 2 remove the cover and extract the filter cartridge Wait until the oil has been removed completely then clean the sump and cover surfaces check the O Ring and repl
105. well using a weak jet of water dry using compressed air and a cloth Empty the carburetor tank 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 running points and bearings Treat the chain with an appropriate spray Also oil the fuel tap To prevent faults in the electric plant treat the emergency stop switch the engine stop button the light switch and the connectors with contact spray gt RECAUTION FOR WINTER USE PRECAL JN FOR WIN US If the motorcycle is also used in winter it is necessary to take the salt on the roads into consideration and measures must be taken against the aggressive salt The motorcycle must be cleaned well after use and left to dry Treat engine carburetor rear fork and all other shiney or galvanised components brake disc exluded with wax based anti corrosives PREVENT CONTACT OF TE ANTICORROSIVE WITH BRAKE DISCS THIS CAUSES GREAT REDUCTION IN THE BRAKING EFFECT A WARNING AFTER TRAVELLING ON ROADS WHERE SALT HAS BEEN SPREAD WASH THE MOTORCYCLE WELL WITH COLD WATERAND LEAVE IT TO DRY D D E If the motorcycle is not to be used for a long period of time take the following measures Clean the motorcycle well see CLEAN
106. wheel must also be centred IF YOU CONTINUE TRAVELLING WITH INSUFFICIENTLY TAUGHT SPOKES THEY MAY TEAR CAUSING PROBLEMS OF INSTABILITY EXCESSIVELY TAUGHT SPOKES MAY TEAR DUE TO LOCAL OVERLOADING axe 52 y 774 EGINE LLANO TYRES TYRE PRESSURE IDARE PRESSURE The type the state and the pressure of the tyres condition the motorcycle s behaviour on the road and they must be controlled before every journey The measurement of the tyres is indicated in the technical data and in the motorcycle book Off the road 1 1 bar 1 1 bar The state of the tyres must be controlled before every journey Control 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 changedat Road only driver 1 7 bar 1 7 bar the latest when the profile has reached a depth of 2 mm The tyre air pressure must be controlled regularly when the tyres are cold Correct adjustment of the pressure guarantees optimal comfort when travelling and maximum duration of the tyre HAVE TYPE AND MEASUREMENT TYPE APPROVED TYRES EXCLUSIVELY MOUNTED ON YOUR VEHICLE AND HOWEVER THAT ARE 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 YOU
107. with respect to nominal thickness The nominal thickness can be measured in point B outside of the contact surface Check wear in different points BRAKE DISCKS WITH WEAR EXCEEDING 0 4 MM ARE ARISK FOR SAFETY WHEN THE LIMIT OF WEAR HAS BEEN REACHED HAVE THE BRAKE DISCS REPLACED IMMEDIATELY IS COMPULSORY TO HAVE THE BRAKE UNIT REPAIRED BY AUTHORISED WORKSHOP 45 L 9 axe 2 7 AND ENGIN LAXE BRAKE FLUID CONTAINER 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 In fact when the pads are worn the fluid in the pipes tends to occupy the space left by the small pistons which have moved so that the pad always rests 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 BRAKEFLUID The braking plants are 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 OFTEN SHOULD BE REPLACED MORE OFTEN THE BRAKE FLUID ABSORBS WATER IN OLD FLUID THEREFORE IT IS POSSIBLE THAT STEAM BUBBLES FORM EVEN AT LOW TEMPERATURES AND THE BRAKING SYSTEM DOES NOT WORK CORRECTLY ADJ USTMENT OF THE FREE PLAY
108. y 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 THREADS 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 to 185 Nm Remount the clasp and re make the safety binding DONOTFORGET TO CARRY OUT THE SAFETY BINDING AT THE ENDS OF THE CLASP IF YOU DO NOT HAVE A DYNOMOMETRIC WRENCH WHEN MOUNTING HAVE THE COUPLING TORQUE CORRECTED AS SOON AS POSSIBLE INA SPECIALISED TM WORKSHOP A LOOSE WHEEL PIN CAN CAUSE UNSTABLE DRIVING THEBRAKE 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 CHECKING 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 control the tension of the spokes particularly on new motorcycles With this aim briefly hit every spoke with the point 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 specialised workshop The
109. you want the motorcycle to move To reduce speed the throttle must be closed Brake and change 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 axe 26 INSTRUCTIONS FOI UST LLANO INDICATION Not all TM models have a radiator cooling fan and their dimensions 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 TM authorised dealer MODELS RE STARTED AT ANY TIME BY KICK OR WITH THE ELECTRIC 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 RESISTANCE 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 ENGINE HAS REACHED ITS WORKING TEMPERATURE AS SOON AS THE RADIATORS BECOME HOT NEVER CHANGE DOWN A GEAR WITHOUT HAVING FIRST SLOWED DOWN THE ENGINE WOULD BE TAKEN TOAN EXCESSIV

2006 4 Stroke Owners Manual

Contents

Download Pdf Manuals

Related Search

Related Contents