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TM Performance TM motorcycle 2008 User's Manual

1. PRAMI 7 1279 CHECK ENGINE 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 The oil window is located on the right side of the engine of all the models but the the 660 SMX in which the oil window is located on the left side see picture 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 window 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 A WARNING LOW OILLEVEL 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 A WARNING LOW OILLEVEL 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 MAGNET OF THE OIL DRAIN BOLT AND REPLACE THE FILTER CARTRIDGE The oil mu
2. YOLOW YALYVLS A3LIHMM MOV I8 NOLLR8 LYVLS MOV TE An ld AMS MOVIE OIVIS VIVOS L89 60 60 55 inis OLSIA 5 OLNAWVLLVYL 3IVISH3lVIN ISSOM J 7 9006 GOW 54 VIYSLLVE 3NOISN3QOOV OOlMH LL3 T3 VWQHOS ONVS3d AYLLY S I 3NOIZVNIIWON3G viva VOIJIQON IdiWail r 3MOMLS oN IVd 1808 oN Il LSOS VNIHOOVIN ON Id SYOLOANNOO 03 1345 YOA lVeovid ONIYIM ILL3LO8MHd ldO LLQ3NNOO 3NOISN3QOOV Yad VIWS3HOS MOTIAXOV T8 915 3SVHd 9 N33H9 42V18 919 3SVHd 9 109 N3dO ISN pl Mov 18 l o 93079 AMS 100 5 ISN ON agy AH3LLIVS 01 6 9 axy 4 MS 9 ISN ON G N3dO ISN ON y ISN ON 3LIHM 2 NMoug 435104 3MIM TVNIWS3L TVNINYSL e 69 09 0 9 0 9 5 09 6 4 OH LINN
3. 17 Fork adjustment in rebound 18 75 eu 4 FRAME AND ENGINE MAINTENANCE 222 37 Frame number IR 8 Free play adjustment of front brake 2 46 Front Drake EVel 53 285425528 he RES 10 E 29 20 12 Om 14 EEEN 14 ioo 16 Idle speed adjustment command 15 If the engine is flooded nnne 26 OO seien E E 17 Indications TOR first Statt UD 22 INSTRUCTIONS FOR USE 23 PICKS iaa 16 MAINTENANCE AND LUBRICATION TABLE _ 31 Manual decompressor lever 10 Mode selection and 11 Modification of rear brake pedal base position 49 elfe m 62 OPERATING CONTROLS 9 POSITION OF SERIAL NUMBER 7 PRECAUTIONS FOR WINTER USE 68 Programming the look edo e cha
4. ENGPISH 77 222 1 5704 2 ONOLINNS A 54104 t ONOLINNS 51 15 OWOLINNS OWOLINNS JV 54104 Z ONOLINNS d rm gt HOLIMS MOWTE FLIHM MOV 1a 64104 OWOLINNS 5 2v HOSNZIS JAMOJ LINN IGO MOTHA 41 JLAM 351 3LIHM 3LIHM C 54104 ONOLINNS 54104 c ONOLINNS Zy G3M G3M Od H LIM 37 5718 J 9 V4 J I N 1 MOTI3A MOTIT3A N33H9 ba 9559 54104 9 ONOLINNS 654104 9 ONOLINNS NOILOf1GO8d 3 18V LON 39NVHO NOLLO2NNOO
5. PRAME AND ENGINE MAINTENANGI LILLE ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH A REQUIRE TECHNICAL MASTERY FOR THIS REASON IT IS INTHE INTEREST OF YOUR SAFETY TO HAVE THESE OPERATIONS CARRIED OUT EXCLUSIVELEY BY A SPECIALISED TM WORKSHOP WHERE YOUR MOTORCYCLE WILL BE MAINTAINED IN AN OPTIMAL MANNER BY SPECIFICALLY TRAINED STAFF A WARNING Periodically check the play of the steering bearings For the check lift the front wheel and shake the fork forward and backwards For adjustment loosen the four screws 1 and nut 2 of the head of the fork and act on the ring nut 3 tightening it until there is no more play Do not tighten the ring nut further to prevent damage to the bearings Tighten the fork head nut and successively the four M8 screws to20 Nm Check for a smooth steering IF THE STEERING BEARINGS DO NOT HAVE THE CORRECT CLEARANCE CHECK OF STEERING BEARINGS AND PLAY USTMENT IF POSSIBLE DO NOT USE HIGH PRESSURE JETS WHEN WASHING THE MOTORCYCLE BECAUSE THE WATER COULD PENETRATE INTO THE BEARINGS THE CARBURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR TM ENSURE THAT IT IS WELL HELD INA VERTICAL POSITION USING BELTS OR OTHER MECHANICAL FIXING DEVICES AND ENSURE THAT THE FUEL TAP IS SWITCHED OFF IF THE MOTORCYCLE SHOULD FALL FUEL COULD ESCAPE FROM THE CABURETOR OR TANK TO FIX THE SHROUDS TO THE TANK ONLY USE THE SPECIAL S
6. ANTE AMS ALIHM N NOLLNG AJY dOLs NNY ANIONS HOLIMS OL 3119 AMS agd Aeld LLVa O 8 gt SIV 154 YALYVLS ANTE AMS aaSN LON MOVIE 1 18 AIS SLHOIT ASNA VOL GAIVAS 161894 ae 3 Ia vslWerddWi VOL 41181504 161894 HOLOSNNOO 5310449 J193e8 93MH MOTTJA MOTTIA MOVY IH 7 Sa Od ONOLINNS 54104 MOVIE MOT1SA MOVTE dad ALIHM V9LCM NOILONGOdd 3 18V LON 39NVHO VIVA NOILOANNOD S3 1Od 2 ONOLINNS ALIHM MOV Ig Q34 Yas ind 549 54104 2 ONOLINNS 76 1 9 I3 199 OLNNALNOO 11 12491 V 38VOINDWOO 38naosdls OLVLAIA 3 LNSINVSOHODOTH 3 39
7. 55 Services fuse all models with lights 55 Replacement of headlight position light bulb 55 Replacement of headlight position light bulb with cyclops 56 Replacement of rear position stop numberplate light bulb END SIMI m E 56 Replacement of direction indicator bulb 56 Gero Hr 57 Check coolant level 58 Emptying filling and bleeding of the cooling system 58 Replacement of exhaust silencer packing material 58 Cleaning air filter 59 Check hand decompressor adjustment 59 Throttle cable command 60 Adjustment of clutch lever basic 60 Check hydraulic clutch oil level 60 Bleeding hydraulic clutch 60 Carburetor Idle speed 61 Basic indications regarding Carburetor 61 Check fuel level float height 62 Emptying the carburetor float 62 6 6
8. 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 A WARNING THE RANGE OF ADJUSTMENT IS LIMITED ONLY TURN THE ADJUSTMENT SCREW MANUALLY WITHOUT FORCE CHECK HYDRAULIC CLUTCH FLUID LEVEL The reservoir is part of the clutch pump positioned on the handlebar and has an inspection window with the reservoir in a horizontal position the level of the fluid must never fall below the centreline of the window nor be above the upper margin If it is necessary to top up the oil remove the screws 2 and then the cover 3 together with the rubber seal 4 Keeping the reservoir 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 CLUTCH The cover of the clutch pump must be removed for bleeding Remov
9. 28 Stopping and parking ex Dae uat tai cu 28 29 MAINTENANCE AND LUBRICATION TABLE 31 FRAME AND ENGINE MAINTENANCE 2 37 Check steering bearings and play adjustment 38 Telescopic fork vent 39 Cleaning telescopic fork dust 39 Basic calibration of the chassis on the basis of pilot weight 40 Shock absorber calibration and spring check 40 Establishing rear shock lowering in running order 40 Establishing rear shock static lowering 41 Check telescopic fork basic calibration 41 Variation of telescopic fork preload 41 Replacement of fork 5 42 LI DED Page Variation of rear shock spring 42 Rear suspension mechanical 42 Check chain tension 43 Adjustment of chain tension all models except SMM 43 Adjustm
10. 5 5 LLCO Page POSITION OF SERIAL NUMBER 7 gcns mtm 8 8 OPERATING 8 2 2 2 2 9 LCT 10 Manual decompressor lever 10 Front brake 10 Control pilot Duci 10 Electronic tachometer 11 Mode selection and 11 Programming the electronic 11 Medi 12 Setting the distance travelled 22 12 Electronic digital backlit display tachometer END SMR SMM 12 Engine stop switch MX SMX 13 Combination switch 13 Combination switch supplied with Electronic digital backlit display 13 Start command and emergency stop 5 5 14 wer M 14 14 Choke command cold starter 15
11. VARIATION OF REAR SHOCK SPRING PRELOAD The pre loading of the spring can be varied by turning the adjustment ring 5 With this aim it is advised to disassemble the rear shock 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 nut By 1 turn of the adjustment ring 5 the spring pre load varies by 1 5 mm Loosen the lock ring nut 6 and turn the adjustment ring nut By turning it anti clockwise viewed from top the pre load decreases by turning it clockwise the pre load increases After the adjustment tighten the lock ring nut 6 REAR SUSPENSION MECHANICAL LINKAGE The rear suspension of all TM motorcycles has a link rod and rocker mechanism that progressively changes the lever relationship between the wheel and the rear shock This mechanism works on bearings which must be cleaned and greased at the envisioned intervals to maintain the working of the suspension efficient When cleaning the motorcycle with high pressure cleaning devices do not aim the jet completely onto the suspension mechanical linkage 42 AND ENGINE 22 7 CHECK CHAIN TENSION Put the motorcycle onto the central stand to control chain tension Push the chain upwards to the end of the drive chain slider The upper part of the chain A must be taught see photo T
12. 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 mainte nance of the filter should be carried out regularly Remove the seat to access the filter and lift the battery holder 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 DONOT CLEAN THE FOAM FILTER WITH FUEL OR KEROSENE WHICH CAN CORRODE IT FOR CORRECT MAINTENANCE OF THE FOAM FILTER USE THE RELEVANT PRODUCTS ON THE MARKET FOR CLEANING AND LUBRICATION NEVER START UP THE MOTORCYCLE WITHOUT THE AIR FILTER THE INFILTRATION OF DUST AND DIRT CAN CAUSE DAMAGE AND INCREASE WEAR Wash the filter carefully using a special liquid detergent and dry well squeeze the filter slightly but do not wring it Also clean the filter case and check that the rubber manifold that connects the carburetor to the filter case is integral and positioned correctly Remount the air filter positioning it correctly on the rest surface taking care that edges of the filter are not raised or not adherent with the rest surface Rescrew the finger screw and tighten it adequately CHECK HAND DECOMPRESSOR UST A ALL 530 AND 660 CC MODELS Take the crankshaft to the TDC with closed valves and activate the hand decompressor A fre
13. DNN OAA 71 ENGINE TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Crankase Allen screws transmission cover clutch cover ignition cover Oil drain screw cap Oil filler screw cap Oil net filter screw cap Oil cartridge filter cover Allen screws Engine oil pump body screws Head cylinder nuts Head cylinder flanged nuts Head cylinder flanged nuts Head cylinder fastenening screws Camshaft bearing cap Allen screw Camshaft cap Allen screws Distribution chain tensioner Allen screws Water pump cover Allen screws Water pump rotor Head cover Allen screws Primary transmission pinion nut Clutch hub nut Clutch springs Allen screws Starter motor bush csk head Allen screw Starter motor fastening Allen screws Mobile chain guide fastening flanged screws Ignition stator Allen screws Ignition pickup fastening Allen screws Allen screws for gear drum lock lever Ignition flywheel flanged nut Kickstart pedal screw Gear pedal Allen screw Exhaust manifold flanged nuts General screws nuts General screws nuts General screws nuts ENGINE OIL Only use premium quality fully synthetic oils SAE10W 50 that correspond to or exceed the quality standards of the SG or SH classes indication on container A WARNING ALEVEL THAT IS TOO LOW LOW QUALITY OILOR MAINTENANCE INTERVALS LONGER THAN ESTABLISHED CAUSE SERIOUS DAMAGE TO THE ENGINE 72 16 1 5 M20x1 5 28 1 5 5 5
14. IMPORTANT YOU ARE ADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM IT CONTAINS ALOT OF INFORMATION AND ADVICE THAT WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE MUCH EASIERAND SAFER IT IS IN YOUR SPECIFIC INTEREST TO PAY PARTICULAR ATTENTION TO THE WARNINGS INDICATED IN THE FOLLOWING WAY N DANGER FAILURE TO COMPLY WITH THESE WARNINGS RISKS LIVES WARNING 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 customer We would like to congratulate you for having chosen a TM motorcycle Your is a competitive and modern motorcycle that will surely give you a lot of satisfaction if you treat it according to the provisions contained in this manual Before starting up your TM motorcycle for the first time you must read this manual carefully so as to understand the regulations for u
15. The type the state and the pressure of the tyres condition the motorcycle s behaviour on the road and they must be checked before every journey The dimension of the tyres is indicated in the technical data and in the registration paper Off road 1 1 bar 1 1 bar The state of the tyres must be controlled before every journey Check the tyres by verifying that they are not cut have nails or other sharp objects pushed into them Regarding the minimum depth of the profile respect the regulations in force in your country We recommend that the tyres are changed at Road rider only 1 7 bar 1 7 bar the latest when the profile has reached a depth of 2 mm The tyre air pressure must be checked regularly when the tyres are cold Correct adjustment of the pressure guarantees optimal comfort when travelling and maximum duration of the tyre HAVE EXCLUSIVELY TYRES OF APPROVED TYPE AND DIMENSIONS MOUNTED ON YOUR VEHICLE AND HOWEVER ESTABLISHED BY TM DIFFERENT TYRES CAN NEGATIVELY CONDITION THE BEHAVIOUR OF THE MOTORCYCLE ON THE ROAD AND BE THE CAUSE OF FINES ENVISIONED BY THE REGULATIONS IN FORCE IN YOUR COUNTRY TO GUARANTEE YOUR SAFETY AND THAT OF OTHERS DAMAGED TYRES MUST BE REPLACED IMMEDIATELY EXCESSIVELY WORN TYRES NEGATIVELY CONDITION THE BEHAVIOUR OF THE MOTORCYCLE MOST OF ALL ON WET SURFACES INCORRECT PRESSURE LEADS TO ANOMALOUS WEAR AND OVERHEATING OF THETYRE FRONT REAR USTMENT OF MAGNET SENSOR
16. COMMAND HOT STARTER All 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 starting of the engine when it is flooded or particularly overheated As soon as the engine is running turn the lever to return it to its normal position IDLE SPEED ADJUSTMENT COMMAND This command is located 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 rpm 15 CONTROLS ENGPISH LENO GEAR SHIFT PEDAL The gear shift pedal is positioned on the engine left side The position of the gears is indicated in the illustration The neutral is between the first and second gears KICKSTART PEDAL The kickstart pedal is positioned on the right side of the engine The upper part is turned outwards to start up the engine and replaced inside as soon as the engine is running BRAKE PEDAL The brake pedal is positioned in front of the ri
17. DISTANCE A ELECTRONIC TACHOMETER In the END model the magnetic sensor is located on the front wheel while in the SMR SMM it is located on the rear wheel ELECTRONIC DIGITAL BACKLIT DISPLAY TACHOMETER In all the models the magnetic sensor is located on the rear wheel The distance between detector 2 and sensor 1 must be 2 Amm Otherwise the tachometer may work irregularly 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 check the level of the electrolyte or top up with water The battery poles only must be cleaned and if necessary slightly greased using grease that does not contain acids Battery disassembly First remove the negative pole and then the positive pole from the battery Disconnect the elastic stripes 1 Remove the battery When assembling the battery place it with the poles pointing back wards see figure first connect the positive pole and then the nega tive pole to the battery 53 ENGLISH 773 FRAME AND ENGINE MAINTENANGI LATE IF FOR SOME REASON THE ELECTROLYTE SULPHURIC ACID SHOULD ESCAPE FROM THE BATTERY BE VERY CAREFUL THE ELECTROLYTE CAN CAUSE SERIOUS BURNS ONCONTACT WITH THE SKIN RINSE WELL WITH WATER IF DROPS OF THE ELECTROLYTE ENTER INTO THE EYES RINSE FOR AT LEAST 15 MINUTES WITH WATER AND CONSULT A DOCTOR IMMEDIATELY EVEN I
18. OPERATE THE STARTER MOTOR FOR MAX 5 SECONDSATATIME WAIT ANOTHER 5 SECONDS BEFORE TRYING AGAIN 25 INSTRUCTIONS FOR USE ENGPISH LATE 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 hot start knob or turn the hot start lever 1 WITHOUT opening the throttle push hardly the kickstart pedal DOWN TO THE BOTTOM once or twice or operate the electric starter On models with a manual decompressor to eliminate the excess fuel from the engine pull the manual decompressor lever and operate 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 the 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 DO IT ONLY ONCE AND NEVER REPEATEDLY BIKE STARTING Pull the clutch lever insert the first gear release the clutch lever slowly accelerating at the same time
19. 2 Check correct tightness of screws nuts and clamps 5 ENGINSEH 34 MAINTENANCE AND LUBRICATION TABLE LLCO CHECKS TO BE CARRIED OUT ON ENGINE 250 450 530 END MX SMX 660 SMX COMPETITION USE 15 HOURS OF SERVICE EQUAL ABOUT 100 LT Tu WOES ER eure OF FUEL CONSUMPTION 200LT 300 Lr 100 600LT 800LT 900LT Check cylinder and piston wear e Check piston pin visual check e Check camshaft and valve lifters wear visual check x Check camshaft supports e Check timing chain besides the one to be done in every race s Check and adjust valve clearance e Check valve spring length Check upper and lower spring retainers wear Check valve cotters and valve stems e Check valve guide wear e Check valve sealing e e Check automatic decompressor working e Check head and cylinder surfaces e e Check engine crankshaft for trueness e Replace conrod axle and roller cage e Check small end for marking damage to plating Check oil pump and lubrication circuit e Replacement of main bearings Check complete gearbox including drum and forks Check clutch plate wear e e e e e e e e Check length of clutch springs 5 E WARNING IF AFTER CHECKING IT IS DETECTED THAT THE WEAR LIMITS OF A SINGLE COMPONENT HAVE BEEN EXCEEDED THE COMPONENT MUST REPLACED THE INSTALLATION OF AN HOUR COUNTER INSTRUME
20. 665506055685 8 M20x1 25 M18x1 5 12 1 55956986 10 Nm 20 20 15 Nm 10 Nm 10 Nm 40 20 12 20 12 12 10 10 Loctite 243 15 10 Nm Loctite 270 100 Nm Loctite 270 80 Nm 8Nm Loctite 243 6Nm 12Nm 12Nm Loctite 243 8 8Nm Loctite 243 10 Nm 60 Nm Loctite 243 25 Nm Loctite 243 10 Nm Loctite 243 12Nm 8Nm 10Nm 20Nm 111 J gt KECHANI DATA CYC TECHNICAL DATA CYCLE PART 250 450 530 END 250 450 530 MX 2008 250 END 450 END 530 END 250 MX 450 MX 530 MX Frame Twin spar high resistance aluminium alloy frame Front suspension Marzocchi USD fork USD fork optional Ohlins USD Rear front suspension travel 300 315 mm Rear suspension Aluminium swing arm Progressive mechanical linkage Sachs rear shock optional Ohlins Front disc brake 270 mm floating caliper Rear disc brake 245 mm floating caliper Brake disc wear limit mm 0 4 below original thickness Front tyre 90 90 21 Off road air pressure 1 1 bar Rear tyre 120 90 18 140 80 18 100 90 19 110 90 19 Off road air pressure 1 1 bar Tank capacity 9 litres Final transmission 13 51 13 50 13 50 13 51 13 49 13 49 O Ring 5 8 x 1 4 5 8 x 1 4 Optional rear sprockets 48 49 50 51 52 53 Bulbs only END Headlight full beam 5212 45 40W BA20d Opt Cyclops H3 12V 55W PK22s Front position light T4W 12V 4
21. By Pass command hot starter 15 Idle speed adjustment 15 Gear smit pedal 16 podaly 16 silio M 16 OS SUNG Me T 16 Side stand fixing for off road 17 GH gre qe t 17 Fork adjustment in compression 17 Fork adjustment rebound 18 Shock absorber adjustment in compression 18 Shock absorber adjustment in rebound 19 silere 20 ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE 21 Indications Tor first 1 22 Running in 2 015 22 INSTRUCTIONS FOR USE 23 Check before every start up 24 Cold engine Start Np 25 18181 nnne 25 If the engine is 26 4 ERR 26 Shifting gear accelerating slowing down 26 BESKIBG weeds seas tim A E
22. 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 Seul 46 AND ENGINE 7 1279 CHECK 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 exception 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 Remove 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
23. IT TO DRY mm STORAGE If the motorcycle is not to be used for a long time take the following measures Clean the motorcycle well see CLEANING chapter Change the engine oil and oil filter cartridge clean the net filter old oil contains dangerous impurities Check the antifreeze and the quantity of the coolant Warm the engine up again close the fuel tap and wait until the engine stops Successively open the carburetor bowl empty screw to empty the remaining fuel Disassemble the spark plug and pour into the plug hole 5 cc of oil Activate the kickstart pedal 10 times to distribute the engine oil onto the walls of the cylinder and then remount the spark plug Bring the piston in compression to induce valve closure Empty the fuel tank collecting the fuel in an appropriate container Adjust tyre pressure Grease bearings or command lever supports footrests etc and also the chain Disassemble the battery and charge it see BATTERY chapter Store it disassembled from the motorcycle The place of storage should be dry and not subject to large temperature changes Cover the motorcycle with a sheet or cover that allows air to pass Do not use materials that do not allow the passage of air as humidity would not be able to escape and could cause oxidation A WARNING IT IS NOT ADVISED TO START THE ENGINE FOR SHORT TIMES THE ENGINE WOULD NOT HEAT UP SUFFICIENTLY AND THEREFORE THE STEAM CREATED DURING THE COMBUSTION PR
24. In this way the fuel flows to the carburetor and the tank empties up to reserve RES 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 14 Sh EN LEAL CHOKE COMMAND COLD STARTER This command is located 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 starting the engine when it 1 cold To disconnect the command push the choke knob inwards to its original position For KEIHIN carburetors Extract the knob and turn it clockwise to block it To disconnect it turn anticlockwise BY PASS COMMAND HOT STARTER All models with electric starter This command is found on the right side of the motor cycle By pulling the by pass 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 starting the engine when it is flooded or particularly overheated As soon as the engine is running push the knob to return it to its normal position 55
25. Minor weight changes can be compensated by varying the spring pre load For greater variations suitable springs rates must be used SHOCK CALIBRATION AND SPRING CHECK If the rear shock spring is suitable for your weight it can be seen by lowering in running order However before establishing the lowering in running order static lowerlng must be adjusted correctly ESTABLISHING REAR SHOCK STATIC LOWERING The static lowering should be35 mm Variations of more than 2 mm can notably influence driving of the motorcycle Procedure Position the motorcycle on a stand so that the rear wheel does not touch the ground Measure the distance between the rear wheel axle and a fixed point e g a mark on the side panel paying attention that the straight line that joins the axle and the fixed point is as perpendicular as possible to the ground and make note of the value as A Rest the motorcycle back on the ground Ask a helper to hold the motorcycle in a vertical position Measure the distance between the rear wheel axle and the fixed point again Make note of this measurement as B The static lowering is the difference between measurement A and B EXAMPLE Motorcycle on stand measurement 600 mm Motorcycle on the ground not loaded measurement B 565 mm Static lowering 35 mm If thestatic lowering is smaller the rear shock spring pre load must be decreased If the static lowering i
26. SEE YOU IN TIME DO NOT DRINK AND DRIVE ONLY USE ORIGINAL TM ACCESSORIES FRONT COVERINGS FOR EXAMPLE CAN NEGATIVELY AFFETCT THE BEHAVIOUR OF THE MOTORCYCLE ON THE ROAD AT HIGH SPEEDS OR HAVE NEGA TIVE INFLUENCE OF THE BEHAVIOUR OF THE MOTORCYCLE DUE TO DIFFERENT WEIGHT DISTRIBUTION THE FRONT AND REAR TYRES MUST HAVE THE SAME TYPE OF PROFILE AFTER THE FIRST 30 MINS OF DRIVING THE WHEEL SPOKE TENSION MUST BE CHECKED SPOKE TENSION DECREASES QUICKLY ON NEW WHEELS IF YOU DRIVE WITH LOOSE SPOKES THE SPOKES MAY BREAK CAUSING UNSTABLE DRIVING CONDITIONS SEE CHECK SPOKE TENSION THE RACING MODELS HAVE BEEN DESIGNED AND PREPARED ONLY FOR ONE PERSON IT IS PROHIBITED TO TAKE ON PASSENGERS FOLLOW THE HIGHWAY CODE DRIVE CAREFULLY 50 AS RECOGNISE DANGERS AS SOON AS POSSIBLE ADAPT SPEED TO THE CONDITIONS OF THE ROAD AND YOUR DRIVING CAPABILITY DRIVE CAREFULLY ON UNKNOWN ROADS OR LAND WHEN OFF ROAD YOU SHOULD ALWAYS BE ACCOMPANIED BYA FRIEND WITH ASECOND MOTORCYCLE SO THAT YOU CAN 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 CHECK BEFOR
27. SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP A LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING AFTERHAVING MOUNTED THE FRONT WHEEL REPEATEDLY ACTIVATE THE BRAKE LEVER UNTIL THE PAD ADHERES TO THE DISC AGAIN THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED DISASSEMBLY AND ASSEMBLY OF THE REAR WHEEL ALL EXCEPT SMM Rest the motor cycle with the frame cradle on a stand a way that the rear wheel does not touch the ground Unscrew the flanged nut 1 and supporting the wheel extract the wheel axle 2 remove the chain tensioning slide 3 remove the chain from the sprocket remove the caliper with its support and carefully extract the rear wheel from the swing arm Pay attention to the thin wheel shim sprocket side and thick shim brake side WARNING DONOT ACTIVATE THE BRAKE PEDAL WHEN THE REAR WHEEL HAS BEEN DISASSEMBLED ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO PREVENT DAMAGE WHEN THEWHEELAXLE IS DISASSEMBLED THE WHEELAXLE THREADS AND THE THREADS OF THE FLANGED NUT MUST BE WELL CLEANED RE GREASE THEM TO PREVENT SEIZING OF THE THREADS To assemble insert the thin shim sprocket into the hub position the chain tensioners insert the wheel into the swing arm and supporting the wheel position the caliper with its support and mount the chain onto the sprocket Insert the axle from the sprocket side into half th
28. TM authorised dealer TMMODELS CAN BE RE STARTED AT ANY TIME BY KICK OR WITH THE ELECTRIC STARTER SWITCH THE ENGINE OFF WHEN YOU INTEND TO KEEP THE MOTORCYCLE AT ASTANDSTILL FOR MORE THAN 2 MINUTES AFTER EVERY FALL THE MOTORCYCLE MUST BE CONTROLLED IN THE SAME WAY AS BEFORE EVERY START UP A DEFORMED HANDLEBAR MUST ALWAYS BE REPLACED NEVER STRAIGHTEN THE HANDLEBAR AS IT COULD LOOSE ITS STRENGTH A WARNING USE OF THE ENGINE AT A HIGH NUMBER OF REVS WHEN IT IS COLD NEGATIVELY AFFECTS THE DURATION OF THE ENGINE BEFORE USING THE MOTORCYCLE AT FULL WORKING CONDITIONS IT IS BETTER TO WARM IT ADEQUATELY BY DRIVING AT AN AVERAGE SPEED THE ENGINE HAS REACHED ITS WORKING TEMPERATURE AS SOON AS THE RADIATORS BECOME NEVER SHIFT DOWN WITHOUT HAVING FIRST SLOWED DOWN THE ENGINE WOULD BE TAKEN TOAN EXCESSIVE 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 ATMAUTHORISED DEALER 27 INSTRUCTIONS FOR USE ENGPISH LATE 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 s
29. USD FORK STANDARD The adjustment screw is located in the upper side of the fork cap 4 For this operation use a screwdriver By turning the screw clockwise braking increases while turning it anticlockwise braking decreases 28 clicks are available in all Never turn the side screw 5 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 17 OFERATING CONTROLS LATE FORK ADJUSTMENT IN REBOUND The hydraulic brake system in extension determines the behaviour of the fork in the rebound stroke The degree of hydraulic braking in rebound can be adjusted on the basis of pilot preferences and or hardness of the spring installed PAIOLI USD FORK STANDARD The adjustment screw is located in the upper side of the fork cap 4 By turning it clockwise braking increases anticlockwise it decreases A total of 28 clicks are available MARZOCCHI USD FORK STANDARD The adjustment screw is located in the lower part of the fork leg 8 For this operation use a screwdriver By turning the screw clockwise braking increases while turning it anticlockwise braking decreases 28 clicks are available in all A WARNING BEFORE STARTING IT
30. aluminium silencers are filled with acoustic insulating material fibreglass to limit motorcycle noise Because of high temperatures reached by the exhaust gases the fibreglass tends to burn leading to a decrease in the effect of noise absorbtion and also causing a de crease power To replace the fibreglass disassemble the silencer from the motorcy cle frame remove the rivets 1 that support the front cap 2 and slide the cap and the wool to be replaced out In END SMM SMR models the fibreglass cartridge 3 must be cut to a length of about 35 cm weight 350 grammes while in the other mod els it is inserted whole Slide the fiberglass cartridge on the punched pipe 4 and push it all into the silencer Hold the clamp and fasten with rivets Never disassemble the rear cap 5 it is not necessary and you run the risk of damaging the silencer WHEN THE ENGINE IS RUNNING THE EXHAUST SYSTEM BECOMES VERY HOT ONLY START TO WORK ON THE EXHAUST SYSTEM WHEN IT HAS COOLED DOWN TO PREVENT BURNS To ease mounting of the silencer grease the ends of the pipes Also fix the retaining spring between the pipe and the silencer When the engine is started up it might generate some smoke from the previously greased parts This is caused by the high temperature that melts the grease 58 FRAU ANDY ENGIN LEAL A WARNING REPLACE THE FIBREGLASS CARTRIDGE WITH ANEW ONE OF THE SAME WEIGHT OR BOUGHT AT ATM AUTHORISED DEALER
31. clockwise direction the quantity of fuel decreases lean mixture by turning in an anticlockwise direction the quantity of fuel increases rich mixture TO SET IDLE SPEED FUNCTIONING CORRECTLY PROCEED AS FOLLOWS 1 Screw the mixture 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 mixture adjustment screw 2 in a clockwise direction until the number of revs of the idle speed begins to decrease Keep this position in mind and now turn the mixture adjustment screw slowly in an anticlockwise direction until the number of revs of the idle speed begins to decrease 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 procedure from point 4 Anyone using the motorcycle for pure racing will set a leaner mixture of about 1 4 of a turn in a clockwise direction with respect to the ideal value because the engine will become hotter than normal NOTE If the described methods are followed and satisfying results are not obtained the cause could be a Pilot jet with unsuitable dimensions a If the mix adjustment sc
32. flanged nut Holding the front wheel still slide the wheel axle out 7 If necessary to help the wheel axle to exit strike lightly with a mallet hammer with plastic ends on the threaded end of the axle itself Alternatively use a normal hammer and place a piece of wood between NEVER USE THE HAMMER DIRECTLY ON THE AXLE YOU RISK TO DAMAGE THE AXLE IRREVERSIBLY Slide the front wheel carefully out of the fork 50 FRAME AND ENGINE MATINTENZANGI LLANE A WARNING NEVER ACTIVATE THE BRAKE LEVER WHEN THE FRONT WHEEL 1 DISASSEMBLED ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO PREVENT DAMAGE To re assemble the front wheel insert it carefully into the fork taking care to insert the disc correctly between the brake pads without damaging them Position it correctly and mount the wheel axle Screw and temporarily tighten the flanged nut 5 until the wheel shim is locked tighten the locking screws 6 on the right fork shoe to prevent the wheel axle from turning and tighten the flanged nut at 40 Nm Tighten the locking screws on the left fork leg at 12Nm Loosen the locking screws on the right shoe again remove the motrcycle from the stand activate the front brake and force the fork down several times to align the rods End by definitively tightening the locking screws on the right fork shoe at 12Nm IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH WHEN MOUNTING HAVE THE TIGHTENING TORQUE CHECKED AS
33. has not been used for more than 1 week the old fuel should THE ENGINE DOES NOT START MODELS WITH KICKSTARTER PEDAL bowl Fuel supply interrupted Engine flooded Spark plug blackened or wet Incorrect spark plug electrodes gap Spark plug cover or spark plug damaged Engine stop button cable damaged engine stop button or emergency shutdown damaged Oxidised CDI unit pickup orcoil connectors Water in the carburetor or clogged jets be emptied from the carburetor bowl When the bowl has been filled with fresh fuel the engine will start immediately Disconnect the fuel hose from the carburetor place it container and open the fuel tap if fuel escapes clean the carburetor if fuel does not escape control the tank vent pipe or clean the fuel tap Use the by pass command as explained in the Operating controls chapter Clean and dry the spark plug or replace it Adjust the gap between the electrodes to 0 8 mm Slide off the spark plug cover unscrew the spark plug put the cover back onto the spark plug and gripping the cover keep the threaded part of the spark plug in contact with the head of the engine Turn the engine with the electric starter or pedal a spark should appear between the electrodes of the spark plug if the spark plug does not produce a spark it must be replaced if there is still no spark remove the spark plug cover from the H T cable coming from the coil hold it
34. table must be carried out by a specialised TM workshop at the envisioned dates otherwise any warranty rights will be forfeited When you must contact your TM Dealer for spare parts updating requests or to signal problems indicate the model cylinder capacity year of manufacture and most of all the frame number and the engine serial number Fuels and lubricants must be those established in the user and maintenance manual and must be used as per maintenance programme Products of other brands can be used as long as they have the equivalent specifications In cases of direct and consequent damage caused by tampering or modifications to the motorcycle no legal warranty claim can be asserted The use of the motorcycle in extreme conditions for example on muddy and very wet ground may lead to greater than average wear of components such as transmission components or the brakes It is therefore possible that maintenance or replacement of some parts is necessary before the limit normally envisioned by the maintenance programme MX AND SMX MODELS CANNOT BE USED ON PUBLIC ROADS The 250 450 and 530 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 competitions Enduro and are not suitable for Motocross
35. the screw 20 and carefully extract the bulb 21 Replace the bulb with an equivalent one Remount the retainer in the correct position and lock with the screw taking care to insert the engine stop eyelet terminal under the head of the screw Reposition the rubber protection POSITION LIGHT BULB Extract the bulb holder 22 from the parabola replace the bulb 23 Remount the bulb holder Repositon the light holder mask and fix it with the elastic stripes A WARNING NEVER TOUCH THE GLASS BULB TO PREVENT LEAVING TRACES OF GREASE TO BE SURE OF INSERTING THE ESTABLISHED BULBS CONSULT THE CYCLE PART TECHNICAL DATA TABLE REPLACEMENT OF REAR POSITION STOP 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 DIRECTION 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 56 AND ENGINE LENE COOLING The water pump 1 housed in the engine induces forced circulation of the coolant liquid There is no thermostat in the system therefore when the engine is cold it is important to moderate the number of revs of the engine and speed Proceed for at least 5 minutes at ha
36. zeroed PROGRAMMING THE ELECTRONIC TACHOMETER 5 5 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 second 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 Kmh will start to flash now press the left hand button yellow to pass to End programming by pressing the grey button on the rear of the instrument for 1 sec 11 1046 ENGPISH LILLE 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 st
37. 0 BEE DOUG 16 28 By Pass command hot Starter 15 Carburetor Idle speed 61 CARBURETOR 71 Chain maintenance 44 45 63 Check adjustment magnet sensor distance 53 Check before every start Up 24 Check chain tension 43 Check coolant level 58 Check engine oil level 2 63 Check front brake fluid level 47 Check front Drake PACS 47 Check fuel level float height 2 62 Check hand decompressor adjustment 59 Check hydraulic clutch oil level 60 Check rear brake fluid level 49 Check Tear brake 50 Check SOOKS tensi 52 Check steering bearings and play adjustment 38 Check telescopic fork basic calibration 41 Choke command cold 15 ea pccm eee 68 Cleaning telescop
38. 2 Check engine oil level 2 63 melo Mee 63 Change engine Oll 22 5 cnt roca aque ded waa 63 TROUBLESHOOTING 34202022200 NOUO ERE Ear E EX Edda ROC RR cR 66 CLEANING ec HM 68 PRECAUTIONS FOR WINTER USE 1 68 STORAGE d Di Aa EXER Max DUM 68 Start up after seasonal 68 TECHNICAL DATA 1 1 69 70 CARBURETOR SETTINGS 2 2 22 2 2 2 71 ENGINE TIGHTENING TORQUES 1 72 TECHNICAL DATA CYCLE PART 73 74 AEPHABETICINDEX 75 WIRING DIAGRAM appendix OF NUMBER POSITION Of SERIAL NUMBER 22 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 u
39. 931 IG ANINYALV JS OLVLS VIVOS e 90 0 60 61 viva 2 S OLSIA OLN3IAV LIVS L ISSOM J SIG 7 9002 3NOISN3OOY ODINLLITA VWAHOS lt lt 9002 ONIMIM P 100 d VOISIGOW E o J3MOMIS JP oN IVd 1808 oN Il 1808 22253 2d 3dlS 190 MOLOSNNOO 81 40 MJN 8 MOTIHA TVNOIS 6 41 G3sn LON 8 gt axy 91 JLIHM G3M M3LIOX3 4 3539 GL d3y MOV 1d H3LIOX3 9 6 D D 0 MOVIE 541 HOLIMS 9 6 8 2 9 5 5 2 MOTI3A HOSNZS 541 L 5 LON 30719 AS 541 cl 5 LON 3559 351 LL MOV 1d GND 2 ALIHM 357104 OL 118 41 AYVNIYd NOLLINOI L 3 amp MIM TVNIIASHSLL ON HO IOO 4 AWVN TVNIAS3 L ON IVNINYAL 3LIHM G3M ATEVIVAV LON SdL ALIHM
40. AND OTHERWISE THE STAND MAY BE DAMAGED AND THE MOTORCYCLE CAN FALL FUEL TM engines require super unleaded fuel with at least 95 RON A WARNING FILL THE TANK WITH UNLEADED FUEL WITHA MINIMUM OCTANE NUMBER 95 NEVER USE FUEL WITH AN OCTANE NUMBER LOWER THAN 95 BECAUSE THIS WOULD DAMAGE THE ENGINE FUEL IS HIGHLY INFLAMMABLE AND TOXIC HANDLE FUEL WITH GREAT CARE DO NOT FILL UP WITH FUEL NEAR TO FLAMES OR CIGARETTES ALWAYS SWITCH THE ENGINE OFF WHEN FILLING UP WITH FUEL NEVER POUR FUEL ONTO THE ENGINE OR ONTO THE EXHAUST PIPE IF ANY FUEL IS ACCIDENTLY POURED ONTO THESE PARTS DRY IT IMMEDIATELY USING A CLOTH IF FUEL IS SWALLOWED OR SPRAYED INTO THE EYES SEEK MEDICAL HELP IMMEDIATELY Fuel expands when heated Therefore never fill the tank completely with high environmental temperatures 29 INSTRUCTIONS FOR UST MISMOS LU BRIGATTION WAS US AND LUBRICATION AND WAS 920420500 5115 5501 518 ROND TOBY USE 1ST SERVICE EVERY 30 HOURS CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS 15 LT OF FUEL 120 LT OF FUEL Se Replacement of engine oil cartridge oil filter Clean of drain bolt 5 5 5 Check conditions and and unbent positioning of rubber pipes Z Check of the timing chain Check tightness of engine fastening screws 5 Check fix
41. ARGING IF THE BATTERY IS CHARGED TOO LONG ORATATOO HIGH VOLTAGE THE CHARGING CHARGING VOLTAGE ELECTROLYTE WILL COME OUT THROUGH THE SAFETY VALVES THE BATTERY THEREFORE LOOSES CAPACITY VOLT 05 AVOID FAST RECHARGING gt 12 7 100 12 5 75 4 hours 14 4V 12 2 50 7 hours 12 0 25 11 hours 11 8 0 14 hours 54 AND ENGIN LEAL RECHARGE FUSE ALL MODELS WITH 5 The fuse 1 is located in the electric starter relay 2 under the remov able battery holder After having removed seat and battery holder 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 sun der the removable battery holder After having removed seat and battery holder and opened the fuse holder it is possible to access the fuse The fuse has a capacity of 7 5 ampere This fuse protects the following lighting system direction indicator acoustic warning device A burned out fuse must be replaced exclusively with an equivalent one If the new fuse should also burn out once mounted contact a special ised TM workshop A WARNING NEVER MOUNT FUSES WITH GREATER POWER OR TRY TO REPAIR THE SAME FUSE UNAPPROPRIATE TREATMENTS COULD CAUS
42. BEFORE STARTING ALWAYS CHECK THAT THE SIDE STAND HAS BEEN LIFTED IF THE STAND SLIDES ALONG THE GROUND YOU COULD LOOSE THE CONTROL OF THE MOTORCYCLE SHIFTING GEAR ACCELERATING SLOWING DOWN 1 gear which should be selected is the pulling away and ascent gear If the circumstances permit speed limits traffic slopes to increase speed insert higher gears To do this close the throttle pull the clutch lever at the same time insert the successive gear release the clutch and accelerate up to 1 2 turn of the throttle Then insert the following gear and repeat this operation until the desired speed is reached and however permitted by the limits in force Gradual opening of the accelerator favours careful driving and limits consumption Learn the correct opening of the throttle on the basis of the pace at which you want the motorcycle to move To reduce speed the throttle must be closed Brake and shift down the gears pulling the clutch lever and inserting a lower gear Release the clutch slowly and accelerate or change gear again Always increase or change down the gears one at a time 26 INSTRUCTIONS FOI A USE 2 INDICATION All TM models do not have a radiator cooling fan and the radiator 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 a
43. CED AFTER MOUNTING CHECK THAT THE SAFETY DEVICES ARE CORRECTLY POSITIONED AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM ACTIVATE THE FRONT BRAKE LEVER AND THE REAR BRAKE PEDAL TO MAKE THE PADS ADHERE TO THE DISC AND TO RESTORE THE CORRECT ADJUSTMENT OF PLAY ENGLISH 48 PRAME AND ENGINE MODIFICATION OF REAR BRAKE PEDAL BASE POSITION A The 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 free play is given by the stroke of the pump piston check that the pedal has a free play of about 1 5cm before starting to brake A WARNING IF THERE IS NO FREE PLAY PRESSURE DEVELOPS IN THE BRAKING SYSTEM AND CONSEQUENTLY THE REAR WHEEL IS BRAKED THE BRAKING SYSTEM OVERHEATS AND IN EXTREME CASE IT WILL NOT WORK CHECK REAR BRAKE FLUID LEVEL ALL THE MODELS The reservoir for the rear disc brake fluid is incorporated into the rear brake pump When the motorcycle is in a vertical position the level must always be over half way on the window 3 positioned on the body of the pump IF THE LEVEL OF THE BRAKE FLUID FALLS BELOW THE MINIMUM LEVEL IT INDICATES A LEAK IN THE BRAKING SYSTEM OR COMPLETE CONSUMPTION OF THE BRAKE PADS TOP UP REAR BRAKE FLUID A ALL THE MODELS As soon as the level of rear brake flui
44. CREWS WITH THE CORRECT LENGTH OF THREAD FOR TM BIKES IF YOU USE DIFFERENT SCREWS OR LONGER SCREWS THE TANK COULD BE DAMAGED WITH CONSEQUENT FUELLEAK DO NOT USE NOTCHED WASHERS OR SPRING WASHERS FOR THE ENGINE FASTENING SCREWS BECAUSE THEY COULD PENETRATE INTO PARTS OF THE FRAME AND LOOSEN CONTINUALLY USE SELF LOCKING NUTS LEAVE THE MOTORCYCLE TO COOL BEFORE STARTINGANY MAINTENANCE THIS WILL PREVENT BURNS DISPOSE OF OILS GREASES FILTERS FUELS DETERGENTS ETC INAREGULAR MANNER COMPLY WITH THE RESPECTIVE REGULATIONS OF YOUR COUNTRY DISPOSE OF WASTE IN A REGULAR MANNER NEVER POUR OLD OIL INTO DRAINS OR RIVERS THE BEHAVIOUR ON THE ROAD WILL BE IRREGULAR AND YOU COULD LOOSE CONTROL OF THE MOTORCYCLE A WARNING MAKING LONG JOURNEYS WITH INCORRECT STEERING BEARINGS ADJUSTMENT YOU RISK TO DAMAGE THE BEARINGS AND THEIR SEATS IN THE FRAME The steering bearings should be re greased at least once a year Seul 38 AND ENGINE LEAL 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 from inside the fork Instead of a screw Marzocchi fork features a tyre valve 3 which is protected by a rubber bulb 4 Remove the rubber bulb and press gently the valve stem Before operating on the screws or on the valve lift the motorcycle onto the stand in a way that the front wheel does no
45. Check wheel bearing play x OTHER IMPORTANT MAINTENANCE OPERATIONS HECCOMMENBDEB EVERY YEAR EVERY YEAR Complete fork maintenance 5 Complete shock absorber maintenance Cleaning greasing of steering bearings and related sealing elements Cleaning and tuning of the carburetor Replacement of silencer packing material 5 Treatment of electric contacts and switches with contact spray Treatment of battery connections with contact grease S Replacement of hydraulic clutch fluid Replacement of brake fluid 5 The distance between maintenance intervals should not be exceeded by more than 2hours 15 litres THE MAINTENANCE CARRIED OUT BY THE AUTHORISED TM DEALER DOES NOT REPLACE THE CHECKS AND MAINTENANCE CARRIED OUT BY THE RIDER 32 MAINTENANCE ANID TABLE 1ST SERVICE A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS 12 LT OF FUEL COMPETITION Replacement of engine oil cartridge oil filter 5 Clean of drain bolt x Check condition and unbent positioning of rubber pipes Y Check of timing chain Ex Check and adjustment of valve clearance Check tightness of engine fastening screws 5 5 Check fasteners for carburetor to engine and filter case E Check idle speed adjustment 5 Check conditions unbent positioning of vent pipes Check for leaks of the cooling system and coolant level 2 Chec
46. D TO MOUNT NEW SELF LOCKING NUTS AND TO TIGHTEN WITH CROSS SEQUENCE TIGHTENING TORQUE AT NUTS 35 NM BASIC INDICATIONS FOR TM DISC BRAKES CALIPERS The mounting system of the calipers of these models is floating 1 they are not rigidly joined to their support The lateral compensation always allows the pads to work in the best way on the discs The brake caliper fastening screws must be assembled using Loctite 243 and tightened at 25 Nm The front calipers of the SMR SMM SMX models are an exception as they are fixed type PADS The minimum thickness of the friction material cannot go under the limit of 1mm In case of replacement it is advised always to use TM original spare parts for your motorcycle BRAKE DISCS With wear the thickness of the brake disc is reduced in the contact area of the pads 1 In the thinnest point A the brake disc may present max wear of 0 4 mm with respect to original thickness The original thickness can be measured in point B outside of the contact area Check wear in different points BRAKE DISCS WITH WEAR EXCEEDING 0 4 MM ARE ARISK FOR SAFETY WHEN THE LIMIT OF WEAR HAS BEEN REACHED HAVE THE BRAKE DISCS REPLACED IMMEDIATELY IT IS COMPULSORY TO HAVE THE BRAKE UNIT REPAIRED BY A TM AUTHORISED WORKSHOP 45 2 ENGPISH FRAME AND ENGINE MATINTIENANG LECLE BRAKE FLUID RESERVOIRS The front and rear brake liquid reservoirs are dimensioned in a
47. E EVERY START UP To use the motorcycle safely it must be in a good shape It is a good idea to carry out a general check up of the motorcycle before every Start up This check must include the following operations 1 LEVEL OF ENGINE OIL To ensure adequate lubrication the level of the oil in the engine must be kept within the envisioned limits Using the engine with the oil level below minimum leads to premature wear and successively to damage and risks to the driver 2 FUEL If the motorcycle does not have a transparent tank open the tank cap and visually check the quantity of fuel contained in the tank Re close the tank making sure that the open vent pipe is not bent and 50 impeding the flow of air 3 CHAIN The drive chain must always be tensioned corretly and well lubricated A loose chain knocks and may escape from the sprockets A too 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 and serious accidents 5 BRAKES Verify correct working Check the level of brake fluid The reservoir on the pumps are dimensioned in a way that in c
48. E FAULTS TO THE ENTIRE ELECTRIC EQUIPMENT REPLACEMENT OF HEADLIGHT POSITION LIGHT BULB WITH STANDARD HEADLIGHTD END SMR SMM Release both elastic stripes and move the light holder mask forward HEADLIGHT TWO LIGHT BULB Disconnect the blue black and white cables and remove the rubber protection 7 Release the retainer and carefully extract the bulb 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 elastic stripes 55 WAINTENVANG ENGPISH FRAME AND ENGINE MARTINE LENO REPLACEMENT OF HEADLIGHT POSITION LIGHT BULB WITH CYCLOPS OPTIONAL HEADLIGHT END SMR SMM Disconnect both of the elastic stripes 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 correct position and lock with the screw taking care to insert the engine stop eyelet terminal under the head of the screw Remount the cover with the seal and connect the terminal HIGH BEAM BULB Remove the rubber protection 19 unscrew
49. F THE BATTERY IS SEALED IT IS POSSIBLE THAT EXPLOSIVE GASES MAY COME OUT KEEP THE BATTERY AWAY FROM SPARKS OR FLAMES KEEP FAULTY BATTERIES AWAY FROM CHILDREN AND DISPOSE OF THEM 4 IN THE CORRECT MANNER 20 WARNING THE CLOSURE STRIP 2 MUST NOT BE REMOVED AS OTHERWISE THE REGULATOR RECTIFIER WOULD BE DESTROYED THE BATTERY MUST BE MOUNTED WITH THE POLES IN FRONT AS IN THE FIGURE IF IT IS MOUNTED IN THE OPPOSITE DIRECTION THE ELECTROLYTE MAY COME OUT PRESERVATION If the motorcycle is kept at a standstill for a long time remove the battery and charge it Keep it at at temperature of 0 35 C away from direct sunlight BATTERY CHARGE Remove the battery and determine if it is charged or not To do this check 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 it is 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 CLOSED SPACES ENSURE GOOD VENTILATION THE BATTERY PRODUCES EXPLOSIVE GASES DURING CHARGING STATE OF CH
50. HE MOTORCYCLE 43 FRAME AND ENGINE MAINTENANG 22 USTMENT OF CHAIN TENSION SMM Loosen both the locking screws 7 of the rear eccentric hub in a way that the hub itself can turn around its axis Using the relevant TM tool code F50806 8 turn the hub until correct chain tension is reached Tighten the two locking screws to 30 Nm Since the movement is an eccentric system alignment of the rear wheel is unvaried and no further adjustment is required At the same time by turning the hub a slight variation in the height of the rear wheel axle may be verified and consequently of the rear part of the motorcycle It is possible to compensate this by varying the projection of the fork legs from the upper clamp For example if the motorcycle by effect of chain adjustment has lifted by 5mm at the rear it is advised to decrease the projection of the fork rods by about 5mm to also raise the front and restore the original levelling of the motorcycle It is advised to use the TM tool code F50806 pairing with two screws and two nuts to turn the hub inserting the two screws into the two holes in the hub itself A ATTENTION IF YOU DO NOT HAVE SUITABLE EXPERIENCE IT IS ADVISED TO HAVE THE OPERATION CARRIED OUT BY ASPECIALISED TM WORKSHOP CHAIN MAINTENANCE Chain duration depends most of all on maintenance Chains without O rings must be regularly cleaned with petroleum and then immersed in w
51. HLINS SHOCK ABSORBER OPTIONAL The adjustment knob 4 is situated low at the end of the damper rod Act manually By turning clockwise looking from the bottom upwards braking increases anticlockwise it decreases A total of 40 clicks are available A WARNING BEFORE STARTING IT IS ADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITION TO THE TOTALLY CLOSED POSITION AND COUNT THE CLICKS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NUMBER OF CLICKS IS INDICATED FROM THE TOTALLY CLOSED POSITION 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 OTHERWISE PARTS COULD BE DAMAGED AND PERSONS INJURED 19 LING CONTROLS ENGPISH LATE STEERING LOCK This lock is situated on the left side of the frame steering tube This lock stops rotation of the handlebar preventing the motorcycle being driven To lock the steering turn the handlebar completely to the right insert the key turn it to the left press turn to the right and extract A WARNING NEVERLEAVE THE KEY IN THELOCK BY TURNING THE HANDLEBAR TO THE LEFT THEKEY COULD BE DAMAGED 20 AND xou ADVICE GENERAL RECCOPMANDATIONS COMMISSIONING The INDICATIONS FOR FIRST START UP Ensure that the PRE DEL
52. IS ADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITION TO THE TOTALLY CLOSED POSITION AND COUNT THE CLICKS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NUMBER OF CLICKS IS INDICATED FROM THE TOTALLY CLOSED POSITION BOTH LEGS MUST HAVE THE SAME ADJUSTMENT A WARNING FOR FURTHER AND MORE DETAILED INFORMATION REGARDING THE FORK BOTH STANDARD AND OPTIONAL REFER TO THE OWNERS MANUAL SUPPLIED BY THE MANUFACTURER OF THE FORK SUPPLIED BY TM ACCOMPANYING THE MOTORCYCLE SHOCK ABSORBER ADJ UST 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 absorbers mounted on the TM offer the possibility of double adjustment in compression for low and high speeds Low and high speeds mean the movement speed of the damper in compression and not the speed of the motorcycle SACHS SHOCK ABSORBER STANDARD Low speeds The adjustment screw 6 is located on the top of the damper gas tank Use a screwdriver By turning clockwise braking increase anticlockwise it decreases A total of 24 clicks are available High speeds The adjuster is a knob 7 and is concentric to the low speed adjustment screw Act manually By turning clockwise braking increase ant
53. IVERY 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 front brake lever and the brake pedal so that they are in the most comfortable position Get used to driving in an empty carpark or on land where it is easy to handle the motorcycle before making a long journey Also try to move at a slow pace on foot to get used to the 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 push the brake pedal if you do not wish to brake If the brake pedal is not released the brake pads rub continuously and the brake overheats Do not modify the motorcycle and always use ORIGINAL TM SPARE PARTS Spare parts made by other manufacturers can jeopardise the safety of the motorcycle Motorcycles are sensitive to the movement of weight When carrying luggage fix it as near as possible to the centre of the motorcycle and distribute the weight equally between the front and rear wheel Follow running in instructions RUNNING IN INSTRUCTIONS The surfaces of 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 nec
54. NECEESARY TO BLEED THE COOLING SYSTEM SEE NEXT PAGE ALWAYS USE GOOD QUALITY PRODUCTS TO PREVENT CORROSION OR FOAM IN EXTREME WEATHER CONDITIONS OR IN STOP AND GO TRAFFIC OVERHEATING MAY OCCUR TO SOLVE THIS PROBLEM AN ELECTROVENTILATOR IS AVAILABLE FORALL MODELS WITH ELECTRIC STARTER ASK AT YOUR TM AUTHORISED DEALER 57 AND 22 CHECK COOLANT LEVEL When the engine is cold the liquid must cover the radiator channels by at least 10 mm If the circuit is emptied fill it immediately and bleed A WARNING WHEN THE COOLANT LIQUID HAS BEEN EMPTIED WHEN RE FILLING IT IS NEC ESSARY 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 comes out To empty the liquid the filling cap must be opened At the end screw the emptying screw and tighten to 12 Nm To fill the cooling system pour the amount of coolant liquid indicated in the Engine Technical Data Table through the inlet Close the radia tor cap and start up the engine for a few seconds Re open the cap and check the level add more liquid if necessary After a brief journey check the level of coolant liquid again REPLACEMENT OF EXHAUST SILENCER PACKING MATERIAL The
55. NT ISADVISED THE ABOVE MENTIONED OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP 35 axe n MAINTENANCE AND LUBRICATION TABLE LACIE ROAD HOBBY USE 60 90 120 180 240 270 0 HOURS OF FUEL CONSUMPTION HOURS HOURS HOURS HOURS Check cylinder and piston wear Check piston pin visual check 5 Check camshaft and valve lifters wear visual check 5 2 Check camshaft supports 5 Check timing chain after 30 hour check 5 Check and adjust valve clearance 5 Check spring valve length e Check upper and lower spring retainers wear 2 Check valve cotters and valve stem Check valve guide wear 5 Check valve sealing Check automatic decompressor working 5 5 Check head and cylinder surfaces e 5 Check engine cranshaft for trueness Replace conrod axle and roller cage 2 Check small end for marking damage to plating 5 Check pump and lubrication circuit x 5 Replacement of main bearings 2 2 Check complete gearbox including drum and forks 5 5 Check clutch plate wear 5 Check length of clutch springs a E S WARNING IF AFTER CHECKING IT IS DETECTED THAT THE WEAR LIMITS OF A SINGLE COMPONENT HAVE BEEN EXCEEDED THE COMPONENT MUST REPLACED THE ISTALLATION OF AN HOUR COUNTER INSTRUMENT ISADVISED THE ABOVE MENTIONED OPERATIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP 36
56. OCESS WOULD CONDENSE CAUSING THE OXIDATION OF THE EXHAUST VALVES START UP AFTER SEASONAL PAUSE Mount the charged battery pay attention to polarity Fill the tank with new fuel Control the motorcycle as before any start up see Instructions for use chapter Make a short inspection trip WARNING Before storing the motorcycle for the season check functioning and wear of all components If maintenance operations repairs or modifications are necessary it is a good idea to have them carried out during the winter time less busy workshops In this way it is possible to avoid long waits in the workshop at the beginning of the spring season 68 DATA ENGINE 250 450 2008 ENGINE Type Displacement Cylinder bore and stroke Compression Fuel Distribution E camshafts Inlet valve diameter Exhaust valve diameter Inlet valve cold clearance Exhaust valve cold clearance Crankshaft supports Conrod bearing Small end plating Piston Rings Lubrication Engine oil Oil capacity Primary transmission Clutch Gearbox with front engagement Gear ratios Ignition Generator Generator with E S optional Spark plug Electrode gap Cooling Coolant fluid capacity Start up 250 250 250 450 450 450 450 END MX SMX SMM SMR END MX SMX SMM SMR 4 stroke single cylinder DOHC liquid co
57. PLACEMENT OF REAR BRAKE PADS FOR ALL MODELS WITH FLOATING CALIPER END MX SMR SMX Push the brake caliper 1 towards the disc until the piston reaches its base position Remove the cap 2 using a screwdriver 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 THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER MOUNTING CHECK THAT THE SAFETY DEVICES ARE 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 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 fastening screws on the left and right fork shoes 6 finish unscrewing the
58. W 9 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 TIGHTENING TORQUES 250 450 530 END 250 450 530 MX Front wheel axle flanged nut M20x1 5 40 Nm Front brake caliper fastening screws END MX 25 Front brake disc fastening screws cl 10 9 15Nm Rear brake disc fastening screws M6 cl 10 9 15Nm Upper fork head fastening screws 20 Lower fork head fastening screws 20 Nm Paioli fork leg fastening screws 12 Ohlins fork leg fastening screws 12 Nm Rear wheel axle flanged nut M22x1 5 80 Nm Swing arm axle flanged nut M16x1 5 80 Nm Handlebar caps fastening screws 20 Handlebar elastic support nut M10 35 Nm Upper end shock nut M10x1 25 40 Nm Lower end shock nut M10x1 25 35 Nm Rear sprocket nuts 35 Nm Rear brake pedal adjustment nut M6 15Nm Engine fastening screws 10 45 General frame screws 10 25 Nm 10 45 General frame nuts 15 Nm 30 Nm M10 50 Nm 73 5 TECHNICAL DATA PANT TECHNICAL DATA 250 450 530 SMR SMM 250 450 530 660 SMX 2008 660 SMX 250 450 530 SMR 250 450 530 SMM 250 450 530 SMX Frame Twin spar high resistance aluminium alloy frame Marzocchi USD fork Paioli USD fork optional Ohlins USD 270 280 mm Aluminium swing arm Single arm on SMM Progressive mechanical linkage Sachs shock Oh
59. WELL WITH WATER AND SEEK MEDICAL ASSISTANCE A WARNING DONOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODES PAINT USE ONLY CLEAN BRAKE FLUID OUT OF A HERMETICALLY SEALED CONTAINER CHECK FRONT BRAKE PADS The brake pads can be checked 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 A WARNING IF THE BRAKE PADS ARE REPLACED TOO LATE AND ARE COMPLETELY WORN THE STEELPARTS OF THE PADS RUB ON THE DISC THIS LEADS TOANOTABLE DECREASE IN THE BRAKING EFFECT AND DAMAGE OF THE BRAKE DISC 47 5 22 REPLACEMENT OF FRONT BRAKE PADS FOR ALL MODELS WITH FLOATING CALIPER END MX Push the brake caliper towards the disc in a way that the brake pistons reach their base position Remove the safety devices 1 extract the pin 2 and remove the pads from the caliper Use compressed air to clean the brake caliper and the caliper support check that the driving pin seals are not damaged and if necessary grease them Mount the right brake pad and fix it with the pin Mount the left brake pad and insert the pin until it stops Mount the safety devices During mounting of the pads ensure that t
60. X 530 SMM SMR 530 SMX 660 SMX Type 4 stroke single cylinder DOHC liquid cooled Displacement 528 657 5cms Cylinder bore and stroke 98x70 mm 104 x 77 4 Compression Mist 11 9 1 12 21 12 4 1 12 4 1 unleaded fuel with min 95 RON Distribution DOHC 4 valves driven by silent chain E camshafts N2 N3 SM2 C1 SM1 C1 Inlet valve diameter 36mm 36 mm Ti 36 mm 36 mm Ti 36mm Ti Exhaust valve diameter 31 mm 31 mm Ti 31mm 31 mm Ti 31 mm Ti Inlet valve cold clearance mm 0 20 mm 0 20 mm 0 20 mm 0 20 mm 0 20 Exhaust valve cold clearance mm 0 25 mm 0 25 mm 0 25 mm 0 25 mm 0 25 Crankshaft supports 2 ball bearings 1 ball bearing 1 roller Conrod bearing silver plated needle cage Small end plating coppering Piston forged light alloy Rings 2 rings 1 oil scraper 1 ring 1 scraper Lubrication double oil pump delivery drainage Engine oil fully synthetic premium quality oil SAE 10W 50 API SG SH Oil capacity 1 4 litres 1 0 litre Primary transmission straight toothing gears 21 53 22 53 Clutch multiple discs in oil bath Gearbox with front engagement 5 speed 5 speed 5 speed 5 speed 5 speed Gear ratios 12 14 28 12 16 27 12 14 28 12 16 27 12 16 27 2 17 25 2817 24 2 11 23 2817 24 2 17 24 3419 23 16 19 19 23 16 19 16 19 4 21 21 4 21 21 4 21 21 4 21 21 4 21 21 24 19 5 23 20 5 23 20 23 20 52 25 22 Ignition Kokusan digital CDI with variable timing Generator 12V180W 12V180W Gener
61. arm chain oil or treated with chain spray Maintenance of chains with O rings is reduced to a minimum The best cleaning method is using lots of water Never use brushes or solvents to clean the chain When the chain is dry use a chain spray that is especially suitable for chains with O rings DO NOT ALLOW THE LUBRICANT TO REACH THE REAR TYRE OR THE BRAKE DISC OTHERWISE ADHERENCE TO THE GROUND OF THE REAR WHEEL AND REAR BRAKE ACTION COULD BE NOTABLY REDUCED AND IT COULD BE EASY TO LOOSE CONTROL OF THE MOTORCYCLE A WARNING ON MOUNTING THE CHAIN SPLIT LINK THE CLOSED PART MUST BE IN THE DIRECTION OF MOVEMENT Always check both engine and rear wheel sprockets and drive slider for wear necessary replace these parts Seul 44 FRAKE AND ENGINE MATINTENANGI LATE CHAIN WEAR To check chain wear follow carefully the instructions given below put the gear into neutral pull the upper part of the chain in an upward direction with a force of 10 15 kilogrammes see figure Now measure the distance of 18 links on the lower part of the chain If the distance exceeds 272 mm it is advised to replace the chain The chains are not always worn in a even way For this reason the measurement must be taken in different points on the chain INDICATION When a new chain is mounted also replace the sprockets A new chain wears more quickly on old and worn sprockets A WARNING WHEN THE CHAIN SPROCKETS ARE REPLACED IT IS ADVISE
62. art 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 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 ELECTRONIC DIGITAL BACKLIT DISPLAY TACHOMETER OPTIONAL FOR SMR SMM As an option to the standard instrument on the models fit with battery and Electric Start you may find the Tachometer Odometer shown in Fig 1 It has a wide backlit display and four pilot lights In the top there are the left indicator pilot light 2 the low beam pilot light 3 the high beam pilot light 4 and the right indicator pilot light 5 Inside the display you find the tachometer 6 the trip odometer 7 and the total k
63. ase of normally worn brake pads the fluid does not need to be topped up If the level of brake fluid falls below the minimum level this indicates a leak in the brake system or complete consumption of the brake pads Have the brake system checked by a specialised TM workshop given that in this case the brakes could fail The state of the brake s flexible pipes and the thickness of the pads must also be checked Check the free play and the smoothness of the front brake lever and the rear brake pedal 6 FLEXIBLE CABLE COMMANDS Check the adjustment and correct working of all flexible cable commands 7 COOLANT Check the level of coolant with cold engine Top up with the liquid stated in the table if necessary 8 ELECTRICAL PLANT With the engine running check for the front headlight the front and rear position lights the rear stopping light the direction indicator lights the control lights and the horn 9 LUGGAGE Check that any luggage is well fixed 24 INSTRUCTIONS FOI A USE LATE COLD ENGINE START 1 Open the fuel tap 1 2 Remove the motorcycle from the stand 3 Put the gears in neutral 4 Activate the choke command 2 which is located on the left side of the motorcycle 5 WITHOUT opening the throttle press hardly the kickstarter DOWN TO THE BOTTOM once or twice or operate the electric starter 6 Start to warm the engine by accelerating slightly for about 30 secs Disconn
64. at a distance of about 5 mm from the head and operate the starting system if there is a spark replace the spark plug cover if there is still no spark check the ignition system Replace the spark plug Hemove the saddle and fuel tank disconnect the emergency shutdown button cable or the engine stop button cable and check the spark If there is a spark look for the fault along the emergency shutdown button cable or the engine stop cable Remove the saddle the left side panel and the fuel tank clean the connectors and treat them with a contact spray Disassemble and clean the carburetor 66 y 77 TROUBLESHOOTING 2 PROBLEM CAUSE SOLUTION Clogged idle speed jet Disassemble the carburetor and clean the jet THE ENGINE WILL NOT Altered idle speed adjustment screws Adjust the idle speed screws RUN AT IDLE SPEED Damaged spark plug Replace the spark plug Faulty Ignition system Have the ignition system 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 worn and the state of the needle valve as described in the Frame REACH FULL SPEED and Engine Maintenance chapter The carburetor jets are loose Tighten the jets The ignition timing is not correct Have the ignition timing checked Fuel supply partially interrupted or dirty carburetor Clean and chec
65. ator with E S optional 12 V 180W Spark plug NGKCR8E Electrodes gap 0 8 Cooling liquid cooled 40 antifreeze 60 water up to 25 C forced circulation with pump Coolant fluid capacity 1 3 litres 1 litre 1 3 litres Start up 5 5 E S K S K S E S opt E S opt LEGEND E S Electric start K S Kickstart ENGLISH 70 SIHOIY OOL 91019600 9 044 9600 909646 90119600 JojeJejeooy 911044 0 904 960 9 041960 9 040 960 011 0 86 86 86 86 e zzou 914 1 87 uni GZ M S 10 4 G I pE pE o pE pE uonisod 320 320 dAON dAON dAON Ief 09 09 jeriolld 961 69 69 081 69 jer Irado 234 gt 4 4 4 Or 220 1 2 UU G LL Q EL joe oud weJos WW 768 0 18 soy 86 86 9 2201 LL LL 10 021 021 jer ub oL M J 10144 0 0402 do WOJ p 0 pE uonisod di5 28 1401 281401 lef 9 4 9 4 09 GV Jer 1014 041 0 1 jor 8 1 LOLOTLOE 8002 SE E a ON DNE S R ONE I9
66. ck absorber maintenance Cleaning and greasing of steering bearings and related sealing elements 5 Cleaning and tuning of the carburetor Treatment of electric contacts and switches with contact spray x Treatment of battery connections with contact grease Replacement of hydraulic clutch fluid Replacement of brake fluid 2 The distance between maintenance intervals should be exceeded by more than 2hours or 15 litres THE MAINTENANCE CARRIED OUT BY THE AUTHORISED TM DEALER DOES NOT REPLACE THE CHECKS AND MAINTENANCE CARRIED OUT BY THE RIDER 33 5 MAINTENANCE AND LUBRICATION BRIEF CHECK AND MAINTENANCE OPERATIONS TO BE PERFORMED BY THE RIDER PILOT Check engine oil level Check brake fluid level 5 Check brake pad wear e Check light system if present Check horn if present x Lubrication and adjustment of command cables Bleed fork legs 5 Disassembly and cleaning of the dust shields Cleaning lubrication and tension check of final transmission chain Cleaning filter case and air filter 2 Check coolant level e Check fuel pipe for leaks Cleaning of caburetor and jets for dirt water removal Check smoothness of all command elements Check braking effect Treatment of bright metal parts apart from brake and exhaust system with anti corrosives Treatment of ignition switch steering lock with contact spray
67. crews 12Nm Rear wheel axle flanged nut 22 1 5 80 Nm Swing arm axle flanged nut M16x1 5 80Nm Handlebar caps fastening screws 20 Handlebar elastic support nut M10 35Nm Upper end shock nut M10x1 25 40 Nm Lower end shock screws M10x1 25 35Nm Rear sprocket nuts 35 Nm Rear brake pedal adjustment nut 15 Engine fastening screws 10 45 Rear wheel nut SMM M50 185 Nm Rear hub locking screws SMM 12 1 25 31 Nm General frame screw M6 10 Nm M8 25 Nm M10 45 Nm General frame nuts 15Nm 30 10 50Nm ENGIISE A A DE ALFFADE Page ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE 21 Adjustment of chain tension all models except SMM 43 Adjustment of chain tension 44 Adjustment of clutch lever basic 60 ALPHABETIC ux doa ntt 75 Basic calibration of the chassis on the basis of pilot weight 40 Basic indications for TM disc 45 Basic indications regarding carburetor 61 Battery all models with 9 53 aprirne 54 PIKO STARI 26 Bleeding hydraulic clutch 6
68. d reaches the centreline on the window situated on the pump it must be topped up Unscrew the two screws 4 and remove the lid Top up with DOT4 brake fluid to the top of the window Remount the lid and tighten the screws Wash any spilled brake fluid away with water NEVER USE DOT5 BRAKE FLUID IT IS A PURPLE SILICONE OIL BASED BRAKE FLUID IT REQUIRES THE USE OF SPECIAL SEALS AND HOSES KEEP THE BRAKE FLUID OUT OF CHIDREN S REACH THE BRAKE FLUID CAN IRRITATE THE SKIN DO NOT ALLOW IT TO TOUCH THE SKIN OR EYES IF THE BRAKE FLUID SHOULD SPRAY INTO THE EYES RINSE WELL WITH WATER AND SEEK MEDICAL ATTENTION A WARNING DONOT ALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS BRAKE FLUID CORRODES PAINT USE ONLY CLEAN BRAKE FLUID FROM A HERMETICALLY SEALED CONTAINER 49 ENGPISH FRAKE 22 CHECK REAR BRAKE PADS The brake pads must be controlled from the rear side The thickness of the pad friction material must not be less than 1 mm AT THE THINNEST POINT THE THICKNESS OF THE BRAKE PAD FRICTION MATERIAL MUST NOT BE LESS THAN 1 MM OTHERWISE A FAULT COULD OCCUR IN THE BRAKES IN THE INTEREST OF YOUR SAFETY HAVE THE PADS REPLACED IN TIME A WARNING IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE FRICTION MATERIAL IS COMPLETELY CONSUMED THE STEEL PARTS OF THE PADS RUB ON THE DISC THIS LEADS TOANOTEWORTHY DECREASE OF THE BRAKING EFFECTAND DAMAGE OF THE BRAKE DISC RE
69. e the screws 2 and remove the cover 3 together with the rubber seal 4 The clutch cylinder 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 reservoir is always sufficient and prevent the pump from taking up air If necessary top up with DOT4 brake fluid WARNING FORTHE HYDRAULIC COMMAND OF THE CLUTCH TMUSES 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 RAMUS ANDY ENGINE 22 CARBURETOR IDLE SPEED ADJ USTMENT The adjustment of the idle speed greatly influences the engine start this means that an engine with the idle speed correctly adjusted will be easier to start than an engine with an incorrect idle speed The idle speed is adjusted using the adjustment knob 1 and the mixture adjustment screw 2 The adjustment knob is used to adjust the basic position of the throttle valve The mixture adjustment screw is used to adjust the mixture for the idle speed which flows through the idle speed system up to the engine By turning a
70. e wheel to permit positioning of the thick shim brake side Finish inserting the axle insert the chain tensioner slide screw the nut and tighten it at 80 Nm Before tightening the flanged nut push the rear wheel forward until the chain tensioners are in contatct with the heads of the adjusting screws IF YOU DO NOT HAVE DYNAMOMETRIC WRENCH WHEN MOUNTING HAVE THE TIGHTENING TORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER HAVING RE ASSEMBLED THE REAR WHEEL ALWAYS ACTIVATE THE BRAKE PEDAL SO THAT THE PADS ADHERE TO THE DISC AGAIN TIGHTEN THE FLANGED NUT WITH THE ESTABLISHED TIGHTENNGTORQUE ALOOSE WHEEL AXLE CAN LEAD TO UNSTABLE DRIVING 51 ENGLISH FRAKE AND ENGINE MATINTENANGI 22 DISASSEMBLY AND ASSEMBLY OF REAR WHEEL SMM Rest the motorcycle with the frame cradle on a stand in a way that the rear wheel does not touch the ground Cut the safety binding 6 slide out the clasp 7 and unscrew the wheel nut M50x1 5 8 Pay attention to the conical shim 9 placed between the nut and ring Extract the wheel carefully A WARNING WHEN THE WHEEL NUT IS DISASSEMBLED THE SHAFT AND NUT THREADS MUST BE CLEANED CAREFULLY RE GREASE THEM TO PREVENT SEIZING OF THE THREADS To assemble proceed in the oppos
71. e play of about 5mm must be perceived on the end of the lever The end of the free play is recognised by the hardening of the lever that starts to open the right exhaust valve Adjust the free play 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 1 2 M S TIN TD TEIN ZAIN CH ENGPISH FRAME AND ENGINE MARTINE 22 THROTTLE CABLE COMMAND ADJ USTMENT The throttle command should always have a free play of 3 5 mm Moreover when the engine is idling the revs must not vary when steering as far as possible to the left and to the right To adjust the play remove the saddle and the tank with the shrouds Push the protection hood backwards 3 Loosen the counter nut 4 and unscrew or screw the adjustment device 5 By screwing the free play increases By unscrewing the free play decreases Tighten the counter nut and control the smoothness of the the throttle command handlebar grip 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 activates the accelerator pump This could flood the engine
72. eck the O Ring and replace it if necessary Insert a new filter cartridge making sure that the open side is towards the outside of the engine The filter must slide into the transmission cover as far as possible in its seat ENGLISH 64 FRAKE AND ENGINE MATINTENANGI LATE Remount the cover being careful to the O Ring and to insert the filter cover nose correctly into the hole of the filter cartridge Greasing the O Ring with a small amount of grease helps to keep it in its seat when assembling Tighten the screws at 10Nm REMEMBER THAT THE FILTER CARTRIDGE CANNOT BE CLEANED IT MUST BE REPLACED AT THE ENVISIONED INTERVALS Prepare a measuring beaker with 1 4 1 0 for 660 SMX Litres of fully 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 LONGER TO PREVENT DAMAGE the cap and finish filling with the oil remaining in the measuring beaker A total of 1 4 1 0 for 660 SMX Litres of oil has been introduced Tighten the cap at 20Nm Start 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 5 WROUBLESHOOTING If you have the envisioned maintenance operations carried out on your
73. ect the choke 2 which is situated 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 KICKBACK AND MAKE YOU KNOCK YOUR FOOT VIOLENTLY ALWAYS PRESS THE KICKSTARTER DOWN HARD WITHOUT ACCELERATING KICKSTARTING WITH LITTLE FORCE OR WITH OPENED THROTTLE INCREASES THE RISK OF ENGINE KICK BACK DONOT START THE ENGINE IN A CLOSED SPACE AND NEVER LEAVE IT RUNNING IN CLOSED SPACES THE EXHAUST FUMES ARE POISONOUS AND MAY LEAD TO RISK OF UNCONSCIOUSNESS AND DEATH WHEN THE ENGINE IS RUNNING ALWAYS ENSURE THERE IS SUFFICIENT VENTILATION ALWAYS CHECK THAT THE GEAR IS IN NEUTRAL BEFORE OPERATING THE STARTER BUTTON IF A GEAR IS INSERTED WHEN STARTING THE ENGINE THE MOTORCYCLE WILL JUMP FORWARDS WARNING OPERATE THE STARTER FOR MAX 5 SECONDS ATATIME WAIT ANOTHER 5 SECONDS BEFORE TRYING AGAIN DONOTALLOW THE ENGINE REVS TO INCREASE TOO MUCH WHILE THE ENGINE IS COLD THIS COULD DAMAGE THE ENGINE BECAUSE THE PISTON HEATS UP AND CONSEQUENTLY IT EXPANDS QUICKER THAN THE CYLINDER WHICH IS WATER COOLED ALWAYS WARM THE ENGINE AT ASTANDSTILL OR MOVE ATLOW REVS WARM ENGINE START 1 Open the fuel tap 1 2 Remove the motorcycle from the stand 3 Insert the neutral gear 4 WITHOUT opening the throttle press hardly the kickstarter DOWN TO THE BOTTOM once or twice or operate the electric starter A WARNING
74. ed TM workshop which is backed by the TM importer Please remember that a lot of technical data and information regarding TM motorcycles is available at www tmracing it Motorcycling is a marvellous sport that you will be able to enjoy with your TM motorcycle Always remember to respect the environment and other people Always use the motorcycle with caution it is in everybodys interest to safeguard the future of our sport Enjoy yourself with your TM motorcycle TM RACING S p A Via Fano 6 61100 PESARO ITALY TM RESERVES THE RIGHT TO CHANGE OR TO EXECUTE MODIFICATIONS AS IT DEEMS NECESSARY 4 IMPORTANT ADVICE REGARDING THE LEGAL WARRANTY AND THE COMMERCIAL WARRANTY TM sport motorcycles are designed and constructed in a manner to support the stress that may be verified in normal road and competition use Competition motorcycles are in compliance with the regulations of the categories actually in force at the most important international motorcycling federations The scrupulous compliance with the established inspections maintenance and tuning of the engine and chassis part of the motorcycle indicated in the user manual is indispensable for correct 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 The maintenance operations established in the Maintenance and Lubrication
75. ent of chain tension 44 Chain 44 Chan 45 Basic indications for disc brakes 45 Free play adjustment of front brake 46 Check front brake fluid level 47 Top up front brake fluid si sicanccs carne 47 Check front brake pads 47 Replacement of front brake 48 Modification of rear brake pedal base position 49 Check rear brake fluid level 49 Top up rear brake fluid 49 Check rear brake pads 50 Replacement of rear brake 50 Disassembly and assembly of front wheel 50 Disassembly and assembly of rear wheel all except SMM 51 Disassembly and assembly of rear wheel SMM 52 Check spoke tension 52 Tyres 53 Battery all models with 53 Check adjustment magnet sensor distance 53 Battery Charge 54 Recharge fuse all models with 5
76. er spring increased by some clicks CHECK TELESCOPIC FORK BASIC CALIBRATION For several reasons the exact lowering in running order of the telescopic fork can not be established Small variations in body weight can be compensated as for the rear shock through the spring pre load If your telescopic fork however lowers completely it is necessary to use an higher rate fork spring to prevent damage to the telescopic fork and frame VARIATION OF TELESCOPIC FORK PRE LOAD To vary the spring pre load on these telescopic forks it is necessary to disassemble them partially see specific manual of the fork mounted on the motorcycle It is possible to add pre load spacers The fork springs however can be pre loaded to a max of 20 mm 41 5 PRAM AND ENGINE MATINTIENANG 22 REPLACEMENT OF FORK SPRINGS If your body weight is less than 70 kg or exceeds 80 kg adequate fork springs must be used If you are in doubt or have any questions please contact your authorised TM dealer According to our experience the dampening grade in compression can remain unvaried With a softer spring the dampening grade in rebound can be reduced by some clicks with a harder spring increased by some clicks A WARNING FOR FURTHER AND MORE DETAILED INFORMATION REGARDING THE STANDARD AND OPTIONAL FORK REFER TO THE INSTRUCTION BOOK SUPPLIED BY THE MANUFACTURER OF THE FORK AND GIVEN BY TM ACCOMPANYING THE MOTORCYCLE
77. essity for running in the new engine To obtain an optimal bedding of the moving parts of a new engine it must be taken to produce maximum performance gradually For this reason during the first 3 hours of use 1 hour for 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 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 WITH NO COMPROMISE FOR OFF ROAD COMPETITIONS 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 22 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 IS 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
78. ge where it is purified from all particles and delivered partly to the crankshaft and partly to the distribution and gearbox The oil delivered to the crankshaft enters through a co axial pipe into the shaft and finally 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 gearbox of which it lubricates through a distributor 7 the gear toothing 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 camshafts bearings and to the contact area between the cam lobes and valve lifters 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 The oil circulation is made only by channels machined inside the engine without using external hoses 62 lt 11 WAINTENVANG 6 lt 1117
79. ght foot rest The basic position can be adjusted on the basis of the position of the saddle see maintenance operations SIDE STAND Push the side stand to the floor using the foot and rest the motorcycle on it Pay attention that the ground is solid and the position stable ix 16 7 1279 SIDE STAND FIXING FOR OFFROAD ROUTES If you drive the motorcycle off road the closed side stand can be additionally fixed using a rubber band 2 IGNITION SWITCH In the SMR and SMM models an ignition key is added on the left side of the dashboard By turning the key clockwise the electric circuit is closed and after the starter button has been pushed so as to close the contact with the battery it is possible to operate 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 anticlockwise FORK ADJ USTMENT IN COMPRESSION The hydraulic brake system determines 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 clockwise braking increases turning anticlockwise it decreases A total of 26 clicks are available MARZOCCHI
80. he distance between the chain and rear fork must be about 10 15 mm Adjust the tension if necessary IF THE CHAIN IS TOO TIGHT THE FINAL TANSMISSION COMPONENTS CHAIN GEARBOX AND REAR WHEEL BEARINGS ARE GREATLY STRESSED AS WELL AS A PREMATURE WEAR IN EXTREME SITUATIONS THE CHAIN OR GEARBOX DRIVEN SHAFT MAY BREAK IF HOWEVER CHAIN TENSION IS INSUFFICIENT IT CAN EXIT FROM THE SPROCKET AND LOCK THE REAR WHEEL OR DAMAGE THE ENGINE INBOTH CASES IT IS EASY TO LOOSE CONTROL OF THE MOTORCYCLE ADJ USTMENT OF CHAIN TENSION ALL MODELS EXCEPT SMM Loosen the wheel axle nut 1 loosen the counter nuts 2 and turn the adjustment bolts 3 to the left and to the right by the same amount To increase chain tension unscrew the adjustment bolts To decrease chain tension screw the adjustment bolts Reach correct chain tension For correct alignment of the rear wheel the marks 4 on the right and left chain tensioner must aligned with respect to the reference markings 5 Tighten the adjustment screw counter nuts Before locking the wheel axle nut check that the chain tensioners 6 are laying on the heads of the adjustment bolts and that the rear wheel is aligned with the front wheel Tighten the wheel axle nut to 80 Nm ATTENTION IFYOU DO NOT HAVE ADYNAMOMETRIC WRENCH FOR ASSEMBLING HAVE THE TIGHTENING TORQUE CHECKED BY ASPECIALISED TM WORKSHOP AS SOON AS POSSIBLE A LOOSE WHEEL AXLE MAY CAUSE UNSTABLE DRIVING OF T
81. he protection sheet steel in the caliper support and the leaf spring are correctly positioned FOR ALL MODELS WITH FIXED CALIPER SMR SMM SMX SMR SMM Unscrew the two M8 screws 1 and remove the caliper Lever the pads to allow the pistons go back 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 lami nate the pin and the safety retainer then remount the caliper and tighten the M8 screws at 25Nm SMX Unscrew the two M10 screws 10 and remove the caliper from the fork shoe Press the two hooks one at a time 8 to release and Slide the retainer pins out 9 Lever on each pair of pads to allow the pistons to go back to their seat Extract the worn pads and insert the new ones Repeat the operation for the other pair of pads Press the two hooks down and re insert the pins make sure that they are fully inserted have their play and are correctly attached Remount the caliper and tighten the M10 screws at 40Nm A WARNING FORALL MODELS WHEN THE CALIPER PISTONS ARE PUSHED BACK TO THEIR SEAT TO PROVIDE ROOM FOR THE NEW PADS PAY ATTENTION THAT THE FLUID CONTAINED IN THE RESERVOIR HAS THE SPACE TO EXPAND DO NOT WORK WITHOUT THE CAP MOUNTED OTHERWISE THE FLUID COULD OVERFLOW AND DAMAGE PARTS OF THE MOTORCYCLE THE BRAKE DISC MUST ALWAYS BE KEPT FREE FROM OILAND GREASE OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY REDU
82. ic fork dust 39 te A HGT 59 10 Cold enone Stai Nc 25 Combination switch END SMR SMM 13 Combination switch supplied with Electronic digital backlit display tachometer scsesscecencedsiecsvesstecaedeadencdodsveddetsieussenssinienesns 13 80 04 TET 10 57 Disassembly and assembly of front wheel 50 Disassembly and assembly of rear wheel all except SMM 51 Disassembly and assembly of rear wheel SMM 52 Electronic digital backlit display tachometer END 5 12 Electronic tachometer 11 Emptying filling and bleeding of the cooling system 58 Emptying the carburetor float 62 ICI NER REC 8 63 Engine stop switch MX SMX 13 ENGINE TIGHTENING 6 9 72 Establishing rear shock lowering in running order 40 Establishing rear shock static lowering 41 Fork adjustment in compression
83. ices consumers ancilleries The engine will not start even with the pedal On these models position it like this to switch the engine off 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 NL enables the use of all services including electric 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 3 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 irying 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 inlet 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 located on the left hand side of the tank base OFF the OFF position the fuel tap is closed ON On the ON position the fuel tap is open When the motorcycle is used turn the tap to the ON position
84. iclockwise it decreases A total of 20 clicks are available 18 OFERATING CONTROLS 2 OHLINS SHOCK ABSORBER OPTIONAL Low speeds The adjustment screw 1 is on the top of the damper gas tank Use a screwdriver By turning clockwise braking increases anticlockwise it decreases A total of 25 clicks are available High speeds The adjuster is a hexagonal ring nut 2 and is concentric to the low speeds adjustment screw Use a 17mm hexagonal spanner By turning clockwise braking increases anticlockwise it decreases A total of 4 clicks are available A WARNING BEFORE STARTING IT IS ADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITION TO THE TOTALLY CLOSED POSITION AND COUNT THE CLICKS TURNS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED FOR CONVENTION THE NUMBER OF CLICKS TURNS ARE INDICATED FROM THE TOTALLY CLOSED POSITION SHOCK ABSORBER USTMENT IN REBOUND The hydraulic brake system in rebound determines the behaviour of the shock absorber in rebound stroke The degree of hydraulic braking in rebound can be adjusted on the basis of pilot preferences and or hardness of the spring installed SACHS SHOCK ABSORBER STANDARD The adjustment screw 3 is situated on the fork of the shock absorber side of mechanical linkage Use a screwdriver By turning clockwise braking increases anticlockwise it decreases A total of 40 clicks are available O
85. ilometers odometer 8 In the bottom there are two buttons SET 9 and MODE 10 The instrument unit is the Kmh but it can be easily changed in Mph in the following way press and hold the SET button while holding it press once the MODE button Repeat the same operation to switch back to Kmh The trip odometer can be reset pressing the SET button once The total kilometres odometer resets automatically when reaching the limit of 99999 Km or Miles The instrument switches on automatically when pressing and posi tioning outwards the red button located near the throttle command and switches off when pressing and positioning inwards the red button itself 12 OPEKAIING CONTROLS ENGINE STOP SWITCH 5 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 A lights off position lights on position lights and lowbeam on D position lights and highbeam on Key 1 activates the horn Use cursor 2 to activate the direction indicators mo
86. ing for carburetor to engine and filter case 5 Check idle speed adjustment 2 5 2 Check conditions and unbent positioning of vent pipes 5 Check for leaks of the cooling system and coolant level Check for leaks and tightness of all drain screws 5 Check conditions smoothness unbent positioning of all pipes and cables dd adjustment and lubrication of throttle and decompressor cables 5 Check fluid level the hydraulic brake and clutch reservoirs 5 2 Clean filter case and air filter 2 y Check conditions and unbent positioning of cables Check headlamp orientation Check electric system head light high beam stop indicators lights horn safety button switch A Check brake fluid level pad thickness brake discs 2 Check conditions of brake hoses Check functionality adjustment smoothness and free play of front brake lever and brake pedal ai Check brake hoses screws tightness 5 Check for leaks and working of shock absorber and forks 5 x i Clean dust screen 5 lt Bleed fork leg 5 Check rear suspension mechanical linkage screw tightness 2 Check and adjustment of steering bearings 5 2 Check tightness of chassis screws fork clamps fork legs wheels axles nuts and screws rear 2 5 fork axle shock absorber Check spoke tension and trueness of rims 5 d Check tyre conditions and pressure 5 2 i Check chain wear chain link sprockets chain tension 5 Chain lubrication
87. ite direction tightening the 50 1 5 wheel nut at 185 Nm Remount the clasp and re make the safety binding DONOT FORGET TO CARRY OUT THE SAFETY BINDING AT THE ENDS OF THE CLASP IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH WHEN MOUNTING HAVE THE TIGHTENING TORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP A LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING THE BRAKE DISC MUST ALWAYS BE PERFECTLY CLEAN FROM OIL AND GREASE ON THE CONTRARY THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER HAVING RE ASSEMBLED THE REAR WHEEL ALWAYS ACTIVATE THE BRAKE PEDAL SO THAT THE PADS ADHERE TO THE DISC AGAIN CHECK SPOKE TENSION Correct tension of the spokes is very important for the stability of the wheel and therefore safety on the road An insufficiently taught spoke leads to unbalancing of the wheel and in brief time loosening of other spokes Regularly check the tension of the spokes particularly on new motorcycles Briefly hit every spoke with the end of a screwdriver see photo the spoke should produce a clear sound Hollow sounds mean loose spokes In this case you must have the spokes adjusted in a specialised workshop The wheel must also be centred IF YOU CONTINUE TRAVELLING WITH INSUFFICIENTLY TIGHT SPOKES THEY MAY TEAR CAUSING PROBLEMS OF INSTABILITY EXCESSIVELY TIGHT SPOKES MAY TEAR DUE TO LOCAL OVERLOADING 52 ERAKI MALIHAN LATE TYRES TYRE PRESSURE N PRESSURE
88. k for leaks and screws tightness of the all exhaust system Check conditions smoothness unbent positioning adjustment and lub of command cables 2 5 Replacement of silencer packing material E 2 Check fluid level in the hydraulic clutch reservoir 2 2 Cleaning of filter case and air filter T Check conditions and unbent positioning of cables Check head light orientation END s Check electric system head light high beam stop indicators lights horn END version safety 5 button switch Check brake fluid level pad thickness brake discs 5 5 v Check conditions of brake hoses 5 2 Check functionality adjustment smoothness and free play of front brake lever and brake pedal 2 hd E Check brake hoses screws tightness 2 Check for leaks and working of shock absorber and forks 5 E Clean dust screen 5 Bleed fork legs 5 Check rear suspension mechanical linkage screw tightness Check and adjustment of steering bearings 2 5 O Check tightness of chassis screws and bolts fork clamps fork legs wheel axles nuts and screws 2 rear fork axle shock absorber Check spoke tension and trueness of rims 5 ud Check tyre condition and pressure 2 Check chain wear chain link sprockets and guides chain tension 2 Chain lubrication Check wheel bearing play 5 9 OTHER IMPORTANT MAINTENANCE OPERATIONS RECCOMMENDED EVERY 3 COMPETITIONS EVERY 3 RACES Complete fork maintenance 5 Complete sho
89. k the fuel circuit and the carburetor Float not leakproof Replace the float Air filter very dirty Clean or replace the air filter contact a specialised workshop POOR ENGINE POWER Exhaust system not leakproof deformed or Check the faulty parts on the exhaust system replace the fibreglass in the silencer packing damaged fibreglass in the silencer Insufficient valve clearance Adjust the valve clearance There is a loss of compression because the hand decompressor hasn t got enough free play it remains Adjust the hand decompressor flexible cable command tight The ignition timing is not correct Have the ignition timing checked SS SS al ENGINE MISFIRINGS OR Fuel missing Clean and check the fuel circuit and the carburetor BACKFIRES FROM THE CARBURETOR Air leaks in the intake manifold Check the rubber manifolds between the filter case and the carburetor and between the carburetor and head and tighten the clamps There is not enough fluid in the cooling system Fill with coolant see and Engine Maintenance chapter check for leaks of the cooling system Insufficient ventilation Continue at sustained speed it is possible to mount a fan optional THE ENGINE OVERHEATS Air in the cooling system Bleed the cooling system EXCESSIVELY The radiator fins are very dirty Clean the radiator fins with jets of water Foam in the cooling system Replace the coolant use good antifreeze The radiator hose is bent Shorten the radiator hose or
90. l data for the correct value for your motorcycle If necessary adjust the height by slightly bending the float adjustment plate 4 If possible also check the tightness and the state of wear of the needle valve cone if in doubt replace the valve and brass seat Mount the float bowl mount the carburetor and adjust the idle speed EMPTYING THE CARBURETOR FLOAT BOWL After washing or driving in wet environments watercourses etc the carburetor float bowl should be emptied to remove any water that may have entered Water in the float bowl causes working problems Carry this operation out when the engine is cold Close the fuel tap and place a container underneath the carburetor to collect the fuel coming out Now open the screw 1 to empty the fuel and water Re close the screw open the fuel tap and control tightness of the system THE FUEL IS HIGHLY INFLAMMABLE AND TOXIC HANDLE THE FUEL WITH CARE NEVER CARRY OUT OPERATIONS ON THE FUEL SYSTEM NEAR TO FLAMES OR CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL USE A CLOTH TO REMOVE ANY OVERFLOWING FUEL MATERIALS IMPREGNATED WITH FUEL ARE ALSO HIGHLY INFLAMMABLE IF YOU SWALLOW FUEL OR IT COMES INTO CONTACT WITH THE EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF FUEL ACCORDING TO THE REGULATIONS ENVISIONED IN YOUR COUNTRY OIL CIRCUIT The delivery pump 3 sucks the oil through the net filter 4 from the sump The oil is delivered pressurised through a pipe 5 to the filter cartrid
91. l soaps found on the market should be used to clean the motorcycle Particularly dirty parts should be cleaned using a brush After having rinsed the motorcycle well using a weak jet of water dry using compressed air and a cloth Empty the carburetor bowl Immediately after make a brief journey until the engine has reached the normal working temperature and at this point activate the brakes Because of the heat the water that is left in the unreachable points and on the brakes will evaporate After the motorcycle has cooled down oil and grease all motion parts and bearings Treat the chain with an appropriate spray Also oil the fuel tap To prevent faults in the electric system treat the emergency shutdown button the engine stop button the light switch and the connectors with contact spray PRECAUTION FOR WINTER USE JIN US If the motorcycle is also used in winter it is necessary to consider the salt on roads and appropriate countermeasures must be taken against the salt aggressiveness The motorcycle must be cleaned well after use and left to dry Treat engine carburetor swing arm and all other bright or galvanised components except brake disc with wax based anti corrosives PREVENT CONTACT OF THE 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 WATER AND LEAVE
92. l the engine has stopped or the red emergency shutdown button In this case it is advised to leave the red button in this way until the engine is started again Close the fuel tap park on solid ground and lock the motorcycle using the steering lock MOTORCYCLES PRODUCE ALOT OF HEAT DURING WORKING THE ENGINE RADIATORS EXHAUST SYSTEM BRAKE DISCS AS WELL AS SHOCK ABSORBERS CAN ALL BECOME VERY HOT NEVER TOUCH THESE PARTS WHEN DRIVING AND AFTER HAVING SWITCHED THE ENGINE OFF PARK THE MOTORCYCLE IN A WAY THAT PEDESTRIANS CANNOT TOUCH THEM AND BEBURNED A WARNING NEVER SWITCH THE ENGINE OFF USING THE DECOMPRESSOR LEVER BUT USE THE ENGINE STOP SWITCH OR THE EMERGENCY SHUTDOWN BUTTON THE FUEL TAP MUST ALWAYS BE CLOSED WHEN THE MOTORCYCLE IS PARKED IF IT IS NOT CLOSED THE FUEL COULD RUN OUT INTO THE CARBURETOR AND PENETRATE THE ENGINE FLOODING IT NEVER PARK WITH THE ENGINE RUNNING OR PARK THE MOTORCYLE IN PLACES WHERE THERE IS THE RISK OF FIRE DUE TO DRY GRASS OR OTHER EASILY INFLAMMABLE MATERIALS 28 INSTRUCTIONS FOI 151 INDICATIONS REGARDING THE SIDE STAND Push the stand forward until it stops and lean the motorcycle on it Ensure that the ground is solid and the parking position is stable For greater safety insert the 1st gear A WARNING THE SIDE STAND IS DESIGNED ONLY FOR THE WEIGHT OF THE MOTORCYCLE NEVER SIT ON THE MOTORCYCLE WHEN IT IS RESTING ON THE SIDE ST
93. lf throttle and at reduced pace to allow the engine to reach an adequate working temperature Cooling takes place thanks to the passage of air through the fins of the radiator the lower the speed the less the cooling effect Dirty radiator fins also decrease the cooling effect The pressure caused by the high liquid temperature is adjusted by a valve on the radiator cap 2 it is possible to reach temperatures of 120 C without problems CHECK THE LEVEL OF THE COOLANT LIQUID WHEN THE ENGINE 1 COLD IF YOU MUST REMOVE THE RADIATOR CAP WHEN THE ENGINE IS HOT COVER IT WITH A CLOTH AND OPEN SLOWLY TO RELEASE THE PRESSURE ATTENTION BURNS HAZARD DONOT DISCONNECT THE RADIATOR HOSES WHEN THE ENGINE IS HOT THE COOLANT LIQUID AND THE HOT STEAM THAT ESCAPE MAY CAU SE 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 HITS THE EYES RINSE IMMEDITAELY WITH COLD WATER AND SEEK MEDICAL ADVICE The coolant liquid is a mixture of antifreeze at 40 and water at 60 The antifreeze protection limit must however be at least 25 C This mixture offers protection against freezing as well as a good protection against corrosion and therefore should not be replaced by pure water A WARNING AFTER THE COOLANT LIQUID HAS BEEN EMPTIED WHEN RE FILLING IT IS
94. lins optional Front Suspension Rear front suspension travel Rear suspension Front disc brake 320 mm 4 piston caliper 320 mm 4 piston radial caliper Rear disc brake 240 mm floating caliper 220 mm rigid caliper 245 mm floating caliper Brake disc wear limit mm 0 4 below original thickness Front tyre 120 70 17 Rider only air pressure 1 7 bar Rear tyre 150 60 17 165 55 17 Rider only air pressure 1 7 bar Tank capacity 9 litres Final transmission 13 40 14 46 15 47 Chain 5 8 x 1 4 Optional rear sprockets 39 40 41 42 43 44 45 46 47 48 49 Bulbs only SMR SMM Head high beam light 5212 45 40W BA20d Opt H3 12V 55W 225 Front position light T4W 12V 4W 9 Opt Ciclope T10 12V 5W Rear 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 TIGHTENING TORQUES 250 450 530 SMR SMM 250 450 530 660 SMX Front wheel axle flanged nut M20x1 5 40 Nm Front brake caliper fastening screws SMR SMM SMX M10 40 Nm Hear brake caliper fastening screws SMM 25 Nm Front brake disc fastening screws cl 10 9 15Nm Rear brake disc fastening screws SMR SMX M6 cl 10 9 15Nm Rear brake disc fastening nut SMM 25 Nm Upper fork head fastening screws 20 Lower fork head fastening screws 20 Nm fork leg fastening screws 12 Ohlins fork leg fastening s
95. motorcycle you will have very few problems 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 THE STARTER MOTOR CANNOT TURN THE ENGINE CAUSE Incorrect command Burned fuse Key not inserted or not turned Battery flat Low external temperature SOLUTION Switch on the emergency shutdown button and where present turn the key to enable start up Remove the right side panel and replace the 30 A fuse in the starter relay Insert the key and turn it in a clockwise direction Charge the battery and identify the cause of discharging contact a specialised workshop Start the engine using the kickstarter pedal THE STARTER MOTOR TURNS THE ENGINE BUT Lack of fuel in the engine THE ENGINE DOES NOT START MODELS WITH ELECTRIC STARTER Open the fuel tap fill up with fuel observe the indications for start up see Instructions for use chapter z M M H P J v H M i D HM S i 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
96. nderneath the chain pinion Make note of this number in the appropriate space on page 3 ENGLISH 8 OPS RATES exe ruso bs OPE RTINGICONTROLS 22 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 pump after having adjusted the lever position and to ensure the correct freeplay MANUAL DECOMPRESSOR LEVER ALL530 AND 660CC The hand decompressor lever 2 is on the left side of the handlebar and is used when after a fall or following overheating the engine is difficult to start up when warm To ventilate the engine pull the decompressor lever during starting The lever must always have a play of about 10 mm measured between the lever and support before starting to open theexhaust valves The time of opening is recognised by greater resistance of the lever see Frame 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 PILOT LIGHTS END SMR SMM The green control pilot light 1 lights up when the indicator 15 s
97. oled 250 cm 449 cm 77 53 6 mm 95x63 4 mm 139 1 12 2 1 unleaded fuel with min 95 RON DOHC 4 valves driven by silent chain A2 N2 N2 N3 N2N3 SM4 S4 N2 N3 30mm 30mmTi 380mm 36mm 36mm Ti 36mm 24 5 245 24 5mm 31mm 31 mm Ti 31 mm mm 0 20 mm 0 20 mm 0 20 mm 0 25 0 20 mm 0 25 0 25 mm 0 25 mm 0 25 mm 0 25 2 ball bearings silver plated needle cage coppering forged light alloy 2 rings 1 oil scraper double oil pump delivery drainage fully synthetic premium quality oil SAE 10W 50 API SG SH 1 4 litres straight toothing gears18 67 straight toothing gears 20 57 multiple discs in oil bath 5speed 5 5speed 5speed 5 speed 5 speed 15 14 28 1515 27 1 14 28 1 14 28 1 16 27 1 14 28 2050 7 254 20901975253 2099 7 25 216 17 25 2 17 24 217 25 3909 231 561923 37 16 19 39 19 23 APA 4 21 21 4 21 21 5 24 19 5 23 20 5 23 20 24 19 5 23 20 5 23 20 Kokusan digital CDI with variable timing 12V180W 12V180W 12V180W 12V 180W 12V180W 12V180W NGK CR 8E 0 8mm liquid cooled 40 antifreeze 60 water up to 25 C forced circulation with pump 1 litre 1 3 litres 1 litre 5 4 5 KS 5 54 5 E S K S E S opt E S opt LEGEND E S Electric start K S Kick start 69 5 TECI gt NICAL DAIA ENGINE TZ TECHNICAL DATA ENGINE 530 END MX SMX SMR SMM 660 SMX 2008 ENGINE 530 END 530 M
98. replace it EXCESSIVE OIL The vent hose is bent Position the vent hose or replace it CONSUMPTION Engine oil level too high Check and correct the engine oil level if necessary Engine oil too thin viscosity Use more viscous oil see Engine oil chapter ALL OF THE BULBS BLOW Remove the saddle and tank and check the connections of the UNEXPECTEDLY The regulator is damaged voltage regulator Have the regulator checked in a specialised TM workshop LIGHTS HORN AND The lights cable fuse is burned out Remove the left side panel and replace the lights cable 7 5A INDICATORS DO NOT fuse WORK the saddle and check the regulator contacts Have the THE BATTERY IS FLAT The battery is not charged by the generator 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 PREMATURE BREAKAGE OF THESE PARTS Before washing close the exhaust pipe rear end to prevent water from entering Norma
99. rew is screwed right down without variation of the number of revs of the idle speed a smaller Pilot jet must be installed b If the engine switches off with the mix adjustment screw still open by two turns a larger Pilot 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 presence of large variations of external temperature and altitude the idle speed must be set again To adjust the idle speed mixture screw a very short screwdriver may be required Notches may be useful on the handgrip BASIC INDICATIONS REGARDING CARBURETOR WEAR The throttle valve jet needle needle jet when present and the float needle valve are subject to great wear caused by engine vibration As a consequence the carburetor may malfunction e g enrichening of the mixture These parts must therefore be controlled after 200 hours 61 5 AND ENGIN CHECK FUEL LEVEL FLOAT HEIGHT A Disassemble the carburetor and remove the float bowl Turn the carburetor upside down and keep it inclined so that the float rests on the needle valve but does not compress the spring with its weight In this position use a gauge to measure the distance between the apex of the float body and the float bowl surface on the carburetor body see image Refer to the technica
100. s greater the spring pre load must be increased See variation of rear shock spring pre load chapter 40 PRAM AND ENGINE MAINTENANT ESTABLISHING REAR SHOCK LOWERING IN RUNNING ORDER Now with the help of a person who holds the motorcycle sit on the motorcycle wearing all protective clothing with feet on the footrests and rock up and down a few times to normalise the set up of the rear suspension A third person must then measure the distance between the same points with the motorcycle loaded and note this measurement as C Lowering in running order is the difference between measurements Motorcycle on stand measurement 600 mm Motorcycle on the ground loaded with the pilots weight 510 Lowering in running 00000 90mm Lowering in running order should be 90 105 mm If lowering in running order is less than 90 mm the spring is too hard spring rate too high If the lowering exceeds 105 mm the spring is too soft spring rate too low The spring rate is indicated on the outside of the spring wire After mounting a different spring static lowering must be adjusted again to 35 mm 2 mm According to our experience the dampening grade in compression can remain unvaried With a softer spring the dampening grade in rebound can be reduced by some clicks with an hard
101. se and the features of your new motorcycle Only in this way will you know how to adjust the motor cycle and to adapt it in the best way possible to your personal characteristics and how to protect yourself from injury This manual also contains important information regarding the maintenance of your new motorcycle This manual is based on the most recent information concerning the product that was available on going to print Further variations owing to succesive constructive developments of the motorcycle are however possible This manualis 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 out by a specialised TM workshop For any information or requests contact a specialis
102. se ao stia bac deant icu uas 12 Programming the electronic 11 Rear suspension mechanical 42 Recharge fuse all models with E S 55 Replacement of direction indicator bulb 56 Replacement of exhaust silencer packing material 58 Replacement of fork 0 1 42 Replacement of front brake 48 Replacement of headlight position light bulb with cyclops 56 Replacement of headlight position light bulb 55 Replacement of rear brake 50 Replacement of rear position stop numberplate light bulb END 5 5 56 22 Services fuse all models with lights 55 Setting the distance travelled 12 Shifting gear accelerating slowing down 26 ele B o ENTE T 16 Side stand fixing for off road 17 Shock absorber adjustment in compression 18 Shock absorber adjustment in rebo
103. st be changed with the engine at working temperature THE ENGINE AT WORKING TEMPERATURE AND THE OIL INSIDE ARE VERY HOT PAY ATTENTION BURNS HAZARD Position the motorcycle on a flat surface loosen and unscrew the cap 1 positioned on the lower face of the engine and allow the oil to flow into a container BEWARE OF HOT OIL Clean the cap and incorporated magnet well After the oil has flowed out completely clean the sealing face remount the cap together with the seal and tighten at 20 Nm Replace the seal if it is damaged 63 ENGINI TEIN ZI GT LUBRICANTS SRA 777774 Uses and recommends pet LLL PERFORMANCE 4 Trans Brake Chassis Filter Motor Bel Ray Thumper N A Racing Motor Oil Bel Ray Bel Ray Super Dot 4 Waterproof Foam Filter Oil Brake Fluid Grease USE ONLY HI OCTANE 98 UNLEADEAD FUEL www belray com ENGPISH AND PINGING 22 REPLACEMENT OF FILTER CARTRIDGE after having emptied the oil from the engine The cartridge oil filter is situated 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 drained completely then clean the sealing surfaces of the transmission cover and filter cover ch
104. t touch the ground If the motorcycle is used mainly on roads it is sufficient only to carry out this operation during periodical maintenance A WARNING VERY HIGH PRESSURE INSIDE THE FORK CAN CAUSE THE FORK TO LEAK IF YOUR FORK PRESENTSALEAK LOOSEN THE VENT SCREWS BEFORE HAVING THE SEALING ELEMENTS REPLACED CLEANING OF TELESCOPIC FORK DUST SCRAPER The dust scraper 2 must scrape the dust and dirt from the fork rods However after some time dirt may also reach behind the dust scrapers If the dirt is not removed the oil seal units which are found behind may leak Use a screwdriver to lever the dust scraper from the outside legs and push it downwards Clean the dust scraper the outside legs and the rods carefully Oil them well with silicone spray or with engine oil Finally push the dust scraper manually into the outside legs 39 Ser dA FRAKE 2 BASIC CALIBRATION OF THE CYCLE PART THE BASIS OF THE PILOT S WEIGHT To obtain optimal driving features of the motorcycle and to prevent damage to the fork rear shock rear swing arm and frame it is necessary that the basic calibration of the suspension is adapted to your body weight In the delivery status the off road TM motorcycles are calibrated on a pilot weight with complete protective clothing of 70 80 kg If your weight is not within these values you must adequately adapt the basic calibration of the suspensions
105. und 19 Shock absorber calibration and spring check 40 Start command and emergency stop 5 5 14 Start up after seasonal pause 68 27 1016 20 Stopping and parking 28 68 TECHNICAL DATA CYCLE PART 73 74 TECHNICAL DATA 69 70 Telescopic fork vent esce inane Ran sun 39 Throttle cable command adjustment 60 Top up front brake fluid eere erinnern 47 Top up rear brake Tluld 1 cierre rsen capu natnra 49 66 Tyres 53 Variation of rear shock spring 42 Variation of telescopic fork preload 41 Warm engine STAIN 25 WIRING DIAGRAM eene appendix axe a O1VHO8V I3 31LN3S3Hd 199 OLNNALNOO 11 IZd3 L V 1 4 39941 3NIWH3I V
106. urfaces operate the brakes and change down the gears gently without locking the wheels Locking the wheels leads to swerving or a fall When following long descending roads make use of the engine s braking effect To do this insert the 1st or 2nd gear without however increasing the revs excessively In this way you will have to brake much less and the brakes will not overheat 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 OPERATED REPEATEDLY UNTIL THE DISCS ARE DRY AND CLEAN THE BRAKING ACTION CAN ALSO BE DELAYED WHEN TRAVELLING DIRTY ROADS OR ROADS COVERED WITH SALT THE BRAKES MUST BE OPERATED UNTIL THE DISCS ARE CLEAN WHEN THE BRAKE DISCS ARE DIRTY THERE IS GREATER WEAR OF THE PADS AND THE BRAKE DISCS THEMSELVES AFTER USING THE BRAKES THE DISC THE PADS THE CALIPERS AND THE BRAKE FLUID HEAT UP THE HOTTER THESE PARTS THE LESS THE BRAKING EFFECT IN CASE OF OVERHEATING THE ENTIRE BRAKING SYSTEM MAY NOT WORK IF THE FORCE AT THE FRONT BRAKE LEVER OR BRAKE PEDAL IS MINIMAL THERE COULD BE A FAULT IN THE BRAKING SYSTEM IN THIS CASE IT IS AGOODIDEA TO HAVE THE MOTORCYCLE CHECKED BY AN AUTHORISED TM DEALER STOPPING AND PARKING Stop the motorcycle and shift into neutral To switch the motorcycle off press at normal minimum revs the engine stop switch unti
107. ve 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 deactivated when there is a battery COMBINATION SWITCH SUPPLIED WITH ELECTRONIC DIGITAL BACKLIT DISPLAY TACHOMETER END SMR SMM With the electronic digital backlit display tachometer you will find the combination switch shown in the picture 1 The use of the switch is very easy When the symbol 3 on the rotating ring is aligned with the symbol 4 on the switch body lights are switched off To switch the lights on turn the ring 2 counterclockwise until the symbol 5 is aligned with the symbol 4 Operate in the same way to switch on the low beam 7 and the high beam 6 Press the button 8 to activate the horn Press the rocker switch 9 on the left to activate the left hand indicator and on the right to activate the right hand indicator 13 OFEINATING CONTROLS ENGPISH 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 serv
108. 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 hoses tends to occupy the space left by the small pistons which have moved so that the pads always lay on the disc If the level of brake fluid falls below the minimum value it indicates that there is a leak in the braking system or brake pad wear is beyond accepted limits BRAKE FLUID The braking system is filled by TM with top quality DOT 4 brake fluid We recommend that top ups and complete replacement are carried out using the same type of fluid DOT 4 HAVE THE BRAKE FLUID REPLACED AT LEAST ONCE A YEAR IF YOU WASH THE MOTORCYCLE FREQUENTLY IT SHOULD BE REPLACED MORE OFTEN THE BRAKE FLUID SOAKS WATER IN OLD FLUID THEREFORE IT IS POSSIBLE THAT STEAM BUBBLES FORM EVEN AT LOW TEMPERATURES AND THE BRAKING SYSTEM DOES NOT WORK CORRECTLY FREE PLAY ADJ USTMENT OF THE OF FRONT BRAKE LEVER The free play of 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 BEAT 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
109. witched on and flashes in time to the indicator The blue control pilot light 2 lights up when the full beam headlight is switched on Seul 10 LATE ELECTRONIC TACHOMETER END SMR SMM The electronic tachometer display is always activated The electronic tachometer is powered by an SR44 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 the new battery 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 circumference and DST total mileage values These values will be re programmed into the instrument after battery replacement MODE 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 Chronometer start and stop autom max time 10 hours MAX Max speed reached from the last RESET DST Total 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

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