TM RACING 2010 STROKE 250, STROKE 300, 2 STROKE 2010, TM 2 STROKE 2010, 2010 2 STROKE 250 User And Maintenance Manual

USER AND

MAINTENANCE

MANUAL

TM RACING

USES and ADVICES

TM 2 STROKE 2010

250/300 cc.

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ENGINE NUMBER

KEY NUMBER

STAMP OF THE AUTHORISED DEALER

TM reserves the right to carry out changes without forewarning. The specications can change from country to country.

All indications are valid subject to spelling and printing errors.

FRAME NUMBER

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.

IMPORTANT

YOU ARE ADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM.
IT CONTAINS A LOT OF INFORMATION AND ADVICE THAT WILL MAKE THE USE AND MAINTENANCE OF THE
MOTORCYCLE MUCH EASIER AND SAFER.

IT IS IN YOUR SPECIFIC INTEREST TO PAY PARTICULAR ATTENTION TO THE WARNINGS INDICATED IN
THE FOLLOWING WAY:

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.

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Dear TM customer,

We would like to congratulate you for having chosen a TM motorcycle.

Your TM is a competitive and modern motorcycle that will surely give you a lot of satisfaction if you treat it
according to the provisions contained in this manual. Before starting up your TM motorcycle for the rst

time, you must read this manual carefully so as to understand the regulations for use and the features
of your new motorcycle.
Only in this way will you know how to adjust the motor cycle, and to adapt it in the best way possible
to your personal characteristics and how to protect yourself from injury. This manual also contains
important information regarding the maintenance of your new motorcycle.

This manual is based on the most recent information concerning the product that was available on going to print.
Further variations owing to succesive constructive developments of the motorcycle are however possible.
This manual is an integral part of the motorcycle, it must be given to the customer at the time of purchase and
must remain with the motor cycle whenever it is re-sold.

Please note that the operations marked with (A) in the “Frame and Engine Maintenance” chapter must be carried
out by a TM.specialised workshop. If these maintenance operations should be necessary during competitions,
they must be carried out by a qualied 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 specialised TM workshop, which is backed by the TM importer.
Please remember that a lot of technical data and information regarding TM motorcycles is available at: www.
tmracing.it.

Motorcycling is a marvellous sport that you will be able to enjoy with your TM motorcycle.
Always remember to respect the environment and other people. Always use the motorcycle with caution, it is in

everybodys interest to safeguard the future of our sport.

Enjoy yourself with your TM motorcycle!

TM RACING S.p.A.

Via Fano 6 - 61100 PESARO

ITALY

TM RESERVES THE RIGHT TO CHANGE OR TO EXECUTE MODIFICATIONS AS IT DEEMS NECESSARY

.

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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
veried 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” 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 specications.

In cases of direct and consequent damage caused by tampering or modications to the motorcycle,
no legal warranty claim can be asserted.

The use of the motorcycle in extreme conditions, for example on muddy and very wet ground, may
lead to greater than average wear of components, such as transmission components or the brakes.
It is therefore possible that maintenance or replacement of some parts is necessary before the limit
normally envisioned by the maintenance programme.

MX AND SMX MODELS CANNOT BE USED ON PUBLIC ROADS.

The 250 and 300 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.

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INDEX

INDEX

Page

POSITION OF SERIAL NUMBER ................................................... 7

Frame number ................................................................................... 8

Engine number ................................................................................... 8

OPERATING CONTROLS ................................................................ 9

Clutch lever AJP pump .................................................................... 10

Clutch lever BREMBO pump .............................................................. 10

Front brake lever NISSIN pump ...................................................... 10

Front brake lever BREMBO radial pump ............................................ 10

Electronic digital tachometer ............................................................. 11

Engine stop switch (MX/SMX) ........................................................... 11

Combination switch (END/SMR/SMM) ............................................. 12

Maps selection switch ......................................................................... 12

Fuel ller cap .................................................................................... 13

Fuel tap ............................................................................................. 13

Choke command (cold starter) .......................................................... 13

Idle speed adjustment command ..................................................... 13

Gear shift pedal ................................................................................. 14

Kickstart pedal .................................................................................... 14

Brake pedal ........................................................................................ 14

Side stand .......................................................................................... 14

Side stand xing for off-road routes .................................................... 15

Ignition switch ..................................................................................... 15

Fork adjustment in compression ........................................................ 15

Fork adjustment in rebound .............................................................. 16

Shock absorber adjustment in compression ...................................... 16

Shock absorber adjustment in rebound ......................................... 17

Steering lock .................................................................................. 18

ADVICE AND GENERAL RECOMMENDATIONS FOR

COMMISSIONING THE MOTORCYCLE ......................................... 19

Indications for rst start-up .......................................................... 20

Running in instructions ................................................................... 20

INSTRUCTIONS FOR USE .............................................................. 21

Check before every start-up ........................................................ 22

Cold engine start ........................................................................... 23

If the engine is “ooded” ................................................................ 24

Bike starting ..................................................................................... 24

Shifting gear, accelerating, slowing down .................................... 24

Braking ........................................................................................... 26

Stopping and parking ..................................................................... 26

Fuel .................................................................................................... 27

MAINTENANCE AND LUBRICATION TABLE ................................. 29

FRAME AND ENGINE MAINTENANCE ........................................... 35

Check steering bearings and play adjustment .............................. 36

Telescopic fork vent screws ......................................................... 37

Cleaning telescopic fork dust scraper ............................................. 37

Basic calibration of the chassis on the basis of pilot weight ........... 38

Shock absorber calibration and spring check ................................ 38

Establishing rear shock static lowering ........................................ 38

Establishing rear shock lowering in running order ........................ 39

Check telescopic fork basic calibration ......................................... 39

Variation of telescopic fork preload .............................................. 39

Replacement of fork springs .......................................................... 40

Variation of rear shock spring preload .......................................... 40

Rear suspension mechanical linkage ............................................. 40

Check chain tension ......................................................................... 41

Adjustment of chain tension (all models except SMM) ..................... 41

Page

Adjustment of chain tension (SMM) .................................................. 42

Chain maintenance ............................................................................ 42

Chain wear ........................................................................................ 43

Basic indications for TM disc brakes ................................................ 43

Front brake NISSIN pump (END/MX) ................................................ 44

Front brake BREMBO radial pump (SMR/SMM/SMX) ...................... 45

Check front brake pads ..................................................................... 45

Replacement of front brake pads ..................................................... 46

Modication of rear brake pedal base position .................................. 47

Check rear brake uid level .............................................................. 47

Top-up rear brake uid ...................................................................... 47

Check rear brake pads ...................................................................... 48

Replacement of rear brake pads ....................................................... 48

Disassembly and assembly of the front wheel .................................. 48

Disassembly and assembly of the rear wheel (all except SMM) ....... 49

Disassembly and assembly of rear wheel (SMM) ............................. 50

Check spoke tension ......................................................................... 50

Tyres, tyre pressure .......................................................................... 51

Check adjustment of magnetic sensor for tachometer ..................... 51

Battery ............................................................................................... 51

Battery charge .................................................................................... 52

Standard headlightd (END/SMR/SMM) ............................................. 53

Halogen light (END/SMR/SMM) ....................................................... 53

Halogen light (END/SMR/SMM) ........................................................ 53

“Ciclops” optional headlight (END/SMR/SMM) ................................ 54

Standard rear light ............................................................................. 54

LED rear light .................................................................................... 55

Direction indicator lamp (END/SMR/SMM) ....................................... 55

Cooling ............................................................................................. 55

Check coolant level .......................................................................... 56

Emptying, lling and bleeding of the cooling system ........................ 56

Replacement of exhaust silencer packing material ........................... 56

Cleaning the air lter ......................................................................... 57

Hydraulic clutch AJP pump ............................................................... 57

Hydraulic clutch BREMBO pump ....................................................... 58

Bleeding hydraulic clutch ................................................................... 58

Throttle cable command adjustment .................................................. 59

Notes on the carburetor ................................................................... 59

Basic indications regarding carburetor wear .................................... 60

Check fuel level (oat height) ........................................................... 61

Emptying the carburetor oat bowl .................................................... 61

Check engine oil level ........................................................................ 62

Engine oil .......................................................................................... 62

Change engine oil .............................................................................. 63

Inspection of the reed valve ............................................................... 63

TROUBLESHOOTING ...................................................................... 64

CLEANING ........................................................................................ 66

PRECAUTIONS FOR WINTER USE ................................................ 66

STORAGE ......................................................................................... 66

Start-up after seasonal pause ........................................................... 66

TECHNICAL DATA - ENGINE ......................................................... 67

CARBURETOR SETTINGS .............................................................. 69

ENGINE TIGHTENING TORQUES .................................................. 70

TECHNICAL DATA-CYCLE PART .................................................... 71

ALPHABETIC INDEX ....................................................................... 72

WIRING DIAGRAM .............................................................. appendix

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POSITION

OF SERIAL

NUMBER

POSITION

OF SERIAL

NUMBER

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POSITION OF SERIAL NUMBER

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 back side of the engine. Make
note of this number in the appropriate space on page 3.

POSITION OF SERIAL NUMBER

7

7

7

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OPERATING

CONTROLS

OPERATING

CONTROLS

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OPERATING CONTROLS

OPERATING CONTROLS

CLUTCH LEVER AJP PUMP

The clutch lever (1) is mounted on the left of the handlebar. The position
of the clutch lever, with respect to the handlebar grip, can be varied
using the adjustment screws (A) (see maintenace operation).
The adjusting screws (B) are used to adjust the pump after having adju-

sted the lever position and to ensure the correct freeplay.

CLUTCH LEVER BREMBO PUMP

The Brembo clutch pump is t on request.
The clutch lever (2) is located on the left side of the handlebar.
With this option, to adjust the clutch lever distance from the handlebar
grip (see maintenance operation), you have to turn the adjustment knob
(3).
Rotate clockwise to increase the distance or counterclockwise to de-

crease the distance.

FRONT BRAKE LEVER NISSIN PUMP (END/MX)

The distance of the front brak lever (5) from the handlebar grip can be
adjusted through the adjustment screw (C). Loosen the lock nut (6) and
turn the screw clockwise to increase the distance, anticlockwise to re­duce the distance. Re-tighten the lock nut (6). (see “Frame and Engine
Maintenance” chapter”).

FRONT BRAKE LEVER BREMBO RADIAL PUMP
(SMR/SMM/SMX)

The front brake pump lever (5) is located on the right side of the handle­bar and activates the front wheel brake. The distance of the brake lever
from the handlebar grip can be adjusted through the adjustment knob
(D) (see “Frame and Engine Maintenance” chapter)

C

4

D

5

3

2

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OPERATING CONTROLS

OPERATING CONTROLS

ELECTRONIC DIGITAL TACHOMETER

See picture (1). It is used on the END/SMR/SMM models. 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 nd the tachometer (6), the trip odometer (7) and
the total kilometers odometer (8).
In the bottom there are two buttons, “SET” (9) and “MODE” (10).

The instrument unit is the Kmh but it can be easily changed in Mph in
the following way: press and hold the “SET” button, while holding it press
once the “MODE” button.
Repeat the same operation to switch back to Kmh.

The trip odometer can be reset by holding pressed the “SET” button
once for 4 seconds.
The total kilometres odometer resets automatically when reaching the
limit of 99999 Km or Miles.

The SMR and SMM models only are supplied with a separate battery
for using the speedometer while the engine is OFF. This is under the

saddle.

ENGINE STOP SWITCH (MX/SMX)

The engine stop switch is found near the clutch piston.

The engine is shutdown using the engine stop switch (1): when it is 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.

1

D

5

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COMBINATION SWITCH WITH BACKLIT DIGITAL
ELECTRONIC SPEEDOMETER
(END/SMR/SMM)

This command (1) is located near the handlebar left grip.

The use of the switch is very easy.

When the symbol (3) on the rotating ring is aligned with the symbol (4)
on the switch body, lights are switched off.
To switch the lights on, turn the ring (2) counterclockwise until the symbol
(5) is aligned with the symbol (4).
Operate in the same way to switch on the low beam (7) and the high
beam (6).
Press the button (8) to activate the horn.
Press the rocker switch (9) on the left to activate the left hand indicator

and on the right to activate the right hand indicator.

Press button (10) to switch off.
The OFF button (10) on the SMR and SMM models is disabled.

MAPS SELECTION SWITCH

Some models are equipped with a central control unit with double map-

ping that can be selected using the button positioned on the left side

of the handlebar. Map 1 corresponds to an aggressive map, Map 2 to
a soft map.

OPERATING CONTROLS

OPERATING CONTROLS

10

10

10

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FUEL FILLER CAP

The fuel ll cap is found on top of the tank.

Open: turn the cap in an anti-clockwise direction
Close: place the cap on the inlet well and tighten it in a clockwise di-

rection.

Position the tank’s open vent pipe (1) preventing bends or crushing and
making sure that it is inserted correctly.

FUEL TAP

The tap is located on the left hand side of the tank base.

OFF On the OFF position, the fuel tap is closed.
ON On the ON position, the fuel tap is open.

When the motorcycle is used, turn the tap to the ON position.

In this way the fuel ows to the carburetor and the tank empties

up to reserve.

RES On the RES position, the reserve is used. After having lled up

the tank, do not forget to move the tap back to the ON position.

Tank capacity (all models)............ 8.5 Lt. + reserve 1 Lt.

CHOKE COMMAND (COLD STARTER)

This command is located on the carburetor.

For KEIHIN 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 is 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.

IDLE SPEED ADJUSTMENT COMMAND

This command is located on the carburetor.
By turning the screws 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

1.400 and 1.600 rpm.

OPERATING CONTROLS

OPERATING CONTROLS

10

10

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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

rst and second gears.

KICKSTART PEDAL

The kickstart pedal is positioned on the right side of the engine. The
upper part is turned outwards to start-up the engine and replaced inside

as soon as the engine is running.

BRAKE PEDAL

The brake pedal is positioned in front of the right foot rest. The basic
position can be adjusted on the basis of the position of the saddle (see
maintenance operations).

SIDE STAND

Push the side stand to the oor using the foot and rest the motorcycle on

it. Pay attention that the ground is solid and the position stable.

OPERATING CONTROLS

OPERATING CONTROLS

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10

10

10

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SIDE STAND FIXING FOR OFFROAD ROUTES

If you drive the motorcycle off-road, the closed side stand can be addi­tionally xed using a rubber band (2).

IGNITION SWITCH

In the SMR and SMM models an ignition key is added on the left side

of the dashboard.

By turning the key clockwise, the electric circuit is closed and you can
press the kickstart pedal up the engine.
Turn the key anticlockwise to turn off the engine.

FORK ADJUSTMENT IN COMPRESSION

The hydraulic brake system determines the behaviour of the fork in the
in compression stroke. The degree of hydraulic dampening in compres­sion can be adjusted on the basis of pilot preferences and/or hardness

of the spring installed.

MARZOCCHI USD FORK

There is an adjusting screw (4) on the fork cover. Operate using a
screwdriver. Turning the screw clockwise the dampening increases,
turning it anticlockwise the dampening decreases. A total of 28 clicks

are available.

Never turn the side screw (5).

PAIOLI USD FORK

Remove the rubber hood (1) situated in the lower part of the fork leg and
turn the adjustment screw (2) using a screwdriver. By turning the screw
clockwise, dampening increases, turning it anticlockwise the dampening
decreases. A total of 26 clicks are available.

OHLINS USD FORK

There is an adjusting screw (3) at the base of the fork foot. Operate using
a screwdriver. Turning the screw clockwise the dampening increases,
turning it anticlockwise the dampening decreases. A total of 20 clicks

are available.

WARNING

BEFORE STARTING IT IS ADVISED TO TIGHTEN THE ADJUSTER FROM THE

STANDARD POSITION TO THE “TOTALLY CLOSED” POSITION AND COUNT

THE NOTCHES DETECTED SO THAT THE STANDARD POSITION CAN BE

RESTORED. FOR CONVENTION, THE NOTCHES ARE INDICATED FROM
THE “TOTALLY CLOSED” POSITION.

BOTH RODS MUST HAVE THE SAME ADJUSTMENT.

OPERATING CONTROLS

OPERATING CONTROLS

5

4

10

10

1

2

3

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OPERATING CONTROLS

OPERATING CONTROLS

6

7

5

4

8

FORK ADJUSTMENT IN REBOUND

The hydraulic dampening in extension determines the behaviour of the
fork in the rebound stroke.
The degree of dampening in rebound can be adjusted on the basis of
pilot preferences and/or hardness of the spring installed.

MARZOCCHI USD FORK

The adjustment screw is located in the lower part of the fork leg (8). For this
operation, use a screwdriver. By turning the screw clockwise, dampening
increases, while turning it anticlockwise, dampening decreases. A total
of 28 clicks are available.

PAIOLI USD FORK

The adjustment screw is located in the top side of the fork cap (4). Tur­ning the screw clockwise, dampening increases, turning it anticlockwise
dampening decreases. A total of 28 clicks are available.

OHLINS USD FORK

The adjustment knob (5) is located in the top side of the fork cap. Operate
by hand. Turning the knob clockwise, dampening increases, turning it
anticlockwise dampening decreases. A total of 20 clicks are available.

WARNING

BEFORE STARTING IT IS ADVISED TO TIGHTEN THE ADJUSTER FROM

THE STANDARD POSITION TO THE “TOTALLY CLOSED” POSITION AND

COUNT THE CLICKS DETECTED SO THAT THE STANDARD POSITION CAN
BE RESTORED.

FOR CONVENTION, THE NUMBER OF CLICKS IS INDICATED FROM THE
“TOTALLY CLOSED” POSITION.

BOTH LEGS MUST HAVE THE SAME ADJUSTMENT.

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 ADJUST. IN COMPRESSION

The hydraulic dampening in compression determines the behaviour of
the shock absorber in the compression stroke.The degree of dampening
in compression can be adjusted on the basis of pilot preferences and/

or hardness of the spring installed.

Both standard and optional shock absorbers mounted on the TM offer
the possibility of double adjustment in compression for low and high

speeds.

Low and high speeds mean the movement speed of the damper in
compression and not the speed of the motorcycle.

SACHS SHOCK ABSORBER (STANDARD)

Low speeds- The (6) is located on the top of the damper gas tank. Use
a screwdriver. By turning the screw clockwise, dampening increases,
anticlockwise dampening decreases. A total of 24 clicks are available.
High speeds - The adjuster is a knob (7) and is concentric to the low
speed adjustment screw. Operate manually. By turning the knob clockwi­se, dampening increases, anticlockwise dampening decreases. A total
of 20 clicks are available.

OHLINS SHOCK ABSORBER (OPTIONAL)

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OPERATING CONTROLS

OPERATING CONTROLS

2

1

Low speeds- The adjustment screw (1) is on the top of the damper gas
tank. Use a screwdriver. By turning the screw clockwise, dampening
increases, anticlockwise dampening decreases. A total of 25 clicks are

available.

High speeds- The adjuster is a hexagonal ring nut (2) and is concentric
to the low speeds adjustment screw. Use a 17mm hexagonal spanner.
By turning the nut clockwise, dampening increases, anticlockwise dam­pening decreases. A total of 4 clicks are available.

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 ADJUSTMENT IN REBOUND

The hydraulic brake system in rebound determines the behaviour of
the shock absorber in rebound stroke.The degree of hydraulic braking
in rebound can be adjusted on the basis of pilot preferences and/or

hardness of the spring installed.

SACHS SHOCK ABSORBER (STANDARD)

The adjustment screw (3) is situated on the 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.

OHLINS SHOCK ABSORBER (OPTIONAL)

The adjustment knob (4) is situated low at the end of the damper rod.
Act manually. By turning clockwise (looking from the bottom upwards)
braking increases, anticlockwise, it decreases. A total of 40 clicks are

available.

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

PERICOLO

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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.

WARNING

NEVER LEAVE THE KEY IN THE LOCK. BY TURNING THE HANDLEBAR TO

THE LEFT, THE KEY COULD BE DAMAGED.

OPERATING CONTROLS

OPERATING CONTROLS

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ADVICE AND

GENERAL

RECOMMENDATIONS

FOR COMMISSIONING

THE MOTORCYCLE

ADVICE AND

GENERAL

RECOMMENDATIONS

FOR COMMISSIONING

THE MOTORCYCLE

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INDICATIONS FOR FIRST START-UP

- Ensure that the “PRE-DELIVERY OPERATIONS” of your mo-

torcycle have been carried out by your TM dealer.

- Carefully read all user instructions before making the rst

journey.

- Become familiar with all operating controls.

- Adjust the clutch lever, the front brake lever and the brake pedal
so that they are in the most comfortable position.

- Get used to driving in an empty carpark or on land where it is
easy to handle the motorcycle before making a long journey.
Also try to move at a slow pace on foot to get used to the mo-

torcycle.

- Do not take routes that are too difcult 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, x it as near as possible to the centre of the
motorcycle and distribute the weight equally between the front

and rear wheel.

- Follow running in instructions.

RUNNING IN INSTRUCTIONS

The surfaces of components of a new motorcycle, even if they
undergo precision workings, are however less smooth than the
same components in a motorcycle that have been driven for a
time: this explains the necessity for running in the new engine.
To obtain an optimal bedding of the moving parts of a new engine,
it must be taken to produce maximum performance gradually.
For this reason, during the rst 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 perfor­mance and longer duration of the motorcycle through time.

WARNING

THE 250 and 300 END/MX/SMX MODELS HAVE BEEN DEVELOPED
WITH NO COMPROMISE FOR OFF-ROAD COMPETITIONS. EVEN
IF THE ENDURO MODELS ARE TYPE-APPROVED, PAY ATTENTION

WHEN USING ON THE ROAD . MOST OF ALL AVOID SUSTAINED

ACCELERATION CONSTANT THROTTLE ON LONG ROADS, ROLL

THE THROTTLE ON AND BACK SLIGHTLY.

- 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 SEE YOU IN TIME.

- DO NOT DRINK AND DRIVE.

- ONLY USE ORIGINAL TM ACCESSORIES. FRONT COVERINGS,
FOR EXAMPLE, CAN NEGATIVELY AFFETCT THE BEHAVIOUR
OF THE MOTORCYCLE ON THE ROAD AT HIGH SPEEDS, OR
HAVE NEGATIVE INFLUENCE OF THE BEHAVIOUR OF THE 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 SO AS TO
RECOGNISE DANGERS AS SOON AS POSSIBLE.

- ADAPT SPEED TO THE CONDITIONS OF THE ROAD AND YOUR
DRIVING CAPABILITY.

- DRIVE CAREFULLY ON UNKNOWN ROADS OR LAND.

- WHEN OFF-ROAD YOU SHOULD ALWAYS BE ACCOMPANIED BY
A FRIEND WITH A SECOND MOTORCYCLE, SO THAT YOU CAN
HELP EACH OTHER IF DIFFICULTIES OCCUR.

- IN DUE TIME, REPLACE THE VISOR OR LENSES OF THE 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.

DANGER

DANGER

ADVICE AND GENERAL RECCOMANDATIONS FOR

COMMISSIONING THE MOTORCYCLE

ADVICE AND GENERAL RECCOMANDATIONS FOR

COMMISSIONING THE MOTORCYCLE

ENGLISH

ENGLISH

21

INSTRUCTIONS

FOR USE

INSTRUCTIONS

FOR USE

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22

CHECK BEFORE EVERY START-UP

To use the motorcycle safely, it must be in a good shape. It is a good
idea to carry out a general check-up of the motorcycle before every
start-up.
This check must include the following operations:

1 LEVEL OF ENGINE OIL

To ensure adequate lubrication, the level of the oil in the engine must

be kept within the envisioned limits. Using the engine with the oil level
below minimum leads to premature wear and successively, to damage
and risks to the driver.

2 FUEL

If the motorcycle does not have a transparent tank, open the tank

cap and visually check the quantity of fuel contained in the tank. Re­close the tank, making sure that the open vent pipe is not bent and
so impeding the ow of air.

3 CHAIN

The drive chain must always be tensioned corretly and well lubrica-

ted.

A loose chain knocks and may escape from the sprockets.
A too tight chain wears early and may cause wear and breakage of

some important transmission components.

4 TYRES

Check for any damage. Tyres with cuts or swellings must be replaced

immediately.
Check the depth of the tread which must correspond to the law.
Finally, check the air pressure and take it to the values envi-

sioned in the table, if necessary.

Worn tread and unsuitable air pressure worsen driving of the

motorcycle and may cause loss of control and serious accidents.

5 BRAKES

Verify correct working.
Check the level of brake uid. The reservoir on the pumps are dimen-

sioned in a way that in case of normally worn brake pads the uid does

not need to be topped-up. If the level of brake uid 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 exible 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 exible cable com-

mands .

7 COOLANT

Check the level of coolant with cold engine. Top-up with the liquid

stated in the table, if necessary.

8 ELECTRICAL PLANT

With the engine running, check for the front headlight, the front and

rear position lights, the rear stopping light, the direction indicator lights,

the control lights and the horn.

9 LUGGAGE

Check that any luggage is well xed.

INSTRUCTIONS FOR USE

INSTRUCTIONS FOR USE

2

1

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23

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 carburetor.
5 WITHOUT opening the throttle, press hardly the kickstarter DOWN

TO THE BOTTOM once or twice, or operate the electric starter.

6 Start to warm the engine by accelerating slightly for about 30 secs.

Disconnect the choke (2), which is situated on the left side of the

carburetor.

- ALWAYS WEAR STRONG MOTORCYCLE BOOTS WHEN STARTING UP

THE MOTORCYCLE TO PREVENT INJURY. YOU COULD SLIP OFF OF THE

PEDAL OR THE ENGINE COULD KICKBACK AND MAKE YOU KNOCK

YOUR FOOT VIOLENTLY.

- ALWAYS PRESS THE KICKSTARTER DOWN HARD WITHOUT ACCE-

LERATING. KICKSTARTING WITH LITTLE FORCE OR WITH OPENED

THROTTLE, INCREASES THE RISK OF ENGINE KICK BACK.

- DO NOT START THE ENGINE IN A CLOSED SPACE AND NEVER LEAVE IT

RUNNING IN CLOSED SPACES. THE EXHAUST FUMES ARE POISONOUS

AND MAY LEAD TO RISK OF UNCONSCIOUSNESS AND DEATH. WHEN

THE ENGINE IS RUNNING, ALWAYS ENSURE THERE IS SUFFICIENT

VENTILATION.

- ALWAYS CHECK THAT THE GEAR IS IN NEUTRAL BEFORE OPERATING

THE KICKSTARTER PEDAL. IF A GEAR IS INSERTED WHEN STARTING

THE ENGINE, THE MOTORCYCLE WILL JUMP FORWARDS.

WARNING

- OPERATE THE STARTER FOR MAX. 5 SECONDS AT A TIME. WAIT ANO-

THER 5 SECONDS BEFORE TRYING AGAIN.

- DO NOT ALLOW THE ENGINE REVS. TO INCREASE TOO MUCH WHILE

THE ENGINE IS COLD. THIS COULD DAMAGE THE ENGINE BECAUSE

THE PISTON HEATS UP AND CONSEQUENTLY, IT EXPANDS QUICKER

THAN THE CYLINDER, WHICH IS WATER-COOLED. ALWAYS WARM THE

ENGINE AT A STANDSTILL OR MOVE AT LOW REVS.

DANGER

INSTRUCTIONS FOR USE

INSTRUCTIONS FOR USE