TM RACING 250Fi SMR, 250Fi SMM, 450Fi EN, 250Fi MX, 250Fi SMX Use And Maintenance Manual
...
www.tmracing.it
USE AND MAINTENANCE
MANUAL
4 STROKES
2
4 T E M PI 4 T E M PI4 T E M PI 4 T E M PI
4 TEMPI
3
4 TEMPI
The displacement, type of power source and use define the model and engine of every TM Racing motorcycle.
The combination of codes 1 and 2 identifies the type of standard engine. The combination of the three codes identifies
the model of the motorcycle.
Normally, this manual indicates all three codes to specify which motorcycle model the given information refers to.
Only codes 1 and 2 followed by the indication “ALL” means that the information refers to all motorcycles with standard
engine, regardless of the type of use.
Code 3 (Type of use) alone means that the information refers to all motorcycles with that type of use, regardless of the
displacement and power source.
All END/SMR/SMM models are equipped with electric start (E.S.) as per standard, in addition to the kick starter (K.S.);
the MX/SMX models are equipped with K.S. as per standard and the E.S. is optional.
RECOGNISING TM RACING MOTORCYCLE MODELS
EXAMPLE OF MOTORCYCLE MODEL
RECOGNITION
DISPLACEMENT TYPE OF POWER SOURCE
INJECTION
FUEL
ENDURO
MOTOCROSS SUPERCROSS
ROAD SUPERMOTO
SINGLE ARM SUPERMOTO
COMPETITION SUPERMOTO
TYPE OF USE
ELECTRIC START
TYPE OF START
(ONLY WHEN INSERTED AS OPTIONAL)
4
4 TEMPI
4 TEMPI
TM reserves the right to apply modifications without prior notice.
Specifications may vary from country to country.
All the indications are valid except for typos and print errors.
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
KEY SERIAL NUMBER
STAMP OF THE DEALER
Please write in the boxes below the serial numbers of your motorcycle. To request spare parts, updates or report problems to TM, always specify model, displacement, year of manufacture and serial number of the frame and of the engine.
IMPORTANT
WE RECOMMEND READING THIS MANUAL CAREFULLY BEFORE STARTING TO USE YOUR TM MOTORCYCLE.
THIS MANUAL CONTAINS INFORMATION AND SUGGESTIONS THAT WILL MAKE THE USE AND MAINTENANCE OF
THE MOTORCYCLE EASIER AND SAFER.
IT IS IN YOUR SPECIFIC INTEREST TO PAY SPECIAL ATTENTION TO THE WARNINGS MARKED AS FOLLOWS:
FAILURE TO COMPLY WITH THIS WARNING PUTS YOUR LIFE AT RISK!
WARNING
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO THE MOTORCYCLE OR MAKE IT UNSAFE TO USE.
DANGER
IMPORTANT
4 TEMPI
5
4 TEMPI
IMPORTANT WARNINGS
ON LEGAL AND COMMERCIAL WARRANTY
WARNINGS ON WARRANTY
TM sport motorcycles are designed and manufactured to withstand stress that can be detected under normal road
and competitive use.
The competitive motorcycles comply with the rules of the respective categories currently in force at the most important international motorcycle associations.
Strictly comply with the control, maintenance, engine and chassis calibration provisions of the motorcycle indicated
in this manual to guarantee proper operation and prevent early wear of the motorcycle parts.
Incorrect engine or chassis calibration may affect your safety and the safety of others.
The maintenance operations described in the “Maintenance Schedule” must by carried out at a TM specialised
workshop at the scheduled intervals, otherwise the warranty is void and null.
To request spare parts, updates or report problems to TM, always specify the model, displacement, year of manufacture and serial number of the frame and the engine.
Use the fuels and lubricants indicated in the use and maintenance manual as described in the maintenance schedule. Products of different brands cannot be used unless they have equivalent specifications.
In case of direct or indirect damage due to tampering with or modifications to the motorcycle, the legal warranty
is void and null.
Using the motorcycle under extreme conditions, e.g. on very muddy and wet terrain, may excessively wear components, such as transmission parts or brakes. Therefore, maintenance or replacement of some parts may be
required before the normal interval indicated in the maintenance schedule.
USE OF ALL MX AND SMX MODELS IS NOT ALLOWED ON PUBLIC ROADS.
Should models 250Fi, 450Fi+F and 530F in versions END, SMR and SMM not comply with their respective approval
due to tampering or modifications, their use is no longer allowed on roads.
All the END models are designed to be used off-road (Enduro) and are not suitable for Motocross.
6
1. IDENTIFICATION OF THE VEHICLE
1.1 POSITION OF THE SERIAL NUMBERS AND CODES
Frame serial number
Engine serial number
Kayaba fork code
TM shock absorber code
2. CONTROL COMPONENTS
2.1 HANDLEBAR CONTROLS
Hydraulic clutch lever
Manual decompression lever (ALL 530F)
NISSIN pump front brake lever (EN/MX)
BREMBO radial pump front brake lever (SMR/SMM)
ACCOSSATO radial pump front brake lever (SMX)
Throttle
Combination switch (EN)
Dimmer switch (SMR/SMM)
Starter and kill switch (EN/SMR/SMM)
Key ignition switch (SMR/SMM)
Start engine button (MXE.S./SMXE.S.)
Engine stop button (MX/SMX)
Map selection switch (ALL 250Fi - ALL 450Fi)
2.2 INSTRUMENTS
Digital electronic speedometer (EN)
Digital electronic speedometer (SMR/SMM)
2.3 PEDAL CONTROLS
Gear shifting pedal
Kick starter
Rear brake pedal
Side stand
Fastener for off road routes
2.4 OTHER CONTROLS
Steering lock (EN/SMR/SMM)
Tank cap
Fuel tap (450F SMR/SMM - ALL 530F)
Choke lever (250Fi EN - 450Fi EN)
Choke lever (250Fi MX/SMX - 450Fi MX/SMX)
Choke lever (250Fi SMR/SMM - 450Fi SMR/SMM)
Cold start knob (450F SMR/SMM - ALL 530F)
Hot start knob (450F SMR/SMM - ALL 530F)
Idle adjustment knob (ALL 250Fi - ALL 450Fi)
Idle adjustment knob (450F SMR/SMM - ALL 530F)
3. USE INSTRUCTIONS
3.1 GENERAL WARNINGS
Indications for commissioning
Safety standards
3.2 ADJUSTING SUSPENSIONS
Fork compression adjustment
Fork rebound adjustment
Varying pre-load and replacing fork springs
Shock absorber compression adjustment
Shock absorber rebound adjustment
Varying pre-load and replacing shock absorber spring
Base suspension setting based on the weight of the rider
Adapting fork base calibration
Adapting shock absorber base calibration
Checking shock absorber static sag
Checking shock absorber rider sag
3.3 PRELIMINARY CHECKS
Engine oil level
Fuel level
Transmission chain
Tyres
9
10
10
10
10
10
11
12
12
12
12
12
13
13
13
14
14
15
15
15
15
16
16
16
17
17
17
17
17
17
18
18
18
18
19
19
19
19
19
20
20
21
22
22
22
23
23
23
24
24
25
26
28
28
28
29
29
30
30
30
30
30
30
30
30
30
30
31
31
32
32
32
33
33
33
34
34
35
35
35
35
36
36
36
37
37
38
38
38
38
39
40
40
42
44
46
48
48
49
49
50
50
50
51
51
51
52
52
53
54
55
56
56
57
58
58
58
59
59
59
60
61
61
62
Brakes
Flexible cable controls
Coolant
Lights and accessories electrical system
Luggage
3.4 BREAK-IN
Break-in instructions
3.5 COLD START
Cold start (ALL 250Fi - ALL 450Fi)
Cold start (450F SMR/SMM - ALL 530F)
3.6 HOT START
Hot start (ALL 250Fi - ALL 450Fi)
Hot start (450F SMR/SMM - ALL 530F)
Start in the event of a fall (250Fi EN/MX/SMX - 450Fi EN/MX/SMX)
Start in the event of a fall (530F EN/MX/SMX)
3.7 RUNNING
Setting off
Accelerating, shifting gears, slowing down
Braking
3.8 STOPPING
Stopping and parking
Using the side stand
3.9 REFILLING
Filling fuel tank
3.10 CLEANING AND STORAGE
W
ashing
P
recautions for winter use
Storage
4. MAINTENANCE
4.1 MAINTENANCE SCHEDULE
250Fi EN/SMR/SMM maintenance table
250Fi MX/SMX maintenance table
450Fi EN - 450Fi+F SMR/SMM - 530F EN/SMR/SMM maintenance table
450Fi MX/SMX - 530F MX/SMX maintenance table
4.2 CHASSIS MAINTENANCE
Checking steering bearings and adjusting play
Bleeding telescopic fork
Cleaning telescopic fork dust seal
Rear suspension linkage
Checking chain tension
Correcting chain tension (EN/MX/SMR/SMX)
Correcting chain tension (SMM)
Chain maintenance
Chain wear
Hydraulic clutch pump
Bleeding hydraulic clutch
Basic indications for TM disc brakes
NISSIN front brake pump (EN/MX)
BREMBO radial front brake pump (SMR/SMM)
ACCOSSATO radial front brake pump (SMX)
Checking front brake pads
Replacing front brake pads
Changing base position of rear brake pedal
Checking rear brake fluid level
Topping up rear brake fluid
Checking rear brake pads
Replacing rear brake pads
Disassembling and assembling front wheel
Disassembling and assembling rear wheel (EN/MX/SMR/SMX)
Disassembling and assembling rear wheel (SMM)
Checking spoke tension
Tyres, tyre pressure
Checking speedometer magnetic sensor distance (EN/SMR/SMM)
Fuel tank
Battery (all models with E.S.)
Charging the battery
Recharge fuse (all models with E.S.)
System fuse (all models with E.S.)
Accessory fuse (EN/SMR/SMM)
Halogen headlight (EN)
Halogen headlight (SMR)
“Cyclope” headlight (SMM)
LED Taillight (EN)
Standard Taillight (SMR/SMM)
Turn signal (EN/SMR/SMM)
4.3 ENGINE MAINTENANCE
Cooling
Checking coolant level
Draining, filling and bleeding cooling system
Replacing exhaust silencer packing material
Cleaning air filter
Checking manual decompressor adjustment (ALL 530F)
Adjusting throttle control cables
Adjusting idle speed (ALL 250Fi - ALL 450Fi)
Adjusting idle speed (450F SMR/SMM - ALL 530F)
Fuel pressure (ALL 250Fi - ALL 450Fi)
Basic indications on fuel wear (450F SMR/SMM - ALL 530F)
Checking fuel level (float height) (450F SMR/SMM - ALL 530F)
Draining carburettor bowl (450F SMR/SMM - ALL 530F)
Oil circuit (ALL 250Fi)
Oil circuit (ALL 450FI+F - ALL 530F)
Engine oil
Checking engine oil level (ALL 250Fi)
Checking engine oil level (ALL 450Fi+F - ALL 530F)
Changing engine oil and filter (ALL 250Fi)
Changing engine oil and filter (ALL 450Fi+F - ALL 530F)
5. DIAGNOSIS
5.1 DIAGNOSIS (ALL 250Fi - ALL 450Fi)
5.2 DIAGNOSIS (450F SMR/SMM - ALL 530F)
5.3 PDA (PALMTOP COMPUTER) (ALL 250Fi - ALL 450Fi)
6. TECHNICAL DATA
6.1 CHASSIS TECHNICAL DATA
Chassis technical data (250Fi/450Fi/530F EN/MX)
Chassis technical data (250Fi/450Fi+F/530F SMR/SMM -
250Fi/450Fi/530F SMX)
Chassis tightening torques
6.2 ENGINE TECHNICAL DATA
Engine technical data (ALL 250 Fi - ALL 450Fi+F)
Engine technical data (ALL 530F)
Engine tightening torques
Programmed control units (ALL 250Fi - ALL 450Fi)
Keihin carburettor setting (450F SMR/SMM - ALL 530F)
7. WIRING DIAGRAMS
7.1 LIGHTS AND ACCESSORIES WIRING DIAGRAM (EN/SMR/SMM)
7.2 ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX)
7.3 ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi
EN/SMR/SMM)
7.4 ENGINE WIRING DIAGRAM (250Fi MXE.S./SMXE.S. - 450Fi
MXE.S./SMXE.S.)
7.5 ENGINE WIRING DIAGRAM (450F SMR/SMM - 530F
EN/MXE.S./SMR/SMM/SMXE.S.)
7.6 ENGINE WIRING DIAGRAM (530F MX/SMX)
ALPHABETICAL INDEX
TABLE OF CONTENTS TABLE OF CONTENTS
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4 S T R OK E S 4 S T R OK E S
1. IDENTIFICATION OF THE VEHICLE
1.1 POSITION OF THE SERIAL NUMBERS AND CODES
Frame serial number
Engine serial number
Kayaba fork code
TM shock absorber code
2. CONTROL COMPONENTS
2.1 HANDLEBAR CONTROLS
Hydraulic clutch lever
Manual decompression lever (ALL 530F)
NISSIN pump front brake lever (EN/MX)
BREMBO radial pump front brake lever (SMR/SMM)
ACCOSSATO radial pump front brake lever (SMX)
Throttle
Combination switch (EN)
Dimmer switch (SMR/SMM)
Starter and kill switch (EN/SMR/SMM)
Key ignition switch (SMR/SMM)
Start engine button (MXE.S./SMXE.S.)
Engine stop button (MX/SMX)
Map selection switch (ALL 250Fi - ALL 450Fi)
2.2 INSTRUMENTS
Digital electronic speedometer (EN)
Digital electronic speedometer (SMR/SMM)
2.3 PEDAL CONTROLS
Gear shifting pedal
Kick starter
Rear brake pedal
Side stand
Fastener for off road routes
2.4 OTHER CONTROLS
Steering lock (EN/SMR/SMM)
Tank cap
Fuel tap (450F SMR/SMM - ALL 530F)
Choke lever (250Fi EN - 450Fi EN)
Choke lever (250Fi MX/SMX - 450Fi MX/SMX)
Choke lever (250Fi SMR/SMM - 450Fi SMR/SMM)
Cold start knob (450F SMR/SMM - ALL 530F)
Hot start knob (450F SMR/SMM - ALL 530F)
Idle adjustment knob (ALL 250Fi - ALL 450Fi)
Idle adjustment knob (450F SMR/SMM - ALL 530F)
3. USE INSTRUCTIONS
3.1 GENERAL WARNINGS
Indications for commissioning
Safety standards
3.2 ADJUSTING SUSPENSIONS
Fork compression adjustment
Fork rebound adjustment
Varying pre-load and replacing fork springs
Shock absorber compression adjustment
Shock absorber rebound adjustment
Varying pre-load and replacing shock absorber spring
Base suspension setting based on the weight of the rider
Adapting fork base calibration
Adapting shock absorber base calibration
Checking shock absorber static sag
Checking shock absorber rider sag
3.3 PRELIMINARY CHECKS
Engine oil level
Fuel level
Transmission chain
Tyres
9
10
10
10
10
10
11
12
12
12
12
12
13
13
13
14
14
15
15
15
15
16
16
16
17
17
17
17
17
17
18
18
18
18
19
19
19
19
19
20
20
21
22
22
22
23
23
23
24
24
25
26
28
28
28
29
29
30
30
30
30
30
30
30
30
30
30
31
31
32
32
32
33
33
33
34
34
35
35
35
35
36
36
36
37
37
38
38
38
38
39
40
40
42
44
46
48
48
49
49
50
50
50
51
51
51
52
52
53
54
55
56
56
57
58
58
58
59
59
59
60
61
61
62
Brakes
Flexible cable controls
Coolant
Lights and accessories electrical system
Luggage
3.4 BREAK-IN
Break-in instructions
3.5 COLD START
Cold start (ALL 250Fi - ALL 450Fi)
Cold start (450F SMR/SMM - ALL 530F)
3.6 HOT START
Hot start (ALL 250Fi - ALL 450Fi)
Hot start (450F SMR/SMM - ALL 530F)
Start in the event of a fall (250Fi EN/MX/SMX - 450Fi EN/MX/SMX)
Start in the event of a fall (530F EN/MX/SMX)
3.7 RUNNING
Setting off
Accelerating, shifting gears, slowing down
Braking
3.8 STOPPING
Stopping and parking
Using the side stand
3.9 REFILLING
Filling fuel tank
3.10 CLEANING AND STORAGE
W
ashing
P
recautions for winter use
Storage
4. MAINTENANCE
4.1 MAINTENANCE SCHEDULE
250Fi EN/SMR/SMM maintenance table
250Fi MX/SMX maintenance table
450Fi EN - 450Fi+F SMR/SMM - 530F EN/SMR/SMM maintenance table
450Fi MX/SMX - 530F MX/SMX maintenance table
4.2 CHASSIS MAINTENANCE
Checking steering bearings and adjusting play
Bleeding telescopic fork
Cleaning telescopic fork dust seal
Rear suspension linkage
Checking chain tension
Correcting chain tension (EN/MX/SMR/SMX)
Correcting chain tension (SMM)
Chain maintenance
Chain wear
Hydraulic clutch pump
Bleeding hydraulic clutch
Basic indications for TM disc brakes
NISSIN front brake pump (EN/MX)
BREMBO radial front brake pump (SMR/SMM)
ACCOSSATO radial front brake pump (SMX)
Checking front brake pads
Replacing front brake pads
Changing base position of rear brake pedal
Checking rear brake fluid level
Topping up rear brake fluid
Checking rear brake pads
Replacing rear brake pads
Disassembling and assembling front wheel
Disassembling and assembling rear wheel (EN/MX/SMR/SMX)
Disassembling and assembling rear wheel (SMM)
Checking spoke tension
Tyres, tyre pressure
Checking speedometer magnetic sensor distance (EN/SMR/SMM)
Fuel tank
Battery (all models with E.S.)
Charging the battery
Recharge fuse (all models with E.S.)
System fuse (all models with E.S.)
Accessory fuse (EN/SMR/SMM)
Halogen headlight (EN)
Halogen headlight (SMR)
“Cyclope” headlight (SMM)
LED Taillight (EN)
Standard Taillight (SMR/SMM)
Turn signal (EN/SMR/SMM)
4.3 ENGINE MAINTENANCE
Cooling
Checking coolant level
Draining, filling and bleeding cooling system
Replacing exhaust silencer packing material
Cleaning air filter
Checking manual decompressor adjustment (ALL 530F)
Adjusting throttle control cables
Adjusting idle speed (ALL 250Fi - ALL 450Fi)
Adjusting idle speed (450F SMR/SMM - ALL 530F)
Fuel pressure (ALL 250Fi - ALL 450Fi)
Basic indications on fuel wear (450F SMR/SMM - ALL 530F)
Checking fuel level (float height) (450F SMR/SMM - ALL 530F)
Draining carburettor bowl (450F SMR/SMM - ALL 530F)
Oil circuit (ALL 250Fi)
Oil circuit (ALL 450FI+F - ALL 530F)
Engine oil
Checking engine oil level (ALL 250Fi)
Checking engine oil level (ALL 450Fi+F - ALL 530F)
Changing engine oil and filter (ALL 250Fi)
Changing engine oil and filter (ALL 450Fi+F - ALL 530F)
5. DIAGNOSIS
5.1 DIAGNOSIS (ALL 250Fi - ALL 450Fi)
5.2 DIAGNOSIS (450F SMR/SMM - ALL 530F)
5.3 PDA (PALMTOP COMPUTER) (ALL 250Fi - ALL 450Fi)
6. TECHNICAL DATA
6.1 CHASSIS TECHNICAL DATA
Chassis technical data (250Fi/450Fi/530F EN/MX)
Chassis technical data (250Fi/450Fi+F/530F SMR/SMM -
250Fi/450Fi/530F SMX)
Chassis tightening torques
6.2 ENGINE TECHNICAL DATA
Engine technical data (ALL 250 Fi - ALL 450Fi+F)
Engine technical data (ALL 530F)
Engine tightening torques
Programmed control units (ALL 250Fi - ALL 450Fi)
Keihin carburettor setting (450F SMR/SMM - ALL 530F)
7. WIRING DIAGRAMS
7.1 LIGHTS AND ACCESSORIES WIRING DIAGRAM (EN/SMR/SMM)
7.2 ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX)
7.3 ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi
EN/SMR/SMM)
7.4 ENGINE WIRING DIAGRAM (250Fi MXE.S./SMXE.S. - 450Fi
MXE.S./SMXE.S.)
7.5 ENGINE WIRING DIAGRAM (450F SMR/SMM - 530F
EN/MXE.S./SMR/SMM/SMXE.S.)
7.6 ENGINE WIRING DIAGRAM (530F MX/SMX)
ALPHABETICAL INDEX
TABLE OF CONTENTS TABLE OF CONTENTS
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4 S T R OK E S 4 S T R OK E S
62
63
65
65
66
66
66
66
67
68
69
69
69
70
70
70
71
71
72
73
73
74
75
75
75
76
76
77
77
77
78
78
79
80
81
82
84
86
87
88
88
88
89
90
90
91
92
93
93
95
96
97
98
99
100
101
102
Checking speedometer magnetic sensor distance (EN/SMR/SMM)
Fuel tank
Battery (all models with E.S.)
Charging the battery
Recharge fuse (all models with E.S.)
System fuse (all models with E.S.)
Accessory fuse (EN/SMR/SMM)
Halogen headlight (EN)
Halogen headlight (SMR)
“Cyclope” headlight (SMM)
LED Taillight (EN)
Standard Taillight (SMR/SMM)
Turn signal (EN/SMR/SMM)
4.3 ENGINE MAINTENANCE
Cooling
Checking coolant level
Draining, filling and bleeding cooling system
Replacing exhaust silencer packing material
Cleaning air filter
Checking manual decompressor adjustment (ALL 530F)
Adjusting throttle control cables
Adjusting idle speed (ALL 250Fi - ALL 450Fi)
Adjusting idle speed (450F SMR/SMM - ALL 530F)
Fuel pressure (ALL 250Fi - ALL 450Fi)
Basic indications on fuel wear (450F SMR/SMM - ALL 530F)
Checking fuel level (float height) (450F SMR/SMM - ALL 530F)
Draining carburettor bowl (450F SMR/SMM - ALL 530F)
Oil circuit (ALL 250Fi)
Oil circuit (ALL 450FI+F - ALL 530F)
Engine oil
Checking engine oil level (ALL 250Fi)
Checking engine oil level (ALL 450Fi+F - ALL 530F)
Changing engine oil and filter (ALL 250Fi)
Changing engine oil and filter (ALL 450Fi+F - ALL 530F)
5. DIAGNOSIS
5.1 DIAGNOSIS (ALL 250Fi - ALL 450Fi)
5.2 DIAGNOSIS (450F SMR/SMM - ALL 530F)
5.3 PDA (PALMTOP COMPUTER) (ALL 250Fi - ALL 450Fi)
6. TECHNICAL DATA
6.1 CHASSIS TECHNICAL DATA
Chassis technical data (250Fi/450Fi/530F EN/MX)
Chassis technical data (250Fi/450Fi+F/530F SMR/SMM 250Fi/450Fi/530F SMX)
Chassis tightening torques
6.2 ENGINE TECHNICAL DATA
Engine technical data (ALL 250 Fi - ALL 450Fi+F)
Engine technical data (ALL 530F)
Engine tightening torques
Programmed control units (ALL 250Fi - ALL 450Fi)
Keihin carburettor setting (450F SMR/SMM - ALL 530F)
7. WIRING DIAGRAMS
7.1 LIGHTS AND ACCESSORIES WIRING DIAGRAM (EN/SMR/SMM)
7.2 ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX)
7.3 ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi
EN/SMR/SMM)
7.4 ENGINE WIRING DIAGRAM (250Fi MXE.S./SMXE.S. - 450Fi
MXE.S./SMXE.S.)
7.5 ENGINE WIRING DIAGRAM (450F SMR/SMM - 530F
EN/MXE.S./SMR/SMM/SMXE.S.)
7.6 ENGINE WIRING DIAGRAM (530F MX/SMX)
ALPHABETICAL INDEX
1. VEHICLE
IDENTIFICATION
Page 9 - 10
2. CONTROL
COMPONENTS
Page 11 - 20
3. USE
INSTRUCTIONS
Page 21 - 38
4. MAINTENANCE
Page 39 - 80
5. DIAGNOSIS
Page 81 - 86
6. TECHNICAL DATA
Page 87 - 93
7. WIRING DIAGRAMS
Page 95 - 101
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7
62
63
65
65
66
66
66
66
67
68
69
69
69
70
70
70
71
71
72
73
73
74
75
75
75
76
76
77
77
77
78
78
79
80
81
82
84
86
87
88
88
88
89
90
90
91
92
93
93
95
96
97
98
99
100
101
102
Checking speedometer magnetic sensor distance (EN/SMR/SMM)
Fuel tank
Battery (all models with E.S.)
Charging the battery
Recharge fuse (all models with E.S.)
System fuse (all models with E.S.)
Accessory fuse (EN/SMR/SMM)
Halogen headlight (EN)
Halogen headlight (SMR)
“Cyclope” headlight (SMM)
LED Taillight (EN)
Standard Taillight (SMR/SMM)
Turn signal (EN/SMR/SMM)
4.3 ENGINE MAINTENANCE
Cooling
Checking coolant level
Draining, filling and bleeding cooling system
Replacing exhaust silencer packing material
Cleaning air filter
Checking manual decompressor adjustment (ALL 530F)
Adjusting throttle control cables
Adjusting idle speed (ALL 250Fi - ALL 450Fi)
Adjusting idle speed (450F SMR/SMM - ALL 530F)
Fuel pressure (ALL 250Fi - ALL 450Fi)
Basic indications on fuel wear (450F SMR/SMM - ALL 530F)
Checking fuel level (float height) (450F SMR/SMM - ALL 530F)
Draining carburettor bowl (450F SMR/SMM - ALL 530F)
Oil circuit (ALL 250Fi)
Oil circuit (ALL 450FI+F - ALL 530F)
Engine oil
Checking engine oil level (ALL 250Fi)
Checking engine oil level (ALL 450Fi+F - ALL 530F)
Changing engine oil and filter (ALL 250Fi)
Changing engine oil and filter (ALL 450Fi+F - ALL 530F)
5. DIAGNOSIS
5.1 DIAGNOSIS (ALL 250Fi - ALL 450Fi)
5.2 DIAGNOSIS (450F SMR/SMM - ALL 530F)
5.3 PDA (PALMTOP COMPUTER) (ALL 250Fi - ALL 450Fi)
6. TECHNICAL DATA
6.1 CHASSIS TECHNICAL DATA
Chassis technical data (250Fi/450Fi/530F EN/MX)
Chassis technical data (250Fi/450Fi+F/530F SMR/SMM 250Fi/450Fi/530F SMX)
Chassis tightening torques
6.2 ENGINE TECHNICAL DATA
Engine technical data (ALL 250 Fi - ALL 450Fi+F)
Engine technical data (ALL 530F)
Engine tightening torques
Programmed control units (ALL 250Fi - ALL 450Fi)
Keihin carburettor setting (450F SMR/SMM - ALL 530F)
7. WIRING DIAGRAMS
7.1 LIGHTS AND ACCESSORIES WIRING DIAGRAM (EN/SMR/SMM)
7.2 ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX)
7.3 ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi
EN/SMR/SMM)
7.4 ENGINE WIRING DIAGRAM (250Fi MXE.S./SMXE.S. - 450Fi
MXE.S./SMXE.S.)
7.5 ENGINE WIRING DIAGRAM (450F SMR/SMM - 530F
EN/MXE.S./SMR/SMM/SMXE.S.)
7.6 ENGINE WIRING DIAGRAM (530F MX/SMX)
ALPHABETICAL INDEX
1. VEHICLE
IDENTIFICATION
Page 9 - 10
2. CONTROL
COMPONENTS
Page 11 - 20
3. USE
INSTRUCTIONS
Page 21 - 38
4. MAINTENANCE
Page 39 - 80
5. DIAGNOSIS
Page 81 - 86
6. TECHNICAL DATA
Page 87 - 93
7. WIRING DIAGRAMS
Page 95 - 101
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1. VEHICLE IDENTIFICATION
10
4 STROKES
4 STROKES
1.1 POSITION OF THE SERIAL NUMBERS AND CODES
FRAME SERIAL NUMBER
The frame serial number is stamped on the right side of the steering
head. Write this number in the specific box on page 4. The serial number
is also indicated on a nameplate located on the left side of the EN, SMR,
SMM models. See photo.
ENGINE SERIAL NUMBER
The engine serial number is engraved on the left of the engine under the
chain pinion. Write this number in the specific box on page 4.
KAYABA FORK CODE
The fork code is a capital letter printed inside each foot.
TM SHOCK ABSORBER CODE
The shock absorber code is printed on an adhesive label applied near the
compression braking valve.
11
2. CONTROL COMPONENTS
12
4 STROKES
4 STROKES
HYDRAULIC CLUTCH LEVER
The Bembo clutch pump (1) is located on the left side of the handlebar.
The clutch lever (2) activates the detachment of the transmission from
the engine.
Fully pull the lever towards the grip to activate the clutch.
The position of the lever compared to the grip can vary depending on the
rider’s preference. See chapter 4.2 “Chassis Maintenance” (page 52).
MANUAL DECOMPRESSION LEVER (ALL 530F)
The manual decompression lever (1) is located on the left side of the
handlebar. It is used when, after a fall or overheating, the motor has
trouble hot starting. To ventilate the engine, pull the decompression lever
during start-up.
NISSIN PUMP FRONT BRAKE LEVER (EN/MX)
The Nissin front brake pump (1) is located on the right side of the handlebar. The front brake lever (2) activates the front wheel brake. The position
of the front lever compared to the grip can vary according to the rider’s
preference. See chapter 4.2 “Chassis Maintenance” (page 54).
BREMBO RADIAL PUMP FRONT BRAKE LEVER (SMR/SMM)
The Brembo front brake pump (1) is located on the right side of the
handlebar. The front brake lever (2) activates the front wheel brake. The
position of the front brake lever compared to the grip can vary according to
the rider’s preference. See chapter 4.2 “Chassis Maintenance” (page 55).
2
1
2.1 HANDLEBAR CONTROLS
2
1
2
1
1
4 STROKES
13
4 STROKES
ACCOSSATO RADIAL PUMP FRONT BRAKE LEVER (SMX)
The radial Accossato front brake pump (1) is located on the right side of the
handlebar. The front brake lever (2) activates the front wheel brake. The
position of the front brake lever compared to the grip can vary according to
the rider’s preference. See chapter 4.2 “Chassis Maintenance” (page 56).
THROTTLE
The throttle control (1) is located on the right side of the handlebar. To
increase the power supplied by the motor (accelerate), rotate the grip
(2) towards yourself and rotate it in the opposite direction to decrease
it. Make sure the grip always has 4-5 mm of free play. See chapter 4.3
“Engine Maintenance” (page 73).
COMBINATION SWITCH (EN)
The combination switch (1) is located near the left handlebar grip.
It is very intuitive to use.
The lights are off when the rotating ring nut (2) is positioned with symbol (3)
aligned with symbol (4) on the switch. To turn on the position lights, rotate
the ring nut (2) anticlockwise until symbol (5) is aligned with symbol (4).
Do the same to turn on the low beams (6) and the high beams (7).
Press button (8) to honk the horn. Press the rocker switch (9) to the left
to activate the LH turn signal or to the right for the RH turn signal.
On the 250 EN and 450 EN models, press button (10) to switch the engine
off.
2.1 HANDLEBAR CONTROLS
2
1
2
1
7
6
4
1
9
8
5
3
2
10
14
4 STROKES
4 STROKES
DIMMER SWITCH (SMR/SMM)
The dimmer switch (1) is located on the handlebar near the left grip.
It is traditional and simple to use.
Button (2) honks the horn, while button (3) activates the LH turn signal if
pressed to the left and the RH turn signal if pressed to the right. Pressed
at the centre, it deactivates the turn signal.
The slider switch (4) selects lights off, position lights on, or low beam on.
The red button (5) selects low or high beam.
Button (6) flashes the high beam.
STARTER AND KILL SWITCH (EN/SMR/SMM)
Models equipped with battery and electric start have a control with two
buttons, a red one (1) and a black one (2), next to the throttle.
The red button (1) has two positions. When pushed in, it interrupts contact
with the battery, disconnecting current to all the accessories. The engine
does not start even with the kick starter.
On these models, put it in this position to switch the
engine off.
We recommend leaving it this way until the next engine start to prevent
the battery from discharging.
On the other hand, when pushed out it closes contact with
the battery and enables all the accessories, including the
electric start. For this reason, never leave it in this position with the engine off, otherwise the ignition control unit,
which consumes current even when the engine is off, can
discharge the battery.
The black button (2) activates the starter motor. Once the
gear has been put in neutral, press this button to start the
engine and release it as soon as the engine is running.
Activate this control for a maximum of 5 seconds at a time
and wait another 5 seconds before trying again.
After 3/4 attempts, stop and try to identify whether there
is a problem.
Never press this button when the engine is already running.
2
1
3
4
5
6
2.1 HANDLEBAR CONTROLS
1
2
4 STROKES
15
4 STROKES
KEY IGNITION SWITCH (SMR/SMM)
The SMR and SMM models are equipped with a cylinder (1) for the ignition
key on the left side of the dashboard.
To start the engine, insert the key and turn it clockwise. Use the starter
described on page 14.
To switch the engine off, use the kill switch described on page 14. Turn
the key anticlockwise and remove it from the cylinder.
START ENGINE BUTTON (MXE.S./SMXE.S.)
The start engine button (1) is located near the right grip on the handlebar.
Once the gear has been put in neutral, press this button to start the engine
and release it as soon as the engine is running.
Activate this control for a maximum of 8/10 seconds at a time and wait a
few seconds before trying again.
After 3/4 attempts, stop and try to identify whether there is a problem.
Never press this button when the engine is already running.
ENGINE STOP BUTTON (MX/SMX)
The engine stop button (1) is located near the left grip on the handlebar.
Press this button to switch the engine off and release it as soon as it is off.
MAP SELECTION SWITCH (ALL 250Fi - ALL 450Fi)
The map selection switch (1) is located on the left side of the handlebar.
This button (2) allows the rider to choose the injection mapping most
suitable to his/her preference and to the circuit conditions. Select Map
1 to activate a map that makes the engine response more aggressive.
Select Map 2 to activate a map that makes the engine response more
progressive.
2
1
2.1 HANDLEBAR CONTROLS
1
1
1
16
4 STROKES
4 STROKES
DIGITAL ELECTRONIC SPEEDOMETER (EN)
The digital electronic speedometer (EN) (1) consists of a large back-lit
display and a series of indicators.
The high beam indicator (2) is at top left, the neutral light (not used) (3)
is at centre left, the ADJUST button (4) is at bottom left.
The turn signal indicator (5) is at top right, the low beam indicator (6) is
at centre right, and the SELECT button (7) is at bottom right.
The display shows the digital speed indicator (speedometer) (8), the trip
odometer (9) or total odometer (ODO).
To switch from TRIP to ODO, briefly press the ADJUST button once. Do
the same to switch from ODO to TRIP.
The unit of measurement of the speedometer and trip and total odometer
is Km/h, but it can be set to Mph as follows: press ADJUST and SELECT
simultaneously for 3 seconds. The current unit of measurement will flash
on the display. Press ADJUST to switch from Km/h to MPH or vice-versa.
Briefly press SELECT 7 times to end the modification and return to the
normal screen.
The trip odometer can be reset by holding the ADJUST button down for
5 seconds.
The total odometer resets automatically when it reaches 99999 Km or
miles.
DIGITAL ELECTRONIC SPEEDOMETER (SMR/SMM)
The digital electronic speedometer (SMR/SMM) (1) consists of a large
back-lit display and a series of indicators.
At the top there is the LH turn signal indicator (2), the low beam indicator
(3), the high beam indicator (4), and the RH turn signal indicator (5).
The display shows the digital speed indicator (speedometer) (6), the trip
odometer (7) and total odometer (8).
There are two buttons at the bottom, “SET” (9) and “MODE” (10).
The unit of measurement of the speedometer is Kmh but it can be set to
Mph as follows: hold down the SET button and simultaneously press the
MODE button once. Do the same to return to Kmh.
The trip odometer can be reset by holding down the SET button for 4
seconds.
The total odometer resets automatically when it reaches 99999 Km or
miles.
2
3
1
8
9
5
6
4 7
4
5
6
7
8
10
9
1
2
3
2.2 INSTRUMENTS
4 STROKES
17
4 STROKES
GEAR SHIFTING PEDAL
The gear shifting pedal (1) is fitted on the left side of the engine. The
position of the gears is indicated in the illustration.
Neutral is between first and second gear.
To engage first gear, pull the clutch lever and press the gear shifting
pedal downwards.
To engage the other gears, pull the clutch lever and press the gear shifting pedal upwards.
KICK STARTER
The kick starter (1) is located on the right side of the engine. Once in
neutral, rotate the pedal outwards in order to activate the mechanism
with your foot to start the engine.
Starting from the highest position, push the starter all the way down
using quick, continuous movements. Once the engine has started, fold
the pedal inwards.
REAR BRAKE PEDAL
The brake pedal (1) is located in front of the right-hand footrest. The basic
position can be adjusted according to the rider’s preference. See chapter
4.2 “Chassis Maintenance” (page 58).
SIDE STAND
Press the side stand (1) to the ground with your foot and lean the motorcycle onto it. Make sure the ground is solid and the position is stable.
FASTENER FOR OFF-ROAD ROUTES
If you go off road with your motorcycle, the folded side stand can be further
secured with a rubber band (1).
2.3 PEDAL CONTROLS
1
1
1
1
1
18
4 STROKES
4 STROKES
STEERING LOCK (EN/SMR/SMM)
The steering lock (1) is located on the left side of the steering head.
This device allows you to block the rotation of the handlebar, preventing
the motorcycle from being driven.
To lock the steering, rotate the handlebar fully to the right, move the
protective tab (2), insert the key, turn it to the left and press it all the way
down. Keeping it pressed down, turn it to the right and remove it.
WARNING
NEVER LEAVE THE KEY IN THE LOCK ONCE YOU HAVE LOCKED THE STEERING.
THE KEY MAY BEND OR BREAK IF YOU STEER TO THE LEFT.
TANK CAP
The fuel cap (1) is located on top of the tank.
To open it, unscrew the tank cap by rotating it anticlockwise.
To close it, place the tank cap on the filler neck and rotate it clockwise.
Arrange the tank bleeder hose (2) avoiding bends or crushing and make
sure it is inserted correctly.
FUEL TAP (450F SMR/SMM - ALL 530F)
The tap (1) is found on the left side of the engine at the bottom of the tank.
OFF In the OFF position, the fuel tap is closed.
ON In the ON position, the fuel tap is open.
Turn the knob to ON when using the motorcycle so that the fuel
flows to the carburettor and the tank empties down to the reserve.
RES IN the RES position, the reserve is used. After filling up, do not
forget to move the knob back to the ON position.
1
2.4 OTHER CONTROLS
1
1
4 STROKES
19
4 STROKES
CHOKE LEVER (250Fi EN - 450Fi EN)
The choke lever (1) is located on the left of the handlebar under the
combination switch.
Activate this lever to facilitate engine start under particular conditions.
Using your thumb, press it all the way down and keep it pressed to activate it.
The device disengages automatically once the lever is released.
CHOKE LEVER (250Fi MX/SMX - 450Fi MX/SMX)
The choke lever (1) is located on the left side of the handlebar near the grip.
Activate this lever to facilitate engine start under particular conditions.
Using your thumb, press it all the way down and keep it pressed to activate it.
The device disengages automatically once the lever is released.
CHOKE LEVER (250Fi SMR/SMM - 450Fi SMR/SMM)
The choke lever (1) is located on the right side of the handlebar near the
starter and kill switch.
Activate this lever to facilitate engine start under particular conditions.
Using your thumb, press it all the way down and keep it pressed to activate it.
The device disengages automatically once the lever is released.
COLD START KNOB (450F SMR/SMM - ALL 530F)
The cold start knob (1) is located on the left side of the motorcycle.
Activate this knob to facilitate engine start under particular conditions.
To activate this knob, pull it towards you as far as it goes and turn it
clockwise to lock it in the work position.
To disengage it, turn the knob anticlockwise and let it go back to its initial
position.
HOT START KNOB (450F SMR/SMM - ALL 530F)
The hot start knob (1) is located on the right side of the motorcycle.
Pull the knob out as far as it goes to activate it.
Push the knob all the way back in to disengage it.
2.4 OTHER CONTROLS
1
1
1
1
1
20
4 STROKES
4 STROKES
1
IDLE ADJUSTMENT KNOB (ALL 250Fi - ALL 450Fi)
The idle adjustment knob (1) is located on the left side of the motorcycle.
Rotate the idle adjustment knob to raise or lower the engine idle speed.
IDLE ADJUSTMENT KNOB (450F SMR/SMM - ALL 530F)
The idle adjustment knob (1) is located on the left side of the motorcycle.
Rotate the idle adjustment knob to raise or lower the engine idle speed.
2.4 OTHER CONTROLS
1
3. USE INSTRUCTIONS
21
3. USE INSTRUCTIONS
22
4 STROKES
4 STROKES
INDICATIONS FOR COMMISSIONING
- Make sure that the motorcycle’s “PRE-DELIVERY OPERATIONS” have been performed by your TM dealer.
- Carefully read all the instructions before using the motorcycle for the first time.
- Be familiar with all the control components.
- Adjust the clutch lever, the front brake lever and the brake pedal to the most comfortable position.
- Practice handling the motorcycle in an empty car park or on easy terrain before going on a long drive. Try to stand up on the
motorcycle at low speed once to get more used to the motorcycle.
- Do not choose routes that are too difficult for your skills and experience.
- Hold the handlebar with both hands and keep your feet on the footrests.
- Be sure not to press the brake pedal with your foot if you do not want to stop. If the brake pedal is not released, the brake pads
rub continuously causing the brake to overheat.
- Do not make changes to the motorcycle and always use TM ORIGINAL SPARE PARTS. Spare parts from other manufacturers may
affect the safety of the motorcycle.
- Motorcycles are sensitive to shifts in weight distribution. Luggage must be fastened at the centre of the motorcycle and its weight
must be evenly distributed between the front and rear wheels.
- Follow the break-in instructions.
WARNING
THE 25 0Fi/450F i/530 F EN/MX /SMX MODELS HAV E BEEN DEVELOPED U NCOMPROMIS INGLY FOR OFF-ROAD COMP ETITIO NS. ALTHOUGH T HE EN
MODELS ARE APPROVED FOR ROAD USE, WE RECOMMEND CAUTION WHEN USING THEM ON THE ROA D. AVOID TR AVELLING LONG DISTANCES
AT FULL SPEED.
SAFETY STANDARDS
- ALWAYS WEAR SUITABLE CLOTHES WHEN USING THE MOTORCYCLE. BIKERS THAT RIDE A TM ALWAYS WEAR APPROVED HELMET, BOOTS,
GLOVE S AND JACKE T, BOTH FOR L ONG JOURNEY S AND SHORT DI STANCES. PRO TECTIVE GE AR SHOULD B E HIGHLY VISIBLE TO A LLOW OTHER
DRIVERS ON THE ROAD TO RECOGNISE THE BIKER IMMEDIATELY.
- ALWAYS TURN ON THE HEADLIGHT DURING TRAVELS IN ORDER TO BE IMMEDIATELY VISIBLE TO OTHER DRIVERS.
- DO NOT DRIVE AFTER CONSUMING ALCOHOLIC BEVERAGES.
- ALWAYS USE TM ORIG INAL ACCE SSORIES. F OR EXAM PLE, FRONT C OATINGS M AY AFFEC T MOTORCYCLE PE RFORMANC E WHEN TRAVEL LING
AT HIGH SPEED. EVEN LUGGAGE, ADDITIONAL TANKS, ETC. MAY AFFECT MOTORCYCLE PERFORMANCE DUE TO THE DIFFERENT WEIGHT
DISTRIBUTION.
- BOTH THE FRONT AND THE REAR WHEELS MUST BE EQUIPPED WITH T YRES WITH THE SAME TYPE OF PROFILE.
- AFTER THE FIRST 30 MINUTES OF DRIVING, IT IS ABSOLUTELY NECESSARY TO CHECK THE TENSION OF THE SPOKES. SPOKE TENSION
DECREASES AFTER A SHORT TIME ON NEW WHEELS. IF YOU KEEP DRIVING WITH LOOSE SPOKES, THEY MAY BREAK CAUSING UNSTABLE
DRIVING (SEE CHECKING SPOKE TENSION)
- THE RACING MODELS WERE DESIGNED AND ARRANGED FOR ONE SINGLE SEAT. TAKING A PASSENGER WITH YOU IS PROHIBITED.
- COMPLY WITH TRAFFIC REGULATIONS. DRIVE WITH CAUTION IN ORDER TO RECOGNISE DANGERS AS SOON AS POSSIBLE.
- ADJUST THE SPEED OF THE VEHICLE ACCORDING TO THE CONDITIONS OF THE ROAD AND YOUR DRIVING SKILL S.
- DRIVE WITH CAUTION ON UNKNOWN ROADS OR TERRAINS.
- WHEN GOING OFF ROAD, ALWAYS GO WITH A FRIEND WITH A SECOND MOTORCYCLE SO YOU CAN HELP EACH OTHER SHOULD THE NEED
ARISE.
- PROMPTLY REPLACE THE VISOR OR LENSES OF YOUR GLASSES. SCRATCHED VISORS OR GL ASSES MAKE IT NEARLY IMPOSSIBLE TO SEE
AGAINST THE LIGHT.
- NEVER LEAVE THE MOTORCYCLE UNATTENDED IF THE ENGINE IS RUNNING.
- THE MX AND SMX MODELS ARE NOT APPROVED FOR USE ON PUBLIC ROADS OR MOTORWAYS.
- ALWAYS KEEP IN MIND WHEN RIDING YOUR MOTORCYCLE THAT EXCESSIVE NOISE MAY ANNOY OTHERS.
DANGER
DANGER
3.1 GENERAL WARNINGS
4 STROKES
23
4 STROKES
FORK COMPRESSION ADJUSTMENT
The compression hydraulic brake system determines how the fork
behaves in the compression phase. The degree of compression hydraulic braking can be adjusted to the rider’s preference and/or installed
spring rate.
MARZOCCHI USD FORKS
The adjustment screw (1) is located on the upper part of the fork cap. Use
a screwdriver. Rotate clockwise to increase braking or anticlockwise to
decrease it. A total number of 28 clicks is available.
WARNING
DO NOT TOUCH THE SIDE BLEED VALVE (2).
DO NOT TOUCH THE RED HEX SCREW (3) AS THERE IS NO NEED TO
VARY THE COMPRESSION BRAKE.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE
STANDA RD POSITION TO THE “ALL CLOSED” POSITION AND COUNT ING THE CLICK S.
WRITE DOWN THE NUMBER OF CLICK S IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT. THE NORM IS TO COUNT THE CLICKS STARTING FROM THE “ALL
CLOSED” POSITION. BOTH RODS MUST BE ADJUSTED THE SAME WAY.
KAYAB A USD FOR KS
The adjustment screw (1) is located on the upper part of the fork cap. Use
a screwdriver. Rotate clockwise to increase braking or anticlockwise to
decrease it. A total number of 19 clicks is available.
WARNING
DO NOT TOUCH THE BLEED VALVE (2).
WARNING
BEFORE S TARTING, WE R ECOMMEND TIGH TENING THE A DJUSTER F ROM THE STANDARD POSITION TO THE “ALL CLOSED” POSITION AND COUNTING THE CLICKS. WRITE
DOWN THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUST MENT. THE NORM IS TO COUNT THE C LICKS STAR TING FROM THE “ALL CLOSE D”
POSITION. BOTH RODS MUST BE ADJUSTED THE SAME WAY.
FORK REBOUND ADJUSTMENT
The rebound hydraulic brake system determines how the fork behaves
in the rebound phase.
The degree of rebound hydraulic braking can be adjusted to the rider’s
preference and/or installed spring rate.
MARZOCCHI USD FORKS
The adjustment screw (1) is located on the lower part of the fork foot. Use
a screwdriver. Rotate clockwise to increase braking or anticlockwise to
decrease it. A total number of 28 clicks is available.
WARNING
DO NOT TOUCH THE HEX SCREW (2) AS THERE IS NO NEED TO VARY
THE REBOUND BRAKE.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE
STANDA RD POSITION TO THE “ALL CLOSED” POSITION AND COUNT ING THE CLICK S.
WRITE DOWN THE NUMBER OF CLICK S IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT. THE NORM IS TO COUNT THE CLICKS S TARTING FROM THE ‘’ALL
CLOSED’’ POSITION. BOTH RODS MUST BE ADJUSTED THE SAME WAY.
2
1
3
1
3.2 ADJUSTING SUSPENSIONS
2
1
24
4 STROKES
4 STROKES
KAYABA USD FORKS
The adjustment screw (1) is located on the lower part of the fork foot. Use
a screwdriver. Rotate clockwise to increase braking or anticlockwise to
decrease it. A total number of 21 clicks is available.
WARNING
DO NOT TOUCH THE HEX SCREW (2) AS THERE IS NO NEED TO
VARY THE REBOUND BRAKE.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE
STANDARD POSITION TO THE ‘’ALL CLOSED’’ POSITION AND COUNTING THE
CLICKS. WRITE DOWN THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT.
THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ‘’ALL CLOSED’’
POSITION.
BOTH RODS MUST BE ADJUSTED THE SAME WAY.
VARYING PRE-LOAD AND REPLACING FORK SPRINGS
Partially disassemble the springs to vary the spring pre-load (see the
specific manual of the fork fitted on the motorcycle).
It is NOT recommended to vary the pre-load of the springs on forks
fitted by TM Racing.
Replace the springs with others featuring different rates if required.
WARNING
FOR FURTHER AND MORE DETAILED INFORMATION ON THE FORKS, REFER TO
THE INSTRUCTIONS SUPPLIED BY THE FORK MANUFACTURER.
SHOCK ABSORBER COMPRESSION ADJUSTMENT
The compression hydraulic brake system determines how the shock
absorber behaves in the compression phase. The degree of compression hydraulic braking can be adjusted to the rider’s preference and/or
installed spring rate. The shock absorbers fitted on TM motorcycles allow
adjustments for both low and high compression speeds.
SACHS SHOCK ABSORBERS
Low speeds - The adjustment screw (1) is located on top of the shock absorber gas tank. Use a screwdriver. Rotate clockwise to increase braking
or anticlockwise to decrease it. A total number of 24 clicks is available.
High speeds - The adjustment knob (2) is concentric to the low speed
adjustment screw. Turn it manually. Rotate clockwise to increase braking
or anticlockwise to decrease it. A total number of 20 clicks is available.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE
STANDARD POSITION TO THE ‘’ALL CLOSED’’ POSITION AND COUNTING THE
CLICKS. WRITE DOWN THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT.
THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ‘’ALL CLOSED’’
POSITION.
1
2
3.2 ADJUSTING SUSPENSIONS
1
4 STROKES
25
4 STROKES
TM SHOCK ABSORBER
Low speeds - The adjustment screw (1) is located on top of the shock absorber gas tank. Use a screwdriver. Rotate clockwise to increase braking
or anticlockwise to decrease it. A total number of 24 clicks is available.
High speeds - The regulator is a hex ring nut (2) concentric to the low
speed adjustment screw. Use a 14 mm hex wrench. Rotate clockwise to
increase braking or anticlockwise to decrease it. A total number of 28
clicks is available.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE STANDARD
POSITION TO THE ‘’ALL CLOSED’’ POSITION AND COUNTING THE CLICKS. WRITE DOWN
THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT.
THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ‘’ALL CLOSED’’ POSITION.
OHLINS TTX SHOCK ABSORBER (OPT. SMX ONLY)
Low speeds
The adjustment screw (1) is located on the top left of the shock absorber
gas tank. Use a 3 mm Allen key. Rotate clockwise to increase braking
or anticlockwise to decrease it. A total number of 23 clicks is available.
High speeds
The adjuster is a 17 mm wrench hex ring nut (2) located on the top right of
the shock absorber gas tank. Use a 17 mm hex wrench and align marks
I, II, and III with the reference notch.
Position I = soft
Position II = medium
Position III = hard.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE STANDARD
POSITION TO THE ‘’ALL CLOSED’’ POSITION AND COUNTING THE CLICKS. WRITE DOWN
THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT.
THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ‘’ALL CLOSED’’ POSITION.
SHOCK ABSORBER REBOUND ADJUSTMENT
The rebound hydraulic brake system determines how the shock absorber
behaves during the rebound phase. The degree of rebound hydraulic braking can be adjusted to the rider’s preference and/or installed spring rate.
SACHS SHOCK ABSORBERS
The adjustment screw (1) is located at the bottom of the fork coupling
connecting the shock absorber to the linkage. Use a screwdriver. Rotate
clockwise to increase braking or anticlockwise to decrease it. A total
number of 40 clicks is available.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE STANDARD
POSITION TO THE ‘’ALL CLOSED’’ POSITION AND COUNTING THE CLICKS. WRITE DOWN
THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT.
THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ‘’ALL CLOSED’’ POSITION.
1
3.2 ADJUSTING SUSPENSIONS
1
2
1
2
26
4 STROKES
4 STROKES
TM SHOCK ABSORBER
The adjustment screw (1) is located on the fork coupling connecting the
shock absorber to the linkage. Use a screwdriver. Rotate clockwise to
increase braking or anticlockwise to decrease it. A total number of 27
clicks is available.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE
STANDARD POSITION TO THE ‘’ALL CLOSED’’ POSITION AND COUNTING THE
CLICKS. WRITE DOWN THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT.
THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ‘’ALL CLOSED’’
POSITION.
OHLINS TTX SHOCK ABSORBER (OPT. SMX ONLY)
The adjustment screw (1) is located on the fork coupling connecting the
shock absorber to the linkage. Use a 3 mm Allen key.
Rotate clockwise to increase braking or anticlockwise to decrease it.
WARNING
BEFORE STARTING, WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE
STANDARD POSITION TO THE ‘’ALL CLOSED’’ POSITION AND COUNTING THE
CLICKS. WRITE DOWN THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT.
THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ‘’ALL CLOSED’’
POSITION.
THE GAS TANK OF THE SHOCK ABSORBER IS FILLED WITH HIGH PRESSURE
NITROGEN. NEVER TRY TO DISASSEMBLE THE SHOCK ABSORBER OR PERFORM
MAINTENANCE WITHOUT THE HELP OF TECHNICIANS IN ORDER TO PREVENT
DAMAGE TO PERSONS OR OBJECTS.
VARYING PRE-LOAD AND REPLACING
SHOCK ABSORBER SPRING
The spring pre-load can be varied by rotating the adjustment ring nut.
The pre-load varies by 1.5 mm at every turn of the regulation ring nut.
To facilitate the operation, we recommend disassembling and carefully
cleaning the shock absorber.
In the event the pre-load variation is not sufficient, replace the spring
with another one with a different spring rate.
WARNING
BEFORE STARTING THE OPERATION, WE RECOMMEND WRITING DOWN
THE BASIC ADJUSTMENT, E.G. HOW MANY THREADED TURNS ARE VISIBLE ABOVE THE ADJUSTMENT RING.
SACHS SHOCK ABSORBERS
Loosen the locking ring nut (1) and rotate the adjustment ring nut (2). Rotate it
anticlockwise (seen from above) to decrease the pre-load or clockwise (seen from
above) to increase it. After adjusting, tighten the locking ring nut (1).
DANGER
1
2
3.2 ADJUSTING SUSPENSIONS
1
1
4 STROKES
27
4 STROKES
TM SHOCK ABSORBER
Loosen the locking screw (1) of ring nut (2) with a 4 mm Allen key and
rotate the ring nut. Rotate it anticlockwise (seen from above) to decrease
the pre-load or clockwise (seen from above) to increase it.
After adjusting, tighten the locking screw (1).
OHLINS TTX SHOCK ABSORBER (OPT. SMX ONLY)
Loosen the upper clamp (1) with a 4 mm Allen key and
rotate the adjustment ring nut (2). Rotate it clockwise (seen from above)
to increase the pre-load or anticlockwise (seen from above) to decrease
it.
After adjusting, tighten the upper clamp (1).
3.2 ADJUSTING SUSPENSIONS
1
2
1
2
28
4 STROKES
4 STROKES
BASE SUSPENSION SETTING BASED ON THE WEIGHT OF THE RIDER
For optimal motorcycle driving performance and to prevent the fork, shock absorber, large swing arm and frame from being damaged,
the base calibration of the suspensions must be adjusted according to your weight. The base calibration of the suspensions (both the
fork and shock absorber) involves assembling a special spring and a series of adjustments of the compression and rebound braking.
TM motorcycles come calibrated for a body weight (considering full protective gear) of 70-80 Kg. Adjust the calibration of the suspensions if your weight does not fall within this range.
The main element to be checked is the spring, both of the fork and the shock absorber. To check for correct spring rate, first measure
the motorcycle sag. Then adapt the compression and rebound braking. For technical clarifications on the operation and calibration of
the TM motorcycle suspensions, refer to the nearest TM dealer.
ADAPTING FORK BASE CALIBRATION
Exact fork sag cannot be established for several reasons. Minor variations of your body weight may be compensated by adjusting the
compression braking. However, if your fork often reaches the end of travel, mount stiffer springs in order to prevent damage to the
fork and frame. Re-adjust the compression and rebound braking.
ADAPTING SHOCK ABSORBER BASE CALIBRATION
To make sure that the shock absorber spring is suitable for your weight, check rider sag. However, the shock absorber static sag must
first be adjusted.
Both the static and rider sag can be checked through simple measurements performed on the motorcycle.
3.2 ADJUSTING SUSPENSIONS
4 STROKES
29
4 STROKES
CHECKING SHOCK ABSORBER STATIC SAG
Correct shock absorber static sag corresponds to a static lowering of
the motorcycle by 35 mm. Variations exceeding 2 mm may influence
motorcycle performance.
Procedure:
- Place the motorcycle on a stand so that the rear wheel does not touch
the ground.
- Measure the distance between the rear wheel pin and a fixed point (e.g.
a reference on a side) making sure that the straight line that connects
the wheel pin to the fixed point is as perpendicular to the ground as
possible and write down the value as measurement A.
- Place the motorcycle on the ground again.
- Ask someone to keep the motorcycle in an upright position.
- Measure the distance between the rear wheel pin and the fixed point
again and write the value down as measurement B.
- The static sag is the difference between measurements A and B.
EXAMPLE:
Motorcycle on stand (measurement A) ……………............................ mm 600 -
Motorcycle on the ground unladen (measurement B) ............. mm 565 =
Static sag ……………………………........................................................ mm 35
If the static sag is smaller, the shock absorber spring pre-load must
be decreased. If the static sag is greater, the spring pre-load must be
increased. See “Varying pre-load and replacing shock absorber spring”
chapter.
CHECKING SHOCK ABSORBER RIDER SAG
Correct shock absorber rider sag should correspond to a lowering of the
motorcycle of about 90-105 mm.
Procedure:
- Ask someone to help you hold the motorcycle. Sit on the bike wearing
full protective gear in normal position (feet on the footrests) and bounce
up and down a couple of times to normalise the rear suspension set
up.
- With the motorcycle loaded, measure the distance between the same
measurement points and write the value down as measurement C.
- The rider sag is the difference between measurements A and C.
EXAMPLE:
Motorcycle on stand (measurement A) ……..………..................... mm 600 -
Motorcycle on the ground with the driver (measurement C).... mm 510 =
Rider sag …………............................................................................ mm 90
If rider sag is less than 90 mm, the spring is too “hard” (spring rate too
high). If the rider sag is higher than 105 mm, the spring is too “soft”
(spring rate too low).
The spring rate is indicated on the spring wire. Once a different spring has
been assembled, the static sag must be readjusted to 35 mm (± 2 mm).
In our experience, after replacing the spring with one with a different
spring rate, the degree of compression damping can remain unvaried.
With a softer spring the degree of rebound damping can be reduced by
some clicks, and with a harder spring it can be increased by some clicks.
3.2 ADJUSTING SUSPENSIONS
A
B
C
30
4 STROKES
4 STROKES
In order to drive safely, the motorcycle must be in good state of maintenance. It is good practice to per form a general check on the motorcycle
before every use.
This verification must include the following checks:
ENGINE OIL LEVEL (page 78)
To guarantee suitable lubrication, the oil level in the engine must be within
the established limits. Running the engine with oil below the set level
causes premature wear, damage to the engine and risks for the rider.
FUEL LEVEL (page 37)
If your motorcycle is not equipped with a transparent tank, open the
tank cap and visually check the amount of fuel inside the tank. Close
the cap and make sure that the bleeder hose does not form bends that
prevent air flow.
TRANSMISSION CHAIN (page 50)
The transmission chain must always be tensioned and lubricated correc tly.
A loose chain knocks and may jump off the sprocket.
An excessively tensioned chain is subject to early wear and may wear
and break important transmission components.
TYRES (page 62)
Check for the presence of damage. Tyres with cuts or bulges must be
immediately replaced.
Check the depth of the tread, which must comply with the laws in force.
Check the air pressure and bring it back to the values indicated in the
tables, if required.
Worn tread and unsuitable air pressure affect motorcycle driveability
and may cause loss of control and serious accidents.
BRAKES (page 53)
Check correct operation.
Check the level of the brake fluid. The tanks located on the pumps are
sized in such a way that in case of normally worn brake pads, the fluid
does not need to be topped-up. If the brake fluid level drops below the
minimum value it means there is a leak in the brake system or that the
brake pads are completely worn. Refer to an authorised TM workshop to
check the brake system, as, in this case, brake operation may be faulty.
Moreover, check the conditions of the brake hoses and the thickness
of the pads. Check the free play and the smoothness of the front brake
lever and rear brake pedal.
FLEXIBLE CABLE CONTROLS (pages 12-13-19-73)
Check the adjustment and correct operation of all the flexible cable
controls.
COOLANT LEVEL (page 70)
Check the coolant level when the engine is cold. Top-up with the coolant
indicated in the tables, if required.
LIGHTS AND ACCESSORIES ELECTRICAL SYSTEM
With the engine running, check the correct operation of the front
headlight, front and rear position lights, rear brake light, turn signals,
control indicators and horn.
LUGGAGE
When taking luggage with you, make sure it is fastened correctly.
3.3 PRELIMINARY CHECKS
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