TM RACING 4 Stroke 2009 User And Maintenance Manual

USER AND

MAINTENANCE

MANUAL

USER AND

MAINTENANCE

MANUAL

TM RACING

USES and ADVICES

TM RACING

USES and ADVICES

TM 4 STROKE 2009

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ENGINE NUMBERENGINE NUMBER

ENGINE NUMBER

KEY NUMBERKEY NUMBER

KEY NUMBER

STST

ST

AMP OF AMP OF

AMP OF

THE THE

THE

AA

A

UTHORISED DEALERUTHORISED DEALER

UTHORISED DEALER

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

All indications are valid subject to spelling and printing errors.

FRAME NUMBERFRAME NUMBER

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.

IMPORIMPOR

IMPOR

TT

T

ANTANT

ANT

YOU ARE ADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM. IT CONT AINS A LOT OF INFORMA TION AND ADVICE THA T WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE MUCH EASIER AND SAFER.

IT IS IN YOUR SPECIFIC INTEREST T O P A Y P ARTICULAR A TTENTION TO THE W ARNINGS INDICA TED IN THE FOLLOWING WA Y :

DD

D

ANGERANGER

ANGER

FAILURE T O COMPL Y WITH THESE W ARNINGS RISKS LIVES!

WARNINGWARNING

WARNING

FAILURE TO COMPLY WITH THESE W ARNINGS COULD CAUSE DAMAGE TO PARTS OF THE MOTORCYCLE OR MAKE IT UNSAFE FOR USE.

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Dear Dear

Dear

TM customerTM customer

TM customer

,,

,

We would like to congratulate you for having chosen a TM motorcycle. Your TM is a competitive and modern motorcycle that will surely give you a lot of satisfaction if you treat it

according to the provisions contained in this manual. Before starting up your TM motorcycle for the first time,

you must 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 qualified mechanic.

For your safety , only use TM original spare parts and accessories. TM does not assume any responsibility for the use of other products and for damage deriving from them.

We advise you to respect the running in period, inspection periods and established maintenance periods scrupulously . Only full compliance with these regulations will lengthen the life of your motorcycle. Overhauls and repairs must only be carried out by a specialised TM workshop. For any information or requests contact a 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 T O CHANGE OR TO EXECUTE MODIFICA TIONS AS IT DEEMS NECESSARY .

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IMPORIMPOR

IMPOR

TT

T

ANT ANT

ANT

ADAD

AD

VICE REGARDINGVICE REGARDING

VICE REGARDING

THE LEGAL WARRANTY AND THETHE LEGAL WARRANTY AND THE

THE LEGAL WARRANTY AND THE

COMMERCOMMER

COMMER

CIAL CIAL

CIAL

WW

W

ARRANTYARRANTY

ARRANTY

TM sport motorcycles are designed and constructed in a manner to support the stress that may be verified in normal road and competition use. Competition motorcycles are in compliance with the regulations of the categories actually in force at the most important international motorcycling federations.

The scrupulous compliance with the established inspections, maintenance and tuning of the engine and chassis part of the motorcycle, indicated in the user manual, is indispensable for correct functioning and to prevent premature wear of the parts of the motorcycle itself. Incorrect tuning of the engine or of the chassis can also jeopardise one’s own safety and that of others.

The maintenance operations established in the “Maintenance and Lubrication” table must be carried out by a specialised TM workshop at the envisioned dates, otherwise any warranty rights will be forfeited.

When you must contact your TM Dealer for spare parts, updating requests or to signal problems, indicate the model, cylinder capacity, year of manufacture and most of all the frame number and the engine serial number

.

Fuels and lubricants must be those established in the user and maintenance manual and must be used as per maintenance programme. Products of other brands can be used as long as they have the equivalent specifications.

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

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

MX AND SMX MODELS CANNOT BE USED ON PUBLIC ROADS.

The 250, 450 and 530 models in the END, SMR and SMM versions can be used on roads only in the unvaried type-approved version (reduced). Without this power limitation (i.e. reduced) these models can only be used off-the-road, but not on public roads. The END models have been designed for off-the-road resistance competitions (Enduro) and are not suitable for Motocross.

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INDEXINDEX

INDEX

INDEXINDEX

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

Manual decompressor lever .......................................................... 10

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

Front brake lever BREMBO radial pump ......................................... 11

Electronic digital backlit display tachometer ...................................... 11

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

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

Start command and emergency stop

(END/MXE.S./SMXE.S./SMR/SMM) .................................................. 12

Fuel filler cap...................................................................................13

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

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

“By-Pass” command (hot starter) All models with electric starter.... 13

“By-Pass” command (hot starter) All models with kickstart ........... 14

Idle speed adjustment command .................................................... 14

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

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

Brake pedal ................................................................................... 15

Side stand ...................................................................................... 15

Side stand fixing for off-road routes...............................................15

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

Fork adjustment in compression .................................................... 16

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

Shock absorber adjustment in compression ................................. 17

Shock absorber adjustment in rebound ......................................... 18

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

ADVICE AND GENERAL RECOMMENDATIONS FOR

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

Indications for first start-up .......................................................... 20

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

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

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

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

Warm engine start .......................................................................... 23

If the engine is “flooded” ................................................................ 24

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

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

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

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

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

MAINTENANCE AND LUBRICATION T ABLE................................. 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 lowering in running order ........................ 38

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

Page

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

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

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

Modification of rear brake pedal base position ............................... 47

Check rear brake fluid level .......................................................... 47

Top-up rear brake fluid .................................................................. 47

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

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

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

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

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

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

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

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

Battery (all models with E.S.)......................................................... 51

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

Recharge fuse (all models with E.S.) ............................................ 53

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

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

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

Standard rear light ......................................................................... 55

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

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

Cooling ........................................................................................... 56

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

Emptying, filling and bleeding of the cooling system........................57

Replacement of exhaust silencer packing material..........................57

Cleaning the air filter ...................................................................... 58

Check hand decompressor adjustment ......................................... 58

Throttle cable command adjustment .............................................. 58

Hydraulic clutch AJP pump ........................................................... 59

Hydraulic clutch BREMBO pump .................................................... 59

Bleeding hydraulic clutch ............................................................. 60

Carburetor - Idle speed adjustment................................................ 60

Basic indications regarding carburetor wear................................. 61

Check fuel level (float height) ....................................................... 61

Emptying the carburetor float bowl..................................................62

Oil circuit........................................................................................ 62

Check engine oil level ................................................................... 63

Engine oil ....................................................................................... 63

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

TROUBLESHOOTING ................................................................. 66

CLEANING ................................................................................. 68

PRECAUTIONS FOR WINTER USE .............................................. 68

STORAGE ................................................................................. 68

Start-up after seasonal pause........................................................... 68

TECHNICAL DATA - ENGINE.................................................... 69/70

CARBURETOR SETTINGS ............................................................ 71

ENGINE TIGHTENING TORQUES .................................................. 72

TECHNICAL DATA-CYCLE PART ............................................ 73-74

ALPHABETIC INDEX ................................................................... 75

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

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POSITION OF SERIAL NUMBERPOSITION OF SERIAL NUMBER

POSITION OF SERIAL NUMBER

FRAME NUMBERFRAME 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 NUMBERENGINE NUMBER

ENGINE NUMBER

The engine number is engraved on the left side of the engine underneath the chain pinion. Make note of this number in the appropriate space on page 3.

POSITION OF SERIAL NUMBERPOSITION OF SERIAL NUMBER

POSITION OF SERIAL NUMBER

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CLUTCH LEVER AJP PUMPCLUTCH LEVER AJP PUMP

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 adjusted the lever position and to ensure the correct freeplay.

CLUTCH LEVER BREMBO PUMPCLUTCH LEVER BREMBO PUMP

CLUTCH LEVER BREMBO PUMP

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

MANUAL DECOMPRESSOR LEVERMANUAL DECOMPRESSOR LEVER

MANUAL DECOMPRESSOR LEVER (ALL 530 AND 660CC.)(ALL 530 AND 660CC.)

(ALL 530 AND 660CC.)(ALL 530 AND 660CC.)

(ALL 530 AND 660CC.)

The hand decompressor lever (4) is on the left side of the handlebar, and is used when, after a fall or following overheating, the engine is difficult to start-up when warm. To ventilate the engine, pull the decompressor lever during starting. The lever must always have a play of about 10 mm measured between the lever and support, before starting to open theexhaust valves. The time of opening is recognised by greater resistance of the lever (see “Frame and Engine Maintenance” chapter).

FRONT BRAKE LEVER NISSIN PUMP (END/MX)FRONT BRAKE LEVER NISSIN PUMP (END/MX)

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”).

OPERAOPERA

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3

C

6

5

4

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1

FRONT BRAKE LEVER BREMBO RADIAL PUMPFRONT BRAKE LEVER BREMBO RADIAL PUMP

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

(SMR/SMM/SMX)(SMR/SMM/SMX)

(SMR/SMM/SMX)

The front brake pump lever (1) 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 (A) (see “Frame and Engine Maintenance” chapter)

ELECTRELECTR

ELECTR

ONIC DIGITONIC DIGIT

ONIC DIGIT

AL BAL B

AL B

AA

A

CKLIT DISPLACKLIT DISPLA

CKLIT DISPLA

YY

Y

TT

T

AA

A

CHOMETERCHOMETER

CHOMETER

See picture (1). It is used on the END/SMR/SMM models. t has a wide backlit display and four pilot lights. In the top there are the left indicator pilot light (2) , the low beam pilot light (3), the high beam pilot light (4) and the right indicator pilot light (5). Inside the display you find the tachometer (6), the trip odometer (7) and the total kilometers odometer (8). In the bottom there are two buttons, “SET” (9) and “MODE” (10).

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

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

The instrument switches on automatically when pressing and positioning outwards the red button located near the throttle command and switches off when pressing and positioning inwards the red button itself.

ENGINE STOP SWITCH (MX/SMX)ENGINE STOP SWITCH (MX/SMX)

ENGINE STOP SWITCH (MX/SMX)

The engine stop switch is found near to the left handlebar grip. The engine is shutdown using the engine stop switch (1): when it is activated a shortcircuit is caused in the ignition, which no longer supplies voltage to the spark plug. Press the button until the engine switches off and then release.

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COMBINCOMBIN

COMBIN

AA

A

TION SWITTION SWIT

TION SWIT

CHCH

CH

(END/SMR/SMM)(END/SMR/SMM)

(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.

STST

ST

ARAR

AR

T COMMAND T COMMAND

T COMMAND

AND EMERAND EMER

AND EMER

GENCY STGENCY ST

GENCY ST

OPOP

OP

(END/MXE.S./SMXE.S./SMR/SMM)(END/MXE.S./SMXE.S./SMR/SMM)

(END/MXE.S./SMXE.S./SMR/SMM)

In the models with battery and electric ignition, a two-button command is found at the side of the throttle command, one button is red, the other black. The red button (1) has two positions. Positioned inwards, it interrupts contact with the battery, removing the current from all services consumers/ancilleries. The engine will not start even with the pedal.

On these models, position it like this to switch the engine off.

It is advised to leave it like this until the engine is started-up again, otherwise the battery will go flat.

Positioned outwards, it closes the contact with the battery , enables the use of all services, including electric starter. For this reason, never leave it like this with the engine switched off, otherwise the ignition control unit, which absorbs current even when the engine is switched off, can make the battery flat. The black button (2) activates the starter. Press to startup the engine and release once running. Activate this command for a maximum of 8/10 sec. at a time and wait a few seconds before re-trying. Do not insist for more than 3/4 times: look for the probable fault. Never press this button when the engine is running.

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FUEL FILLER CAPFUEL FILLER CAP

FUEL FILLER CAP

The fuel fill cap is found on top of the tank.

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

direction. Position the tank’s open vent pipe (1) preventing bends or crushing

and making sure that it is inserted correctly.

FUEL FUEL

FUEL

TT

T

APAP

AP

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 flows to the carburetor and the tank empties up to reserve.

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

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

Tank capacity (all models)............ 8 Lt. + reserve 1 Lt.

CHOKE COMMAND (COLD STCHOKE COMMAND (COLD ST

CHOKE COMMAND (COLD ST

ARAR

AR

TER)TER)

TER)

This command is located on the left side of the motorcycle.

For MIKUNI carburetors

By extracting the choke knob (1) as far as possible, a passage is opened in the carburetor, through which the engine can suck additional fuel. In this way, a “rich” air-fuel mix is obtained. This is necessary for starting the engine when it is cold. T o disconnect the command, push the choke knob inwards to its original position.

For KEIHIN carburetors

Extract the knob and turn it clockwise to block it. To disconnect it, turn anticlockwise.

“BY“BY

“BY

-PASS”-PASS”

-PASS”

COMMAND (HO COMMAND (HO

COMMAND (HO

T STT ST

T ST

ARAR

AR

TER)TER)

TER)

All models with electric starAll models with electric star

All models with electric star

terter

ter

This command is found on the right side of the motor cycle.. By pulling the by-pass knob (1) forward as far as possible, a hole is opened in the feeding pipe, through which the engine can suck an additional amount of air not mixed with fuel. The result is a “lean” airfuel mix. This is required for starting the engine when it is flooded or particularly overheated. As soon as the engine is running, push the knob to return it to its normal position.

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“BY“BY

“BY

-PASS”-PASS”

-PASS”

COMMAND (HO COMMAND (HO

COMMAND (HO

T STT ST

T ST

ARAR

AR

TER)TER)

TER)

All models with kicAll models with kic

All models with kic

kstarkstar

kstar

tt

t

This command is found on the handlebar, near to the right handlebar grip. By turning the by-pass lever (1) as far as possible, a hole is opened in the feeding pipe, through which the engine can suck an additional amount of air not mixed with fuel. The result is a “lean” air-fuel mix. This is required for starting of the engine when it is flooded or particularly overheated. As soon as the engine is running, turn the lever to return it to its normal position.

IDLE SPEED ADJUSTMENT COMMANDIDLE SPEED ADJUSTMENT COMMAND

IDLE SPEED ADJUSTMENT COMMAND

This command is located on the left side of the motorcycle By turning the idle speed adjustment knob, the normal running of the engine at idle speed is raised or lowered. By turning it in a clockwise direction, the idle speed is raised, by turning it in an anti-clockwise direction, the idle speed is lowered. The normal idle speed, when the engine is warm, must be between 1,600 and 1,800 rpm.

GEAR SHIFT PEDGEAR SHIFT PED

GEAR SHIFT PED

ALAL

AL

The gear shift pedal is positioned on the engine left side. The position of the gears is indicated in the illustration. The neutral is between the first and second gears.

KICKSTKICKST

KICKST

ARAR

AR

T PEDT PED

T PED

ALAL

AL

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.

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BRAKE PEDBRAKE PED

BRAKE PED

ALAL

AL

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 STSIDE ST

SIDE ST

ANDAND

AND

Push the side stand to the floor using the foot and rest the motorcycle on it. Pay attention that the ground is solid and the position stable.

SIDE STSIDE ST

SIDE ST

AND FIXING FOR OFFRAND FIXING FOR OFFR

AND FIXING FOR OFFR

OO

O

AD RAD R

AD R

OUTESOUTES

OUTES

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

IGNITION SWITCHIGNITION SWITCH

IGNITION SWITCH

In the SMR and SMM models an ignition key is added on the left side of the dashboard. By turning the key clockwise , the electric circuit is closed and, after the starter button has been pushed so as to close the contact with the battery, it is possible to operate the electric starter. To switch the engine off, remember to position the red starter button to interrupt the battery connection circuit and turn the key anticlockwise.

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3

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FORK ADJUSTMENT IN COMPRESSIONFORK ADJUSTMENT IN COMPRESSION

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

The adjustment screw is located in the upper side of the fork cap (4). For this operation, use a screwdriver. By turning the screw clockwise, dampening increases, while turning it anticlockwise, dampening decreases. A total of 28 clicks is 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

The adjustment screw (3) is located in the bottom of the fork leg. 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 “TOT ALL Y CLOSED” POSITION AND COUNT THE NOTCHES DETECTED SO THAT THE ST ANDARD POSITION CAN BE RESTORED. FOR CONVENTION, THE NOTCHES ARE INDICATED FROM THE “TOTALLY CLOSED” POSITION. BOTH RODS MUST HA VE THE SAME ADJUSTMENT.

FORK ADJUSTMENT IN REBOUNDFORK ADJUSTMENT IN REBOUND

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 to tal 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 “TOT ALL Y CLOSED” POSITION AND COUNT THE CLICKS DETECTED SO THA T THE ST ANDARD POSITION CAN BE RESTORED. FOR CONVENTION, THE NUMBER OF CLICKS IS INDICA TED FROM THE “TOT ALLY CLOSED” POSITION. BOTH LEGS MUST HA VE THE SAME ADJUSTMENT.

WARNING

FOR FURTHER AND MORE DET AILED INFORMA TION 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.

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SHOCK SHOCK

SHOCK

ABSORBER ABSORBER

ABSORBER

ADJUSTADJUST

ADJUST

..

.

IN COMPRESSION IN COMPRESSION

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 (ST ANDARD)

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

OHLINS SHOCK ABSORBER (OPTIONAL)

Low speeds- The adjustment screw (1) is on the top of the damper gas tank. Use a screwdriver. By turning the screw clockwise, dampening increases, anticlockwise dampening decreases. A total of 25 clicks are available. High speeds- The adjuster is a hexagonal ring nut (2) and is concentric to the low speeds adjustment screw. Use a 17mm hexagonal spanner. By turning the nut clockwise, dampening increases, anticlockwise 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 “TOT ALL Y CLOSED” POSITION AND COUNT THE CLICKS/TURNS DETECTED SO THAT THE STANDARD POSITION CAN BE RESTORED. FOR CONVENTION, THE NUMBER OF CLICKS/TURNS ARE INDICA TED FROM THE “TOT ALLY CLOSED” POSITION.

OPERAOPERA

OPERA

TING CONTRTING CONTR

TING CONTR

OLSOLS

OLS

OPERAOPERA

OPERA

TING CONTRTING CONTR

TING CONTR

OLSOLS

OLS

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SHOCK ABSORBER ADJUSTMENT IN REBOUNDSHOCK ABSORBER ADJUSTMENT IN REBOUND

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 (ST ANDARD)

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 “TOT ALL Y CLOSED” POSITION AND COUNT THE CLICKS DETECTED SO THA T THE ST ANDARD POSITION CAN BE RESTORED. FOR CONVENTION, THE NUMBER OF CLICKS IS INDICATED FROM THE “TOT ALLY 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, OTHER WISE P ARTS COULD BE DAMAGED AND PERSONS INJURED

STEERING LOCKSTEERING LOCK

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 lef t, 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.

OPERAOPERA

OPERA

TING CONTRTING CONTR

TING CONTR

OLSOLS

OLS

OPERAOPERA

OPERA

TING CONTRTING CONTR

TING CONTR

OLSOLS

OLS

PERICOLO

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INDICATIONS FOR FIRST STINDICATIONS FOR FIRST ST

INDICATIONS FOR FIRST ST

ARAR

AR

TT

T

-UP-UP

-UP

- Ensure that the “PRE-DELIVERY OPERATIONS” of your motorcycle have been carried out by your TM dealer.

- Carefully read all user instructions before making the first journey.

- Become familiar with all operating controls.

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

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

- Do not take routes that are too difficult for your driving ability and experience.

- On the road, hold the handlebar with both hands and leave your feet on the footrests.

- Be careful not to push the brake pedal if you do not wish to brake. If the brake pedal is not released, the brake pads rub continuously and the brake overheats

- Do not modify the motorcycle and always use ORIGINAL TM SPARE PARTS. Spare parts made by other manufacturers can jeopardise the safety of the motorcycle.

- Motorcycles are sensitive to the movement of weight. When carrying luggage, fix it as near as possible to the centre of the motorcycle and distribute the weight equally between the front and rear wheel.

- Follow running in instructions.

RUNNING IN INSTRUCTIONSRUNNING 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. T o obtain an optimal bedding of the moving part s of a new engine, it must be taken to produce maximum performance gradually. For this reason, during the first 3 hours of use (1 hour for competition use) the engine must only be used up to max. 50% of its power. Moreover, the number of revs. must not exceed 7000/min. In the following 5 hours of use (1 hour for competition use) the engine can be used up to max. 75% of its power. Drive the motorcycle in different conditions (road, easy off-road tracts). Do not make long journeys without ever closing the throttle. By following these regulations, you will obtain maximum performance and longer duration of the motorcycle through time.

WARNING

THE 250/450/530 END/MX/SMX MODELS HAVE BEEN DEVELOPED WITH NO COMPROMISE FOR OFF-ROAD COMPETITIONS. EVEN IF THE ENDURO MODELS ARE TYPE-APPROVED, P A Y A TTENTION WHEN USING ON THE ROAD . MOST OF ALL A VOID SUST AINED ACCELERA TION 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 ALW A YS 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 EASIL Y SEEN BY OTHER ROAD USERS.

- ALWA YS 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 NEGATIVEL Y AFFETCT THE BEHA VIOUR OF THE MOTORCYCLE ON THE ROAD A T HIGH SPEEDS, OR HA VE NEGATIVE INFLUENCE OF THE BEHAVIOUR OF THE MOT ORCYCLE 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 QUICKL Y ON NEW WHEELS. IF YOU DRIVE WITH LOOSE SPOKES, THE SPOKES MAY BREAK, CAUSING UNSTABLE DRIVING CONDITIONS (SEE CHECK SPOKE TENSION).

- THE RACING MODELS HA VE BEEN DESIGNED AND PREP ARED ONL Y FOR ONE PERSON. IT IS PROHIBITED TO T AKE 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 CAP ABILITY.

- DRIVE CAREFULLY ON UNKNOWN ROADS OR LAND.

- WHEN OFF-ROAD YOU SHOULD ALW A YS BE ACCOMPANIED BY A FRIEND WITH A SECOND MOTORCYCLE, SO THA T 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 MOTORW A YS.

- WHEN USING YOUR MOTORCYCLE, ALW A YS KEEP IN MIND THA T EXCESSIVE NOISE DISTURBS OTHERS.

DANGER

ADAD

AD

VICE VICE

VICE

AND GENERAL RECCOMANDAND GENERAL RECCOMAND

AND GENERAL RECCOMAND

AA

A

TIONS FORTIONS FOR

TIONS FOR

COMMISSIONING COMMISSIONING

COMMISSIONING

THE MOTHE MO

THE MO

TT

T

OROR

OR

CYCY

CY

CLECLE

CLE

ADAD

AD

VICE VICE

VICE

AND GENERAL RECCOMANDAND GENERAL RECCOMAND

AND GENERAL RECCOMAND

AA

A

TIONS FORTIONS FOR

TIONS FOR

COMMISSIONING COMMISSIONING

COMMISSIONING

THE MOTHE MO

THE MO

TT

T

OROR

OR

CYCY

CY

CLECLE

CLE

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CHECK BEFORE EVERCHECK BEFORE EVER

CHECK BEFORE EVER

Y STY ST

Y ST

ARAR

AR

TT

T

-UP-UP

-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 flow of air.

3 CHAIN

The drive chain must always be tensioned corretly and well lubricated.

A loose chain knocks and may escape from the sprockets.

A too tight chain wears early and may cause wear and breakage of some important transmission components.

4 TYRES

Check for any damage. Tyres with cut s or swellings must be replaced immediately.

Check the depth of the tread which must correspond to the law.

Finally, check the air pressure and take it to the values envisioned in the table, if necessary. Worn tread and unsuitable air pressure worsen driving of the motorcycle and may cause loss of control and serious accidents.

5 BRAKES

Verify correct working. Check the level of brake fluid. The reservoir on the pumps are dimensioned in a way that in case of normally worn brake pads the fluid does not need to be topped-up. If the level of brake fluid falls below the minimum level, this indicates a leak in the brake system or complete consumption of the brake pads. Have the brake system checked by a specialised TM workshop, given that in this case the brakes could fail.

The state of the brake’s flexible pipes and the thickness of the pads

must also be checked. Check the free play and the smoothness of the front brake lever and the rear brake pedal.

6 FLEXIBLE CABLE COMMANDS

Check the adjustment and correct working of all flexible cable commands .

7 COOLANT

Check the level of coolant with cold engine. Top-up with the liquid stated in the table, if necessary.

8 ELECTRICAL PLANT

With the engine running, check for the front headlight, the front and rear position lights, the rear stopping light, the direction indicator lights, the control lights and the horn.

9 LUGGAGE

Check that any luggage is well fixed.

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COLD ENGINE STCOLD ENGINE ST

COLD ENGINE ST

ARAR

AR

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1 Open the fuel tap (1). 2 Remove the motorcycle from the stand. 3 Put the gears in neutral. 4 Activate the choke command (2), which is located on the left side of

the motorcycle.

5 WITHOUT opening the throttle, press hardly the kickstarter DOWN

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

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

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

- ALWAYS WEAR STRONG MOTORCYCLE BOOTS WHEN STARTING UP THE MOTORCYCLE TO PREVENT INJURY. YOU COULD SLIP OFF OF THE PEDAL OR THE ENGINE COULD KICKBACK AND MAKE YOU KNOCK YOUR FOOT VIOLENTL Y.

- ALWAYS PRESS THE KICKSTARTER DOWN HARD WITHOUT ACCELERATING. KICKSTARTING WITH LITTLE FORCE OR WITH OPENED THROTTLE, INCREASES THE RISK OF ENGINE KICK BACK.

- DO NOT START THE ENGINE IN A CLOSED SP ACE AND NEVER LEA VE IT RUNNING IN CLOSED SPACES. THE EXHAUST FUMES ARE POISONOUS AND MA Y LEAD TO RISK OF UNCONSCIOUSNESS AND DEA TH. WHEN THE ENGINE IS RUNNING , AL WA YS ENSURE THERE IS SUFFICIENT VENTILA TION.

- ALWAYS CHECK THAT THE GEAR IS IN NEUTRAL BEFORE OPERATING THE STARTER BUTT ON. IF A GEAR IS INSERTED WHEN STARTING THE ENGINE, THE MOTORCYCLE WILL JUMP FORW ARDS.

WARNING

- OPERATE THE ST ARTER FOR MAX. 5 SECONDS A T A TIME. W AIT ANOTHER 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 CONSEQUENTL Y , IT EXP ANDS QUICKER THAN THE CYLINDER, WHICH IS WA TER-COOLED. ALW AYS W ARM THE ENGINE A T A ST ANDSTILL OR MOVE A T LOW REVS.

WW

W

ARM ENGINE STARM ENGINE ST

ARM ENGINE ST

ARAR

AR

TT

T

1 Open the fuel tap (1). 2 Remove the motorcycle from the stand 3 Insert the neutral gear. 4 WITHOUT opening the throttle, press hardly the kickstarter DOWN

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

WARNING

- OPERATE THE ST ARTER MOTOR FOR MAX. 5 SECONDS A T A TIME. W AIT ANOTHER 5 SECONDS BEFORE TRYING AGAIN.

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IF THE ENGINE IS “FLOODED”IF THE ENGINE IS “FLOODED”

IF THE ENGINE IS “FLOODED”

In the event of a fall, a certain amount of fuel can flow out of the caburetor and enter the head, “flooding” the engine. To start the engine, pull the “hot start” knob or turn the “hot start” lever (1). WITHOUT opening the throttle push hardly the kickstart pedal DOWN TO THE BOTTOM once or twice or operate the electric starter. On models with a manual decompressor, to eliminate the excess fuel from the engine, pull the manual decompressor lever and operate the kickstart pedal 5 -10 times or the electric starter button respectively twice for 5 seconds. Start the engine as previously described. If necessary, remove the spark plug and dry it.

WARNING: The carburetor has an accelerator pump. Every time that you open the throttle,with the engine running or switched off, a quantity of fuel is sprayed into the inlet tract. If this operation is carried out with the engine switched off, it causes flooding of the engine, with the consequent starting difficulties and a dangerous distribution of fuel. NEVER TURN THE THROTTLE WHEN THE ENGINE IS NOT RUNNING IF NOT STRICTLY NECESSARY . IN ANY CASE DO IT ONL Y ONCE AND NEVER REPEATEDL Y!

BIKE STBIKE ST

BIKE ST

ARAR

AR

TINGTING

TING

Pull the clutch lever, insert the first gear, release the clutch lever slowly, accelerating at the same time.

BEFORE STARTING, ALWAYS CHECK THAT THE SIDE STAND HAS BEEN LIFTED. IF THE STAND SLIDES ALONG THE GROUND YOU COULD LOOSE THE CONTROL OF THE MOTORCYCLE.

SHIFTING GEAR,SHIFTING GEAR,

SHIFTING GEAR,

AA

A

CCELERACCELERA

CCELERA

TINGTING

TING

,,

,

SLOWING DOWNSLOWING DOWN

SLOWING DOWN

1st gear, which should be selected, is the pulling away and ascent gear. If the circumstances permit (speed limits, traffic, slopes), to increase speed, insert higher gears. To do this, close the throttle, pull the clutch lever at the same time, insert the successive gear, release the clutch and accelerate up to 1/2 turn of the throttle. Then insert the following gear and repeat this operation until the desired speed is reached and however, permitted by the limits in force. Gradual opening of the accelerator favours careful driving and limits consumption. Learn the correct opening of the throttle on the basis of the pace at which you want the motorcycle to move. To reduce speed, the throttle must be closed. Brake and shift down the gears, pulling the clutch lever and inserting a lower gear. Release the clutch slowly and accelerate or change gear again . Always increase or change down the gears one at a time!

DANGER

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INDICATION:

All TM models do not have a radiator cooling fan and the radiator dimensions have been studied to optimise compactness and weight. The cooling system is sufficient for touristic or sports use. If you want to use an additional cooling fan contact a TM authorised dealer.

- TM MODELS CAN BE RE-STARTED AT ANY TIME BY KICK OR WITH THE ELECTRIC STARTER. SWITCH THE ENGINE OFF WHEN YOU INTEND TO KEEP THE MOTORCYCLE AT A ST ANDSTILL FOR MORE THAN 2 MINUTES.

- AFTER EVERY FALL, THE MOTORCYCLE MUST BE CONTROLLED IN THE SAME WA Y AS BEFORE EVER Y ST ART -UP .

- A DEFORMED HANDLEBAR MUST ALWAYS BE REPLACED. NEVER STRAIGHTEN THE HANDLEBAR AS IT COULD LOOSE ITS STRENGTH.

WARNING

- USE OF THE ENGINE AT A HIGH NUMBER OF REVS WHEN IT IS COLD, NEGATIVEL Y AFFECTS THE DURA TION OF THE ENGINE. BEFORE USING THE MOTORCYCLE A T FULL WORKING CONDITIONS, IT IS BETTER TO WARM IT ADEQUATELY BY DRIVING AT AN AVERAGE SPEED. THE ENGINE HAS REACHED ITS WORKING TEMPERA TURE AS SOON AS THE RADIATORS BECOME HOT .

- NEVER SHIFT DOWN A GEAR WITHOUT HA VING FIRST SLOWED DOWN. THE ENGINE WOULD BE TAKEN TO AN EXCESSIVE NUMBER OF REVS AND THE VAL VES AND OTHER ENGINE COMPONENTS WOULD BE DAMAGED. THE REAR WHEEL COULD ALSO LOCK, LEADING TO LOSS OF CONTROL OF THE VEHICLE.

- IF THERE ARE ABNORMAL VIBRA TIONS DURING FUNCTIONING , CHECK THAT THE SCREW FASTENERS ARE TIGHTENED WELL.

- IF STRANGE NOISES ARE HEARD DURING DRIVING, STOP IMMEDIA TELY, SWITCH THE ENGINE OFF AND CONT ACT A TM AUTHORISED DEALER.

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BRAKINGBRAKING

BRAKING

Close the throttle and brake at the same time progressively with the front and rear brakes. Insert a lower gear depending on speed. On dusty, wet or slippery surfaces, operate the brakes and change down the gears gently without locking the wheels. Locking the wheels leads to swerving or a fall. When following long descending roads, make use of the engine’s braking effect. To do this, insert the 1st or 2nd gear, without however increasing the revs. excessively. In this way you will have to brake much less and the brakes will not overheat.

- IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER IMMERSION IN WATER OR TRAVELLING OVER WET GROUND, THE BRAKING ACTION COULD BE DELAYED BECAUSE OF WET OR DIRTY BRAKE DISCS.THE BRAKES MUST THEREFORE BE OPERATED REPEATEDLY UNTIL THE DISCS ARE DR Y AND CLEAN.

- THE BRAKING ACTION CAN ALSO BE DELA YED WHEN TRA VELLING ON DIRTY ROADS OR ROADS COVERED WITH SAL T . THE BRAKES MUST BE OPERATED UNTIL THE DISCS ARE CLEAN.

- WHEN THE BRAKE DISCS ARE DIRTY THERE IS GREATER WEAR OF THE PADS AND THE BRAKE DISCS THEMSEL VES.

- AFTER USING THE BRAKES, THE DISC, THE PADS, THE CALIPERS AND THE BRAKE FLUID HEAT UP. THE HOTTER THESE P ARTS, THE LESS THE BRAKING EFFECT. IN CASE OF OVERHEATING THE ENTIRE BRAKING SYSTEM MA Y NOT WORK.

- IF THE FORCE AT THE FRONT BRAKE LEVER OR BRAKE PEDAL IS MINIMAL, THERE COULD BE A F AUL T IN THE BRAKING SYSTEM. I N THIS CASE IT IS A GOOD IDEA TO HA VE THE MOTORCYCLE CHECKED BY AN AUTHORISED TM DEALER.

STST

ST

OPPING OPPING

OPPING

AND PAND P

AND P

ARKINGARKING

ARKING

Stop the motorcycle and shift into neutral. To switch the motorcycle off, press, at normal minimum revs, the engine stop switch until the engine has stopped, or the red emergency shutdown button. In this case, it is advised to leave the red button in this way until the engine is started again.Close the fuel tap, park on solid ground and lock the motorcycle using the steering lock. .

MOTORCYCLES PRODUCE A LOT OF HEA T DURING WORKING . THE ENGINE, RADIATORS, EXHAUST SYSTEM, BRAKE DISCS AS WELL AS SHOCK ABSORBERS CAN ALL BECOME VERY HOT . NEVER T OUCH THESE P ARTS WHEN DRIVING AND AFTER HA VING SWITCHED THE ENGINE OFF , P ARK THE MOTORCYCLE IN A WAY THAT PEDESTRIANS CANNOT T OUCH THEM AND BE BURNED.

WARNING

- NEVER SWITCH THE ENGINE OFF USING THE DECOMPRESSOR LEVER, BUT USE THE ENGINE STOP SWITCH OR THE EMERGENCY SHUTDOWN BUTTON.

- THE FUEL TAP MUST ALWAYS BE CLOSED WHEN THE MOTORCYCLE IS PARKED. IF IT IS NOT CLOSED, THE FUEL COULD RUN OUT INTO THE CARBURETOR AND PENETRA TE THE ENGINE, FLOODING IT .

- NEVER PARK WITH THE ENGINE RUNNING OR P ARK THE MOTORCYLE IN PLACES WHERE THERE IS THE RISK OF FIRE DUE TO DRY GRASS OR OTHER EASILY INFLAMMABLE MATERIALS.

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INDICATIONS REGARDING THE SIDE ST AND:

Push the stand forward until it stops and lean the motorcycle on it. Ensure that the ground is solid and the parking position is stable. For greater safety insert the 1st gear.

WARNING

THE SIDE STAND IS DESIGNED ONL Y FOR THE WEIGHT OF THE MOT ORCYCLE. NEVER SIT ON THE MOTORCYCLE WHEN IT IS RESTING ON THE SIDE STAND, OTHERWISE THE ST AND MA Y BE DAMAGED AND THE MOT ORCYCLE CAN FALL.

FUELFUEL

FUEL

TM engines require super unleaded fuel with at least 9 5 RON.

WARNING

FILL THE T ANK WITH UNLEADED FUEL WITH A MINIMUM OCTANE NUMBER OF

95. NEVER USE FUEL WITH AN OCTANE NUMBER LOWER THAN 95, BECAUSE

THIS WOULD DAMAGE THE ENGINE.

FUEL IS HIGHLY INFLAMMABLE AND TOXIC. HANDLE FUEL WITH GREAT CARE. DO NOT FILL-UP WITH FUEL NEAR TO FLAMES OR CIGARETTES. ALW A YS SWITCH THE ENGINE OFF WHEN FILLING UP WITH FUEL. NEVER POUR FUEL ONTO THE ENGINE OR ONTO THE EXHAUST PIPE. IF ANY FUEL IS ACCIDENTL Y POURED ONT O THESE P ARTS, DRY IT IMMEDIA TEL Y USING A CLOTH. IF FUEL IS SWALLOWED OR SPRAYED INTO THE EYES, SEEK MEDICAL HELP IMMEDIATELY.

Fuel expands when heated. Therefore, never fill the tank completely with high environmental temperatures.

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OTHER IMPORTANT MAINTENANCE OPERATIONS RECCOMMENDED EVERY YEAR

OTHER IMPORT ANT MAINTEN ANCE OPERATIONS RECCOMMENDED EVERY YEAR

The distance between maintenance intervals should not be exceeded by more than 2hours or 15 litres. THE MAINTENANCE CARRIED OUT BY THE AUTHORISED TM DEALER DOES NOT REPLACE THE CHECKS AND MAINTENANCE CARRIED OUT BY THE RIDER .

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

Complete fork maintenance Complete shock absorber maintenance Cleaning and greasing of steering bearings and related sealing elements Cleaning and tuning of the carburetor Replacement of silencer packing material Treatment of electric contacts and switches with contact spray Treatment of battery connections with contact grease Replacement of hydraulic clutch fluid Replacement of brake fluid

EVERY YEAREVERY YEAR

EVERY YEAR

•

MAINTENANCE AND LUBRICATION TABLE

250/450/530 END/SMR/SMM R250/450/530 END/SMR/SMM R

250/450/530 END/SMR/SMM R

OO

O

AD/HOBBY USEAD/HOBBY USE

AD/HOBBY USE

Replacement of engine oil, cartridge oil filter Clean of drain bolt Check conditions and and unbent positioning of rubber pipes Check of the timing chain Check tightness of engine fastening screws Check fixing for carburetor to engine and filter case Check idle speed adjustment Check conditions and unbent positioning of vent pipes Check for leaks of the cooling system and coolant level Check for leaks and tightness of all oil drain screws Check conditions, smoothness and unbent positioning, of all pipes and cables adjustment and lubrication of throttle and decompressor cables Check fluid level in the hydraulic brake and clutch reservoirs Clean filter case and air filter Check conditions and unbent positioning of cables Check headlamp orientation Check electric system (head light, high-beam, stop, indicators, lights, horn, safety button/switch) Check brake fluid level, pad thickness, brake discs Check conditions of brake hoses Check functionality, adjustment, smoothness and free play of front brake lever and brake pedal Check brake hoses screws tightness Check for leaks and working of shock absorber and forks Clean dust screen Bleed fork leg Check rear suspension mechanical linkage screw tightness Check and adjustment of steering bearings Check tightness of chassis screws (fork clamps, fork legs, wheels axles nuts and screws, rear fork axle, shock absorber) Check spoke tension and trueness of rims Check tyre conditions and pressure Check chain wear, chain link, sprockets, chain tension Chain lubrication Check wheel bearing play

EVERY 30 HOURS

OR

150 LT. OF FUEL

1ST SERVICE

AFTER 3 HOURS

OR

15 LT. OF FUEL

•

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONSA CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

ENGINE

CARBURETOR

SERVICESBRAKESCYCLE PARTWHEELS

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONSA CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

MAINTENANCE AND LUBRICATION TABLE

250/450/530 END/SMR/SMM R250/450/530 END/SMR/SMM R

250/450/530 END/SMR/SMM R

OO

O

AD/HOBBY USEAD/HOBBY USE

AD/HOBBY USE

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

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MAINTENANCE AND LUBRICATION TABLE

250/450/530 END/MX250/450/530 END/MX

250/450/530 END/MX

/SMX 660 SMX COMPETITION USE/SMX 660 SMX COMPETITION USE

/SMX 660 SMX COMPETITION USE

MAINTENANCE AND LUBRICATION TABLE

250/450/530 END/MX250/450/530 END/MX

250/450/530 END/MX

/SMX 660 SMX COMPETITION USE/SMX 660 SMX COMPETITION USE

/SMX 660 SMX COMPETITION USE

EVERY

COMPETITION

1ST SERVICE

AFTER 2 HOURS

OR

12 LT. OF FUEL

•

ENGINE

CARBURETOR

SERVICESBRAKESCYCLE P ARTWHEELS

Replacement of engine oil, cartridge oil filter Clean of drain bolt Check condition and unbent positioning of rubber pipes Check of timing chain Check and adjustment of valve clearance Check tightness of engine fastening screws Check fasteners for carburetor to engine and filter case Check idle speed adjustment Check conditions and unbent positioning of vent pipes Check for leaks of the cooling system and coolant level Check for leaks and screws tightness of the all exhaust system Check conditions, smoothness and unbent positioning, adjustment and lub. of command cables Replacement of silencer packing material Check fluid level in the hydraulic clutch reservoir Cleaning of filter case and air filter Check conditions and unbent positioning of cables Check head light orientation (END) Check electric system (head light, high beam, stop, indicators, lights, horn - END version), safety button/switch Check brake fluid level, pad thickness, brake discs Check conditions of brake hoses Check functionality, adjustment, smoothness and free play of front brake lever and brake pedal Check brake hoses screws tightness Check for leaks and working of shock absorber and forks Clean dust screen Bleed fork legs Check rear suspension mechanical linkage screw tightness Check and adjustment of steering bearings Check tightness of chassis screws and bolts (fork clamps, fork legs, wheel axles nuts and screws, rear fork axle, shock absorber) Check spoke tension and trueness of rims Check tyre condition and pressure Check chain wear, chain link, sprockets and guides, chain tension Chain lubrication Check wheel bearing play

The distance between maintenance intervals should not be exceeded by more than 2hours or 15 litres. THE MAINTENANCE CARRIED OUT BY THE AUTHORISED TM DEALER DOES NOT REPLACE THE CHECKS AND MAINTENANCE CARRIED OUT BY THE RIDER .

Complete fork maintenance Complete shock absorber maintenance Cleaning and greasing of steering bearings and related sealing elements Cleaning and tuning of the carburetor Treatment of electric contacts and switches with contact spray Treatment of battery connections with contact grease Replacement of hydraulic clutch fluid Replacement of brake fluid

EVERY 3EVERY 3

EVERY 3

RACESRACES

RACES

•

OTHER IMPORTANT MAINTENANCE OPERATIONS RECOMMENDED EVERY 3 RACES

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONSA CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONSA CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS

ENGLISH

32

Check engine oil level Check brake fluid level Check brake pad wear Check light system (if present) Check horn (if present) Lubrication and adjustment of command cables Bleed fork legs Disassembly and cleaning of the dust shields Cleaning, lubrication and tension check of final transmission chain Cleaning filter case and air filter Check tyre pressure and wear Check coolant level Check fuel pipe for leaks Cleaning of caburetor and jets for dirt and water removal Check smoothness of all command elements Check braking effect Treatment of bright metal parts (apart from brake and exhaust system ) with anti-corrosives Treatment of ignition switch/steering lock with contact spray Check correct tightness of all screws, nuts and clamps

BEFORE EVERYBEFORE EVERY

BEFORE EVERY

STST

ST

ARAR

AR

T UPT UP

T UP

AFTERAFTER

AFTER

OFF-THE-ROADOFF-THE-ROAD

OFF-THE-ROAD

USEUSE

USE

AFTER EVERYAFTER EVERY

AFTER EVERY

WASHWASH

WASH

•

BRIEF CHECK BRIEF CHECK

BRIEF CHECK

AND MAINTENAND MAINTEN

AND MAINTEN

ANCE OPERAANCE OPERA

ANCE OPERA

TIONS TIONS

TIONS

TT

T

O BE PERFORMED BY O BE PERFORMED BY

O BE PERFORMED BY

THE RIDER/PILTHE RIDER/PIL

THE RIDER/PIL

OO

O

TT

T

BRIEF CHECK BRIEF CHECK

BRIEF CHECK

AND MAINTENAND MAINTEN

AND MAINTEN

ANCE OPERAANCE OPERA

ANCE OPERA

TIONS TIONS

TIONS

TT

T

O BE PERFORMED BY O BE PERFORMED BY

O BE PERFORMED BY

THE RIDER/PILTHE RIDER/PIL

THE RIDER/PIL

OO

O

TT

T

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

ENGLISH

33

Check cylinder and piston wear Check piston pin (visual check) Check camshaft and valve lifters wear (visual check) Check camshaft supports Check timing chain (besides the one to be done in every race) Check and adjust valve clearance Check valve spring length Check upper and lower spring retainers wear Check valve cotters and valve stems Check valve guide wear Check valve sealing Check automatic decompressor working Check head and cylinder surfaces Check engine crankshaft for trueness Replace conrod, axle and roller cage Check small end for marking/damage to plating Check oil pump and lubrication circuit Replacement of main bearings Check complete gearbox including drum and forks Check clutch plate wear Check length of clutch springs

•

15 HOURS OF SER15 HOURS OF SER

15 HOURS OF SER

VICE EQVICE EQ

VICE EQ

UU

U

AL AL

AL

ABOUT 100 LABOUT 100 L

ABOUT 100 L

TT

T

..

.

OF FUEL CONSUMPTIONOF FUEL CONSUMPTION

OF FUEL CONSUMPTION

•

30

HOURS

200 LT.

45

HOURS

300 LT.

60

HOURS

400 LT.

90

HOURS

600 LT.

120 HOURS 800 LT .

135 HOURS 900 LT .

WARNINGWARNING

WARNING

IF , AFTER CHECKING , IT IS DETECTED THA T THE WEAR LIMITS OF A SINGLE COMPONENT HA VE BEEN EXCEEDED, THE COMPONENT MUST BE REPLACED. THE INSTALLA TION OF AN HOUR-COUNTER INSTRUMENT IS ADVISED. THE ABOVE-MENTIONED OPERA TIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP .

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/MX/SMX 660 SMXCHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/MX/SMX 660 SMX

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/MX/SMX 660 SMX

COMPETITION USECOMPETITION USE

COMPETITION USE

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/MX/SMX 660 SMXCHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/MX/SMX 660 SMX

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/MX/SMX 660 SMX

COMPETITION USECOMPETITION USE

COMPETITION USE

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

ENGLISH

34

Check cylinder and piston wear Check piston pin (visual check) Check camshaft and valve lifters wear (visual check) Check camshaft supports Check timing chain (after a 30-hour check) Check and adjust valve clearance Check spring valve length Check upper and lower spring retainers wear Check valve cotters and valve stem Check valve guide wear Check valve sealing Check automatic decompressor working Check head and cylinder surfaces Check engine cranshaft for trueness Replace conrod, axle and roller cage Check small end for marking/damage to plating Check oil pump and lubrication circuit Replacement of main bearings Check complete gearbox including drum and forks Check clutch plate wear Check length of clutch springs

•

60 HOURS 300 LT.

90 HOURS 450 LT.

120

HOURS

600 LT.

180 HOURS 900 LT.

240

HOURS

1200 LT .

270

HOURS

1350 LT .

WARNINGWARNING

WARNING

IF , AFTER CHECKING, IT IS DETECTED THA T THE WEAR LIMITS OF A SINGLE COMPONENT HA VE BEEN EXCEEDED, THE COMPONENT MUST BE REPLACED. THE ISTALLA TION OF AN HOUR-COUNTER INSTRUMENT IS ADVISED. THE ABOVE-MENTIONED OPERA TIONS MUST BE CARRIED OUT BY AN AUTHORISED TM WORKSHOP .

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/SMR/SMMCHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/SMR/SMM

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/SMR/SMM

ROAD/HOBBY USEROAD/HOBBY USE

ROAD/HOBBY USE

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/SMR/SMMCHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/SMR/SMM

CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/SMR/SMM

ROAD/HOBBY USEROAD/HOBBY USE

ROAD/HOBBY USE

20 HOURS OF SER20 HOURS OF SER

20 HOURS OF SER

VICE EQVICE EQ

VICE EQ

UU

U

AL AL

AL

ABOUT 100 LABOUT 100 L

ABOUT 100 L

TT

T

..

.

OF FUEL CONSUMPTIONOF FUEL CONSUMPTION

OF FUEL CONSUMPTION

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

MAINTENMAINTEN

MAINTEN

ANCE ANCE

ANCE

AND LAND L

AND L

UBRICAUBRICA

UBRICA

TION TION

TION

TT

T

ABLEABLE

ABLE

ENGLISH

35

ENGLISH

36

DANGER

ALL MAINTENANCE AND ADJUSTMENT OPERA TIONS THA T ARE MARKED WITH (A) REQUIRE TECHNICAL MASTER Y . FOR THIS REASON IT IS IN THE INTEREST OF YOUR SAFETY TO HA VE THESE OPERATIONS CARRIED OUT EXCLUSIVELEY BY A SPECIALISED TM WORKSHOP WHERE YOUR MOTORCYCLE WILL BE MAINT AINED IN AN OPTIMAL MANNER BY SPECIFICALL Y TRAINED ST AFF .

WARNING

- IF POSSIBLE, DO NOT USE HIGH PRESSURE JETS WHEN WASHING THE MOTORCYCLE BECAUSE THE WA TER COULD PENETRA TE INTO THE BEARINGS, THE CARBURETOR, ELECTRIC CONNECTORS, ETC.

- WHEN TRANSPORTING YOUR TM, ENSURE THAT IT IS WELL-HELD IN A VERTICAL POSITION USING BEL TS OR OTHER MECHANICAL FIXING DEVICES AND ENSURE THAT THE FUEL TAP IS SWITCHED OFF . IF THE MOT ORCYCLE SHOULD F ALL, FUEL COULD ESCAPE FROM THE CABURETOR OR T ANK.

- TO FIX THE SHROUDS TO THE T ANK ONLY USE THE SPECIAL SCREWS WITH THE CORRECT LENGTH OF THREAD FOR TM BIKES. IF YOU USE DIFFERENT SCREWS OR LONGER SCREWS, THE T ANK COULD BE DAMAGED WITH CONSEQUENT FUEL LEAK.

- DO NOT USE NOTCHED WASHERS OR SPRING WASHERS FOR THE ENGINE FASTENING SCREWS , BECAUSE THEY COULD PENETRATE INT O PAR TS OF THE FRAME AND LOOSEN CONTINUALL Y. USE SELF-LOCKING NUTS.

- LEAVE THE MOTORCYCLE TO COOL BEFORE ST ARTING ANY MAINTENANCE. THIS WILL PREVENT BURNS.

- DISPOSE OF OILS, GREASES , FIL TERS, FUELS, DETERGENTS, ETC. IN A REGULAR MANNER. COMPLY WITH THE RESPECTIVE REGULATIONS OF YOUR COUNTRY .

- DISPOSE OF WASTE OIL IN A REGULAR MANNER ! NEVER POUR OLD OIL INTO DRAINS OR RIVERS.

CHECK OF STEERING BEARINGSCHECK OF STEERING BEARINGS

CHECK OF STEERING BEARINGS AND PLAAND PLA

AND PLAAND PLA

AND PLA

Y Y

Y

ADJUSTMENT (A)ADJUSTMENT (A)

ADJUSTMENT (A)

Periodically check the play of the steering bearings. For the check, lift the front wheel and shake the fork forward and backwards. For adjustment, loosen the four M8 screws (1) and nut (2) of the head of the fork and act on the ring nut (3), tightening it until there is no more play. Do not tighten the ring nut further to prevent damage to the bearings. Tighten the fork head nut and successively the four M8 screws to20 Nm. Check for a smooth steering.

DANGER

IF THE STEERING BEARINGS DO NOT HAVE THE CORRECT CLEARANCE, THE BEHAVIOUR ON THE ROAD WILL BE IRREGULAR AND YOU COULD LOOSE CONTROL OF THE MOTORCYCLE.

WARNING

MAKING LONG JOURNEYS WITH INCORRECT STEERING BEARINGS ADJUSTMENT , YOU RISK TO DAMAGE THE BEARINGS AND THEIR SEA TS IN THE FRAME.

The steering bearings should be re-greased at least once a year.

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

37

TELESCOPIC FORK VENT SCREWSTELESCOPIC FORK VENT SCREWS

TELESCOPIC FORK VENT SCREWS

Every 5 hours of use in competitions loosen the vent screws (1) by a few turns, so allowing the release of any air-pressure from inside the fork. Instead of a screw, Marzocchi fork features a tyre valve (3), which is protected by a rubber bulb (4). Remove the rubber bulb and press gently the valve stem. Before operating on the screws or on the valve, lift the motorcycle onto the stand in a way that the front wheel does not touch the ground. If the motorcycle is used mainly on roads, it is sufficient only to carry out this operation during periodical maintenance.

WARNING

VERY HIGH PRESSURE INSIDE THE FORK CAN CAUSE THE FORK TO LEAK. IF YOUR FORK PRESENTS A LEAK, LOOSEN THE VENT SCREWS BEFORE HA VING THE SEALING ELEMENTS REPLACED.

CLEANING OF TELESCOPIC FORK DUSTCLEANING OF TELESCOPIC FORK DUST

CLEANING OF TELESCOPIC FORK DUST SCRAPERSCRAPER

SCRAPERSCRAPER

SCRAPER

The dust scraper (2) must scrape the dust and dirt from the fork rods. However, after some time, dirt may also reach behind the dust scrapers. If the dirt is not removed, the oil seal units, which are found behind, may leak. Use a screwdriver to lever the dust scraper from the outside legs and push it downwards.

Clean the dust scraper, the outside legs and the rods carefully. Oil them well with silicone spray or with engine oil. Finally, push the dust scraper manually into the outside legs.

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

2

1

3

4

ENGLISH

38

BB

B

ASIC CALIBRAASIC CALIBRA

ASIC CALIBRA

TION OF TION OF

TION OF

THE CYTHE CY

THE CY

CLE PCLE P

CLE P

ARAR

AR

T ONT ON

T ON

THE BASIS OF THE PILOT’S WEIGHTTHE BASIS OF THE PILOT’S WEIGHT

THE BASIS OF THE PILOT’S WEIGHT

To obtain optimal driving features of the motorcycle and to prevent damage to the fork, rear shock, rear swing arm and frame, it is necessary that the basic calibration of the suspension is adapted to your body weight. In the delivery status, the off-road TM motorcycles are calibrated on a pilot weight (with complete protective clothing) of 70 – 80 kg. If your weight is not within these values, you must adequately adapt the basic calibration of the suspensions. Minor weight changes can be compensated by varying the spring pre-load. For greater variations, suitable springs rates must be used.

SHOCK CALIBRASHOCK CALIBRA

SHOCK CALIBRA

TION TION

TION

AND SPRING CHECKAND SPRING CHECK

AND SPRING CHECK

If the rear shock spring is suitable for your weight, it can be seen by lowering in running order. However, before establishing the lowering in running order, static lowerIng must be adjusted correctly.

ESTEST

EST

ABLISHING REAR SHOCK STABLISHING REAR SHOCK ST

ABLISHING REAR SHOCK ST

AA

A

TIC LTIC L

TIC L

OO

O

WERINGWERING

WERING

The static lowering should be35 mm. Variations of more than 2 mm can notably influence driving of the motorcycle. Procedure:

- Position the motorcycle on a stand so that the rear wheel does not touch the ground.

- Measure the distance between the rear wheel axle and a fixed point (e.g.. a mark on the side panel) paying attention that the straight line that joins the axle and the fixed point is as perpendicular as possible to the ground and make note of the value as A.

- Rest the motorcycle back on the ground.

- Ask a helper to hold the motorcycle in a vertical position.

- Measure the distance between the rear wheel axle and the fixed point again. Make note of this measurement as B.

- The static lowering is the difference between measurement A and B.

EXAMPLE:

Motorcycle on stand (measurement A)………………........... 600 mm

Motorcycle on the ground, not loaded (measurement B) .. - 56 5 mm

Static lowering ……………………………................................. 35 m m

If thestatic lowering is smaller, the rear shock spring pre-load must be decreased. If the static lowering is greater, the spring pre-load must be increased. See variation of rear shock spring pre-load chapter.

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

39

ESTEST

EST

ABLISHING REAR SHOCK LABLISHING REAR SHOCK L

ABLISHING REAR SHOCK L

OO

O

WERING INWERING IN

WERING IN

RUNNING ORDERRUNNING ORDER

RUNNING ORDER

- Now, with the help of a person who holds the motorcycle, sit on the motorcycle wearing all protective clothing (with feet on the footrests) and rock up and down a few times to normalise the set-up of the rear suspension.

- A third person must then measure the distance between the same points, with the motorcycle loaded and note this measurement as C.

- Lowering in running order is the difference between measurements A and C.

EXAMPLE:

Motorcycle on stand (measurement A). …………...…….... 600 mm

Motorcycle on the ground loaded with the pilot’s weight

(measurement C) ......................................................................... - 510 mm

Lowering in running order................ …………………........... 90 mm

Lowering in running order should be 90÷105 mm. If lowering in running order is less than 90 mm, the spring is too hard (spring rate too high). If the lowering exceeds 105 mm, the spring is too soft (spring rate too low). The spring rate is indicated on the outside of the spring wire. After mounting a different spring,static lowering must be adjusted again to 35 mm (± 2 mm). According to our experience, the dampening grade in compression can remain unvaried. With a softer spring, the dampening grade in rebound can be reduced by some clicks, with an harder spring, increased by some clicks.

CHECK TELESCOPIC FORK BASICCHECK TELESCOPIC FORK BASIC

CHECK TELESCOPIC FORK BASIC CALIBRACALIBRA

CALIBRACALIBRA

CALIBRA

TIONTION

TION

For several reasons, the exact lowering in running order of the telescopic fork can not be established. Small variations in body weight can be compensated, as for the rear shock, through the spring pre-load. If your telescopic fork, however, lowers completely, it is necessary to use an higher rate fork spring to prevent damage to the telescopic fork and frame.

VV

V

ARIAARIA

ARIA

TION OF TION OF

TION OF

TELESCOPIC FORK PRE-LTELESCOPIC FORK PRE-L

TELESCOPIC FORK PRE-L

OO

O

ADAD

AD

To vary the spring pre-load on these telescopic forks, it is necessary to disassemble them partially (see specific manual of the fork mounted on the motorcycle). It is possible to add pre-load spacers. The fork springs however, can be pre-loaded to a max. of 20 mm.

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

40

REPLACEMENT OF FORK SPRINGSREPLACEMENT OF FORK SPRINGS

REPLACEMENT OF FORK SPRINGS

If your body weight is less than 70 kg or exceeds 80 kg, adequate fork springs must be used. If you are in doubt or have any questions, please contact your authorised TM dealer.

According to our experience, the dampening grade in compression can remain unvaried. With a softer spring, the dampening grade in rebound can be reduced by some clicks, with a harder spring, increased by some clicks.

WARNING

FOR FURTHER AND MORE DETAILED INFORMATION REGARDING THE STANDARD AND OPTIONAL FORK, REFER TO THE INSTRUCTION BOOK SUPPLIED BY THE MANUFACTURER OF THE FORK AND GIVEN BY TM ACCOMPANYING THE MOTORCYCLE.

VV

V

ARIAARIA

ARIA

TION OF REAR SHOCK SPRING PRELTION OF REAR SHOCK SPRING PREL

TION OF REAR SHOCK SPRING PREL

OO

O

ADAD

AD

The preload of the spring can be varied by turning the adjustment ring nut (5). With this aim, it is advised to disassemble the rear shock and clean it well before operating. INDICATION:

- Before varying the spring preload you should take note of te basic adjustment - e.g. how many thread turns are visible above the lock ring nut (6).

- By 1 turn of the adjustment ring nut (5) the spring pre-load varies by

1.5 mm.

SACHS

Loosen the lock ring nut (6) and turn the adjustment ring nut (5). Turning it clockwise the preload increases, turning it anticlockwise the preload decreases. After the adjustment, tighten the lock ring nut (6).

OHLINS with ring nut

Loosen the lock ring nut (6) and turn the adjustment ring nut (5). Turning it clockwise the preload increases, turning it anticlockwise the preload decreases. After the adjustment, tighten the lock ring nut (6).

OHLINS with clamp

Loosen the clamp (7) using a 4mm. Allen wrench and turn the adjustment ring nut (5). Turning it clockwise the preload increases, turning it anticlockwise the preload decreases. After the adjustment, tighten the clamp (7).

REAR SUSPENSION MECHANICAL LINKAGEREAR SUSPENSION MECHANICAL LINKAGE

REAR SUSPENSION MECHANICAL LINKAGE

The rear suspension of all TM motorcycles has a link-rod and rocker mechanism that progressively changes the lever relationship between the wheel and the rear shock. This mechanism works on bearings, which must be cleaned and greased at the envisioned intervals to maintain the working of the suspension efficient. When cleaning the motorcycle with high pressure cleaning devices, do not aim the jet completely onto the suspension mechanical linkage.

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

7

5

ENGLISH

41

3

2

1

4

5

6

CHECK CHAIN TENSIONCHECK CHAIN TENSION

CHECK CHAIN TENSION

Put the motorcycle onto the central stand to control chain tension. Push the chain upwards to the end of the drive chain slider. The upper part of the chain (A) must be taught (see photo). The distance between the chain and rear fork must be about. 10-15 mm. Adjust the tension, if necessary.

- IF THE CHAIN IS TOO TIGHT , THE FINAL TANSMISSION COMPONENTS

(CHAIN, GEARBOX AND REAR WHEEL BEARINGS) ARE GREATLY STRESSED. AS WELL AS A PREMA TURE WEAR, IN EXTREME SITUA TIONS THE CHAIN OR GEARBOX DRIVEN SHAFT MA Y BREAK.

- IF , HOWEVER, CHAIN TENSION IS INSUFFICIENT, IT CAN EXIT FROM THE

SPROCKET AND LOCK THE REAR WHEEL OR DAMAGE THE ENGINE.

- IN BOTH CASES IT IS EASY TO LOOSE CONTROL OF THE MOTORCYCLE.

ADJUSTMENT OF CHAIN TENSIONADJUSTMENT OF CHAIN TENSION

ADJUSTMENT OF CHAIN TENSION (ALL MODELS EXCEPT SMM)(ALL MODELS EXCEPT SMM)

(ALL MODELS EXCEPT SMM)(ALL MODELS EXCEPT SMM)

(ALL MODELS EXCEPT SMM)

Loosen the wheel axle nut (1), loosen the counter-nuts (2) and turn the adjustment bolts (3) to the left and to the right by the same amount. To increase chain tension, unscrew the adjustment bolts. To decrease chain tension, screw the adjustment bolts. Reach correct chain tension. For correct alignment of the rear wheel, the marks (4) on the right and left chain-tensioner must aligned with respect to the reference markings (5). Tighten the adjustment screw counter-nuts. Before locking the wheel axle nut, check that the chain-tensioners (6) are laying on the heads of the adjustment bolts and that the rear wheel is aligned with the front wheel. Tighten the wheel axle nut to 80 Nm.

A TTENTION

- IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH FOR ASSEMBLING , HA VE THE TIGHTENING TORQUE CHECKED BY A SPECIALISED TM WORKSHOP AS SOON AS POSSIBLE. A LOOSE WHEEL AXLE MAY CAUSE UNSTABLE DRIVING OF THE MOTORCYCLE.

DANGER

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

42

8

7

ADJUSTMENT OF CHAIN TENSION (SMM)ADJUSTMENT OF CHAIN TENSION (SMM)

ADJUSTMENT OF CHAIN TENSION (SMM)

Loosen both the locking screws(7) of the rear eccentric hub in a way that the hub itself can turn around its axis. Using the relevant TM tool, code F50806 (8), turn the hub until correct chain tension is reached. Tighten the two locking screws to 30 Nm. Since the movement is an eccentric system, alignment of the rear wheel is unvaried and no further adjustment is required. At the same time, by turning the hub a slight variation in the height of the rear wheel axle may be verified and consequently of the rear part of the motorcycle. It is possible to compensate this, by varying the projection of the fork legs from the upper clamp. For example, if the motorcycle, by effect of chain adjustment, has lifted by 5mm. at the rear, it is advised to decrease the projection of the fork rods by about 5mm. to also raise the front and restore the original levelling of the motorcycle. It is advised to use the TM tool, code F50806, pairing with two M8 screws and two nuts to turn the hub inserting the two screws into the two holes in the hub itself.

AA

A

TTENTIONTTENTION

TTENTION

- IF YOU DO NOT HAVE SUIT ABLE EXPERIENCE, IT IS ADVISED TO HA VE THE OPERATION CARRIED OUT BY A SPECIALISED TM WORKSHOP.

CHAIN MAINTENANCECHAIN MAINTENANCE

CHAIN MAINTENANCE

Chain duration depends most of all on maintenance. Chains without O-rings must be regularly cleaned with petroleum and then immersed in warm chain oil or treated with chain spray. Maintenance of chains with O-rings is reduced to a minimum. The best cleaning method is using lots of water. Never use brushes or solvents to clean the chain. When the chain is dry, use a chain spray that is especially suitable for chains with O-rings.

DO NOT ALLOW THE LUBRICANT TO REACH THE REAR TYRE OR THE BRAKE DISC, OTHERWISE ADHERENCE TO THE GROUND OF THE REAR WHEEL AND REAR BRAKE ACTION COULD BE NOT ABLY REDUCED AND IT COULD BE EASY TO LOOSE CONTROL OF THE MOTORCYCLE.

WARNING

ON MOUNTING THE CHAIN SPLIT LINK, THE CLOSED P ART MUST BE IN THE DIRECTION OF MOVEMENT .

Always check both engine and rear wheel sprockets and drive slider for wear. If necessary, replace these parts.

DANGER

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

43

CHAIN WEARCHAIN WEAR

CHAIN WEAR

To check chain wear follow carefully the instructions given below : put the gear into neutral, pull the upper part of the chain in an upward direction with a force of 10 - 15 kilogrammes (see figure). Now, measure the distance of 18 links on the lower part of the chain. If the distance exceeds 272 mm it is advised to replace the chain. The chains are not always worn in a even way. For this reason the measurement must be taken in different points on the chain.

INDICATION:

When a new chain is mounted, also replace the sprockets. A new chain wears more quickly on old and worn sprockets.

WARNING

WHEN THE CHAIN SPROCKETS ARE REPLACED, IT IS ADVISED TO MOUNT NEW SELF-LOCKING NUTS AND T O TIGHTEN WITH CROSS SEQUENCE. TIGHTENING TORQUE AT NUTS 35 NM.

BB

B

ASIC INDICAASIC INDICA

ASIC INDICA

TIONS FOR TIONS FOR

TIONS FOR

TM DISC BRAKESTM DISC BRAKES

TM DISC BRAKES

CALIPERS :

The mounting system of the calipers of these models is “floating”, i.e they are not rigidly joined to their support. The lateral compensation always allows the pads to work in the best way on the discs. The brake caliper fastening screws must be assembled using Loctite 243 and tightened at 25 Nm. The front calipers of the SMR/SMM/SMX models are an exception as they are fixed-type.

PADS:

The minimum thickness of the friction material cannot go under the limit of 1mm. In case of replacement, it is advised always to use TM original spare parts for your motorcycle.

BRAKE DISCS:

With wear the thickness of the brake disc is reduced in the contact area of the pads (1). In the thinnest point (A) the brake disc may present max. wear of 0.4 mm with respect to original thickness. The original thickness can be measured in point (B) outside of the contact area. Check wear in different points.

- BRAKE DISCS WITH WEAR EXCEEDING 0.4 MM ARE A RISK FOR SAFETY . WHEN THE LIMIT OF WEAR HAS BEEN REACHED, HAVE THE BRAKE DISCS REPLACED IMMEDIATELY .

- IT IS COMPULSORY TO HAVE THE BRAKE UNIT REPAIRED BY A TM AUTHORISED WORKSHOP .

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BRAKE FLUID RESERVOIRS:

The front and rear brake liquid reservoirs are dimensioned in a way that topping-up is not necessary even if the brake pads are worn. In fact, when the pads are worn, the fluid in the hoses tends to occupy the space left by the small pistons, which have moved so that the pads always lay on the disc. If the level of brake fluid falls below the minimum value, it indicates that there is a leak in the braking system or brake pad wear is beyond accepted limits.

BRAKE FLUID:

The braking system is filled by TM with top-quality DOT 4 brake fluid. We recommend that top-ups and complete replacement are carried out using the same type of fluid (DOT 4).

HAVE THE BRAKE FLUID REPLACED AT LEAST ONCE A YEAR. IF YOU W ASH THE MOTORCYCLE FREQUENTL Y , IT SHOULD BE REPLACED MORE OFTEN . THE BRAKE FLUID SOAKS WA TER. IN OLD FLUID THEREFORE IT IS POSSIBLE THAT STEAM BUBBLES FORM EVEN AT LOW TEMPERATURES AND THE BRAKING SYSTEM DOES NOT WORK CORRECTL Y .

FRONT BRAKE NISSIN PUMP (END/MX)FRONT BRAKE NISSIN PUMP (END/MX)

FRONT BRAKE NISSIN PUMP (END/MX)

FRONT BRAKE LEVER ADJUSTMENTFRONT BRAKE LEVER ADJUSTMENT

FRONT BRAKE LEVER ADJUSTMENTThe distance of the

front brak lever from the handlebar grip can be adjusted through the adjustment screw (1). Loosen the lock nut (2) and turn the screw clockwise to increase the distance, anticlockwise to reduce the distance. Re-tighten the lock nut (2).

WARNING

AT THE END OF THE OPERATION VERIFY THA T THE FRONT BRAKE LEVER HAS A FREE STROKE BEFORE THE BRAKE ST ARTS TO LOCK THE WHEEL AND THAT THE FRONT WHEEL CAN ROT A TE FREELY WITH THE BRAKE LEVER A T REST . IF THE FREE STROKE IS MISSING , PRESSURE IS FORMED IN THE BRAKING SYSTEM AND THE CONSEQUENCE CAN BE LACK OF FUNCTIONING OF THE FRONT WHEEL BRAKE DUE TO OVERHEA TING OR BLOCKING OF THE WHEEL ITSELF .

CHECK FLUID LEVELCHECK FLUID LEVEL

CHECK FLUID LEVEL

The reservoir is part of the front brake pump positioned on the handlebar and has an inspection window (3): with the tank in the horizontal position, the fluid level must never fall below the centreline on the inspection window.

IF THE LEVEL OF BRAKE LIQUID FALLS BELOW THE MINIMUM VALUE, IT INDICATES A LEAK IN THE BRAKING SYSTEM OR CONSUMPTION OF BRAKE PADS BEYOND THE ACCEPTED LIMITS.

TOP-UP FRONT BRAKE FLUID (A)TOP-UP FRONT BRAKE FLUID (A)

TOP-UP FRONT BRAKE FLUID (A)

Remove the screws (4) and remove the lid (5) and the membrane (6). Place the front brake pump in a horizontal position and top-up the brake fluid to 5 mm below the upper edge of the container. Re-mount membrane, lid and screws. Wash any spilled brake fluid away with water. Wash any spilled brake fluid away with water.

- KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN.

- BRAKE FLUID MAY IRRITATE THE SKIN. DO NOT ALLOW IT TO TOUCH SKIN OR EYES. IF THE BRAKE FLUID SHOULD ACCIDENTL Y SPRA Y INT O THE EYES, RINSE WELL WITH WA TER AND SEEK MEDICAL ASSIST ANCE.

WARNING

- DO NOT ALLOW BRAKE FLUID TO COME INT O CONTACT WITH PAINTED PARTS, THE BRAKE FLUID CORRODES PAINT.

- USE ONLY CLEAN BRAKE FLUID OUT OF A HERMETICALLY SEALED CONTAINER.

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FRONT BRAKE BREMBO RADIAL PUMPFRONT BRAKE BREMBO RADIAL PUMP

FRONT BRAKE BREMBO RADIAL PUMP

(SMR/SMM/SMX) (SMR/SMM/SMX)

(SMR/SMM/SMX)

FRONT BRAKE LEVER ADJUSTMENTFRONT BRAKE LEVER ADJUSTMENT

FRONT BRAKE LEVER ADJUSTMENT

The distance of the front brake lever from the handlebar grip can be adjusted through the adjustment knob (1). Turning it clockwise the distance increases, turning it anticlockwise the distance decreases.

WARNING

AT THE END OF THE OPERA TION VERIFY THA T THE FRONT BRAKE LEVER HAS A FREE STROKE BEFORE THE BRAKE ST ARTS TO LOCK THE WHEEL AND THAT THE FRONT WHEEL CAN ROT A TE FREELY WITH THE BRAKE LEVER A T REST . IF THE FREE STROKE IS MISSING , PRESSURE IS FORMED IN THE BRAKING SYSTEM AND THE CONSEQUENCE CAN BE LACK OF FUNCTIONING OF THE FRONT WHEEL BRAKE DUE TO OVERHEA TING OR BLOCKING OF THE WHEEL ITSELF .

CHECK FLUID LEVELCHECK FLUID LEVEL

CHECK FLUID LEVEL

The reservoir (2) is transparent and allows you to check for the fluid level: with the reservoir standing up, the fluid level must be always between MAX and MIN remarks.

IF THE BRAKE FLUID LEVEL FALLS BELOW THE MINIMUM VALUE, IT INDICATES A LEAKING IN THE BREAKING SYSTEM OR CONSUMPTION OF BRAKE PADS BEYOND THE ACCEPT ABLE LIMIT .

TOP-UP FRONT BRAKE FLUID (A)TOP-UP FRONT BRAKE FLUID (A)

TOP-UP FRONT BRAKE FLUID (A)

Unscrew and remove the cap (3) and the membrane (4). Keep the reservoir standing up and top-up the brake fluid to the MAX remark on the reservoir. Reassemble the membrane, the cap and tighten.Wash any spilled brake fluid away with water.

- KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN.

- BRAKE FLUID MAY IRRITATE THE SKIN. DO NOT ALLOW IT TO TOUCH SKIN OR EYES. IF THE BRAKE FLUID SHOULD ACCIDENTL Y SPRA Y INT O THE EYES, RINSE WELL WITH WA TER AND SEEK MEDICAL ASSIST ANCE.

WARNING

- DO NOT ALLOW BRAKE FLUID TO COME INT O CONTACT WITH PAINTED PARTS, THE BRAKE FLUID CORRODES PAINT.

- USE ONLY CLEAN BRAKE FLUID OUT OF A HERMETICALLY SEALED CONTAINER.

CHECK FRCHECK FR

CHECK FR

ONT BRAKE PONT BRAKE P

ONT BRAKE P

ADSADS

ADS

The brake pads can be checked from below. The thickness of the pad friction material must not be less than1 mm.

THE THICKNESS OF THE BRAKE PAD THICKNESS MA TERIAL MUST NOT BE LESS THAN 1 MM, OTHERWISE THERE COULD BE A FAUL T IN THE BRAKES. IN THE INTEREST OF YOUR SAFETY HAVE THE THE PADS REPLACED IN TIME.

WARNING

IF THE BRAKE P ADS ARE REPLACED TOO LA TE AND ARE COMPLETEL Y WORN, THE STEELPAR TS OF THE PADS RUB ON THE DISC. THIS LEADS TO A NOT ABLE DECREASE IN THE BRAKING EFFECT AND DAMAGE OF THE BRAKE DISC.

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REPLAREPLA

REPLA

CEMENT OF FRCEMENT OF FR

CEMENT OF FR

ONT BRAKE PONT BRAKE P

ONT BRAKE P

ADS ADS

ADS

(A)(A)

(A)

FOR ALL MODELS WITH FLOA TING CALIPER (END/MX)

Push the brake caliper towards the disc, in a way that the brake pistons reach their base position. Remove the safety devices (1), extract the pin (2) and remove the pads from the caliper. Use compressed air to clean the brake caliper and the caliper support, check that the driving pin seals are not damaged and, if necessary, grease them. Mount the right brake pad and fix it with the pin. Mount the left brake pad and insert the pin until it stops. Mount the safety devices. During mounting of the pads, ensure that the protection sheet-steel in the caliper support and the leaf spring are correctly positioned.

FOR ALL MODELS WITH FIXED CALIPER (SMR/SMM/SMX)

RADIAL COUPLING - Unscrew the two screws M10 (3) and remove the caliper from the fork shoe. Press the two hooks (4) one at a time to release and slide the retainer pins (5) out. Lever on each pair of pads to allow the pistons to go back to their seat. Extract the worn pads and insert the new ones. Repeat the operation for the other pair of pads. Press the two hooks down and re-insert the pins: be sure that they are fully inserted, have their play and are correctly attached. Reassemble the caliper and tighten the M10 screws at 40Nm.

AXIAL COUPLING - Unscrew the two M8 screws (6) and remove the caliper. Lever the pads to allow the pistons to go back into their seat, then remove the safety pin (7), slide the pin (8) out and then extract the pads, paying attention to the laminated spring (9). Remount the new pads, the laminate, the pin and the safety retainer, then reassemble the caliper and tighten the M8 screws at 25 Nm.

WARNING

- FOR ALL MODELS: WHEN THE CALIPER PISTONS ARE PUSHED BACK TO THEIR SEAT TO PROVIDE ROOM FOR THE NEW P ADS, PA Y ATTENTION THAT THE FLUID CONTAINED IN THE RESERVOIR HAS THE SPACE T O EXPAND. DO NOT WORK WITHOUT THE CAP MOUNTED, OTHERWISE THE FLUID COULD OVERFLOW AND DAMAGE P ARTS OF THE MOTORCYCLE.

- THE BRAKE DISC MUST ALWA YS BE KEPT FREE FROM OIL AND GREASE. OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY REDUCED.

- AFTER MOUNTING, CHECK THA T THE SAFETY DEVICES ARE CORRECTL Y POSITIONED . AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM ACTIVA TE THE FRONT BRAKE LEVER AND THE REAR BRAKE PEDAL TO MAKE THE PADS ADHERE TO THE DISC AND TO REST ORE THE CORRECT ADJUSTMENT OF PLA Y.

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MODIFICATION OF REAR BRAKE PEDMODIFICATION OF REAR BRAKE PED

MODIFICATION OF REAR BRAKE PED

ALAL

AL

BASE POSITION (A) BASE POSITION (A)

BASE POSITION (A)

The base position of the rear brake pedal can be modified in the following way: loosen counter-nut M6 (1) fork side, turn the adjustment screws by acting on the hexagonal head (2). Once the ideal position has been found, tighten the counter-nut. The pedal free play is given by the stroke of the pump piston; check that the pedal has a free play of about 1.5cm before starting to brake.

WARNING

IF THERE IS NO FREE PLA Y , PRESSURE DEVELOPS IN THE BRAKING SYSTEM AND CONSEQUENTLY THE REAR WHEEL IS BRAKED. THE BRAKING SYSTEM OVERHEATS AND IN EXTREME CASE IT WILL NOT WORK.

CHECK REAR BRAKE FLUID LEVELCHECK REAR BRAKE FLUID LEVEL

CHECK REAR BRAKE FLUID LEVEL

ALL THE MODELS

The reservoir for the rear disc brake fluid is incorporated into the rear brake pump. When the motorcycle is in a vertical position, the level must always be over half way on the window (3) positioned on the body of the pump.

IF THE LEVEL OF THE BRAKE FLUID FALLS BELOW THE MINIMUM LEVEL, IT INDICATES A LEAK IN THE BRAKING SYSTEM OR COMPLETE CONSUMPTION OF THE BRAKE PADS.

TOP-UP REAR BRAKE FLUID (A)TOP-UP REAR BRAKE FLUID (A)

TOP-UP REAR BRAKE FLUID (A)

ALL THE MODELS

As soon as the level of rear brake fluid reaches the centreline on the window situated on the pump, it must be topped-up. Unscrew the two screws (4) and remove the lid. Top-up with DOT4 brake fluid to the top of the window. Remount the lid and tighten the screws. Wash any spilled brake fluid away with water

- NEVER USE DOT5 BRAKE FLUID! IT IS A PURPLE SILICONE OIL-BASED BRAKE FLUID. IT REQUIRES THE USE OF SPECIAL SEALS AND HOSES

- KEEP THE BRAKE FLUID OUT OF CHIDREN’S REACH.

- THE BRAKE FLUID CAN IRRITATE THE SKIN. DO NOT ALLOW IT TO TOUCH THE SKIN OR EYES. IF THE BRAKE FLUID SHOULD SPRA Y INTO THE EYES RINSE WELL WITH WA TER AND SEEK MEDICAL A TTENTION

WARNINGWARNING

WARNING

- DO NOT ALLOW BRAKE FLUID TO COME INT O CONTACT WITH PAINTED PARTS. BRAKE FLUID CORRODES P AINT !

- USE ONLY CLEAN BRAKE FLUID FROM A HERMETICALLY SEALED CONTAINER.

DANGER

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CHECK REAR BRAKE PCHECK REAR BRAKE P

CHECK REAR BRAKE P

ADSADS

ADS

The brake pads must be controlled from the rear side. The thickness of the pad friction material must not be less than 1 mm.

AT THE THINNEST POINT, THE THICKNESS OF THE BRAKE PAD FRICTION MATERIAL MUST NOT BE LESS THAN 1 MM, OTHERWISE A FAULT COULD OCCUR IN THE BRAKES. IN THE INTEREST OF YOUR SAFETY HA VE THE PADS REPLACED IN TIME.

WARNING

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE FRICTION MATERIAL IS COMPLETELY CONSUMED, THE STEEL P ARTS OF THE PADS RUB ON THE DISC. THIS LEADS TO A NOTEWORTHY DECREASE OF THE BRAKING EFFECT AND DAMAGE OF THE BRAKE DISC.

REPLAREPLA

REPLA

CEMENT OF REAR BRAKE PCEMENT OF REAR BRAKE P

CEMENT OF REAR BRAKE P

ADS ADS

ADS

(A) (A)

(A)

FOR ALL MODELS WITH FLOA TING CALIPER (END/MX/SMR/SMX)

Push the brake caliper (1) towards the disc, until the piston reaches its base position. Remove the cap (2) using a screwdriver, unscrew the pin (3) and slide the brake pad out. Pay attention to the plates (4) placed between the pads: these must be remounted accurately. Clean the brake caliper with compressed air and check that the drive pin sheaths are not damaged. Remount the new pads, paying attention to the positioning of the plates, insert the pin, re-screw it and tighten. Remount the tap using a screwdriver. Tighten well.

FOR ALL MODELS WITH FIXED CALIPER (SMM)

Remove the safety ring (5) and slide the pin out (6) hitting with a pin-puller with 4mm. diameter on the same side where the safety ring is found.

- THE BRAKE DISC MUST ALW A YS BE PERFECTL Y CLEAN FROM OIL AND GREASE. OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY REDUCED.

- AFTER MOUNTING, CHECK THA T THE SAFETY DEVICES ARE POSITIONED CORRECTL Y.

- AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM, ACTIV A TE THE FRONT BRAKE LEVER AND THE REAR BRAKE PEDAL TO MAKE THE P ADS ADHERE TO THE DISC AND TO RESTORE THE CORRECT ADJUSTMENT OF PLAY.

DISASSEMBLDISASSEMBL

DISASSEMBL

Y Y

Y

AND AND

AND

ASSEMBLASSEMBL

ASSEMBL

Y OF Y OF

Y OF

THE FRTHE FR

THE FR

ONTONT

ONT

WHEELWHEEL

WHEEL

Position the motorcycle with the frame cradle on a stand in a way that the front wheel does not touch the ground. Loosen the flanged nut (7), loosen the fastening screws (8) on the left and right fork shoes, finish unscrewing the flanged nut. Holding the front wheel still, slide the wheel axle out. If necessary, to help the wheel axle to exit, strike lightly with a mallet (hammer with plastic ends) on the threaded end of the axle itself. Alternatively, use a normal hammer and place a piece of wood between. NEVER USE THE HAMMER DIRECTLY ON THE AXLE, YOU RISK TO DAMAGE THE AXLE IRREVERSIBL Y . Slide the front wheel carefully out of the fork.

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WARNING

- NEVER ACTIVATE THE BRAKE LEVER WHEN THE FRONT WHEEL IS DISASSEMBLED

- ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO PREVENT DAMAGE.

To re-assemble the front wheel, insert it carefully into the fork, taking care to insert the disc correctly between the brake pads without damaging them. Position it correctly and mount the wheel axle. Screw and temporarily tighten the flanged nut (7) until the wheel shim is locked, tighten the locking screws (8) on the right fork shoe to prevent the wheel axle from turning and tighten the flanged nut at 40 Nm. Tighten the locking screws on the left fork leg at 12Nm. Loosen the locking screws on the right shoe again, remove the motrcycle from the stand, activate the front brake and force the fork down several times to align the rods. End by definitively tightening the locking screws on the right fork shoe at 12Nm.

- IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH WHEN MOUNTING, HAVE THE TIGHTENING T ORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP. A LOOSE WHEEL AXLE CAN CAUSE UNST ABLE DRIVING .

- AFTER HAVING MOUNTED THE FRONT WHEEL, REPEA TEDL Y ACTIV A TE THE BRAKE LEVER UNTIL THE PAD ADHERES TO THE DISC AGAIN.

- THE BRAKE DISC MUST ALW A YS BE PERFECTL Y CLEAN FROM OIL AND GREASE. ON THE CONTRARY , THE BRAKING EFFECT WOULD BE GREA TL Y REDUCED.

DISASSEMBLDISASSEMBL

DISASSEMBL

Y Y

Y

AND AND

AND

ASSEMBLASSEMBL

ASSEMBL

Y OF Y OF

Y OF

THE REARTHE REAR

THE REAR

WHEEL (ALL EXCEPT SMM)WHEEL (ALL EXCEPT SMM)

WHEEL (ALL EXCEPT SMM)

Rest the motor cycle with the frame cradle on a stand, in a way that the rear wheel does not touch the ground. Unscrew the flanged nut (1) and, supporting the wheel, extract the wheel axle (2), remove the chain

-tensioning slide (3), remove the chain from the sprocket, remove the

caliper with its support and carefully extract the rear wheel from the swing arm. Pay attention to the thin wheel shim (sprocket side) and thick shim (brake side).

WARNING

- DO NOT ACTIVA TE THE BRAKE PEDAL WHEN THE REAR WHEEL HAS BEEN

DISASSEMBLED.

- ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO

PREVENT DAMAGE.

- WHEN THE WHEEL AXLE IS DISASSEMBLED THE WHEEL AXLE THREADS AND

THE THREADS OF THE FLANGED NUT MUST BE WELL CLEANED. RE-GREASE THEM TO PREVENT SEIZING OF THE THREADS.

To assemble, insert the thin shim (sprocket ) into the hub, position the chain tensioners, insert the wheel into the swing arm and, supporting the wheel, position the caliper with its support and mount the chain onto the sprocket. Insert the axle from the sprocket side into half the wheel to permit positioning of the thick shim (brake side). Finish inserting the axle, insert the chain-tensioner slide, screw the nut and tighten it at 80 Nm. Before tightening the flanged nut push the rear wheel forward until the chain tensioners are in contatct w it h the heads of the adjusting screws.

DANGER

- IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH WHEN MOUNTING,

HAVE THE TIGHTENING TORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP. A LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING.

- THE BRAKE DISC MUST ALW A YS BE PERFECTL Y CLEAN FROM OIL AND

GREASE. ON THE CONTRARY , THE BRAKING EFFECT WOULD BE GREA TL Y REDUCED.

- AFTER HA VING RE-ASSEMBLED THE REAR WHEEL ALW A YS ACTIV A TE THE

BRAKE PEDAL SO THA T THE P ADS ADHERE TO THE DISC AGAIN.

- TIGHTEN THE FLANGED NUT WITH THE ESTABLISHED TIGHTENNGT ORQUE.

A LOOSE WHEEL AXLE CAN LEAD T O UNST ABLE DRIVING.

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DISASSEMBLDISASSEMBL

DISASSEMBL

Y Y

Y

AND AND

AND

ASSEMBLASSEMBL

ASSEMBL

Y OF REARY OF REAR

Y OF REAR

WHEEL (SMM) WHEEL (SMM)

WHEEL (SMM)

Rest the motorcycle with the frame cradle on a stand, in a way that the rear wheel does not touch the ground. Cut the safety binding (6), slide out the clasp (7) and unscrew the wheel nut M50x1.5(8). Pay attention to the conical shim (9) placed between the nut and ring. Extract the wheel carefully.

WARNING

- WHEN THE WHEEL NUT IS DISASSEMBLED, THE SHAFT AND NUT THREADS MUST BE CLEANED CAREFULLY. RE-GREASE THEM T O PREVENT SEIZING OF THE THREADS.

To assemble, proceed in the opposite direction, tightening the M50x1.5 wheel nut at 185 Nm. Remount the clasp and re-make the safety binding.

- DO NOT FORGET TO CARRY OUT THE SAFETY BINDING A T THE ENDS OF THE CLASP

- IF YOU DO NOT HAVE A DYNAMOMETRIC WRENCH WHEN MOUNTING, HAVE THE TIGHTENING T ORQUE CHECKED AS SOON AS POSSIBLE IN A SPECIALISED TM WORKSHOP. A LOOSE WHEEL AXLE CAN CAUSE UNSTABLE DRIVING.

- THE BRAKE DISC MUST ALW A YS BE PERFECTL Y CLEAN FROM OIL AND GREASE. ON THE CONTRARY , THE BRAKING EFFECT WOULD BE GREA TL Y REDUCED.

- AFTER HAVING RE-ASSEMBLED THE REAR WHEEL ALWAYS ACTIVATE THE BRAKE PEDAL SO THA T THE P ADS ADHERE TO THE DISC AGAIN.

CHECK SPOKE TENSIONCHECK SPOKE TENSION

CHECK SPOKE TENSION

Correct tension of the spokes is very important for the stability of the wheel and therefore safety on the road. An insufficiently taught spoke leads to unbalancing of the wheel and in brief time loosening of other spokes. Regularly check the tension of the spokes, particularly on new motorcycles. Briefly hit every spoke with the end of a screwdriver (see photo): the spoke should produce a clear sound. Hollow sounds mean loose spokes. In this case you must have the spokes adjusted in a specialised workshop. The wheel must also be centred.

- IF YOU CONTINUE TRAVELLING WITH INSUFFICIENTL Y TIGHT SPOKES, THEY MA Y TEAR CAUSING PROBLEMS OF INST ABILITY.

- EXCESSIVELY TIGHT SPOKES MA Y TEAR DUE TO LOCAL OVERLOADING.

DANGER

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TYRES, TYRE PRESSURETYRES, TYRE PRESSURE

TYRES, TYRE PRESSURE

The type, the state and the pressure of the tyres condition the motorcycle’s behaviour on the road and they must be checked before every journey.

- The dimension of the tyres is indicated in the technical data and in the registration paper.

- The state of the tyres must be controlled before every journey. Check the tyres by verifying that they are not cut, have nails or other sharp objects pushed into them. Regarding the minimum depth of the profile, respect the regulations in force in your country. We recommend that the tyres are changed at the latest, when the profile has reached a depth of 2 mm.

- The tyre air pressure must be checked regularly when the tyres are “cold”. Correct adjustment of the pressure guarantees optimal comfort when travelling and maximum duration of the tyre.

- HAVE EXCLUSIVELY TYRES OF APPROVED TYPE AND DIMENSIONS MOUNTED ON YOUR VEHICLE AND HOWEVER ESTABLISHED BY TM. DIFFERENT TYRES CAN NEGA TIVELY CONDITION THE BEHAVIOUR OF THE MOTORCYCLE ON THE ROAD AND BE THE CAUSE OF FINES ENVISIONED BY THE REGULA TIONS IN FORCE IN YOUR COUNTRY .

- TO GUARANTEE YOUR SAFETY AND THA T OF OTHERS, DAMAGED TYRES MUST BE REPLACED IMMEDIATELY .

- EXCESSIVELY WORN TYRES NEGA TIVEL Y CONDITION THE BEHAVIOUR OF THE MOTORCYCLE, MOST OF ALL ON WET SURF ACES.

- INCORRECT PRESSURE LEADS TO ANOMALOUS WEAR AND OVERHEATING OF THE TYRE.

CHECK ADJUSTMENT OF MAGNETIC SENSORCHECK ADJUSTMENT OF MAGNETIC SENSOR

CHECK ADJUSTMENT OF MAGNETIC SENSOR FOR FOR

FOR FOR

FOR

TT

T

AA

A

CHOMETER (A)CHOMETER (A)

CHOMETER (A)

In all the versions the magnetic sensor is located on the rear wheel. END/SMR - The distance between the head of the screws (2) and the

sensor (1) must be 2-4mm. If not, the tachometer may not work properly .The distance of the sensor is adjusted by the shim (3). Do not remove it, otherwise the sensor may hit the screws and get damaged.

SMM - The distance between the brake disc side face (4) and the sensor (1) must be 2-4mm. If not, the tachometer may not work properly . The distance is adjusted by the shim (3). Do not remove it, otherwise the sensor may hit the disc side face (4) and get damaged.

BABA

BA

TTERY (END/MX/SMR/SMM/SMX)TTERY (END/MX/SMR/SMM/SMX)

TTERY (END/MX/SMR/SMM/SMX)

(ALL MODELS WITH E.S.)(ALL MODELS WITH E.S.)

(ALL MODELS WITH E.S.)

The saddle must be removed to access the battery. The battery does not require maintenance. It is not necessary to check the level of the electrolyte or top-up with water. The battery poles only must be cleaned and, if necessary, slightly greased using grease that does not contain acids. Battery disassembly: First remove the negative pole and then the positive pole from the battery. Disconnect the elastic stripes (5). Remove the battery. When assembling the battery, place it with the poles pointing backwards (see figure), first connect the positive pole and then the negative pole to the battery.

DANGER

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TYRE PRESSURETYRE PRESSURE

TYRE PRESSURE

TYRE PRESSURETYRE PRESSURE

TYRE PRESSURE

FRONTFRONT

FRONT

REARREAR

REAR

Off-road

Road, rider only

1.1 bar

1.7 bar

1.1 bar

1.7 bar

1

3

4

1

2

3

5

END/SMR

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2

DANGER

- IF FOR SOME REASON THE ELECTROLYTE (SULPHURIC ACID) SHOULD ESCAPE FROM THE BATTER Y , BE VER Y CAREFUL. THE ELECTROLYTE CAN CAUSE SERIOUS BURNS.

- ON CONTACT WITH THE SKIN, RINSE WELL WITH WA TER

- IF DROPS OF THE ELECTROLYTE ENTER INTO THE EYES, RINSE FOR A T LEAST 15 MINUTES WITH WATER AND CONSULT A DOCTOR IMMEDIATELY.

- EVEN IF THE BATTERY IS SEALED, IT IS POSSIBLE THAT EXPLOSIVE GASES MA Y COME OUT. KEEP THE BA TTERY AWAY FROM SPARKS OR FLAMES.

- KEEP FAULTY BA TTERIES AW A Y FROM CHILDREN AND DISPOSE OF THEM IN THE CORRECT MANNER.

WARNING

- THE CLOSURE STRIP (2) MUST NOT BE REMOVED, AS OTHERWISE THE REGULAT OR-RECTIFIER WOULD BE DESTROYED.

- THE BATTERY MUST BE MOUNTED WITH THE POLES IN FRONT (AS IN THE FIGURE), IF IT IS MOUNTED IN THE OPPOSITE DIRECTION, THE ELECTROL YTE MAY COME OUT!

PRESERV A TION:

If the motorcycle is kept at a standstill for a long time, remove the battery and charge it. Keep it at at temperature of 0-35°C away from direct sunlight.

BB

B

AA

A

TTERTTER

TTER

Y CHARY CHAR

Y CHAR

GEGE

GE

Remove the battery and determine if it is charged or not. To do this check the voltage between the poles using a voltmetre (rest voltage). To obtain a correct measurement, the battery must not be charged or discharged for at least 30 minutes before the measurement is taken.

If it is not possible to determine the charge, the battery can be charged for a maximum of 10 hours with 0.5 ampere and max. 14.4 volt.

WARNING

- THE CLOSURE STRIP MUST NOT BE REMOVED, AS IT WOULD BE DAMAGED.

- TO RECHARGE, FIRST CONNECT THE BATTER Y TO THE BA TTERY CHARGER, THEN SWITCH THE BATTER Y CHARGER ON.

- WHEN RECHARGING IN CLOSED SPACES, ENSURE GOOD VENTILATION. THE BATTER Y PRODUCES EXPLOSIVE GASES DURING CHARGING .

- IF THE BATTERY IS CHARGED T OO LONG OR A T A TOO HIGH VOL TAGE, THE ELECTROLYTE WILL COME OUT THROUGH THE SAFETY VALVES. THE BATTER Y THEREFORE LOOSES CAP ACITY .

- AVOID FAST RECHARGING.

REST

VOLTAGE

VOLT

>12.7 ~12.5 ~12.2 ~12.0 ~11.8

ST ATE OF

CHARGING

%

100

75 50 25

0

DUR. OF

CHARGING

AT 0.5 A

4 hours 7 hours

11 hours 14 hours

CHARGING

VOLTAGE

Max.

14.4 V

VOLT

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11

RECHARGE FUSERECHARGE FUSE

RECHARGE FUSE

( (

(

ALL MODELS WITHALL MODELS WITH

ALL MODELS WITH

E.S.) E.S.)

E.S.)

The fuse (1) is located in the electric starter relay (2) under the removable battery holder. After having removed seat and battery holder, it is possible to access the fuse. The fuse has a capacity of 30 amperes. This fuse protects the following:

- recharging system

- battery A spare 30 ampere fuse is also found in the starter relay (3).

SERVICES FUSE (ALL MODELS WITH LIGHTS)SERVICES FUSE (ALL MODELS WITH LIGHTS)

SERVICES FUSE (ALL MODELS WITH LIGHTS)

The fuse is found in the relevant rubber fuse-holder (4) situated sunder the removable battery holder. After having removed seat and battery holder and opened the fuse-holder, it is possible to access the fuse. The fuse has a capacity of 7.5 ampere. This fuse protects the following:

- lighting system

- direction indicator

- acoustic warning device A burned out fuse must be replaced exclusively with an equivalent one. If the new fuse should also burn out once mounted, contact a specialised TM workshop.

WARNING

NEVER MOUNT FUSES WITH GREATER POWER OR TRY TO “REP AIR” THE SAME FUSE. UNAPPROPRIATE TREA TMENTS COULD CAUSE FAUL TS TO THE ENTIRE ELECTRIC EQUIPMENT .

ST ST

ST

ANDAND

AND

ARD HEADLIGHTD (END/SMR/SMM)ARD HEADLIGHTD (END/SMR/SMM)

ARD HEADLIGHTD (END/SMR/SMM)

REPLACEMENT OF HEADLIGHT/POSITION LIGHT BULB

Release both elastic stripes and move the light-holder mask forward.

HEADLIGHT TWO-LIGHT BULB

Disconnect the blue, black and white cables and remove the rubber protection (7). Release the retainer and carefully extract the bulb-holder (8). Replace the bulb (9). Remount the bulb holder, the rubber protection and the cables, respecting the position indicated.

POSITION BULB

Extract the bulb-holder (10) from the parabola, replace the bulb. Remount the bulb-holder. Reposition the light-holder mask and fix it using the elastic stripes.

WARNING

NEVER TOUCH THE GLASS BULB, TO PREVENT LEAVING TRACES OF GREASE. TO BE SURE OF INSERTING THE EST ABLISHED BULBS, CONSUL T THE “CYCLE PART TECHNICAL DAT A” TABLE

HALOGEN LIGHT (END/SMR/SMM)HALOGEN LIGHT (END/SMR/SMM)

HALOGEN LIGHT (END/SMR/SMM)

LIGHT HEIGHT ADJUSTMENT

The front light height can be adjusted. First you need to move the rubber stripes on the fork legs so as the light body sits horizontally, then you can rotate the front screw (11) to adjust the light height. Turn the screw clockiwise to lift the light, anticlockwise to lower it.

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BLACK

7

WHITE

BLUE

8

10

9

ENGLISH

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7

8

6

HALOGEN LIGHT (END/SMR/SMM)HALOGEN LIGHT (END/SMR/SMM)

HALOGEN LIGHT (END/SMR/SMM)

REPLACEMENT OF HEADLIGHT/POSITION LIGHT BULB

Release both rubber stripes and move the light-holder mask forward.

HEADLIGHT TWO-LIGHT BULB

Disconnect the cables connector and remove the rubber protection (1). Release the retainer and carefully extract the halogen bulb (2). Reassemble the new bulb, the rubber protection and the connector.

POSITION BULB Disconnect the side connector, extract the bulb-holder (3) from the light body and change the bulb. Reassemble the bulb-

holder.Reposition the light-holder mask and secure it with rubber stripes.

WARNING

NEVER TOUCH THE GLASS BULB, TO PREVENT LEAVING TRACES OF GREASE. TO BE SURE OF INSERTING THE EST ABLISHED BULBS, CONSUL T THE “CYCLE PART TECHNICAL DAT A” TABLEs

“CICLOPS” OPTIONAL HEADLIGHT (END/SMR/SMM)“CICLOPS” OPTIONAL HEADLIGHT (END/SMR/SMM)

“CICLOPS” OPTIONAL HEADLIGHT (END/SMR/SMM)

REPLACEMENT OF HEADLIGHT/POSITION LIGHT BULB

Release both of the elastic stripes and move the light-holder mask forward.

HEADLIGHT BULB

Disconnect the terminal, remove the cover (4) and the seal (5). Unscrew the screws (6) and remove the retainer (7). Loosen the Allen screw (8) and carefully extract the bulb (9). Replace with an equivalent one, tighten the Allen screw again, remount the retainer in the correct position and lock with the screw, taking care to insert the engine stop eyelet terminal under the head of the screw. Remount the cover with the seal and connect the terminal.

HIGH BEAM BULB

Remove the rubber protection (10), unscrew the screw (11) and carefully extract the bulb (12). Replace the bulb with an equivalent one. Remount the retainer in the correct position and lock with the screw, taking care to insert the engine stop eyelet terminal under the head of the screw. Reposition the rubber protection.

1

2

3

9

10

12

11

13

4

5

ENGLISH

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2

1

5

3

4

6

7

STST

ST

ANDAND

AND

ARD REAR LIGHTARD REAR LIGHT

ARD REAR LIGHT

REPLACEMENT OF REAR POSITION /STOP / NUMBER PLATE LIGHT BULB (END/SMR/SMM)

Unscrew the screws (3) and remove the cover (4). Replace the bulb with an equivalent one. Remount the cover and tighten the screws. The bulb is two-light and carries out all above-mentioned functions.

LED REAR LIGHTLED REAR LIGHT

LED REAR LIGHT

REPLACEMENT LED POSITION / STOP / NUMBER PLATE (END/SMR/SMM)

Unscrew the screws (5) and remove the rear light body after disconnecting the wires from the bike harness. Since the led light is a single part, you have to change it completely. Ask for the original spare part to an official TM Dealer.

DIRECTION INDICADIRECTION INDICA

DIRECTION INDICA

TT

T

OR LAMP (END/SMR/SMM)OR LAMP (END/SMR/SMM)

OR LAMP (END/SMR/SMM)

REPLACEMENT OF BULB

Unscrew the screws (6) and remove the cover (7). Replace the bulb with an equivalent one. Remount the cover and tighten the screws.

POSITION LIGHT BULB

Extract the bulb-holder (1) from the parabola, replace the bulb (2). Remount the bulb-holder. Repositon the light-holder mask and fix it with the elastic stripes

WARNING

NEVER TOUCH THE GLASS BULB, TO PREVENT LEAVING TRACES OF GREASE. TO BE SURE OF INSERTING THE EST ABLISHED BULBS, CONSUL T THE “CYCLE PART TECHNICAL DAT A” TABLE

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COOLINGCOOLING

COOLING

The water pump (1) housed in the engine induces forced circulation of the coolant liquid. There is no thermostat in the system, therefore, when the engine is cold, it is important to moderate the number of revs. of the engine and speed. Proceed for at least 5 minutes at half throttle and at reduced pace to allow the engine to reach an adequate working temperature. Cooling takes place thanks to the passage of air through the fins of the radiator, the lower the speed, the less the cooling effect. Dirty radiator fins also decrease the cooling effect. The pressure caused by the high liquid temperature is adjusted by a valve on the radiator cap (2); it is possible to reach temperatures of 120°C without problems.

- CHECK THE LEVEL OF THE COOLANT LIQUID WHEN THE ENGINE IS COLD. IF YOU MUST REMOVE THE RADIA TOR CAP WHEN THE ENGINE IS HOT, COVER IT WITH A CLOTH AND OPEN SLOWLY TO RELEASE THE PRESSURE. ATTENTION, BURNS HAZARD!

- DO NOT DISCONNECT THE RADIATOR HOSES WHEN THE ENGINE IS HOT . THE COOLANT LIQUID AND THE HOT STEAM THA T ESCAPE, MAY CAUSE SERIOUS BURNS.

- IF YOU ARE BURNED, PUT THE INTERESTED PART UNDER COLD RUNNING WA TER.

- THE COOLANT IS TOXIC! THEREFORE PRESERVE IT OUT OF THE REACH OF CHILDREN.

- IF YOU SWALLOW COOLANT, SEEK MEDICAL ADVICE IMMEDIATELY .

- IF THE COOLANT HITS THE EYES, RINSE IMMEDITAELY WITH COLD WA TER AND SEEK MEDICAL ADVICE.

The coolant liquid is a mixture of antifreeze at 40% and water at 60%.The antifreeze protection limit must however be at least -25°C. This mixture offers protection against freezing as well as a good protection against corrosion and therefore should not be replaced by pure water.

WARNING

- AFTER THE COOLANT LIQUID HAS BEEN EMPTIED, WHEN RE-FILLING IT IS NECEESARY TO BLEED THE COOLING SYSTEM (SEE NEXT P AGE).

- ALWA YS USE GOOD QUALITY PRODUCTS T O PREVENT CORROSION OR FOAM.

- IN EXTREME WEATHER CONDITIONS OR IN STOP-AND-GO TRAFFIC, OVERHEATING MAY OCCUR. TO SOLVE THIS PROBLEM, AN ELECTROVENTILAT OR KIT IS A V AILABLE FOR ALL MODELS WITH ELECTRIC STAR TER (ASK A T YOUR TM AUTHORISED DEALER).

CHECK COOLANT LEVELCHECK COOLANT LEVEL

CHECK COOLANT LEVEL

When the engine is cold, the liquid must cover the radiator channels by at least 10 mm. If the circuit is emptied, fill it immediately and bleed.

WARNING

WHEN THE COOLANT LIQUID HAS BEEN EMPTIED, WHEN RE-FILLING IT IS NECESSARY TO BLEED THE COOLING SYSTEM (SEE BELOW).

DANGER

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EMPTYING, FILLING AND BLEEDING OF THEEMPTYING, FILLING AND BLEEDING OF THE

EMPTYING, FILLING AND BLEEDING OF THE COOLING SYCOOLING SY

COOLING SYCOOLING SY

COOLING SY

STEMSTEM

STEM

The coolant liquid may be emptied by removing the screw (5) from the water pump cover on the right side of the engine. Prepare an adequate container to collect the liquid when it comes out. To empty the liquid, the filling cap must be opened. At the end, screw the emptying screw and tighten to 12 Nm. To fill the cooling system, pour the amount of coolant liquid indicated in the “Engine Technical Data” Table, through the inlet. Close the radiator cap and start-up the engine for a few seconds. Re-open the cap and check the level: add more liquid if necessary. After a brief journey, check the level of coolant liquid again.

REPLACEMENT OF EXHAUST SILENCERREPLACEMENT OF EXHAUST SILENCER

REPLACEMENT OF EXHAUST SILENCER PP

PP

P

AA

A

CKING MACKING MA

CKING MA

TERIALTERIAL

TERIAL

The aluminium silencers are filled with acoustic insulating material (fibreglass) to limit motorcycle noise. Because of high temperatures reached by the exhaust gases, the fibreglass tends to burn, leading to a decrease in the effect of noise absorbtion and also causing a decrease in power. To replace the fibreglass, disassemble the silencer from the motorcycle frame, remove the rivets (1) that support the front cap (2) and slide the cap and the wool to be replaced out. In END/SMM/SMR models, the fibreglass cartridge (3) must be cut to a length of about 35 cm (weight 350 grammes) while in the other models it is inserted whole. Slide the fiberglass cartridge on the punched pipe (4) and push it all into the silencer. Hold the clamp and fasten with rivets.

Never disassemble the rear cap (5), it is not necessary and you run the risk of damaging the silencer.

WHEN THE ENGINE IS RUNNING THE EXHAUST SYSTEM BECOMES VERY HOT. ONLY START TO WORK ON THE EXHAUST SYSTEM WHEN IT HAS COOLED DOWN, TO PREVENT BURNS.

To ease mounting of the silencer, grease the ends of the pipes. Also fix the retaining spring between the pipe and the silencer. When the engine is started-up it might generate some smoke from the previously greased parts. This is caused by the high temperature that melts the grease.

WARNING

REPLACE THE FIBREGLASS CARTRIDGE WITH A NEW ONE OF THE SAME WEIGHT OR BOUGHT A T A TM AUTHORISED DEALER.

DANGER

ENGLISH

58

1

3

2

CLEANING CLEANING

CLEANING

THE THE

THE

AIR FILAIR FIL

AIR FIL

TERTER

TER

A dirty air filter jeopardises the filtering of air, reducing engine power and increasing fuel consumption. In some cases, the dust can even reach the engine causing derious damage. For this reason, maintenance of the filter should be carried out regularly.

Remove the seat to access the filter and lift the battery holder. To remove the filter, unscrew the finger screw positioned at the centre of the filter and carefully slide it the filter out of its case.

WARNING

- DO NOT CLEAN THE FOAM FILTER WITH FUEL OR KEROSENE, WHICH CAN CORRODE IT . FOR CORRECT MAINTENANCE OF THE FOAM FIL TER, USE THE RELEVANT PRODUCTS ON THE MARKET FOR CLEANING AND LUBRICA TION.

- NEVER START-UP THE MOTORCYCLE WITHOUT THE AIR FILTER. THE INFILTRA TION OF DUST AND DIRT CAN CAUSE DAMAGE AND INCREASE WEAR.

Wash the filter carefully using a special liquid detergent and dry well: squeeze the filter slightly but do not wring it. Also clean the filter case and check that the rubber manifold that connects the carburetor to the filter case is integral and positioned correctly. Remount the air filter, positioning it correctly on the rest surface, taking care that edges of the filter are not raised or not adherent with the rest surface. Rescrew the finger screw and tighten it adequately.

CHECK HAND DECOMPRESSOR CHECK HAND DECOMPRESSOR

CHECK HAND DECOMPRESSOR

ADJUSTADJUST

ADJUST

..

.

(A) (A)

(A)

(ALL 530 AND 660 CC. MODELS)(ALL 530 AND 660 CC. MODELS)

(ALL 530 AND 660 CC. MODELS)

Take the crankshaft to the TDC with closed valves and activate the hand decompressor. A free play of about 5mm. must be perceived on the end of the lever. The end of the free play is recognised by the hardening of the lever that starts to open the right exhaust valve. Adjust the free play if necessary. To adjust: push the protective hood backwards, loosen the counter-nut (1) and loosen or unscrew the adjustment screw (2). Tighten the counter-nut and replace the protective hood.

WARNING

IF THERE IS NO FREE PLAY ON THE DECOMPRESSION LEVER, THE ENGINE COULD BE DAMAGED.

INDICATION:

The automatic decompressor does not require adjustment.

THROTTLE CABLE COMMAND ADJUSTMENTTHROTTLE CABLE COMMAND ADJUSTMENT

THROTTLE CABLE COMMAND ADJUSTMENT

The throttle command should always have a free play of 3-5 mm. Moreover, when the engine is idling, the revs must not vary when steering as far as possible to the left and to the right. To adjust the play, remove the saddle and the tank with the shrouds. Push the protection hood backwards (1). Loosen the counter-nut (2) and unscrew or screw the adjustment device (3). By screwing, the free play increases. By unscrewing, the free play decreases. Tighten the counter-nut and control the smoothness of the the throttle command handlebar grip. Remount the tank and saddle. When the engine is not running, do not open and close the throttle grip more than 1-2 times: every time it is opened it activates the accelerator pump. This could flood the engine.

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HYDRAULIC CLUTCH AJP PUMPHYDRAULIC CLUTCH AJP PUMP

HYDRAULIC CLUTCH AJP PUMP

ADJUSTMENT OF CLUTCH LEVER BASIC POSITION

Use the adjustment screw (4) to adjust the basic position of the clutch lever. In this way the optimal position for the clutch lever can be found for any hand size. If the adjustment screw is turned clockwise, the clutch lever approaches the handlebar. If the adjustment screw is turned anticlockwise, the clutch lever moves away form the handle bar. The adjustment screw (5) is used to adjust the pump run after having adjusted the position of the lever.

WARNING

THE RANGE OF ADJUSTMENT IS LIMITED. ONLY TURN THE ADJUSTMENT SCREW MANUALLY WITHOUT FORCE.

CHECK HYDRAULIC CLUTCH FLUID LEVEL

The reservoir is part of the clutch pump positioned on the handlebar and has an inspection window: with the reservoir in a horizontal position, the level of the fluid must never fall below the centreline of the window, nor be above the upper margin. If it is necessary to top-up the oil, remove the screws (6) and then the cover (7) together with the rubber seal (8). Keeping the reservoir in a horizontal position,top-up with DOT4 brake fluid.

WARNING

- FOR THE HYDRAULIC COMMAND OF THE CLUTCH, TM USES DOT4 BRAKE FLUID, NEVER USE DOT5 OR OTHER.

- DO NOT ALLOW BRAKE FLUID TO COME INT O CONTACT WITH PAINTED PAR TS. THE BRAKE FLUID CORRODES THE P AINT !

- ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY-SEALED CONTAINERS.

HYDRAULIC CLUTCH BREMBO PUMPHYDRAULIC CLUTCH BREMBO PUMP

HYDRAULIC CLUTCH BREMBO PUMP

ADJUSTMENT OF CLUTCH LEVER BASIC POSITION

With this option, to adjust the clutch lever distance from the handlebar grip (see maintenance operation), you have to turn the adjustment knob (1). Rotate clockwise to increase the distance or counterclockwise to decrease the distance.

CHECK HYDRAULIC CLUTCH FLUID LEVEL

The reservoir is part of the clutch pump positioned on the handlebar. To check the fluid level remove the screws (2) and the cap (3) together with the rubber seal (4). With the reservoir in a horizontal position, the fluid level must be aligned with the mark visible inside the reservoir. If necessary, top up with brake fluid DOT4.

WARNING

- FOR THE HYDRAULIC COMMAND OF THE CLUTCH, TM USES DOT4 BRAKE FLUID, NEVER USE DOT5 OR OTHER.

- DO NOT ALLOW BRAKE FLUID TO COME INT O CONTACT WITH PAINTED PAR TS. THE BRAKE FLUID CORRODES THE P AINT !

- ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY-SEALED CONTAINERS.

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4

2

3

1

8

7

6

5

4

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5

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2

BLEEDING THE HYDRAULIC CLUTCHBLEEDING THE HYDRAULIC CLUTCH

BLEEDING THE HYDRAULIC CLUTCH

For bleeding the hydraulic clutch, remove the cap of the pump (both AJP and Brembo) on the handlebar. Connect the suction machine to the bleeding nipple (5) of the clutch cylinder on the engine. Switch on the suction machine and loosen the nipple. Continue until no more air escapes from the nipple, only oil. Tighten the nipple. Disconnect the suction device. During the operation control that the level in the clutch pump reservoir is always sufficient and prevent the pump from taking up air. If necessary, top-up with DOT4 brake fluid.

WARNING

- FOR THE HYDRAULIC COMMAND OF THE CLUTCH, TM USES DOT4 BRAKE FLUID, NEVER USE DOT5 OR OTHER.

- DO NOT ALLOW BRAKE FLUID TO COME INT O CONTACT WITH PAINTED PARTS. THE BRAKE FLUID CORRODES THE P AINT !

- ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY-SEALED CONTAINERS.

CARBURETOR - CARBURETOR -

CARBURETOR -

IDLE SPEED ADJUSTMENTIDLE SPEED ADJUSTMENT

IDLE SPEED ADJUSTMENT

(A) (A)

(A)

The adjustment of the idle speed greatly influences the engine start, this means that an engine with the idle speed correctly adjusted will be easier to start than an engine with an incorrect idle speed. The idle speed is adjusted using the adjustment knob (1) and the mixture adjustment screw (2). The adjustment knob is used to adjust the basic position of the throttle valve. The mixture adjustment screw is used to adjust the mixture for the idle speed, which flows through the idle speed system up to the engine. By turning in a clockwise direction, the quantity of fuel decreases (lean mixture), by turning in an anticlockwise direction, the quantity of fuel increases (rich mixture).

TO SET IDLE SPEED FUNCTIONING CORRECTLY, PROCEED AS FOLLOWS:

1 Screw the mixture adjustment screw (2) until it stops, without force,

then unscrew it untill you obtain the basic adjustment envisioned by

TM (see Engine Technical Data). 2 Warm-up the engine 3 Use the adjustment knob (1) to adjust the number of revs. of the

normal idle speed (1600 - 1800/min). 4 Slowly turn the mixture adjustment screw (2) in a clockwise direction

until the number of revs of the idle speed begins to decrease. Keep

this position in mind and now turn the mixture adjustment screw

slowly in an anticlockwise direction until the number of revs of the

idle speed begins to decrease again. Set the point between these

two positions in which the number of idle speed revs is highest. If

there is a notable increase in the number of revs., reduce the number

of revs to the normal level using the adjustment knob (1) and repeat

the procedure from point 4. Anyone using the motorcycle for pure racing

will set a leaner mixture of about 1/4 of a turn (in a clockwise direction) with

respect to the ideal value, because the engine will become hotter than

normal.

ENGLISH

61

4

NOTE: If the described methods are followed and satisfying results

are not obtained, the cause could be a Pilot jet with unsuitable

dimensions.

a) If the mix adjustment screw is screwed right down without variation

of the number of revs of the idle speed, a smaller Pilot jet must be

installed.

b) If the engine switches off with the mix adjustment screw still open

by two turns, a larger Pilot jet must be installed. Obviously, after the

jet has been replaced, adjustment must be carried out again from

the beginning. 5 Now, adjust the number of revs. of the idle speed desired using the

adjustment knob. 6 In presence of large variations of external temperature and altitude,

the idle speed must be set again.

To adjust the idle speed mixture screw, a very short screwdriver may be required. Notches may be useful on the handgrip.

BB

B

ASIC INDICAASIC INDICA

ASIC INDICA

TIONS REGARDING CARBTIONS REGARDING CARB

TIONS REGARDING CARB

URETURET

URET

OROR

OR

WEARWEAR

WEAR

The throttle valve, jet needle, needle jet (when present) and the float needle valve are subject to great wear caused by engine vibration. As a consequence the carburetor may malfunction (e.g. enrichening of the mixture). These parts must therefore be controlled after 200 hours.

CHECK FUEL LEVELCHECK FUEL LEVEL

CHECK FUEL LEVEL (FL(FL

(FL(FL

(FL

OO

O

AA

A

T HEIGHT) (A)T HEIGHT) (A)

T HEIGHT) (A)

Disassemble the carburetor and remove the float bowl. Turn the carburetor upside-down and keep it inclined so that the float rests on the needle valve but does not compress the spring with its weight. In this position, use a gauge to measure the distance between the apex of the float body and the float bowl surface on the carburetor body (see image). Refer to the technical data for the correct value for your motorcycle. If necessary, adjust the height by slightly bending the float adjustment plate (4). If possible, also check the tightness and the state of wear of the needle valve cone: if in doubt replace the valve and brass seat. Mount the float bowl, mount the carburetor and adjust the idle speed.

ENGLISH

62

34

5

6

7

8

10

9

11

EMPTYING EMPTYING

EMPTYING

THE CARBTHE CARB

THE CARB

URETURET

URET

OR FLOR FL

OR FL

OO

O

AA

A

T BOT BO

T BO

WLWL

WL

After washing or driving in wet environments (watercourses, etc.) the carburetor float bowl should be emptied to remove any water that may have entered. Water in the float bowl causes working problems. Carry this operation out when the engine is cold. Close the fuel tap and place a container underneath the carburetor to collect the fuel coming out. Now open the screw (1) to empty the fuel and water. Re-close the screw, open the fuel tap and control tightness of the system.

- THE FUEL IS HIGHLY INFLAMMABLE AND TOXIC. HANDLE THE FUEL

WITH CARE. NEVER CARRY OUT OPERATIONS ON THE FUEL SYSTEM NEAR TO FLAMES OR CIGARETTES.

- ALWA YS ALLOW THE ENGINE TO COOL. USE A CLOTH TO REMOVE ANY

OVERFLOWING FUEL. MATERIALS IMPREGNA TED WITH FUEL ARE ALSO HIGHLY INFLAMMABLE. IF YOU SWALLOW FUEL OR IT COMES INTO CONTACT WITH THE EYES, CONSULT A DOCTOR IMMEDIA TELY .

- DISPOSE OF FUEL ACCORDING TO THE REGULA TIONS ENVISIONED IN

YOUR COUNTRY .

OIL CIRCUITOIL CIRCUIT

OIL CIRCUIT

The delivery pump (3) sucks the oil through the net filter (4) from the sump. The oil is delivered pressurised through a pipe (5) t o the filter cartridge where it is purified from all particles and delivered partly to the crankshaft and partly to the distribution and gearbox. The oil delivered to the crankshaft enters through a co-axial pipe into the shaft and finally lubricating the big end bearing (6). The oil delivered to the distribution and gears is made to ascend to the top of the crankcases and, before entering the cylinder, it divides again. A part is channeled towards the gearbox, of which it lubricates, through a distributor (7), the gear toothing. Another part passes through a spray nozzle towards the small end (8) for lubrication of the piston pin. Finally, another part is channeld along the cylinder and through a relevant hole and arrives at the camshafts bearings and to the contact area between the cam lobes and valve lifters (9-10). All pressurised oil delivered to the main parts of the engine is returned by fall and depression to the point in which the drainage pump is found (11) which collects the oil and send it back to the oil sump. Note that the oil sump is separate from the rotating parts of the engine (dry sump) but integrated in the casting of the crankcases. The oil circulation is made only by channels machined inside the engine, without using external hoses.

DANGER

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

63

CHECK ENGINE OIL LEVELCHECK ENGINE OIL LEVEL

CHECK ENGINE OIL LEVEL

The engine oil level must be checked when the engine is running. Start-up the motorcycle on flat ground and keep it in a vertical position (not on the side stand). The oil window is located on the right side of the engine of all the models but the the 660 SMX in which the oil window is located on the left side (see picture). Start-up the engine and keep it at a constant speed, a little above the idle speed: the oil level must be visible from 1/2 to 3/4 of the window positioned on the right side of the motorcycle. If it is too low or cannot be seen at all, top-up immediately with engine oil. Use the same type that has already been introduced into the engine.

WARNING

LOW OIL LEVEL, LOW QUALITY OIL, MAINTENANCE INTERV ALS LONGER THAN THOSE ESTABLISHED, CAUSE SERIOUS DAMAGE TO THE ENGINE .

ENGINE OILENGINE OIL

ENGINE OIL

Use only high grade motor oil SAE 10W-50 or 20W-50 which corresponds to or exceeds the quality standards of the API SG, JASO MA classes. Bel-Ray Thumper 20W-50 and EXS 10W-50 are the only approved, used and recommended by TM.

WARNING

LOW OIL LEVEL, LOW QUALITY OIL MAINTENANCE INTERV ALS LONGER THAN THOSE ESTABLISHED, CAUSE SERIOUS DAMAGE TO THE ENGINE .

CHANGE ENGINE OIL (A)CHANGE ENGINE OIL (A)

CHANGE ENGINE OIL (A)

WARNING: WHEN CHANGING THE OIL, CLEAN THE MAGNET OF THE OIL

DRAIN BOLT AND REPLACE THE FIL TER CARTRIDGE.

The oil must be changed with the engine at working temperature.

THE ENGINE A T WORKING TEMPERA TURE AND THE OIL INSIDE ARE VER Y HOT - P A Y A TTENTION, BURNS HAZARD.

Position the motorcycle on a flat surface, loosen and unscrew the cap (1) positioned on the lower face of the engine and allow the oil to flow into a container.

BEWARE OF HOT OIL!

Clean the cap and incorporated magnet well. After the oil has flowed out completely, clean the sealing face, remount the cap together with the seal and tighten at 20 Nm. Replace the seal if it is damaged.

DANGER

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

Uses and recommends

4-Stroke

Bel-Ray Thumper 20W-50

Engine

Trans

Brake Chassis Filter

www.belray.com

USE ONLY HI OCTANE (98) UNLEADEAD FUEL

Bel-Ray EXS synt. 10W-50

ENGLISH

64

REPLACEMENT OF OIL FILTER CARTRIDGE (after having emptied the oil from the engine)

The cartridge oil filter is situated on the right side of the motorcycle underneath the cover(1). Place a container under the engine to collect the oil that escapes from the filter compartment. Loosen the two screws (2), remove the cover and extract the filter cartridge.

Wait until the oil has drained completely , then clean the sealing surfaces of the transmission cover and filter cover, check the O-Ring and replace it if necessary. Insert a new filter cartridge, making sure that the open side is towards the outside of the engine. The filter must slide into the transmission cover as far as possible in its seat.

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

65

Remount the cover, being careful to the O-Ring and to insert the filter cover nose correctly into the hole of the filter cartridge. Greasing the ORing with a small amount of grease helps to keep it in its seat when assembling. Tighten the screws at 10Nm.

REMEMBER THA T THE FIL TER CARTRIDGE CANNOT BE CLEANED, IT MUST BE REPLACED AT THE ENVISIONED INTERV ALS.

Prepare a measuring beaker with 1.4 (1.0 for 660 SMX) Litres of fully synthetic engine oil of the established type (see engine data). Unscrew the oil load cap and fill with about 0.8 Litres. Close the cap temporarily, start-up the engine and allow it to run for about 5 seconds. DO NOT ALLOW IT TO RUN LONGER T O PREVENT DAMAGE.

Re-open the cap and finish filling with the oil remaining in the measuring beaker. A total of 1.4 (1.0 for 660 SMX) Litres of oil has been introduced. Tighten the cap at 20Nm. Start the engine and check tightness of the filling and emptying caps, the net filter cap and the filter cartridge cover. Finally, check the engine oil level and correct it if necessary.

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCEFRAME AND ENGINE MAINTENANCE

FRAME AND ENGINE MAINTENANCE

ENGLISH

66

TRTR

TR

OUBLESHOOOUBLESHOO

OUBLESHOO

TINGTING

TING

If you have the envisioned maintenance operations carried out on your motorcycle, you will have very few problems. If, however, a problem does occur, please look for it in the following table and try to solve it. Please note that a lot of the operations cannot be carried out without the help of technicians . If in doubt, please contact an authorised TM dealer.

CAUSE

SOLUTION

PROBLEM

Incorrect command

Burned fuse

Key not inserted or not turned Battery flat

Low external temperature

Switch “ON” the emergency shutdown button and where present, turn the key to enable start-up. Remove the right side panel and replace the 30 A fuse in the starter relay Insert the key and turn it in a clockwise direction Charge the battery and identify the cause of discharging, contact a specialised workshop. Start the engine using the kickstarter pedal.

THE STARTER MOT OR

CANNOT TURN THE

ENGINE

Lack of fuel in the engine Open the fuel tap, fill-up with fuel,

observe the indications for start-up (see “Instructions for use” chapter)

THE STARTER MOT OR

TURNS THE ENGINE BUT

THE ENGINE DOES NOT

START

(MODELS WITH ELECTRIC

STARTER)

The motorcycle hasn’t been used for a while, therefore the old fuel has remained in thecarburetor bowl

Fuel supply interrupted

Engine flooded

Spark plug blackened or wet Incorrect spark plug electrodes gap

Spark plug cover or spark plug damaged

Engine stop button cable damaged, engine stop button or emergency shutdown damaged

Oxidised CDI unit, pickup orcoil connectors

Water in the carburetor or clogged jets

The volatile fuel components evaporate easily. If the motorcycle has not been used for more than 1 week, the old fuel should be emptied from the carburetor bowl. When the bowl has been filled with fresh fuel, the engine will start immediately.

Disconnect the fuel hose from the carburetor, place it in a container and open the fuel tap,

- if fuel escapes, clean the carburetor

- if fuel does not escape, control the tank vent pipe or clean the fuel tap

Use the “by-pass” command as explained in the “Operating controls” chapter. Clean and dry the spark plug or replace it. Adjust the gap between the electrodes to 0.8 mm Slide off the spark plug cover, unscrew the spark plug, put the cover back onto the spark plug and, gripping the cover, keep the threaded part of the spark plug in contact with the head of the engine. Turn the engine with the electric starter or pedal, a spark should appear between the electrodes of the spark plug

- if the spark plug does not produce a spark, it must be replaced

- if there is still no spark, remove the spark plug cover from the H.T . cable coming from the coil, hold it at a distance of about 5 mm from the head and operate the starting system

- if there is a spark, replace the spark plug cover

- if there is still no spark, check the ignition system

- Replace the spark plug

Remove the saddle and fuel tank, disconnect the emergency shutdown button cable or the engine stop button cable and check the spark. If there is a spark, look for the fault along the emergency shutdown button cable or the engine stop cable. Remove the saddle, the left side panel and the fuel tank, clean the connectors and treat them with a contact spray. Disassemble and clean the carburetor

THE ENGINE DOES NOT

START

(MODELS WITH

KICKSTARTER PEDAL)

TRTR

TR

OUBLESHOOOUBLESHOO

OUBLESHOO

TINGTING

TING

ENGLISH

67

TROUBLESHOOTINGTROUBLESHOOTING

TROUBLESHOOTING

EXCESSIVE OIL CONSUMPTION

CAUSE

SOLUTION

PROBLEM

THE ENGINE WILL NOT

RUN A T IDLE SPEED

Clogged idle speed jet Altered idle speed adjustment screws Damaged spark plug Faulty Ignition system

Disassemble the carburetor and clean the jet Adjust the idle speed screws Replace the spark plug Have the ignition system checked

THE ENGINE DOES NOT

REACH FULL SPEED

The fuel overflows because the level is adjusted too high or the float needle valve is dirty or worn

The carburetor jets are loose The ignition timing is not correct

Disassemble the carburetor and check the height of the float and the state of the needle valve, as described in the “Frame and Engine Maintenance” chapter Tighten the jets Have the ignition timing checked

POOR ENGINE POWER

Fuel supply partially interrupted or dirty carburetor Float not leakproof Air filter very dirty

Exhaust system not leakproof, deformed or fibreglass in the silencer packing damaged Insufficient valve clearance There is a loss of compression because the hand decompressor hasn’t got enough free play (it remains “tight”) The ignition timing is not correct

Clean and check the fuel circuit and the carburetor Replace the float Clean or replace the air filter, contact a specialised workshop

Check the faulty parts on the exhaust system, replace the fibreglass in the silencer Adjust the valve clearance

Adjust the hand decompressor flexible cable command

Have the ignition timing checked

Fuel missing Air leaks in the intake manifold

Clean and check the fuel circuit and the carburetor Check the rubber manifolds between the filter case and the carburetor and between the carburetor and head and tighten the clamps

THE ENGINE OVERHEATS

EXCESSIVEL Y

There is not enough fluid in the cooling system

Insufficient ventilation

Air in the cooling system The radiator fins are very dirty Foam in the cooling system

The radiator hose is bent

Fill with coolant (see “Frame and Engine Maintenance”) chapter, check for leaks of the cooling system Continue at sustained speed (it is possible to mount a fan optional)

Bleed the cooling system Clean the radiator fins with jets of water Replace the coolant, use good antifreeze

Shorten the radiator hose or replace it

The vent hose is bent Engine oil level too high Engine oil too thin (viscosity)

Position the vent hose or replace it Check and correct the engine oil level if necessary Use more viscous oil, see “Engine oil” chapter

ALL OF THE BULBS BLOW

UNEXPECTEDL Y

The regulator is damaged

Remove the saddle and tank and check the connections of the voltage regulator. Have the regulator checked in a specialised TM workshop

LIGHTS, HORN AND

INDICAT ORS DO NOT

WORK

The lights cable fuse is burned out Remove the left side panel and replace the lights cable 7.5A

fuse

THE BATTER Y IS FLA T

The battery is not charged by the generator

Remove the saddle and check the regulator contacts. Have the regulator and generator checked in a specialised TM workshop

TROUBLESHOOTINGTROUBLESHOOTING

TROUBLESHOOTING

ENGINE MISFIRINGS OR

BACKFIRES FROM THE

CARBURETOR

ENGLISH

68

STST

ST

ORAORA

ORA

GEGE

GE

CLEANINGCLEANING

CLEANING

Clean the motorcycle regularly in a way to maintain the surface of the plastic parts in good condition. To do this, it is advised to use hot water with a detergent and sponge. Most of the dirt can be removed using weak water jets.

WARNING

NEVER CLEAN THE MOTORCYCLE WITH HIGH PRESSURE CLEANING DEVICES OR WITH STRONG JETS OF WA TER! BECAUSE OF THE HIGH PRESSURE THE WA TER COULD REACH THE ELECTRICAL P ARTS, CONNECTORS, FLEXIBLE CABLE COMMANDS, BEARINGS, THE CARBURETOR ETC... AND CAUSE F AUL TS OR PREMA TURE BREAKAGE OF THESE P ARTS.

- Before washing, close the exhaust pipe rear end to prevent water from entering.

- Normal soaps, found on the market, should be used to clean the motorcycle. Particularly dirty parts should be cleaned using a brush.

- After having rinsed the motorcycle well, using a weak jet of water, dry using compressed air and a cloth. Empty the carburetor bowl. Immediately after, make a brief journey until the engine has reached the normal working temperature and at this point activate the brakes. Because of the heat, the water that is left in the unreachable points and on the brakes will evaporate.

- After the motorcycle has cooled down, oil and grease all motion parts and bearings. Treat the chain with an appropriate spray. Also oil the fuel tap.

- To prevent faults in the electric system, treat the emergency shutdown button, the engine stop button, the light switch and the connectors with contact spray.

PRECAPRECA

PRECA

UTION FOR UTION FOR

UTION FOR

WINTER USEWINTER USE

WINTER USE

DANGER

If the motorcycle is not to be used for a long time, take the following measures:

- Clean the motorcycle well (see CLEANING chapter)

- Change the engine oil and oil filter cartridge, clean the net filter (old oil contains dangerous impurities).

- Check the antifreeze and the quantity of the coolant.

- Warm the engine up again, close the fuel tap and wait until the engine stops. Successively open the carburetor bowl empty screw to empty the remaining fuel.

- Disassemble the spark plug and pour into the plug hole 5 cc of oil. Activate the kickstart pedal 10 times to distribute the engine oil onto the walls of the cylinder and then remount the spark plug.

- Bring the piston in compression to induce valve closure

- Empty the fuel tank, collecting the fuel in an appropriate container.

- Adjust tyre pressure.

- Grease bearings or command lever supports, footrests, etc. and also the chain. Disassemble the battery and charge it (see BATTERY chapter). Store it disassembled from the motorcycle.

- The place of storage should be dry and not subject to large temperature changes.

- Cover the motorcycle with a sheet or cover that allows air to pass. Do not use materials that do not allow the passage of air, as humidity would not be able to escape and could cause oxidation.

WARNING

IT IS NOT ADVISED TO ST ART THE ENGINE FOR SHOR T TIMES. THE ENGINE WOULD NOT HEA T UP SUFFICIENTL Y , AND THEREFORE THE STEAM CREATED DURING THE COMBUSTION PROCESS WOULD CONDENSE CAUSING THE OXIDA TION OF THE EXHAUST V ALVES.

START -UP AFTER SEASONAL PAUSE

- Mount the charged battery (pay attention to polarity)

- Fill the tank with new fuel

- Control the motorcycle as before any start-up (see “Instructions for use ” chapter) - Make a short inspection trip.

WARNING: Before storing the motorcycle for the season, check functioning and wear of all components. If maintenance operations, repairs or modifications are necessary, it is a good idea to have them carried out during the winter time (less busy workshops). In this way it is possible to avoid long waits in the workshop at the beginning of the spring season.

CLEANINGCLEANING

CLEANING

PRECAPRECA

PRECA

UTION FOR UTION FOR

UTION FOR

WINTER USEWINTER USE

WINTER USE

STST

ST

ORAORA

ORA

GEGE

GE

If the motorcycle is also used in winter it is necessary to consider the salt on the roads and appropriate countermeasures must be taken against the salt aggressiveness.

- The motorcycle must be cleaned well after use and left to dry.

- Treat engine, carburetor, swing arm and all other bright or galvanised components (except brake disc) with wax-based anticorrosives.

PREVENT CONTACT OF THE ANTICORROSIVE WITH BRAKE DISCS. THIS CAUSES GREA T REDUCTION IN THE BRAKING EFFECT .

WARNING

AFTER TRAVELLING ON ROADS WHERE SAL T HAS BEEN SPREAD, W ASH THE MOTORCYCLE WELL WITH COLD WA TER AND LEA VE IT TO DRY.

ENGLISH

69

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINEA - ENGINE

A - ENGINE

LEGEND: E.S. = Electric start K.S. = Kick start

450450

450

SMM/SMRSMM/SMR

SMM/SMR

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

99

9

450450

450

SMXSMX

SMX

450450

450

MXMX

MX

450450

450

ENDEND

END

250250

250

SMM/SMRSMM/SMR

SMM/SMR

250250

250

MX/SMXMX/SMX

MX/SMX

250250

250

ENDEND

END

ENGINEENGINE

ENGINE

4 stroke single-cylinder DOHC , liquid cooled

250 cm

3

449 cm

3

77x53.6 mm 95x63.4 mm

13.5 : 1 11.5 : 1 12.2 : 1 12.2 : 1 11.5 : 1 unleaded fuel with min. 95 RON

DOHC 4 valves driven by silent chain

A2 / N2 N2 / N3 N1/S1 SM4 / S4 N2 / N3

30 mm 30 mm Ti 30 mm 36 mm 36 mm Ti 36 mm

24.5 mm 24.5 mmTi 24.5 mm 31 mm 31 mm Ti 31 mm mm. 0.20 mm. 0.20 mm. 0.20 mm. 0.25 mm. 0.20 mm. 0.25 mm. 0.25 mm. 0.25 mm. 0.25 mm. 0.25

2 ball bearings

silver-plated needle cage

coppering

forged light alloy

2 rings + 1 oil scraper

1 ring+1 oil scraper

2rings+1scraper

double oil pump ( delivery+ drainage)

fully synthetic premium quality oil SAE 10W-50 API SG-SH

1.4 litres

18 / 67 20 / 57 19 / 57 20 / 57 20 / 57

multiple discs in oil bath

5 speed 5 speed 5 speed 5 speed 5 speed 5 speed

1

st

14:28 1st 15:27 1st 14:28 1st14:28 1st 16:27 1st 14:28

2

nd

17:25 2nd 17:25 2nd 17:25 2

nd

17:25 2nd 17:24 2nd17:25

3

rd

19:23 3rd 19:23 3rd 19:23 3rd 19:23 3rd 16:19 3rd 19:23

4

th

21:21 4th 21:21 4th 21:21 4th 21:21 4th 21:21 4th 21:21

5

th

24:19 5th 23:20 5th 23:20 5th 24:19 5th 23:20 5th 23:20

Kokusan digital CDI with variable timing

12V 180W ----- 12 V 180W 12V 180W ----- 12V 180W

12V180W 12V180W

NGK CR 8E

0.8 mm

liquid cooled 40 % antifreeze, 60 % water(up to -25°C),

forced circulation with pump

1 litre 1.3 litres 1 litre

E.S.+K.S. K.S. E.S.+K.S. E.S.+K.S. K.S. E.S.+K.S.

(E.S.opt.) (E.S.opt.)

Type Displacement Cylinder bore and stroke Compression Fuel Distribution I / E camshafts Inlet valve diameter Exhaust valve diameter Inlet valve cold clearance Exhaust valve cold clearance Crankshaft supports Conrod bearing Small end plating Piston Rings Lubrication Engine oil Oil capacity Primary transmission straight teeth gears Clutch Gearbox (with front engagement) Gear ratios

Ignition Generator Generator with E.S. optional Spark plug Electrode gap Cooling

Coolant fluid capacity Start-up

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINEA - ENGINE

A - ENGINE

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

99

9

ENGLISH

70

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINEA - ENGINE

A - ENGINE

LEGEND: E.S. = Electric start K.S. = Kickstart

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINEA - ENGINE

A - ENGINE

530 SMM/SMR530 SMM/SMR

530 SMM/SMR

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINE 530 END/MX/SMX/SMR/SMM - 660 SMX 2009A - ENGINE 530 END/MX/SMX/SMR/SMM - 660 SMX 2009

A - ENGINE 530 END/MX/SMX/SMR/SMM - 660 SMX 2009

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - ENGINE 530 END/MX/SMX/SMR/SMM - 660 SMX 2009A - ENGINE 530 END/MX/SMX/SMR/SMM - 660 SMX 2009

A - ENGINE 530 END/MX/SMX/SMR/SMM - 660 SMX 2009

530 SMX530 SMX

530 SMX

530 MX530 MX

530 MX

ENGINEENGINE

ENGINE

660 SMX660 SMX

660 SMX

530 END530 END

530 END

Type Displacement Cylinder bore and stroke Compression Fuel Distribution I / E camshafts Inlet valve diameter Exhaust valve diameter Inlet valve cold clearance Exhaust valve cold clearance Crankshaft supports Conrod bearing Small end plating Piston Rings Lubrication Engine oil Oil capacity Primary transmission Clutch Gearbox (with front engagement) Gear ratios

Ignition Generator Generator with E.S. optional Spark plug Electrodes gap Cooling

Coolant fluid capacity Start-up

4 stroke single-cylinder DOHC , liquid cooled

528 cm

3

657,5cm

3

98x70 mm 104 x 77,4 mm

11.3 : 1 1 1.9 : 1 11.3 : 1 12.4 : 1 12.4 : 1 unleaded fuel with min. 95 RON

DOHC 4 valves driven by silent chain

N2/N3 SM2/C1 SM1/C1 36 m m 3 6 mm Ti 36 mm 36 mm Ti 36mm Ti 31 mm 31 mm Ti 31 mm 31 mm Ti 31 mm Ti

mm. 0.20 mm. 0.20 mm. 0.20 mm. 0.20 mm. 0.20 mm. 0.25 mm. 0.25 mm. 0.25 mm. 0.25 mm. 0.25

2 ball bearings

1 ball bearing + 1 roller

silver-plated needle cage

coppering

forged light alloy

2 rings + 1 oil scraper 1 ring + 1 oil scraper

double oil pump (delivery+ drainage)

fully synthetic premium quality oil SAE 10W-50 API SG-SH

1,4 litres 1,0 litre

straight toothing gears 21 / 53 22 / 53

multiple discs in oil bath 5 speed 5 speed 5 speed 5 speed 5 speed 1a 14:28 1a 16:27 1a 14:28 1a 16:27 1a 16:27 2

a

17:25 2a 17:24 2a 17:25 2a 17:24 2a 17:24

3

a

19:23 3a 16:19 3a 19:23 3a 16:19 3a 16:19

4

a

21:21 4a 21:21 4a 21:21 4a 21:21 4a 21:21

5

a

24:19 5a 23:20 5a 23:20 5a 23:20 5a 25:22

Kokusan digital CDI with variable timing

12V 180W ------- 12V 18 0W -------

------- 12 V 180W ------- 12 V 180W NGK CR 8E

0,8 mm

liquid cooled 40 % antifreeze, 60 % water (up to -25°C),

forced circulation with pump

1,3 litres 1 litre 1,3 litres

E.S.+K.S. K.S. E.S.+K.S. K.S.

(E.S.opt.) (E.S.opt.)

ENGLISH

71

CARBCARB

CARB

URETURET

URET

OR SETTINGSOR SETTINGS

OR SETTINGS

CARBCARB

CARB

URETURET

URET

OR SETTINGSOR SETTINGS

OR SETTINGS

NN

N

.B:.B:

.B:

INFORMA INFORMA

INFORMA

TIONS CHANGED FRTIONS CHANGED FR

TIONS CHANGED FR

OM OM

OM

THE PREVIOUS RELEASE THE PREVIOUS RELEASE

THE PREVIOUS RELEASE

ARE IN BOLD ARE IN BOLD

ARE IN BOLD

TYPESTYPES

TYPES

KEIHINKEIHIN

KEIHIN

Type

Main Jet

Slow Jet

Jet Needle

Clip position

Throttle valve

Slow air screw

Float height

Fuel valve

Accelerator pump opening

Accelerator pump closing

FCRD39

165

50

NCYP

3

rd

from top

1,5

1.25 turns

7.0 mm

3,8

0% throttle stroke

100% throttle stroke

FCRD39

180

45

NCYP

3

rd

from top

1,5

1.25 turns

7.0 mm

3,8

0% throttle stroke

100% throttle stroke

11/09

250cc.MX

12/09

250cc.SMX

FCRD39

165

45

OCEMP

3

rd

from top

1,5

1.5 turns

7.0 mm

3,8

0% throttle stroke

80% throttle stroke

13/08

450cc.END

14/09

450cc.MX

530cc.MX

15/09

450cc.SMX

530cc.SMX

16/09

660cc.SMX

17/08 18/08 20/08

FCRD39

165

50

OCEMP

3

rd

from top

1,5

1.5 turns

7.0 mm

3,8

0% throttle stroke

80% throttle stroke

FCRD41

190

45

OCEMP

3

rd

from top

1,5

1.0 turns

7.0 mm

3,8

0% throttle stroke

100% throttle stroke

19/08

FCRD41

190

45

NCYP

3

rd

from top

1,5

1.0 turns

7.0 mm

3,8

0% throttle stroke

100% throttle stroke

TM RATM RA

TM RA

CING 4T CARBCING 4T CARB

CING 4T CARB

URETURET

URET

ORS SETTING ORS SETTING

ORS SETTING

TT

T

ABLE 4T 2009 MODELS 03/11/08 REVABLE 4T 2009 MODELS 03/11/08 REV

ABLE 4T 2009 MODELS 03/11/08 REV

..

.

02 02

02

TM RATM RA

TM RA

CING 4T CARBCING 4T CARB

CING 4T CARB

URETURET

URET

ORS SETTING ORS SETTING

ORS SETTING

TT

T

ABLE 4T 2009 MODELS 03/11/08 REVABLE 4T 2009 MODELS 03/11/08 REV

ABLE 4T 2009 MODELS 03/11/08 REV

..

.

02 02

02

MIKUNIMIKUNI

MIKUNI

Type

Main Jet

Slow Jet

Needle Jet

Jet Needle

Clip position

Throttle valve

Slow air Screw

Slow air Air Jet

Float height

Fuel valve

Acc. Pump Rod Length

Stopper Screw Outs. Length

Accelerator Pump Jet

TDMR 38

170

45

P-6

10E1-52

3

rd

from top

2.0 no holes

1.5 turn

120

11.0 mm.

3.8

81.0 mm.

13.0 mm.

35

TDMR 41

170

50

P-6

10E1-52

3

rd

from top

2.0 no holes

1.0 turn

120

11.0 mm.

3.8

85.0 mm.

11.5 mm.

40

01/08

250cc.

END/SMM/SMR

02/08

450cc.SMR7SMM

530cc.END/SMM/

SMR

03/08 04/08 07/08 08/08 09/0805/08 06/08 10/08

ENGLISH

72

ENGINE OIL

Only use premium quality fully synthetic oils SAE10W-50 that correspond to or exceed the quality standards of the API - SG or SH classes (indication on container).

WARNING

A LEVEL THA T IS TOO LOW , LOW QUALITY OIL OR MAINTENANCE INTERV ALS LONGER THAN EST ABLISHED, CAUSE SERIOUS DAMAGE TO THE ENGINE.

ENGINE TIGHTENING TORQUESENGINE TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Crankase Allen screws, transmission cover , clutch cover , ignition cover Oil drain screw cap Oil filler screw cap Oil net filter screw cap Oil cartridge filter cover Allen screws Engine oil pump body screws Head-cylinder nuts Head-cylinder flanged nuts Head-cylinder flanged nuts Head-cylinder fastenening screws Camshaft bearing cap Allen screw Camshaft cap Allen screws Distribution chain tensioner Allen screws Water pump cover Allen screws Water pump rotor Head cover Allen screws Primary transmission pinion nut Clutch hub nut Clutch springs Allen screws Starter motor bush csk head Allen screw Starter motor fastening Allen screws Mobile chain guide fastening flanged screws Ignition stator Allen screws Ignition pickup fastening Allen screws Allen screws for gear drum lock lever Ignition flywheel flanged nut Kickstart pedal screw Gear pedal Allen screw Exhaust manifold flanged nuts General screws/nuts General screws/nuts General screws/nuts

10 Nm 20 Nm 20 Nm 15 Nm 10 Nm 10 Nm 45 Nm 20 Nm 12 Nm 20 Nm 12 Nm 12 Nm 10 Nm 10 Nm

Loctite 243 + 15 Nm

10 Nm

Loctite 270 + 100 Nm

Loctite 270 + 80 Nm

8 Nm

Loctite 243 + 6 Nm

12 Nm 12 Nm

Loctite 243 + 8 Nm

8 Nm

Loctite 243 + 10 Nm

60 Nm Loctite 243 + 25 Nm Loctite 243 + 10 Nm Loctite 243 + 12 Nm

8 Nm 10 Nm 20 Nm

M6 M16x1.5 M20x1.5 M28x1.5

M6

M10

M8

M6

M8

M6

M8

M6

M20x1.25

M18x1.5

M6

M5

M6

M5

M6

M12x1

M8

M6

M5

M6

M8

ENGINE ENGINE

ENGINE

TIGHTENING TIGHTENING

TIGHTENING

TT

T

OROR

OR

QQ

Q

UESUES

UES

ENGINE ENGINE

ENGINE

TIGHTENING TIGHTENING

TIGHTENING

TT

T

OROR

OR

QQ

Q

UESUES

UES

ENGLISH

73

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - CYA - CY

A - CY

CLE PCLE P

CLE P

ARAR

AR

TT

T

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - CYA - CY

A - CY

CLE PCLE P

CLE P

ARAR

AR

T 250/450/530 END - 250/450/530 MX 2009T 250/450/530 END - 250/450/530 MX 2009

T 250/450/530 END - 250/450/530 MX 2009

Frame Front suspension Rear/front suspension travel Rear suspension Front disc brake Rear disc brake Brake disc wear limit Front tyre Off-road air pressure Rear tyre Off-road air pressure T ank capacity Final transmission Chain Optional rear sprockets Bulbs (only END)

Battery

Twin-spar high resist ance aluminium alloy frame

Marzocchi USD fork / Paioli USD fork / Ohlins USD fork

300/315 mm

Aluminium swing arm, Progressive mechanical linkage, Sachs rear shock (optional Ohlins)

Ø 270 mm floating caliper Ø 245 mm floating caliper

mm. 0.4 below original thickness

90/90 - 21”

1.1 bar

120/90 - 18” 140/80 - 18” 100/90 - 19” 110/90 - 19”

1.1 bar

9 litres

13/51 13/50 13/50 13/51 14/51 14/51 O-Ring 5/8 x 1/4” 5/8 x 1/4” 48, 49, 50, 51, 52, 53 Headlight/full beam

S212V 45/40W BA20d / HS112V 35/35W (Opt.Cyclops H3 12V 55W PK22s)

Front position light

T4W 12V 4W BA9s / W5W12V 5W (Opt. Cyclops T10 12V 5W)

Position/stop/number plate light

P21/5W 12V 21/5W BAY15d / LED 12V 0.9W / 0.06W

Indicator

R10W 12V 10W BA15S

12V 6Ah 12V 6Ah (only with E.S. opt.)

530 MX530 MX

530 MX

250 END250 END

250 END

450 END450 END

450 END

530 END530 END

530 END

250 MX250 MX

250 MX

450 MX450 MX

450 MX

TIGHTENING TORQUES 250/450/530 END - 250/450/530 MXTIGHTENING TORQUES 250/450/530 END - 250/450/530 MX

TIGHTENING TORQUES 250/450/530 END - 250/450/530 MX

Front wheel axle flanged nut Front brake caliper fastening screws (END,MX)

Front brake disc fastening screws Rear brake disc fastening screws Upper fork head fastening screws Lower fork head fastening screws Paioli fork leg fastening screws Ohlins fork leg fastening screws Rear wheel axle flanged nut Swing arm axle flanged nut Handlebar caps fastening screws Handlebar elastic support nut Upper end shock nut Lower end shock nut Rear sprocket nuts Rear brake pedal adjustment nut Engine fastening screws General frame screws

General frame nuts

M20x1.5

M8

M6 cl. 10.9 M6 cl. 10.9

M8 M8 M6

M8 M22x1.5 M16x1.5

M8

M10 M10x1.25 M10x1.25

M8 M6

M10

M6 M8

M10

M6 M8

M10

40 Nm 25 Nm

15 Nm 15 Nm 20 Nm 20 Nm 12 Nm 12 Nm 80 Nm 80 Nm 20 Nm 35 Nm 40 Nm 35 Nm 35 Nm 15 Nm 45 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - CYA - CY

A - CY

CLE PCLE P

CLE P

ARAR

AR

TT

T

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - CYA - CY

A - CY

CLE PCLE P

CLE P

ARAR

AR

T 250/450/530 END - 250/450/530 MX 2009T 250/450/530 END - 250/450/530 MX 2009

T 250/450/530 END - 250/450/530 MX 2009

ENGLISH

74

TIGHTENING TORQUES 250/450/530 SMR/SMM - 250/450/530/660 SMXTIGHTENING TORQUES 250/450/530 SMR/SMM - 250/450/530/660 SMX

TIGHTENING TORQUES 250/450/530 SMR/SMM - 250/450/530/660 SMX

Front wheel axle flanged nut Front brake caliper fastening screws (SMR,SMM,SMX) Rear brake caliper fastening screws (SMM) Front brake disc fastening screws Rear brake disc fastening screws(SMR,SMX) Rear brake disc fastening nut (SMM) Upper fork head fastening screws Lower fork head fastening screws Paioli fork leg fastening screws Ohlins fork leg fastening screws Rear wheel axle flanged nut Swing arm axle flanged nut Handlebar caps fastening screws Handlebar elastic support nut Upper end shock nut Lower end shock screws Rear sprocket nuts Rear brake pedal adjustment nut Engine fastening screws Rear wheel nut(SMM) Rear hub locking screws (SMM) General frame screw

General frame nuts

40 Nm 40 Nm 25 Nm 15 Nm 15 Nm 25 Nm 20 Nm 20 Nm 12 Nm 12 Nm 80 Nm 80 Nm 20 Nm 35 Nm 40 Nm 35 Nm 35 Nm 15 Nm 45 Nm

185 Nm

31 Nm 10 Nm 25 Nm 45 Nm 15 Nm 30 Nm 50 Nm

M20x1,5

M10

M8 M6 cl. 10.9 M6 cl. 10.9

M8

M6

M8

M22x1,5 M16x1.5

M8

M10 M10x1.25 M10x1.25

M8

M6 M10 M50

M12x1.25

M6

M8 M10

M6

M8 M10

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - CYA - CY

A - CY

CLE PCLE P

CLE P

ARAR

AR

TT

T

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A - CYA - CY

A - CY

CLE PCLE P

CLE P

ARAR

AR

TT

T

250/450/530 SMX250/450/530 SMX

250/450/530 SMX

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A 250/450/530 SMR/SMM - 250/450/530/660 SMX 2009A 250/450/530 SMR/SMM - 250/450/530/660 SMX 2009

A 250/450/530 SMR/SMM - 250/450/530/660 SMX 2009

TECHNICAL DTECHNICAL D

TECHNICAL D

AA

A

TT

T

A 250/450/530 SMR/SMM - 250/450/530/660 SMX 2009A 250/450/530 SMR/SMM - 250/450/530/660 SMX 2009

A 250/450/530 SMR/SMM - 250/450/530/660 SMX 2009

660 SMX660 SMX

660 SMX

250/450/530 SMM250/450/530 SMM

250/450/530 SMM

250/450/530 SMR250/450/530 SMR

250/450/530 SMR

Frame Front suspension Rear/front suspension travel Rear suspension Front disc brake Rear disc brake Brake disc wear limit Front tyre “Rider only” air pressure Rear tyre “Rider only” air pressure T ank capacity Final transmission Chain Optional rear sprockets Bulbs (only SMR/SMM)

Battery

Twin-spar high resistance aluminium alloy frame

Marzocchi USD fork / Paioli USD fork (optional Ohlins USD)

270/280 mm

Aluminium swing arm (Single-arm on SMM), Progressive mechanical linkage, Sachs shock (Ohlins optional)

Ø 320 mm 4-pistons caliper Ø 240 mm floating caliper Ø 220 mm rigid caliper Ø 2 45 m m floating caliper

mm. 0.4 below original thickness

120/70 - 17”

1.7 bar

150/60 - 17” 165/55 - 17”

1.7 bar 9 litres

13/40 14/46 (15/46 SMX450) 15/47

5/8 x 1/4”

39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49

Headlight/full beam

S212V 45/40W BA20d / HS112V 35/35W (Opt.Cyclops H3 12V 55W PK22s)

Front position light

T4W 12V 4W BA9s / W5W12V 5W (Opt. Cyclops T10 12V 5W)

Position/stop/number plate light

P21/5W 12V 21/5W BAY15d / LED 12V 0.9W / 0.06W

Indicator

R10W 12V 10W BA15S

12V 6Ah 12V 6Ah (only with E.S. opt.)

ENGLISH

75

ALPHABETIC INDEXALPHABETIC INDEX

ALPHABETIC INDEX

ALPHABETIC INDEXALPHABETIC INDEX

ALPHABETIC INDEX

Page

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

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

ADVICE AND GENERAL RECOMMENDATIONS

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

ALPHABETIC INDEX ................................................................... 75

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

Basic indications for TM disc brakes ................................................ 4 3

Basic indications regarding carburetor wear ................................... 61

Battery (all models with E.S.) ........................................................... 51

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

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

Bleeding hydraulic clutch .................................................................. 6 0

Brake pedal ...................................................................................... 15

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

“By-Pass” command (hot starter) All models with electric starter .... 13

“By-Pass” command (hot starter) All models with kickstart ............. 14

Carburetor - Idle speed adjustment .................................................. 60

CARBURETOR SETTINGS ................................................................. 71

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

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

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

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

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

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

Check coolant level ........................................................................... 5 6

Check engine oil level ....................................................................... 63

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

Check fuel level (float height) ............................................................ 61

Check hand decompressor adjustment ............................................ 58

Check rear brake fluid level .............................................................. 47

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

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

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

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

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

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

CLEANING ........................................................................................ 68

Cleaning telescopic fork dust scraper .............................................. 3 7

Cleaning the air filter ......................................................................... 58

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

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

Cold engine start ............................................................................... 2 3

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

Cooling .............................................................................................. 5 6

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

Disassembly and assembly of rear wheel (SMM) ............................ 5 0

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

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

Electronic digital backlit display tachometer ...................................... 11

Emptying the carburetor float bowl .................................................. 62

Emptying, filling and bleeding of the cooling system ........................ 57

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

Engine oil ........................................................................................... 63

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

ENGINE TIGHTENING TORQUES ........................................................ 72

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

38Establishing rear shock static lowering ........................................ 3 9

Fork adjustment in compression ....................................................... 16

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

Page

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

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

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

Front brake lever BREMBO radial pump ............................................ 11

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

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

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

Fuel filler cap..................................................................................... 13

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

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

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

Hydraulic clutch AJP pump................................................................ 59

Hydraulic clutch BREMBO pump ....................................................... 59

Idle speed adjustment command ....................................................... 14

If the engine is “flooded”.................................................................... 24

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

Indications for first start-up .............................................................. 20

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

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

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

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

Manual decompressor lever ............................................................. 10

Modification of rear brake pedal base position ................................. 47

Oil circuit ........................................................................................... 62

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

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

PRECAUTIONS FOR WINTER USE ..................................................... 68

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

Recharge fuse (all models with E.S.) ................................................ 53

Replacement of exhaust silencer packing material ........................... 57

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

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

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

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

Shifting gear, accelerating, slowing down ....................................... 2 4

Shock absorber adjustment in compression ..................................... 17

Shock absorber adjustment in rebound ............................................ 18

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

Side stand ........................................................................................ 15

Side stand fixing for off-road routes ................................................ 15

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

Standard rear light ............................................................................ 55

Start command and emergency stop

(END/MXE.S./SMXE.S./SMR/SMM) ..................................................... 12

Start-up after seasonal pause .......................................................... 68

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

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

STORAGE.......................................................................................... 68

TECHNICAL DA T A - ENGINE .......................................................... 69/70

TECHNICAL DA T A-CYCLE P ART ................................................. 73-74

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

Throttle cable command adjustment.................................................. 58

Top-up rear brake fluid ...................................................................... 47

TROUBLESHOOTING ........................................................................ 66

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

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

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

Warm engine start............................................................................. 23

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

ENGLISH

76

WIRING DIAWIRING DIA

WIRING DIA

GRAMSGRAMS

GRAMS

WIRING DIAWIRING DIA

WIRING DIA

GRAMSGRAMS

GRAMS

ENGLISH

77

WIRING DIAGRAMSWIRING DIAGRAMS

WIRING DIAGRAMS

WIRING DIAGRAMSWIRING DIAGRAMS

WIRING DIAGRAMS

ENGLISH

78

ENGLISH

79

Grafica e Stampa SERIART - Fabriano (AN) - www.seriart.com

ENGLISH

Published and printed by - Fabriano (AN) - www.seriart.comSERIART

SERIART

TM-02 (ed. 12/08)

TM RACING 4 Stroke 2009 User And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual