TM 2008 UK 1 ENGLISH
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IMPOR TANT IMPORT YOU ARE ADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM. IT CONTAINS A LOT OF INFORMATION AND ADVICE THAT WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE MUCH EASIER AND SAFER. IT IS IN YOUR SPECIFIC INTEREST TO PAY PARTICULAR ATTENTION TO THE WARNINGS INDICATED IN THE FOLLOWING WAY: DA N G E R FAILURE TO COMPLY WITH THESE WARNINGS RISKS LIVES! WARNING FAILURE TO COMPLY WITH THESE WARNINGS COULD CAUSE DAMAGE TO PARTS OF THE MOTORCYCLE OR MAKE IT UNSAFE FOR USE.
Dear TM customer 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.
IMPOR TANT AD VICE REGARDING IMPORT ADVICE THE LEGAL WARRANTY AND THE COMMER CIAL WARRANTY COMMERCIAL 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.
INDEX INDEX Page Variation of rear shock spring preload ........................................... 42 Rear suspension mechanical linkage ............................................. 42 Check chain tension ...................................................................... 43 Adjustment of chain tension (all models except SMM).....................43 Adjustment of chain tension (SMM).................................................44 Chain maintenance .....................................................
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POSITION OF OF SERIAL SERIAL NUMBER NUMBER POSITION FRAME NUMBER The frame number is embossed on the right side of the steering metal tube. Make note of this number in the appropriate space on page 3. In the END, SMR, SMM models, the serial number is also stated on a plate positioned on the left hand side. See photo. ENGINE NUMBER The engine number is engraved on the left side of the engine underneath the chain pinion. Make note of this number in the appropriate space on page 3.
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OPERA TING CONTR OLS OPERATING CONTROLS CLUTCH LEVER The clutch lever (1) is mounted on the left of the handlebar. The position of the clutch lever, with respect to the handlebar grip, can be varied using the adjustment screws (A) (see maintenace operation). The adjusting screws (B) are used to adjust the pump after having adjusted the lever position and to ensure the correct freeplay. MANUAL DECOMPRESSOR LEVER (ALL530 AND 660CC.
TING CONTR OLS OPERATING CONTROLS OPERA ELECTR ONIC TACHOMETER (END/SMR/SMM) ELECTRONIC The electronic tachometer display is always activated. The electronic tachometer is powered by an SR44 1.5 Volt battery, (D357) 11.6x5.4mm. Replace the battery every 2 years or in case of blurring of the display. To replace the battery, open the cover positioned on the rear using a screwdriver, and extract the battery. Insert the new battery in a way that the positive pole is visible from the outside and close the cover.
TING CONTR OLS OPERATING CONTROLS OPERA PROGRAMMING THE CLOCK (END/SMR/SMM) Remove the connector positioned on the back of the instrument. Select the CLK function on the display by pressing the right hand button (blue). Press the grey button on the rear of the instrument for 5 secs.and “CLK” (Clock) will start to flash on the display together with the hours. Press the left hand button (yellow) to set the hour (on 24 hours).
OPERA TING CONTR OLS OPERATING CONTROLS ENGINE STOP SWITCH (MX/SMX) The engine stop switch is found near to the handlebar’s left handlebar grip. The engine is shutdown using the engine stop switch (1): when it is activated a shortcircuit is caused in the ignition, which no longer supplies voltage to the spark plug. Press the button until the engine switches off and then release. 1 COMBIN ATION SWIT CH COMBINA SWITCH (END/SMR/SMM) This command is found on the handlebar near to the left handlebar grip.
TING CONTR OLS OPERATING CONTROLS OPERA ST AR T COMMAND AND EMER GENCY ST OP STAR ART EMERGENCY STOP (END/MXE.S./SMXE.S./SMR/SMM) In the models with battery and electric ignition, a two-button command is found at the side of the throttle command, one button is red, the other black. The red button (1) has two positions. Positioned inwards, it interrupts contact with the battery, removing the current from all services consumers/ancilleries. The engine will not start even with the pedal.
TING CONTR OLS OPERATING CONTROLS OPERA CHOKE COMMAND (COLD ST AR TER) STAR ARTER) 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. To disconnect the command, push the choke knob inwards to its original position.
OPERA TING CONTR OLS OPERATING CONTROLS GEAR SHIFT PED AL PEDAL The gear shift pedal is positioned on the engine left side. The position of the gears is indicated in the illustration. The neutral is between the first and second gears. KICKST AR T PED AL KICKSTAR ART PEDAL The kickstart pedal is positioned on the right side of the engine. The upper part is turned outwards to start-up the engine and replaced inside as soon as the engine is running.
OPERA TING CONTR OLS OPERATING CONTROLS SIDE ST AND FIXING FOR OFFR OAD R OUTES STAND OFFRO ROUTES If you drive the motorcycle off-road, the closed side stand can be additionally fixed using a rubber band (2). IGNITION SWITCH In the SMR and SMM models an ignition key is added on the left side of the dashboard.
TING CONTR OLS OPERATING CONTROLS OPERA FORK ADJUSTMENT IN REBOUND The hydraulic brake system in extension determines the behaviour of the fork in the rebound stroke. The degree of hydraulic braking in rebound can be adjusted on the basis of pilot preferences and/or hardness of the spring installed. PAIOLI USD FORK (STANDARD) The adjustment screw is located in the upper side of the fork cap (4). By turning it clockwise, braking increases, anticlockwise it decreases.
OPERA TING CONTR OLS OPERATING CONTROLS OHLINS SHOCK ABSORBER (OPTIONAL) Low speeds- The adjustment screw (1) is on the top of the damper gas tank. Use a screwdriver. By turning clockwise, braking increases, anticlockwise, it decreases. A total of 25 clicks are available. High speeds- The adjuster is a hexagonal ring nut (2) and is concentric to the low speeds adjustment screw. Use a 17mm hexagonal spanner. By turning clockwise, braking increases, anticlockwise it decreases.
TING CONTR OLS OPERATING CONTROLS OPERA STEERING LOCK This lock is situated on the left side of the frame steering tube. This lock stops rotation of the handlebar, preventing the motorcycle being driven. To lock the steering, turn the handlebar completely to the right, insert the key, turn it to the left, press, turn to the right and extract. WARNING NEVER LEAVE THE KEY IN THE LOCK. BY TURNING THE HANDLEBAR TO THE LEFT, THE KEY COULD BE DAMAGED.
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AD VICE AND AND GENERAL GENERAL RECCOMAND RECCOMAND ATIONS TIONS FOR FOR ADVICE RECCOMANDA VICE A ADVICE RECCOMANDA AD COMMISSIONING THE THE MO MO TOR OR CY CLE MOT ORCY CYCLE COMMISSIONING T CY CLE MOT ORCY CYCLE INDICATIONS FOR FIRST ST AR T-UP STAR ART DANGER - ALWAYS WEAR SUITABLE CLOTHING WHEN USING THE MOTORCYCLE. ASTUTE MOTORCYCLISTS THAT DRIVE A TM ALWAYS WEAR THE TYPE-APPROVED HELMET, BOOTS, GLOVES AND A JACKET, WHETHER IT IS A LONG OR SHORT JOURNEY.
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INSTRUCTIONS INSTRUCTIONS FOR FOR USE USE CHECK BEFORE EVER Y ST AR T-UP EVERY STAR ART 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.
INSTRUCTIONS INSTRUCTIONS FOR FOR USE USE COLD ENGINE ST AR T STAR ART 1 2 3 4 Open the fuel tap (1). Remove the motorcycle from the stand. Put the gears in neutral. 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.
INSTRUCTIONS INSTRUCTIONS FOR FOR USE USE IF THE ENGINE IS “FLOODED” In the event of a fall, a certain amount of fuel can flow out of the caburetor and enter the head, “flooding” the engine. To start the engine, pull the “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.
INSTRUCTIONS INSTRUCTIONS FOR FOR USE USE 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 STANDSTILL FOR MORE THAN 2 MINUTES.
INSTRUCTIONS INSTRUCTIONS FOR FOR USE USE 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.
INSTRUCTIONS INSTRUCTIONS FOR FOR USE USE INDICATIONS REGARDING THE SIDE STAND: Push the stand forward until it stops and lean the motorcycle on it. Ensure that the ground is solid and the parking position is stable. For greater safety insert the 1st gear. WARNING THE SIDE STAND IS DESIGNED ONLY FOR THE WEIGHT OF THE MOTORCYCLE. NEVER SIT ON THE MOTORCYCLE WHEN IT IS RESTING ON THE SIDE STAND, OTHERWISE THE STAND MAY BE DAMAGED AND THE MOTORCYCLE CAN FALL.
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MAINTEN ANCE AND L UBRICA TION TABLE MAINTENANCE LUBRICA UBRICATION MAINTENANCE AND LUBRICATION TABLE 250/450/530 O RO 250/450/530 END/SMR/SMM END/SMR/SMM R R OAD/HOBBY AD/HOBBY USE USE RO A A CLEAN CLEAN VEHICLE VEHICLE PERMITS PERMITS QUICKER QUICKER AND AND THEREFORE THEREFORE CHEAPER CHEAPER INSPECTIONS INSPECTIONS ENGINE 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 tightnes
MAINTEN ANCE AND L UBRICA TION TABLE MAINTENANCE LUBRICA UBRICATION MAINTENANCE AND LUBRICATION TABLE 250/450/530 END/MX/SMX 250/450/530 END/MX END/MX/SMX /SMX 660 660 SMX SMX COMPETITION COMPETITION USE USE A CLEAN VEHICLE PERMITS QUICKER AND THEREFORE CHEAPER INSPECTIONS • • • ENGINE 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 faste
ANCE AND L UBRICA TION TABLE MAINTENANCE LUBRICA UBRICATION MAINTEN BRIEF CHECK AND MAINTEN ANCE OPERA TIONS TO BE PERFORMED BY THE RIDER/PIL OT MAINTENANCE OPERATIONS RIDER/PILO BEFORE EVERY ST AR T UP STAR ART AFTER AFTER EVERY OFF-THE-ROAD WASH USE • • • • • 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,
MAINTEN ANCE AND L UBRICA TION TABLE MAINTENANCE LUBRICA UBRICATION CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/MX/SMX COMPETITION USE 15 HOURS OF SER VICE EQ U AL ABOUT 100 L T. SERVICE LT OF FUEL CONSUMPTION 30 HOURS 200 LT.
MAINTEN ANCE AND L UBRICA TION TABLE MAINTENANCE LUBRICA UBRICATION CHECKS TO BE CARRIED OUT ON ENGINE 250/450/530 END/SMR/SMM ROAD/HOBBY USE 20 HOURS OF SER VICE EQ U AL ABOUT 100 L T. SERVICE EQU LT OF FUEL CONSUMPTION 60 HOURS 300 LT. 90 HOURS 450 LT.
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FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE DANGER ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH (A) REQUIRE TECHNICAL MASTERY. FOR THIS REASON IT IS IN THE INTEREST OF YOUR SAFETY TO HAVE THESE OPERATIONS CARRIED OUT EXCLUSIVELEY BY A SPECIALISED TM WORKSHOP WHERE YOUR MOTORCYCLE WILL BE MAINTAINED IN AN OPTIMAL MANNER BY SPECIFICALLY TRAINED STAFF.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE BASIC CALIBRA TION OF THE CY CLE P AR T ON CALIBRATION CYCLE PAR ART 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE EST ABLISHING REAR SHOCK L O WERING IN ESTABLISHING LO 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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. DANGER - IF THE CHAIN IS TOO TIGHT , THE FINAL TANSMISSION COMPONENTS (CHAIN, GEARBOX AND REAR WHEEL BEARINGS) ARE GREATLY STRESSED.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE CHECK FRONT BRAKE FLUID LEVEL The reservoir is part of the front brake pump positioned on the handlebar and has an inspection window: with the tank in the horizontal position, the fluid level must never fall below the centreline on the inspection window. The SMR/SMM/SMX models are an exception as they have an independent transparent plastic tank . Also in this case, the fluid level must never fall below half of the tank .
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE REPLA CEMENT OF FR ONT BRAKE P ADS (A) REPLACEMENT FRONT PADS FOR ALL MODELS WITH FLOATING CALIPER (END/MX) Push the brake caliper towards the disc, in a way that the brake pistons reach their base position. Remove the safety devices (1), extract the pin (2) and remove the pads from the caliper. Use compressed air to clean the brake caliper and the caliper support, check that the driving pin seals are not damaged and, if necessary, grease them.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE MODIFICATION OF REAR BRAKE PED AL PEDAL BASE POSITION (A) The base position of the rear brake pedal can be modified in the following way: loosen counter-nut M6 (1) fork side, turn the adjustment screws by acting on the hexagonal head (2). Once the ideal position has been found, tighten the counter-nut. The pedal free play is given by the stroke of the pump piston; check that the pedal has a free play of about 1.5cm before starting to brake.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE CHECK REAR BRAKE P ADS PADS The brake pads must be controlled from the rear side. The thickness of the pad friction material must not be less than 1 mm. DANGER AT THE THINNEST POINT, THE THICKNESS OF THE BRAKE PAD FRICTION MATERIAL MUST NOT BE LESS THAN 1 MM, OTHERWISE A FAULT COULD OCCUR IN THE BRAKES. IN THE INTEREST OF YOUR SAFETY HAVE THE PADS REPLACED IN TIME.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE DISASSEMBL Y AND ASSEMBL Y OF REAR DISASSEMBLY ASSEMBLY WHEEL (SMM) 8 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE TYRES, TYRE PRESSURE TYRE TYRE PRESSURE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE DANGER - IF FOR SOME REASON THE ELECTROLYTE (SULPHURIC ACID) SHOULD ESCAPE FROM THE BATTERY, BE VERY CAREFUL. THE ELECTROLYTE CAN CAUSE SERIOUS BURNS. - ON CONTACT WITH THE SKIN, RINSE WELL WITH WATER - IF DROPS OF THE ELECTROLYTE ENTER INTO THE EYES, RINSE FOR AT LEAST 15 MINUTES WITH WATER AND CONSULT A DOCTOR IMMEDIATELY. - EVEN IF THE BATTERY IS SEALED, IT IS POSSIBLE THAT EXPLOSIVE GASES MAY COME OUT. KEEP THE BATTERY AWAY FROM SPARKS OR FLAMES.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE RECHARGE FUSE ((ALL ALL MODELS WITH 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 10 ampere fuse is also found in the starter relay (3).
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE REPLACEMENT OF HEADLIGHT/POSITION LIGHT BULB (WITH “CYCLOPS” OPTIONAL 19 21 HEADLIGHT END/SMR/SMM) Disconnect both of the elastic stripes and move the light-holder mask forward. 20 HEADLIGHT BULB Disconnect the terminal, remove the cover (13) and the seal (14). Unscrew the screws (15) and remove the retainer (16). Loosen the Allen screw (17) and carefully extract the bulb (18).
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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).
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE WARNING REPLACE THE FIBREGLASS CARTRIDGE WITH A NEW ONE OF THE SAME WEIGHT OR BOUGHT AT A TM AUTHORISED DEALER. CLEANING THE AIR FIL TER FILTER A dirty air filter jeopardises the filtering of air, reducing engine power and increasing fuel consumption. In some cases, the dust can even reach the engine causing derious damage. For this reason, maintenance of the filter should be carried out regularly.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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 (3). Loosen the counter-nut (4) and unscrew or screw the adjustment device (5). By screwing, the free play increases.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE CARBURETOR - IDLE SPEED ADJUSTMENT (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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE CHECK FUEL LEVEL (FL OAT HEIGHT) (A) (FLO 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).
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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).
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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.
FRAME FRAME AND AND ENGINE ENGINE MAINTENANCE MAINTENANCE 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 THAT THE FILTER CARTRIDGE CANNOT BE CLEANED, IT MUST BE REPLACED AT THE ENVISIONED INTERVALS. Prepare a measuring beaker with 1.4 (1.
OUBLESHOO TING TROUBLESHOO OUBLESHOOTING TR 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.
TROUBLESHOOTING PROBLEM THE ENGINE WILL NOT RUN AT IDLE SPEED SOLUTION CAUSE Clogged idle speed jet Disassemble the carburetor and clean the jet Altered idle speed adjustment screws Adjust the idle speed screws Damaged spark plug Replace the spark plug Faulty Ignition system Have the ignition system checked The fuel overflows because the level is adjusted Disassemble the carburetor and check the height of the float THE ENGINE DOES NOT too high or the float needle valve is dirty or worn REACH FUL
CLEANING 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 WATER! BECAUSE OF THE HIGH PRESSURE THE WATER COULD REACH THE ELECTRICAL PARTS, CONNECTORS, FLEXIBLE CABLE COMMANDS, BEARINGS, THE CARBURETOR ETC...
TECHNICAL D A DA ATA - ENGINE TECHNICAL D ATA - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200 8 DA 8 DA 2008 TECHNICAL ENGINE 250 END 250 250 MX/SMX SMM/SMR Type 450 SMM/SMR 449 cm3 77x53.6 mm Compression 95x63.4 mm 13.5 : 1 Fuel 11.5 : 1 12.2 : 1 11.5 : 1 unleaded fuel with min. 95 RON Distribution DOHC 4 valves driven by silent chain I / E camshafts A2 / N2 30 mm 30 mm Ti 24.5 mm 24.5mmTi Inlet valve cold clearance mm. 0.20 Exhaust valve cold clearance mm. 0.
TECHNICAL D ATA - ENGINE DA TECHNICAL D A DA ATA - ENGINE 530 END/MX/SMX/SMR/SMM - 660 SMX 2008 ENGINE 530 END 530 SMX 660 SMX 4 stroke single-cylinder DOHC , liquid cooled Type 528 cm3 Displacement Cylinder bore and stroke Compression 530 SMM/SMR 530 MX 657,5cm3 98x70 mm 11.3 : 1 104 x 77,4 mm 11.9 : 1 Fuel 11.3 : 1 12.4 : 1 12.4 : 1 unleaded fuel with min.
120 11.0 mm. 3.8 85.0 mm. 120 11.0 mm. 3.8 81.0 mm. 13.0 mm. Pilot Air Jet Float height Acc. pump rod length Stop screw project. 71 0% throttle 100% throttle Accelerator pump opening Accelerator pump closure Fuel entry nozzle 3,8 Pilot screw Float height 1,5 1.25 turn Throttle valve 35% throttle 0% throttle 3,8 1.25 turn 1,5 3rd 3rd Clip position 45 NCYP 50 NCYP Jet Needle Pilot Jet 100% throttle 0% throttle 3,8 1.
ENGINE TIGHTENING TOR QUES ORQ ENGINE TIGHTENING TORQUES Crankase Allen screws, transmission cover, clutch cover, ignition cover M6 10 Nm Oil drain screw cap M16x1.5 20 Nm Oil filler screw cap M20x1.5 20 Nm Oil net filter screw cap M28x1.
TECHNICAL D ATA - CY CLE P AR T DA CYCLE PAR ART TECHNICAL D A AR T 250/450/530 END - 250/450/530 MX 2008 DA CYCLE PAR ART AT TA A -- CY CYCLE P 450 END 250 END Frame 530 END 250 MX 530 MX 450 MX Twin-spar high resistance aluminium alloy frame Front suspension Marzocchi USD fork / Paioli USD fork (optional Ohlins USD) Rear/front suspension travel 300/315 mm Rear suspension Aluminium swing arm, Progressive mechanical linkage, Sachs rear shock (optional Ohlins) Front disc brake Ø 270 mm floatin
TECHNICAL DA CYCLE PAR ART DA CYCLE PAR ART TECHNICAL D AT TA A -- CY CLE P T TECHNICAL D ATA 250/450/530 SMR/SMM - 250/450/530/660 SMX 2008 DA 250/450/530 SMR 250/450/530 Frame SMM 250/450/530 SMX 660 SMX Twin-spar high resistance aluminium alloy frame Front suspension Marzocchi USD fork / Paioli USD fork (optional Ohlins USD) Rear/front suspension travel Rear suspension 270/280 mm Aluminium swing arm (Single-arm on SMM), Progressive mechanical linkage, Sachs shock (Ohlins optional) Ø 320 mm 4
ALPHABETIC INDEX Page ADVICE AND GENERAL RECOMMENDATIONS FOR COMMISSIONING THE MOTORCYCLE ........................................... 21 Adjustment of chain tension (all models except SMM).....................43 Adjustment of chain tension (SMM).................................................44 Adjustment of clutch lever basic position ....................................... 60 ALPHABETIC INDEX .......................................................................
BLACK-GREEN BLACK-YELLOW YELLOW RED BLACK-PURPLE SWITCH (BLACK BUTTON) ENGINE START (RED BUTTON) ENGINE RUN/STOP SKY BLUE (TO LIGHTS/HORN) NOT USED DC+ BLACK-YELLOW BLACK-GREEN BLACK REG/RECT BLACK-GREEN BLACK-YELLOW BLACK WHITE BROWN FURUKAWA 6 POLES CONNECTOR (REGULATOR SIDE) DC- BLACK-YELLOW RED-BLACK SUMITOMO 3 POLES FEMALE SUMITOMO 3 POLES MALE F68131 FUSIBILE 10A IMPERMEABILE IMP.
ACG PULSER 77 RED-WHITE YELLOW WHITE BLACK-RED SUMITOMO 4 POLES FEMALE SUMITOMO 4 POLES MALE BLACK-RED WHITE YELLOW RED-WHITE GREEN (-) WHITE (+) GREEN (-) WHITE (+) SPARK PLUG COIL BLACK-WHITE WHITE-BLUE SUMITOMO 2 POLES MALE SUMITOMO 2 POLES FEMALE KILL SWITCH SUMITOMO 2 POLES MALE BROWN WHITE-BLUE EXCITER + EXCITER NOT USED SIGNAL 6 7 8 9 BLUE BLACK YELLOW SUMITOMO 3 POLES MALE SUMITOMO 3 POLES FEMALE TPS SENSOR 19/05/05 BLUE RED TxD 12V 1 2 11 3 12 STATO MATERIALE
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