TM RACING 4 Stroke 2009, User And Maintenance Manual

Page 1: ...USER AND MAINTENANCE MANUAL USER AND MAINTENANCE MANUAL TM RACING USES and ADVICES TM RACING USES and ADVICES TM 4 STROKE 2009 ...

Page 2: ...ENGLISH ENGLISH 2 ...

Page 3: ... 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 IMPOR IMPOR IMPOR IMPOR IMPORT T T T TANT ANT ANT ANT ANT YOUAREADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM IT CONTAINS A LOT OF INFORMATION AND ADVICE THAT WIL...

Page 4: ...t 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 pro...

Page 5: ...cialised 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 u...

Page 6: ...ariation 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...

Page 7: ...ENGLISH ENGLISH ENGLISH 7 ...

Page 8: ...s 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 ENGINE NUMBER ENGINE NUMBER ENGINE 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 NUMBE...

Page 9: ...ENGLISH ENGLISH ENGLISH 9 ...

Page 10: ...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 su...

Page 11: ... 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 but...

Page 12: ... 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 ...

Page 13: ... far as possible a passage is opened in the carburetor through which the engine can suck additional fuel In this way a rich air fuel mix is obtained This is necessary for starting the engine when it is cold To disconnect the command push the choke knob inwards to its original position For KEIHIN carburetors Extract the knob and turn it clockwise to block it To disconnect it turn anticlockwise BY B...

Page 14: ... 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 PED GEA...

Page 15: ...UTES OUTES OUTES OUTES If you drive the motorcycle off road the closed side stand can be additionally fixed using a rubber band 2 IGNITION SWITCH IGNITION SWITCH IGNITION SWITCH IGNITION 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 ...

Page 16: ...OSITIONAND COUNTTHE NOTCHESDETECTEDSOTHATTHESTANDARDPOSITIONCANBERESTORED FOR CONVENTION THE NOTCHES ARE INDICATED FROM THE TOTALLY CLOSED POSITION BOTH RODS MUSTHAVETHE SAMEADJUSTMENT FORK ADJUSTMENT IN REBOUND FORK ADJUSTMENT IN REBOUND FORK ADJUSTMENT IN REBOUND FORK ADJUSTMENT IN REBOUND FORK ADJUSTMENT IN REBOUND The hydraulic dampening in extension determines the behaviour of the fork in the...

Page 17: ...s 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 decrea...

Page 18: ...NG BEFORE STARTING IT ISADVISED TO TIGHTEN THE ADJUSTER FROM THE STANDARD POSITIONTOTHE TOTALLYCLOSED POSITIONAND COUNTTHE CLICKS DETECTED SOTHATTHE STANDARD POSITION CAN BE RESTORED FORCONVENTION THENUMBEROFCLICKSISINDICATEDFROMTHE TOTALLY CLOSED POSITION THE DAMPER GAS TANK IS FILLED WITH PRESSURISED NITROGEN NEVER TRY TO DISASSEMBLE THE DAMPER OR CARRY OUT MAINTENANCE OPERATIONS WITHOUT THE HEL...

Page 19: ...ENGLISH ENGLISH ENGLISH 19 ...

Page 20: ...H NOCOMPROMISEFOROFF ROADCOMPETITIONS EVENIFTHEENDURO MODELSARETYPE APPROVED PAYATTENTIONWHENUSINGONTHE ROAD MOST OFALLAVOID SUSTAINED ACCELERATION CONSTANT THROTTLE ON LONG ROADS ROLL THE THROTTLE ON AND BACK SLIGHTLY ALWAYS WEAR SUITABLE CLOTHING WHEN USING THE MOTORCYCLE ASTUTE MOTORCYCLISTS THAT DRIVE A TM ALWAYS WEAR THE TYPE APPROVED HELMET BOOTS GLOVES ANDAJACKET WHETHER IT ISALONG OR SHORT...

Page 21: ...ENGLISH ENGLISH ENGLISH 21 ...

Page 22: ...re 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 o...

Page 23: ...LEAD TO RISK OF UNCONSCIOUSNESSAND DEATH WHEN THE ENGINEISRUNNING ALWAYSENSURETHEREISSUFFICIENTVENTILATION ALWAYS CHECK THAT THE GEAR IS IN NEUTRAL BEFORE OPERATING THE STARTER BUTTON IF A GEAR IS INSERTED WHEN STARTING THE ENGINE THE MOTORCYCLE WILL JUMP FORWARDS WARNING OPERATE THE STARTER FOR MAX 5 SECONDSATATIME WAITANOTHER 5 SECONDS BEFORETRYINGAGAIN DO NOTALLOW THE ENGINE REVS TO INCREASE TO...

Page 24: ...nsert 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 SHIFTING GEAR SHIFTING GEAR A A A A ACCELERA CCELERA CCELERA CCELERA CCELERATING TING TING TING TING SLOWING DOWN SLOWING DOWN ...

Page 25: ...ER OF REVS WHEN IT IS COLD NEGATIVELYAFFECTSTHEDURATIONOFTHEENGINE BEFOREUSINGTHE MOTORCYCLEATFULLWORKING CONDITIONS IT IS BETTERTO WARM IT ADEQUATELY BY DRIVING AT AN AVERAGE SPEED THE ENGINE HAS REACHED ITS WORKING TEMPERATURE AS SOON AS THE RADIATORS BECOMEHOT NEVERSHIFTDOWNAGEARWITHOUTHAVINGFIRSTSLOWEDDOWN THE ENGINE WOULD BE TAKEN TOAN EXCESSIVE NUMBER OF REVSANDTHE VALVESAND OTHER ENGINE COM...

Page 26: ...RE COULD BE A FAULT IN THE BRAKING SYSTEM INTHIS CASE IT IS AGOODIDEATOHAVETHEMOTORCYCLECHECKEDBYAN AUTHORISED TM DEALER ST ST ST ST STOPPING OPPING OPPING OPPING OPPING AND P AND P AND P AND P AND PARKING ARKING ARKING ARKING 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 em...

Page 27: ...E FUELWITHAN OCTANE NUMBER LOWERTHAN 95 BECAUSE THISWOULDDAMAGETHEENGINE FUEL IS HIGHLY INFLAMMABLE AND TOXIC HANDLE FUEL WITH GREAT CARE DO NOT FILL UP WITH FUEL NEAR TO FLAMES OR CIGARETTES ALWAYS SWITCH THE ENGINE OFF WHEN FILLING UP WITH FUEL NEVER POUR FUEL ONTO THE ENGINE OR ONTO THE EXHAUST PIPE IF ANY FUEL ISACCIDENTLY POURED ONTO THESE PARTS DRY IT IMMEDIATELY USING A CLOTH IF FUEL IS SWA...

Page 28: ...ENGLISH ENGLISH 28 ...

Page 29: ...ENGLISH ENGLISH ENGLISH 29 ...

Page 30: ...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 tigh...

Page 31: ...justment 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...

Page 32: ... EVERY AFTER EVERY AFTER EVERY W A S H W A S H W A S H W A S H W A S H BRIEF CHECK BRIEF CHECK BRIEF CHECK BRIEF CHECK BRIEF CHECK AND MAINTEN AND MAINTEN AND MAINTEN AND MAINTEN AND MAINTENANCE OPERA ANCE OPERA ANCE OPERA ANCE OPERA ANCE OPERATIONS TIONS TIONS TIONS TIONS T T T T TO BE PERFORMED BY O BE PERFORMED BY O BE PERFORMED BY O BE PERFORMED BY O BE PERFORMED BY THE RIDER PIL THE RIDER PIL...

Page 33: ...ECKING ITIS DETECTEDTHATTHE WEAR LIMITS OFASINGLE COMPONENT HAVE BEEN EXCEEDED THE COMPONENT MUST BE REPLACED THEINSTALLATIONOFANHOUR COUNTERINSTRUMENTISADVISED THEABOVE MENTIONED OPERATIONS MUSTBE CARRIED OUT BYANAUTHORISEDTM WORKSHOP CHECKS 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 CHECKS TO BE CARRIED OUT ON ENGI...

Page 34: ...END SMR SMM CHECKS 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 CHECKS 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 USE ROAD HOBBY USE ROAD HOBBY USE ROAD HOBBY USE ROAD HOBBY USE CHECKS TO BE CARRIED OUT ON ENGINE 250 450 530 END SMR SMM CHECKS TO BE CARRI...

Page 35: ...ENGLISH ENGLISH ENGLISH 35 ...

Page 36: ...WITHTHERESPECTIVEREGULATIONSOF YOUR COUNTRY DISPOSE OF WASTE OILINAREGULAR MANNER NEVER POUR OLD OILINTO DRAINS OR RIVERS CHECK OF STEERING BEARINGS CHECK OF STEERING BEARINGS CHECK OF STEERING BEARINGS CHECK OF STEERING BEARINGS CHECK OF STEERING BEARINGS AND PLA AND PLA AND PLA AND PLA AND PLAY Y Y Y Y ADJUSTMENT A ADJUSTMENT A ADJUSTMENT A ADJUSTMENT A ADJUSTMENT A Periodically check the play o...

Page 37: ...SCREWSBEFOREHAVING THESEALINGELEMENTSREPLACED CLEANING OF TELESCOPIC FORK DUST CLEANING OF TELESCOPIC FORK DUST CLEANING OF TELESCOPIC FORK DUST CLEANING OF TELESCOPIC FORK DUST CLEANING OF TELESCOPIC FORK DUST SCRAPER SCRAPER SCRAPER SCRAPER 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 ...

Page 38: ...EST ESTABLISHING REAR SHOCK ST ABLISHING REAR SHOCK ST ABLISHING REAR SHOCK ST ABLISHING REAR SHOCK ST ABLISHING REAR SHOCK STA A A A ATIC L TIC L TIC L TIC L TIC LO O O O OWERING WERING WERING WERING 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 tou...

Page 39: ... 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 BASIC CHECK TELESCOPIC FORK BASIC CHECK TELESCOPIC FORK BASIC CHECK TELESCOPIC FORK BASIC CHECK TELESCOPIC FORK BASIC CALIBRA CALIBRA CALIBRA CALIBRA CALIBRATION TION TION TION TION For several reasons the exact l...

Page 40: ... 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 tigh...

Page 41: ...PT 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...

Page 42: ...n the hub itself A A A A ATTENTION TTENTION TTENTION TTENTION TTENTION IFYOU DO NOTHAVE SUITABLE EXPERIENCE IT ISADVISEDTO HAVETHE OPERATION CARRIED OUTBYASPECIALISEDTM WORKSHOP CHAIN MAINTENANCE CHAIN MAINTENANCE CHAIN MAINTENANCE CHAIN MAINTENANCE CHAIN MAINTENANCE Chain duration depends most of all on maintenance Chains without O rings must be regularly cleaned with petroleum and then immersed ...

Page 43: ...ined 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 ...

Page 44: ...YWITHTHEBRAKELEVERATREST IF THEFREESTROKEISMISSING PRESSUREISFORMEDINTHEBRAKINGSYSTEM AND THE CONSEQUENCE CAN BE LACK OF FUNCTIONING OF THE FRONT WHEELBRAKE DUETO OVERHEATING OR BLOCKING OFTHE WHEELITSELF CHECK FLUID LEVEL CHECK FLUID LEVEL CHECK FLUID LEVEL CHECK FLUID LEVEL CHECK FLUID LEVEL The reservoir is part of the front brake pump positioned on the handlebar and has an inspection window 3 ...

Page 45: ...RONT 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 T...

Page 46: ...ns 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 ...

Page 47: ...EL 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 TOP UP REAR BRAKE FLUID A TOP UP REAR BRAKE FLUID A ALLTHEMODELS As soon as the level of rear brake fluid reaches the centreline on the window situated on the pump it must be topped up U...

Page 48: ...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 ALWAYS BE PERFECTLY CLEAN FROM OILAND GREASE OTHERWISE THE BRAKING EFFECT WOULD BE GREATLY REDUCED AFTER MOUNTING CHECK THAT THE SAFETY DEVICESARE POSITIONED CORRECTLY AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM ACTIVATE THE FRONT BRAKE LEVERAND THE REAR BRAK...

Page 49: ...tract 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 NOTACTIVATE THE BRAKE PEDALWHEN THE REAR WHEELHAS BEEN DISASSEMBLED ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO P...

Page 50: ...LEAN FROM OILAND GREASE ONTHECONTRARY THEBRAKINGEFFECTWOULDBEGREATLY REDUCED AFTER HAVING RE ASSEMBLED THE REAR WHEEL ALWAYS ACTIVATE THE BRAKE PEDALSO THAT THE PADSADHERE TO THE DISCAGAIN CHECK SPOKE TENSION CHECK SPOKE TENSION CHECK SPOKE TENSION CHECK 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...

Page 51: ...c 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 ma...

Page 52: ...ine 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 THECLOSURESTRIPMUST...

Page 53: ...END SMR SMM ARD HEADLIGHTD END SMR SMM 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 HEADLIGHTTWO LIGHTBULB Disconnect the blue black and white cables and remove the rubber protection 7 Release the retainer and carefully extract the bulb holder 8 Repla...

Page 54: ...VENTLEAVINGTRACESOFGREASE TOBESUREOFINSERTINGTHEESTABLISHEDBULBS CONSULTTHE CYCLE PARTTECHNICAL DATA TABLEs CICLOPS OPTIONAL HEADLIGHT END SMR SMM CICLOPS OPTIONAL HEADLIGHT END SMR SMM 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 lig...

Page 55: ...GHT 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 INDICA DIRECTION INDICA DIRECTION INDICA DIRECTION INDICA DIRECTION INDICAT T T T TOR...

Page 56: ... IFYOUARE BURNED PUT THE INTERESTED PART UNDER COLD RUNNING WATER THE COOLANT IS TOXIC THEREFORE PRESERVE IT OUT OF THE REACH OF CHILDREN IF YOU SWALLOW COOLANT SEEK MEDICAL ADVICE IMMEDIATELY IF THE COOLANT HITS THE EYES RINSE IMMEDITAELYWITH COLD WATER AND SEEK MEDICAL ADVICE The coolant liquid is a mixture of antifreeze at 40 and water at 60 The antifreeze protection limit must however be at le...

Page 57: ...T SILENCER REPLACEMENT OF EXHAUST SILENCER P P P P PA A A A ACKING MA CKING MA CKING MA CKING MA CKING MATERIAL TERIAL TERIAL TERIAL 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 ca...

Page 58: ...S 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...

Page 59: ... DO NOTALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE BRAKE FLUID CORRODESTHE PAINT ONLY USE CLEAN BRAKE FLUID OUT OF HERMETICALLY SEALED CONTAINERS HYDRAULIC CLUTCH BREMBO PUMP HYDRAULIC CLUTCH BREMBO PUMP HYDRAULIC CLUTCH BREMBO PUMP HYDRAULIC CLUTCH BREMBO PUMP HYDRAULIC CLUTCH BREMBO PUMP ADJUSTMENT OF CLUTCH LEVER BASIC POSITION With this option to adjust the clutch lever dista...

Page 60: ...ans 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 idl...

Page 61: ...ING CARBURET URET URET URET URETOR OR OR OR OR WEAR WEAR WEAR WEAR 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 LEVEL CHECK FUEL LEVEL CHECK FUEL LEVEL CHECK F...

Page 62: ...er 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 divide...

Page 63: ...e the only approved used and recommended by TM WARNING LOW OILLEVEL LOW QUALITYOILMAINTENANCE INTERVALS LONGERTHAN THOSE ESTABLISHED CAUSE SERIOUS DAMAGETOTHE ENGINE CHANGE ENGINE OIL A CHANGE ENGINE OIL A CHANGE ENGINE OIL A CHANGE ENGINE OIL A CHANGE ENGINE OIL A WARNING WHEN CHANGING THE OIL CLEAN THE MAGNET OF THE OIL DRAINBOLTANDREPLACETHEFILTERCARTRIDGE The oil must be changed with the engin...

Page 64: ...pletely 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 MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME ...

Page 65: ... the cap temporarily start up the engine and allow it to run for about 5 seconds DO NOTALLOW IT TO RUN LONGER TO 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 filt...

Page 66: ...s 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...

Page 67: ...sor 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 Checktherubbermanifoldsbetweenthefiltercaseandthecarburetor and between the carburetor and head and tighten the clamps THEENGINEOVERHEATS EXCESSIVELY There is not enough fluid in the cooling system Insufficient ventilation Air in the cooling ...

Page 68: ...lug 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 c...

Page 69: ...y oil SAE 10W 50API 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 1st 14 28 1st 15 27 1st 14 28 1st 14 28 1st 16 27 1st 14 28 2nd 17 25 2nd 17 25 2nd 17 25 2nd 17 25 2nd 17 24 2nd 17 25 3rd 19 23 3rd 19 23 3rd 19 23 3rd 19 23 3rd 16 19 3rd 19 23 4th 21 21 4th 21 21 4th 21 21 4th 21 21 4th 21 21 4th 21 21 5th 24 19 5th 23 2...

Page 70: ...e cold clearance Exhaust valve cold clearance Crankshaft supports Conrod bearing Small end plating Piston Rings Lubrication Engineoil 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 cm3 657 5cm3 98x70mm 1...

Page 71: ...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 RA TM RA TM RA TM RA TM RACING 4T CARB CING 4T CARB CING 4T CARB CING 4T CARB CING 4T CARBURET URET URET URET URETORS SETTING ORS SETTING ORS SETTING ORS SETTING ORS SETTING T T T T ...

Page 72: ...smission 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 fasteningAllen screws Allen screws for gear drum lock lever Ignition flywheel flanged nut Kickstart pedal screw Gear pedal Allen screw Exhaust manifold flanged nuts Genera...

Page 73: ...30 MX 530 MX 250 END 250 END 250 END 250 END 250 END 450 END 450 END 450 END 450 END 450 END 530 END 530 END 530 END 530 END 530 END 250 MX 250 MX 250 MX 250 MX 250 MX 450 MX 450 MX 450 MX 450 MX 450 MX TIGHTENING TORQUES 250 450 530 END 250 450 530 MX TIGHTENING TORQUES 250 450 530 END 250 450 530 MX TIGHTENING TORQUES 250 450 530 END 250 450 530 MX TIGHTENING TORQUES 250 450 530 END 250 450 530 ...

Page 74: ...SMX TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL DA A A A AT T T T TA 250 450 530 SMR SMM 250 450 530 660 SMX 2009 A 250 450 530 SMR SMM 250 450 530 660 SMX 2009 A 250 450 530 SMR SMM 250 450 530 660 SMX 2009 A 250 450 530 SMR SMM 250 450 530 660 SMX 2009 A 250 450 530 SMR SMM 250 450 530 660 SMX 2009 TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL DA A A A AT T T T TA 250 4...

Page 75: ...float bowl 62 Emptying filling and bleeding of the cooling system 57 Engine number 8 Engine oil 63 Engine stop switch MX SMX 11 ENGINETIGHTENINGTORQUES 72 Establishing rear shock lowering in running order 38Establishing rear shock static lowering 39 Fork adjustment in compression 16 Fork adjustment in rebound 16 Page FRAMEANDENGINEMAINTENANCE 35 Frame number 8 Front brake BREMBO radial pump SMR SM...

Page 76: ...ENGLISH ENGLISH 76 WIRING DIA WIRING DIA WIRING DIA WIRING DIA WIRING DIAGRAMS GRAMS GRAMS GRAMS GRAMS WIRING DIA WIRING DIA WIRING DIA WIRING DIA WIRING DIAGRAMS GRAMS GRAMS GRAMS GRAMS ...

Page 77: ...ENGLISH ENGLISH ENGLISH 77 WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS ...

Page 78: ...ENGLISH ENGLISH 78 ...

Page 79: ...ENGLISH ENGLISH ENGLISH 79 ...

Page 80: ...Grafica e Stampa SERIART Fabriano AN www seriart com ENGLISH Published and printed by Fabriano AN www seriart com SERIART SERIART TM 02 ed 12 08 ...