TM RACING 250Fi MX Use And Maintenance Manual Download

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4 S T R O K E S

HYDRAULIC CLUTCH PUMP

ADJUSTING THE LEVER POSITION

The position of clutch lever (1) compared to the grip can be changed with

adjusting knob (2). Turn knob (2) clockwise by clicks to move the lever

away or anticlockwise to move the lever closer.

WARNING

ONCE THE OPERATION IS COMPLETE, MAKE SURE THAT THE CLUTCH LEVER
HAS PLAY BEFORE ENGAGING THE CLUTCH.

CHECKING AND TOPPING UP THE HYDRAULIC FLUID LEVEL (A)

The fluid tank is part of the clutch pump located on the handlebar.

Remove screws (3), cover (4), and membrane (5). The fluid level must

be equal to 5 mm below the edge with the tank in horizontal position.

Top-up if required. Use DOT4 brake hydraulic fluid. Reassemble the

membrane, cover, and tighten the screws. Use water to wash away any

hydraulic fluid that overflowed or was spilled.

- IF THE LEVEL OF THE HYDRAULIC FLUID DROPS BELOW THE ESTABLISHED

MEASUREMENT THERE MIGHT BE LEAKS IN THE SYSTEM OR A MECHANICAL
PROBLEM.

- STORE THE HYDRAULIC FLUID OUT OF THE REACH OF CHILDREN.
- THE HYDRAULIC FLUID MAY IRRITATE SKIN. AVOID CONTACT WITH SKIN AND

EYES. IF THE HYDRAULIC FLUID SPLASHES IN THE EYES RINSE CAREFULLY
WITH WATER AND SEEK MEDICAL ADVICE.

WARNING

- ONLY USE DOT4 BRAKE HYDRAULIC FLUID FOR THE CLUTCH HYDRAULIC

CONTROL. NEVER USE DOT5 OR OTHER FLUIDS.

- KEEP THE BRAKE HYDRAULIC FLUID FROM COMING INTO CONTACT WITH

PAINTED PARTS. BRAKE FLUID CORRODES PAINT.

- ONLY USE CLEAN BRAKE FLUID COMING FROM HERMETICALLY-SEALED

CONTAINERS.

BLEEDING HYDRAULIC CLUTCH (A)

Disassemble the cover of the clutch pump on the handlebar to bleed the

air. Connect the suction device to bleeder screw (1) of the clutch cylinder

on the engine and activate it while loosening bleeder screw (1). Continue

until only fluid comes out of the bleeder screw (1).

Tighten bleeder screw (1). Disconnect the suction device. During this

operation make sure that the clutch pump tank level is always suffi-

cient to prevent the pump from collecting air. Top-up with DOT4 brake

hydraulic fluid, when required.

WARNING

- USE DOT4 BRAKE HYDRAULIC FLUID FOR THE CLUTCH HYDRAULIC CON-

TROL. NEVER USE DOT5 OR OTHER FLUIDS.

- KEEP THE BRAKE FLUID FROM COMING INTO CONTACT WITH PAINTED

PARTS. BRAKE FLUID CORRODES PAINT.

- ONLY USE CLEAN BRAKE FLUID COMING FROM HERMETICALLY-SEALED

CONTAINERS

DANGER

4.2 CHASSIS MAINTENANCE

Summary of Contents for 250Fi MX

Page 1: ...www tmracing it USE AND MAINTENANCE MANUAL 4 STROKES USE AND MAINTENANCE ...

Page 2: ...2 4 T E M P I 4 T E M P I ...

Page 3: ...rcycles with standard engine regardless of the type of use Code 3 Type of use alone means that the information refers to all motorcycles with that type of use regardless of the displacement and power source All END SMR SMM models are equipped with electric start E S as per standard in addition to the kick starter K S the MX SMX models are equipped with K S as per standard and the E S is optional R...

Page 4: ...ems to TM always specify model displacement year of manufacture and serial number of the frame and of the engine IMPORTANT WE RECOMMEND READING THIS MANUAL CAREFULLY BEFORE STARTING TO USE YOUR TM MOTORCYCLE THIS MANUAL CONTAINS INFORMATION AND SUGGESTIONS THAT WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE EASIER AND SAFER IT IS IN YOUR SPECIFIC INTEREST TO PAY SPECIAL ATTENTION TO THE WARNI...

Page 5: ... updates or report problems to TM always specify the model displacement year of manu facture and serial number of the frame and the engine Use the fuels and lubricants indicated in the use and maintenance manual as described in the maintenance sched ule Products of different brands cannot be used unless they have equivalent specifications In case of direct or indirect damage due to tampering with ...

Page 6: ...ssembling rear wheel SMM Checking spoke tension Tyres tyre pressure TABLE OF CONTENTS 4 S T R O K E S 1 IDENTIFICATION OF THE VEHICLE 1 1 POSITION OF THE SERIAL NUMBERS AND CODES Frame serial number Engine serial number Kayaba fork code TM shock absorber code 2 CONTROL COMPONENTS 2 1 HANDLEBAR CONTROLS Hydraulic clutch lever Manual decompression lever ALL 530F NISSIN pump front brake lever EN MX B...

Page 7: ...e 81 86 6 TECHNICAL DATA Page 87 93 7 WIRING DIAGRAMS Page 95 101 TABLE OF CONTENTS 4 S T R O K E S 7 62 63 65 65 66 66 66 66 67 68 69 69 69 70 70 70 71 71 72 73 73 74 75 75 75 76 76 77 77 77 78 78 79 80 81 82 84 86 87 88 88 88 89 90 90 91 92 93 93 95 96 97 98 99 100 101 102 Checking speedometer magnetic sensor distance EN SMR SMM Fuel tank Battery all models with E S Charging the battery Recharge...

Page 8: ......

Page 9: ...1 VEHICLE IDENTIFICATION ...

Page 10: ... also indicated on a nameplate located on the left side of the EN SMR SMM models See photo ENGINE SERIAL NUMBER The engine serial number is engraved on the left of the engine under the chain pinion Write this number in the specific box on page 4 KAYABA FORK CODE The fork code is a capital letter printed inside each foot TM SHOCK ABSORBER CODE The shock absorber code is printed on an adhesive label...

Page 11: ...4 S T R O K E S 11 4 S T R O K E S 2 CONTROL COMPONENTS ...

Page 12: ...tor has trouble hot starting To ventilate the engine pull the decompression lever during start up NISSIN PUMP FRONT BRAKE LEVER EN MX The Nissin front brake pump 1 is located on the right side of the handle bar The front brake lever 2 activates the front wheel brake The position of the front lever compared to the grip can vary according to the rider s preference See chapter 4 2 Chassis Maintenance...

Page 13: ...ction to decrease it Make sure the grip always has 4 5 mm of free play See chapter 4 3 Engine Maintenance page 73 COMBINATION SWITCH EN The combination switch 1 is located near the left handlebar grip It is very intuitive to use The lights are off when the rotating ring nut 2 is positioned with symbol 3 aligned with symbol 4 on the switch To turn on the position lights rotate the ring nut 2 anticl...

Page 14: ...ccessories The engine does not start even with the kick starter On these models put it in this position to switch the engine off We recommend leaving it this way until the next engine start to prevent the battery from discharging On the other hand when pushed out it closes contact with the battery and enables all the accessories including the electric start For this reason never leave it in this p...

Page 15: ...his control for a maximum of 8 10 seconds at a time and wait a few seconds before trying again After 3 4 attempts stop and try to identify whether there is a problem Never press this button when the engine is already running ENGINE STOP BUTTON MX SMX The engine stop button 1 is located near the left grip on the handlebar Press this button to switch the engine off and release it as soon as it is of...

Page 16: ... h to MPH or vice versa Briefly press SELECT 7 times to end the modification and return to the normal screen The trip odometer can be reset by holding the ADJUST button down for 5 seconds The total odometer resets automatically when it reaches 99999 Km or miles DIGITAL ELECTRONIC SPEEDOMETER SMR SMM The digital electronic speedometer SMR SMM 1 consists of a large back lit display and a series of i...

Page 17: ...to activate the mechanism with your foot to start the engine Starting from the highest position push the starter all the way down using quick continuous movements Once the engine has started fold the pedal inwards REAR BRAKE PEDAL The brake pedal 1 is located in front of the right hand footrest The basic position can be adjusted according to the rider s preference See chapter 4 2 Chassis Maintenan...

Page 18: ... THE LEFT TANK CAP The fuel cap 1 is located on top of the tank To open it unscrew the tank cap by rotating it anticlockwise To close it place the tank cap on the filler neck and rotate it clockwise Arrange the tank bleeder hose 2 avoiding bends or crushing and make sure it is inserted correctly FUEL TAP 450F SMR SMM ALL 530F The tap 1 is found on the left side of the engine at the bottom of the t...

Page 19: ...MR SMM The choke lever 1 is located on the right side of the handlebar near the starter and kill switch Activate this lever to facilitate engine start under particular conditions Using your thumb press it all the way down and keep it pressed to ac tivate it The device disengages automatically once the lever is released COLD START KNOB 450F SMR SMM ALL 530F The cold start knob 1 is located on the l...

Page 20: ... on the left side of the motorcycle Rotate the idle adjustment knob to raise or lower the engine idle speed IDLE ADJUSTMENT KNOB 450F SMR SMM ALL 530F The idle adjustment knob 1 is located on the left side of the motorcycle Rotate the idle adjustment knob to raise or lower the engine idle speed 2 4 OTHER CONTROLS 1 ...

Page 21: ...4 S T R O K E S 21 4 S T R O K E S 3 USE INSTRUCTIONS ...

Page 22: ... RIDE A TM ALWAYS WEAR APPROVED HELMET BOOTS GLOVES AND JACKET BOTH FOR LONG JOURNEYS AND SHORT DISTANCES PROTECTIVE GEAR SHOULD BE HIGHLY VISIBLE TO ALLOW OTHER DRIVERS ON THE ROAD TO RECOGNISE THE BIKER IMMEDIATELY ALWAYS TURN ON THE HEADLIGHT DURING TRAVELS IN ORDER TO BE IMMEDIATELY VISIBLE TO OTHER DRIVERS DO NOT DRIVE AFTER CONSUMING ALCOHOLIC BEVERAGES ALWAYS USE TM ORIGINAL ACCESSORIES FOR...

Page 23: ...rease it A total number of 19 clicks is available WARNING DO NOT TOUCH THE BLEED VALVE 2 WARNING BEFORE STARTING WE RECOMMEND TIGHTENING THE ADJUSTER FROM THE STAND ARD POSITION TO THE ALL CLOSED POSITION AND COUNTING THE CLICKS WRITE DOWN THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD AD JUSTMENT THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ALL CLOSED POSITION BOTH RODS MUST BE...

Page 24: ...AILED INFORMATION ON THE FORKS REFER TO THE INSTRUCTIONS SUPPLIED BY THE FORK MANUFACTURER SHOCK ABSORBER COMPRESSION ADJUSTMENT The compression hydraulic brake system determines how the shock absorber behaves in the compression phase The degree of compres sion hydraulic braking can be adjusted to the rider s preference and or installed spring rate The shock absorbers fitted on TM motorcycles allo...

Page 25: ...ated on the top right of the shock absorber gas tank Use a 17 mm hex wrench and align marks I II and III with the reference notch Position I soft Position II medium Position III hard WARNING BEFORESTARTING WERECOMMENDTIGHTENINGTHEADJUSTERFROMTHESTANDARD POSITION TO THE ALL CLOSED POSITION AND COUNTING THE CLICKS WRITE DOWN THE NUMBER OF CLICKS IN ORDER TO BE ABLE TO RESTORE STANDARD ADJUSTMENT THE...

Page 26: ...R TO BE ABLE TO RE STORE STANDARD ADJUSTMENT THE NORM IS TO COUNT THE CLICKS STARTING FROM THE ALL CLOSED POSITION THE GAS TANK OF THE SHOCK ABSORBER IS FILLED WITH HIGH PRESSURE NITROGEN NEVER TRY TO DISASSEMBLE THE SHOCK ABSORBER OR PERFORM MAINTENANCE WITHOUT THE HELP OF TECHNICIANS IN ORDER TO PREVENT DAMAGE TO PERSONS OR OBJECTS VARYING PRE LOAD AND REPLACING SHOCK ABSORBER SPRING The spring ...

Page 27: ... load or clockwise seen from above to increase it After adjusting tighten the locking screw 1 OHLINS TTX SHOCK ABSORBER OPT SMX ONLY Loosen the upper clamp 1 with a 4 mm Allen key and rotate the adjustment ring nut 2 Rotate it clockwise seen from above to increase the pre load or anticlockwise seen from above to decrease it After adjusting tighten the upper clamp 1 3 2 ADJUSTING SUSPENSIONS 1 2 1 ...

Page 28: ...d the shock absorber To check for correct spring rate first measure the motorcycle sag Then adapt the compression and rebound braking For technical clarifications on the operation and calibration of the TM motorcycle suspensions refer to the nearest TM dealer ADAPTING FORK BASE CALIBRATION Exact fork sag cannot be established for several reasons Minor variations of your body weight may be compensa...

Page 29: ...ying pre load and replacing shock absorber spring chapter CHECKING SHOCK ABSORBER RIDER SAG Correct shock absorber rider sag should correspond to a lowering of the motorcycle of about 90 105 mm Procedure Ask someone to help you hold the motorcycle Sit on the bike wearing full protective gear in normal position feet on the footrests and bounce up and down a couple of times to normalise the rear sus...

Page 30: ... air pressure and bring it back to the values indicated in the tables if required Worn tread and unsuitable air pressure affect motorcycle driveability and may cause loss of control and serious accidents BRAKES page 53 Check correct operation Check the level of the brake fluid The tanks located on the pumps are sized in such a way that in case of normally worn brake pads the fluid does not need to...

Page 31: ...ent conditions road easy off road stretches Do not make long journeys without ever closing the throt tle Progressively increase and reduce the opening of the throttle alternating acceleration and deceleration with short periods of constant speed Make sure that the coolant does not reach excessive temperatures defined by fluid leaking from the bleeder hose By following these rules you will obtain m...

Page 32: ...ift into neutral gear page 17 4 Activate the cold start knob page 19 5 With the throttle fully closed use the kick starter page 17 or in models with E S the starter EN SMR SMM page 14 or the start engine button MXE S SMXE S page 15 6 Warm up the engine by accelerating gently and after about 30 seconds disengage the cold start knob Use the adjustment knob if the engine has a low and irregular idle ...

Page 33: ... 35 C 1 Open the fuel tap page 18 2 Retract the side stand page 17 3 Shift into neutral gear page 17 4 Activate the hot start knob page 19 5 With the throttle fully closed use the kick starter page 17 or in models with E S the starter EN SMR SMM page 14 or the start engine button MXE S SMXE S page 15 6 Use the adjustment knob if the engine has a low and irregular idle speed page 20 The idle speed ...

Page 34: ...thus flooding the engine The subsequent re start may be difficult In this case proceed as follows 1 Shift into neutral gear page 17 2 Activate the hot start knob page 19 3 With the throttle fully closed use the kick starter page 17 On 530 cc models equipped with a manual decompressor pull the manual decompression lever page 12 while using the kick starter pedal page 17 5 10 times to eliminate the ...

Page 35: ...WET GROUND BRAKING COULD BE DELAYED BECAUSE OF WET OR DIRTY BRAKE DISCS THEREFORE USE THE BRAKES REPEATEDLY AND CAUTIOUSLY BEING SURE NOT TO OBSTRUCT TRAFFIC UNTIL THE DISCS ARE DRY AND CLEAN BRAKING CAN BE DELAYED EVEN WHEN TRAVELLING ON DIRTY ROADS OR ROADS COVERED WITH SALT ALSO IN THIS CASE THE BRAKES MUST BE ACTIVATED REPEATEDLY AND WITH CAUTION BEING CAREFUL NOT TO OBSTRUCT TRAFFIC UNTIL THE...

Page 36: ...E ENGINE PARK THE MOTORCYCLE IN SUCH A WAY AS TO PREVENT PEDESTRIANS FROM TOUCHING IT AND BURNING THEMSELVES WARNING DO NOT SWITCH OFF THE ENGINE WITH THE DECOMPRESSION LEVER IF AVAILABLE USE THE ENGINE STOP BUTTON OR THE EMERGENCY KILL SWITCH THE FUEL TAP IF AVAILABLE MUST ALWAYS BE CLOSED WHEN YOU PARK THE MOTORCYCLE IF THE TAP IS NOT CLOSED PROPERLY FUEL COULD LEAK INTO THE CARBURETTOR AND PENE...

Page 37: ... 95 NEVER USE PETROL WITH AN OCTANE NUMBER LOWER THAN 95 AS IT WOULD DAMAGE THE ENGINE FUEL EXPANDS WHEN HEATED THEREFORE IN HIGH AMBIENT TEMPERA TURES DO NOT FILL THE TANK UP TO THE UPPER EDGE PETROL IS HIGHLY FLAMMABLE AND TOXIC HANDLE PETROL WITH THE UTMOST CARE DO NOT FILL UP WITH PETROL NEAR FLAMES OR LIT CIGARETTES ALWAYS SWITCH THE ENGINE OFF WHEN FILLING UP WITH PETROL NEVER POUR PETROL ON...

Page 38: ...WHERE SALT HAS BEEN SPREAD WASH THE MOTORCYCLE WELL WITH COLD WATER AND LET IT DRY COM PLETELY STORAGE Take the following measures if the motorcycle is to be left unused for a long period Carefully clean the motorcycle see WASHING chapter Change the engine oil and the cartridge oil filter pages 79 80 Old oil contains harmful impurities Check the coolant level page 70 Only for 450F SMR SMM and ALL ...

Page 39: ...4 S T R O K E S 39 4 S T R O K E S 4 MAINTENANCE ...

Page 40: ...ditions and seal of brake pipes Check operation regulation smoothness and free play of front brake lever and rear brake pedal Check brake system screws tightness Check wheel hubs spoke tension and rim centring Check wheel bearing play Check tyre conditions and pressure Check battery and charge if required Grease battery connections with grease for contacts Grease electrical contacts and switches w...

Page 41: ...D AT A LOWER COST Check distribution chain Replace distribution chain Check cylinder and piston wear Fully replace piston Check head Check camshafts and rocker arms Replace valves springs half cones and plates Fully replace piston rod Check clutch discs Check clutch springs Check transmission and gear Check oil pumps and lubrication circuit Fully replace engine bearings Fully replace engine oil se...

Page 42: ...s and seal of brake pipes Check operation regulation smoothness and free play of front brake lever and rear brake pedal Check brake system screws tightness Check wheel hubs spoke tension and rim centring Check wheel bearing play Check tyre conditions and pressure Check and charge battery only models with E S Grease battery connections with grease for contacts only for models with E S Grease electr...

Page 43: ...LEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST Check head Check camshafts and rocker arms Replace valves springs half cones and plates Fully replace piston rod Check clutch discs Check clutch springs Check transmission and gear Check oil pumps and lubrication circuit Fully replace engine bearings Fully replace engine oil seal EVERY 10 HOURS AFTER EVERY RIDE EVERY 20 HOURS EVERY 30...

Page 44: ...eal of brake pipes Check operation regulation smoothness and free play of front brake lever and rear brake pedal Check brake system screws tightness Check wheel hubs spoke tension and rim centring Check wheel bearing play Check tyre conditions and pressure Check and charge battery Grease battery connections with grease for contacts Grease electrical contacts and switches with spray for contacts Ch...

Page 45: ... Replace spark plug and check cap Check valve clearance Check distribution chain Replace distribution chain Check cylinder and piston wear Fully replace piston Check head Check camshafts and rocker arms 450Fi Check camshafts and cups 450F 530F Replace valves springs half cones and plates Fully replace piston rod Check clutch discs Check clutch springs Check transmission and gear Check oil pumps an...

Page 46: ...f brake pipes Check operation regulation smoothness and free play of front brake lever and rear brake pedal Check brake system screws tightness Check wheel hubs spoke tension and rim centring Check wheel bearing play Check tyre conditions and pressure Check and charge battery only models with E S Grease battery connections with grease for contacts only models with E S Grease electrical contacts an...

Page 47: ...KED MORE QUICKLY AND AT A LOWER COST Replace distribution chain Check cylinder and piston wear Fully replace piston Check head Check camshafts and rocker arms 450Fi Check camshafts and cups 450F 530F Replace valves springs half cones and plates Fully replace piston rod Check clutch discs Check clutch springs Check transmission and gear Check oil pumps and lubrication circuit Fully replace engine b...

Page 48: ...REASE FUELS DETERGENTS ETC IN COMPLIANCE WITH THE STANDARDS IN FORCE IN YOUR COUNTRY DISPOSE OF EXHAUST OIL ACCORDING TO THE STANDARDS IN FORCE NEVER POUR EXHAUST OIL INTO DRAINS OR RIVERS CHECKING STEERING BEARING AND PLAY ADJUSTMENT A Periodically check steering bearing play Position the motorcycle to allow the front wheel to be lifted Turn the handlebar in both directions and move the fork back...

Page 49: ...eed the air Tighten screw 1 again Before using the screw put motorcycle up on its stand so that the front wheel does not touch the ground If the motorcycle is used mostly on the road it is sufficient to carry out this operation only during periodi cal maintenance WARNING EXCESSIVE PRESSURE INSIDE THE FORK MAY CAUSE OIL TO LEAK FROM THE FORK SHOULD YOUR FORK LEAK OIL TRY BLEEDING THE AIR BEFORE REP...

Page 50: ... GEARBOX SHAFT CAN BREAK INSTEAD IF THE CHAIN TENSION IS INSUFFICIENT IT CAN JUMP OFF THE PINION AND LOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN BOTH CASES YOU CAN EASILY LOSE CONTROL OF YOUR MOTORCYCLE CORRECTING CHAIN TENSION EN MX SMR SMX Loosen nut 1 of the wheel pin and counter nuts 2 and turn adjustment screws 3 to the right and left by the same measurement To increase the chain tension loos...

Page 51: ...in hot oil specific for chains or be treated with spray specific for chains Main tenance of chains with O ring is minimised The best cleaning method is using plenty of water Never use brushes or solvents to clean the chain Once the chain is dry use a spray specific for chains with O ring PREVENT THE LUBRICANT FROM REACHING THE REAR TYRE AND THE BRAKE DISC OTHERWISE THE REAR WHEEL S ADHERENCE TO TH...

Page 52: ...ACTWITHSKIN AND EYES IF THE HYDRAULIC FLUID SPLASHES IN THE EYES RINSE CAREFULLY WITH WATER AND SEEK MEDICAL ADVICE WARNING ONLY USE DOT4 BRAKE HYDRAULIC FLUID FOR THE CLUTCH HYDRAULIC CONTROL NEVER USE DOT5 OR OTHER FLUIDS KEEP THE BRAKE HYDRAULIC FLUID FROM COMING INTO CONTACT WITH PAINTED PARTS BRAKE FLUID CORRODES PAINT ONLY USE CLEAN BRAKE FLUID COMING FROM HERMETICALLY SEALED CONTAINERS BLEE...

Page 53: ...fferent points BRAKE DISCS WITH WEAR EXCEEDING 0 4 MM ARE A SAFETY RISK IM MEDIATELY REPLACE THE BRAKE DISCS AS SOON AS WEAR LIMITS ARE REACHED IT IS MANDATORY TO HAVE THE BRAKE SYSTEM REPAIRED BY AN AUTHOR ISED TM WORKSHOP BRAKE FLUID RESERVOIRS The brake fluid reservoirs of the front and rear brake are sized so that topping up is not necessary even if the brake pads are worn In fact when the pad...

Page 54: ...tion indicator 3 With the tank in horizontal position the fluid level must never drop below the indicator centreline IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BE YOND THE LIMITS ALLOWED TOPPING UP BRAKE FLUID A Remove screws 4 cover 5 and membrane 6 Place the tank horizon tally and top up with DOT4 brake fluid up ...

Page 55: ... upright position the fluid level must always be within the MAX and MIN indexes IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED TOPPING UP BRAKE FLUID A Loosen and remove cover 3 and membrane 4 Place the tank upright and top up with DOT4 brake fluid up to the tank s MAX index Remount the membra...

Page 56: ...right and top up with DOT4 brake fluid up to the tank s MAX index Reassemble the membrane the cover and tighten Use water to wash away any brake fluid that has overflowed or was spilled STORE BRAKE FLUID OUT OF THE REACH OF CHILDREN BRAKE FLUID MAY IRRITATE SKIN AVOID CONTACT WITH SKIN AND EYES IF THE BRAKE FLUID SPLASHES IN THE EYES RINSE CAREFULLY WITH WATER AND SEEK MEDICAL ADVICE WARNING KEEP ...

Page 57: ... pads and put in the new ones Repeat the operation for the other pair of pads Press the two hooks again and reinsert the pins Make sure they are all the way in have their play and are hooked correctly Assemble the callipers and tighten the M10 screws by 40 Nm FOR MODELS WITH FIXED CALLIPERS OPT SMX RADIAL CONNECTION Raise the pads to allow the pistons to return to their standard position Remove th...

Page 58: ...pump body IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE COMPLETELY WORN TOPPING UP REAR BRAKE FLUID A Top up as soon as the rear brake fluid level reaches the centreline of the indicator located on the pump body For this purpose loosen the two screws 1 and remove the cover 2 Top up with DOT4 brake fluid up to the end ...

Page 59: ...e new pads paying attention to the position of the fins Insert the pin and tighten it Reassemble the cap with a screwdriver Tighten firmly FOR MODELS WITH FIXED CALLIPERS SMM Remove the safety ring 1 and the pin 2 using a pin punch with a 4 mm diam on the same side as the safety ring AFTERASSEMBLYMAKESURETHATTHESAFETYDEVICESAREPOSITIONED CORRECTLY AFTER EVERY OPERATION ON THE BRAKE SYSTEM ACTIVATE...

Page 60: ...Unscrew the flanged nut 1 and holding up the wheel slide out the wheel pin 2 remove the chain tensioner slide 3 the calliper with its support take the chain off the sprocket and carefully remove the rear wheel from the swing arm Pay attention to the low wheel sprocket side and high wheel brake side spacers WARNING NEVER ACTIVATE THE BRAKE PEDAL WHEN THE REAR WHEEL IS DISASSEM BLED ALWAYS POSITION ...

Page 61: ...INCORRECTLY TIGHTENED WHEEL PIN MAY MAKE THE MOTORCYCLE UNSTABLE AFTER HAVING ASSEMBLED THE REAR WHEEL ACTIVATE THE FRONT BRAKE PEDAL REPEATEDLY AND MAKE THE PADS ADHERE TO THE DISC CHECK THE BRAKE FLUID LEVEL THE BRAKE DISC MUST ALWAYS BE FREE OF OIL AND GREASE TO AVOID SIGNIFICANTLY REDUCING THE BRAKING EFFECT CHECKING SPOKE TENSION Correct spoke tension is important for the stability of the whe...

Page 62: ...IONS PURSUANT TO THE REGULATIONS IN FORCE IN YOUR COUNTRY TO GUARANTEE YOUR SAFETY AND THE SAFETY OF OTHERS DAMAGED TYRES MUST IMMEDIATELY BE REPLACED EXCESSIVELY WORN TYRES NEGATIVELY AFFECT MOTORCYCLE PERFORM ANCE ESPECIALLY ON WET SURFACES INCORRECT PRESSURE CAUSES ANOMALOUS WEAR AND TYRE OVERHEAT ING CHECKING SPEEDOMETER MAGNETIC SENSOR DISTANCE EN SMR SMM A The magnetic sensor is located on t...

Page 63: ...tting 7 on the tank Prevent dust and dirt from entering the fuel pipe as the fuel pump or injector could be clogged To reassemble the tank position it on the frame and reconnect the fuel fitting by pressing the female part towards the male part until they click Place the tank between the two bands of the frame up to the end of travel Screw in the centre screw 4 and those of the two conveyors witho...

Page 64: ...e fuel pipe 5 on the male fitting of the fuel tap 6 pressing all the way in Make sure the elastic band is positioned correctly Place the tank between the two bands of the frame up to the end of travel Screw in the centre screw 4 and those of the two conveyors without tightening Tighten them once they are all screwed in Reinsert the bleeder hose in the steering head FUEL IS EASILY FLAMMABLE AND TOX...

Page 65: ...AND OPEN FLAMES KEEP FAULTY BATTERIES AWAY FROM CHILDREN AND DISPOSE OF THEM IN COMPLIANCE WITH THE STANDARDS IN FORCE WARNING DO NOT REMOVE THE SEALING STRIP 2 AS THE ADJUSTER STRAIGHTENER WOULD BE DESTROYED THE BATTERY MUST BE ASSEMBLED WITH THE POLES TOWARDS THE OPERA TOR SEE FIGURE AS ELECTROLYTE MAY COME OUT IF IT IS ASSEMBLED THE OTHER WAY ROUND STORAGE If the motorcycle is unused for a long...

Page 66: ...lder The fuse has a capacity of 10 Ampere This protects the lighting system turn signals and horn WARNING IMMEDIATELY REPLACE A BURNT FUSE WITH AN EQUIVALENT ONE SHOULD THE NEW FUSE ALSO BURN OUT AFTER BEING ASSEMBLED IMMEDIATELY REFER TO A SPECIALISED TM WORKSHOP NEVER ASSEMBLE A FUSE OF GREATER CAPACITY OR TRY TO REPAIR THE SAME FUSE UNSUITABLE TREATMENTS MAY DAMAGE THE ENTIRE ELECTRICAL SYSTEM ...

Page 67: ...of the headlight Turn it clockwise to lift it or anticlockwise to lower it REPLACING HEADLIGHT BULB Release both elastic straps and move the headlight holder mask for ward Disconnect the centre connector and remove the rubber protection 1 Release the retainer and carefully remove the halogen bulb 2 Assemble the new bulb rubber protection 1 and the connector Reposition the headlight holder mask and...

Page 68: ...Release both elastic straps and move the headlight holder mask for ward Remove the rubber protection 7 loosen the retaining screw 8 and carefully remove the bulb 9 Assemble the new bulb and tighten the retaining screw 8 paying at tention to insert the eyelet terminal under the screw head Reassemble the rubber protection 7 Reposition the headlight holder mask and secure it with the elastic straps R...

Page 69: ...LATE LIGHT Loosen the screws 1 and remove the cover 2 Replace the bulb with an equivalent one Reassemble the cover 2 and tighten the screws The bulb is dual intensity and carries out all the functions mentioned above WARNING NEVER TOUCH THE GLASS BULB WITH YOUR FINGERS TO PREVENT LEAVING TRACES OF GREASE REFER TO TABLE 6 1 CHASSIS TECHNICAL DATA OF YOUR MODEL TO BE SURE YOU INSTALL THE CORRECT BUL...

Page 70: ...UNDER EXTREME WEATHER CONDITIONS OR IN STOP AND GO TRAFFIC THIS PROBLEM IS SOLVED BY AN ELECTRIC FAN KIT WHICH IS AVAILABLE FOR MODELS WITH ELECTRIC STARTER ASK YOUR TM DEALER CHECKING COOLANT LEVEL When the engine is cool open the radiator filler cap The fluid must cover the radiator channels by about 10 mm If the level is insufficient immediately top up with other mixed fluid and bleed the air U...

Page 71: ...ATER AND SEEK MEDICAL ADVICE WARNING ONCE THE COOLANT HAS BEEN DRAINED WHEN YOU FILL IT UP AGAIN IT IS ABSOLUTELY NECESSARY TO BLEED THE COOLING SYSTEM ALWAYS USE HIGH QUALITY PRODUCTS TO PREVENT CORROSION OR FOAM FROM FORMING REPLACING EXHAUST SILENCER PACKING MATERIAL A COMPETITION SILENCER MX SMX The competition silencer is fully packed with soundproof material fibre glass to limit the motorcyc...

Page 72: ... with new rivets Be sure to position the band 4 correctly Reassemble the motorcycle silencer Grease the ends of the pipes to make assembling the silencer easier Secure the seal spring between the pipe and silencer Upon starting the engine smoke can escape from greased parts due to the high temperature that melts the grease used ATTENTION DANGER OF BURNS THE EXHAUST SYSTEM BECOMES VERY HOT WHEN THE...

Page 73: ... OR DIRT INTO THE ENGINE CHECKING MANUAL DECOMPRESSOR ADJUSTMENT ALL 530F A Bring the engine shaft to the UDP with closed valves and use the manual decompression lever There must be 5 mm of play at the end of the lever The end of play corresponds to the point where the lever hardens as it starts to open the right hand discharge valve Adjust play if necessary In order to do so move the protective c...

Page 74: ...ster 5 until you obtain the play required Tighten the adjuster to increase play Loosen the adjuster to reduce play Tighten the counter nut and make sure the grip rotates smoothly Keep in mind that the play is reduced slightly when the tank is mounted Reposition the protective caps Reassemble the tank with conveyors and seat Check grip play again WARNING DO NOT OPEN AND CLOSE THE GAS GRIP WHEN THE ...

Page 75: ...WITH THE ENGINE OFF AS THE ENGINE MAY NOT START FUEL PRESSURE 250Fi ALL 450Fi ALL A In these models fuel is injected into the engine under pressure at pre established amounts which depend on the pressure of the system Any fuel pressure variations involve significant variation of carburation In case the engine malfunctions we recommend checking the fuel pressure circuit This operation can be perfor...

Page 76: ...ettor itself and check the idle speed DRAINING CARBURETTOR BOWL 450F SMR SMM ALL 530F After every washing or ride in wet environments river crossings etc the carburettor bowl should be drained to remove the water in it Water in the carburettor bowl may affect functionality Perform this operation with a cool engine Close the fuel tank and place a basin under the carburettor to catch the leaking fue...

Page 77: ...ough a duct 4 to the cartridge filter 5 where it is cleaned of any impurity Part of it is then pushed to the engine shaft and the other part to the distribution and gearbox The oil sent to the engine shaft enters the shaft duct and lubricates the connecting rod head bearing 6 The oil sent to the distribution and gearbox goes up to the top of the crankcase and branches further before accessing the ...

Page 78: ...n the cap by 20 Nm WARNING AN EXCESSIVELY LOW LEVEL LOW QUALITY OIL OR LONGER MAINTENANCE INTERVALS THAN SCHEDULED CAUSE SERIOUS DAMAGE TO THE ENGINE DO NOT POUR AN EXCESSIVE AMOUNT OF OIL IN THE ENGINE IF THIS HAP PENS DRAIN IT AS DESCRIBED IN CHANGING ENGINE OIL AND FILTER ALL 250FI CHAPTER ON PAGE 79 CHECKING ENGINE OIL LEVEL ALL 450Fi F ALL 530F Park the motorcycle on a flat surface and keep i...

Page 79: ... possible debris and tighten the caps by 20 Nm Prepare a measuring cup with the required amount of engine oil which must be of the type indicated in the table and pour it from the filler hole Check the seal gasket replace if necessary and tighten the cap by 20 Nm Repeat the oil level check Check the seal of the filler cap drain caps and filter cover BEWARE OF HOT OIL AND HOT ENGINE PARTS RISK OF B...

Page 80: ...ount of engine oil which must be of the type indicated in the table and pour about 0 8 litres into the filler hole Temporarily close the filler cap start the engine and let it run for about 5 seconds Do not make it run longer to prevent damage Open the filler cap again and finish filling with the oil left in the meas uring cup Tighten the cap by 20 Nm Repeat the oil level check Check the seal of t...

Page 81: ...4 S T R O K E S 81 4 S T R O K E S 5 DIAGNOSIS ...

Page 82: ...A 86 A Check the injection system PDA 86 A Check the wiring earth connections connector integrity cables and sheaths A Check the spark plug cap and replace it if required Check the starter and kill switch 14 A Check the engine stop button 15 A Incorrect idle speed adjustment Damaged spark plug Faulty start system Insufficient valve clearance Correctly adjust the idle speed 74 Replace the spark plu...

Page 83: ... a good brand of anti freeze 71 A Burnt out accessory fuse Check the 10A accessory fuse and replace it 66 The battery is not charged by the generator The battery is damaged Check the generator and voltage regulator A Replace the battery 65 A Refuel 37 Check the petrol pump connections and fuel pipe 63 Check fuel pressure 75 A Check the 2A system fuse and replace it 66 Replace the spark plug Check ...

Page 84: ...carburettor if fuel escapes from the pipe A If fuel does not leak from the pipe check the tank vent or clean the fuel tap Correctly adjust the idle speed 75 Follow the hot start procedure 33 Clean and dry the spark plug or replace it if required Adjust the distance between electrodes 0 8 mm Check the start system A Check the wiring earth connections connector integrity cables and sheaths A Check t...

Page 85: ...k the seal of the cooling system 70 Ride for a while on a flat road at moderate speed without forcing the engine you can assemble an optional electric fan Bleed the cooling system 71 Clean the radiator fins with water not under pressure Replace the coolant using a good brand of anti freeze 71 A Burnt out accessory fuse Check the 10A accessory fuse and replace it 66 Clean and check the fuel circuit...

Page 86: ...cycle EFI system operation Electronic diagnosis Check some engine functions Mechanical diagnosis Check the data entered in the control unit Change the maps in the control unit Display the engine operating hours Upload new maps provided by TM Racing Acquire data in real time in 2D and numerical format The device is subject to continuous software and firmware updates al lowed by the specific hardwar...

Page 87: ...4 S T R O K E S 87 4 S T R O K E S 6 TECHNICAL DATA ...

Page 88: ...h E S opt 120 80 18 140 80 18 100 90 19 110 90 19 7 5 litres 8 5 litres 7 5 litres 8 5 litres MOTORCYCLE MODEL 7 5 litres 8 5 litres 162 55 17 150 60 17 13 40 14 40 13 40 14 40 12 44 15 47 High low beam Front position light Rear pos stop number plate lights Turning signal HS1 12V 35 35W SMR W5W 12V 5W SMR P21 5W 12V 21 5W R10W 12V 10W H3 12V 55W H3 12V 55W SMM W5W 12V 5W SMM 250Fi 450Fi F 530FSMR ...

Page 89: ...oot tightening screw Rear wheel pin flanged nut Rear wheel nut SMM Rear hub locking screws SMM Swing arm pin flanged nut Handlebar tightening cap screws Handlebar elastic support nut Upper shock absorber nut Lower shock absorber screw Sprocket nuts Rear brake pedal adjusting nut Engine fixing screw Generic frame screws Generic frame nuts M20x1 5 M8 M10 M8 M6 cl 10 9 M6 cl 10 9 M8 M8 M8 M6 M8 M22x1...

Page 90: ...overhead valve twin cam driven by silenced chain Silver needle roller bearing Forged light alloy 2 oil pumps 1 for delivery 1 for recovery SAE 10W 50 API SM JASO MA2 brand oil fluid 40 antifreeze 60 water up to 25 C circulation forced with pump with multiple discs in oil bath 11 6 1 12 8 1 13 2 1 11 6 1 20 57 18 59 17 60 18 59 19 57 19 57 20 57 E S K S K S E S opt E S K S K S E S opt E S K S 1 lit...

Page 91: ...d amount Start RON 95 unleaded fuel ethanol allowed 10 4 overhead valve twin cam driven by silenced chain Kokusan digital CDI variable advance NGK CR 8E 0 8 mm fluid 40 antifreeze 60 water up to 25 C circulation forced with pump 0 20mm 0 25 mm 2 ball bearings Silver needle roller bearing Chrome Forged light alloy 2 segments 1 oil scraper 2 oil pumps 1 for delivery 1 for recovery SAE 10W 50 API SM ...

Page 92: ...ion hex nut ALL 250Fi Primary pinion hex nut ALL 450FI F ALL 530F Clutch hub nut Clutch spring Allen screw Starter motor bushing countersunk head Allen screw Starter motor fixing Allen screw Mobile chain guide fixing flanged screw Ignition stator Allen screw ALL 250Fi 450Fi EN MX SMR SMM SMX Ignition stator Allen screw 450F SMR SMM ALL 530F Ignition pickup fixing Allen screw Allen screw for gear b...

Page 93: ... 165 45 OCEMP 3 1 5 1 5 revs 7 mm 3 8 0 throttle 20 throttle 530F SMX FCRD41 195 45 NCYQ 3 1 5 1 5 revs 7 mm 3 8 0 throttle 100 throttle WARNING The maps assigned to the various motorcycle models are those valid as of 10 01 2014 In order to improve its products continuously TM Racing reserves the right to vary the above mentioned data Thanks to the use of the diagnostic PDA you can correct the bas...

Page 94: ...94 4 S T R O K E S 4 S T R O K E S ...

Page 95: ...4 S T R O K E S 95 4 S T R O K E S 7 WIRING DIAGRAMS ...

Page 96: ...96 4 S T R O K E S 4 S T R O K E S 7 1 LIGHTS AND ACCESSORIES WIRING DIAGRAM EN SMR SMM ...

Page 97: ...4 S T R O K E S 97 4 S T R O K E S 7 2 ENGINE WIRING DIAGRAM 250Fi MX SMX 450Fi MX SMX ...

Page 98: ...98 4 S T R O K E S 4 S T R O K E S 7 3 ENGINE WIRING DIAGRAM 250Fi EN SMR SMM 450Fi EN SMR SMM ...

Page 99: ...4 S T R O K E S 99 4 S T R O K E S 7 4 ENGINE WIRING DIAGRAM 250Fi MXE S SMXE S 450Fi MXE S SMXE S ...

Page 100: ...100 4 S T R O K E S 4 S T R O K E S 7 5 ENGINE WIRING DIAGRAM 450F SMR SMM 530F EN MXE S SMR SMM SMXE S ...

Page 101: ...W WHITE BLACK RED SPARK PLUG CDI UNIT WHITE BLUE KILL SWITCH GREEN WHITE RED WHITE BLACK RED WHITE YELLOW RED WHITE BLACK WHITE BLACK WHITE WHITE BLUE BLACK BROWN GREEN YELLOW BLUE RED BLACK BLACK YELLOW GREEN OPEN RED BLUE YELLOW BLACK BLUE YELLOW BLACK BLUE TERMINAL No TERMINAL NAME WIRE COLOR 1 2 3 4 5 6 IGNITION PRIMARY WHITE BLUE GND BLACK NOT USED KILL SWITCH BROWN EXCITER BLACK RED EXCITER ...

Page 102: ... for off road routes 17 Braking 35 Brakes 30 System fuse all models with E S 66 Recharge fuse all models with E S 66 Accessory fuse EN SMR SMM 66 ALPHABETIC INDEX Lights and accessories electrical system 30 Turn signal EN SMR SMM 69 Basic indications for TM disc brakes 53 Basic indications on carburettor wear 450F SMR SMM ALL 530F 75 Indications for commissioning 22 ALPHABETICAL INDEX 102 Combinat...

Page 103: ...nt brake pads 57 Replacing rear brake pads 59 Bleeding hydraulic clutch 52 PDA PALMTOP COMPUTER ALL 250Fi ALL 450Fi 86 Draining carburettor bowl 450F SMR SMM ALL 530F 76 250Fi EN SMR SMM maintenance table 40 250Fi MX SMX maintenance table 42 450Fi EN 450Fi F SMR SMM 530F EN SMR SMM maintenance table 44 450Fi MX SMX 530F MX SMX maintenance table 46 Digital electronic speedometer EN 16 Digital elect...

Page 104: ...www tmracing it TM Racing S p A Via Fano 6 61122 Pesaro Italy Ph 39 0721 25113 Fax 39 0721 401808 Graphics and printing_Seriart_www seriart com ENGLISH v1 00 ...

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