TM RACING 4 STROKE 2006 User And Maintenance Manual Download

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ENGLISH

Summary of Contents for 4 STROKE 2006

Page 1: ...ENGLISH ENGLISH ENGLISH 1 TM RACING USES and ADVICES TM RACING USES and ADVICES USER AND MAINTENANCE MANUAL USER AND MAINTENANCE MANUAL TM 4 STROKE 2006 TM 4 STROKE 2006 ...

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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: ... 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 product...

Page 5: ... a specialised TM workshop at the envisioned dates otherwise any warranty rights will be forfeited 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 Fuels and lubricants must be those established in the user and maintenance manual and must be used as...

Page 6: ...ical linkage 42 Page Control chain tension 43 Correction of chain tension all except SMM 43 Correction of chain tension SMM 44 Chain maintenance 44 Chain wear 45 Basic indications for TM disc brakes 45 Free play adjustment of the front brake lever 46 Control front brake fluid 47 Top up front brake fluid 47 Control front brake pads 47 Replacement of front brake pads 48 Modification of rear brake pe...

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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...

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Page 10: ...st always have a play of about 10 mm measured between the lever and support before starting to open the valves The moment of opening is recognised by greater resistance of the lever see Fra me and Engine Maintenance chapter FRONT BRAKE LEVER FRONT BRAKE LEVER FRONT BRAKE LEVER FRONT BRAKE LEVER FRONT BRAKE LEVER The front brake lever 3 is located on the right of the handlebar and activates the fro...

Page 11: ... reset theTRP AVS STPand MAXfunctions press the right button blue Select the function and press the left button for 5 sec yellow The values displayed are zeroed P P P P PR R R R ROGRAMMING OGRAMMING OGRAMMING OGRAMMING OGRAMMING THE ELECTR THE ELECTR THE ELECTR THE ELECTR THE ELECTRONIC ONIC ONIC ONIC ONIC T T T T TA A A A ACHOMETER CHOMETER CHOMETER CHOMETER CHOMETER END SMR SMM END SMR SMM END S...

Page 12: ...sired value Repeat the operation until all of the numbers have been set as desired End by pressing the grey button on the rear of the instrument for 1 sec ENGINE STOP SWITCH MX SMX ENGINE STOP SWITCH MX SMX ENGINE STOP SWITCH MX SMX ENGINE STOP SWITCH MX SMX 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...

Page 13: ... button 2 activates the starter Press to start up the engine and release once running Activate this command for a maximum of 8 10 sec at a time and wait a few seconds before re trying Do not insist for more than 3 4 times look for the probable fault Never press this button when the engine is running FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP The fuel fill cap i...

Page 14: ...y overheated As soon as the engine is running push the starter motor to return it to its normal position BY BY BY BY BY PASS PASS PASS PASS PASS COMMAND HO COMMAND HO COMMAND HO COMMAND HO COMMAND HOT ST T ST T ST T ST T STAR AR AR AR ART T T T T All models with kic All models with kic All models with kic All models with kic All models with kickstar kstar kstar kstar kstart t t t t This command is...

Page 15: ...o start up the engine and replaced inside as soon as the engine is running BRAKE PED BRAKE PED BRAKE PED BRAKE PED BRAKE PEDAL AL AL AL AL The brake pedal is positioned in front of the right foot rest The basic position can be adjusted on the basis of the position of the saddle see maintenance operations SIDE ST SIDE ST SIDE ST SIDE ST SIDE STAND AND AND AND AND Press the side stand to the floor u...

Page 16: ...em determines the behaviour of the fork in the in compression stroke The degree of hydraulic braking in compression can be adjusted on the basis of pilot preferences and or hardness of the spring installed PAIOLI USD FORK STANDARD Remove the rubber hood 1 situated in the lower part of the fork leg and turn the adjustment screw 2 using a screwdriver By turning it in a clockwise direction braking in...

Page 17: ...OWNERS MANUAL SUPPLIED BY THE MANUFACTURER OF THE FORK SUPPLIED BY TM ACCOMPANYINGTHE MOTORCYCLE SHOCK ABSORBER ADJUSTMENT IN COMPRESSION SHOCK ABSORBER ADJUSTMENT IN COMPRESSION SHOCK ABSORBER ADJUSTMENT IN COMPRESSION SHOCK ABSORBER ADJUSTMENT IN COMPRESSION SHOCK ABSORBER ADJUSTMENT IN COMPRESSION The hydraulic brake system in compression determines the behaviour of the shock absorber in the co...

Page 18: ...raulic braking in extension can be adjusted on the basis of pilot preferences and or hardness of the spring installed SACHSDAMPER STANDARD The adjustment screw 3 is situated on the attachment ot the fork of the shock absorber mechanical linkage Use a screwdriver By turning in a clockwise direction braking increases in an anticlockwise direction it decreases A total of 40 notches are available OHLI...

Page 19: ...en To block 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 LEAVETHE KEY IN THE LOCK BYTURNING THE HANDLEBAR TOTHE LEFT THE KEY COULD BE DAMAGED OPERA OPERA OPERA OPERA OPERATING CONTR TING CONTR TING CONTR TING CONTR TING CONTROLS OLS OLS OLS OLS OPERA OPERA OPERA OPERA OPERATING CONTR TING CONTR TING CONTR T...

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Page 22: ...OUTHALF MEASURESFOROFF THE ROADCOMPETITIONS EVEN IFTHEENDUROMODELSARETYPE APPROVED PAYATTENTIONWHEN USINGONTHEROAD MOSTOFALLAVOIDSUSTAINEDACCELERATION CONSTANT THROTTLE ON LONG ROADS ROLLTHE 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 AND A JACKET WHETHER IT BE A LONG OR...

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Page 24: ...ssary Worn tread and unsuitable air pressure worsen driving of the motorcycle and may cause loss of control of the means and serious accidents 5 BRAKES Verify correct functioning Check the level of brake fluid The reservoir on the pumps are dimensioned in a way that in the case of normally worn brake pads the fluid does not need to be topped up If the level of brake fluid falls below the minimum l...

Page 25: ...AYLEAD TO RISK OF UNCONSCIOUSNESSAND DEATH WHEN THE ENGINEISRUNNINGASWAYSENSURETHEIRISSUFFICIENTVENTILATION ALWAYS CHECK THAT THE GEAR IS IN NEUTRAL BEFORE ACTIVATING THE STARTER BUTTON IF A GEAR IS INSERTED ON IGNITION THE MOTORCYCLE WILL JUMP FORWARDS WARNING ACTIVATE THE STARTER FOR A MAX OF 5 SECONDS AT A TIME WAIT ANOTHER 5 SECONDS BEFORETRYINGAGAIN DO NOTALLOW THE ENGINE REVS TO INCREASE TOO...

Page 26: ...ar release the clutch lever slowly accelerating at the same time BEFORE DEPARTING ALWAYS CHECK THAT THE SIDE STAND HAS BEEN LIFTED IF THE STAND SLIDES ALONG THE GROUND YOU COULD LOOSE CONTROL OF THE MOTORCYCLE CHANGING GEAR CHANGING GEAR CHANGING GEAR CHANGING GEAR CHANGING GEAR A A A A ACCELERA CCELERA CCELERA CCELERA CCELERATING TING TING TING TING SLOWING DOWN SLOWING DOWN SLOWING DOWN SLOWING ...

Page 27: ...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 NEVER CHANGE DOWNAGEAR WITHOUTHAVING FIRSTSLOWED DOWN THE ENGINE WOULD BETAKENTOAN EXCESSIVE NUMBER OF REVSAND THE VALVESAND OTHER ENGINE COMP...

Page 28: ...D 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 put the gear 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 29: ...ETROLWITHANOCTANENUMBERLOWERTHAN95 BECAUSE THISWOULDDAMAGETHEENGINE PETROL IS HIGHLY INFLAMMABLE AND TOXIC HANDLE PETROL WITH GREAT CARE DO NOT FILL UP WITH PETROL NEAR TO FLAMES OR CIGARETTES ALWAYS SWITCH THE ENGINE OFF WHEN FILLING UP WITH PETROL NEVER POUR PETROL ONTO THE ENGINE OR ONTO THE EXHAUST PIPE IF ANY PETROL IS ACCIDENTLY POURED ONO THESE PARTS ELIMI NATE IT IMMEDIATELY USING A CLOTH ...

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Page 32: ...and clutch Clean filter case and air filter Check conditions and unbent positioning of cables Check headlamp orientation Check electric system function head light high beam stop indicators check lights horn safety button switch Check brake fluid level pad thickness brake discs Check conditions of brake pipes Check functionality adjustment smoothness and front brake lever and brake pedal free play ...

Page 33: ...ering bearings Check tightness of chassis screw and bolts fork plates fork legs wheel pin nuts and screws rear fork pin damper Check spoke tension and centring of wheel rings Check tyre condition and pressure Check chain wear chain link sprockets and guides chain tension Chain lubrication Check wheel bearing play The distance between maintenance intervals should not be exceeded by more than 2hours...

Page 34: ...TER 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 DRIVER PIL THE DRIVER PIL THE DR...

Page 35: ...NGINE 250 450 530 END MX 450 660 SMX CHECKS TO BE CARRIED OUT ON ENGINE 250 450 530 END MX 450 660 SMX CHECKS TO BE CARRIED OUT ON ENGINE 250 450 530 END MX 450 660 SMX COMPETITION USE COMPETITION USE COMPETITION USE COMPETITION USE COMPETITION USE 30 HOURS 200 LT 45 HOURS 300 LT 60 HOURS 400 LT 90 HOURS 600 LT 120 HOURS 800 LT 135 HOURS 900 LT WARNING WARNING WARNING WARNING WARNING IFATTHECHECKI...

Page 36: ...NCE ANCE ANCE ANCE AND L AND L AND L AND L AND LUBRIFICA UBRIFICA UBRIFICA UBRIFICA UBRIFICATION TION TION TION TION T T T T TABLE ABLE ABLE ABLE ABLE MAINTEN MAINTEN MAINTEN MAINTEN MAINTENANCE ANCE ANCE ANCE ANCE AND L AND L AND L AND L AND LUBRIFICA UBRIFICA UBRIFICA UBRIFICA UBRIFICATION TION TION TION TION T T T T TABLE ABLE ABLE ABLE ABLE CHECKS TO BE CARRIED OUT ON ENGINE 250 450 530 END SM...

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Page 38: ...MPLYWITHTHERESPECTIVEREGULATIONS OF YOUR COMPANY DISPOSE OF WASTE OILINAREGULAR MANNER NEVER POUR OLD OILINTO DRAINS OR RIVERS CONTROL OF STEERING BEARINGS CONTROL OF STEERING BEARINGS CONTROL OF STEERING BEARINGS CONTROL OF STEERING BEARINGS CONTROL 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 c...

Page 39: ...t scraper the external pipes and the rods carefully Oil them well with silicone spray or with engine oil Finally push the dust scraper manually into the external pipes B B B B BASIC CALIBRA ASIC CALIBRA ASIC CALIBRA ASIC CALIBRA ASIC CALIBRATION OF TION OF TION OF TION OF TION OF THE CY THE CY THE CY THE CY THE CYCLE P CLE P CLE P CLE P CLE PAR AR AR AR ART ON T ON T ON T ON T ON THE BASIS OF THE ...

Page 40: ... B The static lowering is the difference between measurement A and B EXAMPLE Motorcycle on stand measurement A 600 m m Motorcycle on the ground not loaded measurement B 565 m m Static lowering 35 m m If thestatic lowering is lower the damper spring pre load must be decreased If the static lowering is greater the spring pre load must be inreased See variation of damper spring pre load chapter EST E...

Page 41: ...IATION OF TION OF TION OF TION OF TION OF TELESCOPIC FORK PRE L TELESCOPIC FORK PRE L TELESCOPIC FORK PRE L TELESCOPIC FORK PRE L TELESCOPIC FORK PRE LO O O O OAD AD AD AD AD To vary the spring pre load on these telescopic forks it is necessary to disassemble them partially see Paioli or Ohlins manual It is possible to add pre load bushes The fork springs however can be pre loaded to a max of 20 m...

Page 42: ... pre load inceases After the adjustment tighten the lock nut 6 REAR SUSPENSION MECHANICAL LINKAGE REAR SUSPENSION MECHANICAL LINKAGE REAR SUSPENSION MECHANICAL LINKAGE REAR SUSPENSION MECHANICAL LINKAGE REAR SUSPENSION MECHANICAL LINKAGE The rear suspension of all TM moorcycles has a link rod and rocker mechanism that progressively modifies the lever relationship between the wheel and damper This ...

Page 43: ...ODELS EXCEPT SMM ALL MODELS EXCEPT SMM ALL MODELS EXCEPT SMM Loosen the wheel pin nut 1 loosen the counter nuts 2 and turn the adjustment screws 3 to the left and to the right by the same amount To increase chain tension unscrew the adjustment screws To decrease chain tension screw the adjustment screws Reach correct chain tension For correct alignment of the rear wheel the marks 4 on the right an...

Page 44: ...es in 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 petrol and then immersed...

Page 45: ...hey are not joined to their support The lateral compensation always allows the pads to rest optimally on the discs The brake caliper support screws are held using Loctite 243 and tightened with 25 Nm The front calipers of the SMR SMM SMX models are an exception as they are the fixed type PADS The minimum thickness of the friction material cannot descend under the limit of 1mm In case of replacemen...

Page 46: ...ADJUSTMENT OF ADJUSTMENT OF ADJUSTMENT OF THE FREE PLA THE FREE PLA THE FREE PLA THE FREE PLA THE FREE PLAY OF Y OF Y OF Y OF Y OF THE FRONT BRAKE LEVER THE FRONT BRAKE LEVER THE FRONT BRAKE LEVER THE FRONT BRAKE LEVER THE FRONT BRAKE LEVER The free play to the front brake lever can be varied using the adjustment screw 1 In this way the position of the pressure point the resistance that can be per...

Page 47: ...mbra ne Repeat the top up operation as mentioned above Wash any spilled brake fluid away with water KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN BRAKE FLUID MAY IRRITATE THE SKIN DO NOT ALLOW IT TO TOUCH SKIN OR EYES IF THE BRAKE FLUID SHOULD ACCIDENTLY SPRAY INTO THE EYES RINSE WELL WITH WATER AND SEEK MEDICALASSISTANCE WARNING DO NOTALLOW BRAKE FLUID TO COME INTO CONTACT WITH PAINTED PARTS THE ...

Page 48: ... out extract the worn pads insert the new pads and tighten the pin as far as possible Remount the caliper tighten the M8 screws to 25Nm and finish tightening the retainer pin to 12Nm SMX Unscrew the two M10 screws 10 and remove the caliper from the leg piece Press the two hooks one at a time 8 to release and slide the retainer pin out 9 Lever a couple of pads to allow the small pistons to return t...

Page 49: ...EVEL 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 FOR END MX SMX MODELS As soon as the level of rear brake fluid reaches the centreline on the inspection hatch situated on the pump i...

Page 50: ...ER SMM Remove the safety ring and slide the pin out 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 ONTHECONTRARY THEBRAKINGEFFECTWOULDBEGREATLY REDUCED AFTER MOUNTING CHECK THAT THE SAFETY DEVICESARE POSITIONED CORRECTLY AFTER EVERY INTERVENTION ON THE BRAKING SYSTEM ACTIVATE THE FRONT BRA...

Page 51: ...ed nut 1 and supporting the wheel extract the wheel pin 2 remove the chain tensioning slide 3 remove the chain from the crown wheel remove the caliper with its support and carefully extract the rear wheel from the rear fork Pay attention to the low wheel shims crown wheel side and high shims brake side WARNING DO NOTACTIVATE THE BRAKE PEDALWHEN THE REAR WHEELHAS BEEN DISASSEMBLED ALWAYS POSITION T...

Page 52: ...CLEAN FROM OILAND GREASE ONTHECONTRARY THEBRAKINGEFFECTWOULDBEGREATLY REDUCED AFTER HAVING RE ASSEMBLED THE REAR WHEEL ALWAYS ACTIVATE THE BRAKE PEDALSO THAT THE PADSADHERE TO THE DISCAGAIN CHECKING SPOKE TENSION CHECKING SPOKE TENSION CHECKING SPOKE TENSION CHECKING SPOKE TENSION CHECKING SPOKE TENSION Correct tension of the spokes is very important for the stability of the wheel and therefore sa...

Page 53: ...OF MAGNET SENSOR CONTROL ADJUSTMENT OF MAGNET SENSOR CONTROL ADJUSTMENT OF MAGNET SENSOR DIST DIST DIST DIST DISTANCE A ANCE A ANCE A ANCE A ANCE A The distance between magnet 2 and sensor 1 must be 2 4mm On the contrary the tachometer may functon irregularly In the END versions the magnet is positioned in the rear wheel while in the SMR SMM versions in the front one BA BA BA BA BATTERY END MX SMR...

Page 54: ... it is charged or not To do this measure 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 THECLOSURESTRIPMUSTNOTB...

Page 55: ...rned out fuse must be replaced exclusively with an equivalent one If the new fuse should also burn out once mounted contact a specialised TM workshop WARNING NEVER MOUNT FUSES WITH GREATER POWER OR TRY TO ADJUST THE SAME FUSE UNAPPROPRIATETREATMENTS COULD CAUSE FAULTSTOTHE ENTIREELECTRICPLANT REPLACEMENT OF REPLACEMENT OF REPLACEMENT OF REPLACEMENT OF REPLACEMENT OF HEADLIGHT HEADLIGHT HEADLIGHT H...

Page 56: ...om the parabola replace the bulb 23 Remount the bulb holder Repositon the light holder mask and fix it with the elastics WARNING NEVER TOUCHTHEGLASSBULB TOPREVENTLEAVINGTRACESOFGREASE TOBESUREOFINSERTINGTHEESTABLISHEDBULBS CONSULTTHE CYCLE PART TECHNICAL DATA TABLE REPLACEMENT OF REAR POSITION LIGHT REPLACEMENT OF REAR POSITION LIGHT REPLACEMENT OF REAR POSITION LIGHT REPLACEMENT OF REAR POSITION ...

Page 57: ...T ESCAPE MAY CAUSE SERIOUS BURNS 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 ENTERS THE EYES RINSE IMMEDITAELY WITH COLD WATER AND SEEK MEDICAL ADVICE The coolant liquid is a mixture of antifreeze at 40 and water at 60 The antifreeze pro...

Page 58: ...MENT OF EXHAUST SILENCER REPLACEMENT OF EXHAUST 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 antinoise material fibreglass to limit motorcycle noise Because of high temperatures reached by the exhaust gases the fibreglass tends to melt leading to a decrease in the ef...

Page 59: ...ilter positioning it correctly on the rest surface taking care that edges of the filter are not raised or not adherent with the rest surface Rescrew the finger screw and tighten it adequately CONTROL OF HAND DECOMPRESSOR CONTROL OF HAND DECOMPRESSOR CONTROL OF HAND DECOMPRESSOR CONTROL OF HAND DECOMPRESSOR CONTROL OF HAND DECOMPRESSOR ADJUSTMENT A ADJUSTMENT A ADJUSTMENT A ADJUSTMENT A ADJUSTMENT ...

Page 60: ...VEL CONTROL HYDRAULIC CLUTCH OIL LEVEL CONTROL HYDRAULIC CLUTCH OIL LEVEL The oil tank is part of the clutch pump positioned on the handlebar and has an inspection hatch with the tank in a horizontal position the level of the liquid must never fall below the centreline of the window nor be above the upper margin If it is necessary to top up the oil remove the screws 2 and then the cover 3 together...

Page 61: ...using the adjustment knob 1 and repeat the procedu re from point 4 Anyone using the motorcycle for sport will set a weaker mix of about 1 4 of a turn in a clockwise direction with respect to the ideal value because the engine will become hotter NOTE If the described methods are followed and satisfying results are not obtained the cause could be an idle speed jet with unsuitable dimensions a If the...

Page 62: ... IMPREGNATED WITH FUELAREALSO HIGHLY INFLAMMABLE IF YOU SWALLOW FUEL OR IT COMES INTO CONTACT WITH THE EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF FUEL ACCORDING TO THE REGULATIONS ENVISIONED IN YOUR COUNTRY OIL CIRCUIT OIL CIRCUIT OIL CIRCUIT OIL CIRCUIT OIL CIRCUIT The delivery pump 3 sucks the oil through the net filter 4 from the sump The oil is delivered pressurised through a pipe 5 to the f...

Page 63: ...dications on container 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 WHENCHANGINGTHEOIL CLEANTHEOILSUMPNETFILTER ANDREPLACETHEFILTERCARTRIDGE The oil must be changed with the engine at working temperature THE ENGINE AT ...

Page 64: ...oil from the engine The cartridge oil filter is found on the right side of the motorcycle underneath the cover 1 Place a container under the engine to collect the oil that escapes from the filter compartment Loosen the two screws 2 remove the cover and extract the filter cartridge Wait until the oil has been removed completely then clean the sump and cover surfaces check the O Ring and replace it ...

Page 65: ... Litres Close the cap temporarily start up the engine and allow it to run for about 5 seconds DO NOT ALLOW IT TO RUN FOR LONGER TO PREVENT DAMAGE Re open the cap and finish filling with the oil remaining in the measuring beaker A total of 1 4 Litres of oil has been introduced Tighten the cap to 20Nm Start up the engine and check tightness of the filling and emptying caps the net filter cap and the...

Page 66: ...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 tank When the tank has been filled with fresh fuel the engine will start immediately Disconnect the fuel pipe 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 t...

Page 67: ...and Have the ignition plant checked Fuel missing Dirt in the air boots Clean and control the fuel circuit and the carburetor Check the rubber sheaths between the filter case and the carburetor and betweenthe carburetor and head and tightening of the bands THEENGINEOVERHEATS EXCESSIVELY There is not enough fluid in the cooling system Insufficient ventilation Air in the cooling system The radiator p...

Page 68: ...nto the cylinder through the spark plug hole Activate the kickstart pedal 10 times to distribute the engine oil onto the walls of the cylinder and then remount the spark plug Compress the piston 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 b...

Page 69: ...ight tooth gears18 67 straight tooth gears 20 57 with multiple discs in oil bath 5 gears 5 gears 5 gears 5 gears 5 gears 5 gears 1st 14 28 1st 15 27 1st 14 28 1st 14 28 1st 15 27 1st 14 28 2nd 17 25 2nd 17 25 2nd 17 25 2nd 17 25 2nd 17 25 2nd 17 25 3rd 19 23 3rd 19 23 3rd 19 23 3rd 19 23 3rd 19 23 3rd 19 23 4th 21 21 4th 21 21 4th 21 21 4th 21 21 4th 21 21 4th 21 21 5th 24 19 5a 23 20 5th 23 20 5t...

Page 70: ...mm 104x77 4mm 11 3 1 11 9 1 11 3 1 12 7 1 lead free fuel with at least 95 NO two shaft 4 valve in head activated by silent chain N2 N3 F1 F1 N2 N3 N1 N2 36mm 36mmTi 36mm 40mm 31mm 31mmTi 31mm 33mm mm 0 20 mm 0 30 mm 0 20 mm 0 20 mm 0 25 mm 0 35 mm 0 25 mm 0 25 2 ball bearings silver plated roller cage coppering forged in light alloy 2 segments 1 oil scraper 2 oil pumps 1 delivery 1 recovery comple...

Page 71: ... 84 0 mm 12 5 mm 40 TDMR 40 205 55 P 5 10E1 52 3rd from top 2 0 no holes 1 5 revs 120 11 0 mm 3 8 82 0 mm 11 0 mm 40 TDMR 40 205 55 P 5 10E1 52 3rd from top 2 0 no holes 1 5 revs 120 11 0 mm 3 8 82 0 mm 12 5 mm 40 TDMR 40 200 55 P 5 10E1 52 2nd from top 2 0 no holes 1 0 revs 120 10 0 mm 3 8 82 0 mm 8 0 mm 40 TDMR 41 215 45 P 8 10E1 52 2nd from top 3 0 no noles 1 75 revs 120 11 mm 3 8 82 0 mm 7 5 m...

Page 72: ...llen screw Camshaft flanged nut cap Distribution chain tensioner Allen screws Water pump cover Allen screws Water pump rotor Head cover Allen screws Primary pinion hexagon nut Clutch hub nut Clutch springsAllen nuts Starter motor bush head Allen screws Starter motor fixing Allen screws Mobile chain guide fixing flanged screws Ignition stator Allen screws Ignition pickup fixture Allen screws Allen ...

Page 73: ...X 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 COUPLING TORQUES 250 450 530 END 250 450 530 MX 2006 COUPLING TORQUES 250 450 530 END 250 450 530 MX 2006 COUPLING TORQUES 250 450 530 END 250 450 530 MX 2006 COUPLING TORQUES 250 450 530 END 250 450 530 MX 2...

Page 74: ...tres 13 40 13 44 5 8 x 1 4 39 41 42 43 44 45 42 39 40 41 42 43 45 Head highbeamlight S212V 45 40W BA20d Opt Ciclope H3 12V 55W PK22s Front position light T4W 12V 4W BA9s Opt Ciclope T10 12V 5W Rear position stop number plate light P21 5W 12V 21 5W BAY15d Indicator R10W 12V 10W BA15S 12V 6Ah 12V 6Ah only with E S opt COUPLING TORQUES 250 450 530 SMR SMM 450 660 SMX 2006 COUPLING TORQUES 250 450 530...

Page 75: ...40 Establishment of damper static lowering 16 Fixing for off the road routes 16 ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX Page Fork adjustment in compression 16 Fork adjustment in extension 17 FRAMEANDENGINEMAINTENANCE 37 Frame number 8 Free play adjustment of front brake...

Page 76: ...E CON BATTERIA E S MOD 2006 E ROSSI 23 05 05 GREEN WHITE BROWN WHITE TO LIGHTS HORN BLACK YELLOW RED BLACK BLACK GREEN BLACK YELLOW BLACK BLACK YELLOW BLACK GREEN BLACK PURPLE RED RED SKY BLUE BLACK SPARK PLUG CDI UNIT TERMINAL No TERMINAL NAME WIRE COLOR 1 3 5 7 9 11 PULSER BROWN NO USE GND RXD BLACK PURPLE NO USE GND GND BLACK 13 15 PHASE SIG BLACK GREEN NO USE GND 16 14 12 10 8 6 IGN COIL PRIMA...

Page 77: ...E CON CONNETTORI PROTETTI WIRING DIAGRAM FOR IGNITION WITH SEALED CONNECTORS BLACK YELLOW BLACK BLACK GREEN BLACK GREEN BLACK YELLOW BLACK A TERMINE DI LEGGE E RIGOROSAMENTE VIETATO RIPRODURRE O COMUNICARE A TERZI IL CONTENUTO DEL PRESENTE ELABORATO SOST DAL N DENOMINAZIONE SCALA STATO VISTO DATA DIS MATERIALE FINITURA TRATTAMENTO MACCHINA SOST IL N DATA PZ GRUPPO MODIFICA 4 STROKE 4 TEMPI IGNITIO...

Page 78: ...D 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 RED WHITE 7 8 NOT USED NOT USED 9 SIGNAL YELLOW 16 YELLOW RxD 18 17 12V TxD RED BLUE 15 14 13 12 11 TERMINAL...

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Page 80: ...LISH ENGLISH 80 TM Racing S p A Via Fano 6 61100 PESARO ITALY www tmracing it Grafica e Stampa SERIART Fabriano AN www seriart com Published and printed by SERIART Fabriano AN www seriart com ENGLISH TM 02 ...

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TM RACING 4 STROKE 2006, User And Maintenance Manual

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