TM RACING TM 4 STROKE 2007 User Manual Download Page 1

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Summary of Contents for TM 4 STROKE 2007

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Page 3: ...he 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...

Page 4: ...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 necessa...

Page 5: ...lised 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 mode...

Page 6: ...2 Variation of rear shock spring preload 42 Page Rear suspension mechanical linkage 42 Check chain tension 43 Adjustment of chain tension all models except SMM 43 Adjustment of chain tension SMM 44 Ch...

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

Page 8: ...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 EN...

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

Page 10: ...bout 10 mm measured between the lever and support before starting to open theexhaust valves The time of opening is recognised by greater resistance of the lever see Frame and Engine Maintenance chapte...

Page 11: ...and 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 OG...

Page 12: ...ired 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 M...

Page 13: ...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...

Page 14: ...oon as the engine is running push the knob 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...

Page 15: ...d 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 adjust...

Page 16: ...aviour 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 PAIOLIUSDFORK S...

Page 17: ...TO THE OWNERS MANUAL SUPPLIED BY THE MANUFACTURER OF THE FORK SUPPLIED BY TM ACCOMPANYINGTHE MOTORCYCLE SHOCK SHOCK SHOCK SHOCK SHOCK ABSORBER ABSORBER ABSORBER ABSORBER ABSORBER ADJUST ADJUST ADJUST...

Page 18: ...king in rebound can be adjusted on the basis of pilot preferences and or hardness of the spring installed SACHSSHOCKABSORBER STANDARD The adjustment screw 3 is situated on the fork of the shock absorb...

Page 19: ...lock the steering turn the handlebar completely to the right insert the key turn it to the left press turn to the right and extract WARNING NEVER LEAVETHE KEY IN THE LOCK BYTURNING THE HANDLEBAR TOTH...

Page 20: ...ENGLISH ENGLISH 20...

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

Page 22: ...UT HALF MEASURES FOR OFF ROAD COMPETITIONS EVEN IF THE ENDURO MODELSARETYPE APPROVED PAYATTENTION WHEN USINGONTHEROAD MOSTOFALLAVOIDSUSTAINED ACCELERATION CONSTANT THROTTLE ON LONG ROADS ROLLTHE THROT...

Page 23: ...ENGLISH ENGLISH 23...

Page 24: ...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 Ver...

Page 25: ...D 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 INSERT...

Page 26: ...insert the first gear release the clutch lever slowly accelerating at the same time BEFORE STARTING ALWAYS CHECK THAT THE SIDE STAND HAS BEEN LIFTED IF THE STAND SLIDES ALONG THE GROUND YOU COULD LOO...

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...

Page 28: ...E 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 PAR...

Page 29: ...LWITHAN 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...

Page 30: ...ENGLISH ENGLISH 30...

Page 31: ...ENGLISH ENGLISH 31...

Page 32: ...ch reservoirs Clean filter case and air filter Check conditions and unbent positioning of cables Check headlamp orientation Check electric system head light high beam stop indicators lights horn safet...

Page 33: ...ss 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 we...

Page 34: ...R 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...

Page 35: ...O BE CARRIED OUT ON ENGINE 250 450 530 END MX SMX CHECKS TO BE CARRIED OUT ON ENGINE 250 450 530 END MX SMX CHECKS TO BE CARRIED OUT ON ENGINE 250 450 530 END MX SMX COMPETITION USE COMPETITION USE CO...

Page 36: ...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 ANC...

Page 37: ...ENGLISH ENGLISH 37...

Page 38: ...PLYWITHTHERESPECTIVEREGULATIONSOF 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 BEA...

Page 39: ...SBEFOREHAVING 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...

Page 40: ...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 WE...

Page 41: ...mpression 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 TELESCO...

Page 42: ...ng pre load you should make note of te basic adjustment for example how many thread turns are visible above the adjustment ring nut By 1 turn of the adjustment ring 5 the spring pre load varies by 1 5...

Page 43: ...M 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 adju...

Page 44: ...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...

Page 45: ...rt 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...

Page 46: ...PLA FREE PLA FREE PLAY Y Y Y Y ADJUSTMENT OF ADJUSTMENT OF ADJUSTMENT OF ADJUSTMENT OF ADJUSTMENT OF THE OF THE OF THE OF THE OF THE OF FRONT BRAKE LEVER FRONT BRAKE LEVER FRONT BRAKE LEVER FRONT BRA...

Page 47: ...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 SK...

Page 48: ...screw the two M10 screws 10 and remove the caliper from the fork shoe Press the two hooks one at a time 8 to release and slide the retainer pins out 9 Lever on each pair of pads to allow the pistons t...

Page 49: ...E 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 FL...

Page 50: ...e 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 OTHERWI...

Page 51: ...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...

Page 52: ...EAN 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...

Page 53: ...SENSOR CHECK ADJUSTMENT OF MAGNET SENSOR CHECK 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 Otherwis...

Page 54: ...ne 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 m...

Page 55: ...d 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 NEVERMOUNTFUSESWITHGREATERPOWERORTRYTO REPAIR...

Page 56: ...SITIONLIGHTBULB Extract the bulb holder 22 from the parabola replace the bulb 23 Remount the bulb holder Repositon the light holder mask and fix it with the elastic stripes WARNING NEVER TOUCHTHEGLASS...

Page 57: ...AT ESCAPE MAY CAU SESERIOUSBURNS 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 ME...

Page 58: ...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 silencer...

Page 59: ...ectly Remount the air filter positioning it correctly on the rest surface taking care that edges of the filter are not raised or not adherent with the rest surface Rescrew the finger screw and tighten...

Page 60: ...VEL CHECK HYDRAULIC CLUTCH FLUID LEVEL The reservoir is part of the clutch pump positioned on the handlebar and has an inspection window with the reservoir in a horizontal position the level of the fl...

Page 61: ...the normal level using the adjustment knob 1 and repeat the procedure from point 4 Anyone using the motorcycle for pure racing will set a leaner mixture of about 1 4 of a turn in a clockwise directio...

Page 62: ...L MATERIALS 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 ENVISIO...

Page 63: ...ENANCE 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 WHENCHANGINGT...

Page 64: ...cartridge oil filter is situated on the right side of the motorcycle underneath the cover 1 Place a container under the engine to collect the oil that escapes from the filter compartment Loosen the tw...

Page 65: ...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 be...

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 bowl When the bowl has been filled with fresh...

Page 67: ...lexible cable command Have the ignition timing checked Fuel missing Air leaks in the intake manifold Clean and check the fuel circuit and the carburetor Checktherubbermanifoldsbetweenthefiltercaseandt...

Page 68: ...ug 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 cl...

Page 69: ...itres straight toothing gears18 67 straight toothing gears 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...

Page 70: ...CAL DA A A A AT T T T TA ENGINE A ENGINE A ENGINE A ENGINE A ENGINE TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL DA A A A AT T T T TA ENGINE 530 END MX SMX SMR SMM 2007 A ENGINE 530 END M...

Page 71: ...2 3 rd from top 2 0 no holes 1 5 turn 120 11 0 mm 3 8 85 0 mm 11 5 mm 40 TDMR 40 205 55 P 5 10E1 52 3 rd from top 2 0 no holes 1 5 turn 120 11 0 mm 3 8 84 0 mm 12 5 mm 40 TDMR 40 205 55 P 5 10E1 52 3...

Page 72: ...cylinder fastenening screws Camshaft bearing capAllen screw Camshaft cap Allen screws Distribution chain tensioner Allen screws Water pump cover Allen screws Water pump rotor Head cover Allen screws...

Page 73: ...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 EN...

Page 74: ...ws SMM Front brake disc fastening screws Rear brake disc fastening screws SMR SMX Rear brake disc fastening nut SMM Upper fork head fastening screws Lower fork head fastening screws Paioli fork leg fa...

Page 75: ...ORQUES 72 Establishing rear shock lowering in running order 40 Establishing rear shock static lowering 41 Fork adjustment in compression 16 Fork adjustment in rebound 17 FRAMEANDENGINEMAINTENANCE 37 F...

Page 76: ...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 SP...

Page 77: ...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...

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

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