TM 2008 4 Stroke User Manual Download

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ENGLISH

TECHNICAL D

TECHNICAL DA

TA - ENGINE

A - ENGINE

LEGEND: E.S. = Electric start K.S. = Kick start

450

SMM/SMR

TECHNICAL D

TECHNICAL DA

TA - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 2008

450

SMX

450

END

250

SMM/SMR

250

MX/SMX

250

END

ENGINE

4 stroke single-cylinder DOHC , liquid cooled

250 cm

449 cm

77x53.6 mm

95x63.4 mm

13.5 : 1

11.5 : 1

12.2 : 1

11.5 : 1

unleaded fuel with min. 95 RON

DOHC 4 valves driven by silent chain

A2 / N2

N2 / N3

N2/N3

SM4 / S4

N2 / N3

30 mm

30 mm Ti

30 mm

36 mm

36 mm Ti

36 mm

24.5 mm 24.5 mmTi

24.5 mm

31 mm

31 mm Ti

31 mm

mm. 0.20

mm. 0.20 mm. 0.20

mm. 0.25 mm. 0.20

mm. 0.25

mm. 0.25 mm. 0.25

2 ball bearings

silver-plated needle cage

coppering

forged light alloy

2 rings + 1 oil scraper

double oil pump ( d drainage)

fully synthetic premium quality oil SAE 10W-50 API SG-SH

1.4 litres

straight toothing gears18 / 67 straight toothing gears 20 / 57

multiple discs in oil bath

5 speed

14:28 1

15:27 1

14:28

16:27

14:28

17:25 2

17:25

17:24

17:25

19:23 3

19:23

16:19

19:23

21:21

21:21 4

21:21

24:19

23:20 5

24:19

23:20

Kokusan digital CDI with variable timing

12V 180W

-----

12 V 180W 12V 180W

-----

12V 180W

12V180W

NGK CR 8E

0.8 mm

liquid cooled 40 % antifreeze, 60 % water(up to -25°C),

forced circulation with pump

1 litre

1.3 litres

1 litre

E.S.+K.S.

K.S.

E.S.+K.S. E.S.+K.S.

K.S.

E.S.+K.S.

(E.S.opt.)

Type

Displacement

Cylinder bore and stroke

Compression

Fuel

Distribution

I / E camshafts

Inlet valve diameter

Exhaust valve diameter

Inlet valve cold clearance

Exhaust valve cold clearance

Crankshaft supports

Conrod bearing

Small end plating

Piston

Rings

Lubrication

Engine oil

Oil capacity

Primary transmission

Clutch

Gearbox (with front engagement)

Gear ratios

Ignition

Generator

Generator with E.S. optional

Spark plug

Electrode gap

Cooling

Coolant fluid capacity

Start-up

TECHNICAL D

TECHNICAL DA

TA - ENGINE

A - ENGINE

TECHNICAL D

TECHNICAL DA

TA - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 200

A - ENGINE 250 END/MX/SMX/SMR/SMM - 450 END/MX/SMX/SMR/SMM 2008

Summary of Contents for 2008 4 Stroke

Page 1: ...ENGLISH ENGLISH ENGLISH 1 TM TM TM TM TM 2008 UK 2008 UK 2008 UK 2008 UK 2008 UK ...

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 41 Replacement of fork springs 42 Page Variation of rear shock spring preload 42 Rear suspension mechanical linkage 42 Check chain tension 43 Adjustment of chain tension all models except SMM 43 Adjustment of chain tension SMM 44 Chain maintenance 44 Chain wear 45 Basic indications for TM disc brakes 45 Free play adjustment of front brake lever 46 Check front br...

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: ...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 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 front wheel brake The position...

Page 11: ...S 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 SMR SMM END SMR S...

Page 12: ... instrument for 1 sec ELECTR ELECTR ELECTR ELECTR ELECTRONIC DIGIT ONIC DIGIT ONIC DIGIT ONIC DIGIT ONIC DIGITAL B AL B AL B AL B AL BA A A A ACKLIT DISPLA CKLIT DISPLA CKLIT DISPLA CKLIT DISPLA CKLIT DISPLAY Y Y Y Y T T T T TA A A A ACHOMETER OPTION CHOMETER OPTION CHOMETER OPTION CHOMETER OPTION CHOMETER OPTIONAL FOR END SMR SMM AL FOR END SMR SMM AL FOR END SMR SMM AL FOR END SMR SMM AL FOR END...

Page 13: ... a battery This button is deactivated when there is a battery COMBIN COMBIN COMBIN COMBIN COMBINA A A A ATION SWIT TION SWIT TION SWIT TION SWIT TION SWITCH SUPPLIED CH SUPPLIED CH SUPPLIED CH SUPPLIED CH SUPPLIED WITH WITH WITH WITH WITH ELECTR ELECTR ELECTR ELECTR ELECTRONIC DIGIT ONIC DIGIT ONIC DIGIT ONIC DIGIT ONIC DIGITAL B AL B AL B AL B AL BA A A A ACKLIT DISPLA CKLIT DISPLA CKLIT DISPLA C...

Page 14: ...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 is found on...

Page 15: ...soon 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 AR AR AR ARTER TER TER TER TER 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 found on the h...

Page 16: ...e 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 Push the side stand to the floor using the foot and res...

Page 17: ...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 PAIOLIUSDFORK 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 clockwise braking increases turning anticlockwise i...

Page 18: ...ER 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 ADJUST ADJUST IN COMPRESSION IN COMPRESSION IN COMPRESSION IN COMPRESSION IN COMPRESSION The hydraulic brake system in compression determines the behaviour of the shock absorber in the compression ...

Page 19: ...aking 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 absorber side of mechanical linkage Use a screwdriver By turning clockwise braking increases anticlockwise it decreases A total of 40 clicks are available OHLINS SHOCK ABSORBER OPTIONAL The adjustment knob...

Page 20: ...To lock the steering turn the handlebar completely to the right insert the key turn it to the left press turn to the right and extract WARNING NEVER LEAVE THE KEYIN THE LOCK BYTURNINGTHE 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 TI...

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

Page 22: ...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 23: ...ENGLISH ENGLISH ENGLISH 23 ...

Page 24: ...e 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 of...

Page 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...ENGLISH ENGLISH 30 ...

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

Page 32: ...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 33: ... 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 by more...

Page 34: ... 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 35: ...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 36: ...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 37: ...ENGLISH ENGLISH ENGLISH 37 ...

Page 38: ...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 39: ...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 40: ...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 41: ... 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 42: ... spring 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 mm Loosen the lock ring nut 6 and turn the adjustment ring nut By turning it anti clockwise viewed from top the pre load decreases by turning it clockwise the pre load increases After the adjust...

Page 43: ...ODELS 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 tensioner m...

Page 44: ...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 45: ...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 46: ...LA 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 BRAKE LEVER FRONT BRAKE LEVER The free play of 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 perceived at the fr...

Page 47: ...bra 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 B...

Page 48: ...nscrew 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 to go back to their seat Extract the worn pads and insert the new ones Repeat the operation for the other pair of pads Press the two hooks down and re insert the pins make sure that they are fully ins...

Page 49: ...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 50: ...he 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 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 TH...

Page 51: ...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 52: ...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 53: ...SOR DIST DIST DIST DIST DISTANCE A ANCE A ANCE A ANCE A ANCE A ELECTRONICTACHOMETER In the END model the magnetic sensor is located on the front wheel while in the SMR SMM it is located on the rear wheel ELECTRONICDIGITALBACKLITDISPLAYTACHOMETER In all the models the magnetic sensor is located on the rear wheel The distance between detector 2 and sensor 1 must be 2 4mm Otherwise the tachometer may...

Page 54: ...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 55: ...clusively with an equivalent one If the new fuse should also burn out once mounted contact a special ised TM workshop WARNING NEVERMOUNTFUSESWITHGREATERPOWERORTRYTO REPAIR THESAME FUSE UNAPPROPRIATETREATMENTSCOULDCAUSEFAULTSTOTHEENTIRE ELECTRICEQUIPMENT REPLACEMENT OF REPLACEMENT OF REPLACEMENT OF REPLACEMENT OF REPLACEMENT OF HEADLIGHT HEADLIGHT HEADLIGHT HEADLIGHT HEADLIGHT POSITION LIGHT POSITI...

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 TOUCHTHEGLASSBULB TOPREVENTLEAVINGTRACESOFGREASE TOBESUREOFINSERTINGTHEESTABLISHEDBULBS CONSULTTHE CYCLE PART TECHNICAL DATA TABLE REPLACEMENT OF REAR POSITION STOP REPLACEMENT OF REAR POSITION STOP REPLACEMENT OF...

Page 57: ... THAT 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 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 pro...

Page 58: ...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 causing a de crease in power To replace the fibreglass disassemble the s...

Page 59: ... positioned correctly 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 it adequately CHECK HAND DECOMPRESSOR CHECK HAND DECOMPRESSOR CHECK HAND DECOMPRESSOR CHECK HAND DECOMPRESSOR CHECK HAND DECOMPRESSOR ADJUST ADJUST ADJUST ADJUST ADJUST A A A A A ALL ...

Page 60: ...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 fluid 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 with the rubber seal 4 Keeping t...

Page 61: ...s to 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 direction with respect to the ideal value because the engine will become hotter than normal NOTE If the described methods are followed and satisfying results are not obtained the cause could be a Pilot je...

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 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...

Page 63: ...r SH classes indications 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 WHEN CHANGING THE OIL CLEAN THE MAGNET OF THE OIL DRAINBOLTANDREPLACETHEFILTERCARTRIDGE The oil must be changed with the engine at work...

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: ...1 4 litres 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 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 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: ...CRD41 195 45 OCEMP 3 rd 1 5 1 5 turn 3 8 0 throttle 100 throttle 1 9 0 8 1 9 0 8 1 9 0 8 1 9 0 8 1 9 0 8 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 URETOR SETTING OR SETTING OR SETTING OR SETTING OR SETTING T T T T T ABLE MODELS 2008 30 10 07 REV ABLE MODELS 2008 30 10 07 REV ABLE MODELS 2008 30 10 07 REV ABLE MODELS 2008 30 10 ...

Page 72: ...d 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 Primary transmission 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 Ign...

Page 73: ...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 MX TIGHTEN...

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 2008 A 250 450 530 SMR SMM 250 450 530 660 SMX 2008 A 250 450 530 SMR SMM 250 450 530 660 SMX 2008 A 250 450 530 SMR SMM 250 450 530 660 SMX 2008 A 250 450 530 SMR SMM 250 450 530 660 SMX 2008 TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL DA A A A AT T T T TA 250 4...

Page 75: ... 62 Engine number 8 Engine oil 63 Engine stop switch MX SMX 13 ENGINETIGHTENINGTORQUES 72 Establishing rear shock lowering in running order 40 Establishing rear shock static lowering 41 Fork adjustment in compression 17 Fork adjustment in rebound 18 Page FRAMEANDENGINEMAINTENANCE 37 Frame number 8 Free play adjustment of front brake lever 46 Front brake lever 10 Fuel 29 Fuel filler cap 14 Fuel tap...

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: ...W 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 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 TERM...

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

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

Page 80: ...ENGLISH ENGLISH 80 ...

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