TM RACING 450 Instruction manual
Ed.01 - 03/2019
www.tmracing.it
Workshop Manual
4 STROKE ENGINE
Mx - En - SMx
SMr - SMM-2016 450-530
TM Racing SPA, declines all liability for any errors in the compilation of this manual, and reserves the right to make any modifications required
for the development of its products. Illustrations shown are approximate and, in some cases, may not precisely correspond with the part
referred to. Reproduction of this publication, even partial, without written authorisation is prohibited.
Foreword
This publication, to be used by TM Racing workshops, has been drawn-up to assist authorised personnel in the maintenance and repair of
motorcycles handled. Perfect knowledge of the technical data stated herein is decisive for the most complete professional training of the
operator.
In order to make it easier to understand, the paragraphs have been distinguished by schematic illustrations, which highlight the topic in
question.
Always operate in compliance with the accident-prevention regulations in force, using suitable PPE.
COOLANT LIQUID
DANGER
FIRE RISK: IN SOME CONDITIONS, THE COOLANT IS FLAMMABLE. ITS FLAMES ARE INVISIBLE, BUT CAN CAUSE BURNS.
DO NOT POUR COOLANT ONTO EXHAUST SYSTEM COMPONENTS OR ONTO ENGINE COMPONENTS, SINCE THEY COULD BE HOT
AND IGNITE THE COOLANT, WITH THE RISK OF BURNS. KEEP IN MIND THAT THE FLAMES ARE INVISIBLE.
COOLANT MAY IRRITATE THE SKIN AND IS TOXIC IF SWALLOWED.
KEEP COOLANT OUT OF THE REACH OF CHILDREN
COOLANT IS HIGHLY POLLUTANT. THEREFORE, AFTER USE, IT MUST BE DISPOSED OF AT SPECIAL COLLECTION CENTRES IN COMPLIANCE
WITH THE REGULATIONS IN FORCE IN THE COUNTRY IN WHICH THE MOTORCYCLE IS USED.
USED ENGINE OIL AND GEARBOX OIL
DANGER
KEEP OUT OF THE REACH OF CHILDREN.
ENGINE OIL AND GEARBOX OIL CAN SERIOUSLY DAMAGE SKIN IF HANDLED REGULARLY OVER LONG PERIODS OF TIME.
WASH YOUR HANDS THOROUGHLY AFTER HANDLING THE OIL.
WEAR LATEX GLOVES OR EQUIVALENT DURING MAINTENANCE WORK ON THE MOTORCYCLE.
OIL IS HIGHLY POLLUTANT. THEREFORE, AFTER USE, IT MUST BE DISPOSED OF AT SPECIAL COLLECTION CENTRES IN COMPLIANCE
WITH THE REGULATIONS IN FORCE IN THE COUNTRY IN WHICH THE MOTORCYCLE IS USED.
DO NOT POUR USED OIL INTO DRAINS OR RIVERS. DISPOSE OF FILTERS AT SPECIAL COLLECTION CENTRES IN COMPLIANCE WITH
REGULATIONS IN FORCE IN THE COUNTRY IN WHICH THE MOTORCYCLE IS USED.
Useful advice
In order to prevent problems on reaching an excellent final result, TM Racing srl recommends that the following generic regulations are
complied with:
– in the event of any repair, assess the impressions of the Customer reporting the operating anomalies of the motorcycle and formulate
appropriate questions in order to clarify the symptoms of the problem;
– clearly diagnose the cause of the anomaly. From this manual it is possible to assimilate the essential theoretical bases, which, moreover,
must be integrated by personal experience:
– plan the repair rationally, in order to prevent downtimes, receiving spare parts, preparation of tools etc.;
– reach the item to repair, limiting to the essential operations.
In this regard, consulting the disassembly sequence shown in this manual, will be of great help.
General repair-related regulations
1 Always replace the gaskets, sealing rings and the cotter pins with new parts.
2 When loosening/tightening nuts or screws, always start with the largest ones or from the centre. Lock at the coupling torque prescribed.
following a crosswise pathway.
3 Always mark all parts or positions that could be exchanged on re-mounting.
4 Use original spare parts and recommended lubricants.
5 Use special tools, where specified.
6 Consult official Technical Memos, since they could contain more updated state adjustment data and methods of intervention, with respect
to this manual.
FOREWORD
1
The displacement, type of power source and type of use dene the motorcycle model and engine of each TM Racing motorcycle.
The combinaon of codes 1 and 3 idenes the standard engine type. The combinaon of the three codes fully idenes the motorcycle model.
All 3 codes are usually used in this Manual, to specify the motorcycle model to which certain informaon refers.
If only codes 1 and 3 are indicated, followed by the word “ALL”, it means that the informaon relates to all motorcycles with standard engine,
regardless of the type of use.
Code 2 (Type of Use) used alone means that the informaon refers to all motorcycles with that type of use, regardless of displacement and
power source.
All EN/SMR/SMM models are equipped as standard with electric start (E.S.) as well as kick start ( K.S.). MX/SMX models have K.S. as standard
and may be equipped with E.S. as an opon.
Please make a note of your motorcycle’s serial numbers in the boxes below.
When it is necessary to contact TM for spare parts, updates or to report any issues, always quote the model, displacement, year of manufacture
and, above all, the frame serial number and engine serial number.
RECOGNIZING TM RACING MOTORCYCLE MODELS
EXAMPLE OF MOTORCYCLE MODEL
DISPLACEMENT
250 = 250cc
300 = 300cc
TYPE OF POWER SOURCE
Fi = INJECTION
TYPE OF USE
EN = ENDURO
MX = MOTOCROSS
FT = FLAT TRACK
SMR = ROAD SUPERMOTO
SMM = SINGLE ARM SUPERMOTO
SMX = COMPETITION SUPERMOTO
TYPE OF START
(ONLY WHEN INCLUDED AS AN OPTIONAL)
E.S. = ELECTRIC START
K.S. = KICK START
RECOGNITION
450Fi MX E.S.
2
13
ENGINE SERIAL NUMBER
The engine serial number (1) is embossed into the rear part of the engine,
near to the shock absorber.
Make a note of this number in the relevant space at the beginning of the
manual.
1
1. ADJUSTMENTS/REPLACEMENTS ..........................................................7
....................................8
..................................................................12
.........................................................16
..................................................18
......................................................19
...........................................................21
1.6.1 Disc pack removal ........................................................................ 21
............................. 23
.....................................................................................................28
2. ENGINE DISASSEMBLY........................................................................ 29
............................................................30
...................................................................................31
........................................................................................................32
............................................................................... 32
......................................................................... 33
........................................................................ 35
........................................................................ 36
.............................................................................38
........................................................ 38
........................ 39
....................................................... 39
................................................. 39
...................................................................... 41
...............................................42
............................................................42
....................................................................................................43
............................... 43
................................................................... 43
.................................................................. 43
..........................................................................................44
..............................................................................44
............................................................................. 44
2.9.2 Stator ........................................................................................... 45
2.9.3 Pick-up ......................................................................................... 45
............................................................................................ 46
.....................................................................................48
.................................................................................. 48
................................................................................ 49
..........................................................................................51
...........................................................................53
................................... 54
................................................................. 54
.................................................. 54
............................................56
...................................................................... 56
..................................................................... 57
............................................................... 57
INDEX
2
.......................................................................58
................................................................................. 58
................................................................................. 59
................................................61
..............................................................63
...............................................................................64
..............................................66
.......................................................66
................................................................................................68
2.20.1 Aperture....................................................................................... 68
................................................................................. 69
...............................................69
................................................................... 69
...................................................................... 69
..................................................................... 69
...................................................... 71
.................................................. 71
2.21.6 Gears drum removal .................................................................... 71
........................................................................... 71
.................................................................. 72
............................................................ 72
INDEX
3
ENGINE TECHNICAL DATA 450FiiEN EU4 450Fi-520Fi
ENGINE MODEL 450
Displacement 449 cm3528 cm3
Bore x stroke 95x63.4 mm 98x70 mm
12.9: 1 12.5: 1
N2/N3
36 mm
31 mm
0.15 mm +/- 0.002 mm
0.20 mm +/- 0.002 mm
Piston
1.4/1.5 litres
transmission 20 / 57 21 / 53
1st
2nd
3rd
4
5
14:28
17:25
19:23
21:21
24:19
14:28
17:25
19:23
21:21
24:19
Generator
Electrode distance 0.8 mm
1.3 litres
Start up
Key:
E.S. = Electric Start
K.S. =
WARNING
TECHNICAL SPECIFICATIONS
4
MAINTENANCE TABLE
Every 15
every ride)
Every 45
Every year
•••
•
• •
•••
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
WARNING
MAINTENANCE
5
TM
ENGINE
1.
2.
3.
4.
5.
6.
7.
8. Adjust
9.
1.
2.
3. Adjust
4.
5.
1.
2.
3. Adjust
1.
2.
3.
4.
5. Adjust
6.
7.
8. Adjust
1.
2.
3.
4.
1.
2.
1.
2.
1.
2.
1.
TROUBLESHOOTING
6
INSUFFICIENT ENGINE POWER
Adjust
Adjust
recommended Top-up or replace
Adjust
ELECTRIC PART
overheat
Adjust
The starter motor
TROUBLESHOOTING
7
1. ADJUSTMENTS/REPLACEMENTS
8
1
1
1
2
2
4
1a
1a
ADJUSTMENTS/REPLACEMENTS
9
5
7
6
8
510
11
9
ADJUSTMENTS/REPLACEMENTS
10
10
12
14
11
15
17
16
ADJUSTMENTS/REPLACEMENTS
11
18
19
20
20
21
22
24
25
21a
22
B
25
ADJUSTMENTS/REPLACEMENTS
12
11
10 27
28
28
28
8
5
29
ADJUSTMENTS/REPLACEMENTS
stems.
13
9
11
10 27
28
28
28
29
ADJUSTMENTS/REPLACEMENTS
14
B
25
25
19
19
20
20
21
22
21a
22
ADJUSTMENTS/REPLACEMENTS
15
18
17
16
19
15
1
1
1
2
1a
1a
1
2
ADJUSTMENTS/REPLACEMENTS
16
2
1
1
6
5
4
ADJUSTMENTS/REPLACEMENTS
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1
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