TM RACING 250Fi EN Instruction manual

www.tmracing.it
Ed.02 - 03/2019
Workshop Manual
250 - 300
EN 450

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
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.
This manual states information notes with particular meanings:
DANGER : Accident-prevention regulations for the operator and anyone operating in the vicinity.
WARNING: There is a possibility of damage to the vehicle and/or its components.
NOTE: Additional information inherent the operation in progress.
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 and the participation of courses, which are periodically organised by TM Racing:
– 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 TM Racing 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.
IMPORTANT: Before operating on the motorcycle, disconnect the negative pole on the battery.

1
INDEX
1. IDENTIFICATION OF THE VEHICLE .........................................................3
2. TECHNICAL SPECIFICATIONS.................................................................7
3. DIAGNOSIS ........................................................................................ 19
4. REGISTRATIONS/ADJUSTMENTS......................................................... 21
4.1 CHECKING COOLANT LEVEL ......................................................................23
4.2 DRAINING, FILLING AND BLEEDING COOLING SYSTEM .................................24
4.3 HYDRAULIC CLUTCH PUMP.......................................................................24
4.4 BLEEDING HYDRAULIC CLUTCH.................................................................25
4.5 NISSIN FRONT BRAKE PUMP.....................................................................26
4.6 BREMBO FRONT BRAKE PUMP .................................................................27
4.7 BREMBO RADIAL FRONT BRAKE PUMP ....................................................28
4.8 BREMBO 16X18 RADIAL FRONT BRAKE PUMP .........................................29
4.9 CHANGING BASE POSITION OF REAR BRAKE PEDAL.................................30
4.10 CHECKING REAR BRAKE FLUID LEVEL........................................................30
4.11 CLEANING THE AIR FILTER.........................................................................31
4.12 STARTER AUXILIARY DEVICE......................................................................32
4.13 ACCELERATOR COMMAND CABLES ADJUSTMENT....................................33
4.14 ADJUSTING IDLE SPEED.............................................................................33
4.15 CHECKING CHAIN TENSION ......................................................................34
 ........................................................34
4.17 CHAIN MAINTENANCE..............................................................................35
4.18 CHAIN WEAR.............................................................................................35
4.19 CHECKING SHOCK ABSORBER STATIC SAG ................................................36
4.20 CHECKING SHOCK ABSORBER RIDER SAG.................................................36
4.21 SHOCK ABSORBER COMPRESSION ADJUSTMENT.....................................37
4.22 SHOCK ABSORBER REBOUND ADJUSTMENT ............................................38
4.23 ...................... 38
4.24 FORK COMPRESSION ADJUSTMENT .........................................................39
4.25 FORK REBOUND ADJUSTMENT.................................................................40
 ...............................41
4.27 BLEEDING TELESCOPIC FORK ....................................................................41
4.28 CHECKING STEERING BEARINGS AND PLAY ADJUSTMENT .......................42
4.29 ADJUSTING THE MAIN LIGHT HEIGHT ......................................................43
4.30 HEADLIGHT HEIGHT ADJUSTMENT ...........................................................43
5. GENERAL OPERATIONS ...................................................................... 45
5.1 SEAT REMOVAL .........................................................................................47
5.2 LATERAL PANELS DETACHMENT................................................................47
5.3 RADIATOR CONVEYORS REMOVAL............................................................48
5.4 RADIATOR FINS REMOVAL ........................................................................48
5.5 DISASSEMBLY AND MOUNTING THE FRONT WHEEL ................................49
5.6 DISASSEMBLY AND MOUNTING THE REAR WHEEL...................................50
5.7 SPRAY GUARD REMOVAL ..........................................................................50

2
INDEX
6. PARTS REMOVAL................................................................................ 51
6.1 MUD GUARDS REMOVAL..........................................................................53
6.2 REAR MUD GUARD REMOVAL COMPLETE
WITH LICENCE PLATE HOLDER AND DIRECTION INDICATORS...................55
6.3 REAR POSITION INDICATOR LIGHT REPLACEMENT...................................57
6.4 TAIL LIGHT REPLACEMENT........................................................................58
6.5 LICENCE PLATE HOLDER REMOVAL...........................................................60
 .........................................62
6.7 FRONT DIRECTION INDICATOR LIGHT REPLACEMENT ..............................63
6.8 EXHAUST UNIT..........................................................................................64
6.9 EXHAUST UNIT REMOVAL .........................................................................65
6.10 TANK REMOVAL ........................................................................................68
6.11 TANK DISMANTLING .................................................................................70
6.12 INJECTOR REPLACEMENT..........................................................................71
6.13 SWING ARM REAR SHOCK ABSORBER ......................................................73
6.14  .........................75
6.15 LINKAGES ..................................................................................................77
6.16 REAR SWING ARM REMOVAL ...................................................................78
6.17 FRONT SWING ARM REMOVAL.................................................................83
6.18 FRONT SWING ARM DISMANTLING..........................................................86
 ....................................97
6.20 ACOUSTIC SIGNAL REPLACEMENT..........................................................100
6.21 MAP CHANGE SELECTOR SWITCH REPLACEMENT..................................100
6.22 COMBINATION SWITCH REPLACEMENT .................................................101
6.23 START COMMAND REPLACEMENT..........................................................102
6.24 INSTRUMENT REPLACEMENT .................................................................102
6.25 TENSION ADJUSTER REPLACEMENT .......................................................104
6.26 START CONTACTOR REPLACEMENT ........................................................104
6.27 INDICATOR LIGHT REPLACEMENT...........................................................104
6.28 CONTROL UNIT REPLACEMENT ..............................................................104
6.29 SPEED SENSOR REPLACEMENT...............................................................105
6.30 REAR STOP SENSOR REPLACEMENT .......................................................105
6.31 FRONT STOP SENSOR REPLACEMENT .....................................................106
6.32 COOLING SYSTEM ...................................................................................107
6.33 RADIATORS REMOVAL.............................................................................108
6.34 ENGINE REMOVAL FROM THE MOTORCYCLE .........................................110
  ..........................................................................119

3
1. IDENTIFICATION OF THE VEHICLE

4
1. IDENTIFICATION OF THE VEHICLE

5
RICONOSCERE I MODELLI DI MOTO TM RACING
ESEMPIO DI MODELLO MOTO
CILINDRATA
250 = 250cc
300 = 300cc
TIPO DI ALIMENTAZIONE
Fi = INIEZIONE
TIPO DI USO
EN = ENDURO
MX = MOTOCROSS
FT = FLAT TRACK
SMR = SUPER MOTO STRADALE
SMM = SUPERMOTO MONOBRACCIO
SMX = SUPERMOTO COMPETIZIONE
TIPO DI AVVIAMENTO
(SOLO QUANDO INSERITO COME OPTIONAL)
E.S. = ELECTRIC START
K.S. = KICK START
300Fi MX E.S.
2
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2
1






power source.





FRAME SERIAL NUMBER
     




1. IDENTIFICATION OF THE VEHICLE

6
1
2
2
3
ENGINE SERIAL NUMBER



manual.
KAYABA FORK CODE

TM SHOCK ABSORBER CODE


1. IDENTIFICATION OF THE VEHICLE