TM RACING 4 STROKE 2006 Operating instructions

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

ENGLISH
ENGLISH
2

ENGLISH
ENGLISH
ENGLISH
3
ENGINE NUMBERENGINE NUMBER
ENGINE NUMBERENGINE NUMBER
ENGINE NUMBER
KEY NUMBERKEY NUMBER
KEY NUMBERKEY NUMBER
KEY NUMBER
STST
STST
STAMP OFAMP OF
AMP OFAMP OF
AMP OF THETHE
THETHE
THE AA
AA
AUTHORISED DEALERUTHORISED DEALER
UTHORISED DEALERUTHORISED DEALER
UTHORISED DEALER
TM reserves the right to carry out changes without forewarning. The specifications can change from country to country.
All indications are valid subject to spelling and printing errors.
FRAME NUMBERFRAME NUMBER
FRAME NUMBERFRAME NUMBER
FRAME NUMBER
Please make note of your motorcycle’s serial numbers 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.
IMPORIMPOR
IMPORIMPOR
IMPORTT
TT
TANTANT
ANTANT
ANT
YOUAREADVISEDTOREADTHISMANUALCAREFULLYBEFOREUSINGYOUR MOTOTM.
IT CONTAINSALOT OF INFORMATION ANDADVICETHAT WILLMAKE THE USEAND MAINTENANCE OF THE
MOTORCYCLEMUCHEASIERANDSAFER.
IT IS INYOUR SPECIFIC INTERESTTO PAY PARTICULARATTENTION TO THE WARNINGS INDICATED IN THE
FOLLOWINGWAY:
DD
DD
DANGERANGER
ANGERANGER
ANGER
FAILURE TO COMPLY WITH THESE WARNINGS RISKS LIVES!
WARNINGWARNING
WARNINGWARNING
WARNING
FAILURE TO COMPLY WITH THESE WARNINGS COULD CAUSE DAMAGE TO PARTS OF THE MOTORCYCLE
OR MAKE IT UNSAFE FOR USE.

ENGLISH
ENGLISH
4
DearDear
DearDear
Dear TM customerTM customer
TM customerTM customer
TM customer,,
,,
,
We would like to congratulate you for having chosen a TM motorcycle.
Your TM is a competitive and modern motorcycle that will surely give you a lot of satisfaction if you treat it
accordingto theprovisions containedinthis manual.Before starting up your TM motorcycle for the first time,
you must read this manual carefully so as to understand the regulations for use and the features of your
new motorcycle.
Only in this way will you know how to adjust the motor cycle, and to adapt it in the best way possible to
yourpersonal characteristics andhow to protectyourselffrom injury. This manualalsocontainsimportant
information regarding the maintenance of your new motorcycle.
Thismanual isbased onthemost recentinformation concerningthe productthatwas availableon goingto press.
Furthervariations owingtosuccesive constructivedevelopments ofthemotorcycle arehoweverpossible.
Thismanual isanintegral partofthe motorcycle,itmust begivento thecustomeratthetime ofpurchaseand must
remain with the motor cycle whenever it is re-sold.
Pleasenote thatthe operationsmarked with(A) inthe “Frameand EngineMaintenance” chaptermust becarried
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 products and for damage deriving from them.
Weadviseyoutorespecttherunningin period,inspectionperiodsandestablishedmaintenanceperiodsscrupulously.
Only full compliance with these regulations will lengthen the life of your motorcycle. Overhauls and repairs must
only be carried out by a specialised TM workshop.
For any information or requests contact a specialised TM workshop, which is backed by theTM importer.
PleaserememberthatalotoftechnicaldataandinformationregardingTMmotorcyclesisavailableat:www.tmracing.it.
Motorcycling is a marvellous sport that you will be able to enjoy with your TM motorcycle.
Always remember to respect the environment and other people.Always use the motorcycle with caution, it is in
everybodysinterest tosafe tosafeguard thefuture ofour sport.
Enjoyyourself withyour TMmotorcycle!
TM RACING S.p.A.
Via Fano 6 - 61100 PESARO
ITALY
TMRESERVESTHE RIGHTTOCHANGEORTOEXECUTE MODIFICATIONSAS ITDEEMS NECESSARY.

ENGLISH
ENGLISH
ENGLISH
5
IMPORIMPOR
IMPORIMPOR
IMPORTT
TT
TANTANT
ANTANT
ANT ADAD
ADAD
ADVICE REGARDINGVICE REGARDING
VICE REGARDINGVICE REGARDING
VICE REGARDING
THE LEGAL WARRANTY AND THETHE LEGAL WARRANTY AND THE
THE LEGAL WARRANTY AND THETHE LEGAL WARRANTY AND THE
THE LEGAL WARRANTY AND THE
COMMERCOMMER
COMMERCOMMER
COMMERCIALCIAL
CIALCIAL
CIAL WW
WW
WARRANTYARRANTY
ARRANTYARRANTY
ARRANTY
TM sport motorcycles are designed and constructed in a manner to support the stress that may be
verified innormal roadand competitionuse.
Competitionmotorcycles arein compliancewith theregulations ofthe categoriesactually inforce at
themost importantinternational motorcyclingfederations.
Thescrupulous compliancewith theestablished controls,maintenanceandtuningof theengine and
chassis part of the motorcycle, indicated in the user manual, is indispensable for correct functioning
andto preventpremature wearof theparts ofthe motorcycleitself.
Incorrect tuning of the engine or of the chassis can also jeopardise one’s own safety and that of
others.
Themaintenance operationsestablished inthe “Maintenanceand Lubrication”tablemustbecarried
out by a specialised TM workshop at the envisioned dates, otherwise any warranty rights will be
forfeited.
Whenyoumustcontact TMfor spareparts, updatingrequestsortosignalproblems, indicatethe model,
cylindercapacity,yearof manufactureandmost ofallthe framenumberandthe engineserialnumber.
Fuels and lubricants must be those established in the user and maintenance manual and must be
usedas permaintenanceprogramme. Productsofother brandscanbe usedaslong asthey havethe
equivalentspecifications.
In cases of direct and consequent damage caused by tampering or modifications to the motorcycle,
no legal warranty claim can be asserted.
The use of the motorcycle in extreme conditions, for example on muddy and very wet ground, may
leadto greaterthanaverage wearof components,suchas transmissioncomponents orthebrakes. It
is therefore possible that maintenance or replacement of some parts is necessary before the limit
normallyenvisioned bythemaintenance programme.
MX AND SMX MODELS CANNOT BE USED ON PUBLIC ROADS.
The 250 and 450 models in the END, SMR and SMM versions can be used on roads only in the
unvaried type-approved version (reduced). Without this power limitation (i.e. reduced) these
models can only be used off-the-road, but not on public roads.
TheEND modelshave beendesigned foroff-the-road resistancecompetitions (Enduro)and arenot
suitablefor motor-cross.

ENGLISH
ENGLISH
6
INDEXINDEX
INDEXINDEX
INDEX
Page
POSITION OF SERIAL NUMBERS..................................................... 7
Frame number.................................................................................... 8
Engine number.................................................................................... 8
OPERATING CONTROLS.....................................................................9
Clutch lever.........................................................................................10
Manual decompressor lever............................................................... 10
Front brake lever................................................................................ 10
Control lights.......................................................................................10
Electronic tachometer ....................................................................... 11
Function selection and reset.............................................................. 11
Programming the electronic tachometer............................................. 11
Programming the clock....................................................................... 12
Setting the distance travelled............................................................. 12
Engine stop switch (MX/SMX).............................................................12
Combinationswitch (END/SMR/SMM)................................................ 12
Start command and emergency stop
(END/MXE.S./SMXE.S./SMR/SMM) ..................................................... 13
Fuel fill cap......................................................................................... 13
Fuel tap.............................................................................................. 13
Throttle command (cold starter)......................................................... 14
“By-Pass” command (warm starter)...................................................14
Idle speed adjustment command.........................................................14
Gear shift pedal .............................................................................. 15
Kickstart pedal................................................................................... 15
Brake pedal ...................................................................................... 15
Side stand.......................................................................................... 15
Fixing for off-the-road journeys.........................................................16
Ignition switch.................................................................................... 16
Fork adjustment in compression........................................................ 16
Fork adjustment in extension..............................................................17
Damper adjustment in compression................................................... 17
Damper adjustment in extension........................................................ 18
Steering lock ..................................................................................... 19
ADVICEANDGENERALRECOMMENDATIONSFOR
COMMISSIONING THE MOTORCYCLE .......................................... 21
Indications for the first start-up..........................................................22
Running in instructions....................................................................... 22
INSTRUCTIONSFORUSE...................................................................23
Pre-ride control.................................................................................. 24
Engine ignition when cold...................................................................25
Engine ignition when warm ............................................................... 25
If engine is “flooded”.......................................................................... 26
Departure............................................................................................26
Changing gear, accelerating, slowing down.......................................26
Braking................................................................................................28
Stoping and parking ........................................................................ 28
Petrol.................................................................................................. 29
LUBRICATIONAND MAINTENANCE PROGRAMME ...................... 31
FRAMEANDENGINE MAINTENANCE ............................................. 37
Control of steering bearings and play adjustment...............................38
Telescopic fork vent screws............................................................. 39
Cleaning of telescopic fork dust scraper........................................... 39
Basic calibration of the chassis on the basis of pilot weight .......... 39
Damper calibration and spring control................................................40
Establishment of damper static lowering........................................... 40
Establishment of damper lowering in running order........................... 40
Control of telescopic fork basic calibration........................................ 41
Variation of telescopic fork pre-load.................................................. 41
Replacement of fork springs...............................................................41
Variation of damper spring pre-load ..................................................42
Rear suspension mechanical 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 pedal basic position..................................49
Control rear brake fluid level.............................................................. 49
Top-up rear brake fluid....................................................................... 49
Control rear brake pads......................................................................50
Replacement of rear brake pads........................................................50
Disassembly and assembly of front wheel........................................50
Disassembly and assembly of rear wheel (all except SMM) ......... 51
Disassembly and assembly of rear wheel (SMM)..............................52
Control of spoke tension.....................................................................52
Tyres, tyre pressure.......................................................................... 53
Control/adjustment of magnetic sensor distance................................53
Battery(all models with E.S.) .......................................................... 53
Battery charger...................................................................................54
Recharge fuse (all models with E.S.) ............................................. 55
Services fuse (all models with lights)............................................... 55
Replacement of headlight / position light bulb.................................... 55
Replacement of headlight / position light bulb (with cyclops).............56
Replacement of rear light bulb
positionlight/stop light/numberplate light(END/SMR/SMM) ................56
Replacement of indicator bulb............................................................ 56
Cooling................................................................................................57
Control coolant level........................................................................... 58
Unloading, filling and bleeding of cooling system................................58
Replacement of exhaust silencer filling material.................................58
Cleaning the air filter........................................................................... 59
Control of hand decompressor adjustment........................................ 59
Adjustment of throttle cable command............................................... 60
Adjustment of clutch lever basic position.......................................... 60
Control hydraulic clutch oil level......................................................... 60
Bleeding of hydraulic clutch................................................................60
Carburetor - Adjustment of idle speed............................................... 61
Basic indications regarding wear of the carburetor...........................61
Control fuel level (float height)........................................................... 62
Emptying of carburetor tank............................................................... 62
Oil circuit .................................................................................. 62
Control engine oil level........................................................................63
Engineoil ........................................................................................ 63
Change engine oil ............................................................................ 63
TROUBLESHOOTING......................................................................... 66
CLEANING..........................................................................................68
PRECAUTIONSFOR WINTER USE.................................................... 68
PRESERVATION................................................................................. 68
Start-up after seasonal pause........................................................... 68
TECHNICAL DATA - ENGINE........................................................ 69/70
CARBURETORSETTINGS..................................................................71
ENGINECOUPLINGTORQUES.......................................................... 72
CYCLE PART TECHNICAL DATA .................................................73-74
ALPHABETICAL INDEX......................................................................75
WIRING DIAGRAM................................................................ appendix
INDEXINDEX
INDEXINDEX
INDEX

ENGLISH
ENGLISH
ENGLISH
7

ENGLISH
ENGLISH
8
POSITION OF SERIAL NUMBERPOSITION OF SERIAL NUMBER
POSITION OF SERIAL NUMBERPOSITION OF SERIAL NUMBER
POSITION OF SERIAL NUMBER
FRAME NUMBERFRAME NUMBER
FRAME NUMBERFRAME NUMBER
FRAME NUMBER
The frame number is embossed on the right side of the steering metal
tube. Make note of this 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 NUMBERENGINE NUMBER
ENGINE NUMBERENGINE 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 NUMBERPOSITION OF SERIAL NUMBER
POSITION OF SERIAL NUMBERPOSITION OF SERIAL NUMBER
POSITION OF SERIAL NUMBER

ENGLISH
ENGLISH
ENGLISH
9

ENGLISH
ENGLISH
10
2
21
A
3
B
A
1
CLUTCH LEVERCLUTCH LEVER
CLUTCH LEVERCLUTCH LEVER
CLUTCH LEVER
The clutch lever (1) is mounted on the left of the handlebar. The position
of the clutch lever, with respect to the handlebar grip, can be varied
using the adjustment screws (A) (see maintenace operation).
The adjusting screws (B) are used to adjust the and the ensure correct
freeplay pump after having adjusted the lever position.
MANUAL DECOMPRESSOR LEVERMANUAL DECOMPRESSOR LEVER
MANUAL DECOMPRESSOR LEVERMANUAL DECOMPRESSOR LEVER
MANUAL DECOMPRESSOR LEVER
(ALL530 AND 660CC.)(ALL530 AND 660CC.)
(ALL530 AND 660CC.)(ALL530 AND 660CC.)
(ALL530 AND 660CC.)
The hand decompressor lever (2) is on the left side of the handlebar,
and is used when, or after a fall or following overheating, the engine
finds it difficult to start-up when warm. To ventilate the engine, pull the
decompressor lever during ignition.
The lever must 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 LEVERFRONT BRAKE LEVER
FRONT BRAKE LEVERFRONT 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 of the brake lever with
respect to the handlebar grip can be varied using the adjustment screw
(A) (see “Frame and Engine Maintenance” chapter”).
CONTROL LIGHTS (END/SMR/SMM)CONTROL LIGHTS (END/SMR/SMM)
CONTROL LIGHTS (END/SMR/SMM)CONTROL LIGHTS (END/SMR/SMM)
CONTROL LIGHTS (END/SMR/SMM)
The green control light (1) lights up when the indicator is
switched on and flashes in time to the indicator.
The blue control light (2) illuminates when the full beam
headlight is switched on.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
ENGLISH
11
ELECTRELECTR
ELECTRELECTR
ELECTRONICONIC
ONICONIC
ONIC TT
TT
TAA
AA
ACHOMETER (END/SMR/SMM)CHOMETER (END/SMR/SMM)
CHOMETER (END/SMR/SMM)CHOMETER (END/SMR/SMM)
CHOMETER (END/SMR/SMM)
The electronic tachometer display is always activated.
The electronic tachometer is powered by an SR44 1.5 Volt battery,
(D357) 11.6x5.4mm.
Replace the battery every 2 years or in case of blurring of the display.
To replace the battery, open the cover positioned on the rear using a
screwdriver, and extract the battery.
Insert the new battery, inserting it in a way that the positive pole is
visible from the outside and close the cover.
Beforeextractingthe battery, make note ofthe WS (wheel development)
and DST (total mileage) values.
These values will be re-programmed into the instrument after battery
replacement.
FUNCTION SELECTION AND RESETFUNCTION SELECTION AND RESET
FUNCTION SELECTION AND RESETFUNCTION SELECTION AND RESET
FUNCTION SELECTION AND RESET
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)
Whiletheelectronictachometeralwaysdisplays the speed of the vehicle
expressed in Kmh (or Mph on the basis of the selection made) it also
allows to visualise the following functions on selection:
TRP Daily mileage
AVS Average speed (after 10 hours or 1000Km press RESET)
STP Chronometre (start and stop autom. max. time 10 hours)
MAX Max. speed reached (from the last RESET)
DST Total mileage (up to 99999Km)
CLK Clock
ToresettheTRP, AVS,STPandMAXfunctions,presstherightbutton(blue).
Select the function and press the left button for 5 sec. (yellow).
The values displayed are zeroed.
PP
PP
PRR
RR
ROGRAMMINGOGRAMMING
OGRAMMINGOGRAMMING
OGRAMMING THE ELECTRTHE ELECTR
THE ELECTRTHE ELECTR
THE ELECTRONICONIC
ONICONIC
ONIC TT
TT
TAA
AA
ACHOMETERCHOMETER
CHOMETERCHOMETER
CHOMETER
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM) (only after battery replacement)
Remove the connector positioned on the back of the instrument.
Press the grey button on the rear of the instrument for 5 seconds. Four
numbers appear on the display, of which the first is flashing. “WS”
(Wheel Size) also flashing, appears in the top right of the display.
Now press in sequence, the left hand button (yellow) to change the
value of the first flashing number.
Press the right hand button (blue) to make the second number flash
and press the left hand (yellow) button in sequence to visualise the
desired value.
Repeat the operation to change the value of the following number and
so on until the exact development of the wheel expressed in mm. (=tyre
diam. in mm.x3.14) is visualised.
Finally, with the 4th number still flashing, to change the unit of
measurement from Kmh to Mph, press the right hand button (blue)
and “Kmh” will start to flash,now press the left hand button (yellow) to
pass to “Mph”.
End programming by pressing the grey button on the rear of the
instrument for 1 sec.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
12
1
3
21
A
B
D
C
PROGRAMMING THE CLOCKPROGRAMMING THE CLOCK
PROGRAMMING THE CLOCKPROGRAMMING THE CLOCK
PROGRAMMING THE CLOCK
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)
Remove the connector positioned on the back of the instrument.
Select the CLK function on the display by pressing the right hand button
(blue).
Press the grey button on the rear of the instrument for 5 secs.and “CLK”
(Clock) will start to flash on the display together with the hours.
Press the left hand button (yellow) to set the hour (on 24 hours).
Press the right hand button (blue) again to make the tens of minutes
flash, press the left hand button (yellow) to set the tens of minutes.
Repeat to set the minutes.
End by pressing the grey button on the rear of the instrument for 1 sec.
SETTINGSETTING
SETTINGSETTING
SETTING THE DISTTHE DIST
THE DISTTHE DIST
THE DISTANCEANCE
ANCEANCE
ANCE TRATRA
TRATRA
TRAVELLEDVELLED
VELLEDVELLED
VELLED
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM) (only after battery replacement)
Thevalue of the distance travelled mustonly bere-inserted ifthe battery
has been replaced.
Five zeroes appear in the display, of which the first is flashing along
with DST, which is also flashing.
Press the right hand button (blue) to make the first of the four numbers
to be set flash and press the left hand button (yellow) to set the desired
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 stop switch (1): when it is
activatedashortcircuitiscaused in the ignition, which no longer supplies
voltage to the spark plug.
Press the button until the engine switches off and then release.
COMBINCOMBIN
COMBINCOMBIN
COMBINAA
AA
ATION SWITTION SWIT
TION SWITTION SWIT
TION SWITCHCH
CHCH
CH
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)(END/SMR/SMM)
(END/SMR/SMM)
This command is found on the handlebar near to the left handlebar
grip.
The light selector switch has 4 positions:
(A) = lights off
(B) = position lights on
(C) = position lights and headlights on
(D) = position lights and headlights on
Key (1) activates the horn.
Use cursor (2) to activate the direction indicators: move it to the left
when turning to the left and towards the right when turning tot he right.
Place it back in the central position when the manouevre has been
carried out.
Use button (3) to switch the engine off (only if the motorcycle does not
have a battery). This button is deactivtaed when there is a battery.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
ENGLISH
13
2
1
1
STST
STST
STARAR
ARAR
ART COMMANDT COMMAND
T COMMANDT COMMAND
T COMMAND AND EMERAND EMER
AND EMERAND EMER
AND EMERGENCY STGENCY ST
GENCY STGENCY ST
GENCY STOPOP
OPOP
OP
(END/MXE.S./SMXE.S./SMR/SMM)(END/MXE.S./SMXE.S./SMR/SMM)
(END/MXE.S./SMXE.S./SMR/SMM)(END/MXE.S./SMXE.S./SMR/SMM)
(END/MXE.S./SMXE.S./SMR/SMM)
In the models with battery and electric ignition, a two-button command
is found at the side of the throttle command, one button is red, the other
black.
The red button (1) has two positions. Positioned inwards, it interrupts
contact with the battery, removing the current from all services
consumers/ancilleries. The engine will not start even with the pedal.
On these models, position it like this to switch the
engine off.
It is advised to leave it like this until the engine is started-up again,
otherwise the battery will go flat.
Positionedoutwards,itclosesthecontactwith the battery,
enables the use of all services, including elecctric starter.
For this reason, never leave it like this with the engine
switched off, otherwise the ignition control unit, which
absorbs current even when the engine is switched off,
can make the battery flat.
The black 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.
Donotinsist for more than 3/4 times: look for the probable
fault.
Never press this button when the engine is running.
FUEL FILLER CAPFUEL FILLER CAP
FUEL FILLER CAPFUEL FILLER CAP
FUEL FILLER CAP
The fuel fill cap is found on top of the tank.
Open: turn the cap in an anti-clockwise direction
Close: place the cap on the inlet well and tighten it in a clockwise
direction.
Position the tank’s open vent pipe (1) preventing bends or crushing
and making sure that it is inserted correctly.
FUELFUEL
FUELFUEL
FUEL TT
TT
TAPAP
APAP
AP
The tap is found on the right hand side of the tank base.
OFF On the OFF position, the fuel tap is closed.
ON On the ON position, the fuel tap is open.
When the motorcycle is used, turn the tap to the ON position. In
this way the fuel flows to the carburetor and the tank empties up
to reserve.
RES On the RES position, the reserve is used. After having filled up
the tank, do not forget to move the tap back to the ON position.
Tank capacity (all models)............ 8 Lt. + reserve 1 Lt.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
14
1
1
1
THRTHR
THRTHR
THROO
OO
OTTLE COMMAND (COLD STTTLE COMMAND (COLD ST
TTLE COMMAND (COLD STTTLE COMMAND (COLD ST
TTLE COMMAND (COLD STARAR
ARAR
ARTER)TER)
TER)TER)
TER)
This command is found on the left side of the motorcycle.
For MIKUNI carburetors
By extracting the choke knob (1) as far as possible, a passage is
opened in the carburetor, through which the engine can suck additional
fuel. In this way, a “rich” air-fuel mix is obtained. This is necessary for
ignition when the engine is cold.
To disconnect the command, push the choke knob inwards to its original
position.
ForKEIHINcarburetors
Extract the knob and turn it in a clockwise direction to block it. To
disconnect it, turn in an anticlockwise direction.
“BY“BY
“BY“BY
“BY-PASS”-PASS”
-PASS”-PASS”
-PASS” COMMAND (HOCOMMAND (HO
COMMAND (HOCOMMAND (HO
COMMAND (HOT STT ST
T STT ST
T STARAR
ARAR
ART)T)
T)T)
T)
All models with electric starAll models with electric star
All models with electric starAll models with electric star
All models with electric starterter
terter
ter
This command is found on the right side of the motor cycle..
By pulling the by-pass knob (1) forward as far as possible, a hole is
opened in the feeding pipe, through which the engine can suck an
additional amount of air not mixed with fuel. The result is a “lean” air-
fuel mix. This is required for ignition of the engine when it is flooded or
particularly 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 (HOCOMMAND (HO
COMMAND (HOCOMMAND (HO
COMMAND (HOT STT ST
T STT ST
T STARAR
ARAR
ART)T)
T)T)
T)
All models with kicAll models with kic
All models with kicAll models with kic
All models with kickstarkstar
kstarkstar
kstartt
tt
t
This command is found on the handlebar, near to the right handlebar
grip.
By turning the by-pass lever (1) as far as possible, a hole is opened in
the feeding pipe, through which the engine can suck an additional
amount of air not mixed with fuel. The result is a “lean” air-fuel mix.
Thisis required for ignition of theengine whenit isflooded orparticularly
overheated.
As soon as the engine is running, push the starter motor to return it to
its normal position.
IDLE SPEED ADJUSTMENT COMMANDIDLE SPEED ADJUSTMENT COMMAND
IDLE SPEED ADJUSTMENT COMMANDIDLE SPEED ADJUSTMENT COMMAND
IDLE SPEED ADJUSTMENT COMMAND
This command is found on the left side of the motorcycle
By turning the idle speed adjustment knob, the normal running of the
engine at idle speed is raised or lowered.
By turning it in a clockwise direction, the idle speed is raised, by turning
it in an anti-clockwise direction, the idle speed is lowered.
The normal idle speed, when the engine is warm, must be between
1,600 and 1,800 revs/min.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
ENGLISH
15
N
2,3,4 (5,6)
2,3,4 (5,6)
1
GEAR SHIFT PEDGEAR SHIFT PED
GEAR SHIFT PEDGEAR SHIFT PED
GEAR SHIFT PEDALAL
ALAL
AL
The gear shift pedal is mounted on the engine on the left. The position
of the gears is indicated in the illustration. The neutal position is found
between the first and second gears.
KICKSTKICKST
KICKSTKICKST
KICKSTARAR
ARAR
ART PEDT PED
T PEDT PED
T PEDALAL
ALAL
AL
The kickstart pedal is mounted on the right side of the engine. The
upper part is turned outwards to start-up the engine and replaced
inside as soon as the engine is running.
BRAKE PEDBRAKE PED
BRAKE PEDBRAKE PED
BRAKE PEDALAL
ALAL
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 STSIDE ST
SIDE STSIDE ST
SIDE STANDAND
ANDAND
AND
Press the side stand to the floor using the foot and rest the motorcycle
on it. Pay attention that the ground is solid and the position stable.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
16
2
3
1
2
FIXING FOR OFF-THE-RFIXING FOR OFF-THE-R
FIXING FOR OFF-THE-RFIXING FOR OFF-THE-R
FIXING FOR OFF-THE-ROO
OO
OAD JOURNEYAD JOURNEY
AD JOURNEYAD JOURNEY
AD JOURNEYSS
SS
S
If you drive the motorcycle off-the-road, the closed central stand can be
additionally fixed using a rubber band (2).
IGNITION SWITCHIGNITION SWITCH
IGNITION SWITCHIGNITION SWITCH
IGNITION SWITCH
In the SMR and SMM models an key ignition is added on the left side of
the dashboard.
By turning the key in a clockwise direction, the electric circuit is closed
and, after the startter button has been pushed so as to close the contact
with the battery, it is possible to activate the electric starter.
To switch the engine off, remember to position the red starter button to
interrupt the battery connection circuit and turn the key in an
anticlockwise direction.
FORK ADJUSTMENT IN COMPRESSIONFORK ADJUSTMENT IN COMPRESSION
FORK ADJUSTMENT IN COMPRESSIONFORK ADJUSTMENT IN COMPRESSION
FORK ADJUSTMENT IN COMPRESSION
The hydraulic brake system 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 USDFORK(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 increases, in an anticlockwise direction
it decreases. A total of 26 notches are available.
OHLINSUSD FORK(OPTIONAL)
The adjustment screw is found in the lower part of the fork leg (3).
Turn with a screwdriver. By turning it in a clockwise direction braking
increases, in an anticlockwise direction it decreases A total of 20
notches are available.
WARNING
BEFORESTARTINGITISADVISEDTOTIGHTENTHEADJUSTERFROMTHE
STANDARDPOSITIONTOTHE“TOTALLYCLOSED”POSITIONANDCOUNTTHE
NOTCHESDETECTEDSOTHATTHESTANDARDPOSITIONCANBERESTORED.
FOR CONVENTION, THE NOTCHESARE INDICATED FROM THE “TOTALLY
CLOSED”POSITION.
BOTHRODSMUSTHAVETHESAMEADJUSTMENT.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
ENGLISH
17
5
6
7
4
FORK ADJUSTMENT IN EXTENSIONFORK ADJUSTMENT IN EXTENSION
FORK ADJUSTMENT IN EXTENSIONFORK ADJUSTMENT IN EXTENSION
FORK ADJUSTMENT IN EXTENSION
The hydraulic brake system in extension determines the behaviour of
the fork in the return or rebound stroke.
The degree of hydraulic braking in extension can be adjusted on the
basis of pilot preferences and/or hardness of the spring installed.
PAIOLI USDFORK(STANDARD)
The adjustment screw is found in the upper part of the fork cap (4). By
turning it in a clockwise direction braking increases, in an anticlockwise
direction it decreases. A total of 28 notches are available
OHLINSUSD FORK(OPTIONAL)
The adjustment knob is found in the upper part of the fork cap (5).Act
manually. By turning it in a clockwise direction braking increases, in an
anticlockwise direction it decreases.Atotal of 20 notches are available.
WARNING
BEFORESTARTINGITISADVISED TOTIGHTENTHEADJUSTERFROMTHE
STANDARDPOSITIONTOTHE“TOTALLYCLOSED”POSITIONANDCOUNTTHE
NOTCHESDETECTEDSOTHATTHESTANDARDPOSITIONCANBERESTORED.
FOR CONVENTION, THE NOTCHESARE INDICATED FROM THE “TOTALLY
CLOSED”POSITION.
BOTHRODSMUSTHAVETHESAMEADJUSTMENT.
WARNING
FORFURTHERNADMOREDETAILEDINFORMATIONREGARDINGTHEFORK,
BOTH STANDARD AND OPTIONAL, REFER TO THE “OWNERS MANUAL”
SUPPLIED BY THE MANUFACTURER OF THE FORK SUPPLIED BY TM
ACCOMPANYINGTHEMOTORCYCLE.
SHOCK ABSORBER ADJUSTMENT IN COMPRESSIONSHOCK ABSORBER ADJUSTMENT IN COMPRESSION
SHOCK ABSORBER ADJUSTMENT IN COMPRESSIONSHOCK ABSORBER ADJUSTMENT IN COMPRESSION
SHOCK ABSORBER ADJUSTMENT IN COMPRESSION
The hydraulic brake system in compression determines the behaviour
oftheshockabsorberinthe 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.
Both standard and optional shock absorber mounted on the TM offer
the possibility of double adjustment in compression for low and high
speeds.
Low and high speeds mean the movement speed of the damper in
compression and not the speed of the motorcycle.
SACHSDAMPER(STANDARD)
Low speeds- The adjustment screw (6) is found on the top of the
dampergastank. Usea screwdriver.By turning in aclockwise direction,
braking increase, in an anticlockwise direction it decreases. A total of
24 notches are available
High speeds - The adjuster is a knob (7) and is concentric to the low
speed adjustment screw. Act manually. By turning in a clockwise
direction, braking increase, in an anticlockwise direction it decreases.
A total of 20 notches are available
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
18
4
3
2
1
OHLINSDAMPER (OPTIONAL)
Low speeds- The adjustment screw (1) is found on the top of the
damper gas tank. Use a screwdriver. By turning in a clockwise direction,
braking increases, in an anticlockwise direction, it decreases. A total of
25 notches are available.
High speeds- The adjuster is a hexagonal ring nut (2) and is concentric
to the low speeds adjustment screw. Use a 17mm hexagonal spanner.
By turning in a clockwise direction, braking increases, in an
anticlockwise direction, it decreases. A total of 4 notches are available.
WARNING
BEFORESTARTINGITISADVISEDTOTIGHTENTHEADJUSTERFROMTHE
STANDARDPOSITIONTOTHE“TOTALLYCLOSED”POSITIONANDCOUNTTHE
NOTCHES/TURNSDETECTED SOTHATTHESTANDARD POSITION CAN BE
RESTORED.
FORCONVENTION,THENOTCHE/TURNSSAREINDICATEDFROMTHE“TOTALLY
CLOSED”POSITION.
SHOCK ABSORBER ADJUSTMENT IN EXTENSIONSHOCK ABSORBER ADJUSTMENT IN EXTENSION
SHOCK ABSORBER ADJUSTMENT IN EXTENSIONSHOCK ABSORBER ADJUSTMENT IN EXTENSION
SHOCK ABSORBER ADJUSTMENT IN EXTENSION
The hydraulic brake system in extension determines the behaviour of
the shock absorber in the return or rebound stroke.The degree of
hydraulic 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
ina clockwise direction, braking increases, in an anticlockwisedirection,
it decreases. A total of 40 notches are available.
OHLINSDAMPER (OPTIONAL)
The adjustment knob (4) is situated low at the end of the damper rod.
Act manually. By turning in a clockwise direction (looking from the
bottom upwards) braking increases, in an anticlockwise direction, it
decreases. A total of 40 notches are available.
WARNING
BEFORESTARTINGITISADVISEDTOTIGHTENTHEADJUSTERFROMTHE
STANDARDPOSITIONTOTHE“TOTALLYCLOSED”POSITIONANDCOUNTTHE
NOTCHESDETECTEDSOTHATTHESTANDARDPOSITIONCANBERESTORED.
FOR CONVENTION, THE NOTCHESARE INDICATED FROM THE “TOTALLY
CLOSED”POSITION.
THEDAMPERGASTANK IS FILLED WITH PRESSURISEDNITROGEN.NEVER
TRY TO DISASSEMBLE THE DAMPER OR CARRY OUT MAINTENANCE
OPERATIONSWITHOUTTHEHELPOFTECHNICIANS,OTHERWISEOBJECTS
COULDBEDAMAGEDANDPERSONSINJURED
DANGER
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
ENGLISH
19
STEERING LOCKSTEERING LOCK
STEERING LOCKSTEERING LOCK
STEERING LOCK
This lock is found on the left side of the metal steering tube.
This lock stops rotation of the handlebar, preventing the motorcycle
being driven.
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
NEVERLEAVETHEKEYINTHELOCK.BYTURNINGTHEHANDLEBARTOTHE
LEFT,THE KEYCOULDBEDAMAGED.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

ENGLISH
ENGLISH
20