TM RACING 4 STROKE 2006 Operating instructions

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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

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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.

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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.

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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.

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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
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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

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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

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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