TM RACING 4 Stroke 2009 Operating instructions

Grafica e Stampa SERIART - Fabriano (AN) - www.seriart.com
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USER AND
MAINTENANCE
MANUAL
USER AND
MAINTENANCE
MANUAL
TM RACING
USES and ADVICES
TM RACING
USES and ADVICES
TM 4 STROKE 2009
Published and printed by - Fabriano (AN) - www.seriart.comSERIART
SERIART
TM-02 (ed. 12/08)

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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 andhowto protectyourselffrom injury.This manualalsocontainsimportant
information regarding the maintenance of your new motorcycle.
This manual is based on the most recent information concerning the product that was available on going to print.
Furthervariations owingtosuccesive constructivedevelopments ofthemotorcycle arehoweverpossible.
Thismanual isanintegral partofthe motorcycle,itmust begivento thecustomerat thetimeof purchaseandmust
remain with the motor cycle whenever it is re-sold.
Pleasenote thatthe operationsmarked with(A) inthe “Frameand EngineMaintenance” chaptermustbe 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 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 tosafeguard thefutureof oursport.
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.
The scrupulous compliance with the established inspections, maintenance and tuning of the engine
andchassispartof themotorcycle,indicatedintheuser manual,isindispensableforcorrectfunctioning
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”tablemust becarried
out by a specialised 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
usedas permaintenanceprogramme. Productsofother brandscanbe usedaslong astheyhave the
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 transmissioncomponentsor thebrakes. 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.
The250, 450and530 modelsin theEND, SMRand SMMversions canbe usedon roadsonly inthe
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 Motocross.

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INDEXINDEX
INDEXINDEX
INDEX
INDEXINDEX
INDEXINDEX
INDEX
Page
POSITION OF SERIAL NUMBER ................................................... 7
Frame number ................................................................................ 8
Engine number ............................................................................... 8
OPERATING CONTROLS............................................................... 9
Clutch lever AJP pump.................................................................... 10
Clutch lever BREMBO pump ........................................................... 10
Manual decompressor lever .......................................................... 10
Front brake lever NISSIN pump ...................................................... 10
Front brake lever BREMBO radial pump ......................................... 11
Electronic digital backlit display tachometer ...................................... 11
Engine stop switch (MX/SMX) ....................................................... 11
Combination switch (END/SMR/SMM) ............................................. 12
Start command and emergency stop
(END/MXE.S./SMXE.S./SMR/SMM) .................................................. 12
Fuel filler cap...................................................................................13
Fuel tap.......................................................................................... 13
Choke command (cold starter) ....................................................... 13
“By-Pass” command (hot starter) All models with electric starter.... 13
“By-Pass” command (hot starter) All models with kickstart ........... 14
Idle speed adjustment command .................................................... 14
Gear shift pedal ............................................................................. 14
Kickstart pedal................................................................................ 14
Brake pedal ................................................................................... 15
Side stand ...................................................................................... 15
Side stand fixing for off-road routes...............................................15
Ignition switch ............................................................................... 15
Fork adjustment in compression .................................................... 16
Fork adjustment in rebound .......................................................... 16
Shock absorber adjustment in compression ................................. 17
Shock absorber adjustment in rebound ......................................... 18
Steering lock .................................................................................. 18
ADVICEAND GENERAL RECOMMENDATIONS FOR
COMMISSIONING THE MOTORCYCLE......................................... 19
Indications for first start-up .......................................................... 20
Running in instructions................................................................... 20
INSTRUCTIONS FOR USE ..............................................................21
Check before every start-up ........................................................ 22
Cold engine start ........................................................................... 23
Warm engine start.......................................................................... 23
If the engine is “flooded” ................................................................ 24
Bike starting.....................................................................................24
Shifting gear, accelerating, slowing down .................................... 24
Braking........................................................................................... 26
Stopping and parking ..................................................................... 26
Fuel ................................................................................................ 27
MAINTENANCE AND LUBRICATION TABLE................................. 29
FRAME AND ENGINE MAINTENANCE ........................................... 35
Check steering bearings and play adjustment .............................. 36
Telescopic fork vent screws ......................................................... 37
Cleaning telescopic fork dust scraper.............................................37
Basic calibration of the chassis on the basis of pilot weight ........... 38
Shock absorber calibration and spring check................................ 38
Establishing rear shock lowering in running order ........................ 38
Establishing rear shock static lowering ........................................ 39
Check telescopic fork basic calibration ......................................... 39
Variation of telescopic fork preload .............................................. 39
Replacement of fork springs.......................................................... 40
Variation of rear shock spring preload .......................................... 40
Rear suspension mechanical linkage............................................. 40
Page
Check chain tension ...................................................................... 41
Adjustment of chain tension (all models except SMM)................... 41
Adjustment of chain tension (SMM) ............................................... 42
Chain maintenance ........................................................................ 42
Chain wear..................................................................................... 43
Basic indications for TM disc brakes ............................................. 43
Frontbrake NISSINpump (END/MX)................................................ 44
Front brake BREMBO radial pump (SMR/SMM/SMX)....................... 45
Check front brake pads ................................................................. 45
Replacement of front brake pads................................................... 46
Modification of rear brake pedal base position............................... 47
Check rear brake fluid level .......................................................... 47
Top-up rear brake fluid .................................................................. 47
Check rear brake pads ................................................................. 48
Replacement of rear brake pads.................................................... 48
Disassembly and assembly of the front wheel ............................. 48
Disassembly and assembly of the rear wheel (all except SMM).... 49
Disassembly and assembly of rear wheel (SMM).......................... 50
Check spoke tension ..................................................................... 50
Tyres, tyre pressure ...................................................................... 51
Check adjustment of magnetic sensor for tachometer .................. 51
Battery (all models with E.S.)......................................................... 51
Battery charge ............................................................................. 52
Recharge fuse (all models with E.S.) ............................................ 53
Standardheadlightd(END/SMR/SMM) ............................................ 53
Halogenlight (END/SMR/SMM) ....................................................... 53
“Ciclops” optional headlight (END/SMR/SMM) ................................ 54
Standard rear light ......................................................................... 55
LED rear light ................................................................................ 55
Directionindicator lamp (END/SMR/SMM) ....................................... 55
Cooling ........................................................................................... 56
Check coolant level ...................................................................... 56
Emptying, filling and bleeding of the cooling system........................57
Replacement of exhaust silencer packing material..........................57
Cleaning the air filter ...................................................................... 58
Check hand decompressor adjustment ......................................... 58
Throttle cable command adjustment .............................................. 58
Hydraulic clutch AJP pump ........................................................... 59
Hydraulic clutch BREMBO pump .................................................... 59
Bleeding hydraulic clutch ............................................................. 60
Carburetor - Idle speed adjustment................................................ 60
Basic indications regarding carburetor wear................................. 61
Check fuel level (float height) ....................................................... 61
Emptying the carburetor float bowl..................................................62
Oil circuit........................................................................................ 62
Check engine oil level ................................................................... 63
Engineoil ....................................................................................... 63
Change engine oil ...........................................................................63
TROUBLESHOOTING ................................................................. 66
CLEANING ................................................................................. 68
PRECAUTIONSFOR WINTER USE .............................................. 68
STORAGE ................................................................................. 68
Start-up after seasonal pause........................................................... 68
TECHNICAL DATA - ENGINE.................................................... 69/70
CARBURETORSETTINGS ............................................................ 71
ENGINETIGHTENINGTORQUES .................................................. 72
TECHNICAL DATA-CYCLE PART ............................................ 73-74
ALPHABETIC INDEX ................................................................... 75
WIRING DIAGRAM .......................................................... appendix

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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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CLUTCH LEVER AJP PUMPCLUTCH LEVER AJP PUMP
CLUTCH LEVER AJP PUMPCLUTCH LEVER AJP PUMP
CLUTCH LEVER AJP PUMP
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 pump after having
adjusted the lever position and to ensure the correct freeplay.
CLUTCH LEVER BREMBO PUMPCLUTCH LEVER BREMBO PUMP
CLUTCH LEVER BREMBO PUMPCLUTCH LEVER BREMBO PUMP
CLUTCH LEVER BREMBO PUMP
The Brembo clutch pump is fit on request.
The clutch lever (2) is located on the left side of the handlebar.
With this option, to adjust the clutch lever distance from the handlebar
grip (see maintenance operation), you have to turn the adjustment
knob (3).
Rotate clockwise to increase the distance or counterclockwise to
decrease the distance.
MANUAL DECOMPRESSOR LEVERMANUAL DECOMPRESSOR LEVER
MANUAL DECOMPRESSOR LEVERMANUAL DECOMPRESSOR LEVER
MANUAL DECOMPRESSOR LEVER
(ALL 530 AND 660CC.)(ALL 530 AND 660CC.)
(ALL 530 AND 660CC.)(ALL 530 AND 660CC.)
(ALL 530 AND 660CC.)
The hand decompressor lever (4) is on the left side of the handlebar,
and is used when, after a fall or following overheating, the engine is
difficult to start-up when warm. To ventilate the engine, pull the
decompressor lever during starting.
The lever must always have a play of about 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 NISSIN PUMP (END/MX)FRONT BRAKE LEVER NISSIN PUMP (END/MX)
FRONT BRAKE LEVER NISSIN PUMP (END/MX)FRONT BRAKE LEVER NISSIN PUMP (END/MX)
FRONT BRAKE LEVER NISSIN PUMP (END/MX)
The distance of the front brak lever (5) from the handlebar grip can be
adjusted through the adjustment screw (C). Loosen the lock nut (6)
and turn the screw clockwise to increase the distance, anticlockwise
to reduce the distance. Re-tighten the lock nut (6). (see “Frame and
Engine Maintenance” chapter”).
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
2
3
C
6
5
4