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

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OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
1
A1
FRONT BRAKE LEVER BREMBO RADIAL PUMPFRONT BRAKE LEVER BREMBO RADIAL PUMP
FRONT BRAKE LEVER BREMBO RADIAL PUMPFRONT BRAKE LEVER BREMBO RADIAL PUMP
FRONT BRAKE LEVER BREMBO RADIAL PUMP
(SMR/SMM/SMX)(SMR/SMM/SMX)
(SMR/SMM/SMX)(SMR/SMM/SMX)
(SMR/SMM/SMX)
The front brake pump lever (1) is located on the right side of the
handlebar and activates the front wheel brake. The distance of the
brake lever from the handlebar grip can be adjusted through the
adjustment knob (A) (see “Frame and Engine Maintenance” chapter)
ELECTRELECTR
ELECTRELECTR
ELECTRONIC DIGITONIC DIGIT
ONIC DIGITONIC DIGIT
ONIC DIGITAL BAL B
AL BAL B
AL BAA
AA
ACKLIT DISPLACKLIT DISPLA
CKLIT DISPLACKLIT DISPLA
CKLIT DISPLAYY
YY
Y
TT
TT
TAA
AA
ACHOMETERCHOMETER
CHOMETERCHOMETER
CHOMETER
See picture (1). It is used on the END/SMR/SMM models. t has a wide
backlit display and four pilot lights.
In the top there are the left indicator pilot light (2) , the low beam pilot
light (3), the high beam pilot light (4) and the right indicator pilot light
(5).
Inside the display you find the tachometer (6), the trip odometer (7) and
the total kilometers odometer (8).
In the bottom there are two buttons, “SET” (9) and “MODE” (10).
The instrument unit is the Kmh but it can be easily changed in Mph in
the following way: press and hold the “SET” button, while holding it
press once the “MODE” button.
Repeat the same operation to switch back to Kmh.
The trip odometer can be reset by holding pressed the “SET” button
once for at least 4 seconds.
The total kilometres odometer resets automatically when reaching the
limit of 99999 Km or Miles.
The instrument switches on automatically when pressing and posi-
tioning outwards the red button located near the throttle command and
switches off when pressing and positioning inwards the red button
itself.
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 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.

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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 (1) is located near the handlebar left grip.
The use of the switch is very easy.
When the symbol (3) on the rotating ring is aligned with the symbol (4)
on the switch body, lights are switched off.
To switch the lights on, turn the ring (2) counterclockwise until the
symbol (5) is aligned with the symbol (4).
Operate in the same way to switch on the low beam (7) and the high
beam (6).
Press the button (8) to activate the horn.
Press the rocker switch (9) on the left to activate the left hand indicator
and on the right to activate the right hand indicator.
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 electric 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.
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
1

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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 located on the left 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.
CHOKE COMMAND (COLD STCHOKE COMMAND (COLD ST
CHOKE COMMAND (COLD STCHOKE COMMAND (COLD ST
CHOKE COMMAND (COLD STARAR
ARAR
ARTER)TER)
TER)TER)
TER)
This command is located 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
starting the engine when it is cold.
To disconnect the command, push the choke knob inwards to its original
position.
ForKEIHINcarburetors
Extract the knob and turn it clockwise to block it. To disconnect it, turn
anticlockwise.
“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
ARTER)TER)
TER)TER)
TER)
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 starting the engine when it is flooded or
particularly overheated.
As soon as the engine is running, push the knob to return it to its
normal position.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS

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“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
ARTER)TER)
TER)TER)
TER)
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.
Thisisrequired for starting of the engine when it isflooded or particularly
overheated.
As soon as the engine is running, turn the lever 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 located 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 rpm.
GEAR SHIFT PEDGEAR SHIFT PED
GEAR SHIFT PEDGEAR SHIFT PED
GEAR SHIFT PEDALAL
ALAL
AL
The gear shift pedal is positioned on the engine left side. The position
of the gears is indicated in the illustration. The neutral is between the
first and second gears.
KICKSTKICKST
KICKSTKICKST
KICKSTARAR
ARAR
ART PEDT PED
T PEDT PED
T PEDALAL
ALAL
AL
The kickstart pedal is positioned 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.
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
1

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7
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
Push 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.
SIDE STSIDE ST
SIDE STSIDE ST
SIDE STAND FIXING FOR OFFRAND FIXING FOR OFFR
AND FIXING FOR OFFRAND FIXING FOR OFFR
AND FIXING FOR OFFROO
OO
OAD RAD R
AD RAD R
AD ROUTESOUTES
OUTESOUTES
OUTES
If you drive the motorcycle off-road, the closed side 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 ignition key is added on the left side of
the dashboard.
By turning the key clockwise , the electric circuit is closed and, after the
starter button has been pushed so as to close the contact with the
battery, it is possible to operate 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 anticlockwise.
OPERAOPERA
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OLS
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OPERATING CONTRTING CONTR
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OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
OPERAOPERA
OPERAOPERA
OPERATING CONTRTING CONTR
TING CONTRTING CONTR
TING CONTROLSOLS
OLSOLS
OLS
5
4
8
3
1
2
5
4
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 dampening in
compression can be adjusted on the basis of pilot preferences and/or
hardness of the spring installed.
MARZOCCHIUSDFORK
The adjustment screw is located in the upper side of the fork cap (4).
For this operation, use a screwdriver. By turning the screw clockwise,
dampening increases, while turning it anticlockwise, dampening
decreases. A total of 28 clicks is available.
Never turn the side screw (5).
PAIOLIUSDFORK
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 the
screw clockwise, dampening increases, turning it anticlockwise the
dampening decreases. A total of 26 clicks are available.
OHLINSUSDFORK
The adjustment screw (3) is located in the bottom of the fork leg.
Operate using a screwdriver. Turning the screw clockwise the
dampening increases, turning it anticlockwise the dampening
decreases. A total of 20 clicks are available.
WARNING
BEFORESTARTINGITISADVISEDTOTIGHTENTHEADJUSTER FROMTHE
STANDARDPOSITIONTOTHE“TOTALLYCLOSED”POSITIONANDCOUNTTHE
NOTCHESDETECTEDSOTHATTHESTANDARDPOSITIONCANBERESTORED.
FOR CONVENTION, THE NOTCHESARE INDICATED FROM THE “TOTALLY
CLOSED”POSITION.
BOTHRODSMUSTHAVETHESAMEADJUSTMENT.
FORK ADJUSTMENT IN REBOUNDFORK ADJUSTMENT IN REBOUND
FORK ADJUSTMENT IN REBOUNDFORK ADJUSTMENT IN REBOUND
FORK ADJUSTMENT IN REBOUND
The hydraulic dampening in extension determines the behaviour of
the fork in the rebound stroke.
The degree of dampening in rebound can be adjusted on the basis of
pilot preferences and/or hardness of the spring installed.
MARZOCCHIUSDFORK
The adjustment screw is located in the lower part of the fork leg (8). For this
operation, use a screwdriver. By turning the screw clockwise, dampening in-
creases, while turning it anticlockwise, dampening decreases. A total of 28
clicks are available.
PAIOLIUSDFORK
The adjustment screw is located in the top side of the fork cap (4).
Turning the screw clockwise, dampening increases, turning it
anticlockwise dampening decreases. A total of 28 clicks are available.
OHLINSUSDFORK
The adjustment knob (5) is located in the top side of the fork cap.
Operate by hand. Turning the knob clockwise, dampening increases,
turning it anticlockwise dampening decreases. A total of 20 clicks are
available.
WARNING
BEFORESTARTINGITISADVISEDTOTIGHTENTHEADJUSTER FROMTHE
STANDARDPOSITIONTOTHE“TOTALLYCLOSED”POSITIONANDCOUNTTHE
CLICKSDETECTEDSOTHATTHESTANDARDPOSITIONCANBERESTORED.
FORCONVENTION,THENUMBEROFCLICKSIS INDICATEDFROMTHE“TOTALLY
CLOSED”POSITION.
BOTHLEGSMUSTHAVETHESAMEADJUSTMENT.
WARNING
FORFURTHERANDMOREDETAILEDINFORMATIONREGARDINGTHEFORK,
BOTH STANDARD AND OPTIONAL, REFER TO THE “OWNERS MANUAL”
SUPPLIED BY THE MANUFACTURER OF THE FORK SUPPLIED BY TM
ACCOMPANYINGTHEMOTORCYCLE.

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SHOCKSHOCK
SHOCKSHOCK
SHOCK ABSORBERABSORBER
ABSORBERABSORBER
ABSORBER ADJUSTADJUST
ADJUSTADJUST
ADJUST..
..
.IN COMPRESSIONIN COMPRESSION
IN COMPRESSIONIN COMPRESSION
IN COMPRESSION
The hydraulic dampening in compression determines the behaviour
of the shock absorber in the compression stroke.The degree of
dampening in compression can be adjusted on the basis of pilot
preferences and/or hardness of the spring installed.
Both standard and optional shock absorbers 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.
SACHSSHOCKABSORBER(STANDARD)
Low speeds- The adjustment screw (6) is located on the top of the
damper gas tank. Use a screwdriver. By turning the screw clockwise,
dampening increases, anticlockwise dampening decreases. A total of
24 clicks are available.
High speeds - The adjuster is a knob (7) and is concentric to the low
speed adjustment screw. Operate manually. By turning the knob
clockwise, dampening increases, anticlockwise dampening
decreases. A total of 20 clicks are available.
OHLINSSHOCKABSORBER(OPTIONAL)
Low speeds- The adjustment screw (1) is on the top of the damper
gas tank. Use a screwdriver. By turning the screw clockwise,
dampening increases, anticlockwise dampening decreases. A total of
25 clicks 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 the nut clockwise, dampening increases, anticlockwise
dampening decreases. A total of 4 clicks are available.
WARNING
BEFORESTARTINGIT ISADVISEDTOTIGHTEN THEADJUSTERFROM THE
STANDARDPOSITIONTOTHE “TOTALLYCLOSED”POSITIONANDCOUNTTHE
CLICKS/TURNS DETECTED SO THAT THE STANDARD POSITION CAN BE
RESTORED.
FORCONVENTION,THENUMBEROF CLICKS/TURNSARE INDICATEDFROM
THE“TOTALLYCLOSED”POSITION.
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SHOCK ABSORBER ADJUSTMENT IN REBOUNDSHOCK ABSORBER ADJUSTMENT IN REBOUND
SHOCK ABSORBER ADJUSTMENT IN REBOUNDSHOCK ABSORBER ADJUSTMENT IN REBOUND
SHOCK ABSORBER ADJUSTMENT IN REBOUND
The hydraulic brake system in rebound determines the behaviour of
the shock absorber in rebound stroke.The degree of hydraulic braking
in rebound can be adjusted on the basis of pilot preferences and/or
hardness of the spring installed.
SACHSSHOCKABSORBER(STANDARD)
The adjustment screw (3) is situated on the fork of the shock absorber
(side of mechanical linkage). Use a screwdriver. By turning clockwise,
braking increases, anticlockwise it decreases. A total of 40 clicks are
available.
OHLINSSHOCKABSORBER(OPTIONAL)
The adjustment knob (4) is situated low at the end of the damper rod.
Act manually. By turning clockwise (looking from the bottom upwards)
braking increases, anticlockwise, it decreases. A total of 40 clicks are
available.
WARNING
BEFORESTARTINGITISADVISEDTOTIGHTENTHEADJUSTER FROMTHE
STANDARDPOSITIONTOTHE“TOTALLYCLOSED”POSITIONANDCOUNTTHE
CLICKSDETECTEDSOTHATTHESTANDARDPOSITIONCANBERESTORED.
FORCONVENTION,THENUMBEROFCLICKSISINDICATEDFROMTHE“TOTALLY
CLOSED”POSITION.
THEDAMPERGASTANK IS FILLED WITH PRESSURISEDNITROGEN.NEVER
TRY TO DISASSEMBLE THE DAMPER OR CARRY OUT MAINTENANCE
OPERATIONS WITHOUT THE HELP OF TECHNICIANS, OTHERWISE PARTS
COULDBEDAMAGEDANDPERSONSINJURED
STEERING LOCKSTEERING LOCK
STEERING LOCKSTEERING LOCK
STEERING LOCK
This lock is situated on the left side of the frame steering tube.
This lock stops rotation of the handlebar, preventing the motorcycle
being driven.
To lock the 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.BYTURNINGTHE HANDLEBARTOTHE
LEFT,THEKEYCOULDBE DAMAGED.
OPERAOPERA
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INDICATIONS FOR FIRST STINDICATIONS FOR FIRST ST
INDICATIONS FOR FIRST STINDICATIONS FOR FIRST ST
INDICATIONS FOR FIRST STARAR
ARAR
ARTT
TT
T-UP-UP
-UP-UP
-UP
- Ensure that the “PRE-DELIVERY OPERATIONS” of your
motorcycle have been carried out by your TM dealer.
- Carefully read all user instructions before making the first
journey.
- Become familiar with all operating controls.
- Adjust the clutch lever, the front brake lever and the brake
pedal so that they are in the most comfortable position.
- Get used to driving in an empty carpark or on land where it is
easy to handle the motorcycle before making a long journey.
Also try to move at a slow pace on foot to get used to the
motorcycle.
- Do not take routes that are too difficult for your driving ability
and experience.
- On the road, hold the handlebar with both hands and leave
your feet on the footrests.
- Be careful not to push the brake pedal if you do not wish to
brake. If the brake pedal is not released, the brake pads rub
continuously and the brake overheats
- Do not modify the motorcycle and always use ORIGINAL TM
SPARE PARTS. Spare parts made by other manufacturers
can jeopardise the safety of the motorcycle.
- Motorcycles are sensitive to the movement of weight. When
carrying luggage, fix it as near as possible to the centre of the
motorcycle and distribute the weight equally between the front
and rear wheel.
- Follow running in instructions.
RUNNING IN INSTRUCTIONSRUNNING IN INSTRUCTIONS
RUNNING IN INSTRUCTIONSRUNNING IN INSTRUCTIONS
RUNNING IN INSTRUCTIONS
The surfaces of components of a new motorcycle, even if they
undergo precision workings, are however less smooth than the
same components in a motorcycle that have been driven for a
time: this explains the necessity for running in the new engine.
To obtainanoptimalbeddingofthe moving partsofanewengine,
it must be taken to produce maximum performance gradually.
For this reason, during the first 3 hours of use (1 hour for
competition use) the engine must only be used up to max. 50%
of its power. Moreover, the number of revs. must not exceed
7000/min.
In the following 5 hours of use (1 hour for competition use) the
engine can be used up to max. 75% of its power. Drive the
motorcycle in different conditions (road, easy off-road tracts).
Do not make long journeys without ever closing the throttle.
By following these regulations, you will obtain maximum perfor-
mance and longer duration of the motorcycle through time.
WARNING
THE250/450/530END/MX/SMXMODELSHAVEBEENDEVELOPEDWITH
NOCOMPROMISEFOROFF-ROADCOMPETITIONS.EVENIFTHEENDURO
MODELSARETYPE-APPROVED,PAYATTENTIONWHENUSINGONTHE
ROAD.MOSTOFALLAVOIDSUSTAINED ACCELERATION CONSTANT
THROTTLE ON LONG ROADS, ROLLTHETHROTTLE ONAND BACK
SLIGHTLY.
- ALWAYS WEAR SUITABLE CLOTHING WHEN USING THE
MOTORCYCLE. ASTUTE MOTORCYCLISTS THAT DRIVE A TM
ALWAYS WEAR THETYPE-APPROVED HELMET,BOOTS, GLOVES
ANDAJACKET, WHETHERITISALONG OR SHORT JOURNEY. THE
PROTECTIVE CLOTHING SHOULD BE BRIGHT SO THAT THE
MOTORCYCLIST CAN BE EASILY SEEN BY OTHER ROAD USERS.
- ALWAYS SWITCH THE HEADLIGHTONDURING THE JOURNEY, SO
THAT OTHER ROAD-USERS CAN SEE YOU IN TIME.
- DONOT DRINK AND DRIVE.
- ONLYUSE ORIGINALTMACCESSORIES.FRONTCOVERINGS,FOR
EXAMPLE, CAN NEGATIVELYAFFETCT THE BEHAVIOUR OF THE
MOTORCYCLE ON THE ROADAT HIGH SPEEDS, OR HAVE NEGA-
TIVEINFLUENCEOFTHE BEHAVIOUR OF THE MOTORCYCLE DUE
TODIFFERENTWEIGHTDISTRIBUTION.
- THE FRONT AND REAR TYRES MUST HAVE THE SAME TYPE OF
PROFILE.
- AFTER THE FIRST 30 MINS, OF DRIVING, THE WHEEL SPOKE
TENSION MUST BE CHECKED. SPOKE TENSION DECREASES
QUICKLYON NEWWHEELS. IFYOU DRIVE WITHLOOSE SPOKES,
THE SPOKES MAY BREAK, CAUSING UNSTABLE DRIVING
CONDITIONS(SEECHECK SPOKE TENSION).
- THERACINGMODELSHAVEBEENDESIGNEDANDPREPAREDONLY
FORONE PERSON. IT IS PROHIBITEDTOTAKE ON PASSENGERS.
- FOLLOW THE HIGHWAY CODE, DRIVE CAREFULLY SO AS TO
RECOGNISEDANGERS AS SOON AS POSSIBLE.
- ADAPT SPEED TO THE CONDITIONS OF THE ROAD AND YOUR
DRIVING CAPABILITY.
- DRIVECAREFULLYON UNKNOWN ROADSOR LAND.
- WHENOFF-ROADYOUSHOULDALWAYS BEACCOMPANIED BYA
FRIENDWITHASECOND MOTORCYCLE, SO THATYOUCANHELP
EACHOTHER IF DIFFICULTIESOCCUR.
- INDUETIME,REPLACETHEVISORORLENSESOFTHEGOGGLES.
YOU WILL BE BLINDED AGAINST SUNLIGHT IF THE VISOR OR
GOGGLESARE SCRATCHED.
- DONOTLEAVE THE MOTORCYCLEUNSUPERVISEDIF THEENGINE
ISRUNNING.
- MX AND SMX MODELS ARE NOT TYPE-APPROVED FOR USE ON
PUBLIC ROADS OR MOTORWAYS.
- WHEN USING YOUR MOTORCYCLE,ALWAYS KEEP IN MIND THAT
EXCESSIVENOISEDISTURBSOTHERS.
DANGER
DANGER
ADAD
ADAD
ADVICEVICE
VICEVICE
VICE AND GENERAL RECCOMANDAND GENERAL RECCOMAND
AND GENERAL RECCOMANDAND GENERAL RECCOMAND
AND GENERAL RECCOMANDAA
AA
ATIONS FORTIONS FOR
TIONS FORTIONS FOR
TIONS FOR
COMMISSIONINGCOMMISSIONING
COMMISSIONINGCOMMISSIONING
COMMISSIONING THE MOTHE MO
THE MOTHE MO
THE MOTT
TT
TOROR
OROR
ORCYCY
CYCY
CYCLECLE
CLECLE
CLE
ADAD
ADAD
ADVICEVICE
VICEVICE
VICE AND GENERAL RECCOMANDAND GENERAL RECCOMAND
AND GENERAL RECCOMANDAND GENERAL RECCOMAND
AND GENERAL RECCOMANDAA
AA
ATIONS FORTIONS FOR
TIONS FORTIONS FOR
TIONS FOR
COMMISSIONINGCOMMISSIONING
COMMISSIONINGCOMMISSIONING
COMMISSIONING THE MOTHE MO
THE MOTHE MO
THE MOTT
TT
TOROR
OROR
ORCYCY
CYCY
CYCLECLE
CLECLE
CLE