tm RACING 250-300 SMR 2-STROKE Motorcycle User Manual

tm RACING 250-300 SMR 2-STROKE Motorcycle User Manual

www.tmracing.it

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RECOGNIZING MODELS

The displacement, type of power source and type of use define the model of motorcycle and engine of each TM Racing bike.
The combination of codes 1 and 3 identifies the standard engine type. The combination of the three codes fully identifies the motorcycle model.

In this Manual, all 3 codes are usually used to specify the motorcycle model to which certain information refers.
If only codes 1 and 3 are indicated, followed by the word “ALL”, it means that the information relates to all motorcycles with the standard engine, regardless of the type of use.
Code 2 (Type of Use) used on its own means that the information refers to all motorcycles with that type of use, regardless of displacement and power source.
All EN/SMR/SMM models are equipped as standard with electric start ( E.S.) as well as kick start ( K.S.). MX/SMX models have K.S. as standard and may be equipped with E.S. as an option.

Make a note of your motorcycle’s serial numbers in the boxes below.

If you contact TM for spare parts, updates or to report any issues, always quote the model, displacement, year of manufacture and, above all, the frame serial number and engine serial number.

TM reserves the right to make changes without prior notice. Specifications may vary from country to country.
All indications are valid, subject to typos and printing errors.

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GENERAL SAFETY REGULATIONS

GENERAL SAFETY REGULATIONS
Read this manual carefully before using your TM motorcycle.
Your safety and that of others depends not just on your riding abilities, but also on your knowledge of the vehicle and how to ride it safely.

Do not use the vehicle on public roads or off-road without suitable preparation and apparel.

NOTE: The “Use and maintenance manual” is an integral part of the motorcycle and as such must remain with the vehicle even if it is sold on.

TM reserves the right to make any changes due to further development of its motorcycles. Illustrations are approximate and, in some cases, may not precisely match the part referred to. Reproduction of this publication, even partial, without written authorization is prohibited.

STRUCTURE OF THE MANUAL
The manual is divided into sections and sub-sections.
The following symbols may appear in the text:

DANGER

FAILURE TO COMPLY WITH THIS WARNING MAY LEAD TO SERIOUS INJURY OR DEATH.

DANGER
ALL MAINTENANCE WORK OR ADJUSTMENTS MARKED WITH THE ABOVE SYMBOL REQUIRE TECHNICAL KNOWLEDGE. THEREFORE, FOR YOUR SAFETY, HAVE SUCH OPERATIONS CARRIED OUT ONLY AT A SPECIALIZED TM WORKSHOP, SO THAT YOUR MOTORCYCLE IS SERVICED OPTIMALLY BY SPECIFICALLY TRAINED PERSONNEL.

WARNING
Failure to comply with that warning could result in damage to parts of the motorcycle or make it unsafe to use.

NOTE: Indicates operations or specific advice about the operation described.

INDICATES THAT THE OPERATION DESCRIBED MUST BE PERFORMED BY A SPECIALIZED TECHNICIAN OR BY A SPECIALIZED TM WORKSHOP.

CARBON MONOXIDE
If maintenance has to be carried out with the engine running, make sure that the work area is well ventilated. Never leave the engine running in enclosed spaces unless they have an extractor system for exhaust fumes.

DANGER
EXHAUST FUMES CONTAIN CARBON MONOXIDE, A POISONOUS GAS THAT CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. CARBON MONOXIDE IS ODORLESS AND COLORLESS, MEANING THAT IT CANNOT BE DETECTED BY YOUR SENSE OF SMELL, VISION OR OTHER SENSES. DO NOT UNDER ANY CIRCUMSTANCES INHALE EXHAUST FUMES.

FUEL
Petrol is toxic. Keep petrol out of the reach of children. Do not use your mouth to siphon petrol. Avoid getting petrol on your skin. If you
accidentally get petrol on you, change clothes immediately and use suitable detergents to thoroughly wash the area on which petrol was poured.
If you accidentally swallow petrol, do not induce vomiting. Drink plenty of clean water or milk and seek medical advice immediately.
If you accidentally get petrol in your eyes, rinse them with plenty of clean cool water and seek medical advice immediately.

Petrol containing alcohol
In case you decide to use petrol containing alcohol (petrol-alcohol mix), check that the number of octane is at least equal to the recommended value.
Two types of petrol-alcohol mix exist: one contains ethanol while the other methanol. Do not use petrol-alcohol mix containing more than 10% of ethanol. Do not use petrol-alcohol mix containing methanol (methyl alcohol or wood alcohol) unless they also contain co-solvents and corrosion inhibitors specific for methanol.
Never use petrol containing more than 5% of methanol, even if it contains co- solvents and corrosion inhibitors.
Possible problems to the engine performances caused by the use of fuels containing alcohol are not covered by warranty.
TM Racing cannot endorse the use of fuels containing methanol since the proofs of its adequacy are still insufficient.
Before purchasing petrol from a distributor you don’t know, try to discover if its petrol contains alcohol.
If it does, determine the type and percentage of alcohol used. If, during operation, no negative effects are detected while using petrol containing alcohol or which you think may contain it, replace it with another you’re certain it not contains alcohol.

DANGER
THE FUEL USED IN AN INTERNAL COMBUSTION ENGINE IS HIGHLY FLAMMABLE AND MAY CAUSE EXPLOSIONS.
FILL UP WITH FUEL IN A WELL VENTILATED AREA, WITH THE ENGINE OFF.
SMOKING IS FORBIDDEN DURING REFUELING AND IN THE PRESENCE OF FUEL VAPORS.
AVOID CONTACT WITH NAKED FLAMES, SPARKS OR OTHER IGNITION SOURCES THAT COULD MAKE THE FUEL VAPORS CATCH FIRE OR EXPLODE.
PETROL IS A DANGEROUS SUBSTANCE AND MUST NOT BE DISPOSED OF IN THE ENVIRONMENT. ALWAYS USE APPROPRIATE DISPOSAL METHODS, DICTATED BY THE REGULATIONS IN FORCE IN THE COUNTRY WHERE THE PETROL IS USED.

DANGER OF BURNS
WARNING
During use of the motorcycle, the engine, exhaust system components, cooling system components and braking system components get very hot and remain hot even after the engine has been turned off.
After riding the motorcycle, before touching any part of it, make sure that it has cooled enough to be handled.

COOLANT

DANGER
FIRE RISK: IN SOME CONDITIONS, THE COOLANT IS FLAMMABLE. ITS FLAMES ARE INVISIBLE, BUT CAN CAUSE BURNS.
DO NOT POUR COOLANT ON EXHAUST SYSTEM COMPONENTS OR ON ENGINE COMPONENTS, AS THEY COULD BE HOT AND IGNITE THE COOLANT, WITH THE RISK OF BURNS. REMEMBER THAT THE FLAMES ARE INVISIBLE.
COOLANT MAY CAUSE SKIN IRRITATION AND IS TOXIC IF SWALLOWED.
KEEP COOLANT OUT OF THE REACH OF CHILDREN COOLANT IS HIGHLY POLLUTING. THEREFORE, AFTER USE, IT MUST BE DISPOSED OF AT SPECIAL COLLECTION CENTERS IN COMPLIANCE WITH REGULATIONS IN FORCE IN THE COUNTRY IN WHICH THE MOTORCYCLE IS USED.

2-STROKE OIL AND GEARBOX OIL
DANGER
KEEP OUT OF THE REACH OF CHILDREN.
2-STROKE OIL AND GEARBOX OIL MAY SERIOUSLY DAMAGE SKIN IF REGULARLY HANDLED FOR LONG PERIODS AND REGULARLY.
THOROUGHLY WASH YOUR HANDS AFTER HANDLING THE OIL.
WEAR LATEX OR EQUIVALENT GLOVES DURING MAINTENANCE WORK ON THE MOTORCYCLE.
GEARBOX OIL IS HIGHLY POLLUTING. THEREFORE, AFTER USE, IT MUST BE DISPOSED OF AT SPECIAL COLLECTION CENTERS IN COMPLIANCE WITH REGULATIONS IN FORCE IN THE COUNTRY IN WHICH THE MOTORCYCLE IS USED.
DO NOT POUR USED OIL INTO DRAINS OR RIVERS. DISPOSE OF FILTERS AT SPECIAL COLLECTION CENTERS IN COMPLIANCE WITH REGULATIONS IN FORCE IN THE COUNTRY IN WHICH THE MOTORCYCLE IS USED.

BRAKE AND CLUTCH FLUID
WARNING
Brake and clutch fluids are corrosive and can damage painted, plastic or rubber surfaces.
Protect components using a clean cloth when carrying out maintenance on the braking system and the clutch hydraulic system.
Use suitable personal protective equipment, such as gloves and goggles, for maintenance.
If you accidentally get the fluid in your eyes, immediately rinse them with plenty of fresh, clean water and seek medical advice immediately.
Keep out of the reach of children.
Brake and clutch fluids are highly polluting. Therefore, after use, they must be taken to special collection centers in compliance with regulations in force in the country in which the motorcycle is used.

LITHIUM IRON PHOSPHATE BATTERY
Motorcycles with electric start are fitted with a lithium iron phosphate (LIFEPO) battery Lithium batteries are extremely high performance. Lithium iron phosphate cell technology is safe, but that does not prevent improper use of the battery, a short circuit between the poles, overheating, proximity to naked flames or sparks, charging with chargers other than the dedicated ones, from causing serious danger.

DANGER

• DO NOT EXPOSE THE BATTERY TO HEAT OR FIRE OR MICROWAVES; EXPLOSION HAZARD.
• DO NOT EXPOSE THE BATTERY TO TEMPERATURES HIGHER THAN 50°C; EXPLOSION HAZARD.
• DO NOT INSERT METAL OBJECTS IN THE BATTERY HOLDER COMPARTMENT.
• DO NOT PLACE OR CHARGE THE BATTERY AMONGST OTHER METAL OBJECTS (SUCH AS A TOOL BOX) OR WITH OTHER BATTERIES; DANGER OF GENERATING SHORT CIRCUITS.
• DO NOT IMMERSE THE BATTERY IN WATER OR OTHER LIQUIDS, DANGER OF SHORT CIRCUIT.
• AFTER REMOVING THE BATTERY FROM THE MOTORCYCLE, PLACE IT OUT OF THE REACH OF CHILDREN.

PROHIBITED OPERATIONS

• NEVER DISCHARGE THE BATTERY TO BELOW 8 V
• DO NOT USE INCOMPATIBLE CHARGERS TO CHARGE THE BATTERY.DO NOT USE EXTERNAL JUMPER LEADS – NEVER CHARGE A BATTERY THAT IS COMPLETELY DISCHARGED
• DO NOT PUSH START THE MOTORCYCLE IF THE BATTERY IS COMPLETELY DISCHARGED AND THE INSTRUMENT PANEL DOES NOT COME ON.
• DO NOT PIERCE THE BATTERY OR DAMAGE THE CASING.
• DO NOT CONNECT MORE THAN ONE BATTERY TO THE MOTORCYCLE ELECTRICAL SYSTEM.

RECOMMENDED OPERATIONS

• USE A COMPATIBLE BATTERY CHARGER OR A MAINTAINER.
• CONNECT THE MOTORCYCLE TO THE MAINTAINER IF YOU WILL NOT BE RIDING IT FOR LONGER THAN 7 DAYS. ALTERNATIVELY, DISCONNECT THE MOTORCYCLE BATTERY.
• CHECK THAT THE CHARGING SYSTEM ON THE MOTORCYCLE IS ALWAYS OPERATIONAL.
• CHECK THAT THE VOLTAGE SUPPLIED BY THE CHARGE CONTROLLER IS BETWEEN 13.8 V AND A MAXIMUM OF 14.6 V.

DISPOSAL
Used batteries must be taken to a collection center specializing in separate disposal, in compliance with regulations in force in the country in which the motorcycle is used.
Batteries must not be mixed with domestic or industrial waste.

TRANSPORTING THE MOTORCYCLE

WARNING

• When transporting your TM motorcycle, make sure that it is secured in an upright position using straps or other mechanical fixing devices, to be fixed on sturdy parts of the motorcycle such as the handlebar, forks, large swing arm, etc.
• Do not secure the motorcycle by attaching straps or the like to the plastic panels.
• If the motorcycle falls, petrol could leak out, posing serious risks.

MIX
The motorcycle works by means of a mix of unleaded petrol (E5 – E10) and oil at 3%.

• If the automatic mixer is present, it is necessary to insert unleaded petrol (E5 – E10) in the fuel tank and to pour specific oil for mixers in the oil tank as described in the paragraph “Technical Data”.
• If the mixer is not present, it is necessary to pour a previously created mix composed of unleaded petrol (E5 – E10) and 2-stroke oil at 3% in the fuel tank.

TYPE APPROVAL
All 250-300 versions are approved to be used by the rider only; transporting a passenger is forbidden.

WARNINGS ABOUT WARRANTY

IMPORTANT WARNINGS
TM sport motorcycles are designed and built to withstand stresses causes by normal road and competition use.
Competition motorcycles comply with the rules of the respective categories currently in force at the leading international motorcycle associations.

Strict compliance with the checking, maintenance and calibration instructions for the engine and chassis indicated in this manual is essential for good operation and to prevent premature wear of motorcycle parts.
Incorrect engine or chassis calibration may also compromise your safety and the safety of others.

Maintenance operations described in the “Maintenance schedule” must be carried out by a TM specialized workshop at the scheduled intervals, otherwise the warranty will be null and void.

If you contact TM for spare parts, updates or to report any issues, always quote the model, displacement, year of manufacture and, above all, the frame serial number and engine serial number.

Use the fuels and lubricants indicated in the use and maintenance manual as described in the maintenance schedule. Products of different brands may be used provided that they have equivalent specifications.

In the event of direct and consequential damage caused by tampering with or modification of the motorcycle, the warranty is null and void.

Using the motorcycle under extreme conditions, e.g.: on very muddy and wet terrain, may cause excessive wear on components such as transmission parts or brakes. Therefore, maintenance or replacement of some parts may be necessary sooner than the normal interval indicated in the maintenance schedule.

USE OF ALL MX / SMX MODELS IS NOT ALLOWED ON PUBLIC ROADS
If approved models are modified or tampered with in a way that changes their basic characteristics, their approval will no longer be valid.
All EN models are designed for use off-road (Enduro) and are not suitable for Motocross.

1. VEHICLE IDENTIFICATION

FRAME SERIAL NUMBER
The frame serial number (1) is stamped on the right-hand side of the steering head.
Write this number in the space provided.
The serial number is also shown on a data plate (2) located on the left-hand side for EN / SMR models.

ENGINE SERIAL NUMBER
The engine serial number (1) is engraved on the back of the engine, near the shock absorber.
Write this number in the space provided at the start of the manual.

2. CONTROL COMPONENTS

RIGHT-HAND SIDE MAIN COMPONENTS TOPOGRAPHY
1 Throttle
2 Front light (EN – SMR)
3 Front indicator lights (EN – SMR)
4 Front wheel
5 Front suspensions
6 Exhaust manifold
7 Rear brake lever
8 Engine
9 Kick start lever
10 Pump with rear brake oil tank
11 Rear damper
12 Exhaust silencer
13 Rear wheel
14 Rear brake disc
15 Rear brake caliper
16 Right radiator
17 Radiator cap
18 Front brake lever
19 Mix oil tank cap (TSI)

LEFT-HAND SIDE MAIN COMPONENTS TOPOGRAPHY

1 Front brake disc
2 Front brake caliper
3 Left radiator
4 Voltage regulator
5 Fuel tank
6 Pump with front brake oil tank
7 Engine startup button
8 Double mapping switch (EN – MX)
9 Left switch (EN – SMR)
Engine switching off button (EN – MX – SMX)
10 Clutch lever with oil tank
11 Fuel tap (MX-SMX)
12 Carburettor (MX – SMX)
Throttle body (TSI)
13 Gearbox system lever
14 Kickstand
15 Secondary transmission chain
16 Crown
17 Rear indicator lights (EN – SMR)
18 Rear light/licence plate light (EN – SMR)
19 Seat
20 Battery
21 Air filter
22 Instrument
23 Key switch SMR

HYDRAULIC CLUTCH LEVER
The Brembo clutch pump (1) is located on the left-hand side of the handlebar.
The clutch lever (2) detaches the transmission from the engine.
To operate the clutch, pull the lever towards the grip as far as it will go.
The position of the lever relative to the grip can be altered to suit the rider. See the “Maintenance” section.

NISSIN PUMP FRONT BRAKE LEVER (EN/MX)
The Nissin front brake pump (1) is located on the right-hand side of the handlebar.
The front brake lever (2) applies the front wheel brake.
The position of the front brake lever relative to the grip can be altered to suit the rider.
See the “Maintenance” section.

BREMBO PUMP FRONT BRAKE LEVER
The Brembo front brake pump (1) is located on the right-hand side of the handlebar.
The front brake lever (2) applies the front wheel brake.
The position of the front brake lever relative to the grip can be altered to suit the rider.
See the “Maintenance” section.

BREMBO RADIAL PUMP FRONT BRAKE LEVER (SMR)
The Brembo radial front brake pump (1) is located on the right-hand side of the handlebar.
The front brake lever (2) applies the front wheel brake.
The position of the front brake lever relative to the grip can be altered to suit the rider.
See the “Maintenance” section.

BREMBO 16X18 RADIAL PUMP FRONT BRAKE LEVER (SMX)
The Brembo radial front brake pump (1) is located on the right-hand side of the handlebar.
The front brake lever (2) applies the front wheel brake.
The position of the front brake lever relative to the grip can be altered to suit the rider.
See the “Maintenance” section.

THROTTLE
The throttle control (1) is located on the right-hand side of the handlebar.
To increase the power supplied by the engine (accelerate), turn the grip (2) towards you. To reduce power, turn the grip away from you.
Make sure that the grip always has 1-2 mm of play.
See the “Maintenance” section.

COMBINATION SWITCH (EN)
The combination switch (1) is located near the left-hand handlebar grip.
It is very intuitive to use.
When the motorcycle is started, the low beams come on. Rotate the ring (2) until the symbol (3) is at the symbol (4) to turn on the high beam.
Press button (5) to sound the horn.
Press the rocker switch (6) to the left to activate the LH turn signal, or to the right for the RH turn signal.
On 250 EN and 450 EN models, press button (7) to switch off the engine.

DIMMER SWITCH (SMR)
The dimmer switch (1) is located on the handlebar near the left-hand grip.
Its is traditional and simple to use.
Button (2) sounds the horn, whilst pressing button (3) to the left activates the LH turn signal, and to the right activates the RH turn signal.
Press the button to the center to switch off the turn signals.
The red button (4) selects low or high beam:
• pushed in: high beam;
• out: low beam.
Button (5) is for flashing the high beam.

DOUBLE MAPPING SWITCH
These motorcycles versions are equipped with an engine mapping switch (1).
– If the switch is pressed in position (1a), it activates Map “1” for a “Full power” driving of the motorcycle.
– If the switch is pressed in position (1b), it activates Map “2” for a “Soft” driving of the motorcycle.
– It is possible to switch from a Full power driving to a Soft driving and vice versa while driving the motorcycle.

STARTER SWITCH (SMR)

START ENGINE BUTTON (MX E.S. / SMX E.S.)
The start engine button (1) is located near the right-hand handlebar grip.
– Set the gear control to “neutral”, then press the button to start the engine and release it as soon as the engine is running.
– Only use this control for a maximum of 5 seconds at a time, then wait several seconds before trying again.
– After 3 or 4 attempts stop and look for possible problems.
– Never press this button while the engine is running.

ENGINE STOP BUTTON (MX / SMX)
The engine stop button (1) is located near the left-hand grip on the handlebar.
– Press this button to switch off the engine and release it as soon as the engine is off.

COLD START DEVICE (TSI)
This vehicle provides for a cold start device positioned on the throttle body.
– To activate the cold start device, pull the knob (1) externally, the knob remains in extracted position.
– After the vehicle start, wait a few seconds until the engine speed stabilizes (depending on ambient temperature), then disable the cold start
device by moving the knob (1) to its initial position.

WARNING
ONLY activate the cold start device when the engine is switched off and cold.
NEVER activate it during motion.
Use the cold start device only if necessary.

COLD START DEVICE (MX – SMX)
This vehicle provides for a cold start device positioned on the on the carburettor.
– To activate the cold start device, raise the knob (1), the knob remains in raised position.
– After the vehicle start, wait a few seconds until the engine speed stabilizes (depending on ambient temperature), then disable the cold start device by moving the knob (1) to its initial position.

WARNING
ONLY activate the cold start device when the engine is switched off and cold. NEVER activate it during motion.
Use the cold start device only if necessary.

DIGITAL ELECTRONIC SPEEDOMETER AND INDICATORS (EN / SMR)
The digital speedometer consists of a large backlit display and a set of indicators.

Legend of indicators and buttons:

1. Backlit display.

2. 2a) GREEN left turn signal indicator.
   2b) GREEN right turn signal indicator.

3. BLUE high beam ON indicator.

4. GREEN low beam ON indicator.

5. AMBER fuel reserve indicator. (only for TSI)

6. ORANGE engine fault indicator.
   Contact a TM dealer as soon as possible if this indicator lights up while you are using the motorcycle.

7. “Select” button.
   Press the button to select the following functions:
   • Show time in 12 or 24 hour format.
   • Show speed in km/h or mph.
   • Stopwatch.
   • Maximum speed record.

8. “Adjust” button
   Press the button to view:
   • Odometer;
   • Trip “A” partial km/miles;
   • Trip “B” partial km/miles;
   • Total hours counter;
   • Partial hours counter “A”;
   • Partial hours counter “B”.

DISPLAY

Display legend:

1. Speed indicator
   Shows the vehicle speed. The top speed is 360 km/h – 225 mph. Use the “Select” button to switch between speed in km/h or mph.

2. Odometer / “Trip” partial counters
   This part of the display can be used to see the total km/miles travelled or partial km/miles travelled on the “Trip A” or “Trip B” counter. To show the various functions, use the “Adjust” button.
   • Odometer
   – Indicates total km/miles travelled.
   – Maximum value is 99999 km/miles. When that maximum has been reached, the counter is reset and starts again from “0”.
   – Minimum record is 1 km/mile.
   • “Trip” partial km/miles counters
   Two partial counters, “Trip A” and “Trip B” can be set.
   Indicates the partial km/miles travelled. Maximum value is 9999.9 km/miles. When that maximum has been reached, the counter is reset and starts again from “0”.
   Minimum record is 0.1 km/mile.

3. Clock / Stopwatch / Maximum speed
   This area of the display can show the time, the stopwatch and the maximum speed reached. Use the “Select” button to access the various functions.
   • Time
   The time can be displayed in 12 or 24 hour format.
   • Stopwatch
   The stopwatch can be displayed, set to automatically start when the wheel begins turning and to stop when the wheel stops turning.
   • Average speed / maximum speed
   – The average speed can be displayed.
   – The maximum speed reached can be displayed.
   – The top speed is 360 km/h – 225 mph.

4. Battery status
   The battery status is displayed;

FUNCTIONS
Partial km / miles selection

Starting on the home screen page, press the “Adjust” button once to switch from the odometer function (total km / miles travelled) to the “Trip A” partial km / miles travelled function.

Km / Miles unit of measurement setting
Starting on the home screen page, with the ODO function set, press the “Adjust” button for three seconds to change the unit of measurement from km to miles, from km/h to mph and vice versa.

Hours counter selection
The instrument can count total hours of engine operation and partial hours of operation “A” and “B”.
– Display the “Trip B” section, then press the “Adjust” button once to display the total hours of engine operation (value cannot be reset).

NOTE: To move from one setting to another, press the “Select” button.

• Setting the wheel circumference and sensor setup
Depending on the models, the following values must be set:

Set the wheel circumference and the sensor setup as follows:
From the home screen page simultaneously press the “Adjust” and “Select” buttons for three seconds to enter setup mode. The following screen page appears on the display:

Press the “Adjust” button and the following screen page appears on the display:

• Stopwatch
The stopwatch has been set to work automatically. It starts when the motorcycle begins moving and stops when the motorcycle comes to a stop.
NOTE: The default setting must not be changed. If necessary, go to the setup mode and check that its operation is set to “AUTO”.

• Odo
This function is not active.
NOTE: The default setting must not be changed. If necessary, go to the setup mode and check that operation is set to “OFF”.

GEAR SHIFTING PEDAL
The gear shifting pedal (1) is fitted on the left side of the engine.
The position of the gears is shown in the illustration.
Neutral is between first gear and second gear.

• To engage first gear, pull the clutch lever and press the gear shifting pedal downwards.
• To engage the other gears, pull the clutch lever and push the gear shifting pedal upwards.

KICK STARTER
The kick starter (1) is on the right side of the engine.
Once in “neutral”, rotate the pedal outwards and use your foot to start the engine with it.
For SMR models, turn the key, as described in the relative paragraph, before starting the engine.
For all other models, simply use the pedal to start the engine.
Starting from the highest position, push the starter all the way down with fast, continuous movements.
Once the engine has started, fold the pedal in again.

REAR BRAKE PEDAL
The brake pedal (1) is located in front of the right-hand footrest.
The basic position can be adjusted to suit the rider.
See the “Maintenance” section.

STEERING LOCK (EN/SMR)
The steering lock (1) is on the left-hand side of the steering head.
This device allows you to prevent rotation of the handlebar, so that the motorcycle cannot be ridden.
– To lock the steering, turn the handlebar all the way to the right, move the protective tab (2), insert the key, turn it to the left and press it all the way down. Keeping it pressed down, turn it to the right and remove it.

WARNING
When you have unlocked the steering, do not leave the key in the lock. If you steer left, the key could bend or break.

FUEL TANK (TSI)
The fuel cap (1) is at the top of the fuel tank, in the front area of the motorcycle.
– To open it: unscrew the tank cap by turning it anti-clockwise.
– To close it: place the tank cap in the filler neck and turn it clockwise.

TM engines use super unleaded fuel (E5) – (E10).
E5 = Petrol containing up to 5% of ethanol in proportion to its volume.
E10 = Petrol containing up to 10% of ethanol in proportion to its volume.

Tank capacity:
MX / SMX ALL …………………………………………………. l 6.75 total
EN / SMR / SMM ALL ………… l 6.75 total, of which 1 is reserve

WARNING
Fill the tank with unleaded petrol with a minimum octane number of 95.
Never use petrol with octane lower than 95, as it could damage the engine.
Fuel expands when heated. Therefore, in high temperatures, do not fill the tank to the top.

DO NOT pour petrol mixed with oil inside the tank as the motorcycle is equipped with an automatic mixer.

DANGER
PETROL IS HIGHLY FLAMMABLE AND TOXIC. HANDLE PETROL WITH EXTREME CARE. DO NOT FILL-UP WITH PETROL NEAR NAKED FLAME OR LIT CIGARETTES. ALWAYS TURN OFF THE ENGINE BEFORE FILLING UP WITH PETROL. TAKE CARE NOT TO GET PETROL ON THE ENGINE OR ON THE EXHAUST PIPE. IMMEDIATELY REMOVE ANY SPILT PETROL WITH A CLOTH. IF PETROL IS SWALLOWED OR GETS IN YOUR EYES, SEEK MEDICAL ADVICE IMMEDIATELY.

2 STROKE OIL TANK
The two stroke oil tank (2) is positioned inside the right hand area of the
frame while the filler cap (3) is in its top area.
– Unscrew the cap (3) anticlockwise and pour a 2 stroke oil suitable for 2 stroke engines and for the automatic mixer inside the tank. (see paragraph “Technical Data”).
– Screw the filler cap (3).

WARNING
The tank is equipped with a minimum level indicator (4). When oil level reaches half of the porthole, you have oil available only for one full tank of fuel and it is therefore necessary to restore its level.
Tank capacity: 800 gr of oil.

DANGER
KEEP 2 STROKE OIL AWAY FROM THE REACH OF CHILDREN.
2 STROKE OIL MAY CAUSE SERIOUS DAMAGES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND REGULARLY.
WASH YOUR HANDS WITH EXTREME CARE AFTER HAVING HANDLED OIL.
PAY ATTENTION NOT TO SPILL OIL ON THE EXTERNAL PARTS OF THE MOTORCYCLE, FRAME, ENGINE, RADIATOR.
IF THAT HAPPENS, CLEAN USING WATER AND A CLOTH.
DO NOT POUR OIL IN SEWERAGE OR IN RIVERS.

FUEL TANK (MX – SMX)
The fuel cap (1) is at the top of the fuel tank, in the front area of the motorcycle.
– To open it: unscrew the tank cap by turning it anti-clockwise.
– To close it: place the tank cap in the filler neck and turn it clockwise.
TM engines use a mix of super unleaded fuel (E5) – (E10) and 2 stroke oil at 3%.
E5 = Petrol containing up to 5% of ethanol in proportion to its volume.
E10 = Petrol containing up to 10% of ethanol in proportion to its volume.

Tank capacity:
Total of lt. 9,5, 1 of which is additional

WARNING
Fill the tank with a mix of unleaded petrol with a minimum octane number of 95 and oil at 3%.
Never use petrol with octane lower than 95, as it could damage the engine.
Only use 2 stroke oil suitable for 2 stroke engines, do not use engine oil. (see paragraph “Technical Data).

Fuel expands when heated. Therefore, in high temperatures, do not fill the tank to the top.

DANGER
PETROL IS HIGHLY FLAMMABLE AND TOXIC. HANDLE PETROL WITH EXTREME CARE. DO NOT FILL-UP WITH PETROL NEAR NAKED FLAME OR LIT CIGARETTES. ALWAYS TURN OFF THE ENGINE BEFORE FILLING UP WITH PETROL. TAKE CARE NOT TO GET PETROL ON THE ENGINE OR ON THE EXHAUST PIPE. IMMEDIATELY REMOVE ANY SPILT PETROL WITH A CLOTH. IF PETROL IS SWALLOWED OR GETS IN YOUR EYES, SEEK MEDICAL ADVICE IMMEDIATELY.
DANGER
KEEP 2 STROKE OIL AWAY FROM THE REACH OF CHILDREN. 2 STROKE OIL MAY CAUSE SERIOUS DAMAGES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND REGULARLY.
WASH YOUR HANDS WITH EXTREME CARE AFTER HAVING HANDLED OIL.
PAY ATTENTION NOT TO SPILL OIL ON THE EXTERNAL PARTS OF THE MOTORCYCLE, FRAME, ENGINE, RADIATOR.
IF THAT HAPPENS, CLEAN USING WATER AND A CLOTH.
DO NOT POUR OIL IN SEWERAGE OR IN RIVERS.

SIDE STAND
Use your foot to move the side stand (1) forward until it stops, then lean the motorcycle onto it.
Make sure that the ground is solid and the parking position is stable. For greater safety, engage 1st gear with the engine off.
When you lift the motorcycle, the side stand automatically lifts up.

WARNING
The side stand is only designed to support the weight of the motorcycle.
Never sit on the motorcycle while it is resting on the side stand, as the side stand may be damaged and the motorcycle may fall over.

ENGINE IDLE SPEED ADJUSTMENT
The engine idle speed adjustment knob or the screw (1) is positioned on the left hand side of the motorcycle.
The engine speed is increased or decreased to the minimum by rotating the knob or the screw.

FUEL TAP (MX – SMX)
The fuel tap (1) is positioned under the tank on the left hand side of the motorcycle.
The tap has three positions:
– OFF = tap closed: there’s no insertion of mix in the carburettor.
It’s a normal position when the motorcycle is stationary and switched off.
– ON = tap open: there’s insertion of mix in the carburettor.
It’s a normal position while using the motorcycle.
– RES = reserve, indicates that the minimum level of mix inside the tank has been reached and that it is necessary to restore its level.
– Rotate the tap from “OFF” to “ON” in order to start the motorcycle.
– When, during the motorcycle use, the engine starts to switch off or works at intervals, rotate the tap (1) from position “ON” to “RES” (reserve) and restore the mix level inside the tank as soon as possible.

3. INSTRUCTIONS FOR USE

Indications for first use

• Make sure that the motorcycle’s “PRE-DELIVERY OPERATIONS” have been completed by your TM dealer.
• Carefully read all of the instructions before using the motorcycle for the first time.
• Familiarize yourself with all of the controls.
• Adjust the clutch lever, the front brake lever and the brake pedal to the most comfortable position.
• Practice riding the motorcycle in an empty car park or on easy terrain before going for a long drive. Also try standing up while riding slowly, to get a feel for how the motorcycle handles.
• Do not choose routes that are too difficult for your skill level and experience.
• Hold the handlebar with both hands and keep your feet on the footrests.
• Make sure you do not press the brake pedal with your foot if you do not want to stop. If the brake pedal is not released, the brake pads rub continuously causing the brake to overheat.
• Do not make changes to the motorcycle and always use TM ORIGINAL SPARE PARTS. Spare parts from other manufacturers may affect the safety of the motorcycle.
• Motorcycles are sensitive to shifts in weight distribution. Luggage must be fastened near the center of the motorcycle and its weight must be evenly distributed between the front and rear wheels.
• Follow the running-in instructions.

WARNING
Although EN-SMR models have approval, they must be driven with care on roads. Above all, avoid long stretches with wide open throttle.

SAFETY REGULATIONS
DANGER

• ALWAYS WEAR SUITABLE CLOTHES WHEN USING THE MOTORCYCLE. WISE BIKERS WHO RIDE A TM ALWAYS WEAR APPROVED HELMET, BOOTS, GLOVES AND JACKET, BOTH FOR LONG JOURNEYS AND SHORT DISTANCES. PROTECTIVE GEAR SHOULD BE HIGHLY VISIBLE TO ALLOW OTHER DRIVERS ON THE ROAD TO SEE THE BIKER IMMEDIATELY.
• DO NOT DRIVE AFTER CONSUMING ALCOHOL.
• ALWAYS USE TM ORIGINAL ACCESSORIES. FOR EXAMPLE, FRONT COVERINGS MAY AFFECT MOTORCYCLE PERFORMANCE AT HIGH SPEED. EVEN LUGGAGE, ADDITIONAL TANKS, ETC. MAY AFFECT MOTORCYCLE PERFORMANCE DUE TO THE DIFFERENT WEIGHT DISTRIBUTION.
• BOTH THE FRONT AND THE REAR WHEELS MUST BE FITTED WITH TIRES WITH THE SAME TYPE OF PROFILE.
• AFTER THE FIRST 30 MINUTES OF RIDING, YOU MUST CHECK THE TENSION OF THE SPOKES. SPOKE TENSION DECREASES RAPIDLY ON NEW WHEELS. IF YOU KEEP RIDING WITH LOOSE SPOKES, THEY MAY BREAK, CAUSING INSTABILITY (SEE CHECKING SPOKE TENSION).
• ALL EURO 4 MODELS ARE DESIGNED AND SET UP FOR ONLY 1 RIDER. CARRYING A PASSENGER IS PROHIBITED.
• COMPLY WITH TRAFFIC REGULATIONS AND DRIVE WITH CAUTION SO AS TO RECOGNIZE DA NGER AS SOON AS POSSIBLE.
• ADJUST THE SPEED OF THE VEHICLE ACCORDING TO THE CONDITIONS OF THE ROAD AND YOUR DRIVING SKILLS.
• DRIVE WITH CAUTION ON UNKNOWN ROADS OR TERRAINS.
• WHEN GOING OFF ROAD, ALWAYS GO WITH A FRIEND WITH A SECOND MOTORCYCLE, SO YOU CAN HELP EACH OTHER IF NECESSARY.
• PROMPTLY REPLACE THE VISOR OR LENSES OF YOUR GLASSES. SCRATCHED VISORS OR GLASSES MAKE IT NEARLY IMPOSSIBLE TO SEE IN POOR LIGHT CONDITIONS.
• NEVER LEAVE THE MOTORCYCLE UNATTENDED WITH THE ENGINE RUNNING.

DANGER

• ONLY EN AND SMR MODELS HAVE APPROVAL FOR USE ON PUBLIC ROADS OR MOTORWAYS.
• WHEN RIDING YOUR MOTORCYCLE, ALWAYS BEAR IN MIND THAT LOUD NOISE MAY DISTURB OTHER PEOPLE.

Running-in instructions
The component surfaces of a new motorcycle, despite precision machining, are not as smooth as the components of motorcycles that have been running for a long time. This is why running-in a new motorcycle is so important.
For optimal settling of moving parts, a new motorcycle must be brought to its maximum performance gradually.

The main rules to follow are:

1. After cold start, warm up the engine for about 1 minute before starting to use the motorcycle.
2. During the first 3 hours of use (1 hour for competitive use) the engine must be used only up to a maximum of 50% of its power. Plus, the number of revs must not exceed 9000 rpm for 250cc or 300cc engines and 6000 rpm for 450/530 cc engines.
3. During the subsequent 5 hours of use (1 hour for competitive use) the engine can be used up to a maximum of 75% of its power. Ride the motorcycle under a variety of conditions (road, easy off-road stretches). Do not go on long journeys without ever closing the throttle. Gradually increase and reduce throttle opening, alternating acceleration and deceleration with short periods at constant speed. Make sure that the coolant does not reach temperatures that are too high (indicated by fluid leaking from the bleeder hose).

By following these rules, you will obtain maximum performance and longer engine life.
It is essential that you carry out the operations described in the “Maintenance Schedule” during the running-in period.
Be particularly careful when replacing oil as metal particles that can detach from the surfaces of engine parts in contact during running-in circulate in the oil and are deposited in the cap with magnet. Therefore, replacing oil and cleaning the cap with magnet allows these particles to be definitively removed from the engine.

PRELIMINARY CHECKS
In order to drive safely, the motorcycle must be in good condition and well maintained. It is good practice to perform a general check on the motorcycle before every use.
It must include the following checks:

– 2 stroke oil and fuel level check (TSI)
– brake fluid level check;
– coolant level check;
– brakes correct operation check;
– brakes pipes and pads condition check;
– steering check, turning handlebar all the way in both directions;
– tires pressure and condition check;
– chain tension check;
– flexible cable controls check and adjustment if necessary;
– if carrying luggage, check that it is secured.

– Start the engine: check that the instrument display lights up and;
– turn on the high beam and check that the relative indicator comes on;
– activate the turn signals and check that the relative indicators come on;
– check that the rear brake light comes on;
– check that the horn works;
– check that after starting the “ ” “Engine fault” indicator does not come on.
N.B.: For checks and any adjustments necessary, see the Maintenance section.

Setting off
Put on a protective helmet and start the engine, then pull the clutch lever, engage 1st gear and slowly release the clutch lever while accelerating.

DANGER
NEVER RIDE THE MOTORCYCLE WITHOUT WEARING AN APPROVED PROTECTIVE HELMET AND/OR IF YOU ARE NOT IN GOOD PSYCHOLOGICAL AND PHYSICAL HEALTH.

BEFORE SETTING OFF, ALWAYS MAKE SURE THAT THE SIDE STAND IS FULLY RETRACTED. YOU CAN LOSE CONTROL OF THE MOTORCYCLE IF THE STAND DRAGS ON THE GROUND.

ACCELERATING, Shifting gears , slowing down
1st gear, which you are using, is the gear used to set off and to go uphill. When circumstances permit (speed limit, traffic, incline), you can engage higher gears to increase speed. To do so, release the throttle while pulling the clutch lever, engage the next gear, release the clutch and accelerate up to a 1/2 turn of the throttle grip. Then engage the next gear and repeat until you reach the desired speed, always remaining within the limits in force.

Gradually opening the throttle promotes careful driving and limits consumption. Learn how far you need to turn the throttle grip based on the speed at which you want the motorcycle to move.

Release the throttle grip to reduce speed. If necessary, also brake and down shift, pulling the clutch lever and engaging a lower gear. Release the clutch slowly and accelerate or shift gears again. Always move up or down through the gears one at a time!

Braking
Release the throttle and, at the same time, gradually brake with the front and rear brakes.
Engage a lower gear if necessary. On dusty, wet or slippery surfaces, use the brakes and down shift as gently as possible without locking the wheels. Locking of the wheels leads to swerving and/or falling.
On long downhill roads, make use of engine braking.
To do so, engage 1st or 2nd gear without excessively increasing the revs. This way, you can brake much less and the brakes will not overheat.

DANGER

• IN RAIN, AFTER WASHING THE MOTORCYCLE, AFTER IMMERSION IN WATER, OR TRAVELLING OVER WET GROUND, BRAKING COULD BE DELAYED BECAUSE OF WET OR DIRTY BRAKE DISCS. THEREFORE, USE THE BRAKES REPEATEDLY AND CAUTIOUSLY, BEING SURE NOT TO OBSTRUCT TRAFFIC, UNTIL THE DISCS ARE DRY AND CLEAN.
• BRAKING CAN BE DELAYED EVEN WHEN TRAVELLING ON DIRTY ROADS OR ROADS COVERED WITH SALT. AGAIN, USE THE BRAKES REPEATEDLY AND CAUTIOUSLY, BEING SURE NOT TO OBSTRUCT TRAFFIC, UNTIL THE DISCS ARE CLEAN.
• DIRTY BRAKE DISCS CAUSE GREATER WEAR OF THE PADS AND DISCS.
• THE DISC, PADS, CALIPERS, AND BRAKE FLUID HEAT UP AFTER USING THE BRAKES. THE HOTTER THESE PARTS, THE LESS THE BRAKING EFFECT IS. IF OVERHEATING OCCURS, THE WHOLE BRAKING SYSTEM MAY FAIL.
• IF, WHILE BRAKING, THE FRONT BRAKE LEVER OR THE REAR BRAKE PEDA L STROKES ARE LONGER THAN USUAL, THERE IS A FAULT IN THE BRAKING SYSTEM. IN THIS CASE, HAVE AN AUTHORIZED TM WORKSHOP CHECK THE MOTORCYCLE.
• TM MODELS CAN BE RESTARTED ANY TIME WITH THE KICK STARTER OR ELECTRIC START. THEREFORE, TURN OFF THE ENGINE WHEN YOU INTEND TO KEEP THE MOTORCYCLE AT A STANDSTILL FOR MORE THAN 2 MINUTES.
• CHECK THE MOTORCYCLE AFTER EVERY FALL AS YOU DO BEFORE EVERY START-UP.
• A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. NEVER STRAIGHTEN THE HANDLEBAR, AS IT MAY LOSE ITS STRENGTH.

INFORMATION:
Standard TM motorcycles are not equipped with radiator cooling fans and the radiator dimensions are designed for optimum compactness and weight. The cooling system is sufficient for tourist or sport use.
Consult a TM dealer if you want to use optional cooling fans.

WARNING
– Using the engine at high revs when it is still cold affects the length of engine life. Therefore, before running the engine at full speed, warm it up by driving a few kilometers at medium speed. The engine has reached its operating temperature as soon as the radiators become hot.
– Never down shift without having first slowed down. The engine revs would go too high and some of its components could be damaged. Also, the rear wheel could lock, causing you to lose control of the vehicle.
– If you feel abnormal vibrations while driving, make sure that the fixing screws on the motorcycle are fully tightened.
– If you hear strange noises while riding your motorcycle, stop immediately, turn off the engine and contact a tm dealer.

WASHING
– Regularly clean the motorcycle to keep the surface of plastic parts in good condition.
– Use hot water, a cleaning product available on the market and a sponge. Heavy dirt can be removed with a gentle jet of water.
– Plug the exhaust pipe before cleaning to prevent water from going in.
– Remove the air filter as described in the “Maintenance” section.

WARNING
Do not aim water jets directly at the filter case (1), or water may enter the engine zone.
– Use cleaning products available on the market to wash the engine. Use a suitable brush to clean particularly dirty parts.
– Once you have thoroughly rinsed the motorcycle with a gentle jet of water, dry with compressed air and a cloth.

Immediately go for a short ride until the engine reaches the operating temperature and, at this point, also use the brakes. The water left in the areas that cannot be reached and on the brakes will evaporate thanks to the heat.
– Once the motorcycle has cooled down, oil or grease all sliding parts and bearings. Apply a specific spray to the chain.
– Apply a specific spray for contacts to all the electrical controls on the handlebar and electrical system connectors to prevent faults in the electrical system.

WARNING
Never clean the motorcycle with a high pressure cleaner or with a strong water jet! Otherwise, due to the high pressure, water could reach the electrical parts, connectors, flexible cable controls, bearings, etc. and cause faults or lead to early breakage of these parts.

PRECAUTIONS FOR WINTER USE
If the motorcycle is used in winter, you must consider the salt on the roads and take appropriate measures against the corrosive salt.
– Thoroughly wash the motorcycle after every use and let it dry.
– Apply an anti-corrosion product to the engine, exhaust system, frame, swing arm and all other shiny, galvanized or satin finished metal components (except brake discs).

DANGER
DO NOT ALLOW THE ANTI-CORROSION PRODUCT TO COME INTO CONTACT WITH THE BRAKE DISCS. THIS WOULD REDUCE THE BRAKING EFFECT CONSIDERABLY.

WARNING
After traveling on roads where salt has been spread, thoroughly wash the motorcycle with cold water and let it dry completely.

STORAGE
Take the following measures if the motorcycle is to be left unused for a long period:
– Thoroughly clean the motorcycle (see “WASHING”).
– Change the gearbox oil. Old oil contains harmful impurities (see the “MAINTENANCE” section).
– Check the coolant level.
– Remove the spark plug and pour approx. 5 cc of engine oil into the cylinder through the spark plug hole. Activate the kick starter 10 times to allow the engine oil to be distributed on the cylinder wall. Then fit the spark plug again.
– Compress the piston to make the exhaust ports close.
– Empty the fuel tank and collect the fuel in a suitable container.
– Disconnect the cables and remove the battery. Plan a maintenance schedule if required.
– Adjust the tire pressure.
– Grease the bearings, control lever and footrest supports and the chain.
– The storage area should be dry and not subject to drastic temperature changes.
– Cover the motorcycle, preferably with a breathable sheet or cover. Do not use airtight materials, as moisture would be trapped and could cause corrosion.
– Place the motorcycle on a stand, so that its wheels are raised off the ground.

WARNING
Before storing the motorcycle for the winter, check the operation and wear of all components. If maintenance operations, repairs or modifications are required, it is a good idea to have them carried out during the winter (workshops are less busy). This means that you avoid long waits in the workshop at the start of the spring season.

WARNING
It is highly inadvisable to start the engine for brief periods of time when the motorcycle has been put into storage. The engine would not heat up sufficiently, and so the steam created during combustion would condense, oxidizing the valves and the exhaust system.

START-UP AFTER WINTER
– Fit the charged battery.
– Fill the tank with new fuel.
– Check the motorcycle as you do before any start-up. Go for a short test ride.

4. MAINTENANCE

250-300 en-smr (tsi) MAINTEN ANCE TABLE
A clean motorcycle ca n be inspected faster and at a lower cost

250-300 en-smr (tsi) MAINTEN ANCE TABLE
A clean motorcycle ca n be inspected faster and at a lower cost

WARNING
Change affected components if a defect is found or wear limits exceeded.
The above operations must be performed by an authorized tm workshop or by specialized personnel.
The hour meter is built into the dash.

250-300 (MX – SM X) MAINTEN ANCE TABLE
A clean motorcycle ca n be inspected faster and at a lower cost

250-300 (MX – SM X) MAINTEN ANCE TABLE
A clean motorcycle ca n be inspected faster and at a lower cost

WARNING
Change affected components if a defect is found or wear limits exceeded.
We recommend that you fit an hour meter.
The above operations must be performed by an authorized tm workshop or by specialized personnel.

THIS SYMBOL ALONGSIDE THE TIT LE ME ANS THAT THE OPERATION MUST BE PERFORMED AT AN AUTHORI ZED TM WORKSHOP .

Varying pre-load AND REP LACIN G fork SPRIN GS
To vary the spring pre-load on these forks, you must partly disassemble them (see the specific manual of the fork fitted on the motorcycle).
You should absolutely not vary the spring pre-load on forks fitted by TM Racing.
If necessary, replace the springs with others that have a different rate.

WARNING
For further, more detailed information about the forks, see the instructions supplied by the fork manufacturer.

Basic SUSPENSION cal ibration DEPENDIN G ON THE WEI GHT OF THE rider
For optimum motorcycle driving and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic calibration of the suspensions must be adjusted according to your weight.
The basic calibration of the suspensions (both the fork and shock absorber) involves mounting a certain type of spring and a set of adjustments of the compression and rebound braking.
TM motorcycles come calibrated for a rider weight (with full protective gear) of 70 – 80 kg.
Adjust the calibration of the suspensions if your weight does not fall within this range.
The main element to check is the spring, both of the fork and the shock absorber.
To check for correct spring rate, first measure the motorcycle rider sag.
Then adjust the compression and rebound braking.
For technical clarification regarding operation and calibration of TM motorcycle suspensions, contact your local TM dealer.

ADAPTING fork basic calibration
Precise fork rider sag cannot be established for several reasons.
Minor variations in your body weight can be compensated for by adjusting the compression braking.
But if your fork is often bottoming or topping out, you must fit stiffer springs to avoid damaging the fork and frame.
Then re-adjust the compression and rebound braking.

ADAPTING shock absorber basic calibration
To establish whether or not the shock absorber spring is suitable for your weight, check rider sag.
But first the shock absorber static sag must be adjusted.
Both static sag and rider sag can be checked by taking a simple set of measurements on the motorcycle.

– INSTEAD, IF THE CHAIN TENSION IS INSUFFICIENT IT CAN JUMP OFF THE PINION AND LOCK THE REAR WHEEL OR DAMAGE THE ENGINE .
– IN BOTH CASES YOU CAN EASILY LOSE CONTROL OF THE MOTOR CYCLE.

Chain maintenance
The life span of the chain depends above all on maintenance.
Chains without an O-ring must be regularly cleaned in oil and then immersed
in hot oil or treated with chain spray.
Maintenance of chains with O-ring is minimal.
The best way to clean it is with plenty of water.
Never use brushes or solvents to clean the chain.
When the chain is dry, use a specific spray for chains with O-rings.

DANGER
IT IS ESSENTIAL TO PREVENT THE LUBRICANT FROM REACHING THE REAR TIRE AND THE BRAKE DISC. OT HERWISE THE REAR WHEEL’S GRIP ON THE GROUND AND THE REAR BRAKE ACTION COULD BE SIGNIFICANTLY REDUCED AND YO U COULD EASI LY LOSE CONTRO L OF THE MOTOR CYCLE.

WARNING
When assembling the chain joint (1), the closed part must always be in the direction of travel.
Always check for wear on the pinions, sprocket and guides. Replace these parts if necessary.

Chain wear
To check the level of wear on the chain, carefully follow these instructions:
– Shift into neutral, pull the upper branch of the chain upwards with a force of 10 – 15 kg.
– Now measure the distance of 18 links on the lower branch of the chain.

If the distance is more than 272 mm, replace the chain.
Chains do not always wear evenly, therefore, you must repeat the measurement at various points of the chain.

When a new chain is fitted, also replace the pinion and sprocket. A new chain wears faster on old and worn pinions and sprocket.

WARNING
When replacing the chain, pinion and sprocket, we recommend fitting new self- locking nuts for the sprocket and using criss-cross tightening.
The nut tightening torque is 35 Nm.

DANGER

• IF THE LEVEL OF THE HYDR AULIC FLUID DROPS BELOW THE PRESET LEVEL, THERE COULD BE LEAKS IN THE SYSTEM OR EARLY SIGNS OF A MECHANICAL PROBLEM .
• STORE HYDR AULIC FLUID OUT OF THE RE ACH OF CHILDREN .
• HYDR AULIC FLUID MAY IRRIT ATE SKIN . AVOID CONTACT WITH SKIN AND EYES . IF HYDRAULIC FLUID SPLASHES IN YOUR EYES , RINSE THOROUGHLY WITH WATER AND SEEK MEDICAL ADVICE.

WARNING
– Only use dot 4 brake hydraulic fluid for the clutch hydraulic control. Never use dot 5 or other fluids.
– Prevent contact between brake hydraulic fluid and painted parts. Brake fluid corrodes paint.
– Only use clean brake fluid from a hermetically sealed container.

Basic indications for TM disc brakes

CALIPERS
EN and MX models have floating front and rear calipers, i.e.: they are not joined to their support. Side compensation always allows the pads to rest on the discs in the optimum way.
In contrast, SMR/SMX models front calipers are fixed.
The brake caliper supporting screws must be secured with Loctite 243 and tightened to 25 Nm.

PADS
The minimum thickness of the friction material must never drop below 1 mm.
In the event of replacement, we recommend that you always use the specific
TM original spare part for your motorcycle.

DANGER
– STORE BRAKE FLUID OUT OF THE RE ACH OF CHILDREN .
– BRAKE FLUID MAY IRRIT ATE SKIN . AVOID CONTACT WITH SKIN AND EYES . IF BRAKE FLUID SPLASHES IN YOUR EYES , RINSE THOROUGHLY WITH WATER AND SEEK MEDICAL ADVICE.

WARNING
– Prevent contact between brake fluid and painted parts. Brake fluid corrodes paint.
– Only use clean brake fluid from a hermetically sealed container.

BREMBO front brake PUMP (Optional )
Adjusting the lever POSITION
The position of the front brake lever relative to the grip can be altered using the adjusting screw (1).
– Turn the knob (1) clockwise to move the lever away or anti-clockwise to move the lever closer.

WARNING
When the operation is complete, check that there is 3 mm of play in the front brake lever before the brake is engaged and that the front wheel can turn freely with the lever at rest. If this play is missing, pressure builds in the braking system and the front wheel brake may fail due to overheating or the wheel locking.

Checking BRAKE fluid level
The fluid reservoir is part of the front brake pump located on the handlebar and is equipped with an inspection indicator (2). With the reservoir in the horizontal position, the fluid level must never drop below the indicator center line.

DANGER
IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE, THIS ME ANS THERE IS A LEAK IN THE BRAKIN G SYSTEM OR THAT THE BRAKE PADS ARE WORN BEYOND THE LIMITS ALLOWED .

DANGER
– STORE BRAKE FLUID OUT OF THE RE ACH OF CHILDREN .
– BRAKE FLUID MAY IRRITATE SKIN . AVOID CONTACT WITH SKIN AND EYES . IF BRAKE FLUID SPLASHES IN YO UR EYES , RINSE THORO UGHLY WITH WATER AND SEEK MEDICAL ADVICE.

WARNING
– Prevent contact between brake fluid and painted parts. Brake fluid corrodes paint.
– Only use clean brake fluid from a hermetically sealed container.

WARNING
– Prevent contact between brake fluid and painted parts. Brake fluid corrodes paint.
– Only use clean brake fluid from a hermetically sealed container.

Checking spoke tension

Pull off the seat (2) towards the back of the motorcycle (B).

NOTE:
For more information about the battery, see the introductory part of this manual.

STORAGE
Do not store the battery in a room where temperature is higher than 50° or lower than -10°. If you intend not to use the motorcycle for a period longer than 15 days, it is advised to connect the battery to a charger or, alternatively, remember to recharge it every 15 days to protect it from possible damages. Always recharge the battery before it discharges completely in order to prolong its service life. Damage caused by a prolonged lack of recharge is irreversible and not covered by warranty.
Charge the battery ever three or four months.

In the event of prolonged storage (eight to ten months), charge to 100%, then test the battery with a Voltmeter. For longer battery life, regular battery maintenance must be carried out.

Make sure that batteries are kept out of the reach of children.

WARNING
– Do not use charge maintainers, battery tenders, fast chargers or other similar devices.
– Use of these devices may damage the battery, cause dangerous overheating, fires and explosions if they are not compatible.
– You must ALWAYS be present during battery charging.
– Do not charge the battery beyond the maximum voltage value indicated.

Check the external condition of the terminals and the plastic casing. Any signs of damage or unusual wear can be checked during the service.
If you have any doubts about the condition of the battery, we recommend that you seek the opinion of a professional fitter.

DANGER
– DO NOT REMO VE THE BATTERY COVER , AND DO NOT PIER CE OR CUT THE OUTER PLASTI C CONT AINER : RIS K OF SHORT CIR CUIT .

Charging THE battery
DANGER
– WHEN CHARGIN GLIFEP 04 BATTERIES , ON LY USE LIFEP 04 BATTERY CHARGERS , SPE CIFI CALLY DESI GNED FOR LIT HIUM ION BATTERIES .
– THE USE OF OT HER BATTERY CHARGERS COULD CAUSE DANGERO US OVER HEATIN GAND EVEN BATTERY FIRES AND EXPLOSIONS .

If the battery noticeably heats up during charging, stop the charging. Allow the battery to cool before charging it. Do not under any circumstances short circuit the battery poles to check charging progress: the battery may explode.

Do not charge LIFEP04 batteries using currents higher than those indicated and recommended: it could cause dangerous overheating. To avoid creating sparks, switch off the battery charger before disconnecting its terminals from the battery.

DANGER
– DO NOT CHARGE THE BATTERY BEYOND THE MAXIMUM VOLTAGE VALUE INDICATED .
NOTE : We recommend the following models for battery charging:

The use of other battery chargers may damage the battery.

Battery maintenance
– Do not store the battery in a room where temperature is higher than 50° or lower than -10°. If you intend not to use the motorcycle for a period longer than 15 days, it is advised to connect the battery to a charger or, alternatively, remember to recharge it every 15 days to protect it from possible damages.
– Always recharge the battery before it discharges completely in order to prolong its service life.
Damage caused by a prolonged lack of recharge is irreversible and not covered by warranty.

Cleaning air filter
Regularly clean and maintain the air filter.
A dirty air filter compromises air flow, reduces motorcycle power and increases fuel consumption. In some cases, dust may enter the engine and cause serious damage. Therefore, regular air filter maintenance is necessary.

Opening cable
– Loosen the lock nut (2) and tighten or loosen the adjusting screw (3) to obtain the required play.
– Tightening the adjusting screw increases play.
– Loosening the adjusting screw reduces play.
– Tighten the lock nut and check that the grip rotates smoothly.

Closing cable
– Loosen the lock nut (4) and tighten or loosen the adjusting screw (5) to obtain the required play.
– Tightening the adjusting screw increases play.
– Loosening the adjusting screw reduces play.
– Tighten the lock nut and check that the grip rotates smoothly.
– Put the protective cap back in place at the end of adjustment.

WARNING
– With the engine running, ensure that the idle speed is correct and does not increase when you steer all the way right or left.

5. DIAGNOSIS

Performing the scheduled maintenance on your motorcycle will make encountering problems unlikely. However, should a problem occur, check the troubleshooting table and follow the instructions provided to solve the problem.

The table includes two columns indicating who should perform the work:

6. TECHNICAL DATA

7. WIRING DIAGRAMS

8. ALPHABETICAL INDEX

TM RACING S.p.A.
Via Fano, 6 – 61122 Pesaro – Italy
Tel. +39 0721 25113 – Fax +39 0721 401808

www.tmracing.it

https://www.motomanuals.net/

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References

• TM Moto - TM Racing
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