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TM RACING 4 Stroke 2009 User And Maintenance Manual

Tm 4 stroke 2009
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USER AND
USER AND
MAINTENANCE
MAINTENANCE
MANUAL
MANUAL
TM 4 STROKE 2009
TM RACING
TM RACING
USES and ADVICES
USES and ADVICES

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Summary of Contents for TM RACING 4 Stroke 2009

  • Page 1 USER AND USER AND MAINTENANCE MAINTENANCE MANUAL MANUAL TM 4 STROKE 2009 TM RACING TM RACING USES and ADVICES USES and ADVICES...
  • Page 2 ENGLISH ENGLISH...
  • Page 3 IMPOR IMPOR IMPORT T T T T ANT IMPOR IMPOR YOU ARE ADVISED TO READ THIS MANUAL CAREFULLY BEFORE USING YOUR MOTO TM. IT CONTAINS A LOT OF INFORMATION AND ADVICE THAT WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE MUCH EASIER AND SAFER.
  • Page 4 Always remember to respect the environment and other people. Always use the motorcycle with caution, it is in everybodys interest to safeguard the future of our sport. Enjoy yourself with your TM motorcycle! TM RACING S.p.A. Via Fano 6 - 61100 PESARO ITALY TM RESERVES THE RIGHT TO CHANGE OR TO EXECUTE MODIFICATIONS AS IT DEEMS NECESSARY .
  • Page 5 IMPOR IMPOR T T T T T ANT IMPOR ANT AD AD VICE REGARDING VICE REGARDING VICE REGARDING VICE REGARDING IMPOR IMPOR VICE REGARDING THE LEGAL WARRANTY AND THE THE LEGAL WARRANTY AND THE THE LEGAL WARRANTY AND THE THE LEGAL WARRANTY AND THE THE LEGAL WARRANTY AND THE COMMER COMMER...

  • Page 6: Table Of Contents

    INDEX INDEX INDEX INDEX INDEX INDEX INDEX INDEX INDEX INDEX Page Page POSITION OF SERIAL NUMBER ........... 7 Check chain tension ..............41 Frame number ................8 Adjustment of chain tension (all models except SMM) ....41 Engine number ................8 Adjustment of chain tension (SMM) ..........
  • Page 7 ENGLISH ENGLISH ENGLISH...

  • Page 8: Position Of Serial Number

    POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER POSITION OF SERIAL NUMBER FRAME NUMBER FRAME NUMBER FRAME NUMBER...

  • Page 9: Operating Controls

    ENGLISH ENGLISH ENGLISH...

  • Page 10: Clutch Lever Ajp Pump

    OPERA OPERA OPERATING CONTR OPERA OPERA TING CONTR TING CONTR TING CONTROLS TING CONTR OPERA OPERA OPERA OPERA OPERATING CONTR TING CONTR TING CONTR TING CONTR TING CONTROLS CLUTCH LEVER AJP PUMP CLUTCH LEVER AJP PUMP CLUTCH LEVER AJP PUMP CLUTCH LEVER AJP PUMP CLUTCH LEVER AJP PUMP The clutch lever (1) is mounted on the left of the handlebar.

  • Page 11: Front Brake Lever Brembo Radial Pump

    OPERA OPERA OPERATING CONTR TING CONTR TING CONTR TING CONTROLS OPERA OPERA TING CONTR OPERA OPERATING CONTR OPERA TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR FRONT BRAKE LEVER BREMBO RADIAL PUMP FRONT BRAKE LEVER BREMBO RADIAL PUMP FRONT BRAKE LEVER BREMBO RADIAL PUMP FRONT BRAKE LEVER BREMBO RADIAL PUMP FRONT BRAKE LEVER BREMBO RADIAL PUMP...

  • Page 12: Combination Switch (End/Smr/Smm)

    OPERA OPERA OPERA OPERA OPERATING CONTR TING CONTR TING CONTR TING CONTROLS TING CONTR OPERA OPERA OPERATING CONTR OPERA OPERA TING CONTR TING CONTR TING CONTROLS TING CONTR COMBIN COMBINA A A A A TION SWIT COMBIN TION SWIT TION SWIT TION SWITCH COMBIN COMBIN...

  • Page 13: Fuel Filler Cap

    OPERA OPERA OPERATING CONTR TING CONTR TING CONTR TING CONTROLS OPERA OPERA TING CONTR OPERA OPERATING CONTR OPERA TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP The fuel fill cap is found on top of the tank.

  • Page 14: By-Pass" Command (Hot Starter) All Models With Kickstart

    OPERA OPERA OPERATING CONTR TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR OPERA OPERATING CONTR OPERA TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR “BY “BY “BY-PASS” -PASS” -PASS” -PASS” COMMAND (HO COMMAND (HO COMMAND (HO COMMAND (HOT ST T ST T ST...

  • Page 15: Brake Pedal

    OPERA OPERA OPERATING CONTR TING CONTR TING CONTR TING CONTROLS OPERA OPERA TING CONTR OPERA OPERA OPERATING CONTR TING CONTR TING CONTR TING CONTROLS OPERA OPERA TING CONTR BRAKE PED BRAKE PED BRAKE PEDAL BRAKE PED BRAKE PED 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).

  • Page 16: Fork Adjustment In Compression

    OPERA OPERA OPERATING CONTR TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR OPERA OPERATING CONTR OPERA TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR FORK ADJUSTMENT IN COMPRESSION FORK ADJUSTMENT IN COMPRESSION FORK ADJUSTMENT IN COMPRESSION FORK ADJUSTMENT IN COMPRESSION FORK ADJUSTMENT IN COMPRESSION The hydraulic brake system determines the behaviour of the fork in the...

  • Page 17: Shock Absorber Adjustment In Compression

    OPERA OPERA TING CONTR TING CONTR OPERA OPERA OPERATING CONTR TING CONTR TING CONTROLS OPERA OPERA TING CONTR TING CONTR OPERA OPERA OPERATING CONTR TING CONTR TING CONTROLS SHOCK SHOCK SHOCK ABSORBER ABSORBER ABSORBER ABSORBER ADJUST ADJUST ADJUST ADJUST..IN COMPRESSION IN COMPRESSION IN COMPRESSION IN COMPRESSION...

  • Page 18: Shock Absorber Adjustment In Rebound

    OPERA OPERA OPERATING CONTR TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR OPERA OPERATING CONTR OPERA TING CONTR TING CONTROLS TING CONTR OPERA OPERA TING CONTR SHOCK ABSORBER ADJUSTMENT IN REBOUND SHOCK ABSORBER ADJUSTMENT IN REBOUND SHOCK ABSORBER ADJUSTMENT IN REBOUND SHOCK ABSORBER ADJUSTMENT IN REBOUND SHOCK ABSORBER ADJUSTMENT IN REBOUND The hydraulic brake system in rebound determines the behaviour of...

  • Page 19: Advice And General Recommendations For Commissioning The Motorcycle

    ENGLISH ENGLISH ENGLISH...

  • Page 20: Indications For First Start-Up

    VICE VICE AND GENERAL RECCOMAND AND GENERAL RECCOMAND AND GENERAL RECCOMANDA A A A A TIONS FOR TIONS FOR TIONS FOR ADVICE VICE VICE AND GENERAL RECCOMAND AND GENERAL RECCOMAND TIONS FOR TIONS FOR VICE VICE AND GENERAL RECCOMAND AND GENERAL RECCOMAND AND GENERAL RECCOMANDA A A A A TIONS FOR TIONS FOR TIONS FOR...
  • Page 21 ENGLISH ENGLISH ENGLISH...

  • Page 22: Instructions For Use

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE CHECK BEFORE EVER CHECK BEFORE EVER CHECK BEFORE EVERY ST Y ST Y ST Y STAR...

  • Page 23: Cold Engine Start

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE COLD ENGINE ST COLD ENGINE ST COLD ENGINE STAR ART T T T T COLD ENGINE ST COLD ENGINE ST 1 Open the fuel tap (1).

  • Page 24: If The Engine Is "Flooded

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE IF THE ENGINE IS “FLOODED” IF THE ENGINE IS “FLOODED” IF THE ENGINE IS “FLOODED”...
  • Page 25 INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INDICATION: All TM models do not have a radiator cooling fan and the radiator dimensions have been studied to optimise compactness and weight.

  • Page 26: Braking

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE BRAKING BRAKING BRAKING BRAKING BRAKING Close the throttle and brake at the same time progressively with the front and rear brakes.

  • Page 27: Fuel

    INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INSTRUCTIONS FOR USE INDICATIONS REGARDING THE SIDE STAND: Push the stand forward until it stops and lean the motorcycle on it. Ensure that the ground is solid and the parking position is stable.
  • Page 28 ENGLISH ENGLISH...
  • Page 29 ENGLISH ENGLISH ENGLISH...

  • Page 30: Maintenance And Lubrication Table

    MAINTEN MAINTEN ANCE ANCE AND L AND L UBRICA UBRICA TION TION TION T T T T T ABLE ABLE ABLE MAINTEN MAINTENANCE MAINTEN ANCE ANCE AND L AND L AND LUBRICA UBRICA UBRICATION TION ABLE ABLE MAINTEN MAINTEN MAINTENANCE MAINTEN MAINTEN ANCE...
  • Page 31 MAINTEN MAINTEN ANCE ANCE AND L AND L UBRICA UBRICA TION TION TION T T T T T ABLE ABLE ABLE MAINTEN MAINTENANCE MAINTEN ANCE ANCE AND L AND L AND LUBRICA UBRICA UBRICATION TION ABLE ABLE MAINTEN MAINTEN MAINTENANCE ANCE ANCE ANCE AND L...
  • Page 32 MAINTEN MAINTEN MAINTEN MAINTEN MAINTENANCE ANCE ANCE ANCE ANCE AND L AND L AND L AND L AND LUBRICA UBRICA UBRICA UBRICATION UBRICA TION TION TION TION T T T T T ABLE ABLE ABLE ABLE ABLE MAINTEN MAINTEN MAINTEN MAINTEN MAINTENANCE ANCE...
  • Page 33 MAINTEN MAINTEN MAINTEN MAINTEN MAINTENANCE ANCE ANCE ANCE ANCE AND L AND L AND L AND L AND LUBRICA UBRICA UBRICA UBRICATION UBRICA TION TION TION TION T T T T T ABLE ABLE ABLE ABLE ABLE MAINTEN MAINTEN MAINTENANCE MAINTEN MAINTEN ANCE...
  • Page 34 MAINTEN MAINTEN MAINTEN MAINTEN MAINTENANCE ANCE ANCE ANCE ANCE AND L AND L AND L AND L AND LUBRICA UBRICA UBRICA UBRICATION UBRICA TION TION TION TION T T T T T ABLE ABLE ABLE ABLE ABLE MAINTEN MAINTEN MAINTENANCE MAINTEN MAINTEN ANCE...
  • Page 35 ENGLISH ENGLISH ENGLISH...

  • Page 36: Frame And Engine Maintenance

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE DANGER ALL MAINTENANCE AND ADJUSTMENT OPERATIONS THAT ARE MARKED WITH (A) REQUIRE TECHNICAL MASTERY.

  • Page 37: Telescopic Fork Vent Screws

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE TELESCOPIC FORK VENT SCREWS TELESCOPIC FORK VENT SCREWS TELESCOPIC FORK VENT SCREWS...

  • Page 38: Basic Calibration Of The Chassis On The Basis Of Pilot Weight

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE B B B B B ASIC CALIBRA ASIC CALIBRA ASIC CALIBRA...

  • Page 39: Establishing Rear Shock Static Lowering

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE ESTABLISHING REAR SHOCK L ABLISHING REAR SHOCK L ABLISHING REAR SHOCK L...

  • Page 40: Replacement Of Fork Springs

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE REPLACEMENT OF FORK SPRINGS REPLACEMENT OF FORK SPRINGS REPLACEMENT OF FORK SPRINGS...

  • Page 41: Check Chain Tension

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CHECK CHAIN TENSION CHECK CHAIN TENSION CHECK CHAIN TENSION...

  • Page 42: Adjustment Of Chain Tension (Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE ADJUSTMENT OF CHAIN TENSION (SMM) ADJUSTMENT OF CHAIN TENSION (SMM) ADJUSTMENT OF CHAIN TENSION (SMM)

  • Page 43: Chain Wear

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CHAIN WEAR CHAIN WEAR CHAIN WEAR...

  • Page 44: Front Brake Nissin Pump (End/Mx)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE BRAKE FLUID RESERVOIRS: The front and rear brake liquid reservoirs are dimensioned in a way that topping-up is not necessary even if the brake pads are worn.

  • Page 45: Front Brake Brembo Radial Pump (Smr/Smm/Smx)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRONT BRAKE BREMBO RADIAL PUMP FRONT BRAKE BREMBO RADIAL PUMP FRONT BRAKE BREMBO RADIAL PUMP...

  • Page 46: Replacement Of Front Brake Pads

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE REPLA REPLA REPLACEMENT OF FR...

  • Page 47: Modification Of Rear Brake Pedal Base Position

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE MODIFICATION OF REAR BRAKE PED MODIFICATION OF REAR BRAKE PED MODIFICATION OF REAR BRAKE PEDAL...

  • Page 48: Check Rear Brake Pads

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CHECK REAR BRAKE P CHECK REAR BRAKE P CHECK REAR BRAKE PADS...

  • Page 49: Disassembly And Assembly Of The Rear Wheel (All Except Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE WARNING - NEVER ACTIVATE THE BRAKE LEVER WHEN THE FRONT WHEEL IS DISASSEMBLED...

  • Page 50: Disassembly And Assembly Of Rear Wheel (Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE DISASSEMBL DISASSEMBL DISASSEMBLY Y Y Y Y AND...

  • Page 51: Tyres, Tyre Pressure

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE TYRES, TYRE PRESSURE TYRES, TYRE PRESSURE TYRES, TYRE PRESSURE...

  • Page 52: Battery Charge

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE DANGER - IF FOR SOME REASON THE ELECTROLYTE (SULPHURIC ACID) SHOULD ESCAPE FROM THE BATTERY, BE VERY CAREFUL.

  • Page 53: Recharge Fuse (All Models With E.s.)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE RECHARGE FUSE RECHARGE FUSE RECHARGE FUSE ( ( ( ( (ALL MODELS WITH...

  • Page 54: Ciclops" Optional Headlight (End/Smr/Smm)

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE HALOGEN LIGHT (END/SMR/SMM) HALOGEN LIGHT (END/SMR/SMM) HALOGEN LIGHT (END/SMR/SMM)

  • Page 55: Standard Rear Light

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE POSITION LIGHT BULB Extract the bulb-holder (1) from the parabola, replace the bulb (2).

  • Page 56: Cooling

    COOLING COOLING COOLING COOLING COOLING The water pump (1) housed in the engine induces forced circulation of the coolant liquid. There is no thermostat in the system, therefore, when the engine is cold, it is important to moderate the number of revs. of the engine and speed.

  • Page 57: Emptying, Filling And Bleeding Of The Cooling System

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE EMPTYING, FILLING AND BLEEDING OF THE EMPTYING, FILLING AND BLEEDING OF THE EMPTYING, FILLING AND BLEEDING OF THE...

  • Page 58: Cleaning The Air Filter

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CLEANING CLEANING CLEANING THE...

  • Page 59: Hydraulic Clutch Ajp Pump

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE HYDRAULIC CLUTCH AJP PUMP HYDRAULIC CLUTCH AJP PUMP HYDRAULIC CLUTCH AJP PUMP...

  • Page 60: Bleeding Hydraulic Clutch

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE BLEEDING THE HYDRAULIC CLUTCH BLEEDING THE HYDRAULIC CLUTCH BLEEDING THE HYDRAULIC CLUTCH...

  • Page 61: Basic Indications Regarding Carburetor Wear

    NOTE: If the described methods are followed and satisfying results are not obtained, the cause could be a Pilot jet with unsuitable dimensions. a) If the mix adjustment screw is screwed right down without variation of the number of revs of the idle speed, a smaller Pilot jet must be installed.

  • Page 62: Emptying The Carburetor Float Bowl

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE EMPTYING EMPTYING EMPTYING THE CARB...

  • Page 63: Check Engine Oil Level

    FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL...
  • Page 64 FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE REPLACEMENT OF OIL FILTER CARTRIDGE (after having emptied the oil from the engine) The cartridge oil filter is situated on the right side of the motorcycle...
  • Page 65 FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE FRAME AND ENGINE MAINTENANCE Remount the cover, being careful to the O-Ring and to insert the filter cover nose correctly into the hole of the filter cartridge.
  • Page 66 TR OUBLESHOO OUBLESHOO OUBLESHOO OUBLESHOO TING TING TING TING OUBLESHOO TING TR OUBLESHOO OUBLESHOO OUBLESHOO OUBLESHOO TING TING TING TING OUBLESHOO TING If you have the envisioned maintenance operations carried out on your motorcycle, you will have very few problems. If, however, a problem does occur, please look for it in the following table and try to solve it.

  • Page 67: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING SOLUTION PROBLEM CAUSE Clogged idle speed jet Disassemble the carburetor and clean the jet THE ENGINE WILL NOT Altered idle speed adjustment screws Adjust the idle speed screws RUN AT IDLE SPEED Damaged spark plug Replace the spark plug Faulty Ignition system...

  • Page 68: Cleaning

    CLEANING CLEANING CLEANING CLEANING CLEANING CLEANING CLEANING CLEANING CLEANING CLEANING Clean the motorcycle regularly in a way to maintain the surface of the plastic parts in good condition. To do this, it is advised to use hot water with a detergent and sponge. Most of the dirt can be removed using weak water jets. WARNING NEVER CLEAN THE MOTORCYCLE WITH HIGH PRESSURE CLEANING DEVICES OR WITH STRONG JETS OF WATER! BECAUSE OF THE HIGH PRESSURE THE WATER COULD REACH THE ELECTRICAL PARTS, CONNECTORS, FLEXIBLE CABLE COMMANDS, BEARINGS, THE CARBURETOR...

  • Page 69: Technical Data - Engine

    TECHNICAL D TECHNICAL D A A A A A T T T T T A - ENGINE TECHNICAL D A - ENGINE A - ENGINE A - ENGINE TECHNICAL D TECHNICAL D A - ENGINE TECHNICAL D TECHNICAL D TECHNICAL D A A A A A T T T T T A - ENGINE A - ENGINE A - ENGINE A - ENGINE...
  • Page 70 TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL DA A A A A T T T T T A - ENGINE A - ENGINE A - ENGINE A - ENGINE A - ENGINE TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL D TECHNICAL DA A A A A T T T T T A - ENGINE A - ENGINE...

  • Page 71: Carburetor Settings

    CARB CARB URET CARB URET URET URET OR SETTINGS OR SETTINGS OR SETTINGS OR SETTINGS CARB CARB URET OR SETTINGS CARB CARB URET CARB URET URET OR SETTINGS URET OR SETTINGS OR SETTINGS OR SETTINGS CARB CARB URET OR SETTINGS ENGLISH ENGLISH ENGLISH...

  • Page 72: Engine Tightening Torques

    ENGINE ENGINE TIGHTENING ENGINE TIGHTENING TIGHTENING TIGHTENING T T T T T OR OR Q Q Q Q Q UES ENGINE ENGINE TIGHTENING ENGINE ENGINE TIGHTENING TIGHTENING T T T T T OR TIGHTENING OR Q Q Q Q Q UES ENGINE ENGINE TIGHTENING ENGINE...
  • Page 73 TECHNICAL D TECHNICAL D A A A A A T T T T T A - CY TECHNICAL D A - CY A - CY CLE P A - CY CLE P CLE P CLE P AR AR T T T T T TECHNICAL D TECHNICAL D A - CY...
  • Page 74 TECHNICAL D TECHNICAL D TECHNICAL DA A A A A T T T T T A - CY TECHNICAL D TECHNICAL D A - CY A - CY A - CY A - CYCLE P CLE P CLE P CLE P CLE PAR ART T T T T TECHNICAL D...

  • Page 75: Technical Data-Cycle Part

    ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX ALPHABETIC INDEX Page Page Adjustment of chain tension (all models except SMM) ..... 41 FRAME AND ENGINE MAINTENANCE ..........35 Adjustment of chain tension (SMM) ..........42 Frame number ................
  • Page 76 WIRING DIA WIRING DIA GRAMS WIRING DIA GRAMS GRAMS GRAMS WIRING DIA WIRING DIA GRAMS WIRING DIA WIRING DIA GRAMS WIRING DIA GRAMS GRAMS GRAMS WIRING DIA WIRING DIA GRAMS ENGLISH ENGLISH...

  • Page 77: Wiring Diagram

    WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS WIRING DIAGRAMS ENGLISH ENGLISH ENGLISH...
  • Page 78 ENGLISH ENGLISH...
  • Page 79 ENGLISH ENGLISH ENGLISH...
  • Page 80 Grafica e Stampa SERIART - Fabriano (AN) - www.seriart.com ENGLISH TM-02 (ed. 12/08)

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