TM RACING 250Fi EN Use And Maintenance Manual
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TM RACING 250Fi EN Use And Maintenance Manual

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USE AND MAINTENANCE
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Summary of Contents for TM RACING 250Fi EN

  • Page 1 USE AND MAINTENANCE USE AND MAINTENANCE MANUAL 4 STROKES www.tmracing.it...
  • Page 2 4 T E M P I 4 T E M P I...
  • Page 3 COMPETITION SUPERMOTO The displacement, type of power source and use define the model and engine of every TM Racing motorcycle. The combination of codes 1 and 2 identifies the type of standard engine. The combination of the three codes identifies the model of the motorcycle.
  • Page 4 IMPORTANT IMPORTANT WE RECOMMEND READING THIS MANUAL CAREFULLY BEFORE STARTING TO USE YOUR TM MOTORCYCLE. THIS MANUAL CONTAINS INFORMATION AND SUGGESTIONS THAT WILL MAKE THE USE AND MAINTENANCE OF THE MOTORCYCLE EASIER AND SAFER. IT IS IN YOUR SPECIFIC INTEREST TO PAY SPECIAL ATTENTION TO THE WARNINGS MARKED AS FOLLOWS: DANGER FAILURE TO COMPLY WITH THIS WARNING PUTS YOUR LIFE AT RISK! WARNING...
  • Page 5 WARNINGS ON WARRANTY IMPORTANT WARNINGS ON LEGAL AND COMMERCIAL WARRANTY TM sport motorcycles are designed and manufactured to withstand stress that can be detected under normal road and competitive use. The competitive motorcycles comply with the rules of the respective categories currently in force at the most im- portant international motorcycle associations.

  • Page 6: Table Of Contents

    Hot start (450F SMR/SMM - ALL 530F) Hot start (450F SMR/SMM - ALL 530F) ..............................................Start in the event of a fall (250Fi EN/MX/SMX - 450Fi EN/MX/SMX) Start in the event of a fall (250Fi EN/MX/SMX - 450Fi EN/MX/SMX) Throttle Throttle ....
  • Page 7 7.2 ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX) 7.2 ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX) ......7.3 ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi 7.3 ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi EN/SMR/SMM) EN/SMR/SMM) 7. WIRING DIAGRAMS 7.

  • Page 9: Identification Of The Vehicle

    1. VEHICLE IDENTIFICATION...

  • Page 10: Position Of The Serial Numbers And Codes

    1.1 POSITION OF THE SERIAL NUMBERS AND CODES FRAME SERIAL NUMBER The frame serial number is stamped on the right side of the steering head. Write this number in the specific box on page 4. The serial number is also indicated on a nameplate located on the left side of the EN, SMR, SMM models.

  • Page 11: Control Components

    2. CONTROL COMPONENTS 4 S T R O K E S 4 S T R O K E S...

  • Page 12: Handlebar Controls

    2.1 HANDLEBAR CONTROLS HYDRAULIC CLUTCH LEVER The Bembo clutch pump (1) is located on the left side of the handlebar. The clutch lever (2) activates the detachment of the transmission from the engine. Fully pull the lever towards the grip to activate the clutch. The position of the lever compared to the grip can vary depending on the rider’s preference.

  • Page 13: Accossato Radial Pump Front Brake Lever (Smx)

    2.1 HANDLEBAR CONTROLS ACCOSSATO RADIAL PUMP FRONT BRAKE LEVER (SMX) The radial Accossato front brake pump (1) is located on the right side of the handlebar. The front brake lever (2) activates the front wheel brake. The position of the front brake lever compared to the grip can vary according to the rider’s preference.

  • Page 14: Dimmer Switch (Smr/Smm)

    2.1 HANDLEBAR CONTROLS DIMMER SWITCH (SMR/SMM) The dimmer switch (1) is located on the handlebar near the left grip. It is traditional and simple to use. Button (2) honks the horn, while button (3) activates the LH turn signal if pressed to the left and the RH turn signal if pressed to the right.

  • Page 15: Key Ignition Switch (Smr/Smm)

    2.1 HANDLEBAR CONTROLS KEY IGNITION SWITCH (SMR/SMM) The SMR and SMM models are equipped with a cylinder (1) for the ignition key on the left side of the dashboard. To start the engine, insert the key and turn it clockwise. Use the starter described on page 14.

  • Page 16: Instruments

    2.2 INSTRUMENTS DIGITAL ELECTRONIC SPEEDOMETER (EN) The digital electronic speedometer (EN) (1) consists of a large back-lit display and a series of indicators. The high beam indicator (2) is at top left, the neutral light (not used) (3) is at centre left, the ADJUST button (4) is at bottom left. The turn signal indicator (5) is at top right, the low beam indicator (6) is at centre right, and the SELECT button (7) is at bottom right.

  • Page 17: Pedal Controls

    2.3 PEDAL CONTROLS GEAR SHIFTING PEDAL The gear shifting pedal (1) is fitted on the left side of the engine. The position of the gears is indicated in the illustration. Neutral is between first and second gear. To engage first gear, pull the clutch lever and press the gear shifting pedal downwards.

  • Page 18: Other Controls

    2.4 OTHER CONTROLS STEERING LOCK (EN/SMR/SMM) The steering lock (1) is located on the left side of the steering head. This device allows you to block the rotation of the handlebar, preventing the motorcycle from being driven. To lock the steering, rotate the handlebar fully to the right, move the protective tab (2), insert the key, turn it to the left and press it all the way down.

  • Page 19: Choke Lever (250Fi En - 450Fi En)

    2.4 OTHER CONTROLS CHOKE LEVER (250Fi EN - 450Fi EN) The choke lever (1) is located on the left of the handlebar under the combination switch. Activate this lever to facilitate engine start under particular conditions. Using your thumb, press it all the way down and keep it pressed to ac- tivate it.

  • Page 20: Idle Adjustment Knob (All 250Fi - All 450Fi)

    2.4 OTHER CONTROLS IDLE ADJUSTMENT KNOB (ALL 250Fi - ALL 450Fi) The idle adjustment knob (1) is located on the left side of the motorcycle. Rotate the idle adjustment knob to raise or lower the engine idle speed. IDLE ADJUSTMENT KNOB (450F SMR/SMM - ALL 530F) The idle adjustment knob (1) is located on the left side of the motorcycle.

  • Page 21: Use Instructions

    3. USE INSTRUCTIONS 4 S T R O K E S 4 S T R O K E S...

  • Page 22: General Warnings

    3.1 GENERAL WARNINGS INDICATIONS FOR COMMISSIONING - Make sure that the motorcycle’s “PRE-DELIVERY OPERATIONS” have been performed by your TM dealer. - Carefully read all the instructions before using the motorcycle for the first time. - Be familiar with all the control components. - Adjust the clutch lever, the front brake lever and the brake pedal to the most comfortable position.

  • Page 23: Adjusting Suspensions

    3.2 ADJUSTING SUSPENSIONS FORK COMPRESSION ADJUSTMENT The compression hydraulic brake system determines how the fork behaves in the compression phase. The degree of compression hydrau- lic braking can be adjusted to the rider’s preference and/or installed spring rate. MARZOCCHI USD FORKS The adjustment screw (1) is located on the upper part of the fork cap.

  • Page 24: Varying Pre-Load And Replacing Fork Springs

    Partially disassemble the springs to vary the spring pre-load (see the specific manual of the fork fitted on the motorcycle). It is NOT recommended to vary the pre-load of the springs on forks fitted by TM Racing. Replace the springs with others featuring different rates if required. WARNING FOR FURTHER AND MORE DETAILED INFORMATION ON THE FORKS, REFER TO THE INSTRUCTIONS SUPPLIED BY THE FORK MANUFACTURER.

  • Page 25: Shock Absorber Rebound Adjustment

    3.2 ADJUSTING SUSPENSIONS TM SHOCK ABSORBER Low speeds - The adjustment screw (1) is located on top of the shock ab- sorber gas tank. Use a screwdriver. Rotate clockwise to increase braking or anticlockwise to decrease it. A total number of 24 clicks is available. High speeds - The regulator is a hex ring nut (2) concentric to the low speed adjustment screw.

  • Page 26: Varying Pre-Load And Replacing Shock Absorber Spring

    3.2 ADJUSTING SUSPENSIONS TM SHOCK ABSORBER The adjustment screw (1) is located on the fork coupling connecting the shock absorber to the linkage. Use a screwdriver. Rotate clockwise to increase braking or anticlockwise to decrease it. A total number of 27 clicks is available.
  • Page 27 3.2 ADJUSTING SUSPENSIONS TM SHOCK ABSORBER Loosen the locking screw (1) of ring nut (2) with a 4 mm Allen key and rotate the ring nut. Rotate it anticlockwise (seen from above) to decrease the pre-load or clockwise (seen from above) to increase it. After adjusting, tighten the locking screw (1).

  • Page 28: Base Suspension Setting Based On The Weight Of The Rider

    3.2 ADJUSTING SUSPENSIONS BASE SUSPENSION SETTING BASED ON THE WEIGHT OF THE RIDER For optimal motorcycle driving performance and to prevent the fork, shock absorber, large swing arm and frame from being damaged, the base calibration of the suspensions must be adjusted according to your weight. The base calibration of the suspensions (both the fork and shock absorber) involves assembling a special spring and a series of adjustments of the compression and rebound braking.

  • Page 29: Checking Shock Absorber Static Sag

    3.2 ADJUSTING SUSPENSIONS CHECKING SHOCK ABSORBER STATIC SAG Correct shock absorber static sag corresponds to a static lowering of the motorcycle by 35 mm. Variations exceeding 2 mm may influence motorcycle performance. Procedure: - Place the motorcycle on a stand so that the rear wheel does not touch the ground.

  • Page 30: Preliminary Checks

    3.3 PRELIMINARY CHECKS In order to drive safely, the motorcycle must be in good state of mainte- nance. It is good practice to perform a general check on the motorcycle before every use. This verification must include the following checks: ENGINE OIL LEVEL (page 78) To guarantee suitable lubrication, the oil level in the engine must be within the established limits.

  • Page 31: Break-In

    3.4 BREAK-IN BREAK-IN INSTRUCTIONS The component surfaces of a new motorcycle, despite undergoing precision processing, are not as smooth as the components of motorcycles that have been running for a long time. This explains why running-in a new motorcycle is so important. To achieve optimal settling of the moving parts, a new motorcycle must reach maximum performance gradually.

  • Page 32: Cold Start

    3.5 COLD START COLD START (ALL 250Fi - ALL 450Fi) Cold start is the condition in which the coolant temperature is below 35°C. As it works by injection, these models are not equipped with a fuel tap. 1. Retract the side stand (page 17) 2.

  • Page 33: Hot Start

    3.6 HOT START HOT START (ALL 250Fi - ALL 450Fi) Hot start is the condition in which the coolant temperature is above 35°C. 1. Retract the side stand (page 17) 2. Shift into neutral gear (page 17) 3. Press the choke lever (page 19) corresponding to the model of your motorcycle all the way down and keep it pressed.

  • Page 34: Start In The Event Of A Fall (250Fi En/Mx/Smx - 450Fi En/Mx/Smx)

    3.6 HOT START START IN THE EVENT OF A FALL (250Fi EN/MX/SMX - 450Fi EN/MX/SMX) Should the motorcycle fall during sport or competitive use, the engine accidentally turns off making it difficult to restart. In this case, proceed as follows: 1.

  • Page 35: Running

    3.7 RUNNING SETTING OFF Once you have put on a protective helmet and started the engine, pull the clutch lever (page 12), engage first gear (page 17) and slowly release the clutch lever while accelerating (page 13). DANGER NEVER RIDE THE MOTORCYCLE WITHOUT WEARING AN APPROVED PROTECTIVE HELMET AND/OR IF YOU ARE NOT IN GOOD PSYCHO-PHYSICAL HEALTH.

  • Page 36: Stopping

    3.8 STOPPING STOPPING AND PARKING With the throttle (page 13) fully released, brake the motorcycle until it stops while pulling the clutch lever (page 12). Shift into neutral gear (page 17) and release the clutch. Keeping the engine at minimum idle speed, push the red emergency kill switch (EN/SMR/SMM page 14) in or press the engine stop button (MX/SMX page 15) until the engine stops.

  • Page 37: Refilling

    3.9 REFILLING FILLING FUEL TANK The type of fuel required for the TM engines is DIN EN228 unleaded fuel (ROZ 95). The engine tolerates a percentage of ethanol lower than 10% (E10 fuel). Tank capacity: ALL 250Fi - ALL 450Fi ............... L 7.5 total 450F SMR/SMM - ALL 530F ......

  • Page 38: Cleaning And Storage

    3.10 CLEANING AND STORAGE 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 light jet of water. - Plug the exhaust pipe before cleaning to prevent water from going in.

  • Page 39: Maintenance

    4. MAINTENANCE 4 S T R O K E S 4 S T R O K E S...

  • Page 40: Maintenance Schedule

    4.1 MAINTENANCE SCHEDULE 250Fi EN/SMR/SMM MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY 1 HOUR 15 HOURS 30 HOURS 45 HOURS 135 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (AFTER EVERY (75 HOURS...
  • Page 41 4.1 MAINTENANCE SCHEDULE 250Fi EN/SMR/SMM MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY 1 HOUR 15 HOURS 30 HOURS 45 HOURS 135 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (AFTER EVERY (75 HOURS...

  • Page 42: 250Fi Mx/Smx Maintenance Table

    4.1 MAINTENANCE SCHEDULE 250Fi MX/SMX MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY EVERY EVERY 1 HOUR 10 HOURS 20 HOURS 30 HOURS 40 HOURS 50 HOURS 75 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (AFTER EVERY RIDE) •...
  • Page 43 4.1 MAINTENANCE SCHEDULE 250Fi MX/SMX MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY EVERY EVERY 1 HOUR 10 HOURS 20 HOURS 30 HOURS 40 HOURS 50 HOURS 75 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (AFTER EVERY RIDE) •...

  • Page 44: 450Fi En - 450Fi+F Smr/Smm - 530F En/Smr/Smm Maintenance Table

    4.1 MAINTENANCE SCHEDULE 450Fi EN - 450Fi+F SMR/SMM - 530F EN/SMR/SMM MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY 1 HOUR 15 HOURS 30 HOURS 45 HOURS 135 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (AFTER EVERY (75 HOURS RIDE)
  • Page 45 4.1 MAINTENANCE SCHEDULE 450Fi EN - 450Fi+F SMR/SMM - 530F EN/SMR/SMM MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY 1 HOUR 15 HOURS 30 HOURS 45 HOURS 135 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (AFTER EVERY (75 HOURS RIDE)

  • Page 46: 450Fi Mx/Smx - 530F Mx/Smx Maintenance Table

    4.1 MAINTENANCE SCHEDULE 450Fi MX/SMX - 530F MX/SMX MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY EVERY EVERY 1 HOUR 10 HOURS 20 HOURS 30 HOURS 40 HOURS 50 HOURS 75 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (DOPO OGNI CORSA) •...
  • Page 47 4.1 MAINTENANCE SCHEDULE 450Fi MX/SMX - 530F MX/SMX MAINTENANCE TABLE AFTER EVERY EVERY EVERY EVERY EVERY EVERY EVERY 1 HOUR 10 HOURS 20 HOURS 30 HOURS 40 HOURS 50 HOURS 75 HOURS YEAR A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY AND AT A LOWER COST (DOPO OGNI CORSA) •...

  • Page 48: Chassis Maintenance

    4.2 CHASSIS MAINTENANCE DANGER ALL MAINTENANCE OR ADJUSTMENT OPERATIONS MARKED WITH (A) REQUIRE TECHNICAL KNOWLEDGE. FOR THIS REASON AND FOR YOUR SAFETY REFER TO AN AUTHORISED TM WORKSHOP TO CARRY OUT THESE OPERATIONS. YOUR MOTORCYCLE WILL BE SERVICED OPTIMALLY BY SPECIFICALLY TRAINED PERSONNEL.

  • Page 49: Bleeding Telescopic Fork

    4.2 CHASSIS MAINTENANCE BLEEDING TELESCOPIC FORK Every 5 hours of use during competitions, use the bleeder screws or valves to release any over-pressure inside the fork. MARZOCCHI USD FORKS Marzocchi forks are equipped with a tyre valve (1), which is protected by a rubber cap (2).

  • Page 50: Rear Suspension Linkage

    4.2 CHASSIS MAINTENANCE REAR SUSPENSION LINKAGE (A) The rear suspension of all TM motorcycles is provided with a rod and rocker mechanism that progressively modifies the leverage ratio be- tween the wheel and shock absorber. This mechanism works on the bearings, which must be cleaned and greased at the scheduled intervals to keep suspension operation ef- ficient.

  • Page 51: Correcting Chain Tension (Smm)

    4.2 CHASSIS MAINTENANCE CORRECTING CHAIN TENSION (SMM) Loosen the two locking nuts (1) of the rear eccentric hub to allow the hub to rotate on its axis. Use the specific TM tool, code F50806 (2), to rotate the hub until the chain reaches its correct tension.

  • Page 52: Hydraulic Clutch Pump

    4.2 CHASSIS MAINTENANCE HYDRAULIC CLUTCH PUMP ADJUSTING THE LEVER POSITION The position of clutch lever (1) compared to the grip can be changed with adjusting knob (2). Turn knob (2) clockwise by clicks to move the lever away or anticlockwise to move the lever closer. WARNING ONCE THE OPERATION IS COMPLETE, MAKE SURE THAT THE CLUTCH LEVER HAS PLAY BEFORE ENGAGING THE CLUTCH.

  • Page 53: Basic Indications For Tm Disc Brakes

    4.2 CHASSIS MAINTENANCE BASIC INDICATIONS FOR TM DISC BRAKES CALLIPERS END and MX models mount floating front and rear callipers, i.e. they are not joined to their support. Side compensation allows there to always be optimal support of the pads on the discs. The brake callipers sup- port screws must be secured with Loctite 243 and tightened by 25 Nm.

  • Page 54: Nissin Front Brake Pump (En/Mx)

    4.2 CHASSIS MAINTENANCE NISSIN FRONT BRAKE PUMP (EN/MX) ADJUSTING THE LEVER POSITION The position of the front brake lever compared to the grip can be changed with adjusting screw (1). Loosen counter-nut (2) and rotate the screw clockwise to move the lever away or anticlockwise to move the lever closer.

  • Page 55: Brembo Radial Front Brake Pump (Smr/Smm)

    4.2 CHASSIS MAINTENANCE BREMBO RADIAL FRONT BRAKE PUMP (SMR/SMM) ADJUSTING THE LEVER POSITION The position of the front brake lever compared to the grip can be changed with adjusting ring nut (1). Rotate clockwise to move the lever away or anticlockwise to move it closer.

  • Page 56: Accossato Radial Front Brake Pump (Smx)

    4.2 CHASSIS MAINTENANCE ACCOSSATO RADIAL FRONT BRAKE PUMP (SMX) ADJUSTING THE LEVER POSITION The position of the front brake lever compared to the grip can be changed with adjusting wheel (1). Rotate clockwise to move the lever away or anticlockwise to move it closer. WARNING ONCE THE OPERATION IS COMPLETE, MAKE SURE THAT THE FRONT BRAKE LEVER HAS PLAY BEFORE ENGAGING THE BRAKE AND THAT THE FRONT WHEEL...

  • Page 57: Replacing Front Brake Pads

    4.2 CHASSIS MAINTENANCE REPLACING FRONT BRAKE PADS (A) FOR MODELS WITH FLOATING CALLIPERS (EN/MX) Push the brake callipers towards the disc to allow the brake piston to return to its standard position. Remove the two clips (1), pull out pin (2) and remove the pads from the callipers.

  • Page 58: Changing Base Position Of Rear Brake Pedal

    4.2 CHASSIS MAINTENANCE CHANGING BASE POSITION OF REAR BRAKE PEDAL (A) Loosen the M6 counter-nut (1) downwards and rotate the adjustment screw using the hex head (2). Once you have found the ideal position, tighten the counter-nut. The pedal play is given by the run of the pump piston. Make sure that the pedal has about 1.5 cm of play before starting to brake.

  • Page 59: Checking Rear Brake Pads

    4.2 CHASSIS MAINTENANCE CHECKING REAR BRAKE PADS The brake pads must be checked from the rear. The thickness of the friction material must not be less than 1 mm. Replace them as soon as they reach this limit. DANGER IN THE THINNEST POINT THE THICKNESS OF THE BRAKE PAD FRICTION MA- TERIAL MUST NOT BE LESS THAN 1 MM, OTHERWISE THE BRAKES MAY FAIL.

  • Page 60: Disassembling And Assembling Rear Wheel (En/Mx/Smr/Smx)

    4.2 CHASSIS MAINTENANCE WARNING - NEVER ACTIVATE THE BRAKE LEVER WHEN THE FRONT WHEEL IS DISAS- SEMBLED. - ALWAYS POSITION THE WHEEL WITH THE BRAKE DISC UPWARDS TO PREVENT DAMAGE. To reassemble the front wheel carefully insert it in the fork, inserting the disc between the brake pads without damaging them.

  • Page 61: Disassembling And Assembling Rear Wheel (Smm)

    4.2 CHASSIS MAINTENANCE DISASSEMBLING AND ASSEMBLING REAR WHEEL (SMM) Position the motorcycle with the frame cradle on a stand to keep the rear wheel off the ground. Cut the safety wiring (1), remove the clip (2) and loosen the M50x1.5 wheel nut (3). Be careful of the conical shim (4) located between the nut and rim.

  • Page 62: Tyres, Tyre Pressure

    4.2 CHASSIS MAINTENANCE TYRE PRESSURE TYRES, TYRE PRESSURE FRONT REAR Tyre type, status and pressure influence motorcycle performance on road and must be checked before every ride. - The size of the tyres is indicated in the technical data and in the reg- Off road MX and EN 1.0 bar 1.0 bar...

  • Page 63: Fuel Tank

    4.2 CHASSIS MAINTENANCE FUEL TANK DISASSEMBLING THE FUEL TANK (ALL 250Fi - ALL 450Fi) Normally tank (1) is disassembled leaving the two air conveyors (2) se- cured to the tank itself. With the engine switched off loosen the four fixing screws (3) (two on the right and two on the left) of the conveyors and the centre screw (4) on the top.
  • Page 64 4.2 CHASSIS MAINTENANCE DISASSEMBLING FUEL TANK (450F SMR/SMM - ALL 530F) Normally tank (1) is disassembled leaving the two air conveyors (2) se- cured to the tank itself. With the engine switched off loosen the four fixing screws (3) (two on the right and two on the left) of the conveyors and the centre screw (4) on the top.

  • Page 65: Battery (All Models With E.s.)

    4.2 CHASSIS MAINTENANCE BATTERY (ALL MODELS WITH E.S.) Remove the seat to access the battery. The battery does not require maintenance. It is not necessary to check the electrolyte level or top-up with water. The battery poles must be cleaned and, if required, greased slightly with acid-free grease.

  • Page 66: Charging The Battery

    4.2 CHASSIS MAINTENANCE RECHARGE FUSE (ALL MODELS WITH E.S.) The fuse (1) is located in the relay (2) of the electric starter motor under the removable battery holder. You can access the fuse once you have removed the seat and the battery holder. The fuse has a capacity of 30 Ampere.

  • Page 67: Halogen Headlight (Smr)

    4.2 CHASSIS MAINTENANCE REPLACING POSITION LIGHT BULB Release both elastic straps and move the headlight holder mask for- ward. Disconnect the side connector, remove the bulb holder (1) from the reflector dish and replace the bulb (2). Reassemble the bulb holder (1) and connect the connector.

  • Page 68: Cyclope" Headlight (Smm)

    4.2 CHASSIS MAINTENANCE “CYCLOPE” HEADLIGHT (SMM) REPLACING LOW BEAM LIGHT BULB Release both elastic straps and move the headlight holder mask for- ward. Disconnect the terminal, remove the cover (1) and gasket (2). Loosen the retaining screw (3) and remove the retainer (4). Loosen the Allen screw (5) by 5 turns and carefully remove the bulb.

  • Page 69: Led Taillight (En)

    4.2 CHASSIS MAINTENANCE LED TAILLIGHT (EN) REPLACING POSITION LED/STOP LED/NUMBER PLATE LED Loosen the screws (1) and remove the rear light body once you have disconnected the terminals from the motorcycle lighting system. You must fully replace it as it is one single unit. Request the original spare part from a TM dealer.

  • Page 70: Engine Maintenance

    4.3 ENGINE MAINTENANCE COOLING The water pump (1), housed in the engine, induces forced coolant cir- culation. The system is not equipped with a thermostat therefore it is important to moderate the number of revs and speed when the engine is cold. Proceed for at least 5 minutes at half throttle and at reduced pace to allow the engine to reach an adequate operating temperature.

  • Page 71: Draining, Filling And Bleeding Cooling System

    (5) in its seat. Remove the soundproof material to be replaced. Pack with 500 g of original TM Racing fibreglass, inserting it in the gap between the internal and external pipe. Use a pipe of suitable size to push the fibreglass into the space and gently press.

  • Page 72: Cleaning Air Filter

    (5) sealed to it. Remove the soundproof material to be replaced. Pack with about 400 g of original TM Racing fibreglass, using a specific pipe to be positioned in the chamber instead of the perforated cap, which has been removed with the cap.

  • Page 73: Checking Manual Decompressor Adjustment (All 530F)

    4.3 ENGINE MAINTENANCE Separate the sponge element (3) from the plastic cage (4). Carefully wash the sponge element with a special cleaning solution and let it air dry thoroughly. If necessary, squeeze the sponge gently but never wring it. Clean the plastic cage and the filter case and check that the sleeve that connects the throttle body or the carburettor to the filter case is intact and positioned correctly.

  • Page 74: Adjusting Idle Speed (All 250Fi - All 450Fi)

    Every TM Racing motorcycle comes with idle speed adjustment suitable for the type of motorcycle. This adjustment can be varied when needed.

  • Page 75: Adjusting Idle Speed (450F Smr/Smm - All 530F)

    Every TM Racing motorcycle comes with idle speed adjustment suitable for the type of motorcycle and average weather conditions. This adjust- ment can be varied when needed.

  • Page 76: Checking Fuel Level (Float Height) (450F Smr/Smm - All 530F)

    4.3 ENGINE MAINTENANCE CHECKING FUEL LEVEL (FLOAT HEIGHT) (450F SMR/SMM - ALL 530F) (A) To check the float height disassemble the carburettor and remove the bowl. Overturn the carburettor (upside down) and keep it inclined to allow the float to rest on the needle valve; it shouldn’t press the spring with its weight.

  • Page 77: Oil Circuit (All 250Fi)

    Only use high quality engine oil, such as SAE 10W-50, which corresponds to or exceeds the standards of classes API SM, JASO MA2. “VROOAM 4T 10W-50 100% Synthetic” oil is the only one used and rec- ommended by TM Racing. WARNING AN EXCESSIVELY LOW LEVEL, LOW QUALITY OIL OR LONGER MAINTENANCE INTERVALS THAN SCHEDULED CAUSE SERIOUS DAMAGE TO THE ENGINE.

  • Page 78: Checking Engine Oil Level (All 250Fi)

    4.3 ENGINE MAINTENANCE CHECKING ENGINE OIL LEVEL (ALL 250Fi) Park the motorcycle on a flat surface and keep it upright (not on the side stand). With the engine off, check for the presence of oil through the level indicator (1) located on the right side of the engine. If you do not see oil, incline the motorcycle to the right for a few seconds and check the indicator again.

  • Page 79: Changing Engine Oil And Filter (All 250Fi)

    Check the seal O-rings (6 and 7) and replace them if necessary. Put in a new original TM Racing filter. Be sure to have the open side facing the outside of the engine. The filter must be all the way in its seat.

  • Page 80: Changing Engine Oil And Filter (All 450Fi+F - All 530F)

    Check the seal O-rings (5 and 6) and replace them if necessary. Put in a new original TM Racing filter. Be sure to have the open side facing the outside of the engine. The filter must be all the way in its seat.

  • Page 81: Diagnosis

    5. DIAGNOSIS 4 S T R O K E S 4 S T R O K E S...

  • Page 82: Diagnosis (All 250Fi - All 450Fi)

    5.1 DIAGNOSIS (ALL 250Fi - ALL 450Fi) Performing the scheduled maintenance operations 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. Please note that operations marked with (A) require techni- cal knowledge.
  • Page 83 5.1 DIAGNOSIS (ALL 250Fi - ALL 450Fi) PROBLEM CAUSE SOLUTION No fuel in the engine Refuel (37). Check the petrol pump connections and fuel pipe (63). Check fuel pressure (75) (A). Burnt out system fuse (only EN/SMR/SMM) Check the 2A system fuse and replace it (66). THE ENGINE MISFIRES OR SWITCHES OFF Damaged spark plug...
  • Page 84 5.2 DIAGNOSIS (450F SMR/SMM - ALL 530F) Performing the scheduled maintenance operations 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. Please note that operations marked with (A) require techni- cal knowledge.
  • Page 85 5.2 DIAGNOSIS (450F SMR/SMM - ALL 530F) PROBLEM CAUSE SOLUTION Partly interrupted fuel supply or Clean and check the fuel circuit and the carburettor (A) dirty fuel Clogged air filter Clean or replace the air filter (72). Exhaust system not sealed, Check the faulty parts on the exhaust system, INSUFFICIENT ENGINE deformed or exhaust fibreglass in silencer...

  • Page 86: Pda (Palmtop Computer) (All 250Fi - All 450Fi)

    It is strictly prohibited, for the safety of people and in order to retain the warranty, to use maps created by TM Racing for a specific model on another motorcycle of different displacement and/or type.

  • Page 87: Technical Data

    6. TECHNICAL DATA 4 S T R O K E S 4 S T R O K E S...

  • Page 88: Chassis Technical Data

    Marzocchi USD / Kayaba USD fork Front/rear suspension run 270/280 mm Rear suspension Aluminium swing arm (Single arm on SMM), Progressive linkage, Sachs / TM Racing / Ohlins TTX Shock absorber (only SMX) Front disc brake Ø 320 mm 4-piston calliper Rear disc brake Ø...

  • Page 89: Chassis Tightening Torques

    6.1 CHASSIS TECHNICAL DATA CHASSIS TIGHTENING TORQUES Front wheel pin flanged nut M20x1.5 40 Nm Front brake calliper fix. screw (EN/MX) 25 Nm Front brake calliper fix. screw (SMR/SMM/SMX) 40 Nm 25 Nm Rear brake calliper fix. screw (SMM) Front brake disc fix. screw M6 cl.

  • Page 90: Engine Technical Data

    6.2 ENGINE TECHNICAL DATA 250Fi ALL - ALL 450Fi+F ENGINE TECHNICAL DATA 250Fi 250Fi 250Fi 450Fi 450Fi 450Fi 450Fi+F MOTORCYCLE MODEL MX/SMX SMR/SMM SMR/SMM Type Twin cam single cylinder 4-stroke, liquid-cooled Displacement 249 cm 449 cm Bore/stroke 77x53.6 mm 95x63.4 mm Compression 11.6 : 1 12.8 : 1...

  • Page 91: Engine Technical Data (All 530F)

    6.2 ENGINE TECHNICAL DATA ALL 530F ENGINE TECHNICAL DATA MOTORCYCLE MODEL 530F EN 530F MX 530F SMR/SMM 530F SMX Type Twin cam single cylinder 4-stroke, liquid-cooled Displacement 528 cm Bore/stroke 98x70 mm Compression 11.3 : 1 11.9 : 1 11.3 : 1 12.4 : 1 Fuel RON 95 unleaded fuel (ethanol allowed <10%)

  • Page 92: Engine Tightening Torques

    6.2 ENGINE TECHNICAL DATA ENGINE TIGHTENING TORQUES Crankcase Allen screw 12 Nm Ignition cover Allen screw, clutch, transmission (ALL 250Fi) 8 Nm Ignition cover Allen screw, clutch (ALL 450FI+F / ALL 530F) 8 Nm 10 Nm Transmission cover Allen screw (ALL 450Fi+F / ALL 530F) Oil drain screw cap (ALL 250Fi) M12x1.5 20 Nm...

  • Page 93: Programmed Control Units (All 250Fi - All 450Fi)

    This device also allows you to change the map to an already mapped control unit and adapt it to another type of motorcycle. It is strictly prohibited, for the safety of people and in order to retain the warranty, to use maps created by TM Racing for a specific model on another motorcycle of different displacement and/or type.
  • Page 94 4 S T R O K E S 4 S T R O K E S...

  • Page 95: Wiring Diagrams

    7. WIRING DIAGRAMS 4 S T R O K E S 4 S T R O K E S...

  • Page 96: Lights And Accessories Wiring Diagram (En/Smr/Smm)

    7.1 LIGHTS AND ACCESSORIES WIRING DIAGRAM (EN/SMR/SMM) 4 S T R O K E S 4 S T R O K E S...

  • Page 97: Engine Wiring Diagram (250Fi Mx/Smx - 450Fi Mx/Smx)

    7.2 ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX) 4 S T R O K E S 4 S T R O K E S...

  • Page 98: Engine Wiring Diagram (250Fi En/Smr/Smm - 450Fi En/Smr/Smm)

    7.3 ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi EN/SMR/SMM) 4 S T R O K E S 4 S T R O K E S...

  • Page 99: Mxe.s./Smxe.s.)

    7.4 ENGINE WIRING DIAGRAM (250Fi MXE.S./SMXE.S. - 450Fi MXE.S./SMXE.S.) 4 S T R O K E S 4 S T R O K E S...

  • Page 100: Engine Wiring Diagram (450F Smr/Smm - 530F En/Mxe.s./Smr/Smm/Smxe.s.)

    7.5 ENGINE WIRING DIAGRAM (450F SMR/SMM - 530F EN/MXE.S./SMR/SMM/SMXE.S.) 4 S T R O K E S 4 S T R O K E S...

  • Page 101: Engine Wiring Diagram (530F Mx/Smx)

    7.6 ENGINE WIRING DIAGRAM (530F MX/SMX) 4 S T R O K E S 4 S T R O K E S...

  • Page 102: Alphabetical Index

    Key ignition switch (SMR/SMM) ..........15 Cold start (450F SMR/SMM - ALL 530F) ........32 Map selection switch (ALL 250Fi - ALL 450Fi) ......15 Start in the event of a fall (250Fi EN/MX/SMX - Break-in instructions ...............31 450Fi EN/MX/SMX) ..............34 Washing ..................38 Start in the event of a fall (530F EN/MX/SMX) ......34...
  • Page 103 Bleeding hydraulic clutch ............52 PDA (PALMTOP COMPUTER) (ALL 250Fi - ALL 450Fi) ...86 Draining carburettor bowl (450F SMR/SMM - ALL 530F) ..76 250Fi EN/SMR/SMM maintenance table .........40 250Fi MX/SMX maintenance table ...........42 450Fi EN - 450Fi+F SMR/SMM - 530F EN/SMR/SMM maintenance table ..............44...
  • Page 104 © TM Racing S.p.A. Via Fano, 6 - 61122 Pesaro - Italy Ph. +39 0721 25113 - Fax +39 0721 401808 ENGL I SH v 1. 0 0 www.tmracing.it...

This manual is also suitable for:

250fi smr450fi en250fi mx250fi smm250fi smx450fi mx ... Show all

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