TECHNICAL DATA-CYCLE PART. TM Performance TM motorcycle 2008

TECHNICAL D A T A - CY CLE P AR T

TECHNICAL D A T A - CY CLE P AR T 250/450/530 END - 250/450/530 MX 2008

Frame

Front suspension

Rear/front suspension travel

Rear suspension

Front disc brake

Rear disc brake

Brake disc wear limit

Front tyre

Off-road air pressure

Rear tyre

Off-road air pressure

Tank capacity

Final transmission

Chain

Optional rear sprockets

Bulbs (only END)

Twin-spar high resistance aluminium alloy frame

Marzocchi USD fork / Paioli USD fork (optional Ohlins USD)

300/315 mm

Aluminium swing arm, Progressive mechanical linkage, Sachs rear shock (optional Ohlins)

Ø 270 mm floating caliper

Ø 245 mm floating caliper mm. 0.4 below original thickness

90/90 - 21”

120/90 - 18” 140/80 - 18”

1.1 bar

100/90 - 19”

1.1 bar

9 litres

110/90 - 19”

13/51 13/50 13/50 13/51 13/49

O-Ring 5/8 x 1/4” 5/8 x 1/4”

48, 49, 50, 51, 52, 53

Headlight/full beam S212V 45/40W BA20d

13/49

(Opt.Cyclops H3 12V 55W PK22s)

Front position light

Position/stop/number plate light

T4W 12V 4W BA9s

P21/5W 12V 21/5W BAY15d

(Opt. Cyclops T10 12V 5W)

Indicator R10W 12V 10W BA15S

12V 6Ah 12V 6Ah (only with E.S. opt.) Battery

Front wheel axle flanged nut

Front brake caliper fastening screws (END,MX)

Front brake disc fastening screws

Rear brake disc fastening screws

Upper fork head fastening screws

Lower fork head fastening screws

Paioli fork leg fastening screws

Ohlins fork leg fastening screws

Rear wheel axle flanged nut

Swing arm axle flanged nut

Handlebar caps fastening screws

Handlebar elastic support nut

Upper end shock nut

Lower end shock nut

Rear sprocket nuts

Rear brake pedal adjustment nut

Engine fastening screws

General frame screws

General frame nuts

M20x1.5

M8

M6 cl. 10.9

M6 cl. 10.9

M8

M8

M6

M8

M22x1.5

M16x1.5

M8

M10

M10x1.25

M10x1.25

M8

M6

M10

M6

M8

M10

M6

M8

M10

40 Nm

25 Nm

20 Nm

35 Nm

40 Nm

35 Nm

35 Nm

15 Nm

45 Nm

10 Nm

15 Nm

15 Nm

20 Nm

20 Nm

12 Nm

12 Nm

80 Nm

80 Nm

25 Nm

45 Nm

15 Nm

30 Nm

50 Nm

73

Battery

TECHNICAL D A T A - CY CLE P AR T

TECHNICAL D A T A 250/450/530 SMR/SMM - 250/450/530/660 SMX 2008

Frame

Front suspension

Rear/front suspension travel

Rear suspension

Front disc brake

Rear disc brake

Brake disc wear limit

Front tyre

“Rider only” air pressure

Rear tyre

“Rider only” air pressure

Tank capacity

Final transmission

Chain

Optional rear sprockets

Bulbs (only SMR/SMM)

Twin-spar high resistance aluminium alloy frame

Marzocchi USD fork / Paioli USD fork (optional Ohlins USD)

270/280 mm

Aluminium swing arm (Single-arm on SMM), Progressive mechanical linkage, Sachs shock (Ohlins optional)

Ø 320 mm 4-piston caliper Ø 320 mm 4-piston radial caliper

Ø 240 mm floating caliper Ø 220 mm rigid caliper Ø 245 mm floating caliper mm. 0.4 below original thickness

120/70 - 17”

1.7 bar

150/60 - 17” 165/55 - 17”

1.7 bar

9 litres

13/40

Head/high beam light S212V 45/40W BA20d

14/46

5/8 x 1/4”

39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49

15/47

(Opt. Ciclope H3 12V 55W PK22s)

Front position light T4W 12V 4W BA9s

Rear position/stop/number plate light P21/5W 12V 21/5W BAY15d

Indicator

12V 6Ah

R10W 12V 10W BA15S

(Opt. Ciclope T10 12V 5W)

12V 6Ah (only with E.S. opt.)

Front wheel axle flanged nut

Front brake caliper fastening screws (SMR,SMM,SMX)

Rear brake caliper fastening screws (SMM)

Front brake disc fastening screws

Rear brake disc fastening screws(SMR,SMX)

Rear brake disc fastening nut (SMM)

Upper fork head fastening screws

Lower fork head fastening screws

Paioli fork leg fastening screws

Ohlins fork leg fastening screws

Rear wheel axle flanged nut

Swing arm axle flanged nut

Handlebar caps fastening screws

Handlebar elastic support nut

Upper end shock nut

Lower end shock screws

Rear sprocket nuts

Rear brake pedal adjustment nut

Engine fastening screws

Rear wheel nut(SMM)

Rear hub locking screws (SMM)

General frame screw

General frame nuts

M10x1.25

M10x1.25

M8

M6

M10

M50

M12x1.25

M6

M8

M10

M6

M8

M10

M20x1,5

M10

M8

M6 cl. 10.9

M6 cl. 10.9

M8

M8

M8

M6

M8

M22x1,5

M16x1.5

M8

M10

40 Nm

35 Nm

35 Nm

15 Nm

45 Nm

185 Nm

31 Nm

10 Nm

25 Nm

45 Nm

15 Nm

30 Nm

50 Nm

40 Nm

40 Nm

25 Nm

15 Nm

15 Nm

25 Nm

20 Nm

20 Nm

12 Nm

12 Nm

80 Nm

80 Nm

20 Nm

35 Nm

74

Page

ADVICE AND GENERAL RECOMMENDATIONS FOR

COMMISSIONING THE MOTORCYCLE ........................................... 21

Adjustment of chain tension (all models except SMM).....................43

Adjustment of chain tension (SMM).................................................44

Adjustment of clutch lever basic position ....................................... 60

ALPHABETIC INDEX ....................................................................... 75

Basic calibration of the chassis on the basis of pilot weight ........... 40

Basic indications for TM disc brakes ............................................. 45

Basic indications regarding carburetor wear................................. 61

Battery (all models with E.S.) ......................................................... 53

Battery charge ............................................................................. 54

Bike starting.....................................................................................26

Bleeding hydraulic clutch ............................................................. 60

Brake pedal ................................................................................... 16

Braking ........................................................................................... 28

“By-Pass” command(hot starter) ................................................ 15

Carburetor - Idle speed adjustment ................................................ 61

CARBURETOR SETTINGS ............................................................... 71

Chain maintenance ......................................................................... 44

Chain wear..................................................................................... 45

Change engine oil ........................................................................... 63

Check/adjustment magnet sensor distance .................................. 53

Check before every start-up ........................................................ 24

Check chain tension ...................................................................... 43

Check coolant level ...................................................................... 58

Check engine oil level ................................................................... 63

Check front brake fluid level ......................................................... 47

Check front brake pads ................................................................ 47

Check fuel level (float height) ....................................................... 62

Check hand decompressor adjustment ......................................... 59

Check hydraulic clutch oil level ..................................................... 60

Check rear brake fluid level .......................................................... 49

Check rear brake pads ................................................................. 50

Check spoke tension ..................................................................... 52

Check steering bearings and play adjustment .............................. 38

Check telescopic fork basic calibration ......................................... 41

Choke command (cold starter) ....................................................... 15

CLEANING ..................................................................................... 68

Cleaning telescopic fork dust scraper.............................................39

Cleaning the air filter ...................................................................... 59

Clutch lever .................................................................................... 10

Cold engine start .............................................................. 25

Combination switch (END/SMR/SMM) ............................................. 13

Combination switch supplied with Electronic digital backlit display tachometer ................................................................ 13

Control pilot lights ........................................................................ 10

Cooling ........................................................................................... 57

Disassembly and assembly of front wheel ................................... 50

Disassembly and assembly of rear wheel (all except SMM) ......... 51

Disassembly and assembly of rear wheel (SMM) .......................... 52

Electronic digital backlit display tachometer (END/ SMR/SMM) ......... 12

Electronic tachometer (END/SMR/SMM)........................................... 11

Emptying, filling and bleeding of the cooling system........................58

Emptying the carburetor float bowl..................................................62

Engine number ............................................................................... 8

Engine oil ....................................................................................... 63

Engine stop switch (MX/SMX) ....................................................... 13

ENGINE TIGHTENING TORQUES.......................................................72

Establishing rear shock lowering in running order ........................ 40

Establishing rear shock static lowering ........................................ 41

Fork adjustment in compression .................................................... 17

Fork adjustment in rebound .......................................................... 18

Page

FRAME AND ENGINE MAINTENANCE .............................................. 37

Frame number ................................................................................ 8

Free play adjustment of front brake lever ....................................... 46

Front brake lever ............................................................................ 10

Fuel ................................................................................................ 29

Fuel filler cap...................................................................................14

Fuel tap .......................................................................................... 14

Gear shift pedal...............................................................................16

Idle speed adjustment command .................................................... 15

If the engine is “flooded! ................................................................ 26

Ignition switch ............................................................................... 17

Indications for first start-up .......................................................... 22

INSTRUCTIONS FOR USE .............................................................. 23

Kickstart pedal................................................................................ 16

MAINTENANCE AND LUBRICATION TABLE .................................... 31

Manual decompressor lever .......................................................... 10

Mode selection and reset .............................................................. 11

Modification of rear brake pedal base position .............................. 49

Oil circuit ........................................................................................ 62

OPERATING CONTROLS ............................................................... 9

POSITION OF SERIAL NUMBER ...................................................... 7

PRECAUTIONS FOR WINTER USE .................................................. 68

Programming the clock ................................................................... 12

Programming the electronic tachometer ......................................... 11

Rear suspension mechanical linkage ............................................. 42

Recharge fuse (all models with E.S.) ............................................ 55

Replacement of direction indicator bulb ......................................... 56

Replacement of exhaust silencer packing material..........................58

Replacement of fork springs .......................................................... 42

Replacement of front brake pads ................................................... 48

Replacement of headlight/position light bulb (with cyclops) ........... 56

Replacement of headlight/position light bulb .................................. 55

Replacement of rear brake pads .................................................... 50

Replacement of rear position/stop/numberplate light bulb

(END/ SMR/SMM) ........................................................................... 56

Running in instructions .............................................................. 22

Services fuse (all models with lights) ............................................ 55

Setting the distance travelled ......................................................... 12

Shifting gear, accelerating, slowing down .................................. 26

Side stand ...................................................................................... 16

Side stand fixing for off-road routes...............................................17

Shock absorber adjustment in compression....................................18

Shock absorber adjustment in rebound ......................................... 19

Shock absorber calibration and spring check ................................ 40

Start command and emergency stop

(END/MXe.s./SMXe.s./SMR/SMM) ................................................... 14

Start-up after seasonal pause ....................................................... 68

Steering lock .................................................................................. 20

Stopping and parking ..................................................................... 28

STORAGE ..................................................................................... 68

TECHNICAL DATA-CYCLE PART ............................................... 73-74

TECHNICAL DATA - ENGINE ..................................................... 69/70

Telescopic fork vent screws ......................................................... 39

Throttle cable command adjustment .............................................. 60

Top-up front brake fluid ................................................................. 47

Top-up rear brake fluid ................................................................... 49

TROUBLESHOOTING ...................................................................... 66

Tyres, tyre pressure ...................................................................... 53

Variation of rear shock spring preload ........................................... 42

Variation of telescopic fork preload .............................................. 41

Warm engine start .......................................................................... 25

WIRING DIAGRAM .............................................................. appendix

75

WIRING DIA GRAMS

CDIUNIT

STROKE 4TEMPI

BLACK-YELLOW

BLACK-GREEN BLACK-YELLOW

BLACK-GREEN

30A

SKYBLUE

RED

BLACK

YELLOW

WHITE

RED

SKYBLUE

BLACK

ORANGE

KWHITE

BLACK

ENGINE RUN/ST

ENGINE ST

76

BLUE

BLACK

YELLOW

STROKE 4TEMPI

BLACK-RED WHITE YELLOW RED-WHITE

77

78

79

80