TM RACING 450Fi EN - Use And Maintenance Manual

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USE AND MAINTENANCE

MANUAL

4 STROKES

USE AND MAINTENANCE

Main Page

Table of Contents6
Identification of the Vehicle9
Position of the Serial Numbers and Codes10
Frame Serial Number10
Engine Serial Number10
Kayaba Fork Code10
TM Shock Absorber Code10
Control Components11
Handlebar Controls12
Hydraulic Clutch Lever12
Manual Decompression Lever (ALL 530F)12
NISSIN Pump Front Brake Lever (EN/MX)12
BREMBO Radial Pump Front Brake Lever (SMR/SMM)12
ACCOSSATO Radial Pump Front Brake Lever (SMX)13
Throttle13
Combination Switch (EN)13
Dimmer Switch (SMR/SMM)14
Starter and Kill Switch (EN/SMR/SMM)14
Key Ignition Switch (SMR/SMM)15
Start Engine Button (MXE.S./SMXE.S.)15
Engine Stop Button (MX/SMX)15
Map Selection Switch (ALL 250Fi - ALL 450Fi)15
Instruments16
Digital Electronic Speedometer (EN)16
Digital Electronic Speedometer (SMR/SMM)16
Pedal Controls17
Gear Shifting Pedal17
Kick Starter17
Rear Brake Pedal17
Side Stand17
Fastener for off Road Routes17
Other Controls18
Steering Lock (EN/SMR/SMM)18
Tank Cap18
Fuel Tap (450F SMR/SMM - ALL 530F)18
Choke Lever (250Fi en - 450Fi EN)19
Choke Lever (250Fi MX/SMX - 450Fi MX/SMX)19
Choke Lever (250Fi SMR/SMM - 450Fi SMR/SMM)19
Cold Start Knob (450F SMR/SMM - ALL 530F)19
Hot Start Knob (450F SMR/SMM - ALL 530F)19
Idle Adjustment Knob (ALL 250Fi - ALL 450Fi)20
Idle Adjustment Knob (450F SMR/SMM - ALL 530F)20
Use Instructions21
General Warnings22
Indications for Commissioning22
Safety Standards22
Adjusting Suspensions23
Fork Compression Adjustment23
Fork Rebound Adjustment23
Varying Pre-Load and Replacing Fork Springs24
Shock Absorber Compression Adjustment24
Shock Absorber Rebound Adjustment25
Varying Pre-Load and Replacing Shock Absorber Spring26
Base Suspension Setting Based on the Weight of the Rider28
Adapting Fork Base Calibration28
Adapting Shock Absorber Base Calibration28
Checking Shock Absorber Static Sag29
Checking Shock Absorber Rider Sag29
Preliminary Checks30
Engine Oil Level30
Fuel Level30
Transmission Chain30
Tyres30
Brakes30
Flexible Cable Controls30
Coolant30
Lights and Accessories Electrical System30
Luggage30
Break-In31
Break-In Instructions31
Cold Start32
Cold Start (ALL 250Fi - ALL 450Fi)32
Cold Start (450F SMR/SMM - ALL 530F)32
Hot Start33
Hot Start (ALL 250Fi - ALL 450Fi)33
Hot Start (450F SMR/SMM - ALL 530F)33
Start in the Event of a Fall (250Fi EN/MX/SMX - 450Fi EN/MX/SMX)34
Start in the Event of a Fall (530F EN/MX/SMX)34
Running35
Setting off35
Accelerating, Shifting Gears, Slowing down35
Braking35
Stopping36
Stopping and Parking36
Using the Side Stand36
Refilling37
Filling Fuel Tank37
Cleaning and Storage38
Washing38
Precautions for Winter Use38
Storage38
Maintenance39
Maintenance Schedule40
250Fi EN/SMR/SMM Maintenance Table40
250Fi MX/SMX Maintenance Table42
450Fi en - 450Fi+F SMR/SMM - 530F EN/SMR/SMM Maintenance Table44
450Fi MX/SMX - 530F MX/SMX Maintenance Table46
Chassis Maintenance48
Checking Steering Bearings and Adjusting Play48
Bleeding Telescopic Fork49
Cleaning Telescopic Fork Dust Seal49
Rear Suspension Linkage50
Checking Chain Tension50
Correcting Chain Tension (EN/MX/SMR/SMX)50
Correcting Chain Tension (SMM)51
Chain Maintenance51
Chain Wear51
Hydraulic Clutch Pump52
Bleeding Hydraulic Clutch52
Basic Indications for TM Disc Brakes53
NISSIN Front Brake Pump (EN/MX)54
BREMBO Radial Front Brake Pump (SMR/SMM)55
ACCOSSATO Radial Front Brake Pump (SMX)56
Checking Front Brake Pads56
Replacing Front Brake Pads57
Changing Base Position of Rear Brake Pedal58
Checking Rear Brake Fluid Level58
Topping up Rear Brake Fluid58
Checking Rear Brake Pads59
Replacing Rear Brake Pads59
Disassembling and Assembling Front Wheel59
Disassembling and Assembling Rear Wheel (EN/MX/SMR/SMX)60
Disassembling and Assembling Rear Wheel (SMM)61
Checking Spoke Tension61
Tyres, Tyre Pressure62
Checking Speedometer Magnetic Sensor Distance (EN/SMR/SMM)62
Fuel Tank63
Battery (All Models with E.S.)65
Charging the Battery65
Charging the Battery66
Recharge Fuse (All Models with E.S.)66
System Fuse (All Models with E.S.)66
Accessory Fuse (EN/SMR/SMM)66
Halogen Headlight (EN)66
Halogen Headlight (SMR)67
Cyclope" Headlight (SMM)68
LED Taillight (EN)69
Standard Taillight (SMR/SMM)69
Turn Signal (EN/SMR/SMM)69
Engine Maintenance70
Cooling70
Checking Coolant Level70
Draining, Filling and Bleeding Cooling System71
Replacing Exhaust Silencer Packing Material71
Cleaning Air Filter72
Checking Manual Decompressor Adjustment (ALL 530F)73
Adjusting Throttle Control Cables73
Adjusting Idle Speed (ALL 250Fi - ALL 450Fi)74
Adjusting Idle Speed (450F SMR/SMM - ALL 530F)75
Fuel Pressure (ALL 250Fi - ALL 450Fi)75
Basic Indications on Fuel Wear (450F SMR/SMM - ALL 530F)75
Checking Fuel Level (Float Height) (450F SMR/SMM - ALL 530F)76
Draining Carburettor Bowl (450F SMR/SMM - ALL 530F)76
Oil Circuit (ALL 250Fi)77
Oil Circuit (ALL 450FI+F - ALL 530F)77
Maintenance77
Checking Engine Oil Level (ALL 250Fi)78
Checking Engine Oil Level (ALL 450Fi+F - ALL 530F)78
Changing Engine Oil and Filter (ALL 250Fi)79
Changing Engine Oil and Filter (ALL 450Fi+F - ALL 530F)80
Diagnosis81
DIAGNOSIS (ALL 250Fi - ALL 450Fi)82
PDA (PALMTOP COMPUTER) (ALL 250Fi - ALL 450Fi)86
Technical Data87
Chassis Technical Data88
Chassis Technical Data (250Fi/450Fi/530F EN/MX)88
250Fi/450Fi/530F SMX)88
Chassis Tightening Torques89
Engine Technical Data90
Engine Technical Data (ALL 250 Fi - ALL 450Fi+F)90
Engine Technical Data (ALL 530F)91
Engine Tightening Torques92
Programmed Control Units (ALL 250Fi - ALL 450Fi)93
Keihin Carburettor Setting (450F SMR/SMM - ALL 530F)93
Wiring Diagrams95
Lights and Accessories Wiring Diagram (En/Smr/Smm)96
ENGINE WIRING DIAGRAM (250Fi MX/SMX - 450Fi MX/SMX)97
ENGINE WIRING DIAGRAM (250Fi EN/SMR/SMM - 450Fi EN/SMR/SMM)98
Mxe.s./Smxe.s.)99
Engine Wiring Diagram (450F Smr/Smm - 530F En/Mxe.s./Smr/Smm/Smxe.s.)100
Engine Wiring Diagram (530F MX/Smx)101
Alphabetical Index102

TM RACING 450Fi EN - Use And Maintenance Manual

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