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TM RACING 450Fi SMR - User Manual

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USE AND MAINTENANCE
MANUAL
4 STROKES
USE AND MAINTENANCE

Table of Contents

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Summary

RECOGNITION

RECOGNISING TM RACING MOTORCYCLE MODELS

Explains how to identify TM Racing motorcycle models using codes.

IMPORTANT

IMPORTANT WARNINGS

Emphasizes warnings for safety and proper use of the motorcycle.

IMPORTANT WARNINGS ON LEGAL AND COMMERCIAL WARRANTY

WARNINGS ON WARRANTY

Details legal and commercial warranty conditions and user responsibilities.

1. VEHICLE IDENTIFICATION

1.1 POSITION OF THE SERIAL NUMBERS AND CODES

Locates frame and engine serial numbers and fork/shock absorber codes.

2. CONTROL COMPONENTS

2.1 HANDLEBAR CONTROLS

Details the various controls located on the handlebars.

HYDRAULIC CLUTCH LEVER

Explains the function and operation of the hydraulic clutch lever.

NISSIN PUMP FRONT BRAKE LEVER (EN;MX)

Details the Nissin front brake lever and its adjustment.

THROTTLE

Explains the throttle control for acceleration and deceleration.

COMBINATION SWITCH (EN)

Describes the functions of the combination switch on EN models.

STARTER AND KILL SWITCH (EN;SMR;SMM)

Explains the starter and kill switch operations.

KEY IGNITION SWITCH (SMR;SMM)

Describes the ignition key switch operation.

2.2 INSTRUMENTS

DIGITAL ELECTRONIC SPEEDOMETER (EN)

Details the digital speedometer and indicators for EN models.

DIGITAL ELECTRONIC SPEEDOMETER (SMR;SMM)

Details the digital speedometer and indicators for SMR/SMM models.

2.3 PEDAL CONTROLS

GEAR SHIFTING PEDAL

Explains the operation of the gear shifting pedal.

KICK STARTER

Details the operation of the kick starter.

REAR BRAKE PEDAL

Explains the rear brake pedal and its adjustment.

SIDE STAND

Describes how to use the side stand.

2.4 OTHER CONTROLS

STEERING LOCK (EN;SMR;SMM)

Explains how to use the steering lock.

TANK CAP

Details the operation of the fuel tank cap.

FUEL TAP (450 F SMR;SMM - ALL 530 F)

Explains the function and positions of the fuel tap.

CHOKE LEVER (250 Fi EN - 450 Fi EN)

Explains the choke lever for 250Fi/450Fi EN models.

COLD START KNOB (450 F SMR;SMM - ALL 530 F)

Details the cold start knob operation.

HOT START KNOB (450 F SMR;SMM - ALL 530 F)

Explains the hot start knob operation.

IDLE ADJUSTMENT KNOB (ALL 250 Fi - ALL 450 Fi)

Explains how to adjust idle speed on 250/450Fi models.

3. USE INSTRUCTIONS

3.1 GENERAL WARNINGS

Provides essential guidance and safety precautions for using the motorcycle.

INDICATIONS FOR COMMISSIONING

Provides initial guidance for using the motorcycle.

SAFETY STANDARDS

Outlines essential safety precautions for riding.

3.2 ADJUSTING SUSPENSIONS

FORK COMPRESSION ADJUSTMENT

Explains how to adjust fork compression damping.

FORK REBOUND ADJUSTMENT

Details how to adjust fork rebound damping.

VARYING PRE-LOAD AND REPLACING FORK SPRINGS

Describes how to adjust spring pre-load and replace fork springs.

SHOCK ABSORBER COMPRESSION ADJUSTMENT

Explains how to adjust shock absorber compression damping.

SHOCK ABSORBER REBOUND ADJUSTMENT

Details how to adjust shock absorber rebound damping.

VARYING PRE-LOAD AND REPLACING SHOCK ABSORBER SPRING

Explains how to adjust spring pre-load and replace shock absorber springs.

BASE SUSPENSION SETTING BASED ON THE WEIGHT OF THE RIDER

Guides on setting suspension based on rider weight.

ADAPTING FORK BASE CALIBRATION

Explains how to adapt fork calibration for sag.

ADAPTING SHOCK ABSORBER BASE CALIBRATION

Details adapting shock absorber calibration for sag.

CHECKING SHOCK ABSORBER STATIC SAG

Describes how to check static sag for shock absorbers.

CHECKING SHOCK ABSORBER RIDER SAG

Explains how to check rider sag for shock absorbers.

3.3 PRELIMINARY CHECKS

ENGINE OIL LEVEL

How to check engine oil level before use.

FUEL LEVEL

How to check fuel level before use.

TRANSMISSION CHAIN

How to check transmission chain tension and lubrication.

TYRES

How to check tyre condition, tread, and pressure.

BRAKES

How to check brake operation, fluid level, and pads.

COOLANT LEVEL

How to check coolant level.

3.4 BREAK-IN

BREAK-IN INSTRUCTIONS

Provides instructions for properly breaking in a new motorcycle.

3.5 COLD START

COLD START (ALL 250 Fi - ALL 450 Fi)

Instructions for starting the engine when cold on Fi models.

COLD START (450 F SMR;SMM - ALL 530 F)

Instructions for cold starting on SMR/SMM/530F models.

3.6 HOT START

HOT START (ALL 250 Fi - ALL 450 Fi)

Instructions for starting the engine when hot on Fi models.

HOT START (450 F SMR;SMM - ALL 530 F)

Instructions for hot starting on SMR/SMM/530F models.

START IN THE EVENT OF A FALL (250 Fi EN;MX;SMX - 450 Fi EN;MX;SMX)

How to restart the engine after a fall for specific models.

START IN THE EVENT OF A FALL (530 F EN;MX;SMX)

How to restart the engine after a fall for 530F models.

3.7 RUNNING

SETTING OFF

Guidance on starting off and engaging first gear.

ACCELERATING, SHIFTING GEARS, SLOWING DOWN

How to accelerate, shift gears, and slow down.

BRAKING

Proper braking techniques and considerations.

3.8 STOPPING

STOPPING AND PARKING

Instructions for stopping the motorcycle and parking it safely.

USING THE SIDE STAND

How to use the side stand properly.

3.9 REFILLING

FILLING FUEL TANK

Details the type of fuel and how to fill the tank.

3.10 CLEANING AND STORAGE

WASHING

Instructions for cleaning the motorcycle.

PRECAUTIONS FOR WINTER USE

Guidance for using the motorcycle in winter.

STORAGE

Instructions for storing the motorcycle long-term.

START-UP AFTER WINTER

How to start the motorcycle after winter storage.

4. MAINTENANCE

4.1 MAINTENANCE SCHEDULE

250 Fi EN;SMR;SMM MAINTENANCE TABLE

Maintenance schedule for 250Fi EN/SMR/SMM models.

250 Fi MX;SMX MAINTENANCE TABLE

Maintenance schedule for 250Fi MX/SMX models.

450 Fi EN - 450 Fi+F SMR;SMM - 530 F EN;SMR;SMM MAINTENANCE TABLE

Maintenance schedule for 450Fi/530F EN/SMR/SMM models.

450 Fi MX;SMX - 530 F MX;SMX MAINTENANCE TABLE

Maintenance schedule for 450Fi/530F MX/SMX models.

4.2 CHASSIS MAINTENANCE

CHECKING STEERING BEARING AND PLAY ADJUSTMENT (A)

How to check and adjust steering bearing play.

BLEEDING TELESCOPIC FORK

Instructions for bleeding air from the telescopic fork.

CLEANING TELESCOPIC FORK DUST SEAL

How to clean fork dust seals to maintain fork integrity.

REAR SUSPENSION LINKAGE (A)

Explains the rear suspension linkage mechanism.

CHECKING CHAIN TENSION

How to check transmission chain tension.

CORRECTING CHAIN TENSION (EN;MX;SMR;SMX)

How to adjust chain tension on specific models.

CORRECTING CHAIN TENSION (SMM)

How to adjust chain tension on SMM models.

CHAIN MAINTENANCE

General instructions for chain cleaning and maintenance.

CHAIN WEAR

How to check for chain wear.

HYDRAULIC CLUTCH PUMP

Details on adjusting the clutch lever and checking fluid.

BLEEDING HYDRAULIC CLUTCH (A)

Instructions for bleeding air from the hydraulic clutch.

BASIC INDICATIONS FOR TM DISC BRAKES

General information on TM disc brakes, callipers, and pads.

BRAKE FLUID RESERVOIRS

Explains brake fluid reservoirs and low level indicators.

BRAKE FLUID

Information on DOT4 brake fluid and its importance.

NISSIN FRONT BRAKE PUMP (EN;MX)

Adjusting lever position and checking/topping up brake fluid.

BREMBO RADIAL FRONT BRAKE PUMP (SMR;SMM)

Adjusting lever position and checking/topping up brake fluid.

ACCOSSATO RADIAL FRONT BRAKE PUMP (SMX)

Adjusting lever position and checking/topping up brake fluid.

CHECKING FRONT BRAKE PADS

How to check front brake pad thickness.

REPLACING FRONT BRAKE PADS (A)

Instructions for replacing front brake pads on various models.

CHANGING BASE POSITION OF REAR BRAKE PEDAL (A)

How to change the rear brake pedal position.

CHECKING REAR BRAKE FLUID LEVEL

How to check rear brake fluid level.

TOPPING UP REAR BRAKE FLUID (A)

How to top up rear brake fluid.

CHECKING REAR BRAKE PADS

How to check rear brake pad thickness.

REPLACING REAR BRAKE PADS (A)

Instructions for replacing rear brake pads.

DISASSEMBLING AND ASSEMBLING FRONT WHEEL

Steps to remove and install the front wheel.

DISASSEMBLING AND ASSEMBLING REAR WHEEL (EN;MX;SMR;SMX)

Steps to remove and install the rear wheel (non-SMM).

DISASSEMBLING AND ASSEMBLING REAR WHEEL (SMM)

Steps to remove and install the rear wheel for SMM models.

CHECKING SPOKE TENSION

How to check and adjust spoke tension for wheel stability.

TYRES, TYRE PRESSURE

Information on tyre types, condition, and pressure.

CHECKING SPEEDOMETER MAGNETIC SENSOR DISTANCE (EN;SMR;SMM) (A)

How to check the speedometer sensor distance.

FUEL TANK

Instructions for disassembling the fuel tank.

DISASSEMBLING FUEL TANK (450 F SMR;SMM - ALL 530 F)

Instructions for disassembling the fuel tank on specific models.

BATTERY (ALL MODELS WITH E.S.)

Information on battery maintenance, removal, and storage.

CHARGING THE BATTERY

How to charge the motorcycle battery correctly.

RECHARGE FUSE (ALL MODELS WITH E.S.)

How to check and replace the recharge fuse.

SYSTEM FUSE (EN;SMR;SMM)

How to check and replace the system fuse.

ACCESSORY FUSE (EN;SMR;SMM)

How to check and replace the accessory fuse.

HALOGEN HEADLIGHT (EN)

Adjusting headlight height and replacing the bulb.

REPLACING POSITION LIGHT BULB

How to replace position light bulbs.

HALOGEN HEADLIGHT (SMR)

Adjusting headlight height and replacing the bulb.

“CYCLOPE” HEADLIGHT (SMM)

Replacing low and high beam bulbs for SMM models.

LED TAILLIGHT (EN)

Replacing LED taillight components.

STANDARD TAILLIGHT (SMR;SMM)

Replacing bulbs for standard taillights.

TURN SIGNAL (EN;SMR;SMM)

Replacing turn signal bulbs.

4.3 ENGINE MAINTENANCE

COOLING

Explains the cooling system and its operation.

CHECKING COOLANT LEVEL

How to check and top up the coolant level.

DRAINING, FILLING AND BLEEDING COOLING SYSTEM (A)

Steps to drain, fill, and bleed the cooling system.

REPLACING EXHAUST SILENCER PACKING MATERIAL (A)

How to replace fibreglass packing in the exhaust silencer.

APPROVED SILENCER (EN;SMR;SMM)

Explains replacing fibreglass in approved silencers.

CLEANING AIR FILTER

Instructions for cleaning the air filter.

CHECKING MANUAL DECOMPRESSOR ADJUSTMENT (ALL 530 F) (A)

How to check and adjust the manual decompressor.

ADJUSTING THROTTLE CONTROL CABLES

How to adjust throttle control cable play.

ADJUSTING IDLE SPEED (ALL 250 Fi - ALL 450 Fi)

How to adjust idle speed on 250/450Fi models.

ADJUSTING IDLE SPEED (450 F SMR;SMM - ALL 530 F)

How to adjust idle speed on 450/530 models.

FUEL PRESSURE (250 Fi ALL - 450 Fi ALL(A)

How to check fuel pressure on Fi models.

BASIC INDICATIONS ON CARBURETTOR WEAR (450 F SMR;SMM - ALL 530 F)

Notes on carburettor wear and potential issues.

CHECKING FUEL LEVEL (FLOAT HEIGHT) (450 F SMR;SMM - ALL 530 F) (A)

How to check fuel float height on carburettor models.

OIL CIRCUIT (ALL 250 Fi)

Explains the oil circulation system for 250Fi models.

OIL CIRCUIT (ALL 450 Fi+F - ALL 530 F)

Explains the oil circulation system for 450Fi/530F models.

ENGINE OIL

Recommends specific engine oil types and quality.

CHECKING ENGINE OIL LEVEL (ALL 250 Fi)

How to check engine oil level on 250Fi models.

TOPPING UP ENGINE OIL (ALL 250 Fi)

How to add engine oil to 250Fi models.

CHECKING ENGINE OIL LEVEL (ALL 450 Fi+F - ALL 530 F)

How to check engine oil level on 450Fi/530F models.

TOPPING UP ENGINE OIL (ALL 450 Fi+F - ALL 530 F)

How to add engine oil to 450Fi/530F models.

CHANGING ENGINE OIL AND FILTER (ALL 250 Fi) (A)

Steps for changing engine oil and filter on 250Fi models.

CHANGING ENGINE OIL AND FILTER (ALL 450 Fi+ F - ALL 530 F) (A)

Steps for changing engine oil and filter on 450Fi/530F models.

5. DIAGNOSIS

5.1 DIAGNOSIS (ALL 250 Fi - ALL 450 Fi)

THE ENGINE DOES NOT TURN OVER (Fi MODELS WITH E.S.)

Troubleshooting for when the engine doesn't turn over.

THE ENGINE TURNS OVER BUT FAILS TO START (ALL Fi MODELS)

Troubleshooting for when the engine turns over but won't start.

THE ENGINE DOES NOT STAY RUNNING IN IDLE

Troubleshooting for engine idling issues.

THE ENGINE DOES NOT REACH FULL SPEED

Troubleshooting for lack of full engine speed.

INSUFFICIENT ENGINE POWER

Troubleshooting for insufficient engine power.

THE ENGINE MISFIRES OR SWITCHES OFF WHILE RUNNING

Troubleshooting for engine misfires or stalling.

LIGHTS, SPEEDOMETER, HORN AND TURN SIGNALS DO NOT WORK

Troubleshooting for lighting and signal issues.

5.2 DIAGNOSIS (450 F SMR;SMM - ALL 530 F)

THE ENGINE DOES NOT TURN OVER (MODELS WITH E.S.)

Troubleshooting for non-starting engines with electric start.

THE ENGINE TURNS OVER BUT FAILS TO START (ALL MODELS)

Troubleshooting for engines that turn but don't start.

THE ENGINE DOES NOT STAY RUNNING IN IDLE

Troubleshooting for engine idling problems.

THE ENGINE DOES NOT REACH FULL SPEED

Troubleshooting for engines not reaching full speed.

INSUFFICIENT ENGINE POWER

Troubleshooting for insufficient engine power.

THE ENGINE MISFIRES OR SWITCHES OFF WHILE RUNNING

Troubleshooting for engine misfires or stalling.

THE ENGINE OVERHEATS EXCESSIVELY

Troubleshooting for engine overheating.

LIGHTS, SPEEDOMETER, HORN AND TURN SIGNALS DO NOT WORK

Troubleshooting for electrical system components.

5.3 PDA (PALMTOP COMPUTER) (ALL 250 Fi - ALL 450 Fi)

6. TECHNICAL DATA

6.1 CHASSIS TECHNICAL DATA

250 Fi;450 Fi;530 F EN;MX CHASSIS TECHNICAL DATA

Technical chassis specifications for EN/MX models.

CHASSIS TIGHTENING TORQUES

Specifies torque values for various chassis components.

6.2 ENGINE TECHNICAL DATA

250 Fi ALL - ALL 450 Fi+F ENGINE TECHNICAL DATA

Engine specifications for 250/450Fi models.

ALL 530 F ENGINE TECHNICAL DATA

Engine specifications for 530F models.

ENGINE TIGHTENING TORQUES

Specifies torque values for engine components.

MAPPED CONTROL UNITS (ALL 250 Fi - ALL 450 Fi)

Lists control unit codes for EFI models.

KEIHIN CARBURETTOR SETTING (450 F SMR;SMM - ALL 530 F)

Carburettor settings for specific models.

7. WIRING DIAGRAMS

7.1 LIGHTS AND ACCESSORIES WIRING DIAGRAM (EN;SMR;SMM)

7.2 ENGINE WIRING DIAGRAM (250 Fi MX;SMX - 450 Fi MX;SMX)

7.3 ENGINE WIRING DIAGRAM (250 Fi EN;SMR;SMM - 450 Fi EN;SMR;SMM)

7.4 ENGINE WIRING DIAGRAM (250 Fi MXE.S.;SMXE.S. - 450 Fi MXE.S.;SMXE.S.)

7.5 ENGINE WIRING DIAGRAM (450 F SMR;SMM - 530 F EN;MXE.S.;SMR;SMM;SMXE.S.)

7.6 ENGINE WIRING DIAGRAM (530 F MX;SMX)

TM RACING 450Fi SMR Specifications

General IconGeneral
BrandTM RACING
Model450Fi SMR
CategoryMotorcycle
LanguageEnglish

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