250 SER (2016) - Motorcycle Sherco - Free user manual and instructions

Frequently Asked Questions - 250 SER (2016) Sherco

USER MANUAL 250 SER (2016) Sherco

MANUEL DU PROPRIÉTAIRE | OWNER'S MANUAL | MANUAL DE PROPietARIO

250-300 SE/R

INDEX

SHERCO

■ FRANÇAIS P.1
■ ENGLISH P.68
■ ESPAGNOL P. 135

DEFYGRAVITY

SHERCO

Enforcement statique 30mm

We want to thank you for the trust that you have placed in us by purchasing this product.

■ You are now the owner of a SHERCO 250-300 SE/R. All the pleasures of driving are promised to you if you follow the advice and instructions that SHERCO has set in this manual, and ride it in compliance with the applicable traffic laws.
This manual explains the operation, inspection, basic maintenance and focus of your SHERCO. If you have any questions about this manual or your machine, you should contact your SHERCO dealer: www.sherco.com / under «Dealers».
■ Be sure to carefully read this manual in its entirety before using your machine.
To keep your SHERCO in perfect condition for many years, perform all of the care and maintenance described in the manual.

(The vehicle you purchased may differ slightly from the vehicle presented in this manual.)

SHERCO reserves the right to make changes without providing notice.

Serial number registration

Save the serial numbers of the vehicle in a safe location

Dealer stamp

Frame number (p.73)

Type and serial number of the motor (p.73)

SUMMARY

Technical Specifications. 4

Description of the vehicle. 8

location of the serial numbers. 9

Control devices and controls. 10

Hand operated controls: 10

Clutch lever, front brake lever and control switches. 10

Foot controls: gear selector, side stand, rear brake 13

Motorcycle computer instructions 14

Opening and closing the fuel tank. 18

Riding the motorcycle 20

Safety information 21

Cooling System 22

Servicing the cooling system 22

Draining the coolant. 23

Filling the coolant. 24

Motor settings 25

Checking the play in the throttle cable 25

Setting the main valves cable. 26

Setting the idle speed 27

Engine maintenance 28

Checking the engine oil level 28

Draining the gear box oil 28

Refilling the gear box with oil 29

Adjusting the chassis. 30

Handlebar position 30

Adjusting the steering angle 31

Basic setting of the chassis according to the rider weight..31

Setting the fork compression 31

Fork rebound adjustment 32

Setting the fork spring preload. 32

Adjusting the rear shock low-speed compression setting ...33

Adjusting the rear shock high-speed compression setting..33

Rebound damper 34

Setting the depression of the rear shock with no load 34

Setting the rear shock sag. 34

Changing the preload of the shock 35

Changing the shock spring. 35

Chassis maintenance 36

Removing the saddle. 36

Reinstalling of the saddle 36

Removing the Air Filter 36

Cleaning the air filter. 37

Reinstalling the air filter. 37

Chassis maintenance (continued) 38

Removing the fuel tank 38

Reinstalling the fuel tank. 39

Purging the air from the forks. 39

Cleaning the fork dust seals. 40

Checking the play of the steering head bearings. 40

Adjusting the steering head bearing play. 41

Cleaning the chain. 41

Checking the chain tension 41

Adjusting the chain tension 42

Adjusting the lever 42

Checking the clutch fluid level 43

Removing the rear shock. 44

Reinstalling the rear shock 45

Wheels, tires 46

Removing the front wheel. 46

Reinstalling the front wheel 46

Removing the rear wheel. 47

Reinstalling the rear wheel 47

Wheels, tires (continued). 48

Checking the tire pressure 48

Checking for wear and damage 49

Checking spoke tension 49

Brakes 50

Checking the front brake lever adjustment 50

Adjusting the front brake lever. 50

Checking the front brake fluid level 50

Filling the front brake reservoir with brake fluid 51

Adjusting the position of the rear brake pedal. 51

Checking the travel of the rear brake pedal. 51

Adjusting the travel of the rear brake pedal. 52

Checking the rear brake fluid level 52

Filling the rear brake reservoir with brake fluid. 52

Removing the front and rear brake pads .53

Checking the condition of the brake pads. 53

Reinstalling the front and rear brake pads. 53

Electrical system maintenance. 54

Removing the battery. 54

Reinstalling the battery 55

Charging the battery 55

Replacing the main fuse. 56

Replacing the fuse for the lights (250-300 SE/R) 56

Removing the headlight housing. 56

Reinstalling the headlight housing. 57

Replacing the headlight bulb or the pilot lamp.57

Adjusting the headlight beam 58

Replacing the motorcycle computer battery

(250-300 SE/R) 58

Washing and storage. 59

Washing the bike 59

Storing the bike 59

Recommissioning after storage 59

Maintenance schedule. 60

Maintenance. 60

Torques 63

Technical Specifications

DIMENSIONS

Overall length 2260 mm
Overall width 820 mm
Seat height 970 mm
Wheelbase 1470 mm
Ground clearance 350 mm

MOTOR

Type : Single cylinder 2 stroke liquid cooled
Displacement : 249.32 cc / 293.14 cc
Bore / Stroke 66,4 x 72 mm / 72 x 72 mm
Fuel system Carburator KEIHIN PWK 36
Cooling Liquid system with forced circulation
Starting System Electric starter
Battery 12 V / 4 Ah
Ignition system DC-CDI no switch with digital advance
Spark plug NGK BR8ES / DENSO W24ESRU
Spark plug gap	0.7 mm
Alternator	220W
Engine oil	750 ml 10 W 40

CARBURETOR

Type of carburetor	KEIHIN PWK 36S AG
Needle position 4th position from the top / 3th position from the top
Needle jet	N8RJ (N84K) / N8RG
Main jet	KEA 165 (KEA 115)
Pilot jet	KEP 40 (KEA38) / KEP 38
Starter jet	85 (50)
Air screw adjustment	1 1/2 turns
Slide cut	N°7

TRANSMISSION

Type	6 speed
Clutch	Multi disc clutch in oil bath, hydraulically operated
Primary drive	27 x 75
Gearbox	6 speed
Secondary drive	14 x 49
CHASSIS
Frame	Semi-perimeter CrMo steel with aluminum sub-frame
Fork	SACHS USD Gold Series 48mm dia. (standard)WP USD 48mm dia. (racing)
Rear suspension WP Suspension with separate cylinder
Travel front/rear 300/300mm
Front brake disc 270mm (standard), 256mm (racing)
Rear brake disc disque Ø 220mm
Disc brakes wear limit : 2.7mm front and 3.6mm rear
Front tire 90/90-21"
Rear tire 140/80-18"
Pressure off-road front / rear 0,9 bar
Fuel tank capacity with reserve 9,5l with 1l of reserve
Fuel requirement	Unleaded gasoline with an octane index of at least 95 mixed with 2 stroke oil (2%)

Technical Specifications (continued)

ELECTRICAL EQUIPMENT

Battery Yuasa YTX5 LBS 12V 4Ah
Headlight S2 12V 35/35W
Pilot W5W 12V 5W
Rear tail / stop LED
Flasher	R10W	12V 10W
Speedometer battery	CR 2032	Battery voltage: 3V
Plate light	W5W	12V 5W

ADJUSTMENT - SACHS FRONT FORK USD GOLD SERIES 048MM

Compression	12 clicks back
Rebound	12 clicks back
Spring stiffness	4.5N/mm
Type of oil	SAE 5
Quantity of oil per fork leg	600cm3
Oil level measurement (fork compressed and spring removed) from the top of the fork tube	130mm

REGLAGES - FOURCHE WP SUSPENSION USD 048MM

Compression	Comfort 20 clicks back
	Standard 13 clicks back
	Sport 8 clicks back
Rebound	Comfort 18 clicks back
	Standard 13 clicks back
	Sport 10 clicks back
Preload	Comfort 4 tours
	Standard 6 tours
	Sport 8 tours
Spring stiffness	Rider weight : 65-75 kg 4.0N/mm
	Rider weight : 75-85kg 4.2N/mm (origine)
	Rider weight : 85-95kg 4.4N/mm
Type of oil SAE 4
Oil level measurement (fork compressed and spring removed) from the top of the fork tube		110mm
ADJUSTMENT - WP REAR SUSPENSION UNIT
Low-speed compression	Comfort 20 clicks back
	Standard 15 clicks back
	Sport 12 clicks back
High-speed compression	Comfort 2,5 clicks back
	Standard 2 clicks back
	Sport 1,5 clicks back
Rebound	Comfort 15 clicks back
	Standard 13 clicks back
	Sport 11 clicks back
Spring stiffness	Rider weight: : 65-75 kg 48N/mm
	Rider weight: : 75-85 kg 51N/mm (original)
	Rider weight: : 85-95kg 54N/mm

CLEANING PRODUCTS AND CONSUMABLES
Engine oil	SAE J 300 10 W 40	Minerva SAE 10W40
Coolant		Minerva Perma Universal D 4 seasons -25°C
Brake Fluid DOT 4		Minerva brake fluid DOT 4
Fork oil SAE 4
Shock oil SAE2.5
Aerosol chain lube Minerva aerosol chain lub
Air filter cleaner Minerva air filter cleaner
Air filter lubricant Minerva Protect Air
Plastic cleaner		Minerva Renovator clea- ner
Wheel Cleaner Minerva Multi clean Pro
Disc brake Cleaner Minerva brake cleaner
Universal lubricant Minerva F4

Description of the vehicle

Right side

Rear turn signals
Saddle
Rear brake pedal
Fuel tank
Front turn signals
6 Headlight

Left side

Fuel tank cap
Rear light (tail / brake light / plate light)
Gear selector pedal

Description of the vehicle (continued)

Controls

10 Left mirror
1 Clutch lever
12 Left switch

13 Dashboard
14 Key switch
15 Right switch

location of the serial numbers

Vehicle serial number location

The serial number of the vehicle is stamped on the right side of the steering tube.

Engine serial number location

Engine serial number location

The engine serial number is stamped on the right side crankcase.

Control devices and controls

HAND OPERATED CONTROLS:

CLUTCH LEVER, FRONT BRAKE LEVER AND CONTROL SWITCHES

Clutch lever

The clutch lever ① is on the left handlebar and has an adjustment screw A

Front brake lever

The front brake lever 2 is on the right side of the handlebar and has an adjustment screw B

Left switch (250-300 SE)

High beam (Headlight)
Low beam (Headlight)
Side light (Night)
4 Horn
Flashers

Light switch on / off (250-300 SE/R)

Two possible positions:

Position ON 1: All lights are on.

Position OFF 2 : All lights are off.

Rigth switch

Starter button
Injection system mapping selection button

■ Dashboard (250-300 SE/R)

1 Dashboard
Mode selection button
Key switch (250-300 SE)

Key switch (250-300 SE)

The main switch has two positions
Position 1 The engine is off and can not be started.
Position 2 The motor can be started.

■ Flasher switch (250-300 SE)

Left turn position
Right turn position
3 Off position G and D

Control devices and controls (continued)

Engine on / off switch (250-300 SE/R)

Two possible positions:

The button is released: in this position, the bike can be ridden. The button is held down: in this position the motor is Off when released the motor can be restarted.

ATTENTION

• If you use the emergency stop button to stop the motorcycle, do not forget to move the ON / OFF switch into the OFF position.
• If you do not, there is a risk that the battery will discharge.-Under normal conditions, use the ON / OFF switch to stop the bike.

Injection system mapping switch

Position 1 "Soft"
Position 2 "Hard"

FOOT CONTROLS:

GEAR SELECTOR, SIDE STAND, REAR BRAKE

Gear selector

The drawing shows the path of the gear selector for each of the 6 speeds.

Footbrake

Rear brake control

Side stand

Remove the rubber safety latch 1, using your foot on the shaft unfold it until it supports the weight of the bike.

ATTENTION

• The stand has a security system which automatically folds the stand when the bike is moved into an upright position.
• The stand has been designed to withstand the sheer weight of the bike.

Control devices and controls (continued)

MOTORCYCLE COMPUTER INSTRUCTIONS

Screen 1: DST Adjust

Screen 2: DST2 Adjust

Button 2:

Change screens 1,2,3

Hold button 2:

Screen 1: Reset DST

Screen 2: Reset DST2

Screen 3: Reset MAX/AVG

257

DST 42.7

1257

3602

Screen 1: Speed, Clock, Distance 1 Screen 2: Speed, Clock, Distance 2

2079ART 34800.6

Screen 3: Alternating AVG/MAX speed, Accumulated run time, ODO

Turn indicator

High beam

Fuel injection (MIL): EFI problem

Low fuel

Mode buttons

The vehicle doesn't need to be switched on

Left button:

Switch between the three display screens Enter adjustable trip distance mode ( DST and DST2)

Decrement distance while in adjustable distance mode

Right button:

Switch between the three display screens Resets Trip distance 1, Trip distance 2, maximum and average speed (when pressed and held for three seconds)

Increments distance while in adjustable distance mode

Fig 1 SPD function

Fig 2 MAX speed function

Fig 3 AVG function

Fig 4 DST function

Fig 5 DST2 function

SPD function Current speed (screens 1 and 2):

displays the current speed of the vehicle.

The speed can be displayed in km/h (default)

or mph. (p.81)

MAX speed (screen 3): displays the maximum speed since the last reset was performed.

The maximum speed can be displayed in km/h (default) or mph. (p.81)

Reset to 0 → MAX Function → Hold the right

Button down for 3seconds 0 Reset to O done

AVG function Average speed (screen 3): displays the average speed of the vehicle since the last reset was performed.

The average speed is displayed in the chosen units, km/h (default) or mph (p.81)

Reset to 0 AVG Function Hold the right Button down for 3seconds 0 Reset to 0 done

DST function (screen 1): displays the mileage traveled by the vehicle since the last reset was performed.

The distance is displayed in the selected units, km/h (default) or mph (p.81)

Reset to 0 DST Function Hold the right Button down for 3seconds 0.0 Reset to O done

DST2 function (screen 1): displays the mileage traveled by the vehicle since the last reset was performed.

The distance is displayed in the selected units, km/h (default) or mph (p.81)

Reset to 0 DST2 Function Hold the right Button down for 3seconds 0.0 Reset to 0 done

Control devices and controls (continued)

Fig 6 Adjustable trip distance function

DST and DST2 can be incremented or decremented by the user

DST set up (screen 1) Hold the left Button down for 3 seconds «DST» icon will flash Hold left Button to decrement/ Hold the right Button to increment back to screen 1

DST2 set up (screen 2) → Hold the left Button down for 3 seconds → «DST2» icon will flash → Hold left Button to decrement/ Hold the right Button to increment → back to screen 2

Fig 7 ODO function

ODO function Odometer (screen 3): displays the total mileage traveled by the vehicle.

The total distance is displayed in the selected units, km/h (default) or mph (p.17)

This information can not be reset to 0.

Beyond 399 999 km (or miles), the counter goes back to 0.

Fig 8 ART function

ART function Accumulated Ride Time (screen 3): displays the hours of operation of the vehicle

This information can not be reset to 0.

Until 99h59min displayed in one minute increments

After 99h59min up to 9999h displayed in one hour increments

If the unit should reach 9999 hours of accumulated ride time, the display will stop incrementing, and will remain at that number.

Fig 9 Clock function

Clock function (screens 1 et 2): displays clock information

Fig 11 Low battery/ Low battery error function

Low battery/ Low battery error function:

• When the battery voltage drops to less than 2.40V, the LO battery warning will turn on.

->When the internal battery is critically low, the unit will only display a blinking «LO» icon.

Set up menu

Left and right buttons pressed simultaneously for 3s activates the Set up mode
Left button Right button
Toggle between M/H and KM/H settings Toggle between 24 Hour et 12 Hour
Decrement time of day value Decrement maintenance reminder value	Increment time of day value Increment maintenance reminder value

Maintenance reminder: maintenance reminder function is a countdown from a user defined number. When the maintenance countdown gets to zero, the maintenance icon will appear on the LCD. Follow these steps to reset or display the remaining accumulated ride time until next service reminder:

Displaying the remaining accumulated ride time (screen 3) Hold the left Button down for 3 seconds the remaining value is displayed no button activation back to screen 3

Resetting the remaining accumulated ride time (screen 3) Hold the left Button down for 3seconds the remaining value is displayed Hold the right Button down for 3seconds The maintenance reminder is reset to zero (will begin the countdown again according to the maintenance interval already chosen in the set up menu)

Note:

If the maintenance icon is already on, the distance displayed will be zero If the maintenance reminder is turned off , the information displayed on the screen will be OFF

Control devices and controls (continued)

OPENING AND CLOSING THE FUEL TANK

Fuel

Use only unleaded fuel with an octane index of at least 95 mixed with 2 stroke oil (2%)

Fillercap

Open: Turn the cap counter clockwise. The opposite direction to the hands of a watch

Close: Turn the cap clockwise. The same direction as the hands of a watch

Fuel tap

The fuel tap is on the right side of fuel tank.

Tap handle 1 on the fuel tap is used to open or close the supply of fuel to the carburetor.

OFF Fuel cannot flow from the fuel tank to the carburetor.

ON Fuel can flow from the fuel tank to the carburetor. The fuel tank empties to the point of reserve capacity.

RES Fuel can flow from the fuel tank to the carburetor. The fuel tank empties fully.

Choke

The choke lever 1 is fitted on the left side of the carburetor.

Choke function activated The choke lever is pulled out all the way.

Choke function deactivated The choke lever is pushed in all the way.

ATTENTION

If the engine is warm, the choke function must be deactivated.

Cold engine starting

1. Turn the ignition key to start position (right)
2. Make sure the gear selector is in neutral
3. Activate the choke
4. Start the engine by pressing the starter button, with the throttle closed
5. Allow the engine to warm up for few minutes
6. Deactivate the choke

Hot engine starting

Follow the instructions above without step 3-5 and 6.

■ Shifting gears

• The positions of the gear selector are shown on (p.77)

• To find the neutral position, press the selector down into first gear (a resistance will be felt), then move the selector up slightly.

• Close the throttle before changing gears.

• Engage the lowest gear.
• Partially open the throttle while engaging the clutch.

■ Parking

• Stop the engine and remove the ignition key.

Become familiar with all of the controls and their functions before using the vehicle.

Safety information

• Do not drive after consuming alcohol.
• Wear a helmet when using the vehicle.
• Keep the machine in good working order and maintain it properly so that it is reliable and safe for use.
• Gasoline is flammable, refuel the motorcycle when the engine is stopped.
• Exhaust fumes are toxic, you should never start the engine in a closed building.
• Always park the vehicle on a flat hard surface, do not park the vehicle on a slope or on soft ground. Always control the balance of the vehicle.
• Check the following every day before riding the motorcycle:

Tires : Wear and pressure

Engine oil : Level ( p.92)

Gasoline : Check the level and make sure there are no leaks

Transmission chain Properly lubed and adjusted ( p.105)

Direction of travel : Make sure that your path is clear

Brakes: Operation, fluid leakage, brake pad wear ( p.114 to p.118)

Throttle: Proper operation ( p.89)

Clutch: Proper operation ( p.106 to p.107)

Electrical Equipment : Operation of the horn and lights ( p.74 and p.76)

Components (nut, bolts ...): Verify that all components of the vehicle are properly tightened (p.127)

If you experience a problem with any of the components of the motorcycle, consult the Service and Adjustments section of this manual or contact a Sherco dealer.

Cooling System

SERVICING THE COOLING SYSTEM

Motorcycle horizontal

ATTENTION

• The hot liquid can cause severe injuries.
• The coolant is harmful
• After contact with skin or eyes, or ingestion, or injuries caused by hot liquids: Consult a physician
• Use protective gloves.
• Do not replace the coolant with water or other not approved fluids: it could damage your engine.

• Follow these procedures carefully and always fill the engine with coolant when the engine is cold.

• Place the bike upright on a horizontal surface.

• Remove the cap 1.

Fill the radiator full so that there is no air in the system.

Approved Coolant

Minerva Perma Universal D 4 seasons -25°C

Replace the screw 2.

Radiator Bleed screw

M6X8 8Nm

Fill the coolant to the top of the radiator.

Replace the cap 1 and check to make sure it is tight.

ATTENTION

It is important to follow this procedure. The lack of fluid, or the presence of a pocket of air left in the radiator can cause serious damage to the engine.

Check the fluid level in the expansion container.

The liquid should reach the level on the container where it indicates "LEVEL"

If the level is not correct, unscrew the cap ② Fill with fluid until it reaches the LEVEL mark.

Coolant

de refroidissement

Minerva Perma Universal

D 4 - 25^ C

Replace the cap 2

Make sure the bike is vertical and on a horizontal surface.

-Place a container under the bike

-Remove the cap 1 and screw 2

-Allow the coolant to drain.

NOTE

To protect the environment deposit the drained coolant at an approved collection center.

Cooling System (continued)

FILLING THE COOLANT

• Remove the bleed screw using a new gasket
• Pour the coolant into the radiator through the cap ①.

Coolant Minerva Perma Universal

D4-25°C

Radiator bleed screw

M6X70 8Nm

• Continue filling.
• Fill until the coolant reaches the level (approximately 1.1 liters)
• Put the bike on the side stand and follow the rest of the filling procedure (p.86)

Motor settings

CHECKING THE PLAY IN THE THROTTLE CABLE

Checking the throttle cable play

With the handlebars facing straight ahead, check that the throttle twist grip functions properly.

Throttle cable play 2....4mm

If the cable play is not correct, adjust the accelerator throttle cable play. (p.89)

Start the bike and let it run at idle. Turn the handlebars and check that the idle speed is constant. If the speed changes, readjust the play in the throttle cable. (p.89)

Adjusting the play in the throttle cable

Adjust the throttle cable play at the location shown 1 with the adjuster.

If this is not enough, adjust the play directly on the throttle body.

ADJUSTING THE TENSION OF THE VALVE CABLES

• Make sure that the tensioning cables are completely relaxed.
• Adjust the top position on the cable pulley 1 at the stop located on the cylinder.
• For the present time do not adjust the lower cable 2.
• Turn the bike ignition switch ON.
• Wait until the electric motor initializes the valves and then shuts down.
  -Turn the bike ignition switch OFF.
• Start adjusting the upper cable tensioner 3 by unscrewing the nut from the sleeve stop.

Do not continue to tighten the cable, tighten only until the stop is no longer pulling (WITH FORCE) attempting to move the sheath toward the rear of the bike, stop adjusting at this time.

• Note: In this configuration, the central valves must be fully lowered.
• Then tighten the nut 1, 1 full turn = 1mm
• The measurement between the tensioning cable crimping sleeve and bottom of the cylinder sheath should be 0.5mm minimum, 1mm maximum when pulling (WITH FORCE) on the cable to the rear of the bike, if this measurement is not correct, correct by tightening or loosening the nut 1.
• Tighten the nut 4 against the stop.

Motor settings

• Insert the lower cable 2 into the cable stop on the cylinder.
• Start adjusting the lower cable tensioner by unscrewing the nut 5 until it abuts on the sleeve stop.

Do not continue to tighten the cable, tighten only until the stop is no longer pulling (WITH FORCE) attempting to move the sheath toward the rear of the bike, stop adjusting at this time.

• Tighten the nut then 5, 1 full turn = 1mm
• The measurement between the tensioning cable crimping sleeve and bottom of the cylinder sheath should be 0.5mm minimum, 1mm maximum when pulling (WITH FORCE) on the cable to the rear of the bike, if this measurement is not correct, correct by tightening or loosening the nut 5.
• Tighten the nut 6 against the stop.
• Lubricate with spray grease the cables on the pulley, the pulley groove and the steel plate to prevent oxidation.

SETTING THE IDLE SPEED

• The idle speed is adjust with adjusting screw
• The idle mixture is adjusted with the idle air adjusting screw 2.

Start the bike and allow it to reach operating temperature.

Adjust the idle speed by turning the air screw 2200 +/- 100 rpm

Turn the adjust screw idle mixture all the way and turn it to 1 turn 1/2.

Idle speed 2200 +/- 100 rpm

Idle air adjusting open 1T 1/2

SETTING THE CARBURETOR

How the opening of the throttle slide influences performance:

The composition of the mixture (Air-Gas) is a function of the opening of the slide:

A: Idle range

From 0 to 18 opening of the throttle slide, this range is regulated by the idle screw 1 and the air screw 2 .

B: Transition range

From 18 to 14 opening of the throttle slide, this range is regulated by the idle jet and the shape of the slide.

C:Mid-range :

From 14 to 34 opening of the throttle slide, this range is regulated by the needle valve (shape and position). In the lower range, the idle circuit, and in the higher range, the main jet take into account the control of the motor.

D:Full load

From 3 / 4 to full throttle slide opening, this range is controlled by the main jet and the needle jet.

Motor settings

Pilot jet and pilot (air) screw:

In order to adjust the idle range A to B transition you can change the pilot jet (its size is stamped on it) and adjust the air screw, turning the screw in richens the mixture.

Proceed by turning the screw 1/8 of a turn at a time, if you move out of the rage of 1T-2.5T, change the size of the pilot jet.

Needle :

The needle has 5 notches for adjustment, 1 to 5, from rich to lean.

The reference number of the needle is engraved on it. In the tables the adjusting position of the clip on the needle is defined from the upper position.

Main jet :

The main jet is shown in the photo as 1. The size of the jet is engraved on it.

CARBURETOR SETTING TABLE FOR THE SE-R 250 :

SEA LEVEL TEMPERATURE -20°C ...		-7°C	-6°C ... 5°C	6°C ... 15°C	16°C ... 24°C	25°C ... 36°C	37°C ... 49°C
3 000 m to 2 301 m	Air Screw	1T1/2	1T1/2	2T	2T	2T1/2
	Pilot jet	40	40	40	40	40
	Needle	N8RJ	N8RJ	N8RK	N8RK	N8RL
	Needle position	4	3	3	3	3
	Main jet	165	165	162	160	158
2 300 m to 1 501 m	Air Screw	1T	1T1/2	1T1/2	2T	2T	2T1/2
	Pilot jet	40	40	40	40	40	40
	Needle	N8RW	N8RJ	N8RK	N8RK	N8RK	N8RL
	Needle position	4	4	3	3	2	158
	Main jet	168	165	165	162	160
1 500 m to 751 m	Air Screw	1T	1T	1T1/2	1T1/2	2T	2T
	Pilot jet	42	40	40	40	40	40
	Needle	N8RH	N8RW	N8RJ	N8RJ	N8RK	N8RK
	Needle position	4	4	4	3	3	2
	Main jet	170	168	165	165	162	160
750 m to 301 m	Air Screw	1/2T	1T	1T	1T1/2	1T1/2	2T
	Pilot jet	45	42	40	40	40	40
	Needle	N8RH	N8RH	N8RW	N8RW	N8RK	N8RK
	Needle position	5	4	4	3	3	162
	Main jet	172	170	168	165	165
300 m to 0 m	Air Screw	1/2T	1/2T	1T	1T	1T1/2	1T1/2
	Pilot jet	45	45	42	40	40	40
	Needle	N8RG	N8RH	N8RH	N8RW	N8RK	N8RK
	Needle position	5	5	4	4	4	165
	Main jet	175	172	170	168	165

CARBURETOR SETTING TABLE FOR THE SE-R 300:

SER LEVEL TEMPERATURE -20°C ...		-7°C	-6°C ... 5°C	6°C ... 15°C	16°C ... 24°C	25°C ... 36°C	37°C ... 49°C
3 000 m to 2 301 m	Air Screw Pilot jet Needle Needle position Main jet	1T1/2 38 N8RG 3 165	1T1/2 38 N8RG 2 165	2T 38 N8RH 2 162	2T1/2 38 N8RH 2 160	3T 38 N8RH 2 158
2 300 m to 1 501 m	Air Screw Pilot jet Needle Needle position Main jet	1T 38 N8RF 3 168	1T1/2 38 N8RG 3 165	1T1/2 38 N8RG 2 165	2T 38 N8RH 2 162	2T1/2 38 N8RH 2 160	3T 38 N8RH 2 158
1 500 m to 751 m	Air Screw Pilot jet Needle Needle position Main jet	1T 38 N8RF 3 170	1T 38 N8RF 3 168	1T1/2 38 N8RG 3 165	1T1/2 38 N8RG 2 165	2T 38 N8RH 2 162	2T1/2 38 N8RH 2 160
750 m to 301 m	Air Screw Pilot jet Needle Needle position Main jet	1T 40 N8RF 4 172	1T 38 N8RF 3 170	1T 38 N8RF 3 168	1T1/2 38 N8RG 3 165	1T1/2 38 N8RG 2 165	2T 38 N8RH 2 162
300 m to 0 m	Air Screw Pilot jet Needle Needle position Main jet	1T 40 N8RF 4 175	1T 40 N8RF 4 172	1T 38 N8RF 3 170	1T 38 N8RF 3 168	1T1/2 38 N8RG 3 165	1T1/2 38 N8RG 2 165

Engine maintenance

CHECKING THE ENGINE OIL LEVEL

• Make sure that the bike is on its two wheels, vertical and on a horizontal surface.
• Check the gear oil level, the oil should flow out of the screw opening 1

If necessary add oil to achieve the correct oil level.
- unscrew the engine oil filer cap 2 located on the clutch housing ②

Topping up the engine oil

Engine oil

0,7L SAE

10W40

ATTENTION

• Improved oil level can damage your engine.
• Do not use bike if the level is below the minimum.

• Remove the engine guard (p.107)
• When draining the oil the engine should be warm.

ATTENTION

Use protective gloves.

• Position the motorcycle upright on a level surface.
• Place a container under the bike to catch the old oil.
• Remove the drain plug 1
• Remove the drain plug ②
• Allow the oil to drain
• Clean the drain plugs① and ② with a degreaser.

Engine maintenance (continued)

REFILLING THE GEAR BOX WITH OIL

• Install the drain plug 1 and 2 with a new gasket.

Drain plug ①②	M16 15Nm
- Remove the engine oil filler cap②. (p.92) - Fill the engine with oil
Motor oil 0,81 SAE 10W40

• Install the engine guard.

ATTENTION

To protect the environment, oil, oil filters and used material must be deposited in a collection center and not down drain or in the wild.

Emptying the carburetor float chamber

• Turn handle of fuel tap to the OFF position
• Place a cloth beneath the carburetor to soak up emerging fuel.
• Remove plug 1
• Completely drain the fuel.
• Mount and tighten the plug.

Adjusting the chassis

HANDLEBAR POSITION

The triple clamps have two holes separated by a distance A.

Distance between holes A 13mm

The handlebar clamps are offset by a distance B

Handlebar offset B 4mm

The bike comes standard with the handlebars in the rear most position.

Remove the four screws 1. Remove the handlebar top clamps and remove the handlebar.
Remove the two screws 2. Remove the lower clamps and place them in the desired position.

Handlebar lower clamp

M10x35

40Nm

Loctite® 243TM

Replace the handlebars and top clamps. Replace the four screws 1 and tighten evenly.

Handlebar clamps fixing screws

M8x25 24Nm

The handlebars can be rotated forward and rearward in the clamps.

ADJUSTING THE STEERING ANGLE

The steering angle can be changed using the set screws located on the bottom of the steering column.

Loosen the nut 1 and tighten the screw 2 until you have the steering angle desired.

Tighten the nut and do the same operation on the other side.

Steering angle lock nut

M8 20Nm

BASIC SETTING OF THE CHASSIS ACCORDING TO THE RIDER WEIGHT

Standard weight of the- rider (with equipment)

75 à 85kg

If the weight of the rider is above or below the standard, compensate by changing the stiffness of the springs (forks and shock).

SETTING THE FORK COMPRESSION

Screws 2 determine the behavior of the fork when it is compressed. Turning in the screw-clockwise increases the hydraulic force (and vice versa).

Remove the caps 1 located at the lower end the fork.

Turn screw 2 clockwise to the stop and go back the number of clicks required.

Adjusting the compression Sachs Series Gold Ø48mm	12 clicks
Adjustable compression WP Suspension USD Ø48mm	Comfort	20 clicks
	Standard	13 clicks
	Sport	8 clicks

Replace the cap 1.

Adjusting the chassis (continued)

FORK REBOUND ADJUSTMENT

The adjusting screws 1 determine the behavior of the fork when it rebounds. Turning the screws clockwise increases the hydraulic force (and vice versa).

The adjustment screws 1 are located at the end of the upper fork legs.

Turn the screw 1 clockwise to the stop then go back the number of clicks required.

Rebound Sachs Gold Series USD Ø48mm	12 clicks
Rebound WP suspension USD Ø48mm	Comfort	18 clicks
	Standard	13 clicks
	Sport	10 clicks

SETTING THE FORK SPRING PRELOAD

The adjusting nut allows the preload of the Spring to be adjusted. Turning the nut clockwise increases the preload (and vice versa).

Turn the nut with a wrench counterclockwise until it stops and then turn it the number of turns required.

Suspension spring preload WP USD Ø48mm	Comfort 4 turns
	Standard 6 turns
	Sport 8 turns

ADJUSTING THE REAR SHOCK LOW-SPEED COMPRESSION SETTING

The adjusting screw determines the slow speed behavior of the rear shock (sensitivity Turning the screw clockwise increases the hydraulic force (and vice versa).

Turn the screw 1 clockwise with a screwdriver until it stops and then turn it back the number of clicks required.

Do not loosen the nut 2.

Low-speed compression setting	Comfort 20 clicks
	Standard 15 clicks
	Sport 12 clicks

ADJUSTING THE REAR SHOCK HIGH-SPEED COMPRESSION SETTING

The adjusting screw determines the high speed behaviour of the rear shock (big hits). Turning the screw clockwise increases the hydraulic force (and vice versa).

Turn the screw 1 clockwise with a socket wrench until it stops and then back the number of clicks required.

Do not loosen the nut 2

High-speed compression setting	Comfort 2,5 turns
	Standard 2 turns
	Sport 1,5 turns

Adjusting the chassis (continued)

REBOUND DAMPER

The adjusting screw determines the Shock rebound behavior. Turning the screw clockwise increases the hydraulic force (and vice versa).

Turn the screw 1 clockwise to the stop then go back the number of clicks required.

Rebound damping	Comfort 15 clicks
	Standard 13 clicks
	Sport 11 clicks

SETTING THE DEPRESSION OF THE REAR SHOCK WITH NO LOAD

With the bike on an appropriate stand

Measure the dimension R1 between a fixed point on the chassis and the rear axle.

With the bike setting on its wheels

Measure the dimension R2 from the same fixed point on the chassis and the rear axle. The static deflection is the difference between R1-R2.

Static deflection 30mm

If the static deflection is not correct, adjust the preload of the shock (p.99)

SETTING THE REAR SHOCK SAG

With the rider on the motorcycle

Measure the dimension R3 between the same fixed point on the chassis and the rear axle. The sag is the difference between R1-R3.

Sag 95mm à 105mm

If the sag is not correct, change the spring. (p.99)

CHANGING THE PRELOAD OF THE SHOCK

Remove and clean the rear shock unit (p.108). Loosen the locking nut ①.

Loosen / tighten the adjusting nut 2 depending on the length required..

Indications	Loosening one turn	Decreases the ove- rall length by 3mm.
	Tightening one turn	Increases the overall length by 3mm.

Tighten the locking nut 1.

Reinstall the shock (p.109)

Recheck the settings (p.98)

CHANGING THE SHOCK SPRING

Remove and clean the rear shock unit (p.108)
Select and install a spring based on your weight.

Spring Rate
Rider Weight (with equipment) : 65-75kg 48N/mm
Rider Weight (with equipment) : 75-85kg 51N/mm
Rider Weight (with equipment) : 85-95kg 54N/mm

Reinstall the shock.

Adjust the sag (p.98)

Adjust the static deflection (p.98)

Chassis maintenance

REMOVING THE SADDLE

Turn the Dzeus fastner a quarter turn counterclockwise to release the saddle.

Remove the seat by pulling it towards the back of the bike.

REINSTALLING OF THE SADDLE

Install the saddle by sliding it forward, making sure that the slot 1 in the seat pan engages the post 2 in the reservoir. The three notches in the saddle must pass through the tabs on the subframe 4 that are provided for this purpose.

Lock the Dzeus fastner by turning it a quarter turn clockwise.

REMOVING THE AIR FILTER

The air filter is vital for the smooth operation of your engine. Maintenance is therefore essential.

A dirty air filter reduces the performance of your bike, increases fuel consumption and, at worst, impurities can pass into the engine and cause premature wear.

Remove the seat (p.100)

Unscrew the thumb screw 1

Remove the filter with the plastic carrier 2

Separate the filter from its plastic holder.

CLEANING THE AIR FILTER

Clean the foam air filter with a special liquid cleaner and let dry.

INFO

Do not clean the air filter with a solvent or gasoline.

Air filter cleaner Minerva air filter cleaner

INFO

Do not wring out the filter by twisting. Press only. Soak the air filter in an air filter oil.

Air Filter oil Minerva protect Air

If necessary clean the inside of the air box with a cloth.

REINSTALLING THE AIR FILTER

Reposition the filter on its support.

Be sure to engage on all six tabs.

Apply a film of grease on the face of the filter element.

Reinstall the filter and its support by taking special care to make sure it is centered. Refit the knurled screws 2.

Check to make sure the air filter is properly seated. Install the saddle (p.100)

Chassis maintenance (continued)

REMOVING THE FUEL TANK

Remove the seat (p.100)

Unscrew the fuel tank fixing screws 1.

Remove the hose that attaches to the fork crown 2

Disconnect the fuel pump electrical connector 3.

Remove the fuel hose by pressing the connector 4 and pulling on the hose 5.

ATTENTION

Attention, there is a risk of spraying fuel. do not put your face near the fuel line exit.

Prevent ingress of dirt in the gasoline fuel line. This can lead to a seizure of the injector.

Unscrew the screws 6 don the right and left radiator grill.

Remove the fuel tank by pulling upwards, provide lateral clearance by slightly moving the radiator grills. Use caution when removing the fuel tank and do not damage any of the fuel hoses or electrical connections.

REINSTALLING THE FUEL TANK

Reassembly of the fuel tank. Be sure to correctly position the throttle 1 and clutch cable 2.

Locate all of the fuel hoses / electrical connections under the fuel tank well.

Install the tank by moving the radiator guards away from the radiator to provide clearance for the fuel tank and makesure that all of the cables, wires and hoses are free, clear and not pinched. Check the adjustment of the radiator guards in relationship to the fuel tank.

Connect the fuel line 3.

Install the fuel tank mounting screws ④ along with their rubber inserts.

Install the radiator grill mounting screws.

Chassis screws M6 10Nm

Install the fuel vent hose.

Reinstall the saddle (p.100)

PURGING THE AIR FROM THE FORKS

After some time of operation, the air accumulates under pressure in the fork.

Every 5 to 10 hours (depending on the riding intensity), it should be purged. With the fork cold and fully extended, loosen and then retighten both fork caps.

Chassis maintenance (continued)

CLEANING THE FORK DUST SEALS

Place the motorcycle on a suitable stand.

Remove the front wheel (p.110)

Remove the fork protectors. Slide the dust cover down. Clean and lubricate the dust cover and the fork tube.

Lubrifiant universal Minerva F4

Reinstall the dust cover and clean off any left over oil.

Reinstall the fork protection.

Reinstall the front wheel (p.110)

Take the bike off of the stand.

CHECKING THE PLAY OF THE STEERING HEAD BEARINGS

Place the motorcycle on a suitable stand.

Exert a back and forth force on the fork legs.

There should not be any play in the bearings in any direction in the steering bearings.

If there is play and / or resistance, adjust and / or change the bearings.

Adjust the bearing free play (p.105)

Take the bike off of the stand.

ADJUSTING THE STEERING HEAD BEARING PLAY

Place the motorcycle on a suitable stand.

Loosen screws 1 and 2

Loosen or tighten the nut 3 to adjust the steering bearing play.

Steering nut M20 30Nm

Tighten the screws 1

SACHS top fork screws M8x35 12Nm

WP top fork screws M8x35 17Nm

Tighten screw 2

Top clamping screw M8x30 17Nm Loctite® 243^TM

Check the play of the steering head bearings. (p.104)

Remove the bike from the stand.

The bearings should be greased at least once a year with a good quality grease.

CLEANING THE CHAIN

Regularly cleaning the chain considerably increases its service life.

Clean the chain and apply chain lubricant.

Minerva Chain Cleaner

CHECKING THE CHAIN TENSION

Place the motorcycle on a suitable stand

Push the chain up and measure the chain movement as shown in the diagram.

Chain tension 50mm...53mm

If the chain tension is not correct, see how to adjust the chain. (p.106)

Otherwise, remove the bike from the stand.

ADJUSTING THE CHAIN TENSION

ADJUSTING THE LEVER

ATTENTION

Improper chain tension can cause mechanical damage.

Place the motorcycle on a suitable stand.

Loosen nut 1

Loosen the nuts 2

Loosen or tighten the screws 3 until you have the correct chain tension.

Chain tension 50mm...53mm

Monitor the symmetry of the two sides by observing the position of the marks 4

Tighten the screws 5

Tighten the nut 6

Rear axle nut M24 100Nm

Remove the bike from the stand.

NOTE

The sliding piece is designed to accommodate longer chains by turning it 180 degrees.

The position of the lever can be adjusted to meet the needs of the rider.

• Turn the knob B clockwise to move the lever closer to the handlebar.

• Turn the knob in the opposite direction to move the lever away from the handlebar.

Clutch lever free play A ≥3mm

CHECKING THE CLUTCH FLUID LEVEL

ATTENTION

• The hydraulic fluid is highly corrosive it can be dangerous to the skin.
• Read the recommendations on the container.

Position the master cylinder horizontally.

• Remove the two screws, the cover and the membrane
• Check the fluid level and fill if necessary.

Level of brake fluid below the top of the reservoir.	4mm
Minerva brake fluid DOT 4

• Reinstall the lid with the membrane and the screws.

REMOVING THE ENGINE PROTECTOR

Remove the screws 1 and remove the engine protector.

Chassis maintenance (continued)

REMOVING THE REAR SHOCK

Place the motorcycle on a suitable stand.

Remove the right side plate.

Remove the escape (p.90).

Remove the screws 1 and 2 and the muffler along with the intermediate exhaust pipe.

ATTENTION

Do not remove the muffler after operating the motorcycle. It can behot and there is a risk of being burned.

Remove the shaft 3.

Remove the screw 4

Remove the top screw of the shock.

Remove the shock from the top.

REINSTALLING THE REAR SHOCK

Install the shock from the top.
Install the top screw and tighten.

Upper shock screw

M10 40Nm Loctite® 2701

Position the rods and "H" link. Install the lower shock screw 1 and tighten.

Lower shock screw

M10 4ONm Loctite®2701

Install the lower shock shaft 2 and tighten.

Lower shock shaft M12 40Nm

Reassemble the exhaust, the 2 springs and the 2 "silent bloc".

Reassemble the rear silencer and loosely tighten screws using the nylock self-locking nuts.

Chassis screws M6 10Nm

Install right side plate. Remove the bike from the stand.

Wheels, tires

REMOVING THE FRONT WHEEL

Place the motorcycle on a suitable stand.

Remove the two screws 1 and the nut 2

Loosen the two screws 3

Pull the axle through the right side.

Remove the wheel from the fork.

ATTENTION

Do not operate the front brake lever when the front wheel is removed.

REINSTALLING THE FRONT WHEEL

Check that the brake disc is not dirty or contaminated with oil or grease. If it is, clean the disc with brake cleaner.

Brake cleaner

Minerva brake cleaner and degreaser

Install the spacer 1 on the left side of the wheel hub.

Install the front wheel in the fork and install the axle (grease the axle prior to installation).

Tighten the screws 2.

Fork screws M8 12Nm

Install and tighten the axle nut 3.

Front axle nut M20 25Nm

Tighten the screws on the right side of the bike.

Fork screws M8 12Nm

Operate the front brake lever several times until the pads touch the disc. Remove the bike from the stand and push down on the fork several times.

REMOVING THE REAR WHEEL

Place the motorcycle on a suitable stand.

• Unscrew the nut 1 and remove the adjuster. 2
• Tap the axle ③ out using a nylon hammer.
• Remove the axle.
• Move the wheel as far forward as possible.
• Remove the chain and wheel.

ATTENTION

Do not operate the rear brake pedal when the rear wheel is removed.

REINSTALLING THE REAR WHEEL

Check that the brake disc is not dirty or contaminated with oil or grease. If it is, clean the disc with brake cleaner.

Brake cleaner

Minerva brake cleaner and degreaser

Install the two spacers 1 and 2 and make sure they are positioned correctly.

Wheels, tires (continued)

Install the rear wheel in the swing arm and install the axle (grease the axle prior to installation)
Mount the chain.

Install the chain tensioner 1 and install the nut 2 but do not tighten.

Check the chain tension (p.105)

Tighten the nut 2.

Rear Axle nut M24 100Nm

Operate the rear brake pedal several times until the pads touch the disk.

Remove the bike from the stand.

CHECKING THE TIRE PRESSURE

Regularly check the tire pressure with a precision pressure gauge.

• Remove the valve cap.
• Check air pressure when the tire is cold.

Tire air pressure when used in rough terrain.

Front 0,9bar (13 psi)
Rear 0,9bar (13 psi)

If the pressure does not comply with the above table :

• Correct the pressure.
• Replace the valve cap.

CHECKING FOR WEAR AND DAMAGE

• Regularly check the depth of the tread.

Tread depth ≥ 3mm

If the depth is less than the value shown :

• Change the tire

Check for cuts, cracks, nails, sharp objects and bulges on the tire.

If the tire is damaged :

• Change the tire

• Changer le pneumatique

CHECKING SPOKE TENSION

Do not neglect the tension of the spokes.

ATTENTION

Proper tension ensures stability and secure riding.

• Check the spoke tension before and after each use of the bike, especially if the spokes are new or have been recently adjusted.
• Use a screwdriver to tap on each spoke. The sound must be sharp.
• If it is dull, take the bike to a SHERCO dealer to get the spokes properly adjusted.

Brakes

Pull the lever toward the handlebar and check the free play A

Free play of the front brake lever ≥3mm

If the free play does not meet the specification, do the following.

Set the free play using the adjustment screw 1

• Turn clockwise to decrease the free play.

• Turn it counterclockwise to increase the free play.

Make sure that the reservoir is in a horizontal position.

Check the fluid level through the sight glass. Ensure that the level is (between the arrows) it should be closest to the up arrow.

If the level is below the MIN mark, top up the brake fluid according to the instructions below.

• The hydraulic fluid is highly corrosive.
• It can be dangerous to the skin.

• Read the recommendations on the container.

• Remove the two screws 1.

Remove the cover 2 and the membrane 3.

Fill the reservoir with brake fluid to the correct level A.

Level of brake fluid below the top of the reservoir.	5mm
Minerva brake fluid

• Reinstall the membrane, the cover and the screws.

The position of the brake pedal can be adjusted as follows: loosen the lock nut 1 loosen or tighten the screw 2 to obtain the desired position.

Tighten the lock nut when the pedal is properly located.

Brake pedal lock nut M6 10Nm

Check the pedal travel (p.115)

CHECKING THE TRAVEL OF THE REAR BRAKE PEDAL

• Remove the spring 1
• Operate the pedal several times

Rear brake pedal travel

3mm≥ A≥ 5mm

• Replace the spring 1

If the travel does not meet the specification, refer to the rear brake travel adjustment. (p.116)

Brakes (continued)

ADJUSTING THE TRAVEL OF THE REAR BRAKE PEDAL

• Remove the spring 1
• Loosen the nut ② and turn the shaft 3

Rear brake pedal travel

3mm≥A ≥5mm

Hold the shaft 3 and tighten the nut 2.

Nut 2

M6 10Nm

• Reinstall the spring 1

Position the motorcycle on a flat surface.

Check the fluid level through the sight glass. Ensure that the level (between the arrows) is closest to the up arrow.

If the level is below the MIN mark, top up the brake fluid according to the instructions below.

Remove the cap 1 with its membrane 2.

Fill with fluid to the mark as shown A

Minerva brake fluid DOT 4

• Reinstall the membrane and the cover using a new O-ring.

REMOVING THE FRONT AND REAR BRAKE PADS

• Remove the clip ① and retaining pin ②.
• Remove the brake pads.

Do not operate the front brake lever or rear brake pedal when the brake pads are removed.

CHECKING THE CONDITION OF THE BRAKE PADS

Check the pads for wear

Minimum pad thickness

A ≥1mm

If replacement is necessary, always change the pads in pairs.

REINSTALLING THE FRONT AND REAR BRAKE PADS

Check that the brake discs are not contaminated with oil or grease. In they are, clean the discs with brake cleaner.

Brake cleaner

Minerva brake cleaner and degreaser

Brakes (continued)

Install the new pads.

Reinstall the retaining pins 2 and clips 1

Check the brake fluid level and fill if necessary. (p.114 et p. 116)

ATTENTION

Do not use the bike until the brake lever and the pedal are operational. «Pump» the brake lever / brake pedal up and down until the brake pads are in contact with the discs.

Electrical system maintenance

REMOVING THE BATTERY

Turn off all electric devices and stop the engine.

ATTENTION

• 250-300 SE (standard): Confirm that the key start is in the OFF position.
• 250-300 SE/R (racing): Confirm that the on / off switch is in the OFF position.

Risk of damage to the CDI.

• Remove the seat (p.100)
• Remove the air filter (p.100).
• The battery is located at the bottom of the filter housing.
• Remove the two screws that retain the battery retaining bracket.
• Disconnect the negative cable from the battery ②.
• Disconnect the battery positive cable 3.
• Remove the battery from the top.

Electrical system maintenance (continued)

REINSTALLING THE BATTERY

CHARGING THE BATTERY

• Insert the battery into place.
• Connect the positive cable to the battery.
• Connect the negative cable to the battery.
  Install the battery retaining bracket and tighten the two screws 1.

Chassis screws M610Nm

• Check the positioning of the battery cables to make sure that they do not interfere with the installation of the air filter.
  -Replace the air filter (p.101).
  -Replace the saddle (p.100).

The battery is a maintenance-free type. If the vehicle is not used for an extended period, it is recommended that the battery be disconnected and stored in a dry place. See removing the battery (p.118)

Check the voltage of the battery with a voltmeter :

Battery voltage >12.5V

If the voltage is below the specification, remove the battery and recharge it using a battery charger.

Battery charging (12V)

0.5 A for 10 hours or 5A for 30 minutes

Disconnect the charger after charging. Install the battery (p.119).

Electrical system maintenance (continued)

REPLACING THE MAIN FUSE

Remove the seat (p.100)

The main fuse 1 is on a relay by the starter.

Remove the defective fuse and replace with a new fuse of the same value.

Main fuse 30A

Put a new spare fuse in the reserve location in the fuse box.

• Replace the saddle (p.100).

REPLACING THE FUSE FOR THE LIGHTS (250-300 SE/R)

Remove the seat (p.100)

The light fuse 1 is located in a high location on the wiring harness on the right side of the bike.

Remove the defective fuse and replace with a new fuse of the same value.

Light fuse 15A

-Replace the saddle (p.100).

REMOVING THE HEADLIGHT HOUSING

Turn the ignition to the off position.

Unclip the left and right rubber fastners 1 on each side of the fork.

Separate all of the brake hoses / cables from the meter bracket at the top and bottom.

Move the top plate up to clear the housing.

Disconnect the connector 2 and remove theheadlight housing.

REINSTALLING THE HEADLIGHT HOUSING

Connect the electrical connector.

Engage the light plate, ensuring that the holes in the plate 1 are in place 2.

Place all of the brake hoses / cables in the interior of meter upper guide 3.

Attach the rubber fastners.

Check the setting of headlight beam. (p.122)

REPLACING THE HEADLIGHT BULB OR THE PILOT LAMP

Remove the headlight housing assembly (p.120)

Remove the protective rubber 1

Turn the socket a quarter turn counterclockwise to remove it from the headlight assembly.

Gently press the bulb in while turning it counterclockwise and remove it from the socket.

Install a new bulb 2.

Headlight bulb S2 12V 35/35W S2

Reinstall the socket with the bulb in the headlight assembly by turning it in a clockwise direction.

Reinstall the protective rubber.

To replace the pilot light 3 simply remove the socket from the reflector 2.

Pilot light W5W 12V 5W

Reinstall the headlight housing assembly (p.121)

Electrical system maintenance (continued)

ADJUSTING THE HEADLIGHT BEAM

The headlight beam is adjusted with the motorcycle in a state of operation with its driver seated on the saddle.

To set the headlight beam, tighten or loosen the screw at the base of the headlight housing.

Tightening the screw 1 raises the headlight beam.

Loosening the screw ① lowers the headlight beam.

REPLACING THE MOTORCYCLE COMPUTER BATTERY (250-300 SE/R)

1. Remove the headlight housing (p.120).
2. Remove the turn signal flasher in order to access the motorcycle computer screws.
3. Remove the screws and remove the computer to get it out of the way.
4. Disconnect the main connector from the computer
5. Open the dashboard with a coin.
6. Install a new battery (with the marking up).

Computer battery CR 2032 3V

1. Replace the cover, taking care not to damage the O-ring.
2. Plug the main connector into the computer.
3. Install it on the bike and check to make sure the meter works.
4. Reinstall the computer support.
5. Install screws and replace the turn signal flasher.
6. Replace the headlight housing (p.121)
7. Set the computer (p.81)

Washing and storage

WASHING THE BIKE STORING THE BIKE

SHERCO advises you to wash your 250-300 SE/R as often as possible in order to maintain it in good working order and prolong its life.

1. Cover the end of the exhaust silencer and the air filter (plastic bag, special cover or a special cap).
2. To degrease the engine, apply a degreaser, clean with a brush then rinse the engine with a water hose.
3. Wash the rest of the vehicle with hot soapy water.
4. Rinse with clear water.
5. Dry with a chamois or a clean, soft cloth.
6. Clean the chain and lubricate it with a special chain lube.
7. When the cleaning is finished, remove the air filter and exhaust protection, Start the engine and let it run at idle for a few minutes.

Avoid using high pressure equipment which may cause water to leak into the bearings and fork seals and cause serious damage. Use an average strength detergent rather than a strong detergent.

Before storing the vehicle Long-Term (more than 2 months), follow these instructions :

1. Wash the whole bike.
2. Empty the fuel tank.
3. Remove the spark plug and inject a protective spray inside the engine through the hole in the cylinder. Install the spark plug. Cycle the engine a few revolutions to apply a protective film on the cylinder walls.
4. Remove the battery (p.118)
5. Charge the battery (p.119)
6. Lubricate all cables with a spray lubricant.
7. Jack the motorcycle up so that the wheels are off the ground.
8. Cover the exhaust outlet with a plastic bag to prevent moisture from entering.
9. Spray a protective oil film on all unpainted metal surfaces of the motor and also on the electrical wiring.
10. Cover the motorcycle with a cover.

RECOMMISSIONING AFTER STORAGE

Reinstall the battery (p.119)

Fill the fuel tank.

Perform lubrication and maintenance (p.125) Perform a road test.

Maintenance schedule

Maintenance	After 5 hours	Every 20 hours
ENGINE
Change gear box oil	●	●
Check the valves and booster system	●	●
Replace spark plug (after 50 hours)
Check the valves cables and check the setting	●	●
CARBURATOR
Clean the carburator and emptying float chamber		●
ACCESSORIES
Check cooling system for leaks	●	●
Check sealing and attachment of the exhaust	●	●
Check status, flexibility and position of the cables, adjust and lubricate	●	●
Check oil level in clutch master cylinder	●	●
Clean air filter and housing	●	●
Check status and position of the electrical wiring	●	●
Check function of electric components (headlight/tail/stop turn signals, computer control unit, etc.)	●	●
BRAKES
Check brake fluid level, brake pad thickness and the brake discs	●	●
Check status and sealing of the brake lines	●
Check status, of the foot brake pedal and hand brake lever	●	●
Check tightness of brake system fastners and discs	●	●
CHASSIS
Check for leaks and function of fork and shock	●	●
Clean the dust covers		●
Purge air from the fork legs		●
Check general tightness of bolts and screws		●
Check / adjust steering head bearings	●	●
WHEELS
Check rims and spoke tension		●
Check condition of the tires and tire pressure	●	●
Check chain, sprockets, guides, chain tension	●	●
Lubricate the chain	●	●
Check wheel bearing clearance	●	●

ANNUAL MAINTENANCE

Major maintenance items that should be performed by the dealer	Au moins 1X par an
Fork	●
Shock	●
Clean and grease steering head bearings and seals	●
Replace fiberglass in the muffler	●
Treat electric contacts and switches with an aerosol protector	●
Replace the clutch hydraulic fluid	●
Replace the brake fluid	●
Checks and major maintenance to be performed by the rider	Before each use	After each use
Check the engine oil level	●
Check brake fluid level	●
Check status of the brake pads	●
Verify operation of the lights	●
Verify operation of the horn	●
Lubricate throttle cable		●
Regularly purge the air from the fork legs		●
Regularly clean the fork dust seals		●
Clean and lubricate chain, check tension and adjust if necessary		●
Clean air filter and box		●
Check tires and tire pressure	●
Check the coolant level	●
Check fuel lines for leaks	●
Check status of all the controls	●
Check the brakes	●	●
Spray anti-corrosion protector on all non painted parts (except for the brake parts and the exhaust system)		●
Spray protector on electrical switches		●
Check tightness of nuts, screws and clamps		●

ATTENTION

In competition you have to perform the 20 hour maintenance schedule after each race!

This should not be exceeded by more than 2 hours.

The services performed by the Sherco dealer do not replace routine service and maintenance by the rider!

Maintenance schedule (continued)

IMPORTANT CHECKS AND MAJOR MAINTENANCE ITEMS THAT SHOULD BE PERFORMED BY THE SHERCO DEALER

Competition use	At 10H	At 20H	At 40H	At 80H
Recreational user	At 20H	At 40H	At 80H
Check the clutch disc wear		●	●
Check the length of the clutch springs		●	●
Check that the clutch nut is not loose			●	●
Check that the clutch housing is not loose			●	●
Check the wear of the cylinder and piston			●	●
Replace the piston 300			●
Check the good working of valves and boosters			●	●
Check the run-out at the end of the crankshaft			●	●
Check the condition of the connecting rod			●	●
Replace the big end bearing			●	●
Replace the crankshaft bearings			●	●
Check all of the gearbox components for wear			●	●
Check the reed valve petals			●	●
Replace fiberglass packing in the muffler	●	●	●

Torques

ENGINE TIGHTENING TORQUES
Drain Plug M16 15Nm
Sparkplug (apply grease to the copper washer) 15Nm
Water pump housing screws M6 10Nm
Clutch cover screws M6 8Nm

CHASSIS TIGHTENING TORQUES
Shock screw lock nut M5 5Nm
Other chassis screws M6 10Nm
Other chassis screws M8 24Nm
Disc brake screws front / rear M8 24Nm Loctite			® 243TM
Crown screw M8 23Nm
Handlebar clamp fastening screws	M8 25Nm
Sach fork upper screw	M8 12Nm
WP fork upper screw	M8 17Nm
Sachs lower fork screw	M8 15Nm
WP fork lower screw M8 12Nm
Upper screw	M8 17Nm
Fork pinch bolt screw M8 12Nm
Side support screw	M8 25Nm Loctite	® 243TM
Other chassis screws	M10	40Nm
Handlebar fixing screws	M10	40Nm Loctite	® 243TM
Top shock screw	M10	40Nm	Loctite® 2701
Lower shock screws	M10	40Nm	Loctite® 2701
Motor mounting bolts M10 40Nm
Suspension delta / H link bolts	M12	40Nm
Swing arm pivot bolt	M16	100Nm
Front wheel nut M20 25Nm
Steering shaft nut	M20	30Nm
Rear wheel nut	M24	100Nm

INDEX

SHERCO

FRANCÉSP.1
■INGLES P.68
ESPANOL P.135

DEFYGRAVITY

SHERCO

Characteristicas techniques

DIMENSIONES

Interruptor luz on/off (250-300 SE/R)