SE2.5iF (2009) - Motorcycle Sherco - Free user manual and instructions

USER MANUAL SE2.5iF (2009) Sherco

ENGLISH P.49 P.9550 INTRODUCTION Thank you for the confidence you have shown in SHERCO by buying one of our products Congratulations! You are now the owner of a 2,5i / 3,0i SHERCO Motorcycle. You will enjoy many miles or riding pleasure if you follow the instructions in this manual and obey the local vehicle codes. This manual explains the operation, inspection, basic maintenance and upkeep of your SHERCO. Should you have any questions on the content of this manual or on your bike, please contact your SHERCO dealer. We recommend that you read and understand everything in this manual before you ride your motorcycle. In order to keep your SHERCO in perfect condition it is necessary that you follow the maintenance procedures described in this manual. (The vehicle you have bought may differ slightly from the vehicle shown in this manual). SHERCO reserves the right to make any modifications without prior notification.ENGLISH

4. Front turn signal

10. Left rear view mirror

Record the numbers of the ignition key and vehicle serial numbers in the appro- priate places. Ignition key number Vehicle serial number Engine type and number

1. The vehicle serial number 1 is stam-

ped on the right hand side of the stee- ring column. Engine type and number

2. The engine number 2 is stamped on

the top of the oil filter box.

Key Number56 CONTROLS Clutch lever The clutch lever 1 is on the left side of the handlebars and has an adjustment screw A Front brake lever The front brake lever 2 is on the right side of the handlebars and has an adjustment screw B Left handlebar control switch

1. Headlight (high beam)

2. Headlight (low beam)

CONTROLS Main electrical switch The switch has two positions Position 1. The engine is off and can- not be started Position 2. The engine can be started Dashboard

3. Push in to cancel

Twin ignition mapping switch Position 1. Curve “soft” Position 2. Curve “hard”

Side Stand Remove the safety rubber 2 , press on the stand with your foot, and keep in this position until stand supports full weight of bike. The side stand has a safety system that automatically folds it back as soon as the bike is moved into the upright position. The side stand is designed to support the motor bike alone.

1. Turn lights (green)

2. Hight beam (blue)

Dashboard functions Speedometer Current speed function. (Km/h) TOTAL Total distance function. (Km) TD Automatic trip function. (Km) AVE Mean speed (Km/h) LAP Time meter MAX Maxi speed (Km/h) CTDWN Countdown (Km) HPERC Operating Time (h) RPM RPM sensor (Tr/min) TOTAL TD AVE LAP MAX CTDWN HPERC RPM STDBY Button pulsations Current speed function This function describes the function/ display of current speed. If the measu- rement unit selected is k.p.h. (default value), the relative digit is displayed; by pressing the button and gaining access to the Set-Up menu, it is possible to select m.p.h.; in this case, the speed indication will not be accompanied by any text showing the unit of measure- ment selected.. Fig1 Current speed function60 Total distance function This function describes the function/ display of the total distance traveled. The information depending on the unit of measurement selected, the figure is shown in kilometres (default value) or miles. In normal conditions of use of the instrument, it is not possible to zero this information. The maximum figure that can be displayed is 99,999 km. (or miles); once this is exceeded, the counter is reset to zero. The figure shown increases by integer values of 1 km. /mile. TRIP function automatic TD This function describes the function/dis- play of the unit's automatic trip function ; the figure shown represents the dis- tance run by the bike expressed in kilo- metres or miles (depending on the unit of measurement selected), with a reso- lution of 0.1 (kilometres or miles); this counter is automatic: it is activated by the first impulse from the speed sensor. The figure is not saved permanently. It is possible to zero the counter associa- ted with this parameter by pressing the button (below the TD function) for about 3 seconds until the value 000.0 appears. The zeroing of the TD can be effected both while stationary and whilst moving, and also zeroes the LAP function. If the figure exceeds 999.9, the system will automatically zero the TD and LAP, and will then restart the trip. Fig2 TOTAL function Fig3 TD functionENGLISH

AVE Function Mean speed This function determines your mean speed. A pressure of 3 sec on the button initia- lizes the mean speed to 0. LAP function Automatic chronometer This function describes the function/display of the chronometer associated with theTD. The figure displays the time lapse of the bike (in mm:ss format if hours = 0, and in hh:mm format if hours > 0), associated with the TD parameter It is therefore an automatic counter: It is automatically activated with the first impulse from the speed sensor (when LAP is opera- tive, the digit separating hours and minutes, and minutes and seconds, flashes, and is displayed fixed when LAP is not operative), and stops 3 seconds after reception of the last impulse sent by the speed sensor. The data is not saved permanently to memory. It is possible to zero the counter associa- ted with this parameter by pressing the button (below the LAP function) for about 3 seconds until the value 00'00" appears. The zeroing of the LAP can be effected both while stationary and whilst moving, and also zeroes the TD function. If the figure exceeds 23-59 (that is 23 h 59 min and 59 sec), the system will automatically zero the LAP and TD, and will then restart the trip function. MAX function Maxi speed This function shows the maximum speed of the vehicle. A pressure of 3 sec on the button initializes the mean speed to 0. Fig4 AVE function Fig5 LAP function Fig6 MAX function62 TRIP function Automatic trip Countdown This function describes the function/dis- play of the unit's countdown trip func- tion. The counter is always active and counts down with a resolution of 0.1 (kilometres or miles depending on the unit of measurement selected). It is possible to modify the value asso- ciated with this parameter by pressing the button (below the TD function and whilst stationary) for about 3 seconds until only the segments relative to the countdown function and the letters TD (still flashing) are active, while all the other segments are switched off, as shown in Fig.8 It is possible to modify the different figures in the counter, starting with the largest figure and moving successively to the lesser one; depending on the data selected (shown flashing with f=1Hz, Duty=50%), a brief pressure on the button will decrease the figure by one, while a longer pressure will enable the selection of a different parameter. Once the adjustment has been finished, normal operation mode is activated by pressing the button for about 3 seconds while the lesser figure is selected. If the figure counts down to 000.0, the system will Re-initialize the value at 999.9. Fig7 Trip functon Fig8 Parameter countdown function.ENGLISH

HPERC function Operating Time (hours) This function makes it possible to visuali- ze the operating hours of the vehicle. It is not possible in normal time to modify this value or to give to zero this information. The representable largest value is 9.999 hours, exceeded such a value, the meter east gave to zero. Fig9 HPERC function RPM function RPM engine This function makes it possible to visua- lize in real time, the engine speed in tr/min. Set up Adjustement of wheel circumference The modification to the wheel circumfe- rence, units of measurement and number of wheel impulses can only be effected while stationary, maintaining the button pressed under the TOD function until the only information displayed is the wheel circumference and all the other seg- ments are off (see Fig.11). It is possible to modify the various figu- res constituting the value for the wheel circumference, starting with the largest figure and moving successively to the lesser one; depending on the digit selec- ted, a brief pressure on the button will increase the figure by one, whilst a lon- ger pressure will enable the selection of a different figure. Fig10 RPM Function Fig11 set up adjustement of wheel circumference ENDURO Set up: 2191 SUPERMOTARD Set up: 185564 Fuel tank cap Opening: Turn the cap counterclockwise Closing: Turn the cap clockwise Fuel Only use unleaded fuel with an octane index of a least 95 or 98 FUEL NOTE

Do not fill to the brim as fuel increases in volume as it gets hotter.ENGLISH

- Do not check when the engine is hot as the hot liquid can cause severe injuries. - Cooling liquid is poisonous: - In the event of contact with the skin or the eyes, or ingestion, or injuries cau- sed by hot liquid:

- Use protective gloves. - Do not replace cooling liqid by water: It could damage your bike engine . - Always use pre-mixed coolant With the engine cold check the cooling fluid level and top up if necessary.

- Bike is on side stand (on left) - unscrew radiator bleed screw 2 - Adjust the level until liquid get out without air - Replace screw 2 tight at 8Nm - Take again the operation above for control level - Check that the cooling liquid level is approximately 10mm above the radiator tubes. - Replace the cap 1 and make sure it is seated correctly It is extremely important to follow these instructions carefully. Incorrect coolant levels can cause serious damage to the engine.

Bike on side stand Bike is on a horizontal surface WARNING L66 ENGINE OIL Checking oil level - Make sure that your bike is on its two wheels, vertical and on a horizontal surface. - Through the clutch sump window, check the level of engine oil as shown in diagram 1 Adjust the level if necessary - Unscrew the filler cap 2 on the clutch engine oil sump, - Top up using engine Minerva recom- mended by Sherco Level with engine warm Level with engine cold WARNING

- Wrong level of oil can damage your engine - Do not use your bike if the level is below the minimum

Checking the front and rear brake fluid level - With the brake reservoir in a horizontal position, the brake fluid should be able to be seen in the observation window - The fluid should be between the two arrows as shown in the diagram below. It should be nearest to the upper arrow. Topping up the front and rear brake fluid - Hydraulic fluid is highly corrosive, it can be harmful to the skin. - Please read the recommendations on the container carefully. - Loosen the two screws - Remove the cap and its diaphragm. - Fill the reservoir with DOT4 brake fluid - Replace the diaphragm, the cap and the two screws WARNING K68

CHECKING CLUTCH HYDRAULIC FLUID LEVEL

Checking the level - Place the master cylinder horizontally - Check the level through window. The level should be between the two arrows Adjust the level if necessary Topping the clutch hydraulic fluid level - Loosen the two screws - Remove the cap 2 and its diaphragm - Fill the reservoir with DOT4 fluid - Replace the diaphragm, the cap and the two screws - Hydraulic fluid is highly corrosive - It can de harmful to the skin. - Please read the recommendations on the container. Tire pressure

1. Check the tire pressure on a reguar basis

with an accurate tire pressure gauge.

2. The tire pressure must comply with

the chart shown page 95 Tire wear and damage

1. Check the tire pressure on a reguar

basis with an accurate tire pressure gauge.

2. If the tread depth is less than 2 mm it

is mandatory that the tire be replaced.

3. Check the tires to make sure that

they do not have any cuts or bulges.

4. If there is a lot of damage to the tires

it is mandatory that you replace them.ENGLISH

Do not forget to check the tension of the spokes Checking the front and rear brake pads Wear on brake pads should be checked regularly for the sake of your safety Under no circumstances should it be less than one millimetre thick. Min. thickness = 1 mm If you should need to replace it please approach your Sherco dealer WARNING

Correct tension ensures stability and safe riding. - Check before and after each time you use your bike, especially when it is new or if any of the spokes have been changed. - Using a screwdriver, gently tap each spoke. The sound should ring clear - If the sound is flat, you will need to get your spokes tensioned at a Sherco-dealership70 RIDING POSITION WARNING

Throttle control - The throttle control has two set- tings: slow action or quick action To change the setting - Reverse the cable position 1 on the throttle twist grip 2 Quick action: “CROSS” side of the axis of the bike Slow Action: “ENDURO” side of the axis of the bike Clutch lever adjustment - The screw 1, allows you to adjust the position of the lever. - If you turn it clockwise the lever moves away from the grip. - If you turn it counter clockwise the lever moves closer to the grip. Handlebar position adjustment - The bike comes with the handlebars in the forward position. To change to the rear position: - Remove the handlebar - Loosen the bottom bolts - Turn the asymétricclamps around 180°. - The handlebar can also be directed respect to handlebar clamps. At rest the screw should have in pressu- re on the piston. Leave free play (move- ment) minimum of 1 mm

Bike on a suitable stand Lift the chain as shown Adjusting the brake pedal position - The free travel of the brake pedal must be 3 mm as minimum. - Loosen the locknut 2 - Turn the stem 1 until you achieve the desired result. - Re-tighten the locknut 2 Free position - The upper extremity of the brake pedal should be located at approximately 15 mm below the upper part of the foo- trest. 15mm 15mm WARNING

Poorly adjusted chain tension can lead to mechanical damage The position of the chain must be close to that represented on the picture.72

Chain tension adjustment To adjust the chain tension - Loosen bolts 3 and 1 - Loosen the screws 2 until the chain is correctly tensioned. - Check the symmetry on either side of the arm using the marks 4. - Tighten the bolts 1 - Tighten the bolt 3 The sliding part is designed to adapt to the longest chains by turning it through 180°.

The bearings must be lubricated at least once a year with grease You will need to check the steering fre- quently for your safety - To do this, loosen all of the bolts mar- ked 1. - Tighten the steering stem nut 2 untill there is no more play in the bearings. The steering should still turn freely and not bind. - Do not tighten so much that the stee- ring will not turn freely. - Re-tighten all of the 1 bolts (torque 24Nm) - Finish by tightening nut 2 WARNING

FORK Fork rebound adjustment The screws 2 determine the behaviour of the forks in the rebound mode. Turning them clockwise increases the rebound and vice-versa. Standard adjustment: Turn clockwise to the stop, then back off 12 clicks Fork compression adjustment The screws 1 determine the behaviour of the fork when compressed. Turning them clockwise increses the compres- sion and vice-versa. Standard adjustment: Turn clockwise to the stop, then back off 14 clicks Fork air purge After a period of operation, air pressure builds up in the fork. Every 5 to 10 hours of use (depending on intensity), you will need to bleed the air. With the forks cold, fully extend the fork, remove and then replace and tighten each screw 3 on both fork caps.

SHOCK ABSORBER Shock absorber compression Toothed wheel 1 controls fast compres- sion (major impacts) Screw 2 controls slow compression (sensitivity). turning them clockwise (+) increases the compression and vice-versa. Standard adjustment Toothed wheel: Turn clockwise to the stop, then back off 12 clicks Screw : Idem Checking play in link rods With the bike supported by a suitable stand, press the top and bottom of the back wheel. If any play is found, please contact your Sherco dealer. Shock absorber rebound - The rebound is adjusted by turning the black ring 3 at the base of the shock absorber There are 10 adjust- ment possibilities - If you require a softer rebound, turn the black ring in the direction of the arrow marked (-). - If you require a firmer rebound, turn the black ring in the direction of the arrow marked (+). Standard adjustment: Turn clockwise to the stop, then back off 7 clicks

Pre-load adjustment of the rear shock absorber spring To adjust the rear shock absorber spring pre-load

Adjust with precision pre-load of the rear shock absorber spring

Bike supported by a suitable stand - Measure the R1 dimension enters a fixed point of the frame and the axis of the wheels

2. The bike on 2 wheels

- Measure the R2 dimension enters the same fixed point of the frame and the axis of the wheels - Set spring preloading in order to have: R1 - R2 = 30mm

3. The pilot on bike

- Measure the R2 dimension enters the same fixed point of the frame and the axis of the wheels - Set spring preloading in order to have: R1 - R3 = 95mm IMPORTANT

- It is preferable to respect the dimen- sion of 30mm. - If the dimension of 95mm is not res- pected, it is possible to change the stiffness of the spring to reach correct measure.ENGLISH

SAFETY RECOMMENDATIONS - Never ride after drinking alcohol. - Wear an approved helmet when riding. - Keeping your machine in good working order and maintaining it correctly increa- ses its reliability and safety during use. - Petrol is inflammable, fill the fuel tank when the engine is not running. - Exhaust fumes are toxic, never run the engine in an enclosed area. - Always park the vehicle on a hard flat surface, do not park on a slope or soft sur- face. Always check that the bike is balanced. - Before taking to the road each day, please check the following: - Tires Wear and pressure - Engine oil Level (page 82) - Fuel Level + Absence of leaks - Secondary drive chain Tightness (page 71) - Steering Not blocked - Brakes Operation, play, no brake fluid leaks and that the brake pads are serviceable (pages 69 and 71) - Throttle control Play (page 70) - Clutch Play (page 70) - Electrical equipment Operation of horn and lights (page 86) - Fixings (nuts, bolts, etc.) Check that all vehicle components are well secu red (page 95) If, during these checks, you find a fault, consult the Maintenance and Adjustments Chapter in this manual or contact your Sherco dealer.78 RIDING Cold start

1. Turn the ignition key to start position (on the right).

2. Using the gear shift lever place the transmission in neutral

3. Start the motor by pressing on the start button, without accelerating.

4. Let the engine warm up for a few minutes.

Warm start Follow the previous instructions but omit step 4. - Accelerate the engine slightly after it starts Changing gears - The gear shift lever positions are shown page 58 - To find neutral, push down on the pedal until it is in first gear (you will feel a resis- tance to further movement). Lift up slightly on the pedal.

1. Close the throttle and pull in the clutch lever.

2. Step on the gear shift lever.

3. Smoothly open the throttle and slowly release the clutch lever.

4. Once you have reached the proper speed, shift into the next higher gear.

Parking - Stop the engine and remove key. Give yourself time to learn the controls and their functionsbefore using the vehicle.ENGLISH

3. Speedometer fuse (5A)

- Always use fuses with the right ampe- rage - If a fuse repeatedly blows, please con- sult yourSherco dealer.

Cleaning the air filter To access the air filter : - Loosen screw 1 on the seat by a quar- ter turn counter clockswise. - Pull the seat back towards the back of the bike. The air filter is vital to the correct operation of your bike, so it is important to take good care of it. A clogged air filter reduces the performance of your bike, increases fuel con- sumption and at the worst, dirt can enter into your engine and cause premature wear and tear. Press part 3 towards the filter 2 to remove part 3 from his support.

- Remove the filter with its housing. - Separate the filter from its housing. - Clean the filter foam with a suitable detergent. (NEUTRAL) Do not use solvent or petrol ! - Dry the filter element. - Spray the air filter with air filter product oil until it achieves a uniform color. - Replace the filter element in its housing with care Make sure that the three lugs 4 are properly located - Apply a thin film of grease to the air filter seal. - If necessary clean the inside of the air chamber with a cloth. - Replace the filter and its housing, taking care to centre it correctly. - Replace the blocking part 3 (See previous page) by inserting it first into the filter assembly and then into his support. - Replace the seat forwards, making sure that the recess 5 is located in the tab 6 of the tank and the tongue is under the tank. - Lock the screw by turning it one quar- ter turn clockwise.

OIL CHANGE - Position the bike vertically on a hori- zontal surface. - Place a container under the bike to catch the old oil. - Unscrew the drain plug 1 - Unscrew the drain plug 2 - Remove the pre-filter 3 - Let the oil flow out - Unscrew plug 10 - Remove oil filter 11 (see next page). - Let the oil flow out - Clean the plugs 1 and 2 with solvent - Clean and inspect the pre-filter 3 and change it if necessary

The oil should be changed when the engine is warm. WARNING

Use protective gloves. The plugs must 1 and 2 have new seals 4 and 5 when they are replaced. Remove oil filter - Unscrew screws 6 and remove drive sprocket cover 7 - Unscrew screws 8 (differents lenghts) and remove chain guide 9 - Unscrew plug 10 - Remove the filter 11 with an hookENGLISH

OIL CHANGE Filling engine oil - Fit a new oil filter, in the correct direc- tion, as shown on photo. - Replace the cap 10 and screw to 15Nm - Replace the plug 2 and screw to 22Nm - Replace the pre-filter 3 and the plug 1 as shown on photo - Tighten the plug 1 to 35 Nm - Unscrew the engine oil filler cap num- ber 2 page 66 - Pour in approx. 1 litre of oil recommen- ded by the manufacturer. - Check the level of oil through window as explained on page 66. - Top up the level if necessary

To protect the environment, old oil and filters should be deposited at a collection center. NOTE The filter 11 must be replaced after every oil change. Torque Plug 1 22Nm Plug 2 15Nm Plug 10 15Nm

To protect the environment, deposit your purged liquid at a collection center WARNING

- Place a container under the bike - Remove the cap 1and the screw 3 - Let the liquid flow out - Replace the screw 3 with a new washer - Tighten to 8 Nm Make sure that your bike is vertical and on a horizontal surface. Filling - Loosen the bleed screw 2 on the left radiator - Fill new coolant through the radiator filler 1 - As soon as liquid runs through the screw 2 without bubbles - Replace the screw with a new washer and tighten to 8Nm - Continue filling - Once the level is reached (approx. 1,1 litre) - Put the bike standing on the side stand and recover the operations described in page 65 VidangeENGLISH

BATTERY To access the battery - Remove the seat and the air filter. See page 80 - The battery is housed at the bottom of the filter box - Always start by disconnecting the earth terminal (-). - Check the battery voltage when idle using a voltmeter. - The voltage should be higher than 12,7V. - If it is less, recharge the battery at 0,5 Ah for a maximum of 10 hours. - Replace the battery by reversing the procedure. WARNING

Always use the battery that is recom- mended by the manufacturer. It is specifically equipped by Sherco with special protection. Do not cross over the terminals. This can damage the electrical circuit86

REPLACING A LIGHT BULB

Replacing a headlight or driving light bulb - Remove the rubber protection 1 - Turn the pin 2, - Withdraw the headlight unit. - Press lightly on the bayonet bulb - Turn counter clockwise to remove. - Reverse the procedure to re-assemble. - The driving light 3 is easily replaced by removing the bulb holder from the reflector Removing the headlight plate The headlight plate can be removed very quickly. - Unclip the left and right rubbers either side of the forks - Release the headlight plate upwards.. Reassembling the headlight plate - Reverse the removal procedure. - Make sure that the lugs 4 on the headlight plate are securely in the holes 5 in the front mud guard. WARNING

Always use bulbs with the right wattage.

REMOVING AND REPLACING THE FRONT WHEEL

To remove the front wheel - Unscrew the two screws 1 and nut 2 - Loosen the two screws 3 - Remove the axle from the right side - Remove the wheel Check that the screws 1 and 3 and the nut 2 are fully tightened - Degrease the disc with solvent - Prime the brake Torque Refer to table page 95 To replace the front wheel - Reverse the procedure. greasing the axle, with grease.88

REMOVING AND REPLACING THE REAR WHEEL

To remove the rear wheel - Unscrew nut 1 and remove the sliding

- Tap the axle 3 with a nylon mallet - Remove it, - Move the wheel as far forward as possible - Remove the chain and the wheel. To replace the rear wheel - Reverse the procedure, greasing the axle, with grease. - Degrease the disc with solvent Brake cleaner - Prime the brake Check and make sure that you have pro- perly tightened the rear axle by ushing it forward. NOTE

REMOVING AND REPLACING THE FUEL TANK

To remove the fuel tank - Unscrew the tank's central screw 2 - Unscrew the right and left lower inlet screws 1 - Disconnect the fuel pump's wiring har- ness pin 3 - Loosen the two hose clamps securing the fuel supply hose 4. - Disconnect the fuel supply hose. Wear appropriate eye protection, gloves and use a cloth - Drain any remaining fuel into the cloth - Lift the tank upwards. In the event of fuel being splashed into the eyes or swallowed

This operation should be performed when the engine is cold90 Fuel tank replacement - Reverse the removal procedure - Make sure that the throttle and clutch cables are correctly located, as shown in photo - Reconnect the fuel supply line. - Make sure you hear the connector “click” into place - Reconnect the fuel pump's wiring har- ness. - Replace the 3 screws and refit the seat Using a flat bladed screwdriver - Carefully remove the spring - Carefully remove the dust seal - Clean thoroughly taking care to not damage the rubber - Replace the dust seal - Replace the spring

CLEANING AND STORAGE

SHERCO recommends that you clean your new SHERCO 2,5i / 3,0i on a regu- lar basis in order to maintain its appea- rance and prolong its life.

1. Cover the exhaust outlet and the air

filter intake with an appropriate cover. (a piece of plastic with a rubber band will work)

2. To clean the engine, apply a good

quality degreaser, scrub with a brush and then rinse the engine with a water hose.

3. Wash the motorcycle first with a gar-

3. Wash the rest of the vehicle with hot

4. Rinse with water.

6. Dry the chain and lubricate it with

7. Once you are finished cleaning the

bike remove the covers from the intake and the exhaust. Start the engine and let it idle a few minutes. Avoid the use of high pressure washers, the water can enter the bearings, the steering housing, etc. and cause severe damage. Use a detergent specifically designed to wash automobiles or motorcycles, this will eliminate the possibility of damage to the tires. Before storing the vehicle for a prolonged period (more than two months), it is recommended that you follow these instructions:

1. Wash the motorcycle as described above.

2. Drain the fuel tank.

3. Remove the spark plug and place some drops of engine oil in the cylinder. Turn the

engine doing several impulsions with electric starter, this will cover the internal sur faces of the cylinder with oil. Replace the spark plug.

4. Lubricate all of the pivot points and cables.

5. Lift the motorcycle in order that the wheels leave the ground.

6. Cover the exhaust exit with a piece of plastic to keep moisture from entering the

7. Place a thin coating of engine oil on all non painted metallic surfaces.

8. Cover the motorcycle with an appropriate cover.92

MAINTENANCE After 5 hours Every 20 hours Change oil, change filter and clean prefilter ( change if necessary) Clean drain plug magnet Replace spark plug (After 50 hours) Check and adjust valve clearance Check engine mounting bolts for tigtness Clean venturi Check cooling system for leaks, check quantity of anti freeze Check exhaut system for leaks and fitment Check cables for damage, smooth operation and bends adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check function of electric systems (low, high beam, break light, indica- tor lamps, speedometer illumination, emergency OFF switch or button) check brake fluid, lining thickness, brake lining Check brake lines for damage and leaks Check / adjust smooth operation and free travel of handbrake / foot brake lever Check tightness of brake system screws and leaks Check shock absorber and fork for leaks and function Clean dust bellows Bell fork legs Check tigthness of general bolt and screw Check / adjust steering head bearings Check joint tension and rim join Check tyres and air pressure Check chain, rear sprockets and chain guides for wear, fit and tension Lubricate chain Check clearance of wheel bearings INJECTION

MAINTENANCE IMPORTANT THE FOLLOWING CHECKS SOULD BE CARRIED OUT ONCE A YEAR ! At least once a year Fork Absorber Change hydraulic clutch fluid Change brake fluid Before each start After every cleaning Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables / gaz Bleed fork legs regulary Remove and clean dust bellows regulary Clean and lubricate chain, cheque tension and adjust if necessary Clean air filter and filter box Check tyres for pressure and wear Check cooling fluid level Check fuel lines for leaks Check all control elements for smooth operation Check brake performance Treat bare metal parts (with the exception of brake and exhaut system) Treat and steering locks and light swiches with contact spray Check tightness of screws, nuts and hose clamps regulary Clean and grease steering head bearings and gasket elements SERVICE SOULD BE DONE EVERY 20 HOURS IF MOTORCYCLE IS USED FOR COMPETITIONTHE SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE !SERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 2 HOURS.MAINTENANCE WORK DONE BY SHERCO AUTHORiZED WORKSSHOPS ISNOT A SUBTITUTE OF CARE AND CHECKS DONE BY THE RIDER! Treat electric contacts and swiches with contact spray Important checks and maintenance to be carried out by the rider Replace glass fibre yarn filing of the exhaust main silencer L94 FORK PAIOLI VISCOSITY SAE-5 ENDURO 580cm

80mm volume air Competition usage Every 10h Every 20h Every 40h Every 80h Hobby usage Every 20h Every 40h Every 80h Check the clutch disks for wear Check the length of the clutch springs Check the clutch drive for indentations Check the outer clutch hub for indentations Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check) Check the camshaft for wear (visual check) Check the spring cap for wear Check the valve guides for wear Replace the valves Replace the valve springs Check the function of the chain tensioner Check the eccentricity of the crankshaft journal Check the conrod bearings Check piston pin bearing Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear Check the length of the bypass valve spring Replace the glass-fiber yarn filling in silencer Check the length chains distribution Check plain camshaft bearings

Apply thread locker on all screws inside the engine M5 6 Nm M6 12 Nm M8 24 Nm M10 40 Nm Loctite Magnetic drain plug 22 Nm Drain plug with prefilter 35 Nm Oil filter cover 15 Nm Spark plug (with copper grease) 15 Nm Bolt for bleeding cooling system 8 Nm Drain bolt for cooling system 8 Nm Rear wheel axle nut 100 Nm Aluminium sub frame bolts 24 Nm Front wheel axle nut 40 Nm Front fork/axle bolts / axle M6 15 Nm Brake pad bolt 8 Nm Triple clamp bolts 17 Nm Allen head screw R.P.M sensor M6 10 Nm TIGHTENING TORQUES