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

USER MANUAL SE2.5iF (2009) Sherco

Alésage x course : 78mm x 52mm / 84mm x 52,35mm

Distribution 4 soupapes DOHC entrainemer

Taux de compression : 12,6:1 / 12:1

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.

CONTENTS

1. INTRODUCTION. P 50

2. GENERALITIES

3. Specifications.. P 52

4. Vehicule description.. P 54

5. Location of serial numbers.. P 55

6. Recording the identification numbers. P 55

7. CONTROLS

8. Hands commands : clutch lever, front brake , switches. P 56

9. Feet commands : gear shift lever, side stand, rear brake.

10. Controls: dashboard, speedometer. P 59

11. VERIFICATIONS, LEVEL AND FILLING CHECKS

12. Fluids: fuel, cooling, engine oil, clutch and brake hydraulic fluid. P 64
    -Tires P68

13. Spoke tension. P 69

14. Front and rear brake pads.. P 69

15. SET UP

16. Riding Position

17. Handlebar, clutch lever, throttle, brake pedal. P 70

-Chain tension. P 71
- Steering bearings.. P 73

• Suspensions

• Fork: compression, rebound, purge. P 74

• Absorber: pre-load spring, compression, rebound. P 75

6.SAFETY RECOMMENDATIONS P77

1. RIDING

2. Start engine. P 78

3. Change gear. P 78

4. Parking. P 78

5. MAINTENANCE

-Fuses. P 79
- Air filter. P 80

• Oil change / Checking oil level / replacing filter. P 82
• Emptying, filling and bleeding the cooling. P 84

• Battery. P 85

• Replacing a headlight or driving light bulb (+ removing the headlight plate)......P 86

• Removing and replacing the front wheel. P 87
• Removing and replacing the rear wheel. P 88
• Removing and replacing the fuel tank. P 89
• Cleaning the fork dust seal. P 90

• Cleaning and storage. P 91

• TABLES

• Maintenance. P 92

• Annual maintenance.. P 93
• Recommended maintenance works by autorized sherco workshop. P 94
• Forks specifications.. P 94
• Tightening torque. P 95
• Capacites (fuel tank, oil...) P 95
• Tire pressure . P 95

SPECIFICATIONS

DIMENSIONS

Overall length : TT : 2110 mm SM : 2060 mm

Overall width : 830 mm

Height : TT : 1220 mm SM: 1190 mm

Wheelbase : 1485 mm

ENGINE

Design Liquidcooled single cylinder 4 stro

Cooling : water

Displacement : 249,4 cm3 / 290,1cm3

Bore x Stroke : 78mm x 52mm / 84mm x 52,35mm

Compression ratio : 12,6:1 / 12:1

Valve timing : 4 valves, DOHC driven by tooth type chain

Ignition system : electric start

Batterie 12V 6,5Ah

Electronic Injection : Magnetti Marelli

Engine oil : 1 litre SAE 10 W 60

TRANSMISSION

Type : 6 speed

Clutch : multi-disk in oil bath. Hydraulic command

Transmission system : chain

Primary reduction ratio : 3,33 (21/70)

Secondary reduction ratio : TT : 13-48

SPECIFICATIONS

CHASSIS

Frame	: Central tube Chrome-moly-steel fra
Angle of the steering column. : 27,6°
Fork : Paioli USD Ø 46mm
Front wheel travel : 300 mm
Rear Suspension : Sachs with separated tank, aluminium
swing arm
Rear wheel Travel : 300 mm
Front brake : disk Ø 270mm
Rear brake : disk Ø 240mm

Tire size

Pressure TT : front and rear: 1 bar Fuel tank capacity : 7,5 litres, Unleaded 95 and 98

ELECTRICAL EQUIPMENT

Headlight	: 12 V 35/35 W
Drive light	: 12 V 5 W
Rear light / stop	: 12 V 21/5 W
Indicators	: 12 V 10 W

TT: Enduro model SM: Supermotard model

Specifications subject to change.

VEHICLE DESCRIPTION

1. Rear turn signal
2. Seat
3. Fuel tank
4. Front turn signal
5. Rear brake pedal

1. Headlight
2. Fuel tank cap
3. Tail light / brake light / license plate light

4. Gear shift lever

5. Left rear view mirror

6. Clutch lever
7. Left handlebar control switch
8. Speedometer panel
9. Main electrical switch
10. Right handlebar control switch
11. Front brake lever
12. Accelerator grip

LOCATION OF SERIAL NUMBERS

Frame number

1. The vehicle serial number 1 is stamped on the right hand side of the steering column.

Engine type and number

1. The engine number 2 is stamped on the top of the oil filter box.

RECORDING THE IDENTIFICATION NUMBERS

Record the numbers of the ignition key and vehicle serial numbers in the appropriate places.

Vehicle serial number

Engine type and number

Ignition key number

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)
3. Side lights
4. Horn button
5. Indicators

Right handlebar control switch

1. Electric start button
2. Twin ignition mapping switch

CONTROLS

Dashboard

1. Dashboard
2. Dashboard functions button
3. Main electrical switch

Main electrical switch

The switch has two positions

Position 1. The engine is off and cannot be started

Position 2. The engine can be started

Turn signal switch

1. Left hand turn switch
2. Right hand turn switch
3. Push in to cancel

Twin ignition mapping switch

Position 1. Curve "soft"

Position 2. Curve "hard"

CONTROLS

Gear shift lever

Diagram showing the six gear positions

Rear brake

1. Rear brake pedal

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.

1

WARNING

The side stand has a safety system that automatically folds it back as soon as the bike is moved into the upright position.

1

WARNING

The side stand is designed to support the motor bike alone.

DASHBOARD

Display and lights

1. Turn lights (green)
2. Hight beam (blue)
3. Affichage multifonctions
4. Speedometer
5. Time
6. Speedo command

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)

Fig1 Current speed function

Current speed function

This function describes the function/ display of current speed. If the measurement 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 measurement selected..

Fig2 TOTAL function

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.

Fig3 TD function

TRIP function automatic TD

This function describes the function/display of the unit's automatic trip function; the figure shown represents the distance run by the bike expressed in kilometres or miles (depending on the unit of measurement selected), with a resolution 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 associated 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.

Fig4 AVE function

Fig5 LAP function

Fig6 MAX function

AVE Function Mean speed

This function determines your mean speed.

A pressure of 3 sec on the button initializes 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 operative, 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 associated 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.

TRIP function Automatic trip Countdown

Fig7 Trip functor

Fig8 Parameter countdown function.

This function describes the function/display of the unit's countdown trip function. 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 associated 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.

Fig9 HPERC function

HPERC function Operating Time (hours)

This function makes it possible to visualize 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.

Fig10 RPM Function

RPM function RPM engine

This function makes it possible to visualize in real time, the engine speed in tr/min.

Fig11 set up adjustment of wheel circumference

Set up Adjustment of wheel circumference

The modification to the wheel circumference, 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 segments are off (see Fig.11).

It is possible to modify the various figures constituting the value for the wheel circumference, starting with the largest figure and moving successively to the lesser one; depending on the digit selected, a brief pressure on the button will increase the figure by one, whilst a longer pressure will enable the selection of a different figure.

FUEL

Fuel

Only use unleaded fuel with an octane index of a least 95 or 98

Fuel tank cap

Opening: Turn the cap counterclockwise

Closing: Turn the cap clockwise

① NOTE

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

COOLING

Bike on side stand

Bike is on a horizontal surface

1. Radiator cap
2. Radiator bleed screw
3. Radiator

WARNING

• 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 caused by hot liquid:

CONSULT A DOCTOR

• Use protective gloves.
• Do not replace cooling liquid 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

1

WARNING

It is extremely important to follow these instructions carefully. Incorrect coolant levels can cause serious damage to the engine.

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 recommended by Sherco

0

WARNING

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

CHECKING THE BRAKES LEVELS

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

WARNING

• 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

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

WARNING

• Hydraulic fluid is highly corrosive
• It can de harmful to the skin.
• Please read the recommendations on the container.

TIRES

Tire pressure

1. Check the tire pressure on a regular 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 regular basis with an accurate tire pressure gauge.
2. If the tread depth is less than 2mm 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.

SPOKE TENSION

Do not forget to check the tension of the spokes

1

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-dealership

CHECKING THE FRONT AND REAR BRAKE PADS

#

WARNING

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

RIDING POSITION

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.

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.

0

WARNING

At rest the screw should have in pressure on the piston. Leave free play (movement) minimum of 1mm

Throttle control

• The throttle control has two settings: 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

BRAKE PEDAL POSITION

Adjusting the brake pedal position

• The free travel of the brake pedal must be 3mm 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 footrest.

DRIVE CHAIN TENSION

Bike on a suitable stand

Lift the chain as shown

The position of the chain must be close to that represented on the picture.

WARNING

Poorly adjusted chain tension can lead to mechanical damage

DRIVE CHAIN ADJUSTMENT

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

NOTE

The sliding part is designed to adapt to the longest chains by turning it through 180^ .

CHECKING THE FORK: TIGHTENING AND ADJUSTING THE STEERING BEARINGS

WARNING

You will need to check the steering frequently for your safety

• To do this, loosen all of the bolts marked 1.
• Tighten the steering stem nut 2 until there is no more play in the bearings. The steering should still turn freely and not bind.
• Do not tighten so much that the steering will not turn freely.
• Re-tighten all of the 1 bolts (torque 24Nm)
• Finish by tightening nut 2

① NOTE

The bearings must be lubricated at least once a year with grease

FORK

Fork compression adjustment

The screws 1 determine the behaviour of the fork when compressed. Turning them clockwise increases the compression and vice-versa.

Standard adjustment:

Turn clockwise to the stop, then back off 14 clicks

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 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 compression (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

Shock absorber rebound

• The rebound is adjusted by turning the black ring 3 at the base of the shock absorber There are 10 adjustment 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

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.

Pre-load adjustment of the rear shock absorber spring

To adjust the rear shock absorber spring pre-load

1. Loosen bolt 1
2. Turn bolt 2
3. Re-tighten 1

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

1. Bike supported by a suitable stand

2. Measure the R1 dimension enters a fixed point of the frame and the axis of the wheels

3. The bike on 2 wheels

4. Measure the R2 dimension enters the same fixed point of the frame and the axis of the wheels

5. Set spring preloading in order to have: R1 - R2 = 30mm

6. The pilot on bike

7. Measure the R2 dimension enters the same fixed point of the frame and the axis of the wheels

8. Set spring preloading in order to have: R1 - R3 = 95mm

0

IMPORTANT

• It is preferable to respect the dimension of 30mm .
• If the dimension of 95mm is not respected, it is possible to change the stiffness of the spring to reach correct measure.

SAFETY RECOMMENDATIONS

• Never ride after drinking alcohol.

• Wear an approved helmet when riding.

• Keeping your machine in good working order and maintaining it correctly increases 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 surface. 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 secured

If, during these checks, you find a fault, consult the Maintenance and Adjustments Chapter in this manual or contact your Sherco dealer.

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 resistance to further movement). Lift up slightly on the pedal.

• Close the throttle and pull in the clutch lever.

• Step on the gear shift lever.
• Smoothly open the throttle and slowly release the clutch lever.
• 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 functions before using the vehicle.

FUSES

1. Général fuse (30A)
2. Spare fuse
3. Speedometer fuse (5A)

WARNING

• Always use fuses with the right amperage

• If a fuse repeatedly blows, please consult yourSherco dealer.

Speedometer fuse

To access this fuse:

• Remove the front headlight plate. (page 86)

CLEANING THE AIR FILTER

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 consumption and at the worst, dirt can enter into your engine and cause premature wear and tear.

Cleaning the air filter

To access the air filter :

• Loosen screw 1 on the seat by a quarter turn counter clockwise.
• Pull the seat back towards the back of the bike.

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 quarter turn clockwise.

OIL CHANGE

The oil should be changed when the engine is warm.

Use protective gloves.

• Position the bike vertically on a horizontal 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 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 hook

OIL CHANGE

Filling engine oil

• Fit a new oil filter, in the correct direction, 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 35Nm
• Unscrew the engine oil filler cap number 2 page 66
• Pour in approx. 1 litre of oil recommended by the manufacturer.
• Check the level of oil through window as explained on page 66.
• Top up the level if necessary

The filter 11 must be replaced after every oil change.

To protect the environment, old oil and filters should be deposited at a collection center.

Torque

Plug 1 22Nm

Plug 2 15Nm

Plug 10 15Nm

COOLING

Vidange

0

WARNING

Make sure that your bike is vertical and on a horizontal surface.

• Place a container under the bike
• Remove the cap 1 and the screw 3
• Let the liquid flow out
• Replace the screw 3 with a new washer
• Tighten to 8 Nm

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

0

NOTE

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

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

Do not cross over the terminals. This can damage the electrical circuit

NOTE

Always use the battery that is recommended by the manufacturer.

It is specifically equipped by Sherco with special protection.

REPLACING A LIGHT BULB

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...

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

WARNING

Always use bulbs with the right wattage.

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.

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

To replace the front wheel

• Reverse the procedure. greasing the axle, with grease.

WARNING

Check that the screws 1 and 3 and the nut 2 are fully tightened

Degrease the disc with solvent
- Prime the brake

NOTE

Torque

Refer to table page 95

REMOVING AND REPLACING THE REAR WHEEL

To remove the rear wheel

• Unscrew nut 1 and remove the sliding part 2

• 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

WARNING

Check and make sure that you have properly tightened the rear axle by ushing it forward.

NOTE

Torque

Refer to table page 95

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

WARNING

Wear appropriate eye protection, gloves and use a cloth

• Disconnect the fuel pump's wiring harness pin 3
• Loosen the two hose clamps securing the fuel supply hose 4.
• Disconnect the fuel supply hose.

NOTE

This operation should be performed when the engine is cold

• Drain any remaining fuel into the cloth
• Lift the tank upwards.

WARNING

In the event of fuel being splashed into the eyes or swallowed

CONSULT YOUR DOCTOR

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 harness.
• Replace the 3 screws and refit the seat

CLEANING THE FORK DUST SEAL

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 regular basis in order to maintain its appearance 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 garden hose.
4. Wash the rest of the vehicle with hot soapy water.
5. Rinse with water.
6. Dry with a chamois or a clean lint free cloth.
7. Dry the chain and lubricate it with chain lubricant.
8. 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 surfaces 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 engine.
7. Place a thin coating of engine oil on all non painted metallic surfaces.
8. Cover the motorcycle with an appropriate cover.

MAINTENANCE	After 5 hours	Every 20 hours
ENGINE
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 tightness	●	●
INJECTION
Clean venturi		●
ADD - ON PARTS
Check cooling system for leaks, check quantity of anti freeze	●	●
Check exhaust 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, indicator lamps, speedometer illumination, emergency OFF switch or button)	●	●
BRAKE
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	●	●
CHASSIS
Check shock absorber and fork for leaks and function	●	●
Clean dust bellows		●
Bell fork legs		●
Check tightness of general bolt and screw		●
Check / adjust steering head bearings	●	●
WHEELS, SPOKE
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	●	●

MAINTENANCE
IMPORTANT THE FOLLOWING CHECKS SOULD BE CARRIED OUT ONCE A YEAR!		At least once a year
Fork		●
Absorber		●
Clean and grease steering head bearings and gasket elements		●
Replace glass fibre yarn filing of the exhaust main silencer		●
Treat electric contacts and swiches with contact spray		●
Change hydraulic clutch fluid		●
Change brake fluid		●
Important checks and maintenance to be carried out by the rider	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 regulatory		●
Remove and clean dust bellows regulatory		●
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 exhaust system)		●
Treat and steering locks and light swiches with contact spray		●
Check tightness of screws, nuts and hose clamps regulatory		●
SERVICE SOULD BE DONE EVERY 20 HOURS IF MOTORCYCLE IS USED FOR COMPETITION THE SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE ! SERVICE INTERVALS SHOULD NEVER BE EXCEEDED BY MORE THAN 2 HOURS. MAINTENANCE WORK DONE BY SHERCO AUTHORIZED WORKSSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
RECOMMENDED INSPECTIONS AND MAINTENANCE WORKS BY AUTORIZED SHERCO WORKSHOP
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			●	●

FORK PAIOLI
VISCOSITY SAE-5
ENDURO 580cm		3 110mm volume air
SUPERMOTARD 615cm		3 80mm volume air
STANDARD TIGHTENING TORQUES
M5 6 Nm
M6 12 Nm
M8 24 Nm
M10 40 Nm
TIGHTENING TORQUES		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	●

#

NOTE

Apply thread locker on all screws inside the engine

TIRE PRESSURE
OFF-ROAD	FRONT	REAR
	1,0 bar	1,0 bar
ROAD	1,5 bar	2,0 bar

CAPACITIES
FUEL TANK	7,5 litres
MOTOR OIL	0,9 litre

SHERCO

Motorcycles

ESPANOL

P.97

P.143

INTRODUCCION

SHERCO

Dimetro X carrera : 78mm x 52mm / 84mm x 52,35mm

Mando 4

Recorrodedusipensiondelantera :300mm

Suspension trasera : Amortiguidores Sachs, basculante

de aluminio

Recorro suspensa: 300mm

Freno delantero : disco Ø 270mm

Freno trasero : disco Ø 240mm

SM 120^

trasero TT

SM 150