250 SER (2019) - Motorcycle Sherco - Free user manual and instructions

USER MANUAL 250 SER (2019) Sherco

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N1EI N1EH N1EG N1EF N1EE RICHEPAUVRE

68INDEX n FRANÇAIS P. 2 n ENGLISH P. 7 0 n ESPAGNOL P. 138 ENGLISH n DEUTSCH P. 206INTRODUCTION 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. n 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». n Be sure to carefully read this manual in its entirety before using your machine. n 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.) n SHERCO reserves the right to make changes without providing notice. Dealer stamp Frame number (

DIMENSIONS Overall length 2260 mm Overall width 820 mm Seat height 950 mm Wheelbase 1480 mm Ground clearance 355 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 forcced circulation Starting System Electric starter Battery 12 V / 4 Ah Ignition system DC-CDI no switch with digital advance Spark plug NGK BR7ES / DENSO W22ESR-U Spark plug gap 0.7 mm Alternator 220W Engine oil 750 ml 10 W 40 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 Technical Specifications CARBURETOR 250 SE-R 2018 Type of carburetor KEIHIN PWK 36S AG Needle position 3th position from the top Needle jet N1EG (N84K) Main jet KEA 165 (KEA 115) Pilot jet KEP 42 (KEA 38) Starter jet 85 (50) Air screw adjustment 1 1/4 turns Slide cut N°5.5 72CHASSIS Frame Semi-perimeter CrMo steel with aluminum subframe Fork SACHS USD Gold Series 48mm dia. (standard) WP Suspension Xplor (Racing) Rear suspension WP Suspension XPLOR (RACING) Travel front/rear 300/330mm Front brake disc 270mm (standard), 260mm (Racing) Rear brake disc isque Ø 220mm Disc brakes wear limit : 2.7mm front and 3.6mm rear Front tire 90/90-21’’ or 90/100-21’’ Rear tire 140/80-18’’ Pressure off-road front / rear 0,9 bar Fuel tank capacity with reserve 10.4l with 1l of reserve Fuel requirement Unleaded gasoline with an octane index of at least 98 mixed with 2 stroke oil (2%) Technical Specifications CARBURETOR 300 SE-R 2018 Type of carburetor KEIHIN PWK 36S AG Needle position 3rd position from the top Needle jet N8RE (N84K) Main jet KEA 172 (KEA 115) Pilot jet KEP 42 (KEA 38) Starter jet 85 (50) Air screw adjustment 1 1/2 turns Slide cut N°7

ADJUSTMENT – WP REAR SUSPENSION UNIT

Low-speed compression Comfort 20 clicks back Standard 20 clicks back Sport 12 clicks back High-speed compression Comfort 2,5 turns back Standard 2 turns back Sport 1,5 turns 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

Description of the vehicle

Rear light (tail / brake light / plate light)

Description of the vehicle (continued) Location of the serial numbers n Engine serial number location n Vehicle serial number location

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

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

High beam (Headlight)

Low beam (Headlight)

: All lights are on. Position OFF

: All lights are off. n Clutch lever The clutch lever

is on the left handlebar and has an adjustment screw

n Front brake lever The front brake lever

is on the right side of the handlebar and has an adjustment screw

Control devices and controls

Injection system mapping selection button n Rigth switch The main switch has two positions Position

The engine is off and can not be started. Position

Off position G and D n Flasher switch (250-300 SE) Control devices and controls

Control devices and controls (continued) Position

“Hard” n Injection system mapping switch n Motor emergency stop button (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. n KEYLESS System The bike has a "Keyless" system. It allows the bike to start without any key or ON/OFF switch. It automatically turns on and it turns off after 30 secondes of no use of the bike. When the motorcycle is not used for a long time or during a strong cold (<10°C) the lithium battery can go into sleep. To wake her up, press few short blows on the starter button. 801N23456

Control devices and controls (continued) FOOT CONTROLS:

GEAR SELECTOR, SIDE STAND, REAR BRAKE

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

Rear brake control n Side stand Remove the rubber safety latch

, 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

Button 1: Change screens 1,2,3 Hold button 1: 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 Hold buttons 1 et 2: Setup mode Screen 1: Speed, Clock, Distance 1 Screen 2: Speed, Clock, Distance 2Screen 3: Alternating AVG/MAX speed, Accumulated run time, ODO n 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, maxi- mum and average speed (when pressed and held for three seconds) Increments distance while in adjustable distance mode Turn indicator High beam Fuel injection (MIL): EFI problem Low fuel CAUTION In order to avoid any water ingress, keep a minimal washing distance of 20cm. 82Control devices and controls (continued) 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.85) 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.85) Reset to 0 →MAX Function→ Hold the right Button down for 3seconds →0→ Reset to 0 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.85) 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.85) Reset to 0 →DST Function→ Hold the right Button down for 3seconds →0.0→ Reset to 0 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 (

DST and DST2 can be incremented or decremented by the user DST set up (screen 1) → Hold the left Button down for 3seconds → «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 3seconds → «DST2» icon will flash

• Hold left Button to decrement/ Hold the right Button to increment → back to screen 2 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.85) This information can not be reset to 0. Beyond 399 999 km (or miles), the counter goes back to 0. 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. Clock function (screens 1 et 2): displays clock information 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. Fig 6 Adjustable trip distance function Fig 7 ODO function Fig 8 ART function Fig 9 Clock function Fig 11 Low battery/ Low battery error function Control devices and controls (continued) 84Maintenance 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 3seconds

• 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 n 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 UNIT (Unit type) LIFE (Wheel circumference) Do not modify these settings PPr (Pulse per revolution) (Clock format) (Clock setup) (Maintenance reminder) The meter will automatically advance from one setting option to the next, after 5s of no button activation Miles or Km Default: km 12 or 24h Default: 24h Clock setup Maintenance reminder setting ( in hours) Default setting: 5h (first oil change) OFF: disabled Set the value Control devices and controls (continued)

n Fuel tap The fuel tap is on the right side of fuel tank. Tap handle

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. n Fuel Use only unleaded fuel with an octane index of at least 95 mixed with 2 stroke oil (2%) n Filler cap 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 Control devices and controls (continued)

n Choke The choke lever

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. Control devices and controls (continued)

Riding the motorcycle n Cold engine starting 1. Make sure the gear selector is in neutral2. Activate the choke3. Start the engine by pressing the starter button, with the throttle closed4. Allow the engine to warm up for few minutes5. Deactivate the choke n Hot engine starting Follow the instructions above without step 2-4 and 5. n Shifting gears - The positions of the gear selector are shown on ( p.81)- To find the neutral position, press the selector down into first gear (a resistance will be felt), then move the selector up slightly.1. Close the throttle before changing gears.2. Engage the lowest gear.3. Partially open the throttle while engaging the clutch. n Parking - Stop the bike with the stop button. The Keyless system will automatically switch off the ignition after 30 secondes of no use of the bike.Become familiar with all of the controls and their functions before using the vehicle. 88Safety 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.98 to p.99) Gasoline : Check the level and make sure there are no leaks Transmission chain Properly lubed and adjusted (

p.113) Direction of travel : Make sure that your path is clear Brakes : Operation, fluid leakage, brake pad wear (

p.114 to p.115) Electrical Equipment : Operation of the horn and lights (

p.78 and p.80) Components (nut, bolts ...): Verify that all components of the vehicle are properly tightened (

p.135) 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.

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. 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. - Place the bike upright on a horizontal surface. - Remove the cap

Fill the radiator full so that there is no air in the system. Fill the coolant to the top of the radiator. Replace the cap

and check to make sure it is tight. Replace the screw

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

ATTENTION Make sure the bike is vertical and on a horizontal surface. -Place a container under the bike -Remove the cap

-Allow the coolant to drain.

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

Cooling System (continued)

using a new gasket - Pour the coolant into the radiator through the cap

Coolant Minerva Perma Universal D 4 -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 (

Motor settings CHECKING THE PLAY IN THE THROTTLE CABLE 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. (

below) Start the bike and let it run at idle. Turn the hand- lebars and check that the idle speed is constant. If the speed changes, readjust the play in the throttle cable. (

below) n Checking the throttle cable play n Adjusting the play in the throttle cable Adjust the throttle cable play at the location shown

Motor setting (continued)

- The idle speed is adjust with adjusting screw

- The idle mixture is adjusted with the idle air adjusting screw

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 opening of the throttle slide, this range is regulated by the idle screw

• B: Transition range From to ¼ opening of the throttle slide, this range is regulated by the idle jet and the shape of the slide.

• C: Mid-range : From ¼ to ¾ 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 ¾ to full throttle slide opening, this range is controlled by the main jet and the needle jet.

94Motor setting (continued) 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 : Main jet : 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. The main jet is shown in the photo as

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

ATTENTION - Improved oil level can damage your engine .- Do not use bike if the level is below the minimum .Topping up the engine oilEngine oil SAE 10W40

DRAINING THE GEAR BOX OIL

- Remove the engine guard ( p.115)- 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 - Remove the drain plug - Allow the oil to drain- Clean the drain plugs and with a degreaser.

Engine maintenance (continued) - Install the drain plug

with a new gasket. Drain plug

M16 15Nm - Remove the engine oil filler cap

- Fill the engine with oil Motor oil 0,8l SAE 10W40 - Install the engine guard.

REFILLING THE GEAR BOX WITH OIL

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. n 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

- 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 handle- bars in the rear most position. Remove the four screws

. Remove the handle- bar top clamps and remove the handlebar. Remove the two screws

. Remove the lower clamps and place them in the desired position. Handlebar lower clamp M10x35 40Nm Loctite

Replace the handlebars and top clamps. Replace the four screws

and tighten evenly. Handlebar clamps fixing screws M8x25 24Nm The handlebars can be rotated forward and rearward in the clamps.

Adjusting the chassis

ADJUSTING THE STEERING ANGLE

BASIC SETTING OF THE CHASSIS ACCORDING TO THE RIDER WEIGHT If the weight of the rider is above or below the standard, compensate by changing the stiffness of the springs (forks and shock). The steering angle can be changed using the set screws located on the bottom of the steering column. Loosen the nut

and tighten the screw

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 Standard weight of the- rider (with equipment) 75 à 85kg

Adjusting the chassis (continued)

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

located at the lower end the fork. Turn screw

clockwise to the stop and go back the number of clicks required. Setting compression WP suspension XPLOR Ø48mm (racing) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Setting compression KAYABA (factory) Comfort 20 clicks Standard 12 clicks Sport 8 clicks Replace the cap

The adjusting screws

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

are located at the end of the upper fork legs. Turn the screw

clockwise to the stop then go back the number of clicks required. Setting rebound WP suspension XPLOR Ø48mm (racing) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Setting rebound KAYABA (factory) Comfort 18 clicks Standard 12 clicks Sport 10 clicks 102Adjusting the chassis (continued)

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 XPLOR Ø48mm (racing) Comfort 0 turn Standard 0 turn Sport 2 turns

Adjusting the chassis (continued)

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

clockwise with a screwdriver until it stops and then turn it back the number of clicks required. Do not loosen the nut

Adjusting the chassis (continued)

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

clockwise with a socket wrench until it stops and then back the number of clicks required. Do not loosen the nut

Adjusting the chassis (continued)

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 pre- load of the shock (

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.

Adjusting the chassis (continued)

CHANGING THE PRELOAD OF THE SHOCK

Remove and clean the rear shock unit (

Loosen / tighten the red plastic ring

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 collar

Loosen / tighten the red plastic ring

Remove and clean the rear shock unit (

p.116) 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.104) REAR SHOCK KAYABA (FACTORY) Indications Loosening one turn Decreases the ove- rall length by 4mm. Tightening one turn Increases the overall length by 4mm. Tighten the collar

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

in the seat pan engages the post

in the reservoir. The three notches in the saddle must pass through the tabs on the subframe

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 (

Remove the filter with the plastic carrier

Separate the filter from its plastic holder.

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

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

Chassis maintenance (continued) Remove the seat (

p.108) Unscrew the fuel tank fixing screws

Remove the hose that attaches to the fork crown

Disconnect the fuel pump electrical connector

Remove the fuel hose by pressing the connector

and pulling on the hose

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

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.

Chassis maintenance (continued) Reassembly of the fuel tank. Be sure to correctly position the throttle

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

Install the fuel tank mounting screws

along with their rubber inserts. Install the radiator grill mounting screws. Chassis screws M6 10Nm Install the fuel vent hose. Reinstall the saddle (

p.108) 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) Place the motorcycle on a suitable stand. Remove the front wheel (

p.118) Remove the fork protectors. Slide the dust cover down. Clean and lubricate the dust cover and the fork tube. Lubrifiant universel Minerva F4 Reinstall the dust cover and clean off any left over oil. Reinstall the fork protection. Reinstall the front wheel (

p.118) Take the bike off of the stand. 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.113) Take the bike off of the stand.

CLEANING THE FORK DUST SEALS

Chassis maintenance (continued) Place the motorcycle on a suitable stand. Loosen screws

to adjust the steering bearing play. Steering nut M20 30Nm Tighten the screws

Check the play of the steering head bearings.

p.113) Remove the bike from the stand. The bearings should be greased at least once a year with a good quality grease. Regularly cleaning the chain considerably increases its service life. Clean the chain and apply chain lubricant. Minerva Chain Cleaner 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. (

CHECKING THE CHAIN TENSION

Chassis maintenance (continued) ATTENTION Improper chain tension can cause mechanical damage.Place the motorcycle on a suitable stand. Loosen nut Loosen the nuts Loosen or tighten the screws until you have the correct chain tension.Chain tension 50mm...53mmMonitor the symmetry of the two sides by observing the position of the marks Tighten the screws Tighten the nut Rear axle nut M24 100NmRemove the bike from the stand. NOTE The sliding piece is designed to accommodatelonger chains by turning it 180 degrees.The position of the lever can be adjusted to meet the needs of the rider.- Turn the knob

clockwise to move the lever closer to the handlebar. 114B

Chassis maintenance (continued) - Turn the knob

in the opposite direction to move the lever away from the handlebar. Clutch lever free play A ≥3mm

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

- 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.

and remove the engine protector.

Place the motorcycle on a suitable stand. Remove the right side plate. Remove the escape. Remove the screw

Remove the top screw of the shock. Remove the shock from the top. Chassis maintenance (continued) Remove the screws

and the muffler along with the intermediate exhaust pipe.

ATTENTION Do not remove the muffler after operating the motor-cycle. It can behot and there is a risk of being burned. Remove the shaft

Chassis maintenance (continued)

REINSTALLING THE REAR SHOCK

Install the shock from the top. Install the top screw and tighten. Upper shock screw M10 40Nm Loctite

Position the rods and “H” link. Install the lower shock screw

and tighten. Lower shock screw M10 40Nm Loctite

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.

WHEEL Place the motorcycle on a suitable stand. Remove the two screws

Loosen the two screws

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. 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

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

Fork screws M8 12Nm Install and tighten the axle nut

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. Wheels, tires

REMOVING THE REAR WHEEL

REINSTALLING THE REAR WHEEL

Place the motorcycle on a suitable stand. - Unscrew the nut

and remove the adjuster.

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. 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

and make sure they are positioned correctly.

Wheels, tires (continued)

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. Install the chain tensioner

but do not tighten. Check the chain tension (

Rear Axle nut M24 100Nm Operate the rear brake pedal several times until the pads touch the disk. Remove the bike from the stand. Install the rear wheel in the swing arm and install the axle (grease the axle prior to installation) Mount the chain. 120Wheels, tires (continued)

CHECKING FOR WEAR AND DAMAGE

CHECKING SPOKE TENSION

- 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 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.

Pull the lever toward the handlebar and check the free play

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

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

ATTENTION - The hydraulic fluid is highly corrosive.- It can be dangerous to the skin.- Read the recommendations on the container. - Remove the two screws

Fill the reservoir with brake fluid to the correct level

- Operate the pedal several times Rear brake pedal travel 3mm ≥

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

p.124) The position of the brake pedal can be adjusted as follows: loosen the lock nut

loosen or tighten the screw

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 (

Brakes (continued) - Remove the spring

Fill with fluid to the mark as shown

Minerva brake fluid DOT 4 - Reinstall the membrane and the cover using a new O-ring. ADJUSTING THE TRAVEL OF THE REAR BRAKE PEDAL 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. MIN If the level is below the MIN mark, top up the brake fluid according to the instructions below.

Brakes (continued) - Remove the clip

- Remove the brake pads. Do not operate the front brake lever or rear brake pedal when the brake pads are removed. Check the pads for wear Minimum pad thickness

≥1mm If replacement is necessary, always change the pads in pairs. 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 REMOVING THE FRONT AND REAR BRAKE PADS CHECKING THE CONDITION OF THE BRAKE PADS REINSTALLING THE FRONT AND REAR BRAKE PADS

Brakes (continued) Turn off all electric devices and stop the engine. CAUTION WAIT AT LEAST 30 SECONDES BIKE TURNED OFF AND STOPPED SO THAT THE KEYLESS SYSTEM TURNS OFF.IF THIS IS NOT DONE THERE IS A SIGNIFICANT RISK OF DAMAGE TO THE COMPUTER (ECU) - Remove the seat (

p.108). - 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

- Disconnect the battery positive cable

- Remove the battery from the top. Install the new pads. Reinstall the retaining pins

p.124 and p.126) CAUTION 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.

REMOVING THE BATTERY

Electrical system maintenance

Electrical system maintenance (continued) - 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

Chassis screws M6 10Nm - 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.108). 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.130) 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)

or 5A for 30 minutes Disconnect the charger after charging. Install the battery (

Electrical system maintenance (continued) Remove the seat (

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 (

REPLACING THE MAIN FUSE

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 (

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

and remove theheadlight housing.

Electrical system maintenance (continued) Connect the electrical connector. Engage the light plate, ensuring that the holes in the plate

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

Attach the rubber fastners. Check the setting of headlight beam. (

Remove the headlight housing assembly

Turn the socket a quarter turn counterclockwise to remove it from the headlight assembly. Gently press the bulb in while turning it counter- clockwise and remove it from the socket. Install a new bulb

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

simply remove the socket from the reflector

Pilot light W5W 12V 5W Reinstall the headlight housing assembly

Electrical system maintenance (continued) 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

raises the headlight beam. Loosening the screw

lowers the headlight beam.

1. Remove the headlight housing (

signal flasher in order to access the motorcyle computer screws.

3. Remove the screws

and remove the computer to get it out of the way.

4. Disconnect the main connector from

5. Open the dashbord with a coin.

6. Install a new battery (with the marking up).

Computer battery CR 2032 3V

7. Replace the cover, taking care not to damage

8. Plug the main connector into the computer.

9. Install it on the bike and check to make sure

10. Reinstall the computer support.

and replace the turn signal flasher.

12. Replace the headlight housing (

13. Set the computer (

(250-300 SE/R) 130SHERCO advises you to wash your 250-300 SE/R as often as possible in order to main- tain 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 degrea-

ser, clean with a brush then rinse the engine with a water hose.

3. Wash the rest of the vehicle with hot

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 atidle 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 (

5. Charge the battery (

6. Lubricate all cables with a spray lubricant.

7. Jack the motorcycle up so that the wheels

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.

Reinstall the battery (

RECOMMISSSIONING AFTER STORAGE Washing and storage CAUTION In order to avoid any water ingress, keep a mini- mal washing distance of 20cm.

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) 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

WHEELS Check rims and spoke tension

Check condition of the tires and tire pressure

Check wheel bearing clearance

Clean and grease steering head bearings and seals

Treat electric contacts and switches with an aerosol protector

Checks and major maintenance to be performed by the rider Before each use After each use Check the engine oil level

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 air filter and box

Check tires and tire pressure

Check the coolant level

Check fuel lines for leaks

Check status of all the controls

Spray anti-corrosion protector on all non painted parts (except for the brake parts and the exhaust system)

Check tightness of nuts, screws and clamps

ATTENTION Check the tightening of the screws of your bike after the first ride / the first hours of use. 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 80Hh 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

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

Check all of the gearbox components for wear

Replace fiberglass packing in the muffler

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