CityCorp (2003) - Motorcycle Sherco - Free user manual and instructions

USER MANUAL CityCorp (2003) Sherco

FRAME Tire mark : Michelin Size : Front : TT: 3.00 – 21 : SM: 100/80 - 17 Rear : TT: 4.10 – 18 SM: 130/70 – 17 Fuel tank capacity : 7.5 L, 87/93 octane unleaded gasoline ELECTRICAL EQUIPEMENT Headlight : 12 V 35/35 W Tail/brake light : 12 V 21/5 W Flasher light : 12 V 10 W TT : Enduro model SM : Supermotard model Technical data is subject to change without prior notice. IDENTIFICATION NUMBERS Record in the spaces below, the ignition key number, the steering lock number and the vehicle serial number of your motorcycle. Ignition key number (see the picture) Steering lock key number (see the picture) Engine serial number (see the picture)

1. Rear turn signal lights 11. Clutch lever

10. Left hand rear-view mirror 20. Steering blocking device

VEHICLE DESCRIPTION VEHICLE IDENTIFICATION V ehicle serial number

1. The serial number of the vehicle is

recorded on the right side of the steering tube.

2. The identification plate is attached

to the right side of the frame. This plate indicates the emissions control number of the vehicle and the noise level in dba at a given RPM. The identification plate also includes the machine serial num ber. key number key number

1. Main electrical switch (two active positions)

a. Engine can be started b. Engine is off and cannot be started

2. High beam indicator light.

3. Neutral warning light: illuminated (engine must be running) when the gearbox is in

the neutral position.

4. Turn signal indicator light: flashes when the turn signals flash.

5. Headlight indicator light: illuminated when the headlight is in the low beam position.

7. Odometer in kilometers.

2. Turn signal switch.

1. The gear shift lever which is located

on the left side of the engine is used to select the 5 gears in the transmission. Gearshift lever

1. The fuel petcock has three positions:

OFF: When the lever is in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: This is the reserve position. If you run out of fuel while riding, move the lever to this position. Fuel petcock INITIAL OPERATION The break in period if 500 km. During this period it is mandatory that you follow the procedures described below. If these procedures are not followed the life of your motorcycle may be drastically reduced. Do not accelerate or race the engine immediately after starting. Let the engine idle for a few minutes in order for it to warm up. Do not run at full load during the break in period. In order to validate the manufacturers warranty, you must return your Sherco motorcycle to your authorized Sherco dealer at the end of the 500 km break in period.

Riding your Motorcycle Starting a cold engine :

1. Turn the fuel petcock to the ON

2. Set the sidestand up (the sidestand

is equipped with a switch which prevents the engine from starting when it is down)

3. Turn the ignition key to the on posi

tion, first position to the right. (clockwise)

4. Using the gearshift lever, place the

transmission in neutral.

5. Engage the choke and slightly open

6. To start the motor push the engine

start button, once the engine is started remove your finger from the button. The engine may also be started by using the kick starter lever. Follow the same process as above but ins tead of pushing the engine start button, unfold the kick starter lever and push down on it with your foot. Once the engine starts return the kickstarter lever to its ori ginal position.

7. Allow the engine to warm up for

several minutes in neutral before shifting into 1st gear and riding off. Follow the above instructions but omit steps 5 and 7. Accelerate the engine slightly after it starts. Starting warm engine : Shifting gears The gear shift lever positions are shown on page 8. 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.

1. Close the throttle and pull in the

place the transmission into firs gear.

3. Smoothly open the throttle and

slowly release the clutch lever. Once you have reached the proper speed, shift into the next higher gear. Stopping: Using the ignition key stop the engi- ne, remove the key from the main switch and place the petcock in the off position. You must know these functions completely prior to operating your motorcycle for the first time. SAFTEY We recommend that you always wear an approved helmet when you ride your motorcycle. For optimum safety and reliability you have to keep your motorcycle in good repair with a rigorous maintenance schedule. Gasoline is inflammable, fill the fuel tank when the engine is not running. Exhaust gases are toxic, do not run the engine in a closed space. Always park the motorcycle on a flat hard surface. Do not park the motorcycle on a soft surface or on a slope. Check the stability before leaving your motor cycle. You should inspect the following items daily, before you ride your motorcycle: - Tires: :Check for wear and pressure. - Engine oil: : Level. (see the maintenance and adjustment chapter) - Fuel: : Make sure there are no leaks. - Primary drive chain: : Tightness. (see the maintenance and adjustment chapter) - Steering: : Make sure that it turns freely. - Brakes: : Check for proper operation, make sure that there is plenty of brake fluid and that the pads are serviceable. (see the maintenance and adjustment chapter) - Throttle control: : Check for proper operation, the throttle should turn freely and not stick. (see the maintenance and adjust ment chapter) - Clutch: : Check for proper operation. (see the maintenance and adjustment chapter) - Sidestand: : Check the operation of the safety switch, the engine should not start when the sidestand is down and should run when it is up. - Electrical System: : Check the operation of the horn, the lights and the star ting system. Fasteners (bolts, nuts, screws): Inspect all bolts, nuts and screws, make sure they are properly tightened. If during this inspection you find a defect, refer to the Maintenance and Adjustment chapter which follows, or contact your authorized Sherco dealer.

Engine IDLE speed 1.Start the engine and let it warm up for a few minutes.

2. Adjust the idle speed by turning the

adjustment screw Oil pump adjustment Spark plugs Standard spark plugs

2 years2 years2 years2 years2 years2 years1000 kms1000 kms

S - 0 S - 0S - O -C - 0 - L - 0 - ou 0DISTANCEEVERYSee Page(in KM)(the first of either)FREQUENCYSpark plug gapAir filterBrake pad and disc wearBrake fluid levelBrake fluidFront brake, back brakeClutchClutchEngine oilOil filterTransmission chainTransmission chain movementTire wearSteeringTightness of wheel spokes and disksTightness of nuts, bolts, jointsGeneral lubricationFront fork oilSwing arm pivotLubricate steering bearingsMaster cylinderCalliperBrake hoseFuel inlet tubeValve clearanceOil strainerS - 0 - L -S - 0 - L -S - 0 S - 0 S - 0 - CS - 0 - C S -

2. Remove the air filter cover (1).

3. Remove the air filter (2).

4. Clean the element with soap and

water, squeeze the element to remove any excess water. Allow to dry completely.

5. Impregnate the element with spe

cialair filter oil. ref. 530

6. Reinstall the air filter element.

7. Reinstall the cover, making sure

that it makes good contact with the airbox. 8 Reinstall the seat. IIf the brake fluid level is below the minimum level, add DOT 4 brake fluid to the maximum mark. Always use the same type of brake fluid. Brake fluid level Brake pad wear Remove both pads, if one or both pads measure less than 1mm they should be replaced. Front brake adjustment

1. Loosen the lock nut (1).

2. Turn the adjuster (2) until you

obtain a 10 mm (approx.) clearan ce between the brake lever and the handlebar grip.

3. Tighten the lock nut (1).

Rear brack adjustment The top of the brake pedal should be approx. 15 mm belos the top of the foot peg.

1. Loosen the lock nut (2).

2. Turn the adjuster (1) until you obtain

the 15 mm dimension. Apply pressure to the brake pedal when you have the correct dimension.

3. Tighten the lock nut (2).

The rear brake pedal should have a clearance of approx. 3 mm with the stop screw.

1. 1. Loosen the lock nut (3).

2. Turn the adjuster until you obtain

Drive chain adjustment To check the drive chain for slack:

1. The wheels have to be on the ground.

2. The motorcycle has to be vertical.

3. No one can be on the motorcycle.

If the vertical deflection is between 25 and 40 mm the chain must be adjusted.

1. Loosen the rear wheel axle nut (2).

2. Turn the chain adjusters (3) on both sides of the motorcycle until the chain

deflection is between 12 and 24 mm. Make sure that the adjusters are in the same position on both sides.

3. Tighten the rear wheel axle nut (2) to 90 Nm.

We recommend that you lubricate the chain with chain lubricant.

SPRAY CHAIN REF. 704/702

Engine oil Check the oil level (stop the engi ne and wait a few minutes)

1. Stand the vehicle perpendicular to

2. Remove the cap (2) and check the

amount of the approved oil to bring it to the correct level.

1. Warm up the engine and then shut

2. Place the vehicle over an approved

3. Remove the oil drain plug (3).

Note: the picture does not look like the drain plug

4. Once the oil has completely drai

ned, replace the drain plug (3) and torque it to 18 Nm.

5. Remove the cap (2) and fill the

engine with the approved amount There are two places to adjust the clutch cable: one is on the lever and the other is on the cable near the engine. This illustration shows the clut- ch lever adjustment.

1. Loosen the lock nut (1).

2. Adjust the adjuster (2) until you obtain a free

play of approx. 10 to 15 mm.

3. Tighten the lock nut (1).

Clutch lever adjustment 10 to 15 mm

CLEARING AND STORAGE

SHERCO recommends that you clean your new SHERCO 125 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. MOTO WASH ref.768

3. Wash the motorcycle first with a garden hose.

3. Wash the rest of the vehicle with hot soapy water.

4. Rinse with water.

5. Dry with a chamois or a clean lint free cloth.

6. Dry the chain and lubricate it with chain lubricant.

SPRAY CHAIN ref. 704/702

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 and the carburetor.

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

Replace the spark plug and turn the engine over several times with the kick star ter with the ignition switch in the off position, this will cover the internal sur faces of the cylinder with oil. SPRAY PROTECTOR3 ref. 731

4. Lubricate all of the pivot points and cables. SPRAY PROTECTOR3 ref. 731

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.

SPRAY PROTECTOR3 ref. 731

8. Cover the motorcycle with an appropriate cover.

Tires Tire pressure:

1. Check the tire pressure on a regu

ar basis with an accurate tire pres sure gauge.

2. The tire pressure must comply

with the chart shown below. Tire wear and damage:

1. Check the tread depth on a regu

lar basis with a tread depth 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. Maximum Load 180 kg Max load (Total weight of lugages, passenger and pilot) 165 kg Pressure (cold condition) Until 90 kg Between 90 kg and max load ENDURO SUPERMOTARD Front 130kPa (1,3 kg/cm

This manual has to be presented to the SHERCO vendor who is the sole enable to apply any overhaul operation or to answer to any application for warranty. The overhauls and oil changes are mandatory to keep the right to warranty. Don’t forget to note each of it. You have not to modify your SHERCO. It is homologated with respect of precise conditions, according with official rules of «code de la Route». Any modification applied to your SHERCO will immediately cancel the warranty. Please you have to read attentively the SHERCO warranty conditions and also the using advices here after described.

SHERCO WARRANTY CONDITIONS

Any new SHERCO motorcycle which is delivered with this present manual : Is covered by legal warranty of hidden defects, in agreement with present laws of each country. Is covered by a contractual warranty during one year without mileage limitation and parts. Said warranty starts at the time of the first delivery to the final customer. This warranty can be applied by any vendor duly agreed by SHERCO. This manual contains a first delivery card which has to be entirely filled up and returned to the SHERCO warranty desk by the SHERCO agreed vendor immediatly after the first delivery to final customer. The owner signature prove the acceptation by owner of the present contract terms. The SHERCO warranty is dedicated to the motorcycle. By this way any charge of property don’t modify the warranty application. In order to have the benefit of said warranty the owner has to mandatory present the warranty manual and the warranty card duly filled up which the prove that the SHERCO overhaul operations has been completed in time, (with a allowance of plus or minus 60 miles (100 km) compared to the specified mileage). The SHERCO warranty apply for free (labour and parts) connection of any defect concerning material or assembly, which appear after following conditions : All overhaul works have been achieved in the agreed SHERCO workshop vendor under responsibility of said vendor, the choice to change or repare any part wich is admittedly defective is the sole SHERCO responsibility. SHERCO warranty don’t apply if it is proven that the defects are comming from : Motorcycle not normally maintained and non respect of instructions included in the SHERCO overhaul manual. Fitting on the motorcycles of parts, modifications or adaptations non permitted by SHERCO. Overhaul of the motorcycle made by another work shop than this agreed by SHERCO. Abnormal use of the motorcycle (for example : participation to sport races, overloads, motorcycle unutilised during a too long time) Normal wear of parts. The parts with normal wear as : tyres, wiring, spark plugs, spark plug, cap, lights, chains, brackets, brakes pads and calipers exhaust pipes (by internal con) are not covered by the warranty ; Also, engine blocking, holes on pistons, yellowing of chrome plating, due to bad adjustments, bad oil/ fuel mix or too low oil level are not covered by the warranty. This contractual warranty don’t apply for normal overhaul expenses, oil grease etc..., an also expenses related to emergency repairs, immobilisation of the motorcycle and removal expenses, damages of carried goods. WARNING : The use of, silencer or air filter which are non original parts, or modified original parts in order to increase the level of noise cancels automatically any warranty application. In addition, said modifications which increase noise, power and speed are under total responsibility of the owner. NOTA : In case of damage in a limitrophe country we are asking you to present the warranty claim to your vendor and to join the associated defective parts with corresponding invoices. Visual control . Paint . Fairing fixation . Scratches . Cleanliness ❐ O.K. Static control after road trial . Hot start . Starter operational . Idling (while turning the handle bars) . Smooth steering rotation . Leaks ❐ O.K. Running control . Hydraulic braking circuit . Mechanical braking circuit . Clutch . Four stroke motor . Lever movement . Brake actuating lever and/or pedal . Throttle operational control . Check paperwork . Verification of chassis n° and engine n° . Assembly of registration plate . Check locks . Check tyre pressure . Assembly of rear view mirrors and any accessories ❐ O.K. Electric circuits . On / off circuit . Headlights, indicators, parking lights and their corresponding dashboard lights . Beam setting in line with legislation . Rear light, parking light, stop light . Front and rear stop contacts . Indicators and their dashboard lights . Side lights . Dashboard instrument test . Horn . Starter ❐ O.K. Road trial . Cold start . Dashboard instruments operational . Throttle control response . Stability upon acceleration and braking . Effectiveness of front and rear brakes . Effectiveness of front and rear suspension . Unusual noises ❐ O.K. Fluid circuits . Hydraulic braking circuit fluid level . Engine oil level in 4 stroke motors ❐ O.K. Tightness control . Security tightness (wheel, handle bars) ❐ O.K.

If the control form is not duly stamped, the guarantee will be considered null and void.

CONDITION DE LA GARANTIE SHERCO