500 SEF (2024) - Motorcycle Sherco - Free user manual and instructions

USER MANUAL 500 SEF (2024) Sherco

478,22 cc 95mm X 63.9mm

300 4T Factory Line Off Road Motul

C3 Chain Lub Off Road 50mm...53mm

300V 4T Factory Line Off Road Motul

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 450-500 SEF. All the pleasures of driving are promised to you if you follow the advice and instructions that SHERCO has set in this manual, and ride it in compliance with the applicable traffic laws. This manual explains the operation, inspection, basic maintenance and focus of your SHERCO. If you have any questions about this manual or your machine, you should contact your SHERCO dealer: www.sherco.com / under «Dealers». Be sure to carefully read this manual in its entirety before using your machine. To keep your SHERCO in perfect condition for many years, perform all of the care and maintenance described in the manual. (The vehicle you purchased may differ slightly from the vehicle presented in this manual.) SHERCO reserves the right to make changes without providing notice. Dealer stamp. Save the serial numbers of the vehicle in a safe location Frame number (p.91) Type and serial number of the motor (p.91)85

Overall length Overall width Seat height Wheelbase Ground clearance Type Clutch Primary drive Gearbox Secondary drive Type Displacement Bore / Stroke Compression ratio Distribution Starting System Intake valve diameter Exhaust valve diameter Intake valve cold clearance Exhaust valve cold clearance Spark plug Spark plug gap Electronic injection Alternator Engine oil 2260 mm 820 mm 950 mm 1490 mm 355 mm Manual Multi disc clutch in oil bath, hydraulically operated 25 : 68 6 speed 14 X 50 Single cylinder 4 stroke liquid cooled 4-valve DOHC chain drive Electric starter 38 mm 30,5 mm 0.15-0.2mm 0.2-0.25mm

478,22 cc 95mm X 63.9mm

TECHNICAL SPECIFICATIONS CHASSIS ELECTRICAL EQUIPMENT Frame Fork Rear suspension Travel front/rear Front brake disc Rear brake disc Disc brakes wear limit Front tire Rear tire Pressure off-road front / rear Fuel tank capacity with reserve Fuel requirement Battery Headlight Pilot Rear tail / stop Flasher Speedometer battery Plate light Semi-perimeter CrMo steel with aluminum subframe KAYABA USD Ø48mm Closed cartridge (Factory) KAYABA USD Ø48mm Open cartridge (Racing) KAYABA suspension with separate cylinder 300/330mm Disc Ø260mm Disc Ø220mm 2.7mm avant et 3.6mm back 90/90-21’’ 140/80-18’’ 0,9 bar 9.7L with 1L of reserve Unleaded gasoline with an octane index of at least 95 BS BSLi-02 Lithium (Factory) Yuasa YTX5 LBS (Racing)

Compression Rebound Spring stiffness Type of oil Oil level measurement (fork compressed and spring removed) from the top of the fork tube Comfort Standard Sport Comfort Standard Sport Rider weight: 65-75kg Rider weight: 75-85kg Rider weight: 85-95kg KAYABA 01M 18 clicks back 14 clicks back 12 clicks back 14 clicks back 12 clicks back 10 clicks back 4.2N/mm 4.4N/mm (original) 4.6N/mm 345 cm³ 120 mm

CLEANING PRODUCTS AND CONSUMABLES

Engine oil Engine oil on high temperature or sand condition Coolant Brake Fluid Fork oil Shock oil Aerosol chain lube Air filter cleaner Air filter lubricant Plastic cleaner Wheel Cleaner Disc brake Cleaner Universal lubricant SAE 10W50 SAE 15W60 DOT 4 KAYABA 01M

300 4T Factory Line Off Road Motul

1 - Rear turn signals.

3 - Rear brake pedale.

5 - Front turn signals.

(tail / brake light / plate light).

Controls The serial number of the vehicle is stamped on the right side of the steering tube. The engine serial number is stamped on the left side of the engine housing.

LOCATION OF THE SERIAL NUMBERS

Vehicle serial number location Engine serial number location

The clutch lever is on the left handlebar and has an adjustment screw . High beam (Headlight) Low beam (Headlight) Side light (Night-light) Horn Turn light The front brake lever is on the right side of the handlebar and has an adjustment screw . Two possible positions: Position ON : All lights are on. Position OFF : All lights are off.

Starter button. Injection system mapping selection button. Available with the homologation kit. The main switch has two positions: Position . The engine is off and can not be started. Position . The motor can be started. Dashboard. Mode selection button. Key switch. Left turn position. Right turn position. Off position.

The bike has a “Keyless” system. It allows the bike to start without a key or ON/OFF switch. It automatically turns on and it turns off after 30 seconds of non-use of the bike. Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batteries. Multiple starting attempts may be needed. Press the electric starter button for 5 seconds, and wait 30 seconds between attempts. The pauses are necessary so that the created heat can distribute through the lithium-ion battery and the battery is not damaged. If the charged lithium-ion battery does not or only weakly turns over the electric starter when temperatures are below 15 °C (60 °F), then the battery is not faulty, but needs to be warmed up internally to increase its starting power (current output). The starting power increases as the battery warms up. KEYLESS system 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. Position . “Soft”. Position . “Hard”. Injection system mapping switch Egine emergency stop

Footbrake Side stand The drawing shows the path of the gear selector for each of the 6 speeds. Rear brake pedal. Remove the rubber safety latch , using your foot on the shaft unfold it until it supports the weight of the bike. - The stand has a security system which automatically folds the stand when the bike is moved into an upright position. - The stand is designed to support the weight of the motorcycle only. Gear selector FOOT CONTROLS: GEAR SELECT

Hold buttons 1 et 2: Setup mode Button 1: Change screens 1,2,3 Button 2: Change screens 1,2,3 Hold button 1: Screen 1: DST Adjust Screen 2: DST2 Adjust Screen 1: Speed, Clock, Distance 1 Screen 3: Alternating AVG/MAX speed, Accumulated run time, ODO Screen 2: Speed, Clock, Distance 2 Hold button 2: Screen 1: Reset DST Screen 2: Reset DST2 Screen 3: Reset MAX/ AVG Turn indicator High beam Fuel injection (MIL):EFI problem Low fuel 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) Allows you to decrement the distance in DST. Right button: Allows you to navigate between the different screens Reset DST/DST2, speed MAX/AVG (hold button 3s) Allows to increment the distance in DST. Button mode To avoid water water infiltration, respect a minimum distance distance of 20 cm. CAUTION FI97

Fig 1 SPD function Fig 2 MAX speed function Fig 4 DST function Fig 3 AVG function Fig 5 DST2 function SPD function Current speed (screens 1 and 2): displays the current speed of the vehicle. The speed can be displayed in km/h (default) or mph. (p.99). 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. 99). Reset to 0 MAX 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.99). Reset to 0 DST Function Hold the right. Button down for 3seconds 0.0 Reset to 0 done. AVG function Average speed (screen 3): 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.99). Reset to 0 AVG Function Right button down for 3seconds 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. ( p.99). Reset to 0 DST2 Function Hold the right. Button down for 3seconds 0.0 Reset to 0 done.98

CONTROL DEVICES AND CONTROLS

Fig 6 Adjustable trip distance function Fig 7 ODO function Fig 9 Clock function Fig 8 ART function Fig 10 Low battery/ Low battery error function DST and DST2 can be incremented or decremented by the user. DST set up (screen 1) Hold the left Button down for 3 seconds DST» icon will flash Hold left Button to decrement/ Hold the right Button to increment back to screen 1. DST set up (screen 2) Hold the left Button down for 3 seconds DST2» icon will flash Hold left Button to decrement/ Hold the right Button to increment back to screen 2. 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.99). This information can not be reset to 0. Beyond 399 999 km (or miles), the counter goes back to 0. Clock function (screens 1 et 2): displays clock information. 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. 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.99

Miles or km Default: km 12 or 24h Default: 24h Clock setup Maintenance reminder setting ( in hours) Default setting: 5h (first oil change) The meter will automatically advance from one setting option to the next, after 5s of no button activation Set up menu UNIT (Unit type) (Clock format) (Clock setup) (Maintenance reminder) Left and right buttons pressed simultaneously for 3s activates the Set up mode Toggle between M/H and KM/H settings Toggle between 24 Hour et 12 Hour Left button Decrement time of day value Decrement maintenance reminder value Right button Increment time of day value Increment maintenance reminder value OFF : disabled Set the value LIFE (Wheel circumference) Do not modify these settings PPr (Pulse per revolution) Maintenance reminder: Allows user to define a countdown for maintenance operations. When the maintenance countdown gets to zero, the maintenance icon will appear on the LCD. Displaying the remaining accumulated ride time : From main screen hold the left button down for 3 seconds the remaining value is displayed no button activation automatic return to screen 3. Note : If the maintenance reminder is turned off , the information displayed on the screen will be OFF. Resetting the remaining accumulated ride time : From main screen, hold the left button down for 3 seconds the remaining value is displayed hold the right button down for 3 seconds the maintenance reminder is reset to zero (will begin the countdown again according to the maintenance interval already chosen in the set up menu).100

Filler cap Use only unleaded fuel with an octane index of at least 95. Open: Turn the cap counterclockwise. The opposite direction to the hands of a watch. Close: Turn the cap clockwise. The same direction as the hands of a watch. Fuel101

1. Set the gear selector to neutral.

3. Start the engine by pressing the starter button, without accelerating.

4. Allow the engine to warm up for a few minutes.

5. Push in the choke.

Follow the previous instructions without steps 2-4 and 5. - The positions of the gear selector are shown on (p.95). - To find the neutral position, press the selector down into first gear (a resistance will be felt), then move the selector up slightly. - Close the throttle before changing gears. - Engage the lowest gear. - Partially open the throttle while engaging the clutch. - Stop the engine with the stop button. The Keyless system will automatically switch off the ignition after 30 seconds of non-use of the bike. Become familiar with all of the controls and their functions before using the vehicle. Cold engine starting Hot engine starting Shifting gears Parking102 SAFETY INFORMATION - Do not drive after consuming alcohol. - Wear a helmet when using the vehicle. - Keep the machine in good working order and maintain it properly so that it is reliable and safe for use. - Gasoline is flammable, refuel the motorcycle when the engine is stopped. - Exhaust fumes are toxic, you should never start the engine in a closed building. - Always park the vehicle on a flat hard surface, do not park the vehicle on a slope or on soft ground. Always control the balance of the vehicle. - Check the following every day before riding the motorcycle: 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. Tires: Engine oil: Gasoline: Transmission chain: Direction of travel: Brakes: Throttle: Clutch: Electrical Equipment: Components (nut, bolts ...): Wear and pressure. Level (p.107). Check the level and make sure there is no leaks. Properly lubed and adjusted (p.122). check for hard spots. Operation, fluid leakage, brake pad wear (p.129 to p.133). Proper operation ( p.106). Proper operation ( p.122). Operation of the horn and lights ( p.92 to p.93). Verify that all components of the vehicle are properly tightened ( p.146).103

- The hot liquid can cause severe injuries. - The coolant is harmful. - In case of skin or eye contact, or ingestion, or injury from hot liquid hot liquid: SEEK MEDICAL ADVICE. - 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. 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. WARNING ATTENTION - Place the bike upright on a horizontal surface. - Remove the cap . - Remove the bleed screw . - Fill until the liquid comes out without air. Fill the coolant to the top of the radiator. Replace the cap and check to make sure it is tight. Motorcycle horizontal

Approved Coolant Motul

Make sure the motorbike is upright and on level ground. - Place a container under the bike. - Remove the cap and screw . - Allow the coolant to drain. To protect the environment, dispose of the drained liquid to a collection point. WARNING Check the fluid level in the expansion container. The liquid should reach the level on the container where it indicates “LEVEL MIN”. If the level is not correct, unscrew the cap . Fill with fluid until it reaches the LEVEL MIN mark. Replace the cap .

Approved Coolant Motul

- Replace the bleed screw using a new sealt. - Refill the coolant into the radiator through the cap . - Fill coolant until is going out from the screw . - Put the screw back in with a new seal. - Continue filling. - Fill until the coolant reaches the level (approximately

Throttle cable play 2....4mm MOTOR SETTINGS CHECKING THE PLAY IN THE THROTTLE CABLE With the handlebars facing straight ahead, check that the throttle twist grip functions properly. If the cable play is not correct, adjust the accelerator throttle cable play.. ( ci-dessous). Start the bike and let it run at idle. Turn the handlebars and check that the idle speed is constant. If the speed changes, readjust the play in the throttle cable ( ci-dessous). Checking the throttle cable play Adjusting the play in the throttle cable Adjust the tension of the gas cable at the handle with the tensioner . Loosen locknut and adjust the tension of the cable with the tensioner . Once the desired play has been reached, tighten the lock nut .

- Make sure that the bike is on its two wheels, vertical and on a horizontal surface. - Check the engine oil level by viewing the sight gage located on the clutch housing . - Adjust the level according to the diagram shown below. If necessary add oil to achieve the correct oil level: - Unscrew the engine oil filler cap located on the clutch housing Topping up the engine oil.

Engine Oil SAE 10W501,1L - Improper oil level can damage your engine. - Do not use your bike if the level is below the minimum. WARNING

Level warm engine Level cold engine108 MOTOR MAINTENANCE DRAINING THE ENGINE OIL AND REMOVING THE OIL FILTER - When draining the oil the engine should be warm. - Position the motorcycle upright on a level surface. - Place a container under the bike to catch the old oil. - Remove the drain plug and . - Remove the magnetic drain plug . - Remove the pre-filter and . - Allow the oil to drain - Remove the screws and remove the chain guard . - Remove the oil filter cover . - Use a hook to remove the oil filter . - Let the oil drain. - Clean the drain plugs , and with a degreaser. - Clean and inspect the pre-filters and and change them if necessary.

- Install a new oil filter , install in the direction shown in the photo. - Install the cap using a new O-ring. - Install the plug using a new gasket. - Install the pre-filters and the drain plugs and with new seal and . - Remove the engine oil filler cap ( p.107). - Fill the engine with oil. - Install the engine guard. - Check the oil level in the sight gage. - Add additional oil if necessary.

Oil Filter cap Magnetic drain plug Motor oil Drain plug Drain plug 15Nm 15Nm SAE 10w50 15Nm 20Nm M45 M12 1,1L M18 M21 The oil filter should be replaced at each oil change. NOTE To protect the environment, oil, oil filters and used material must be deposited in a collection center and not down the drain or in the wild. WARNING

HANDLEBAR POSITION The triple clamps have two holes separated by a distance A. The handlebar clamps are offset by a distance B. The bike comes standard with the handlebars in the rear most position. Remove the four screws . Remove the handlebar top clamps and remove the handlebar. Remove the two screws . Remove the lower clamps and place them in the desired position. Replace the handlebars and top clamps. Replace the four screws and tighten evenly. The handlebars can be rotated forward and rearward in the clamps. Distance between holes A Handlebar offset B 13mm 4mm

BASIC SETTING OF THE CHASSIS ACCORDING TO THE RIDER WEIGHT 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. If the weight of the rider is above or below the standard, compensate by changing the stiffness of the springs (forks and shock). Steering angle lock nut Standard weight of therider (with equipment) M8 20Nm 75 to 85kg

Screws determine the behavior of the fork when it is compressed. Turning in the screwclockwise increases the hydraulic force (and vice versa). Turn screw clockwise to the stop and go back the number of clicks required. 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 lower fork legs. Turn the screw clockwise to the stop then go back the number of clicks required.

ADJUSTING THE REAR SHOCK LOW-SPEED COMPRESSION SETTING ADJUSTING THE REAR SHOCK HIGH-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 .

The adjusting nut determines the high speed behaviour of the rear shock (big hits).Turning the screw clockwise increases the hydraulic force (and vice versa). Turn the nut clockwise with a socket wrench until it stops and then back the number of clicks required. Do not loosen the screw .

The adjusting screw determines the Shock rebound behavior. Turning the screw clockwise increases the hydraulic force (and vice versa). Turn the screw clockwise to the stop then go back the number of clicks required.

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. If the static deflection is not correct, adjust the preload of the shock ( p.115). 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. If the sag is not correct, change the spring ( p.115).

- Remove and clean the rear shock unit ( p.124). - Select and install a spring based on your weight. - Reinstall the shock. - Adjust the sag ( p.114). - - Adjust the riding sag ( p.114). Indications Loosening one turn Tightening one turn Decreases the overall length by 4mm. Increases the overall length by 4mm.

Spring Rate Rider Weight (with equipment): 65-75kg Rider Weight (with equipment): 75-85kg Rider Weight (with equipment): 85-95kg KAYABA 44N/mm 46N/mm 48N/mm

Turn the Dzeus fastner a quarter turn counterclockwise to release the saddle. Remove the seat by pulling it towards the back of the bike. 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. 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. Unscrew the thumb screw . Remove the filter with the plastic carrier . Separate the filter from its plastic holder.

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 seat ( p.120). Clean the foam air filter with a special liquid cleaner and let dry. If necessary clean the inside of the air box with a cloth.

Do not clean the air filter with a solvent or gasoline. Do not wring out the filter by twisting. Press only. Soak the air filter in an air filter oil. INFO INFO Air filter cleaner Air Filter oil Motul

Remove the seat ( p120). Unscrew the fuel tank fixing screws . Remove the fuel tank breather hose . 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 of the injector. Unscrew the screws on the right and left radiator panel. Remove the fuel tank by pulling upwards, provide lateral clearance by slightly moving the radiator panelss. Use caution when removing the fuel tank and do not damage any of the fuel hoses or electrical connections.

Reassembly of the fuel tank. Be sure to correctly position the throttle and clutch hose . 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 make sure 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 pump wire and the fuel hose . Install the fuel tank mounting screw along with its rubber insert . Install the radiator side panel screws . Install the fuel tank breather hose. Reinstall the seat ( p.120). Chassis screws M6 10Nm

CLEANING THE FORK DUST SEALS

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 screws caps . 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.121). Take the bike off of the stand. Place the motorcycle on a suitable stand. Remove the front wheel ( p.125). Remove the fork protectors. Slide the dust cover down. Clean and lubricate the dust cover and the fork tube. Reinstall the dust cover and clean off any left over oil. Reinstall the fork protection. Reinstall the front wheel ( p.125). Take the bike off of the stand.

CHECKING THE CHAIN TENSION

Place the motorcycle on a suitable stand. Loosen screws and . Loosen or tighten the nut to adjust the steering bearing play. Tighten the screws . Tighten the screws . Check the play of the steering head bearings. ( p.120). Remove the bike from the stand. Place the motorcycle on a suitable stand. Push the chain up and measure the chain movement as shown in the diagram. If the chain tension is not correct, see how to adjust the chain ( p.122). Otherwise, remove the bike from the stand.

243™ M20 M8x35 M8x35 M8x30 25Nm 30Nm 17Nm 12Nm The bearings should be greased at least once a year with a good quality grease. NOTE Regularly cleaning the chain considerably increases its service life. Clean the chain and apply chain lubricant. Chain Cleaner Chain grease Chain tension Motul

C3 Chain Lub Off Road 50mm...53mm

Place the motorcycle on a suitable stand. Loosen nut . Loosen the nuts . Loosen or tighten the screws until you have the correct chain tension. Monitor the symmetry of the two sides by observing the position of the marks . Tighten the screws . Tighten the nut . Remove the bike from the stand. 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. Improper chain tension can cause mechanical damage. WARNING

Chain tension 50mm...53mm Rear axle nut M24 100Nm The sliding piece is designed to accommodate longer chains by turning it 180 degrees. NOTE

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

Clutch lever free play A ≥3mm WARNING - The hydraulic fluid is highly corrosive it can be dangerous to the skin. - Read the recommendations on the container. Position the master cylinder horizontally. - Remove the two screws , the cover and the membrane . - Check the fluid level and fill if necessary. - Reinstall the lid with the membrane and the screws.

Level of brake fluid below the top of the reservoir. 4mm Motul

Place the motorcycle on a suitable stand. Remove the right side plate. Remove the screws and and the muffler along. Do not remove the muffler after operating the motorcycle. It can behot and there is a risk of being burned. Remove the shaft . Remove the screw . Remove the top screw of the shock. Remove the shock from the top. Install the shock from the top. Install the top screw and tighten. Position the rods and “H” link. Install the lower shock screw and tighten. Install the lower shock shaft and tighten. Reassemble the exhaust, the 2 springs and the 2 bush. Reassemble the rear silencer and tighten screws using the nylock self-locking nuts. Install right side plate. Remove the bike from the stand. ATTENTION

Upper shock screw Lower shock screw Loctite

Link axle Chassis screws M12

Place the motorcycle on a suitable stand. Remove the two screws and the nut . Loosen the two screws . Pull the axle through the right side. Remove the wheel from the fork. Do not operate the front brake lever when the front wheel is removed. Check if the brake disc is not dirty or contaminated with oil or grease. If it is, clean the disc with brake cleaner. 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 . Install and tighten the axle nut . Tighten the screws on the right side of the bike. Loosen screws . Actuate the front brake lever several times until the brake pads touch the disc. Remove the motorbike from the stand and push the fork several times. Tighten the 2 screws . WARNING Motul

P2 Brake CleanBrake cleaner

Fork screws Fork leg screws Front wheel axle nut

REMOVING THE REAR WHEEL

REINSTALLING THE REAR WHEEL

Place the motorcycle on a suitable stand. - Unscrew the nut and remove the adjuster . - Tap the axle out using a nylon hammer. - Remove the axle. - Move the wheel as far forward as possible. - Remove the chain and wheel. Do not operate the rear brake pedal when the rear wheel is removed. Check if the brake disc is not dirty or contaminated with oil or grease. If it is, clean the disc with brake cleaner. Install the two spacers and and make sure they are positioned correctly.

P2 Brake CleanBrake cleaner

Install the rear wheel in the swing arm and install the axle (grease the axle prior to installation). Mount the chain. Install the chain tensioner and install the nut but do not tighten. Check the chain tension ( p.122). Tighten the nut . Operate the rear brake pedal several times until the pads touch the disk. Remove the bike from the stand. 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. If the pressure does not comply with the above table: - Correct the pressure. - Replace the valve cap. 0,9bar (13 psi) 0,9bar (13 psi) Front Rear

CHECKING FOR WEAR AND DAMAGE

- Regularly check the depth of the tread. 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. Tread depth ≥3mm

CHECKING SPOKE TENSION

Do not neglect the tension of the spokes. 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. WARNING Indicative tightening torque 5 - 6 Nm129

Pull the lever toward the handlebar and check the free play . 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. If the level is below the MIN mark, top up the brake fluid according to the instructions below. Free play of the front brake lever ≥3mm

BRAKES - The hydraulic fluid is highly corrosive. - It can be dangerous to the skin. - Read the recommendations on the container. - Remove the two screws . Remove the cover and the membrane . Fill the tank with brake fluid to the correct level . - Reinstall the membrane, the cover and the screws. 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. Check the pedal travel ( below). - Remove the spring . - Operate the pedal several times. - Replace the spring . If the travel does not meet the specification, refer to the rear brake travel adjustment.( p.135). WARNING

BRAKES - Remove the spring . - Loosen the nut and turn the shaft . Hold the shaft and tighten the nut . Position the motorcycle on a flat surface. Check the fluid level through the sight glass. Ensure that the level (between the arrows) is closest to the up arrow. If the level is below the MIN mark, top up the brake fluid according to the instructions below. Remove the cap with its membrane . Fill with fluid to the mark as shown . - Reinstall the membrane and the cover using a new O-ring.

BRAKES - Remove the clip and retaining pin . - Remove the brake pads. Do not operate the front brake lever or rear brake pedal when the brake pads are removed. Check if the brake discs are not contaminated with oil or grease. In they are, clean the discs with brake cleaner. REMOVING THE FRONT AND REAR BRAKE PADS REINSTALLING THE FRONT AND REAR BRAKE PADS

Check the pads for wear. If replacement is necessary, always change the pads in pairs. CHECKING THE CONDITION OF THE BRAKE PADS

Minimum pad thickness ≥1mm Motul

P2 Brake CleanBrake cleaner

BRAKES Install the new pads. Reinstall the retaining pins and clips . Check the brake fluid level and fill if necessary ( p.129 and p.131). Do not use the bike until the brake lever and the pedal are operational. ÿPumpŸ the brake lever / brake pedal up and down until the brake pads are in contact with the discs. Turn off all electric devices and stop the engine. 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.116). - Remove the air filter ( p.116). 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.

- 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 . - 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.116). - Replace the seat ( p.116). 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.133). Check the voltage of the battery with a voltmeter: If the voltage is below the specification, remove the battery and recharge it using a battery charger. Factory version need a specific lithium charger. Disconnect the charger after charging. Install the battery ( above).

or 5A for 30 minutes

Remove the seat ( p.116). The main fuse is on a relay by the starter. Remove the defective fuse and replace with a new fuse of the same value. Put a new spare fuse in the reserve location in the fuse box. - Replace the seat ( p.116). Remove the seat ( p.116). The light 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. - Replace the seat ( p.116).

REPLACING THE MAIN FUSE

Unclip the left and right rubber fastners 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.

Connect the electrical connector. Engage the light plate, ensuring that the holes in the plate are in place . Place all of the brake hoses / cables in the interior of meter upper guide . Attach the rubber fastners. Check the setting of headlight beam.( p.137). Remove the headlight housing assembly ( p.139) Remove the protective rubber . Turn the socket a quarter turn counterclockwise to remove it from the headlight assembly. Gently press the bulb in while turning it counterclockwise and remove it from the socket. Install a new bulb . 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 . Reinstall the headlight housing assembly.

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 ( p.139).

2. Remove the turn 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 the computer.

5. Open the dashbord with a coin.

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

7. Replace the cover, taking care not to damage the

8. Plug the main connector into the computer.

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

10. Reinstall the computer support.

11. Install screws and replace the turn signal flasher.

SHERCO advises you to wash your bike as often as possible in order to maintain it in good working order and prolong its life.

1. Cover the end of the exhaust silencer and the air

filter (to cover the exhaust outlet use part number 8527, to cover the air intake use part number 4476).

2. To degrease the engine, apply a degreaser, clean

with a brush then rinse the engine with a water hose.

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

4. Rinse with clear water.

5. Dry with a chamois or a clean, soft cloth.

6. Clean the chain and lubricate it with a special

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. In order to avoid any water ingress, keep a minimal washing distance of 20cm. 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.

6. Lubricate all cables with a spray lubricant.

7. Jack the motorcycle up so that the wheels are

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.

MAINTENANCE SCHEDULE MAINTENANCE Every 20 hours After 5 hours ENGINE Change engine oil, filter, clean pre filter and change if necessary Clean the magnetic drain plug Replace spark plug (after 50 hours) Check and adjust valve clearances Check engine mounting bolts for tightness INJECTION Clean the venturi ACCESSORIES Check cooling system for leaks Check sealing and attachment of the exhaust Check status, flexibility and position of the cables, adjust and lubricate Check oil level in clutch master cylinder Clean air filter and housing Check status and position of the electrical wiring Check function of electric components (headlight/tail/stop turn signals, computer control unit, etc.) BRAKES Check brake fluid level, brake pad thickness and the brake discs Check status and sealing of the brake lines Check status, of the foot brake pedal and hand brake lever Check tightness of brake system fastners and discs CHASSIS Check for leaks and function of fork and shock Clean the dust covers Purge air from the fork legs Check general tightness of bolts and screws Check / adjust steering head bearings WHEELS Check rims and spoke tension Check condition of the tires and tire pressure Check chain, sprockets, guides, chain tension Lubricate the chain Check wheel bearing clearance140 ANNUAL MAINTENANCE After each use Au moins 1X par an Before each use MAJOR MAINTENANCE ITEMS THAT SHOULD BE PERFORMED BY THE DEALER Fork Shock Clean and grease steering head bearings and seals Replace fiberglass in the muffler Treat electric contacts and switches with an aerosol protector Replace the brake fluid Check the engine oil level Check brake fluid level Check status of the brake pads Verify operation of the lights Verify operation of the horn Lubricate throttle cable Regularly purge the air from the fork legs Regularly clean the fork dust seals Clean and lubricate chain, check tension and adjust if necessary Clean air filter and box Check tires and tire pressure Check the coolant level Check fuel lines for leaks Check status of all the controls Check the brakes Spray anti-corrosion protector on all non painted parts (except for the brake parts and the exhaust system) Spray protector on electrical switches Check tightness of nuts, screws and clamps 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! WARNING MAINTENANCE SCHEDULE CHECKS AND MAJOR MAINTENANCE TO BE PERFORMED BY THE RIDER141

FRANÇAISENGLISHESPAÑOLDEUTSCH

MAINTENANCE SCHEDULE Check the clutch discs for wear Check the length of the clutch springs Check that the clutch nut is not marked Check that the clutch bell is not marked Check the wear of the cylinder Replace the piston Check valve clearances Check camshafts for wear Check the wear of the cups Check valve guides for wear Replace the valves Replace the valve springs Check the operation of the timing chain tensioner Check the run-out at the end of the crankshaft Replacement of the connecting rod Replace crankshaft bearings Check the total wear of the gearbox (sprockets, bearings, forks) Replace the rock wool in the exhaust silencer Check the length of the timing chain Check the camshaft bearings Checking ECU errors with the Sherco diagnostic tool Checking and charging the battery Checking the fuel pressure Checking oil pumps Injection body cleaning + stepper Every 50hours Every 30hours Every 20hours Every race

IMPORTANT CHECKS AND MAINTENANCE WORK

TO BE CARRIED OUT BY A SHERCO WORKSHOP Sand competition use142 TIGHTENING TORQUES

TIGHTENING TORQUES CYCLE PART

Screw emergency stop button Spoke nut Battery screw Injection body cover screw Master cylinder cover screw T map sensor screw Odometer screw Rear light screws Frame protection screw Other frame screw Air filter support nut Lever return plate Actuator screw slows down Filter flap screw TPS sensor screw Gas control screw Light switch screw Brake pedal end screw Fork air bleed screw Regulator screw Brake hose support screw Injector support screw Hand guard support screw Expansion tank screw Other frame screw Starter cable nut Battery screw Screw Db killer Odometer support screw Front mudguard screw Chain guide screw Skid plate bottom screw Rear master cylinder screw Clutch master cylinder screw Front brake master cylinder screw Radiator side panel screw ( Tank) Chain slider screw Chain guard screw Fork protection screw Chain sprocket protection screw Value (Nm) 3Nm 5Nm 7Nm 3Nm 7Nm 5Nm 5Nm 1Nm 2Nm 7nm 10Nm 7Nm 8Nm 7Nm 8Nm 10Nm 7Nm 7Nm 3Nm 8Nm 7Nm 8Nm 10Nm 10Nm 10Nm 7Nm 10Nm 10Nm 10Nm 12Nm 12Nm 8Nm 8Nm 10Nm 10Nm 3Nm 8nm 8Nm 12Nm Dimension

M10 M10 M10 M10 M10 M10 M10 M12 M12 M12 M12 M16 M20 M20 M24 Thread Blue Blue Blue Cooper grease Blue Red Cooper grease Blue Blue Cooper grease Cooper grease Blue Blue Cooper grease Cooper grease Red Cooper grease Grease144 TIGHTENING TORQUES Hose guide screw Headlight switch screw (Racing) Hand protector screws Flap support screw Fan screw Clamp Value (Nm) 2Nm 2nm 3Nm 3Nm 3nm 7Nm Dimension Parker Parker Parker Parker Auto-perforate Thread

TIGHTENING TORQUES ENGINE PART

Engine speed sensor screw Stator screws Decompressor screw Bearing lock plate screw Oil collecting screw Water pump impeller nut Limiter shaft screw Starter pinion shaft screw Oil pump intermediate pinion shaft screw Cylinder head cover screw Clutch slave cylinder screw Ignition casing screw Clutch housing screw Crankcase screws Water pump cover screw Electric starter screw Camshaft guide plate screws Locking finger screw selection Oil pump cover screws Selector star screw External cylinder head screw Timing tensioner shutter screw Distribution guide pad screw Timing tensioner pad screw Clutch spring screw Timing tensioner screw Coolant drain screw Exhaust pipe nut Exhaust pipe stud Selection shaft stop screw Camshaft bearing screw Value (Nm) 7Nm 7Nm 8Nm 8Nm 7Nm 10Nm 12Nm 12Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 10Nm 7Nm 12Nm 12Nm 10Nm 10Nm 7Nm 25Nm 25Nm 15Nm 12Nm Dimension

DIMENSIONS Overall length Overall width Seat height Wheelbase Ground clearance CHASSIS Frame Fork Rear suspension Travel front/rear Front brake disc Rear brake disc Disc brakes wear limit Front tire / Tire pressure Rear tire / Tire pressure Fuel tank capacity with reserve Fuel requirement ENGINE Type Displacement Bore / Stroke Compression ratio Distribution Starting System Intake valve diameter Exhaust valve diameter Intake valve cold clearance Exhaust valve cold clearance Spark plug Spark plug gap Electronic injection Alternator Engine oil 2270mm 825mm 885mm 1488mm 280mm Semi-perimeter CrMo steel with aluminum sub-frame KAYABA USD Ø48mm Closed cartridge KAYABA USD Ø48mm Open cartridge 300mm/300mm Ø310mm Ø220mm 2.7mm front and 3.6mm rear 120/70 R 17 / 2bar 150/60 R 17 / 2,2bar 9,7 L with 1L of reserve Unleaded gasoline with an octane index of at least 95d’au moins 95 Single cylinder 4 stroke liquid cooled 478,22cc 98X63,4mm 11.60:1 4-valve DOHC chain drive Electric starter 38mm 30,5mm 0.15-0.2mm 0.2-0.25mm

TRANSMISSION Type Clutch Primary drive Gerarbox Secondary drive

ADJUSTMENTS - KAYABA USD Ø48MM

Compression Rebound Type of oil

CLEANING PRODUCTS AND CONSUMABLES

Engine oil Coolant Brake Fluid Fork oil Shock absorber oil Aerosol chain lube Air filter cleaner Air filter lubrican Plastic cleaner Wheel Cleaner Disc brake Cleaner Universal lubricant Motul

300V 4T Factory Line Off Road Motul

CHASSIS Every year After each race Every 100 using hours/Every 5000kms Every 50 using hours/Every 2500kms Every 40 using hours/ Every 2000kms Every 30 using hours / Every 1500kms Every 20 using hours / Every 1000kms Every 10 using hours / Every 500 kms After 1 using hour Check fault code Check state and tire pressure Check spoke tension Check chain tension Check status and sealing of the brake/clutch lines Check general tightness of bolts and screws Change engine oil, filter, clean pre filter and change if necessary Check battery Check / Adjust steering head bearings Check brake pad thickness Check status, of the foot brake pedal and hand brake lever Check/Adjust brake fluid level Check Discs thickness and screws tightness Check the chassis Check the swingarm Check general bearings clearance (Swingarm, Links, wheels…) Check Rims and Hubs Check/Adjust coolant fluid level Check status, flexibility and position of the cables, adjust and lubricate Clean air filter and box Fork maintenance Shock absorber maintenance Replace exhaust Rockwool Grease Links bearings Grease direction bearings149

ENGINE Every year After each race Every 100 using hours/Every 5000kms Every 50 using hours/Every 2500kms Every 40 using hours/ Every 2000kms Every 30 using hours / Every 1500kms Every 20 using hours / Every 1000kms Every 10 using hours / Every 500 kms After 1 using hour Change engine oil, filter, clean pre filter and change if necessary Change Spark plug Check the clutch disc wear Replace the piston Check the wear of the cylinder and piston Control cylinder head Control the valve clearance Control the wear and state of the camshaft Replace the valves the valve springs, washers Replace the connecting rod Check/replace the gear box (gears, shift forks…) Replace oil Pump Replace timing chain Replace all bearings of the central carters Replace all O-ring of the engine Replace timing chain tensionerWARRANTY ENGLISH153

FRANÇAISENGLISHESPAÑOLDEUTSCH

WARRANTY Dealer’s stamp. VEHICLE: DATE : VIN: SELLER : ENGINE N°: CUSTOMER: ADDRESS: POSTAL CODE : COUNTRY: VEHICLE INFORMATION154 WARRANTY WARRANTY TERMS SHERCO MOTORCYCLES grants a contractual guarantee that can vary from one month to two years depending on the model. The duration of this will be indicated to you by your dealer in accordance with the warranty conditions. The conditions and cover of this contractual guarantee are detailed below. VEHICULE REGISTRATION: On the day of delivery of the motorcycle, the dealer and the customer undertake to complete this booklet as well as the vehicle acceptance form. The vehicle must then be registered by the dealer on the dedicated website. No warranty will be accepted if the vehicle has not been registered. In case of resale of the vehicle, the contractual guarantee is transferable to the new owner by means of this book. OBTAINING SERVICES UNDER THE CONTRACTUAL WARRANTY: Any questions regarding the warranty should be discussed directly with your dealer. All warranty repairs should be performed by an authorized SHERCO dealer. When requesting warranty coverage, present this booklet to your dealer. SHERCO MOTORCYCLES suggests contacting your dealer who sold the vehicle; however, all authorized SHERCO dealers can perform warranty repairs.

CONDITIONS FOR OBTAINING THE CONTRACTUAL WARRANTY

Any request for coverage under the contractual warranty is subject to compliance with the maintenance procedures and intervals detailed in this booklet and in the owner’s manual. This duly completed booklet, as well as the invoices, are proof of vehicle maintenance. The supporting documents (invoices) detailing the operations carried out will be essential to benefit from the contractual warranty granted by SHERCO MOTORCYCLES. INFORMATIONS: It is recommended that maintenance be carried out with an authorized SHERCO dealer because only he has the specific tools and technical information for proper maintenance. The use of genuine SHERCO parts only will guarantee the validity of the contractual warranty The recommended maintenance does not in any way exempt the user from performing certain daily checks (refer to the owner’s manual). In the event of an anomaly, contact your dealer as soon as possible. It is the responsibility of the vehicle owner to take all precautions and measures to avoid further damage. Any indirect damage resulting from continued use of the vehicle after a problem has been identified will not be covered by the contractual warranty.

CONTRACTUAL WARRANTY COVERAGE

Excluded from the warranty are all round-trip transport costs to the dealership, accommodation or meals costs, breakdown assistance or delivery costs and loss of use of the vehicle. This warranty does not cover accidental damage, natural disasters, fires, nor does it cover any other cause which is beyond the control of SHERCO MOTORCYCLES. Will not be covered by the contractual guarantee, any damage resulting from modifications which would have to increase the engine power, poor lubrication due to incorrect carburetion settings, fitting of a part or accessory not sold by SHERCO MOTORCYCLES, Use lubricants or fluids not recommended by SHERCO MOTORCYCLES and failure to follow periodic and daily maintenance procedures. Not covered by the contractual warranty, maintenance and upkeep work, replacement of wearing parts, aesthetic phenomena that do not affect the proper functioning of the vehicle, surface imperfections related to external constraints (heat, cold …) And with aging, vibrations and noises linked to the operation of the vehicle, the replacement of parts in the context of design changes.155

FRANÇAISENGLISHESPAÑOLDEUTSCH

WARRANTY LIMITATION OF WARRANTY AND REMEDIES: The warranty does not provide cover for consumer products, wear parts, products in contact with friction surfaces, or exposed to the elements. SHERCO MOTORCYCLES assumes no liability towards anyone for direct or indirect damage of any kind whatsoever covered by any other warranty, express or implied or resulting from any other contract, negligence or abuse of any kind.

CONTROL AND MAINTENANCE

Mandatory minimum annual check To ensure safe driving and allow you to fully enjoy your motorcycle, a minimum annual check must be carried out (refer to the owner’s manual). Frequency of maintenance The frequency of maintenance has been defined according to average use. For vehicles subjected to extreme driving, maintenance should be carried out more frequently. Extreme driving definition - Prolonged use at high speed - Prolonged use at low speed - Use in cold weather - Use in dusty or saline environment Please present this log at every service so that the dealer can stamp it and provide service information.156 WARRANTY Dealer stamp & signature. Sherconetwork

478,22 cc 95mm X 63.9mm

4T Factory Line Motul

300 4T Factory Line Off Road Motul

C3 Chain Lub Off Road 50mm...53mm

300V 4T Factory Line Off Road Motul

478,22 cc 95mm X 63.9mm

4T Factory Line Motul

300 4T Factory Line Off Road Motul

C3 Chain Lub Off Road 50mm...53mm

CLEANING PRODUCTS AND CONSUMABLES

300V 4T Factory Line Off Road Motul