DEFYGRAVITY SHERCO 250-300 SE/R Manual Download | Manualshive

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250-300 SE/R

1

2

A

B

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

1

. Remove the handle-

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

2

. Remove the lower

clamps and place them in the desired position.

Handlebar
lower clamp

M10x35 40Nm Loctite

®

243

™

Replace the handlebars and top clamps. Replace
the four screws

1

and tighten evenly.

Handlebar clamps
fixing screws

M8x25

24Nm

The handlebars can be rotated forward and
rearward in the clamps.

98

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Summary of Contents for SHERCO 250-300 SE/R

Page 1: ...ENGLISH INDEX n FRANÇAIS P 1 n ENGLISH P 68 n ESPAGNOL P 135 ...

Page 2: ...ve 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 th...

Page 3: ...from the forks 39 Cleaning the fork dust seals 40 Checking the play of the steering head bearings 40 Adjusting the steering head bearing play 41 Cleaning the chain 41 Checking the chain tension 41 Adjusting the chain tension 42 Adjusting the lever 42 Checking the clutch fluid level 43 Dépose du sabot moteur 43 Removing the rear shock 44 Reinstalling the rear shock 45 Wheels tires 46 Removing the f...

Page 4: ...ition system DC CDI no switch with digital advance Spark plug NGK BR8ES DENSO W24ESRU Spark plug gap 0 7 mm Alternator 220W Engine oil 750 ml 10 W 40 Technical Specifications CARBURETOR Type of carburetor KEIHIN PWK 36S AG Needle position 4th position from the top 3th position from the top Needle jet N8RJ N84K N8RG Main jet KEA 165 KEA 115 Pilot jet KEP 40 KEA38 KEP 38 Starter jet 85 50 Air screw ...

Page 5: ...der Travel front rear 300 300mm Front brake disc 270mm standard 256mm racing Rear brake disc disque Ø 220mm Disc brakes wear limit 2 7mm front and 3 6mm rear Front tire 90 90 21 Rear tire 140 80 18 Pressure off road front rear 0 9 bar Fuel tank capacity with reserve 9 5l with 1l of reserve Fuel requirement Unleaded gasoline with an octane index of at least 95 mixed with 2 stroke oil 2 69 ...

Page 6: ...95kg 4 4N mm Type of oil SAE 4 Oil level measurement fork compressed and spring removed from the top of the fork tube 110mm Battery Yuasa YTX5 LBS 12V 4Ah Headlight S2 12V 35 35W Pilot W5W 12V 5W Rear tail stop LED Flasher R10W 12V 10W Speedometer battery CR 2032 Battery voltage 3V Plate light W5W 12V 5W ADJUSTMENT SACHS FRONT FORK USD GOLD SERIES Ø48MM Compression 12 clicks back Rebound 12 clicks...

Page 7: ... weight 75 85 kg 51N mm original Rider weight 85 95kg 54N mm CLEANING PRODUCTS AND CONSUMABLES Engine oil SAE J 300 10 W 40 Minerva SAE 10W40 Coolant Minerva Perma Universal D 4 seasons 25 C Brake Fluid DOT 4 Minerva brake fluid DOT 4 Fork oil SAE 4 Shock oil SAE2 5 Aerosol chain lube Minerva aerosol chain lub Air filter cleaner Minerva air filter cleaner Air filter lubricant Minerva Protect Air P...

Page 8: ...re 2 Selle 3 Pédale de frein arrière 4 Réservoir 5 Clignotants avant 6 Phare n Right side 1 Rear turn signals 2 Saddle 3 Rear brake pedal 4 Fuel tank 5 Front turn signals 6 Headlight 7 Fuel tank cap 8 Rear light tail brake light plate light 9 Gear selector pedal n Left side 72 ...

Page 9: ...ial number location q Left mirror w Clutch lever e Left switch r Dashboard t Key switch y Right switch u Front brake lever i Poignée d accélérateur n Controls 2 The engine serial number is stamped on the right side crankcase 1 The serial number of the vehicle is stamped on the right side of the steering tube Engine serial number location 73 ...

Page 10: ...ight Night 4 Horn 5 Flashers n Light switch on off 250 300 SE R Two possible positions Position ON 1 All lights are on Position OFF 2 All lights are off n Clutch lever The clutch lever 1 is on the left handlebar and has an adjustment screw A B n Front brake lever The front brake lever 2 is on the right side of the handlebar and has an adjustment screw B Control devices and controls 74 ...

Page 11: ...ch has two positions Position 1 The engine is off and can not be started Position 2 The motor can be started n Key switch 250 300 SE 1 Dashboard 2 Mode selection button 3 Key switch 250 300 SE n Dashboard 250 300 SE R 1 Left turn position 2 Right turn position 3 Off position G and D n Flasher switch 250 300 SE 75 ...

Page 12: ...rré 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 ATTENTION If you use the emergency stop button to stop the motorcycle do not forget to move the ON OFF swit ch into the OFF position If you do not there is a risk that ...

Page 13: ...peeds n Footbrake 1 Rear brake control n Side stand Remove the rubber safety latch 1 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 77 ...

Page 14: ...tance 2 Screen 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 dis tance mode Right button Switch between the three display screens Resets Trip distance 1 Trip distance 2 maxi mum and average spee...

Page 15: ...its km h default or mph p 81 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 81 Reset to 0 DST Function Hold the right Button down for 3seconds 0 0 Reset to 0 done DST2 function screen 1 display...

Page 16: ...es 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 accu mulated ride time the display will stop incre menting and will remain at that number Clock function scr...

Page 17: ...al 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 D...

Page 18: ...rom 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 ...

Page 19: ...d 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 83 ...

Page 20: ... starting Follow the instructions above without step 3 5 and 6 n Shifting gears The positions of the gear selector are shown on p 77 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 Sto...

Page 21: ...llowing every day before riding the motorcycle Tires Wear and pressure Engine oil Level p 92 Gasoline Check the level and make sure there are no leaks Transmission chain Properly lubed and adjusted p 105 Direction of travel Make sure that your path is clear Brakes Operation fluid leakage brake pad wear p 114 to p 118 Throttle Proper operation p 89 Clutch Proper operation p 106 to p 107 Electrical ...

Page 22: ... 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 1 Fill the radiator full so that there is no air in the system Fill the coolant to the top of the radiator Re...

Page 23: ...w the cap 2 Fill with fluid until it reaches the LEVEL mark Coolant de refroidissement Minerva Perma Universal D 4 25 C Replace the cap 2 ATTENTION Make sure the bike is vertical and on a horizontal surface Place a container under the bike Remove the cap 1 and screw 2 Allow the coolant to drain N NOTE To protect the environment deposit the drained coolant at an approved collection center 87 ...

Page 24: ...as ket Pour the coolant into the radiator through the cap 1 Coolant Minerva Perma Universal D 4 25 C Radiator bleed screw M6X70 8Nm Continue filling Fill until the coolant reaches the level approxi mately 1 1 liters Put the bike on the side stand and follow the rest of the filling procedure p 86 88 ...

Page 25: ...the accelerator throttle cable play p 89 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 p 89 n Checking the throttle cable play n Adjusting the play in the throttle cable Adjust the throttle cable play at the location shown 1 with the adjuster If this is not enough adjust the play dir...

Page 26: ...crewing the nut from the sleeve stop Do not continue to tighten the cable tighten only until the stop is no longer pulling WITH FORCE attempting to move the sheath toward the rear of the bike stop adjusting at this time Note In this configuration the central valves must be fully lowered Then tighten the nut 1 1 full turn 1mm The measurement between the tensioning cable crimping sleeve and bottom o...

Page 27: ... bike stop adjusting at this time Tighten the nut then 5 1 full turn 1mm The measurement between the tensioning cable crimping sleeve and bottom of the cylinder sheath should be 0 5 mm minimum 1mm maximum when pulling WITH FORCE on the cable to the rear of the bike if this measurement is not correct correct by tightening or loosening the nut 5 Tighten the nut 6 against the stop Lubricate with spra...

Page 28: ...he 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 1 and the air screw 2 B Transition range From to opening of the throttle slide this range is regulated by the idle jet and the shape of the slide C Mid range From to opening of the throttle slide this range is regulated by th...

Page 29: ...main jet is shown in the photo as 1 The size of the jet is engraved on it Pilot jet and pilot air screw In order to adjust the idle range A to B transition you can change the pilot jet 1 its size is stamped on it and adjust the air screw 2 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 pilo...

Page 30: ...2T1 2 40 N8RL 2 158 1 500 m to 751 m Air Screw Pilot jet Needle Needle position Main jet 1T 42 N8RH 4 170 1T 40 N8RW 4 168 1T1 2 40 N8RJ 4 165 1T1 2 40 N8RJ 3 165 2T 40 N8RK 3 162 2T 40 N8RK 2 160 750 m to 301 m Air Screw Pilot jet Needle Needle position Main jet 1 2T 45 N8RH 5 172 1T 42 N8RH 4 170 1T 40 N8RW 4 168 1T1 2 40 N8RJ 4 165 1T1 2 40 N8RJ 3 165 2T 40 N8RK 3 162 300 m to 0 m Air Screw Pil...

Page 31: ...2 160 3T 38 N8RH 2 158 1 500 m to 751 m Air Screw Pilot jet Needle Needle position Main jet 1T 38 N8RF 3 170 1T 38 N8RF 3 168 1T1 2 38 N8RG 3 165 1T1 2 38 N8RG 2 165 2T 38 N8RH 2 162 2T1 2 38 N8RH 2 160 750 m to 301 m Air Screw Pilot jet Needle Needle position Main jet 1T 40 N8RF 4 172 1T 38 N8RF 3 170 1T 38 N8RF 3 168 1T1 2 38 N8RG 3 165 1T1 2 38 N8RG 2 165 2T 38 N8RH 2 162 300 m to 0 m Air Screw...

Page 32: ...tch housing 2 ATTENTION Improved oil level can damage your engine Do not use bike if the level is below the minimum Topping up the engine oil Engine oil 0 7L SAE 10W40 DRAINING THE GEAR BOX OIL Remove the engine guard p 107 When draining the oil the engine should be warm h ATTENTION Use protective gloves Position the motorcycle upright on a level sur face Place a container under the bike to catch ...

Page 33: ...l 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 1 Completely drain the fuel Mount and tighten...

Page 34: ... the handle bars in the rear most position Remove the four screws 1 Remove the handle bar top clamps and remove the handlebar Remove the two screws 2 Remove the lower clamps and place them in the desired position Handlebar lower clamp M10x35 40Nm Loctite 243 Replace the handlebars and top clamps Replace the four screws 1 and tighten evenly Handlebar clamps fixing screws M8x25 24Nm The handlebars c...

Page 35: ... steering angle desired Tighten the nut and do the same operation on the other side Steering angle lock nut M8 20Nm Screws 2 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 1 located at the lower end the fork Turn screw 2 clockwise to the stop and go back the number of clicks required Adjusting the...

Page 36: ...he screw 1 clockwise to the stop then go back the number of clicks required Rebound Sachs Gold Series USD Ø48mm 12 clicks Rebound WP suspension USD Ø48mm Comfort 18 clicks Standard 13 clicks Sport 10 clicks 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 t...

Page 37: ...red Do not loosen the nut 2 Low speed compression setting Comfort 20 clicks Standard 15 clicks Sport 12 clicks ADJUSTING THE REAR SHOCK HIGH SPEED COMPRESSION SETTING The adjusting screw 1 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 1 clockwise with a socket wrench until it stops and then bac...

Page 38: ...on 30mm If the static deflection is not correct adjust the preload of the shock p 99 The adjusting screw 1 determines the Shock rebound behavior Turning the screw clockwise increases the hydraulic force and vice versa Turn the screw 1 clockwise to the stop then go back the number of clicks required Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks SETTING THE REAR SHOCK SAG With...

Page 39: ...g one turn Increases the overall length by 3mm Tighten the locking nut 1 Reinstall the shock p 109 Recheck the settings p 98 CHANGING THE SHOCK SPRING Remove and clean the rear shock unit p 108 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 sh...

Page 40: ... the saddle must pass through the tabs on the subframe 4 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 th...

Page 41: ...ir 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 spe cial care to make sure it is centered Refit the knurled screws 2 Chec...

Page 42: ...TTENTION Attention there is a risk of spraying fuel do not put your face near the fuel line exit Prevent ingress of dirt in the gasoline fuel line This can lead to a seizure of the injector Unscrew the screws 6 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...

Page 43: ...heck the adjustment of the radiator guards in relationship to the fuel tank Connect the fuel line 3 Install the fuel tank mounting screws 4 along with their rubber inserts Install the radiator grill mounting screws Chassis screws M6 10Nm Install the fuel vent hose Reinstall the saddle p 100 After some time of operation the air accumulates under pressure in the fork Every 5 to 10 hours depending on...

Page 44: ...left over oil Reinstall the fork protection Reinstall the front wheel p 110 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 105 Take the bike o...

Page 45: ...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 ...

Page 46: ...ntil you have the correct chain tension Chain tension 50mm 53mm Monitor the symmetry of the two sides by observing the position of the marks 4 Tighten the screws 5 Tighten the nut 6 Rear axle nut M24 100Nm Remove the bike from the stand N NOTE The sliding piece 7 is designed to accommodate longer chains by turning it 180 degrees The position of the lever can be adjusted to meet the needs of the ri...

Page 47: ... dan gerous to the skin Read the recommendations on the container Position the master cylinder horizontally Remove the two screws 1 the cover 2 and the membrane 3 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 REMOVING THE ENGINE PROTECTOR Remove the screws 1 and remove...

Page 48: ... Remove the screw 4 Remove the top screw of the shock Remove the shock from the top Chassis maintenance continued Remove the screws 1 and 2 and the muffler along with the intermediate exhaust pipe h 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 3 112 ...

Page 49: ...l the lower shock screw 1 and tighten Lower shock screw M10 40Nm Loctite 2701 Install the lower shock shaft 2 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 3 using the nylock self locking nuts Chassis screws M6 10Nm Install right side plate Remove the bike from the stand 113 ...

Page 50: ...h oil or grease If it is clean the disc with brake cleaner Brake cleaner Minerva brake cleaner and degreaser Install the spacer 1 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 2 Fork screws M8 12Nm Install and tighten the axle nut 3 Front axle nut M20 25Nm Tighten the screws on the right side of t...

Page 51: ... 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 1 and 2 and make sure they are positioned correctly 1...

Page 52: ...ar 13 psi If the pressure does not comply with the above table Correct the pressure Replace the valve cap Install the chain tensioner 1 and install the nut 2 but do not tighten Check the chain tension p 105 Tighten the nut 2 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 ins...

Page 53: ...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 ...

Page 54: ...meet the specification do the following Set the free play using the adjustment screw 1 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 mar...

Page 55: ...LING THE FRONT BRAKE RESERVOIR WITH BRAKE FLUID ADJUSTING THE POSITION OF THE REAR BRAKE PEDAL CHECKING THE TRAVEL OF THE REAR BRAKE PEDAL Remove the spring 1 Operate the pedal several times Rear brake pedal travel 3mm A 5mm Replace the spring 1 If the travel does not meet the specification refer to the rear brake travel adjustment p 116 The position of the brake pedal can be adjusted as follows l...

Page 56: ...s shown A 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 CHECKING ...

Page 57: ...for wear Minimum pad thickness A 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 121 ...

Page 58: ...e filter housing Remove the two screws 1 that retain the battery retaining bracket Disconnect the negative cable from the battery 2 Disconnect the battery positive cable 3 Remove the battery from the top Install the new pads Reinstall the retaining pins 2 and clips 1 Check the brake fluid level and fill if necessary p 114 et p 116 ATTENTION Do not use the bike until the brake lever and the pedal a...

Page 59: ...he air filter p 101 Replace the saddle p 100 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 118 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 b...

Page 60: ... SE R REMOVING THE HEADLIGHT HOUSING Remove the seat p 100 The light fuse 1 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 p 100 Turn the ignition to the off position Unclip the left and right rubber fastners 1 on each side of the fork Separate all of the bra...

Page 61: ...tive rubber 1 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 2 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 l...

Page 62: ...otorcyle computer screws 3 Remove the screws 2 and remove the com puter to get it out of the way 4 Disconnect the main connector from the compu ter 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 the O ring 8 Plug the main connector into the computer 9 Install it on the bike and check to make sure...

Page 63: ...se 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 pro tective 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 wal...

Page 64: ...nd 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 fo...

Page 65: ...ubricate 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 ...

Page 66: ...utch 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 Replace the piston 300 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 Replace the big end bearing Replace the crankshaft bearings Check all of the gearbox components for wear ...

Page 67: ...p fastening screws M8 25Nm Sach fork upper screw M8 12Nm WP fork upper screw M8 17Nm Sachs lower fork screw M8 15Nm WP fork lower screw M8 12Nm Upper screw M8 17Nm Fork pinch bolt screw M8 12Nm Side support screw M8 25Nm Loctite 243TM Other chassis screws M10 40Nm Handlebar fixing screws M10 40Nm Loctite 243TM Top shock screw M10 40Nm Loctite 2701 Lower shock screws M10 40Nm Loctite 2701 Motor mou...

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