SHERCO 125 Workshop Manual
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SHERCO 125 Workshop Manual

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  • Page 3: Table Of Contents

    TABLE OF CONTENTS ❱❘ Kickstarter shaft removal ......24 FOREWORD ..........3 ❱❘ Shifting mechanism removal ....24 SPECIAL TOOLS REQUIRED ......4 ❱❘ Left side disassembling..... 25 ❱❘ Ignition removal........25 TECHNICAL DATA ........5 ❱❘ Crankcase splitting ......26 ENGINE .............
  • Page 4 ELECTRICAL ........... 50 ❱❘ Electric components ......... 50 ❱CDI .............. 51 ❱❘ Voltage regulator ........51 ❱❘ Temperature sensor ......... 52 ❱❘ Ventilator ........... 52 ❱❘ Injector specs ..........53 ❱❘ MAP specs ..........53 ❱❘ Fuel pump specification ......53 ❱❘...

  • Page 5: Foreword

    The success of the various operations requires some mechanical skills and the SHERCO specific tools for the 125 / 250 / 300 ST engines. This workshop manual complements the SHERCO 125 / 250 and 300 ST owner’s manual. ST SERIES...

  • Page 6: Special Tools Required

    SPECIAL TOOLS REQUIRED Tool part number Designation 10981 Crankshaft fitting tool 10982 Clutch lock tool 10983 Coolant connector fitting/ removal tool 10984 Flywheel puller Flywheel locking tool 10985 Primary drive locking tool 10986 Clutch spring centering tool 10987 Shifter spring locking tool 10988 Engine support R455...

  • Page 7: Technical Data

    TECHNICAL DATA ENGINE Single cylinder, liquid cooled, two-stroke Type Displacement 123,70 cc 249,70 cc 294 cc 72,8X60 mm 79X60 mm BoreXstroke 54X54 mm Premix with unleaded fuel (RON 98 minimum) and special injection 2 stroke oil, Fuel Premix ratio : 1,5% Liquid, forced circulation Cooling Hidria Digital...

  • Page 8: Chassis

    TECHNICAL DATA CHASSIS Frame Tubular, Chrome-Molybdenum steel Tech 39mm Aluminium Fork 2 way Reiger shock Rear shock Aluminium swingarm Front / rear stroke 165 / 175mm Disc Ø 185mm Front brake Rear brakee Disc Ø 145mm Front tyre 2,75-21’’ Rear tyre 4,00 - 18’’...

  • Page 9: Chassis

    CHASSIS CAUTION Before every operation, make sure the bike is steady and won’t fall. ❱❘Front end 1.1 Wheel bearings change • Undo locking screw on the right fork foot • Unlock wheel spindle and remove it. • Remove the wheel •...

  • Page 10: Fork Disassembly And Steering Head Bearings Change

    CHASSIS 1.3 Fork disassembly and steering head bearings change • Undo the two M8 screws and remove the caliper • Check brake pads minimum thickness. Wear limit : 1mm • Undo four M8 screws of the handlebar clamps and remove handlebar. •...

  • Page 11: Tech Fork Servicing

    CHASSIS 1.4 TECH fork servicing CAUTION Service the fork every 20 hours of use or every 6 months 1.4.1 Right side oil change • Place the fork tube in a vise with a suitable support so as not to damage it •...

  • Page 12: Left Side Oil Change

    CHASSIS • Do a back and forth movement as shown in the picture to prime the hydraulic system, until you feel resistance. • Compress the fork tube and damping rod to the maximum. • Measure oil level from the top of the tube, then fill until you reach the desired height.
  • Page 13 CHASSIS • Remove the spring and clean it with a cloth. • Drain the oil. • Put fork leg vertically and pour 250cc of new oil inside. • Do a back and forth movement as shown in the picture to prime the hydraulic system, until you feel resistance.

  • Page 14: Rear End

    ❱❘ Rear end 2.1 Wheel bearings change • Hold wheel spindle on the left side and undo the nut on the right side. • Remove the spindle from the left. • Remove the wheel and the wheel spacers. Rear wheel spindle tightening torque : 100 Nm •...

  • Page 15: Brake Disc Change

    CHASSIS 2.2 Brake disc change • As changing front brake disc, during assembling apply medium threadlocker ( Loctite 243 ) on the screws and tighten them to a 12Nm torque.. Reassemble the wheel following the reverse procedure , applying a thin coat of grease on the wheel spindle.

  • Page 16: Suspension Linkage Check

    CHASSIS • Check the needle bearings of both sides.. In case of rust, replace them. Otherwise, apply grease before reassembling. • Reassemble the set following the reverse procedure and applying grease on swingarm spindle and linkage shafts. 2.4 Suspension linkage check •...

  • Page 17: Operations Requiring The Removal Or Not Of The Engine

    ENGINE OPERATIONS REQUIRING THE REMOVAL OR NOT OF THE ENGINE OPERATIONS REQUIRING OPERATIONS NOT THE REMOVAL OF THE REQUIRING THE REMOVAL ENGINE OF THE ENGINE • Crankshaft ( also connecting rod ) Shifting mechanism • Whole gearbox • • Crankshaft bearings •...

  • Page 18: Engine Removal/Fitting

    ENGINE REMOVAL/FITTING ❱❘ Engine removal CAUTION To withdraw the engine, you must remove the swingarm spindle, which allows pulling away the rear wheel/swingarm unit. In order to prevent bike from falling, make sure it is held by the frame. • Drain coolant and gearbox (see user’s manual) •...

  • Page 19: Engine Disassembling

    ENGINE DISASSEMBLING ❱❘ Gearbox draining • Remove draining screws and the filler cap , help the oil flow out by tilting the bike. ❱❘ Front sprocket removal • Remove snap ring • Remove front sprocket ❱❘ Top-end removal • Undo the screws and remove cylinderhead cover •...
  • Page 20 ENGINE DISASSEMBLING • Remove the four nuts • Remove the cylinder • Mask the opening in the crankcase. • remove the wrist pin snap ring • Remove the wrist pin • Remove the piston • Remove the needle cage ST SERIES...

  • Page 21: Reeds Valve Removal

    ENGINE DISASSEMBLING • tilt the inlay to the rear and remove it to the top. • remove base gasket ❱❘ Reeds valve removal • Undo the 4 CHC screws • Remove the reeds valve as well as the gasket ❱❘ Right side disassembling ❱❘...

  • Page 22: Coolant Pump Disassembling

    ENGINE DISASSEMBLING • Remove the screws as well as the clutch case. ❱❘ Coolant pump disassembling • Remove the CHC screw of the coolant pump idle gear, and its washer. • Remove idle gear shaft • Remove coolant pump gear •...

  • Page 23: Clutch And Primary Drive Removal

    ENGINE DISASSEMBLING • Remove coolant pump snap ring • With a pair of pliers, pull away the pump shaft in order to extract the pump body. ❱❘ Clutch and primary drive removal • Place the tool part number 10986 between the crankshaft gear and the clutch gear.
  • Page 24 ENGINE DISASSEMBLING • Remove clutch spring • Remove pressure plate • Remove diaphragm pads • Remove the clutch pusher , and the pushrod • Remove all the discs in one batch, taking care to keep them in the same position. •...
  • Page 25 ENGINE DISASSEMBLING • Remove the needle cage , and the clutch basket • Remove the washer • Remove the snap ring and the crankshaft gear • Remove the spring washer • Remove the snap ring from the crankshaft ST SERIES...

  • Page 26: Kickstarter Shaft Removal

    ENGINE DISASSEMBLING ❱❘ Kickstarter shaft removal • Remove snap ring and idle gear • Remove spring lock screw • Remove kickstarter shaft and the washer ❱❘ Shifting mechanism removal • Remove the snap ring • Remove the return spring and the holding plate. •...

  • Page 27: Left Side Disassembling

    ENGINE DISASSEMBLING • Slightly loosen the screw alowing the removal of the shifting mecanism. • Loosen the shifting locator screw , remove it, as well as its spring. • Remove the shifting drum snap gear ❱❘ Left side disassembling. ❱❘ Ignition removal. •...

  • Page 28: Crankcase Splitting

    ENGINE DISASSEMBLING • Using the flywheel puller part number 10984 , remove the flywheel. • Remove the 3 stator screws • Remove the pick-up holding screws the wiring holding plate’s screw • Remove the flywheel woodruff key ❱❘ Crankcase splitting •...

  • Page 29: Gearbox Removal

    ENGINE DISASSEMBLING • Remove the central gasket. CAUTION Take care about the gearbox shafts’s trust shims. They may stick in the crankcase. • Slightly hitting its end with a rubber mallet, remove the crankshaft. ❱❘ Gearbox removal • Once you have done the previous steps, you may be able to remove the whole gearbox.

  • Page 30: Disassemble The Selector Fork- Drum Assembly

    ENGINE DISASSEMBLING • To withdraw the gearbox, you must remove all the components ( shifting drum, primary and secondary shafts ) in one batch. If needed, slightly hit the shafts with a rubber mallet. CAUTION Take care about the gearbox shafts’s •...
  • Page 31 ENGINE DISASSEMBLING • Using a pin driver, push the pin to the inside of the drum. • Slide the forks the opposite way of the shifting star. ST SERIES...

  • Page 32: Engine Parts Check

    ENGINE PARTS CHECK ❱❘ Crankshaft removal • Take the crankshaft out from its bearing ( eventually hitting slightly its end with a rubber mallet) • Clean all the parts and check for wear, replace them if needed. CAUTION When completely dismantling the motor, it’s advised to replace all the gaskets, seals , O’rings as well as bearings.

  • Page 33: Crankshaft Width Measure

    ENGINE PARTS CHECK ❱❘ Crankshaft width measure • Using a vernier caliper, measure the distance between both crank webs. Value : 125cc  56mm +0 / -0.2 250cc / 300cc  56mm +0 / -0.2 ❱❘ Big-end radial play • Put the crankshaft on machinist V-blocks and place a dial gauge against conrod big end...

  • Page 34: Crankshaft Runout Check

    ❱❘ Crankshaft runout check • Put the crankshaft on an alignment device, or V-blocks, and place a dial gauge on the crankshaft axles, as shown : • • • • Then slowly rotate the crankshaft. The difference between measures means the runout.

  • Page 35: Piston

    Measure end gap using a thickness gauge. Ring end gap : Standard : 125 : 0.35mm – 0.50mm 250 / 300 : 0.2mm – 0.4mm CAUTION If the end gap is greater than specified, you must check cylinder and piston condition. If they are within tolerance, only replace the rings.

  • Page 36: Cylinder - Piston Wear Condition

    ENGINE PARTS CHECK ❱❘ Cylinder – piston wear condition • To determinate cylinder wear, measure cylinder bore with a dial bore gauge, about 10 mm from the cylinder deck. Make a cross-measurement in order to check ovalization. 125cc 250cc 300cc Ø...

  • Page 37: Clutch

    EGINE PARTS CHECK ❱❘ Clutch • Clutch pusher Check wear. Pushrod check wear, minimum length : 128.8 mm. • Pads check condition, looking for abnormal marks. • Basket check for grooves, on the fingers. • check for marks on the discs seating surface. •...

  • Page 38: Gearbox Shafts

    ENGINE PARTS CHECK ❱❘ Gearbox shafts Check all the gears : • Check the coupling dogs • Check pignon teeths • Check the fork grooves • Check the fork condition. • Minimum thickness : 3,97 mm Check the fork bore , looking for deep •...

  • Page 39: Engine Assembling

    ENGINE ASSEMBLING ❱❘ Gearbox assembling. Prior to assembling, thoroughly oil all the parts • with the correct oil. Assembling order of the forks is stamped on • each fork.: The “Outside” mark matches the outside of the shifting drum. The arrow points to the front forward direction.
  • Page 40 ENGINE ASSEMBLING • Insert the gear selector shaft through the shifting drum. • Pinch the pawls, so that the gearbox is at neutral, as shown in the picture • Install the selector shaft’s snap ring • Place the forks in this way : •...

  • Page 41: Accoupling The Crankcases

    ENGINE ASSEMBLING • Install the shifting drum’s snap ring 2 and remove the shifting locator locking tool. • Install the secondary shaft’s snap ring ❱❘ Accoupling the crankcases • Install the crankshaft in the crankcase. • Make sure the two dowel pins are well positioned, and install the gasket.

  • Page 42: Right-Hand Side Assembling

    ENGINE ASSEMBLING Fit the stator and tighten its screw at a • 7Nm torque. • Fit the CHC screws and the screw with the wiring holding plate. • Fit the flywheel, and using the locking tool Part number 10985 , tighten the CHC screw at a 80Nm torque.
  • Page 43 ENGINE ASSEMBLING , and • Using medium threadlocker, fit the screw tighten it to a 7Nm torque. • Loosen the screw in order to place the retaining plate • Fit the screw and tighten it to a 20Nm torque, tighten the screw to a 7Nm torque, fit the holding plate and tighten the screw a 5Nm...

  • Page 44: Fit The Clutch Basket And The Clutch Hub

    ENGINE ASSEMBLING • Fit the clutch basket and the clutch hub. Using the tool Part number 10982, hold the basket, fit the screw and tighten it to a 60Nm torque. Fit the first snap ring on the crankshaft, then the spring washer its little diameter towards the snap ring, and its big diameter facing the primary...
  • Page 45 ENGINE ASSEMBLING • Fit the pressure plate • • Fit the diaphragm spring and its centering tool Part number 10987. • Fit the pressure plate and slightly tighten the screws. • Remove the centering tool Part number 10987. • The pressure plat features 3 hardness settings : Screw in the middle hole = standard setting.
  • Page 46 ENGINE ASSEMBLING • Fit the drive pin in the water pump’s shaft. • Fit the water pump’s drive gear • Place the water pump idler shaft • Place the gear on its shaft. • Fit the screw as well as the washer •...

  • Page 47: Top-End Assembling

    ENGINE ASSEMBLING • Fit the clutch case and its screws • Be sure to use a new copper washer when refitting the screw • Fit the clutch cover and its five screws ❱❘ Top-end assembling ❱❘Piston fitting • Place the base gasket •...
  • Page 48 ENGINE ASSEMBLING • Place the needle cage • Fit the wrist pin • Fit the clips on both sides of the piston • Make sure the piston is in the right way : the arrow engraved on its crown must point towards the exhaust port.

  • Page 49: Squish Check

    ENGINE ASSEMBLING • Place inside and outside O-rings. • Place the two dowel pins • Fit the combustion chamber and its O-ring ❱❘ Squish check The squish check is carried out measuring the distance between the piston crown , at Top •...

  • Page 50: Reed Valve And Intake Boot

    ENGINE ASSEMBLING ❱❘ Reed valve and intake boot Place a new reed valve gasket. • Fit the reed valve. • Place a new intake boot gasket. • Fit the intake boot and tighten its four M5 • screws at a 6Nm torque. ❱❘...

  • Page 51: Tightening Torques

    TIGHTENING TORQUES Cylinder head screws 10 N·m Cylinder base nuts 22 N·m Ignition cover screws 0,7 N·m Stator screws 0,7 N·m Flywheel screw 100 N·m Pressure plate screws 0,7 N·m Clutch nut 40 N·m (With medium threadlocker Loctite 243) Intake boot screws 0,7 N·m Crankcase halves screws 15 N·m...

  • Page 52: Electrical

    ELECTRICAL ❱❘ Electric components Position Designation Ignition Temperature probe Fuel pump Wiring harness Throttle body ST SERIES...

  • Page 53: Cdi

    ELECTRICAL ❱CDI ❱❘ Voltage regulator Voltage Regulator: • Regulator output (Calibre 20V) At 3500 Tr/min : 14.4V +/- 0.5V Maximum output current : 15 A Max operating temperature : 110°C ST SERIES...

  • Page 54: Temperature Sensor

    ELECTRICAL ❱❘ Temperature sensor Drain the coolant. • Remove the temperature • sensor from the cylinder head. Immerse the sensor [1] in a • container filled with coolant [2] making sure to leave the terminals out of the liquid. Immerse a thermometer [3] •...

  • Page 55: Injector Specs

    ELECTRICAL ❱❘ Injector specs ❱❘ MAP specs ❱❘ Fuel pump specification 8691 11207 Disconnect the fuel pump line and  place pressure gauge Part number 8691 as well as connector Part number 11207. Make the pump build up pressure,  connecting the shunt Part number 11212.

  • Page 56: Reset Tps

    ELECTRICAL ❱❘ Reset TPS In case of replacement of Throttle  Position Sensor or the whole throttle body, it is necessary to proceed a zero TPS : First, connect the shunt Part number  11212 to the two-pins connector, on the left side of the bike [1].

  • Page 57: Wiring Diagram

    ELECTRICAL ❱❘ Wiring diagram ST SERIES...

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