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Summary of Contents for SHERCO 125 SE-R 2017
- Page 1 MANUEL D’ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER...
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Page 2: Table Of Contents
CONTENTS PREAMBLE ............................................................................... 4 LIST OF ENGINE TOOLS .......................................................................... 5 TECHNICAL CHARACTERISTICS ...................................................................... 6 ❱❘ Engi n e ........................................................................6 ❱❘ Cycl e part ......................................................................... 7 ORIGINAL SETTINGS ..........................................................................8 ❱❘ Yoke .......................................................................... 8 ❱❘ Shock absorber ....................................................................9 OPERATIONS REQUIRING ENGINE REMOVAL OR NOT I ..........................................................10 ENGINE REMOVAL / ASSEMBLY ..................................................................... - Page 3 ❱❘ Control of val v e operati o ns ................................................................29 ❱❘ Adj u stment of the exhaust val v e pul l e y cl e arance ........................................................ 30 ❱❘ Cl a pper box, pi p e i n take sl e eve ..............................................................31 ❱❘...
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Page 4: Preamble
Performing the various operations requires both a solid knowledge in mechanics and the set of SHERCO tools specific to the 125 SE-R engines. This workshop manual serves as a complement to the SHERCO 125 SE-R user’s manual. 125 SE-... -
Page 5: List Of Engine Tools
LIST OF ENGINE TOOLS ❱❘ 125 SE-R Tooling reference Designation Clutch drum block 1814 Ignition block 1815 Oscillating arm shaft tool 2067 2072 Right-hand casing primary shaft bearing tool Secondary shaft bearing tool 2074 Out-of-gearbox shaft bearing tool R467 Out-of-gearbox gasket tool 2069 Right-hand drum bearing selection tool 2071... -
Page 6: Technical Characteristics
TECHNICAL CHARACTERISTICS ❱❘ Engine Type Liquid cooled, 2-stroke single cylinder Displacement 124.81 CC Bore diameter / Stroke 54 / 54.5 mm Gasoline Unleaded with an octane index of at least 95 mixed with two-stroke oil (2%) Coolant with forced circulation Ignition system A DC-CDI without a contact breaker, digital advance Spark plug... -
Page 7: Cycle Part
TECHNICAL CHARACTERISTICS ❱❘ Cycle part Frame Semi-perimeter made of CrMo steel with an aluminium back clip Yoke WP suspension X Plor Ø48 mm Rear suspension WP suspension with a separate cylinder, oscillating aluminium arm Front/back stroke 300/330 mm Front brake disc Ø... -
Page 8: Original Settings
ORIGINAL SETTINGS ❱❘ Yoke Original settings - WP yoke suspension X Plor Ø48 mm Compression Comfort 14 clicks backwards Standard 12 clicks backwards Sport setting 10 clicks backwards Recreation Comfort 14 clicks backwards Standard 12 clicks backwards Sport setting 10 clicks backwards Prestressing Comfort 0 Clicks... -
Page 9: Shock Absorber
ORIGINAL SETTINGS ❱❘ Shock absorber Original settings - WP suspension shock absorber Low-speed compression Comfort 20 clicks backwards Standard 12 clicks backwards Sport setting 6 clicks backwards High-speed compression Comfort 2 revolutions backwards Standard 1.5 revolutions backwards Sport setting 1 revolution backwards Recreation Comfort 15 clicks backwards... -
Page 10: Operations Requiring Engine Removal Or Not I
OPERATIONS REQUIRING ENGINE REMOVAL OR NOT Operation requiring engine Operation not requiring engine removal removal • Crankshaft (including the crank kit) • Complete gearbox • Crankshaft bearing • Gearbox bearing • Piston • Cylinder • Cylinder head • Ignition • Starter gear set •... -
Page 11: Engine Removal / Assembly
ENGINE REMOVAL / ASSEMBLY ❱❘ Engine removal - Drainage (see User’s Manual) • Motor oil • Coolant - Remove the saddle. - Disconnect the battery. - Unhook the tank using its louvres. - Disconnect the wire harness attached to the engine (starter lug, anti-parasitic device). - Remove the exhaust (see User’s Manual). -
Page 12: Reassembly Of The Engine Into Its Frame
ENGINE REMOVAL / ASSEMBLY ❱❘ Reassembly of the engine into its frame For the reassembly step, proceed in the opposite order from disassembly, in complying with the tightening torques of both screws and nuts: Engine screws: 60 N-m Oscillating arm nut: 100 N-m Clutch slave cylinder screws: 10 N-m Cylinder head-frame screws: 23 N-m - Remove the two M4 screws and withdraw the... - Page 13 ENGINE REMOVAL / ASSEMBLY - Place the mapping contactor in the “Hard” position (toward the right) and turn on the motorcycle contact switch. Wait for completion of the electric engine valve initialisation and its subsequent shut-off. Turn off the motorcycle contact switch and check that the pulley is correctly positioned facing right.
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Page 14: Engine Disassembly
ENGINE DISASSEMBLY For the blow-up drawings, please refer to the 125 SE-R spare parts catalogue ❱❘ Gearbox drainage - Remove drainage plugs [1] and [2], let the oil flow out. ❱❘ Removal of the pinion and selector - Unfold the safety washer tab [3] using a pushing device. -
Page 15: Removal Of The Cyl I N Der Head, The Cyl I N Der And The Pi S Ton
ENGINE DISASSEMBLY ❱❘ Removal of the cylinder head, the cylinder and the piston - Remove the shoulder screws [1] and release both the cylinder head and the two O-rings - Remove all four nuts [2] and proceed with deinstallation. - Conceal the casing. - Remove the piston shaft clips. -
Page 16: Disassemble The Clutch Casing
ENGINE DISASSEMBLY ❱❘ Disassemble the clutch casing - Unscrew the water pump screws and cover. Remove the form joint. - Remove the screws first and then the clutch casing. Extract the joint. ❱❘ Removal of both the pressure tray and discs - Loosen the screws of the clutch pressure plate [1]. -
Page 17: Removal Of The Electric Starter
ENGINE DISASSEMBLY - Release both the pressure plate and discs from the housing. - Remove the support part [1] positioned in the primary shaft. ❱❘ Removal of the electric starter - Unscrew both screws [2] ❱❘ Removal of the main transmission - Block the pinion at the end of the crankshaft using tool reference 1817 [3]. -
Page 18: Removal Of The Locking Mechanism
ENGINE DISASSEMBLY - Removal of the main transmission pinion CAUTION at the wedge and O-ring. The main transmission pinion and clutch housing crown match, which is why they cannot be changed separately. They must always be renewed as a pair. ❱❘... -
Page 19: Removal Of The Ignition Casing
ENGINE DISASSEMBLY ❱❘ Removal of the ignition casing - Remove the screws first and then the ignition casing with its gasket. ❱❘ Removal of the ignition - Hold the steering wheel with tool 1815 [1] and unscrew the shoulder nut [2]. - Introduce extractor R462 [3] and tear out the magnetic wheel [4]. -
Page 20: Removal Of The Starter
ENGINE DISASSEMBLY ❱❘ Removal of the starter - Take out the starter [1] ❱❘ Intake pipe and clapper box - Remove all 4 plastic hex sprocket screws [5]. - Remove pipe, clapper corresponding joint. 125 SE-... -
Page 21: Separate Out The Half-Casings
ENGINE DISASSEMBLY ❱❘ Separate out the half-casings - Reposition the engine so that the ignition side is facing you. - Remove all the fastening screws. - Now lift the left half-casing by gently striking the gearbox output shaft with a plastic mallet in order to dislodge the other half-casing. -
Page 22: Removal Of The Rod Assembly
ENGINE DISASSEMBLY - Remove both the primary and secondary shafts from their bearing. ❱❘ Removal of the rod assembly - Disengage the connecting rod assembly from its bearing (ultimately by lightly striking at the end of the crankshaft with a plastic mallet). - Clean all the parts and check whether they exhibit wear. -
Page 23: Engine Part Control
ENGINE PART CONTROL ❱❘ Connecting rod assembly - If the roller bearings have been changed, then the internal ring that sits against the balance weight must also be changed. - Heat the R464 tool to roughly 150°C, then immediately insert it onto the internal ring. Ensure that the tool sits squarely on the ring in order to more effectively transmit the heat and extract the ring. -
Page 24: Crank Head Lateral Clearance
ENGINE PART CONTROL ❱❘ Crank head lateral clearance - Measuring the lateral clearance of the crank head [A]. Crank head lateral clearance: Standard: 0.7 mm - 0.9 mm Tolerance limit: 1.15 mm If the clearance exceeds the tolerance limit, replace the crankshaft. ❱❘... - Page 25 edge of the cylinder). - With a shim, it is possible to measure the cross- sectional clearance. Cross-sectional clearance: max. 0.40 mm...
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Page 26: Standard Exchange Cylinder / Squish Control
ENGINE PART CONTROL CAUTION Should the clearance be greater than indicated, it would be necessary to check the condition of both the cylinder and piston. If these measurements lie within the tolerance dimensions, replace the segment. ❱❘ Verification of the state of cylinder wear / Piston - To detect cylinder wear, the bore diameter is measured using a micrometer located approx. -
Page 27: Disassemble The Exhaust Valve System
ENGINE PART CONTROL ❱❘ Disassemble the exhaust valve system Disassemble all parts, clean them, verify their condition and state of wear. For this step, follow the disassembly and control procedure. - Remove the valve control protective cover. - Loosen the control cables and remove them from the pulley. -
Page 28: 125 Se-R
ENGINE PART CONTROL - Remove the retaining rings on both sides of the valve. - Remove the O-ring and pulley spacer. - Remove the lids from each side of the valve. CAUTION: During the reassembly step, reposition the O-rings with precision in back of each lid along with the set ring on the left side [2]. -
Page 29: Control Of Valve Operations
ENGINE PART CONTROL ❱❘ Control of valve operations - Turn the control as far as possible in the counter- clockwise direction. - Ensure that the central valve [1] and 2nd-stage boosters [2] are fully open. - Control the lateral clearance of the valve in ensuring the absence of any hard points when rotating. -
Page 30: Adj U Stment Of The Exhaust Val V E Pul L E Y Cl E Arance
ENGINE PART CONTROL ❱❘ Adjustment of the exhaust valve pulley clearance CAUTION: To guarantee optimal motorcycle operations, it is essential to proceed with the exhaust pulley clearance adjustment by following the procedure detailed below: For this purpose, be sure to use a shim so as to be able to Insert it via the exhaust and maintain the valve in the upper position at the time of clamping. -
Page 31: Clapper Box, Pipe Intake Sleeve
ENGINE PART CONTROL ❱❘ Clapper box, pipe intake sleeve - Over time, the carbon tabs gradually lose their elasticity, which in turn causes a loss in power. - Replace the worn or damaged gearbox. - Verifier the condition of the intake sleeve, especially if it is not split. -
Page 32: Engine Reassembly
ENGINE REASSEMBLY For the blow-up drawings, please refer to the 250 SE-R / 300 SE-R spare parts catalogue. ❱❘ Connecting rod assembly - Insert the connecting rod assembly into the ball bearing by the top, in exercising precaution, until reaching the stop. CAUTION The crank must be positioned on the cylinder side. -
Page 33: Assembly Of The Half-Casings
ENGINE REASSEMBLY ❱❘ Assembly of the half-casings - Install the transmission gearbox lubrication tube on the right-hand half-casing. CAUTION Beware of the tube indexation, flat spot on the oil plug rivet side. - Install the O-ring on the gearbox lubrication tube. -
Page 34: Selection Mechanism
ENGINE REASSEMBLY ❱❘ Selection mechanism - Place the spring into the casing with the curved strand pointing upwards. - Insert the spacer, the locking finger and the washer, then coat the CHC M6 x 20 screw with blue brake fluid and assemble all the parts. - Hook the spring to the lever arm. -
Page 35: Main Transmission And Clutch
ENGINE REASSEMBLY ❱❘ Main transmission and clutch - Lubricate the connecting rod assembly gasket. - Install the half-moon wedge in its housing. - Insert the pinion with the shoulder in a downward position onto the crankshaft shank. - Insert the washer [1], housing spacer and pre- lubricated needle cage [2] on the main shaft. -
Page 36: Clutch Discs, Pressure Plate
ENGINE REASSEMBLY ❱❘ Clutch discs, pressure plate - Oil the push finger [1] and insert it onto the main shaft. - Prior to the assembly step, oil the lined discs. - Begin with a lined disc. The 8 lined discs and the 7 smooth discs are positioned in an alternating pattern. -
Page 37: Piston And Cylinder
ENGINE REASSEMBLY ❱❘ Piston and cylinder - Oil the parts well before lifting. - Insert the needle bearing into the foot crank, position the piston (the arrow on top of the piston is pointed toward the exhaust). - Place the shaft and clips with the open side downward. -
Page 38: Clapper Box And Pipe Intake
ENGINE REASSEMBLY ❱❘ Clapper box and pipe intake - Install a gearbox joint with new clappers. - Place the complete clapper box into the intake pipe. - Assemble the intake pipe with the four M6 screws and its metal collar. ❱❘... -
Page 39: Ignition Assembly And Its Lid
ENGINE REASSEMBLY ❱❘ Ignition assembly and its lid - Place the half-moon wedge in its housing on the connecting rod assembly. - Insert the rotor on the connecting rod assembly. - Apply blue brake fluid on the threading. - Insert tool 1815, install the nut and tighten to 80 N-m. - Set up the 2 centring bushings. -
Page 40: Table Of Tightening Torques
TABLE OF TIGHTENING TORQUES Standard tightening torque Brake fluid 6 N-m 10 N-m 24 N-m Chassis tightening torque Brake fluid Rear wheel nut 100 N-m • Rear cradle fastening screw 24 N-m Front wheel nut 40 N-m Yoke foot clamping screw 15 N-m •... - Page 41 TABLE OF TIGHTENING TORQUES Engine tightening torque Brake fluid • Revolution sensor screw 8 N-m Coolant drainage screw 10 N-m Clutch slave cylinder screw 10 N-m Cylinder head, cross-patterned tightening 10 N-m torque Crankshaft inspection plug 8 N-m Clutch pressure plate screw 10 N-m Water pump casing screw 10 N-m...
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Page 42: Table Of Carburettor Settings
TABLE OF CARBURETTOR SETTINGS ❱❘ Table of settings for the SE-R 125 carburettor: -20°C … -7°C -6°C … 5°C 6°C … 15°C 16°C … 24°C 25°C … 36°C 37°C … 49°C Sea level Temperature 3,000 m Air screw 1T1/4 1T3/4 1T3/4 2T1/4 2T1/4... -
Page 43: Load Circuit Control
LOAD CIRCUIT CONTROL ❱❘ Static control values (engine turned off) 125 SE-R Battery voltage > 12.5 V Stator winding resistance values: Measurement of the resistance between each winding 0.39 Ω ± 20% (at 20°C) Verify the absence of continuity between the windings and the motorcycle mass - Resistance of the “Pick UP”... -
Page 44: Wire Map
WIRE MAP ❱❘ Main bundle 6827 125 SE-... - Page 45 WIRE MAP...
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Page 46: Light Beam 125 Se-R
WIRE MAP ❱❘ Light beam 125 SE-R 125 SE-... -
Page 47: Racing Light Beam 125 Se-R
WIRE MAP ❱❘ Racing light beam 125 SE-R... -
Page 48: Accessory Bundle
WIRE MAP ❱❘ Accessory bundle 125 SE-...
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