Related Manuals for SHERCO ST Series
Summary of Contents for SHERCO ST Series
- Page 1 MANUAL DE TALLER / MANUEL D’ATELIER / WORKSHOP MANUAL MANUAL DE TALLER / MANUEL D’ATELIER / WORKSHOP MANUAL 800-607-8742...
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Page 2: Table Of Contents
Engine parts section __________________________________________________________39 Changing the piston ................. 40-41-42-43-44-45 Verifying piston and cylinder ....................46 Ignition ...........................47-48 Clutch discs ........................49 Start routine ......................50-51-52 Gear selector ........................53-54 Gears and crankshaft ..................55-56-57-58-59 Water pump ........................60 ST SERIES ST SERIES... -
Page 3: Prologue
PROLOGUE All the information contained in this manual has been prepared to provide the most information on possible operations on a Sherco motorcycle within ST trial line. Bearing in mind that many of the specifi c operations must be performed in a specialised workshop, this manual is intended as a very useful guide for operators carrying out these tasks, bearing in mind that, in many cases, they are exceptional, infrequent tasks, this manual will help you to follow an order of assembly and action upon elements to be verifi... -
Page 4: List Of Special Tools And Equipment
Engine closure screws (carter) 15Nm Primary cog nut 60Nm M-5 Screws 0.6Nm M-6 Screws 12Nm M-8 Screws 24Nm M-10 Screws 40Nm Rear wheel axle nut 100Nm Front wheel axle 100Nm Lower steering nut 20Nm Upper steering nut 20Nm Tilting axle 50Nm ST SERIES... -
Page 5: Technical Features Of The Engine
TECHNICAL FEATURES OF THE ENGINE ❱❘ ENGINE 80 ST 125 ST 250 ST 290 ST 305 ST Engine 2 stroke by Sherco Capacity 74.60 cc 123.70 cc 249.70 cc 272 cc 294 cc Diameter x Stroke 44.50 x 50.70 54 x 54 72.80 x 60... -
Page 6: Technical Features Of The Frame
Distance between axles 1322 mm 1322 mm 1322 mm 1322 mm 1322 mm Minimum clearance from ground 310 mm 310 mm 310 mm 310 mm 310 mm Seat height 645 mm 645 mm 645 mm 645 mm 645 mm ST SERIES... -
Page 7: Cycle Parts Section
CYCLE PART... -
Page 8: Changing Wheel Bearing
- When dismantling, it is convenient to heat the surface where the bearing is lodged and remove it using a ø20 pushing tube. Decant the pusher slightly on the front wheel in order to remove the bearing. ST SERIES... -
Page 9: Changing Front Fl Exible Brake Hose. Formula, Ajp, Braktec
CHANGING FRONT FLEXIBLE BRAKE HOSE ❱❘ FORMULA - Dismantle the front fork bridge and remove the fl exible brake hose from the bridge, as well as the upper fl ange. Dismantle the fl exible brake hose. - Once the fl exible brake hose has been changed, fi... - Page 10 fl exible brake hose by pressing successively until the brake lever limit is reached. Repeat this operation until the lever at pressure feels to have reached maximum hardness. - Fluid level must be checked once bleeding has been completed. ST SERIES...
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Page 11: Front Brake Maintenance. Formula, Ajp, Braktec
FRONT BRAKE MAINTENANCE ❱❘ FORMULA - Remove the safety clip. - Loosen the brake pad fi xation screw. - Loosen the grasper securing screws. - Clean the assembly with Minerva Brake Cleaner. - Remove the brake pads. - Measure the depth of the sheathing. The inner groove measurement should be no less than 1mm. - Page 12 - Remove the safety clip. - Loosen the brake pad fastening screw. - Loosen the grasper securing screws. - Remove the brake pads. - Measure the depth of the lining. This cannot be less than 1mm. ❱❘ PARTS BREAKDOWN BRAKTEC FORMULA ST SERIES...
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Page 13: Changing Front Brake Disc
CHANGING FRONT FLEXIBLE BRAKE HOSE - Loosen axle block nut - Loosen and remove front axle - Loosen the nuts that secure the discs, taking care not to damage the edges of the discs which may present burrs from the wear and tear. - When assembling the discs, apply Loctite 243 to the screws in order to ensure greater adherence. -
Page 14: Steering Shaft
20NM and then lock it with the lower nut until the assembly is released and is able to turn freely and precisely. Use the marks to adjust the ❱❘ PARTS BREAKDOWN fi nal handlebar position. ST SERIES... -
Page 15: Front Suspension
FRONT SUSPENSION - Loosen the front bridge that joins the two suspension bars and the mudguard support. - Remove the front wheel. - Remove the front mudguard. - Loosen the locking screws from the upper and lower platens. - Release the front brake grasper. - Cut the securing fl... -
Page 16: Changing Right Suspension Bar Seal
- Remove the cartridge from the bar. - Turn the bar and remove the end-of-run cone. - Push the compression group inward and remove the circlip from its seat. - Place the hydraulic group back in the cartridge. - Insert the end-of-run cone. ST SERIES... - Page 17 CHANGING RIGHT SUSPENSION BAR SEAL - Lever the edge of the dust cover and remove it from the bottle. - Remove the circlip from its seat. - Dismantle the bottle seal and cap. - Apply grease to the bottle mouth to make assembly easier.
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Page 18: Changing Left Suspension Bar Seal
- Place all the elements on a clean surface and empty the oil into a container. - Secure the protected bottle and loosen the pumping die to be able to remove the oil-retaining washer and screw. ST SERIES... - Page 19 CHANGING LEFT SUSPENSION BAR SEAL - Fully remove the pumping group. - Invert the bar and remove the end-of-run cone. - Lever the edge of the dust cover and remove it from its seat on the bar. - Remove the circlip from its seat. - Secure the protected bar with the screw and slide the bottle until it is fully removed.
- Page 20 - Pump a few times, pushing the tube to the end of its run. Fill with oil up to 110mm from the brim. - Insert the spring. - Insert the separating washer. - Insert the spacer. ST SERIES...
- Page 21 CHANGING LEFT SUSPENSION BAR SEAL - Insert the tapered spacer. - Fully tighten the upper plug of the tube to 17NM using a dynamometric spanner. ❱❘ PARTS BREAKDOWN...
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Page 22: Carburettor And Reed Block
fi lter box and the 3 screws from the rear mudguard. - Remove the CDI and the clamps securing the carburettor to the inlet nozzles and fi lter. - Close the fuel petcock valve. Remove the carburettor towards one side and dismantle the draining tube. ST SERIES... - Page 23 CARBURETTOR AND REED BLOCK - Dismantle the fuel input tube. Open the upper cap and remove the sliding hood. This leaves the carburettor completely unfastened. - On a clean table, loosen and remove the fl oat chamber by rotating it slightly. In an inverted position, test the height of the fl...
- Page 24 - Reassemble the carburettor, connecting the tubes and assembling the fuel cable. Assemble the fi lter box. - Position the carburettor and secure it with the fl anges. Place the air fi lter, the cover and the CDI. ST SERIES...
- Page 25 CARBURETTOR AND REED BLOCK Dell’orto Keihin 80c.c. 125 c.c. 250 c.c. 290 c.c. 300 c.c. Carburettor fl oat height 18.5 Idle jet Main jet Needle position P2 +0.5(*) P4+0.5(*) P4+0.5(*) 0.5mm ❱❘ PARTS BREAKDOWN Dell’orto Keihin...
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Page 26: Clutch Pump
- The clutch pump can be changed with no need to dismantle the fl exible brake hose at the pump end. - Remove the fl exible brake hose and the pump through the upper part of the chassis. ❱❘ PARTS BREAKDOWN ST SERIES... -
Page 27: Radiator
RADIATOR - Loosen and remove the radiator cap. - Have a receptacle ready to collect the fl uid. - Loosen and remove the cooling circuit draining screw. - Empty the fl uid from the engine. - Replace and close the draining screw. - Release the sleeves. -
Page 28: Footrests
- It is necessary to check the engine protector periodically, as well as its position and the condition of the rubber damper mounted between the protector and the engine carter. - Ensure it is correctly positioned at its anchoring points. ❱❘ PARTS BREAKDOWN ST SERIES... -
Page 29: Electrical System
ELECTRICAL SYSTEM - Most of the Sherco's electrical circuit is practically integrated into the chassis and only the connectors are visible. All the connection points,as well as the spark plug, coil, CDI, magnetic fl ywheel, and the ground anchoring point are accessed by dismantling the fi... -
Page 30: Changing Headlight Leds
- To release the headlight support plate, cut the supporting fl ange - Disconnect the plate feed - Separate the headlight plate with clear- glass covering and the incorporated LEDs using the central fi xing screw. ❱❘ PARTS BREAKDOWN ST SERIES... -
Page 31: Tilting Axle
TILTING AXLE - Loosen and remove the shaft. - Check the condition of the sleeve and the bearings that are fi xed into the swivel itself. Check and replace if necessary. - Use a pusher to remove the bearings. - Place the shaft and correctly tighten the nut to 50NM. -
Page 32: Rear Suspension
The connecting rod is forwarded. Check the condition of the sleeves and the bearings and replace them if necessary. Adequately grease the parts before reassembling them. ❱❘ PARTS BREAKDOWN ST SERIES... -
Page 33: Rear Brake And Secondary Transmission Maintenance
REAR BRAKE AND TRANSMISSION MAINTENANCE - Loosen the rear axle and remove the axle towards the left. - Release the wheel from the chain so that it can easily be removed. - Carry out maintenance operations on the rear brake, dismantling the brake pads and checking the height of the friction lining with the help of a calliper gauge. - Page 34 - Replace the wheel, taking care to place the bushing stoppers correctly, place the chain and center the wheel using the cams before fi nally tightening the axle. ❱❘ PARTS BREAKDOWN ST SERIES...
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Page 35: Fuel Tank
FUEL TANK - With the fuel tank in view after dismounting the rear mudguard, remove the protector and loosen the securing screws. - Slightly lift the tank to be able to manipulate and unhook the gas tubes connected to the gas pump. Always close the fuel petcock valve. -
Page 36: Exhaust Pipe Assembly Maintenance
fi lter box, as well as those of the muffl er protector and the tank. - Loosen and remove the muffl er fastening screws in order to remove it. Invert the process to replace the muffl er. ST SERIES... - Page 37 EXHAUST PIPE ASSEMBLY MAINTENANCE - Apply lubricant to the collector to make it easier to assemble it with the muffl er. - Assemble the collector and tighten the screws that join the collector to the cylinder. ❱❘ PARTS BREAKDOWN...
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Page 38: Changing Muffler Fibres
- Remove the inner tube and replace the fi bres. - Place the new fi bres inside the muffl er, taking care not to obstruct the inner tube. - Replace the removable part of the tube as well as the protective fastening cone. ST SERIES... -
Page 39: Engine Parts Section
ENGINE PART... -
Page 40: Changing The Piston
Replace and close the draining screw. Open the cover and remove the air fi lter. Loosen and remove the fi lter box's fastening screws as well as those of the rear mudguard. Loosen the rear mudguard. Remove the CDI ST SERIES... - Page 41 CHANGING THE PISTON Loosen the clamps that secure the carburettor to the inlet nozzles and the fi lter box. Remove the fi lter box. Remove the spark plug. Loosen the screws from the joining beam between the cylinder head to the chassis.
- Page 42 Remove the clips that fasten the bolt to the piston using pointed pliers. Remove the bolt by pushing with a special tool. Check the condition of the connecting rod ball bearing. Replace the gasket between the en- ST SERIES...
- Page 43 CHANGING THE PISTON Lubricate the ends of the connecting rod and the roller bearings. Check the tolerance between piston and cylinder. See tolerance table. Prepare the piston with the compressed rings to be introduced into the cylinder. With the piston fi tted into the cylinder, insert the bolt into the piston without reaching connecting...
- Page 44 Screw in the spark plug. Apply lubricant to the area where the exhaust pipe joins the muffl er in order to facilitate the connection. Place the exhaust pipe gasket and make sure it fi ts correctly. ST SERIES...
- Page 45 CHANGING THE PISTON Tighten the screws that anchor the exhaust pipe to the cylinder. Fill the cooling circuit with anti-freezing fl uid (430cc). Place the cap on the radiator. ❱❘ PARTS BREAKDOWN...
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Page 46: Verifying Piston And Cylinder
- Measure the interior of the cylinder. Check between the two readings depending on the capacities. - Check the tolerances in the technical specifi cations table. ❱❘ PARTS BREAKDOWN ST SERIES... -
Page 47: Ignition
IGNITION - Remove the drive sprocket circlip. Shift the pinion and chain assembly outward. Loosen and remove the gear- shift lever. - Loosen and remove the ignition cover. Check and gauge the pick-up distance using a 0.7-1mm gauge. - Loosen the rotor using special tool ref: R075. - Page 48 Loctite 243 fastener and set the dynamometer to 100NM. - Before replacing the cover, make sure the o-ring seal has been correctly placed on the cover. - Replace the ignition cover. ❱❘ PARTS BREAKDOWN ST SERIES...
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Page 49: Clutch Discs
CLUTCH DISCS - First remove the brake pedal. Loosen and remove the clutch cover screws. - Loosen the clutch spring screws. - Remove the spring-bearing plate. - Pay attention to the position of the washer. - Using a calliper gauge, check the wear and tear of the disc lining, max 2.6mm, min 2.4mm. -
Page 50: Start Routine
- Before assembling, check the axle and pawl are of the same brand. - Lay out the pieces in the same order in which they were dismantled in order to facilitate the assembly process. ST SERIES... - Page 51 START ROUTINE - Incorporate the washers. - Assemble the bearing and pawl pinion. - Place the spring and washer in position. - Place the clutch sleeve and bearing. - Assemble the clutch bearing. - Apply Loctite 243 to the nut. - Tighten using special tool ref: R037 and...
- Page 52 50NM. - Mount the discs, starting with a lined disc. Alternate 1 lined and 1 unlined disc. - Complete the process by assembling the semi-carter, screwing it in and mounting the starter lever. ❱❘ PARTS BREAKDOWN ST SERIES...
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Page 53: Gear Selector
GEAR SELECTOR - Loosen and remove the radiator. - Loosen and remove the cooling circuit draining screw. - Have a receptacle ready to collect the fl uid. Empty the cooling fl uid from the engine. - Replace and close the draining screw. - Loosen and remove the gear-shift lever. - Page 54 GEAR SELECTOR - Loosen the sprocket, remove the discs and dismantle the assembly. - Pull back the scorpion and remove the axle. Check the alignment of the selector spring. ❱❘ PARTS BREAKDOWN ST SERIES...
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Page 55: Gears And Crankshaft
GEARS AND CRANKSHAFT - Dismantle the gear-shift lever, the ignition box cover and the ignition system and pick-up. - Remove the circlip and then the drive sprocket. - Dismantle the inlet nozzle. - Loosen and remove the cylinder head. - Loosen and remove the cylinder. - Page 56 - Remove the carter and remove the centring devices and the gasket. - Loosen the clutch. - Dismantle the clutch and remove the clutch rod to be able to loosen the clutch housing. - Remove the clutch housing and the selector shaft. ST SERIES...
- Page 57 GEARS AND CRANKSHAFT - Loosen and remove toothed washer. Take care not to damage the needles. - Remove the circlip and intermediary pinion. - Loosen the primary transmission pinion. Remove the nut and washer. - Remove the pinion using an extractor. - Loosen and remove the carter screw plugs.
- Page 58 - Remove the two upper forks. - Remove the desmodromic drum and the third fork. - Remove the complete gear pinion assembly. - Dismantle the primary axle using the 4521200 Knipey pliers. - Repeat the operation with the secondary ST SERIES...
- Page 59 GEARS AND CRANKSHAFT axle. - Keep the parts in the same order to make reassembly easier. ❱❘ PARTS BREAKDOWN...
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Page 60: Water Pump
- Empty the oil from the engine carter. - Loosen the screws of the engine's right- hand semi-carter. Remove the semi- carter including its cover. - Check the axle and make sure that the seal is leak-tight. ❱❘ PARTS BREAKDOWN ST SERIES...