Table of Contents
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Table of Contents
Related Manuals for SHERCO 250
Summarization of Contents
TECHNICAL DATA
Engine Specifications
Details engine type, displacement, bore/stroke, fuel, cooling, ignition, spark plug, and gearbox oil.
Chassis Specifications
Provides frame, fork, shock absorber, brake, tyre, and wheelbase dimensions and types.
Fork Settings and Service
Factory settings for fork preload, rebound, compression, and oil change procedures for front fork legs.
Shock Absorber Specifications
Details settings for the rear shock absorber, including spring, preload, restrictor, rebound, and compression.
Front End Maintenance
Procedures for changing front wheel bearings and brake discs, including torque specs and spacer checks.
Steering Head Bearings Service
Instructions for fork disassembly and steering head bearing replacement, with critical torque values.
Left Fork Oil Change
Steps for changing the oil in the left side of the TECH front fork.
Rear End Maintenance
Procedures for changing rear wheel bearings, brake discs, and checking swingarm/suspension linkages.
Suspension Linkage Inspection
Detailed check of suspension linkage shafts and bushings, with associated tightening torques.
ENGINE
Engine Service Considerations
Table indicating which engine components can be serviced with or without engine removal.
ENGINE REMOVAL AND FITTING
Engine Removal Procedure
Step-by-step guide for removing the engine from the frame, detailing necessary disconnections and precautions.
Engine Fitting Procedure
Instructions for reinstalling the engine into the frame, following reverse steps and torque specifications.
ENGINE DISASSEMBLY
Gearbox Draining and Sprocket Removal
Procedures for draining gearbox oil and removing the front sprocket.
Top-End Disassembly
Detailed steps for disassembling the cylinder head, combustion chamber, piston, and related top-end components.
Reeds Valve and Coolant Pump Removal
Steps for removing the reeds valve and the coolant pump assembly.
Right Side Engine Disassembly
Procedures for disassembling the engine's right side, including clutch cover.
Clutch and Primary Drive Removal
Process for removing the clutch assembly, pressure plates, discs, and primary drive components.
Kickstarter and Shifting Mechanism Removal
Steps for removing the kickstarter shaft and the shifting mechanism components.
Left Side Engine Disassembly
Procedures for disassembling the engine's left side, including ignition cover, flywheel, and stator.
CRANKCASE SPLITTING
Gearbox Removal from Crankcase
Steps for removing the gearbox assembly, including shafts, drum, and snap rings.
Selector Fork-Drum Assembly Disassembly
Procedure for disassembling the selector fork and drum assembly, involving pin retaining clips.
ENGINE PARTS CHECK
Crankshaft Inspection
Instructions for removing the crankshaft and checking for wear, recommending gasket replacement.
Crankshaft Dimensional Checks
Procedures for measuring crankshaft width, big-end radial play, and axial play.
Crankshaft Runout Check
Method for checking crankshaft runout using dial gauges and an alignment device.
Piston and Ring Inspection
Checks for piston skirt, grooves, pins, and ring end gap, including wear limits.
Cylinder-Piston Wear Analysis
How to measure cylinder bore and piston diameter to assess wear and ovalization.
Clutch and Gearbox Shafts Inspection
Checks for wear on clutch components and gearbox shafts, including disc thickness.
Reeds Valve and Intake Boot Condition
Inspection of reed valves for elasticity and intake boot for cracks, recommending replacement.
ENGINE ASSEMBLY
Gearbox Assembly
Steps for assembling the gearbox, focusing on lubrication, fork orientation, and clip installation.
CRANKCASE COUPLING AND SIDE ASSEMBLY
Procedures for coupling crankcases, installing crankshaft, dowel pins, and gasket.
Left Hand Side Assembly
Steps for assembling the engine's left side, including crankshaft and ignition fitting.
Right Hand Side Assembly
Procedures for assembling the engine's right side, including clutch and kickstarter components.
Top-End Assembly
Steps for reassembling the engine's top end, including piston, cylinder, and combustion chamber.
Piston Fitting Procedure
Detailed instructions for fitting the piston, needle cage, wrist pin, and clips into the cylinder.
Squish Check Procedure
Method to measure squish clearance using tin wire between piston crown and combustion chamber.
Reed Valve and Intake Boot Installation
Steps for installing new reed valve gasket, reed valve, intake boot gasket, and intake boot.
Gearbox Output Sprocket Installation
Procedure for fitting the engine-side snap ring, output sprocket, and outer snap ring for the gearbox output.
ELECTRICAL SYSTEM
Electric Components Overview
Identification and location of key electrical components on the motorcycle.
CDI Unit and Wiring
Details on the CDI unit, including its wiring diagram and specifications.
Voltage Regulator Specifications
Key parameters for the voltage regulator, such as output voltage and current.
Temperature Sensor Resistance Chart
Table showing resistance values of the temperature sensor at different temperatures.
Ventilator Test Procedure
Method to test the fan's functionality by direct battery connection.
Injector Specifications
Performance parameters for fuel injectors, including flow rates and pressure resistance.
MAP Sensor Identification
Pinout and identification of the Manifold Absolute Pressure (MAP) sensor.
Fuel Pump Pressure Test
Procedure for testing fuel pump pressure and maintaining a steady 3.5 bars.
Throttle Position Sensor (TPS) Reset
Steps to perform a zero TPS calibration after replacing the throttle position sensor or body.
Motorcycle Wiring Diagram
Comprehensive electrical wiring diagram illustrating component connections and color codes.
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