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SHERCO 125 SE-R 2017 User Manual

SHERCO 125 SE-R 2017
49 pages
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MANUEL D’ATELIER I WORKSHOP MANUAL I MANUAL DE
TALLER

Table of Contents

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SHERCO 125 SE-R 2017 Specifications

General IconGeneral
Displacement124.8 cc
Bore x Stroke54 mm x 54.5 mm
Transmission6-speed
Fuel SystemCarburetor
Front Suspension BrandWP
Front Suspension Diameter48 mm
Rear Suspension BrandWP
Front BrakeDisc
Front Brake Diameter260 mm
Rear BrakeDisc
Rear Brake Diameter220 mm
Seat Height950 mm
Engine Type2-stroke
Cooling SystemLiquid-cooled
Rear SuspensionShock absorber
Rear Suspension TypeMonoshock
Dry Weight94 kg

Summary

Preamble

List of Engine Tools

Technical Characteristics

Engine Specifications

Details technical specifications for the engine, including type, displacement, bore/stroke, fuel, and coolant.

Cycle Part Specifications

Details technical specifications for the motorcycle's chassis, suspension, brakes, and tires.

Original Settings

Yoke Settings

Provides original settings for the WP yoke suspension, including compression, recreation, and spring stiffness.

Shock Absorber Settings

Details original settings for the WP suspension shock absorber, covering compression and spring stiffness.

Operations Requiring Engine Removal

Engine Removal and Assembly

Engine Removal Procedure

Step-by-step instructions for safely removing the engine from the motorcycle frame, including necessary precautions.

Engine Reassembly Procedure

Details the process for reassembling the engine into the frame, including valve cable tension adjustment.

Valve System Reassembly

Focuses on reassembly steps for the engine's valve system, including mapping contactor and cable tension.

Engine Disassembly

Gearbox Drainage

Instructions for draining the gearbox oil by removing the drainage plugs.

Pinion and Selector Removal

Steps for removing the gearbox output pinion and the speed selector mechanism.

Cylinder Head, Cylinder, and Piston Removal

Detailed procedure for removing the cylinder head, cylinder, and piston assembly from the engine.

Clutch Casing Disassembly

Instructions for removing the clutch casing and its associated joint.

Clutch Pressure Tray and Discs Removal

Steps for removing the clutch pressure plate, springs, and discs from the engine.

Electric Starter Removal

Procedure for removing the electric starter motor from the engine assembly.

Main Transmission Removal

Detailed steps for removing the main transmission components, including the pinion and nut.

Main Transmission Pinion Removal

Specific instructions for removing the main transmission pinion, noting its pairing with the clutch housing.

Locking Mechanism Removal

Steps for removing the engine's locking mechanism, including the selection star.

Ignition Casing Removal

Procedure for removing the ignition casing and its gasket.

Ignition System Removal

Steps for removing the ignition system components, including the magnetic wheel.

Starter Motor Removal

Instructions for removing the starter motor from the engine.

Intake Pipe and Clapper Box Removal

Procedure for removing the intake pipe and clapper box assembly.

Separating Engine Half-Casings

Steps for separating the engine's left and right half-casings, with precautions for the parting surface.

Speed Selection Mechanism Removal

Procedure for removing the speed selection components, including fork shafts and drum.

Primary and Secondary Shaft Removal

Instructions for removing the primary and secondary shafts from their bearings.

Rod Assembly Removal

Procedure for removing the connecting rod assembly from its bearing, with cleaning and inspection advice.

Engine Part Control and Verification

Connecting Rod Assembly Checks

Procedure for checking and replacing the connecting rod assembly, including bearing and ring installation.

Balance Masses Verification

Instructions for measuring the exterior distance of the balance masses using a caliper.

Crank Head Radial Clearance

Procedure for measuring crank head radial clearance using a dial gauge and checking against tolerances.

Crank Head Lateral Clearance

Method for measuring crank head lateral clearance and checking against tolerance limits.

Crankshaft Radial Runout Control

Procedure for measuring crankshaft radial runout (eccentricity) using an alignment device and gauge.

Piston Inspection

Points to verify when reusing a piston, including apron smears and segment grooves.

Cross-Sectional Clearance Measurement

Method for measuring the cross-sectional clearance of piston segments using a shim.

Cylinder Wear and Piston Verification

Procedure for detecting cylinder wear by measuring bore diameter and piston diameter.

Cylinder/Piston Squish Control

Guidance on squish control, cylinder relining, and piston/cylinder dimension verification.

Exhaust Valve System Disassembly

Steps for disassembling the exhaust valve system, including removing covers, cables, and pulley.

Valve Operations Control

Procedure for controlling valve operations, ensuring central valve and boosters are fully open, and checking clearance.

Exhaust Valve Pulley Clearance Adjustment

Essential steps for adjusting the exhaust valve pulley clearance to guarantee optimal motorcycle operations.

Clapper Box and Intake Sleeve Condition

Checks for the clapper box and intake sleeve, noting wear on carbon tabs and potential splitting.

Clutch Component Verification

Verification of clutch components including rod, springs, lined discs, and smooth discs for wear and thickness.

Engine Reassembly Procedures

Connecting Rod Assembly Reassembly

Instructions for inserting the connecting rod assembly into the ball bearing, ensuring proper crank positioning.

Transmission Gearbox Reassembly

Steps for reassembling the transmission gearbox, including fork guiding, shafts, and drum insertion.

Engine Half-Casings Assembly

Procedure for assembling the engine half-casings, including lubrication, centring rings, and checking shaft rotation.

Selection Mechanism Reassembly

Detailed steps for reassembling the selection mechanism, including springs, spacers, and locking levers.

Main Transmission and Clutch Reassembly

Instructions for reassembling the main transmission and clutch components, including pinion, washers, and nuts.

Clutch Discs and Pressure Plate Reassembly

Steps for oiling and installing clutch discs, pressure plate, springs, and tightening screws.

Clutch Casing Reassembly

Procedure for installing the clutch casing, ensuring proper alignment and mesh with the crankshaft.

Piston and Cylinder Reassembly

Instructions for reassembling the piston and cylinder, including oiling, positioning, and securing.

Cylinder Head Reassembly

Steps for cleaning, positioning, and tightening the cylinder head with new shoulder screws and washers.

Clapper Box and Pipe Intake Reassembly

Procedure for installing the clapper box, intake pipe, and associated screws and collar.

Gearbox Output Pinion Reassembly

Steps for installing the gearbox output pinion, securing it with a nut and safety washer.

Ignition Starter Assembly

Instructions for installing the ignition starter and lubricating its pinions.

Ignition Assembly and Lid Reassembly

Procedure for assembling the ignition rotor, nut, and cover, including setting centring bushings.

Electric Starter Assembly

Steps for assembling the electric starter, O-ring, and securing it with screws, plus clutch control rod insertion.

Table of Tightening Torques

Engine Tightening Torques

Lists tightening torques for various engine components, including screws, nuts, and sensor.

Carburettor Settings Table

SE-R 125 Carburettor Settings

Provides carburettor settings (air screw, injectors, needle) based on altitude and temperature.

Load Circuit Control and Testing

Static Control Values (Engine Off)

Measures stator winding resistance and checks for continuity between windings and chassis ground.

Dynamic Control Values

Tests voltage regulator for alternating and continuous current outputs at different engine speeds.

Wiring Diagrams

Main Wiring Bundle 6827

Detailed wiring diagram for the main electrical bundle, showing connections and component layouts.

Light Beam Wiring 125 SE-R

Wiring diagram specifically for the front light beam assembly of the 125 SE-R model.

Racing Light Beam Wiring 125 SE-R

Wiring diagram for the racing version's front light beam assembly.

Accessory Bundle Wiring

Wiring diagram for the accessory bundle, showing connections for additional equipment.

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