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SHERCO 125 SE-R 2017, Workshop Manual, Page: 2 / 49

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SHERCO 125 SE-R 2017 Workshop Manual Download Page 2

125 SE-
R 

  

2 

 

 

 

 

CONTENTS 

 

PREAMBLE ....................................................................................................................................................................................................................................................................................................................................................................................................... 4

 

LIST OF ENGINE TOOLS .......................................................................................................................................................................................................................................................................................................................................................................... 5

 

TECHNICAL CHARACTERISTICS ...................................................................................................................................................................................................................................................................................................................................................... 6

 

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Engine ...................................................................................................................................................................................................................................................................................................................................................................... 6

 

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Cycle part ................................................................................................................................................................................................................................................................................................................................................................. 7

 

ORIGINAL SETTINGS ................................................................................................................................................................................................................................................................................................................................................................................. 8

 

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Yoke .......................................................................................................................................................................................................................................................................................................................................................................... 8

 

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Shock absorber .................................................................................................................................................................................................................................................................................................................................................... 9

 

OPERATIONS REQUIRING ENGINE REMOVAL OR NOT I ............................................................................................................................................................................................................................................................................................. 10

 

ENGINE REMOVAL / ASSEMBLY ..................................................................................................................................................................................................................................................................................................................................................... 11

 

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Engine removal .................................................................................................................................................................................................................................................................................................................................................. 11

 

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Reassembly of the engine into its frame ................................................................................................................................................................................................................................................................................................... 12

 

ENGINE DISASSEMBLY ......................................................................................................................................................................................................................................................................................................................................................................... 14

 

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Gearbox drainage ............................................................................................................................................................................................................................................................................................................................................. 14

 

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Removal of the pinion and selector ............................................................................................................................................................................................................................................................................................................. 14

 

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Removal of the cylinder head, the cylinder and the piston ................................................................................................................................................................................................................................................................. 15

 

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Disassemble the clutch casing ..................................................................................................................................................................................................................................................................................................................... 16

 

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Removal of both the pressure tray and discs ......................................................................................................................................................................................................................................................................................... 16

 

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Removal of the electric starter ........................................................................................................................................................................................................................................................................................................................ 17

 

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Removal of the main transmission ............................................................................................................................................................................................................................................................................................................. 17

 

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Removal of the locking mechanism........................................................................................................................................................................................................................................................................................................... 18

 

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Removal of the ignition casing....................................................................................................................................................................................................................................................................................................................... 19

 

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Removal of the ignition ..................................................................................................................................................................................................................................................................................................................................... 19

 

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Removal of the starter ...................................................................................................................................................................................................................................................................................................................................... 20

 

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Intake pipe and clapper box ........................................................................................................................................................................................................................................................................................................................... 20

 

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Separate out the half-casings ........................................................................................................................................................................................................................................................................................................................ 21

 

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Removal of the speed selection ................................................................................................................................................................................................................................................................................................................... 21

 

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Removal of the rod assembly ....................................................................................................................................................................................................................................................................................................................... 22

 

ENGINE PART CONTROL ..................................................................................................................................................................................................................................................................................................................................................................... 23

 

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Connecting rod assembly .............................................................................................................................................................................................................................................................................................................................. 23

 

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Balance masses, verification of the exterior side .................................................................................................................................................................................................................................................................................... 23

 

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Radial clearance of the crank head ............................................................................................................................................................................................................................................................................................................ 23

 

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Crank head lateral clearance ........................................................................................................................................................................................................................................................................................................................ 24

 

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Control of the crankshaft radial runout ........................................................................................................................................................................................................................................................................................................ 24

 

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Piston ...................................................................................................................................................................................................................................................................................................................................................................... 24

 

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Cross-sectional clearance .............................................................................................................................................................................................................................................................................................................................. 24

 

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Standard exchange cylinder / Squish control ......................................................................................................................................................................................................................................................................................... 26

 

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Disassemble the exhaust valve system ................................................................................................................................................................................................................................................................................................... 27

 

Summary of Contents for 125 SE-R 2017

Page 1: ...MANUEL D ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER...

Page 2: ...fboththepressuretrayanddiscs 16 Removaloftheelectricstarter 17 Removalofthemaintransmission 17 Removalofthelockingmechanism 18 Removaloftheignitioncasing 19 Removaloftheignition 19 Removalofthestarter...

Page 3: ...e 36 Clutchcasing 36 Pistonandcylinder 37 Cylinderhead 37 Clapperboxandpipeintake 38 Gearboxoutputpinion 38 Assemblyoftheignitionstarter 38 Ignitionassemblyanditslid 39 Assemblyoftheelectricstarter 39...

Page 4: ...echanics working in an appropriately equipped workshop 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...

Page 5: ...f gearbox gasket tool 2071 Right hand drum bearing selection tool 5398 Left hand drum bearing selection tool 5399 Crankshaft bearing tool 2069 Crankshaft gasket tool 5402 HK0808 needle bearing cage to...

Page 6: ...sparkplugelectrodes 0 7mm Piston Forgedaluminium Motoroil 500mlSAE10W40 Maintransmission 20x72 Gearbox 1st2nd 3rd4th 5th6th 6speeds 15 33 17 30 19 28 21 26 23 24 25 22 Finaltransmission 13x51 Clutch M...

Page 7: ...n with a separate cylinder oscillating aluminium arm Front back stroke 300 330 mm Front brake disc 260 mm Rear brake Disc 220 mm Disc brakes Wearing limit 2 7 mm front and 3 6 mm rear Front tyre 90 90...

Page 8: ...ort 14 clicks backwards Standard 12 clicks backwards Sport setting 10 clicks backwards Prestressing Comfort 0 Clicks Standard 1 Click 3 Sport setting 2 Clicks 6 Spring stiffness Rider s weight 65 75 k...

Page 9: ...clicks backwards High speed compression Comfort 2 revolutions backwards Standard 1 5 revolutions backwards Sport setting 1 revolution backwards Recreation Comfort 15 clicks backwards Standard 12 clic...

Page 10: ...requiring engine removal Operation not requiring engine removal Crankshaft including the crank kit Complete gearbox Crankshaft bearing Gearbox bearing Piston Cylinder Cylinder head Ignition Starter g...

Page 11: ...Remove the chain protection Remove the clutch slave cylinder Remove the water hoses connected to the engine Remove the left side radiator Unscrew the entire set of engine screws Loosen the oscillating...

Page 12: ...frame screws 23 N m Remove the two M4 screws and withdraw the valve pulley cover plate Place the mapping contactor in the Soft position toward the left and place the motorcycle contact switch in the O...

Page 13: ...and its subsequent shut off Turn off the motorcycle contact switch and check that the pulley is correctly positioned facing right Proceed with the right cable tension adjustment 2 so as to remove all...

Page 14: ...talogue 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 Remove the gearbox output pinion 4...

Page 15: ...rews 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 Release the piston shaft Remove th...

Page 16: ...ew 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 clutc...

Page 17: ...w both screws 2 Removal of the main transmission Block the pinion at the end of the crankshaft using tool reference 1817 3 Unscrew the main transmission nut 4 and then remove it with the tapered washe...

Page 18: ...Unscrew the hex socket screw 2 and remove the selection star 3 CAUTION at the wedge and O ring The main transmission pinion and clutch housing crown match which is why they cannot be changed separatel...

Page 19: ...n 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...

Page 20: ...SE R 20 I I ENGINEDISASSEMBLY Removal of the starter Take out the starter 1 Intake pipe and clapper box Remove all 4 plastic hex sprocket screws 5 Remove the pipe clapper box and corresponding joint...

Page 21: ...wo selector fork shafts 2 and push them to the side to free the drum Now disengage the selection drum from its bearing Remove the selector forks CAUTION Avoid to the greatest extent possible introduci...

Page 22: ...he 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 Replace them as ne...

Page 23: ...immediately position it on the reach of the connecting rod assembly Balance masses verification of the exterior side Using a calliper measure the outer distance of the balance masses Exterior value 57...

Page 24: ...ndness Standard 0 03 mm maximum Tolerance limit 0 05 mm If the eccentricity is incorrect replace the crankshaft or else align it to ensure lying within the tolerance limits Piston If you introduce a p...

Page 25: ...25 edge of the cylinder With a shim it is possible to measure the cross sectional clearance Cross sectional clearance max 0 40 mm...

Page 26: ...linder The clearance must be 0 otherwise use another head gasket in order to obtain the desired value CAUTION Should the clearance be greater than indicated it would be necessary to check the conditio...

Page 27: ...tion 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 Take off the nut a...

Page 28: ...e the O ring and pulley spacer Remove the lids from each side of the valve Remove the M4 connecting screw 3 Remove the valve by disassembling both parts CAUTION During the reassembly step reposition t...

Page 29: ...nsure 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 Should you observe an abnorma...

Page 30: ...er position at the time of clamping Insert the shim into the exhaust light and exert pressure toward the bottom in a way that keeps the valve in the maximum open position Tighten the pulley nut 2 whil...

Page 31: ...eeve especially if it is not split Clutch Stop 8 Verify the state of wear Rod 1 Verify its state of wear Minimum length 162 5 mm Springs 14 Verify their length Minimum spring length 37 5 mm Replace th...

Page 32: ...hafts together then drive them into their respective bearings until reaching the stop Hook the forks into the grooves of the moving pinions and insert the drum into its ball bearing Lubricate the fork...

Page 33: ...alf casing and moreover that the gearbox shaft washers are in their appropriate place Lubricate the gaskets of the left half casing and proceed with installation of this half casing Introduce the scre...

Page 34: ...der to install the selection star Coat the screw with blue brake fluid and then assemble the selection star on the drum 2 Lubricate the axis of the now assembled selection and insert it into the needl...

Page 35: ...ke fluid on the main shaft threading Assemble the clutch drum and its nut on the main shaft in applying red brake fluid and a new safety washer Introduce tool reference 1814 and tighten the nut to 100...

Page 36: ...g Verify whether the two centring bushings are indeed well installed Introduce the casing joint and hold it in place with a bit of lubricant Stick the water pump set ring 2 with a bit of lubricant Pre...

Page 37: ...joint Properly position the segments with the reference pointing upward Insert the pre fitted cylinder fasten the cylinder with 2 nuts on opposite sides Raise the other two screws and washers then ti...

Page 38: ...th the four M6 screws and its metal collar Gearbox output pinion Place the gearbox output pinion on the secondary shaft Apply blue brake fluid on the threading Insert the safety washer Install the nut...

Page 39: ...of the electric starter Replace the O ring on the starter by a new joint Apply a bit of lubricant on the O ring Insert the starter into the right hand casing Fasten the starter with the 2 hex sprocket...

Page 40: ...tening 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 Brake pad axis screw 8 N m Lower yoke tee clamping screw 12 N...

Page 41: ...oss patterned tightening torque 10 N m Crankshaft inspection plug 8 N m Clutch pressure plate screw 10 N m Water pump casing screw 10 N m Ignition wheel nut 80 N m Clutch drum nut 100 N m Main transmi...

Page 42: ...EG N1EH N1EH N1EI Needle position 3 3 2 2 2 2 Main injector 168 168 165 162 160 158 1 500 m Air screw adjustment 1T 1T1 4 1T1 4 1T3 4 1T3 4 2T1 4 to Slow injector 45 45 42 42 40 38 751 m Needle N1EF N...

Page 43: ...motorcycle mass Resistance of the Pick UP regime sensor Red Greens 120 20 at 20 C High voltage coil Primary coil 0 30 15 at 20 C Secondary coil 6 3 k 20 at 20 C Dynamiccontrolvalues Voltage regulator...

Page 44: ...125 SE R 44 I I WIREMAP Main bundle 6827...

Page 45: ...45 WIREMAP...

Page 46: ...125 SE R 46 I I WIREMAP Light beam 125 SE R...

Page 47: ...47 WIREMAP Racing light beam 125 SE R...

Page 48: ...125 SE R 48 I I WIREMAP Accessory bundle...

Page 49: ...49...

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