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SHERCO X-RIDE 1.25, Assembly Instructions Manual, Page: 34 / 48

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SHERCO X-RIDE 1.25 Assembly Instructions Manual Download Page 34

7/22/2002

Sherco Assembly 

Instructions

34

www.shercousa.com

If you need to add coolant we recommend Maxima 
premixed coolant 50/50 mixture.

Also shown are the Maxima gear oil and 2 stroke 
oil we recommend.

These items are available from Ryan Young 
Products.

Summary of Contents for X-RIDE 1.25

Page 1: ...different but the principles shown will apply to all of the models indicated The technician shown in the photographs is David Chaves who received his training at the Sherco factory in Spain David is a...

Page 2: ...7 22 2002 Sherco Assembly Instructions 2 www shercousa com Set the crate upright as shown These pictures show how the bike is packaged and shipped from the factory...

Page 3: ...7 22 2002 Sherco Assembly Instructions 3 www shercousa com Remove both of the straps Preparation for assembly...

Page 4: ...7 22 2002 Sherco Assembly Instructions 4 www shercousa com Lift the box off of the bike and set aside...

Page 5: ...7 22 2002 Sherco Assembly Instructions 5 www shercousa com These pictures show the bike in it s shipping configuration...

Page 6: ...7 22 2002 Sherco Assembly Instructions 6 www shercousa com This picture shows how the axle bolt is used to retain the bike to the crate...

Page 7: ...7 22 2002 Sherco Assembly Instructions 7 www shercousa com Set the front wheel and the package containing the plastic parts aside...

Page 8: ...7 22 2002 Sherco Assembly Instructions 8 www shercousa com Carefully remove all of the protective plastic wrap...

Page 9: ...7 22 2002 Sherco Assembly Instructions 9 www shercousa com The bike is now ready to be assembled...

Page 10: ...rco Assembly Instructions 10 www shercousa com David removes the 2 rear bolts and loosens the front 2 This allows him to install the handlebars without having to completely remove the clamps Handlebar...

Page 11: ...7 22 2002 Sherco Assembly Instructions 11 www shercousa com The handlebar adjustment is unique to each rider David usually rolls them forward These 4 bolts should be tightened to 15 ft lbs...

Page 12: ...2002 Sherco Assembly Instructions 12 www shercousa com In order to remove the bike from the wooden crate you must remove the front axle The first step is to loosen the 2 bolts on the front of the fork...

Page 13: ...7 22 2002 Sherco Assembly Instructions 13 www shercousa com Carefully remove the front axle If it is in a bind you may have to loosen the fork brace bolts...

Page 14: ...7 22 2002 Sherco Assembly Instructions 14 www shercousa com David now sets the bike on a stand so that he can install the front wheel Front Wheel Installation...

Page 15: ...7 22 2002 Sherco Assembly Instructions 15 www shercousa com Make sure that the threads in the fork are clean David uses an air gun and blows out any foreign material that may be present...

Page 16: ...ercousa com David makes sure that the axle fits perfectly before he installs the wheel If the fork legs are not aligned properly the threads on the axle can be ruined You may have to loosen the fork b...

Page 17: ...7 22 2002 Sherco Assembly Instructions 17 www shercousa com Make sure that there is enough clearance between the brake pads to install the brake disc In this case the pads were touching...

Page 18: ...Sherco Assembly Instructions 18 www shercousa com Loosen the brake adjusting screw enough so that the brake lever has free play This will allow the brake pads to be pushed apart so that the brake disc...

Page 19: ...erco Assembly Instructions 19 www shercousa com David used a small screw driver and gently opened up the brake pads so he can install the front wheel assembly DO NOT FORCE THE PADS APART AS YOU COULD...

Page 20: ...7 22 2002 Sherco Assembly Instructions 20 www shercousa com Carefully slide the disc between the brake pads Install the axle...

Page 21: ...7 22 2002 Sherco Assembly Instructions 21 www shercousa com Install the spacer Tighten the axle to 44 ft lbs Tighten the pinch bolts to 8 ft lbs...

Page 22: ...embly Instructions 22 www shercousa com Take the bike off of the wooden shipping frame and set it back on the stand in preparation for the final assembly The Bike Is Now Ready To Have The Headlight an...

Page 23: ...7 22 2002 Sherco Assembly Instructions 23 www shercousa com Open the package that contains the plastic parts and lay them out in preparation for installation...

Page 24: ...7 22 2002 Sherco Assembly Instructions 24 www shercousa com Remove the lower brake caliper fixing bolt Remove the small bolt from the bottom of the fork leg Front Brake Caliper Guard Installation...

Page 25: ...nstructions 25 www shercousa com Install the plastic caliper guard using the 2 bolts that were removed in the previous step Tighten the brake caliper bolt to 15 ft lbs and tighten the small lower bolt...

Page 26: ...7 22 2002 Sherco Assembly Instructions 26 www shercousa com The next step is to install the front fender Remove the 2 fender mounting bolts from the fender mounting bracket Front Fender Installation...

Page 27: ...7 22 2002 Sherco Assembly Instructions 27 www shercousa com Set the fender in place on the bracket Install the fender bolts...

Page 28: ...7 22 2002 Sherco Assembly Instructions 28 www shercousa com Attach the headlight wire to the chassis wiring harness Fasten the headlight to the fork tubes using the 2 zip ties Headlight Installation...

Page 29: ...7 22 2002 Sherco Assembly Instructions 29 www shercousa com Tighten and then cut the loose ends off of the zip ties Push the cut ends in towards the back of the headlight...

Page 30: ...mbly but it is prudent to take the time to check the coolant level in the radiator David will take the time to go through the steps to check the coolant level before he finishes putting the bike toget...

Page 31: ...7 22 2002 Sherco Assembly Instructions 31 www shercousa com Remove the front mounting bolt and disconnect the fuel tank overflow line Disconnect the fuel line from the fuel valve...

Page 32: ...7 22 2002 Sherco Assembly Instructions 32 www shercousa com Remove the fuel tank...

Page 33: ...bly Instructions 33 www shercousa com Carefully remove the radiator cap you can remove it without removing the ignition coil Check the coolant level It should cover the fins and not be up in the fille...

Page 34: ...nstructions 34 www shercousa com If you need to add coolant we recommend Maxima premixed coolant 50 50 mixture Also shown are the Maxima gear oil and 2 stroke oil we recommend These items are availabl...

Page 35: ...7 22 2002 Sherco Assembly Instructions 35 www shercousa com Carefully reinstall the radiator cap David uses a screw driver as a lever to tighten the radiator cap...

Page 36: ...7 22 2002 Sherco Assembly Instructions 36 www shercousa com Reinstall the fuel tank Install and tighten the front mounting bolt Reattach the fuel tank overflow hose Fuel Tank Installation...

Page 37: ...7 22 2002 Sherco Assembly Instructions 37 www shercousa com Reconnect the fuel line...

Page 38: ...7 22 2002 Sherco Assembly Instructions 38 www shercousa com Rear Fender Installation Remove the 2 fender mounting screws Route the tail light harness as shown...

Page 39: ...7 22 2002 Sherco Assembly Instructions 39 www shercousa com Connect the tail light harness to the chassis harness Install the fender note that the lip on the fender overlaps the lip on the air box...

Page 40: ...7 22 2002 Sherco Assembly Instructions 40 www shercousa com This picture shows the installed fender note how the lip on the fender fits over the lip on the air box...

Page 41: ...22 2002 Sherco Assembly Instructions 41 www shercousa com Install and tighten the front fender rear fuel tank bolt Install and tighten the 2 rear fender mounting bolts Rear Fender Installation Continu...

Page 42: ...mbly Instructions 42 www shercousa com The foot peg mounting bolts are tightened at the factory so that they are in an upright fixed position for shipping Loosen the bolts just enough to allow the foo...

Page 43: ...ons 43 www shercousa com The bike should look like this except it should have the headlight installed we removed the headlight while taking pictures for another project As pictured the bike is ready f...

Page 44: ...y Instructions 44 www shercousa com David is shown tightening the rear sprocket bolts Finishing Touches David Goes Around The Bike and Tightens all of These Bolts In this picture he is tightening the...

Page 45: ...7 22 2002 Sherco Assembly Instructions 45 www shercousa com Here he is tightening the front brake caliper bolts Tighten the fork brace bolts...

Page 46: ...7 22 2002 Sherco Assembly Instructions 46 www shercousa com Here we see David tightening the triple clamp bolts...

Page 47: ...7 22 2002 Sherco Assembly Instructions 47 www shercousa com David also tightens the exhaust flange bolts...

Page 48: ...re and test ridden We recommend that you take the time to check all of the bolts for tightness we showed the ones that David believes are extremely critical We also suggest that you use a good brand o...

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