SHERCO X-RIDE 1.25 Instruction manual

1

1
TABLE OF CONTENTS
FOREWORD ................................................ 3
SPECIAL TOOLS REQUIRED .......................... 4
TECHNICAL DATA ........................................ 5
ENGINE ..................................................... 5
CHASSIS ................................................... 6
FORK ......................................................... 6
SHOCK ABSORBER ................................. 6
CHASSIS ..................................................... 7
❱❘Front end .................................................... 7
1.1 Whee bearings change ................... 7
1.2 Front brake disc change : ............... 7
1.3 Fork disassemb y and steering head
bearings change ........................................... 8
1.4 TECH fork servicing ........................ 9
1.4.1 Right side oi change ....................... 9
1.4.2 Left side oi change ........................ 10
❱❘
Rear end .............................................. 12
2.1 Whee bearings change ................. 12
2.2 Brake disc change ......................... 13
2.3 Swingarm bearings check ............. 13
2.4 Suspension inkage check ............ 14
OPERATIONS REQUIRING THE
REMOVAL OR NOT OF THE ENGINE .... 15
ENGINE REMOVAL/FITTING .................. 16
❱❘
Engine removal ................................... 16
❱❘
Fitting t e engine in t e frame ........... 16
ENGINE DISASSEMBLING ..................... 17
❱❘ Gearbox draining ...................................... 17
❱❘ Front sprocket removal ............................. 17
❱❘ Top end removal ....................................... 17
❱❘ Reeds valve removal ................................ 19
❱❘
Rig t side disassembling ................... 19
❱❘ Clutch cover removal ................................ 19
❱❘ Coolant pump disassembling.................... 20
❱❘ Clutch and primary drive removal ............. 21
❱❘ Kickstarter shaft removal .......................... 24
❱❘ Shifting mechanism removal .................... 24
❱❘
Left side disassembling. .................... 25
❱❘ Ignition removal. ....................................... 25
❱❘
Crankcase splitting ............................. 26
❱❘ Gearbox removal ...................................... 27
• ❱❘ Disassemble the selector fork drum
assembly ...................................................... 28
ENGINE PARTS CHECK ......................... 30
❱❘ Crankshaft removal................................... 30
❱❘ Crankshaft width measure ........................ 31
❱❘ Big end radial play .................................... 31
❱❘ Axial play of the big end ........................... 31
❱❘ Crankshaft runout check ........................... 32
❱❘ Piston ........................................................ 33
❱❘ End gap .................................................... 33
❱❘ Wrist pin check ......................................... 33
❱❘ Cylinder – piston wear condition ............... 34
❱❘ Reeds valve, intake boot .......................... 34
❱❘ Clutch ........................................................ 35
❱❘ Discs check ............................................... 35
❱❘ Gearbox shafts ......................................... 36
ENGINE ASSEMBLING ....................... 37
❱❘ Gearbox assembling. ................................ 37
❱❘
Accoupling t e crankcases................ 39
❱❘
Left and side assembling ................. 39
❱❘ Fitting the ignition ...................................... 39
❱❘
Rig t- and side assembling .............. 40
❱❘Clutch assembling ..................................... 40
• Fit the clutch basket and the clutch hub.
42
Using the tool ............................................... 42
❱❘
Top-end assembling ........................... 45
❱❘Piston fitting ............................................... 45
❱❘ Squish check ............................................ 47
❱❘ Reed valve and intake boot ...................... 48
❱❘ Gearbox output sprocket .......................... 48
TIGHTENING TORQUES .............................. 49

ELECTRICAL ........................................... 50
❱❘ Electric components ................................. 50
❱CDI .............................................................. 51
❱❘ Voltage regulator ...................................... 51
❱❘ Temperature sensor ................................. 52
❱❘ Ventilator ................................................... 52
❱❘ Injector specs ............................................ 53
❱❘ MAP specs ................................................ 53
❱❘ Fuel pump specification ............................ 53
❱❘ Reset TPS .................................................. 54
❱❘ Wiring diagram ......................................... 55

3
ST SERIES
FOREWORD
This manual is primarily intended for qualified mechanics working in a properly equipped
workshop.
The success of the various operations requires some mechanical skills and the SHERCO
specific tools for the 125 / 250 / 300 ST engines.
This workshop manual complements the SHERCO 125 / 250 and 300 ST owner’s manual.

4
ST SERIES
SPECIAL TOOLS REQUIRED
Too part number Designation
10981 Crankshaft fitting tool
10982 Clutch lock tool
10983 Coolant connector fitting/ removal tool
10984 Flywheel puller
10985 Flywheel locking tool
10986 Primary drive locking tool
10987 Clutch spring centering tool
10988 Shifter spring locking tool
R455 Engine support
R481 Oil pan

5
ST SERIES
TECHNICAL DATA
ENGINE
125 250 300
Type Single cylinder, liquid cooled, two stroke
Disp acement 123,70 cc 249,70 cc 294 cc
BoreXstroke 54X54 mm 72,8X60 mm 79X60 mm
Fue Premix with unleaded fuel (RON 98 minimum) and special injection 2 stroke oil,
Premix ratio : 1,5%
Coo ing Liquid, forced circulation
Ignition system Hidria Digital
Spark p ug NGK BPMR6A
E ectrodes gap 0.7 mm
Piston Cast, graphite coated skirt
Gearbox oi 450 ml , ATF type
Primary drive 82 x 23 82 x 23 78 x 28
Gears 5 gears
1st 13 : 41
2nd 15 : 38
3rd 17 : 37
4th 21 : 30
5th 30 : 24
Secondary drive 9 X 42 10 x 42 9 X 44
C utch Hydraulic , diaphragm spring
Starting Geared, foldable kickstarter

6
ST SERIES
TECHNICAL DATA
CHASSIS
Frame Tubular, Chrome Molybdenum steel
Fork Tech 39mm Aluminium
Rear shock
2 way Reiger shock
Aluminium swingarm
Front / rear stroke 165 / 175mm
Front brake Disc Ø 185mm
Rear brakee Disc Ø 145mm
Front tyre 2,75 21’’
Rear tyre 4,00 18’’
A terrain pressure
FRONT/REAR 0.4/0.3 bar
Fue tank capacity 2,2L / 0.58 US Gal (no reserve)
Whee base 1322 mm
FORK
Factory settings , TECH 39mm fork :
Spring pre oad
From fully closed, turn 5 ½ turns
Rebound
From fully closed , count 19 clicks
Stroke end setting
From fully closed , turn 2 ½ turns
Compression
From fully closed, open 1¾ turns
Left hand side eg oi
eve
140 mm
Righ hand side e
go i
eve
85 mm
SHOCK ABSORBER
Factory settings, – REIGER shock :
Spring
70 N/mm
Spring pre oad
7.0mm +/ 0.8mm
Restrictor
1.55 mm
Rebo
u
nd
From fully closed , count 33 clicks
Compression
From fully closed , count 9 clicks

7
ST SERIES
CHASSIS
❱❘Front end
1.1 Wheel bearings change
• Undo locking screw on the right fork foot
• Unlock wheel spindle and remove it.
• Remove the wheel
• Front wheel spindle tightening torque :
100Nm.
• With a heat gun, heat the bearing housing on
the hub.
• Extract bearings with a suitable tool and
replace them by new ones.
1. Front brake disc change :
• As changing front brake disc, during
assembling apply medium threadlocker (
Loctite 243 ) on the screws and tighten
them to a 12Nm torque.
• Reassemble the wheel following the
reverse procedure , applying a thin coat
of grease on the front wheel spindle.
CAUTION
Before every operation, make sure the bike is steady and won’t fall.
CAUTION
Using a vernier caliper, check intern spacer’s length and replace it if needed.
Minimum length : 67.5mm

8
ST SERIES
CHASSIS
1.3 Fork disassembly and steering head bearings change
• Undo the two M8 screws 1 and remove
the caliper
• Check brake pads minimum thickness.
Wear imit : 1mm
• Undo four M8 screws of the handlebar
clamps and remove handlebar.
• Undo the steering column nut 2 , then
the triple tree clamp M8 screws 3 and
remove it
• Undo the steering stem counternut, 4 and its dust cover, then remove the fork from the frame.
• Replace both top and bottom bearings : the ones in the steering head and the steering stem 5 by new
ones (part number C009 ) , applying grease on it.
• During reassembly, tighten steering stem counternut so the front end can swing freely , without play and
without hard point. Then place upper fork clamp and tighten its nut.
Tightening torques :
Steering stem counternut : 20 Nm.
Trip e c amp screws : 15 Nm
Ca iper screw: 24 Nm
2
1
2
1
3
4
5

9
ST SERIES
CHASSIS
1.4 TECH fork servicing
1.4.1 Right side oil change
• Place the fork tube in a vise with a suitable
support so as not to damage it
• Using a 17mm wrench, undo the cap
• Remove the cap
1
from the fork tube in
order to reach the nut
2
.
• Hold the cap
1
and unlock the nut
2
using a 14mm wrench
• Remove the cap from the damping rod
• Hold the damping rod
3
then drain oil in a
container , doing a back and forth
movement, as shown in the picture:
• Put fork leg vertically and pour 250cc of new oil inside.
CAUTION
Service the fork every 20 hours of use or every 6 months
CAUTION
Use SAE 5 type oil.
1
2
3

10
ST SERIES
CHASSIS
• Do a back and forth movement as shown in
the picture to prime the hydraulic system,
until you feel resistance.
• Compress the fork tube and damping rod
to the maximum.
• Measure oil level from the top of the tube,
then fill until you reach the desired height.
Oi eve : 85mm
• Undo totally the damping rod nut and
place the cap
• Tighten the cap 4 with the nut 5 to a
12Nm torque.
• Tighten the cap to the tube at a 12Nm
torque.
1.4. Left side oil change
• Using a 17mm wrench, undo the cap 6
• Remove conical spacer 7 .
• Remove spacer 8 , as well as the
washer placed between it and the spring.
4
5
6
8
7

11
ST SERIES
CHASSIS
• Remove the spring 9 and clean it
with a cloth.
• Drain the oil.
• Put fork leg vertically and pour 250cc of
new oil inside.
• Do a back and forth movement as shown in
the picture to prime the hydraulic system,
until you feel resistance.
• Compress the fork tube and damping rod
to the maximum .
• Measure oil level from the top of the tube,
then fill until you reach the desired height.
Oi eve : 140mm
• Reassemble, in this order : the spring, the
washer, the spacer, the conical spacer then the
cap.
• Place the fork tube in a vise with a suitable
support so as not to damage it and tighten
the cap to a 12Nm torque.
9

12
ST SERIES
CAUTION
Using a vernier caliper, check intern spacer’s length and replace it if needed.
Minimum length : 118.5mm
❱❘ Rear end
.1 Wheel bearings change
• Hold wheel spindle on the left side and undo
the nut on the right side.
• Remove the spindle from the left.
• Remove the wheel and the wheel spacers.
Rear whee spind e tightening torque :
100 Nm
• Using a heat gun, heat the hub at the bearing
seat.
• Extract bearings using a suitable tool ( ø 20 )
• Replace bearings by new ones .
•

13
ST SERIES
CHASSIS
. Brake disc change
• As changing front brake disc, during assembling
apply medium threadlocker ( Loctite 243 ) on the
screws and tighten them to a 12Nm torque..
Reassemble the wheel following the
reverse procedure , applying a thin coat
of grease on the wheel spindle.
.3 Swingarm bearings check
• Undo the nut on the bottom part of the
swingarm and remove linkage shaft.
• Unlock swingarm spindle 1 and remove it.
Linkage shaft tightening torque :
40 Nm
Swingarm spind e tightening torque :
50 Nm
• Remove swingarm and take the two
intern spacers 2 out.
1
1
2

14
ST SERIES
CHASSIS
• Check the needle bearings of both
sides.. In case of rust, replace them.
Otherwise, apply grease before
reassembling.
• Reassemble the set following the
reverse procedure and applying grease
on swingarm spindle and linkage shafts.
.4 Suspension linkage check
• Loosen lower suspension shaft 1 and linkage
shafts 2 .
• Loosen the tie rod screw 3 .
• Remove all the shafts and the linkages.
Remove the linkage inner ring and check
the bushings 4 . In c se of we r sign,
repl ce them by new ones.
Reassemble the set following the reverse
procedure , applying grease on the shafts and
bushings.
• Shock screw tightening torque : 40 Nm
• Linkage shaft tightening torque : 40 Nm
Tie-rod screw tightening torque : 40 Nm
1
2
3
4
2
4

15
ST SERIES
EN INE
OPERATIONS REQUIRING THE REMOVAL OR NOT OF THE ENGINE
OPERATIONS REQUIRING
THE REMOVAL OF THE
ENGINE
OPERATIONS NOT
REQUIRING THE REMOVAL
OF THE ENGINE
Crankshaft ( a so
connecting rod )
•
Shifting mechanism
•
Who e gearbox
•
Crankshaft bearings
•
Gearbox bearings
•
Piston
•
Cy inder
•
Cy inderhead
•
Ignition
•
Kickstarter gears
•
Who e c utch
•
Coo ant pump
•

16
ST SERIES
ENGINE REMOVAL/FITTING
❱❘ Engine removal
• Drain coolant and gearbox (see user’s manual)
• Remove airbox.
• Remove fuel tank.
• Disconnect the engine connected part of the wiring harness. (Ignition, spark plug, CDI ).
• Remove the exhaust header
• Remove the ignition coil
• Remove the throttle body
• Undo the quick release clip of the transmission chain, and remove the chain.
• Remove clutch slave cylinder.
• Remove coolant hoses connected to the engine
• Loosen all the engine holding screws.
• Loosen the swingarm spindle.
• Remove the frame cylinder head bracket.
• Remove the engine holding screws
• Remove the swingarm spindle
• Withdraw the engine.
❱❘ Fitting the engine in the frame
To fit the engine in the frame, follow the reverse procedure, observing the tightening torques :
Engine screw: 40Nm
Swingarm spind e nut: 50 Nm
C utch s ave cy inder screw: 10 Nm
Cy inderhead-frame bracket: 23Nm
Exhaust nut: 10Nm
CAUTION
To withdraw the engine, you must remove the swingarm spindle, which allows pulling away the
rear wheel/swingarm unit. In order to prevent bike from falling, make sure it is held by the frame.
CAUTION
When the clutch slave cylinder is removed, the piston is no held anymore. Make sure it
remains stuck , using a zip tie, for example.

17
ST SERIES
ENGINE DISASSEMBLING
❱❘ Gearbox draining
• Remove draining screws 1 and the filler cap
2 , help the oil flow out by tilting the bike.
❱❘ Front sprocket removal
• Remove snap ring 3 .
• Remove front sprocket 4 .
❱❘ Top end removal
• Undo the screws 5 and remove cylinderhead
cover 6 .
• remove the insert ( combustion chamber) 7 .

18
ST SERIES
ENGINE DISASSEMBLING
• Remove the four nuts 8.
• Remove the cylinder
• Mask the opening in the crankcase.
• remove the wrist pin snap ring q .
• Remove the wrist pin w .
• Remove the piston e .
• Remove the needle cage r.