Sherco Engine Engine Removal and Case Splitting Manual

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Filed Under (Sherco) by admin on 20-04-2011

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Engine Removal and Case Splitting Preparation 1. Wash the bike and engine thoroughly. 2. Drain transmission oil by removing drain bolt and copper washer with 5mm Allen. 3. Drain coolant by removing 3 bolts of water pump cover and lifting off engine side case.4. Remove: a. rear fender- two bolts plus one long with washer using 4mm Allen b. fuel tank hose from petcock c. fuel tank- one short bolt and washer using 4mm Allen d. chain master link and chain from front sprocket e. kick starter- one large button head bolt and washer f. rear brake- one bolt/washer using 13mm wrench g. rear brake master cylinder- 2 button head bolts h. gear shifter- one bolt i. flywheel cover – 3 bolts j. clutch slave cylinder- two button head bolts using 4mm Allen k. clutch actuating rod by pulling it out of the case l. airbox three 4mm Allen bolts and loosening Phillips head carb hose clamp m. carburetor cap/slide assembly n. carburetor by loosening Phillips head manifold hose clamp o. spark plug cap p. spark plug q. header pipe 2 bolts into cylinder head r. silencer- 3 bolts (one with washer and nut using 10mm wrench) s. cylinder head coolant hose clamp and hose t. rear shock upper bolt u. radiator plastic cover bolt, then lever up the radiator with screwdriver until the radiator “legs” pop out of frame retaining holes 5. Remove flywheel using flywheel puller tool, taking care not to lose the small Woodruff
key by placing it inside of the magnetic flywheel for safe storage. 6. Remove ignition (3 bolts) and slide rubber grommet and ignition wiring assembly out of the case and out of the way, taking special note of the ignition timing marks. 7. Remove front sprocket and 2 retaining circlips. 8. Remove clutch side case and its 10 bolts using 5mm Allen, being careful not to lose to lose the 2 aluminum alignment pins (dowel pins). Insert the dowel pins into their holes within the Right Crankcase

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1999 – 2003 1.25, 2.0, 2.5 and 2.9 Sherco Ignition Timing Removal And Installation Manual

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Filed Under (Sherco) by admin on 20-04-2011

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Remove the gear shift lever bolt by using a 5mm Allen wrench. Insert the wrench through the hole in the skid plate. Holding the gear shifter up in second gear makes it easier to align the wrench into the head of the bolt. Pull the gear shift lever as far as possible towards the chain. (The chain does not have to be removed in order to remove the ignition cover and flywheel) Remove the three ignition cover bolts by using a 4mm Allen wrench. Carefully remove the ignition cover-which requires a little twisting and some outward pressure on the gear shift lever. The shift lever may also have to be pressed down into the first gear position. Inspect the rubber ring gasket for cracks or cuts while the ignition cover is off. Replace if necessary. We recommended applying a ring of high grade silicone sealant to further improve the seal of the rubber ring gasket. Tap a chisel-mark across the flywheel retaining nut and the crankshaft by using a small, sharp chisel. This mark serves as a reference point for retightening the flywheel in its original position during reassembly.

Sherco Engine Teardown and Assembly Manual/ Engine Removal and Case Splitting

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Filed Under (Sherco) by admin on 25-11-2010

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Remove: a. rear fender- two bolts plus one long with washer using 4mm Allen b. fuel tank hose from petcock c. fuel tank- one short bolt and washer using 4mm Allen d. chain master link and chain from front sprocket e. kick starter- one large button head bolt and washer f. rear brake- one bolt/washer using 13mm wrench g. rear brake master cylinder- 2 button head bolts h. gear shifter- one bolt i. flywheel cover – 3 bolts j. clutch slave cylinder- two button head bolts using 4mm Allen k. clutch actuating rod by pulling it out of the case l. airbox three 4mm Allen bolts and loosening Phillips head carb hose clamp m. carburetor cap /slide assembly n. carburetor by loosening Phillips head manifold hose clamp o. spark plug cap p. spark plug q. header pipe 2 bolts into cylinder head r. silencer- 3 bolts (one with washer and nut using 10mm wrench ) s. cylinder head coolant hose clamp and hose t. rear shock upper bolt u. radiator plastic cover bolt, then lever up the radiator with screwdriver until the radiator “legs” pop out of frame retaining holes 5. Remove flywheel using flywheel puller tool, taking care not to lose the small Woodruff key by placing it inside of the magnetic flywheel for safe storage. 6. Remove ignition (3 bolts) and slide rubber grommet and ignition wiring assemblyout of the case and out of the way, taking special note of the ignition timing marks. 7. Remove front sprocket and 2 retaining circlips. 8. Remove clutch side case and its 10 bolts using 5mm Allen, being careful not to lose to lose the 2 aluminum alignment pins (dowel pins). Insert the dowel pins into their holes within the Right Crankcase.

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