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

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.

Cobra Motorcycle Z-Ball Clutch Installation Manual

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Filed Under (Cobra) by admin on 10-11-2010

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1. Vehicle preparation a. Shut off the fuel flow to the carburetor at the fuel petcock b. Tilt / rotate the quad over on it’s side so that the clutch cover is up for easy access. 2. Disassemble the old clutch a. Using a 10mm wrench remove the four bolts holding the clutch slave cylinder to the clutch cap. b. You can now remove the entire clutch lever / master cylinder, line and slave from the vehicle, although it would be easier to do at a later time when the vehicle is back resting with four wheels on the ground. c. Using a medium flat blade screwdriver, remove the clutch cap retaining ring and pull off the clutch cap. d. Place the throw out bearing and push rod aside as they will be needed later. e. Using a 4mm hex key, remove the six bolts holding the spring plate and springs. The spring plate will be required for auto clutch installation. f. With a 6mm hex key remove the clutch center bolt, and remove the entire clutch assembly and washers, leaving only the basket in place. The pressure plate (hub) will be required for auto clutch installation. 3. Clutch cover removal to replace thrust washer & eliminate oil shield a. Remove the water pump impeller cover (four socket head cap screws with 4mm hex key). b. Remove the water pump impeller (4mm hex key with piston stop or use an impact driver) c. Remove the kick lever (10mm wrench) d. Remove the clutch cover (5mm hex key)

Ducati Clutch slave cylinder mounting procedure

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Filed Under (Ducati) by admin on 26-10-2010

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- Remove the oil pressure line from the old slave cylinder. – Remove the slave cylinder (3 hexagon socket screws M6). – Remove the seals (model-dependent). – Clean the push rod and the area around the push rod. – Lightly grease the O-ring and insert it into the groove of the new slave cylinder. – Install the slave cylinder. – Use the syringe to fill in brake fluid up to the upper edge – Reinstall the oil pressure line with new copper seals. – Bleed the hydraulic system. Bleed the system as follows: A second person may be helpful in this process. Take care to not pump the reservoir empty! Connect a transparent plastic tube to the bleeder valve of the clutch slave cylinder. Actuate the clutch lever several times until pressure has built up. With the lever pulled, shortly open and immediately close the bleeder screw. Repeat this procedure until the fluid escapes without bubbles. Always make sure that the reservoir doesn’t get empty, permanently control the reservoir!

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