Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Espaol ........................................................................................... p. 3
Franais........................................................................................ p. 63
English.......................................................................................... p.123
NDICE
Prlogo _______________________________________________________________________ 3
Lista de utillajes y herramientas especiales ............................................................................ 4
Pares de apriete .................................................................................................................... 4
Caractersticas tcnicas motor............................................................................................... 5
Caractersitcas tcnicas bastidor ........................................................................................... 6
Seccin parte ciclo ____________________________________________________________ 7
Cambio cojinetes ruedas ....................................................................................................... 8
Cambio latiguillo freno delantero. Formula, AJP, Braktec ...................................................9-10
Mantenimiento freno delantero. Formula, AJP, Braktec ...................................................11-12
Cambio disco de freno delantero ......................................................................................... 13
Eje direccin ........................................................................................................................ 14
Suspensin delantera .......................................................................................................... 15
Cambio retn barra suspensin lado derecho .................................................................16-17
Cambio retn barra suspensin lado izquierdo .................................................... 18-19-20-21
Carburador y caja de lminas ................................................................................... 23-24-25
Bomba embrague ............................................................................................................... 26
Radiador ............................................................................................................................. 27
Estribos ............................................................................................................................... 28
Protector del motor ............................................................................................................. 28
Sistema elctrico ................................................................................................................. 29
Cambio leeds faro delantero ................................................................................................ 30
Eje basculante ..................................................................................................................... 31
Suspensin posterior ........................................................................................................... 32
Mantenimiento freno trasero y transmisin secundaria ....................................................33-34
Depsito de combustible ..................................................................................................... 35
Mantenimiento conjunto escape .....................................................................................36-37
Cambio fibras silenciador..................................................................................................... 38
Seccin parte motor __________________________________________________________39
Cambio de pistn ..................................................................................... 40-41-42-43-44-45
Verificar pistn y cilindro ...................................................................................................... 46
Encendido ......................................................................................................................47-48
Discos de embrague ........................................................................................................... 49
Sistema de arranque ................................................................................................ 50-51-52
Selector de cambio ........................................................................................................53-54
Cambio y cigeal ..........................................................................................55-56-57-58-59
Bomba de agua................................................................................................................... 60
44 ST SERIES
PRLOG0
Toda la informacin que contiene este manual se ha preparado para dar la mxima informacin sobre posibles operaciones a rea-
lizar en una motocicleta Sherco de la gama de trial ST. Teniendo en cuenta que muchas de las operaciones puntuales que deben
realizarse en un taller especializado, este manual pretende ser una gua muy til para los operarios que deben realizar estas tareas,
teniendo en cuenta que, en muchos casos, son trabajos excepcionales y muy poco frecuentes, este manual ayudar a seguir
un orden en el montaje y actuacin sobre los elementos a verificar o sustituir. A su vez ayudar a cualquier operario o tcnico a
familiarizarse con los procesos y resolver dudas.
ESPAOL
Sherco quiere dar la mxima informacin a sus centros tcnicos para poder realizar el mantenimiento y reparacin de las mo-
tocicletas con las mximas garantas. Hay que tener en cuenta que todas los procesos descritos en este manual as como las
medidas, hacen referencia a procedimientos estandard y siempre utilizando piezas originales Sherco.
La pulcritud y la correcta ejecucin de cualquier operacin de revisin o cambio de piezas, el rigor en el desarrollo de todos los
procesos, garantizan el perfecto funcionamiento dinmico, objetivo de Sherco para que los propietarios de una ST puedan disfrutar
de sus cualidades.
La constante investigacin y desarrollo de Sherco hace posible que sus motocicletas estn en constante evolucin. Sherco Motor-
cycles, dado el carcter informativo de este manual, se reserva el derecho de efectuar cambios sin previo aviso
5
LISTA DE UTILLAJES Y HERRAMIENTAS
UTILLAJES ESPECIALES
6 ST SERIES
CARACTERSTICAS TCNICAS MOTOR
MOTOR
80 ST 125 ST 250 ST 290 ST 305 ST
ESPAOL
Cilindrada 74,60 cc 123,70 cc 249,70 cc 272 cc 294 cc
Dimetro x Carrera 44,50 x 50,70 54 x 54 72,80 x 60 76 x 60 79 x 60
Cilindro Nikasil tolerancia pistn 0,02 mm 0,04 mm 0,03 mm 0,035 mm 0,05 mm
Pistn Aleacin de aluminio
Encendido electrnico Leonelli Digital Hidria Digital Hidria Digital Hidria Digital Hidria Digital
Buja W16EPR-U3021 W16EPR-U3021 W16EPR-U3021 W16EPR-U3021 W16EPR-U3021
Distancia electrodos 0,7 0,7 0,7 0,7 0,7
Lubricacin Mezcla 2% de aceite
Combustible Gasolina sin plomo 98 oct
Carburador DellOrto PHBL26BS Keihin 28 mm DellOrto PHBL26BS Keihin 28 mm Keihin 28 mm
Reglaje del carburador Chicle principal 105 Chicle principal 122 Chicle principal 122 Chicle principal 125 Chicle principal 128
Chicle ralent 45 Chicle ralent 50 Chicle ralent 33 Chicle ralent 42 Chicle ralent 42
Posicin aguja P3 P5 P2 +0,5 P4+0,5 P4+0,5
Refrigeracin Circuito cerrado de lquido de circulacin forzada
Arranque Sistema de engranajes con pedal retrctil
Escape Tubo en inox con silencioso final de aluminio
Transmisin Primaria 5 v. accionamiento secuencial mediante selector anti punto muerto.
1 13:33
2 15:35
3 18:33
4 24:26
5 31:20
Transmisin final 9:54 9:48 10:42 10:42 10:42
Embrague Hidrulico multidisco en bao de aceite
Capacidad aceite 450c.c 10W50W Minerva
7
CARACTERSTICAS TCNICAS BASTIDOR
CHASIS
80 ST 125 ST 250 ST 290 ST 305 ST
8 ST SERIES
PARTE CICLO
ESPAOL
9
CAMBIO COJINETES RUEDAS
10 ST SERIES
CAMBIO LATIGUILLO FRENO DELANTERO
FORMULA
ESPAOL
como la brida superior. Desmontar el
latiguillo.
AJP
- Desmontar el latiguillo.
11
CAMBIO LATIGUILLO FRENO DELANTERO
BRAKTEC
- Desmontar el latiguillo.
- Un vez cambiado el latiguillo, llenar
con lquido de freno nuevo el depsito
hasta la mitad.
- Aflojar el sangrador de la pinza y vaciar
de aire el latiguillo mediante sucesivas
presiones hasta llegar a tope con la
maneta de freno. Repetir la operacin
hasta que el tacto de la maneta a la
presin alcance mxima dureza.
- Es necesario revisar el nivel de lquido
en el depsito una vez finalizado el
sangrado.
12 ST SERIES
MANTENIMIENTO FRENO DELANTERO
FORMULA
ESPAOL
pastillas.
AJP
- Extraer clip de seguridad.
- Aflojar tornillo de fijacin de las
pastillas.
13
MANTENIMIENTO FRENO DELANTERO
BRAKTEC
DESPIECE
BRAKTEC
FORMULA
14 ST SERIES
CAMBIO DISCO FRENO DELANTERO
ESPAOL
- Aflojar los tornillos de fijacin del disco
teniendo cuidado con los bordes del
disco que pueden presentar rebabas
por el desgaste.
DESPIECE
15
EJE DIRECCION
16 ST SERIES
SUSPENSION DELANTERA
ESPAOL
- Quitar guardabarros delantero
17
CAMBIO RETEN BARRA SUSPENSION LADO DERECHO
18 ST SERIES
CAMBIO RETEN BARRA SUSPENSION LADO DERECHO
ESPAOL
- Desmontar el retn y el casquillo de la
botella
DESPIECE
19
CAMBIO RETEN BARRA SUSPENSION LADO IZQUIERDO
20 ST SERIES
CAMBIO RETEN BARRA SUSPENSION LADO IZQUIERDO
ESPAOL
- Hacer palanca sobre el borde
del guarda polvo y sacarlo de su
alojamiento en la barra
- Sacar el seeger de su alojamiento
21
CAMBIO RETEN BARRA SUSPENSION LADO IZQUIERDO
22 ST SERIES
CAMBIO RETEN BARRA SUSPENSION LADO IZQUIERDO
ESPAOL
17Nm
DESPIECE
23
CARBURADOR Y CAJA DE LAMINAS
24 ST SERIES
CARBURADOR Y CAJA DE LAMINAS
ESPAOL
- Desmontar el tubo de entrada de
gasolina. Abrir tapa superior y sacar la
campana corredera. De esta forma el
carburador queda completamente libre
de cualquier sujecin.
25
CARBURADOR Y CAJA DE LAMINAS
26 ST SERIES
CARBURADOR Y CAJA DE LAMINAS
Dellorto Keihin
80c.c. 125 c.c. 250 c.c. 290c.c. 300c.c. P4
P5
P4
P3 P3
P2 P2
Altura boyas carburador 18,5 19 19 20 20 P1 P1
Gliceur baja 45 50 33 42 42
Gliceur alta 110 122 122 125 128
Posicin aguja P3 P5 P2+0,5(*) P4+0,5(*) P4+0,5(*)
ESPAOL
(*)
0,5mm
DESPIECE
Dellorto Keihin
27
BOMBA DE EMBRAGUE
DESPIECE
28 ST SERIES
RADIADOR
ESPAOL
- Tener preparado un recipiente para
recoger el lquido.
- Aflojar y quitar tornillo desage circuito
de refrigerante.
- Vaciar el motor del lquido.
- Volver a poner el tornillo de cierre del
desage.
- Liberar los manguitos
DESPIECE
29
ESTRIBOS / PROTECTOR DEL MOTOR
DESPIECE
DESPIECE
30 ST SERIES
SISTEMA ELECTRICO
ESPAOL
filtro se accede a todos los puntos de
conexin, buja, bobina, CDI, volante
magntico, as como al anclaje del
punto de masa.
- Conector CDI
- Conexiones regulador y rectificador
DESPIECE
31
CAMBIO LEEDS FARO DELANTERO
DESPIECE
32 ST SERIES
EJE BASCULANTE
ESPAOL
propio basculante. Revisar y sustituir si
es necesario.
- Para estraer los cojinetes utilizar un
empujador.
- Colocar el eje y realizar un correcto
apriete de la tuerca a 50NM. El eje del
basculante es uno de los principales
puntos de anclaje del motor.
DESPIECE
33
SUSPENSION POSTERIOR
DESPIECE
34 ST SERIES
MANTENIMIENTO FRENO TRASERO Y TRANSMISION
ESPAOL
- Liberar la rueda de la cadena por lo
que se podr retirar con facilidad.
35
MANTENIMIENTO FRENO TRASERO Y TRANSMISION
36 ST SERIES
DEPOSITO DE COMBUSTIBLE
ESPAOL
fijacin.
DESPIECE
37
MANTENIMIENTO CONJUNTO ESCAPE
38 ST SERIES
MANTENIMIENTO CONJUNTO ESCAPE
ESPAOL
- Montar el colector y realizar el apriete
de los tornillos de unin del colector
con el cilindro.
DESPIECE
39
CAMBIO FIBRAS SILENCIADOR
40 ST SERIES
PARTE MOTOR
ESPAOL
41
CAMBIO DE PISTON
42 ST SERIES
CAMBIO DE PISTON
ESPAOL
- Extraer la caja de filtro.
- Quitar buja.
43
CAMBIO DE PISTON
44 ST SERIES
CAMBIO DE PISTON
ESPAOL
- Controlar la tolerancia entre pistn y
- cilindro. Ver tabla de tolerancias
Preparar el pistn con los aros
presionados para su introduccin en el
cilindro.
45
CAMBIO DE PISTON
46 ST SERIES
CAMBIO DE PISTON
ESPAOL
- Llenar el circuito de refrigeracin con
lquido antcongelante (430cc).
- Colocar el tapn del radiador.
DESPIECE
47
VERIFICAR PISTON Y CILINDRO
DESPIECE
48 ST SERIES
ENCENDIDO
ESPAOL
- Aflojar y quitar la tapa del encendido.
Comprobar y galgar la distancia del
pick-up utilizando una
galga de 0,7-1mm.
49
ENCENDIDO
DESPIECE
50 ST SERIES
DISCOS EMBRAGUE
ESPAOL
- Extraer plato porta muelles. Prestar
atencin en la posicin de la arandela
DESPIECE
51
SISTEMA DE ARRANQUE
52 ST SERIES
SISTEMA DE ARRANQUE
ESPAOL
- Montar el rodamiento y el pin del
trinquete.
53
SISTEMA DE ARRANQUE
DESPIECE
54 ST SERIES
SELECTOR DEL CAMBIO
ESPAOL
- Tener preparado un recipiente para
recoger el lquido. Vaciar el motor de
lquido refrigerante
- Volver a poner el tornillo de bloqueo del
desage.
55
SELECTOR DEL CAMBIO
DESPIECE
56 ST SERIES
CAMBIO Y CIGEAL
ESPAOL
- Extraer el circlip de sujecin y sacar el
pin de salida.
57
CAMBIO Y CIGEAL
- Aflojar embrague
58 ST SERIES
CAMBIO Y CIGEAL
ESPAOL
- Extraer seeger y pin intermedio.
59
CAMBIO Y CIGEAL
60 ST SERIES
CAMBIO Y CIGEAL
ESPAOL
DESPIECE
61
BOMBA DE AGUA
DESPIECE
62 ST SERIES
Espaol ........................................................................................... p. 3
Franais........................................................................................ p. 63
English.......................................................................................... p.123
TABLE DES MATIRES
64
64 ST SERIES
AVANT-PROPOS
L'ensemble des informations de ce manuel est conu de manire orir un maximum de renseignements sur toutes les interven-
tions pouvant s'avrer ncessaires sur une motocyclette Sherco de la gamme trial ST. La plupart de ces interventions sont raliser
dans un atelier spcialis, et ce manuel cherche tre un guide aussi utile que possible pour les techniciens , chargs de celles-ci.
Il s'agit souvent de tches exceptionnelles, peu frquentes. Ce manuel sera donc un prcieux aide-mmoire quand l'ordre des
oprations de dmontage et de montage, et quant aux actions prcises raliser sur les lments vrifier ou remplacer. Il aidera
aussi tout oprateur ou tout technicien se familiariser avec les procdures et lever les doutes.
Sherco souhaite fournir un maximum d'informations ses centres techniques, afin que la maintenance et la rparation des motos
puissent tre menes avec un maximum de garantie. Sachez bien que toutes les procdures dcrites dans ce manuel, ainsi que
les mesures indiques, concernent des procdures standard avec des pices Sherco d'origine.
Ce sont le soin apport toutes les oprations d'inspection ou d'change, la bonne excution de celles-ci, la rigueur dans le res-
pect de toutes les procdures, qui garantissent un fonctionnement dynamique parfait. Tel est l'objectif que se pose Sherco pour
que les propritaires d'une ST puissent profiter au maximum de toutes ses qualits.
FRANAIS
Grce l'incessante activit de Sherco en matire de recherche et dveloppement, ses motos sont en permanente volution.
tant donn le caractre informatif de ce manuel, Sherco Motorcycles se rserve le droit d'y apporter des modifications sans avis
pralable.
65
LISTE D'OUTILLAGE
OUTILS SPCIAUX
66 ST SERIES
CARACTRISTIQUES TECHNIQUES MOTEUR
MOTEUR
80 ST 125 ST 250 ST 290 ST 305 ST
FRANAIS
Piston Alliage alu
Allumage lectronique Leonelli numrique Hidria numrique Hidria numrique Hidria numrique Hidria numrique
Bougie W16EPR-U3021 W16EPR-U3021 W16EPR-U3021 W16EPR-U3021 W16EPR-U3021
cartement lectrodes 0,7 0,7 0,7 0,7 0,7
Lubrification Mlange huile 2 %
Carburant Essence sans plomb 98 oct.
Carburateur DellOrto PHBL26BS Keihin 28 mm DellOrto PHBL26BS Keihin 28 mm Keihin 28 mm
Rglage carburateur Gicleur principal 105 Gicleur principal 122 Gicleur principal 122 Gicleur principal 125 Gicleur principal 128
Gicleur ralenti 45 Gicleur ralenti 50 Gicleur ralenti 33 Gicleur ralenti 42 Gicleur ralenti 42
Position aiguille P3 P5 P2 +0,5 P4+0,5 P4+0,5
Refroidissement Liquide en circuit ferm circulation force
Dmarrage engrenages avec pdale rtractable
chappement Tube inox av. pot alu
Transmission primaire 5 vit. actionnement squentiel par slecteur anti point mort.
1e 13:33
2e 15:35
3e 18:33
4e 24:26
5e 31:20
Transmission finale 9:54 9:48 10:42 10:42 10:42
Embrayage Hydraulique multidisque en bain d'huile
Capacit huile 450 cc 10W50 Minerva
67
CARACTRISTIQUES TECHNIQUES CADRE
CADRE
80 ST 125 ST 250 ST 290 ST 305 ST
68 ST SERIES
PARTIE CYCLE
FRANAIS
69
REMPLACEMENT COUSSINETS ROUES
70 ST SERIES
REMPLACEMENT FLEXIBLE FREIN AVANT
FORMULA
FRANAIS
- Aprs avoir remplac le flexible, faites
le plein du rservoir de liquide de freins
avec du DOT4 Minerva.
- Desserrez le purgeur de la pince
et purgez d'air le flexible par des
pressions successives, jusqu' ce que
le liquide arrive au ras du levier de frein.
Refaire l'opration jusqu' ce que la
duret du levier devant la sollicitation
atteigne son maximum.
- Refaites l'appoint dans le rservoir
aprs la purge.
AJP
- Dmontez le flexible.
71
REMPLACEMENT FLEXIBLE FREIN AVANT
BRAKTEC
- Dmontez le flexible.
- Aprs avoir remplac le flexible, faites
le plein du rservoir de liquide de freins
avec du liquide neuf.
- Desserrez le purgeur de l'trier
et purgez d'air le flexible par des
pressions successives, jusqu' ce que
le liquide arrive au ras du levier de frein.
Refaites l'opration jusqu' ce que la
duret du levier devant la sollicitation
atteigne son maximum.
- Refaites l'appoint dans le rservoir
aprs la purge.
72 ST SERIES
MAINTENANCE FREIN AVANT
FORMULA
FRANAIS
Brake Cleaner de Minerva
AJP
- Extrayez le clip de scurit.
- Desserrez la vis de fixation des
plaquettes.
73
MAINTENANCE FREIN AVANT
BRAKTEC
VUE CLATE
BRAKTEC
FORMULA
74 ST SERIES
REMPLACEMENT DISQUE DE FREIN AVANT
FRANAIS
qui peuvent prsenter des bavures
produites par l'usure.
VUE CLATE
75
AXE DE DIRECTION
76 ST SERIES
SUSPENSION AVANT
FRANAIS
- Dgagez l'trier du frein avant
77
REMPLACEMENT DU JOINT DE LA BARRE DE SUSPENSION
78 ST SERIES
REMPLACEMENT DU JOINT DE LA BARRE DE SUSPENSION
FRANAIS
- Dmontez le joint et le bouchon de la
bombonne
VUE CLATE
79
REMPLACEMENT DU JOINT DE LA BARRE DE SUSPENSION
80 ST SERIES
REMPLACEMENT DU JOINT DE LA BARRE DE SUSPENSION
FRANAIS
logement dans la barre.
- Retirez l'anneau Seeger de son
emplacement
81
REMPLACEMENT DU JOINT DE LA BARRE DE SUSPENSION
- Glissez le cache-poussire, en le
faisant osciller lgrement, jusqu' son
emplacement sur la bonbonne.
82 ST SERIES
REMPLACEMENT DU JOINT DE LA BARRE DE SUSPENSION
VUE CLATE
FRANAIS
83
CARBURATEUR ET BOTE CLAPETS
84 ST SERIES
CARBURATEUR ET BOTE CLAPETS
FRANAIS
la cloche coulissante. Le carburateur
se trouve ainsi libr de toute fixation.
85
CARBURATEUR ET BOTE CLAPETS
86 ST SERIES
CARBURATEUR ET BOTE CLAPETS
DellOr- Keihin
80 cc 125 cc 250 cc 290 cc 300 cc P4
P5
P4
P3 P3
P2 P2
Hauteur flotteurs carburateur 18,5 19 19 20 20 P1 P1
Gicleur secondaire 45 50 33 42 42
Gicleur principal 110 122 122 125 128
Position pointeau P3 P5 P2 +0,5 P4+0,5 P4+0,5
(*)
0,5 mm
FRANAIS
VUE CLATE
DellOrto Keihin
87
POMPE D'EMBRAYAGE
VUE CLATE
88 ST SERIES
RADIATEUR
FRANAIS
- Desserrez et enlevez la vis de vidange
du circuit de refroidissement.
- Vidangez le liquide du moteur.
- Revissez la vis de vidange.
- Dgager les durites
VUE CLATE
89
REPOSE-PIEDS / BOUCLIER DU MOTEUR
VUE CLATE
VUE CLATE
90 ST SERIES
SYSTME LECTRIQUE
FRANAIS
- Connecteurs et interrupteurs des feux
- Masses
- Connecteur CDI
- Connexions rgulateur et redresseur
VUE CLATE
91
REMPLACEMENT DES LED DU PHARE
VUE CLATE
92 ST SERIES
AXE BASCULANT
FRANAIS
- Replacez l'axe et serrez l'crou au
couple (50 Nm). L'axe du basculant
est un des principaux points d'ancrage
du moteur.
VUE CLATE
93
SUSPENSION ARRIRE
VUE CLATE
94 ST SERIES
MAINTENANCE FREIN ARRIRE ET TRANSMISSION
FRANAIS
- Eectuez les tches de maintenance
du frein arrire, en dmontant les
plaquettes et en vrifiant l'paisseur
des garnitures l'aide d'une jauge de
profondeur.
95
MAINTENANCE FREIN ARRIRE ET TRANSMISSION
VUE CLATE
96 ST SERIES
RSERVOIR DE CARBURANT
FRANAIS
la pompe. Fermez toujours la vanne
d'arrt de l'essence.
VUE CLATE
97
MAINTENANCE DE L'ENSEMBLE D'CHAPPEMENT
98 ST SERIES
MAINTENANCE DE L'ENSEMBLE D'CHAPPEMENT
FRANAIS
- Replacez le collecteur et serrez les vis
qui le fixent au cylindre,
VUE CLATE
99
REMPLACEMENT DES FIBRES DU POT D'CHAPPEMENT
100 ST SERIES
PARTIE MOTEUR
FRANAIS
101
REMPLACEMENT DU PISTON
-
- Ouvrez le couvercle et
dposez le filtre air.
102 ST SERIES
REMPLACEMENT DU PISTON
FRANAIS
- Desserrez les vis du tirant qui relie la
culasse au cadre
- Dbranchez la bobine.
-
- Desserrez les vis de fixation
du tuyau d'chappement au cylindre.
103
REMPLACEMENT DU PISTON
-
Enlevez le boulon en poussant avec
- l'outil spcial.
Vrifiez l'tat du roulement rouleaux
- de la bielle
Remplacez le joint plac entre le bloc
104 ST SERIES
REMPLACEMENT DU PISTON
FRANAIS
segments pour l'introduire dans le
cylindre.
105
REMPLACEMENT DU PISTON
106 ST SERIES
REMPLACEMENT DU PISTON
FRANAIS
- Replacez le bouchon de radiateur.
VUE CLATE
107
VRIFICATION DU PISTON ET DU CYLINDRE
VUE CLATE
108 ST SERIES
ALLUMAGE
FRANAIS
- Desserrez et dposez le couvercle du
systme d'allumage. Vrifiez et jaugez
l'cartement du pick-up l'aide d'une
jauge de 0,7 1 mm.
109
ALLUMAGE
VUE CLATE
110 ST SERIES
DISQUES D'EMBRAYAGE
FRANAIS
Faites attention la position de la
rondelle
VUE CLATE
111
DMARREUR
112 ST SERIES
DMARREUR
FRANAIS
d'encliquetage.
113
DMARREUR
VUE CLATE
114 ST SERIES
SLECTEUR DE VITESSES
FRANAIS
de refroidissement du moteur.
- Revissez la vis de vidange.
115
SLECTEUR DE VITESSES
VUE CLATE
116 ST SERIES
CHANGEMENT DE VITESSES ET VILEBREQUIN
FRANAIS
- Dposez la tuyre d'admission
117
CHANGEMENT DE VITESSES ET VILEBREQUIN
- Desserrez l'embrayage.
118 ST SERIES
CHANGEMENT DE VITESSES ET VILEBREQUIN
FRANAIS
- Desserrez le pignon de la transmission
primaire. Extrayez l'crou et la rondelle.
119
CHANGEMENT DE VITESSES ET VILEBREQUIN
120 ST SERIES
CHANGEMENT DE VITESSES ET VILEBREQUIN
FRANAIS
VUE CLATE
121
POMPE EAU
VUE CLATE
122 ST SERIES
Espaol ........................................................................................... p. 3
Franais........................................................................................ p. 63
English.......................................................................................... p.123
TABLE OF CONTENTS
Prologue ______________________________________________________________________ 3
List of special tools and equipment ........................................................................................ 4
Tightening torques ................................................................................................................. 4
Technical features of the engine ............................................................................................. 5
Technical features of the frame .............................................................................................. 6
Cycle parts section ____________________________________________________________ 7
Changing wheel bearing ........................................................................................................ 8
Changing front flexible brake hose. Formula, AJP, Braktec ................................................9-10
Front brake maintenance. Formula, AJP, Braktec ............................................................11-12
Changing front brake disc.................................................................................................... 13
Steering shaft ...................................................................................................................... 14
Front suspension ................................................................................................................. 15
Changing right suspension bar seal ................................................................................16-17
Changing left suspension bar seal ....................................................................... 18-19-20-21
Carburettor and reed block ....................................................................................... 23-24-25
Clutch pump ....................................................................................................................... 26
Radiator .............................................................................................................................. 27
Footrests ............................................................................................................................. 28
Engine protector .................................................................................................................. 28
Electrical system .................................................................................................................. 29
Changing headlight LEDs .................................................................................................... 30
Tilting axle ........................................................................................................................... 31
Rear suspension .................................................................................................................. 32
Rear brake and secondary transmission maintenance ....................................................33-34
Fuel tank ............................................................................................................................. 35
Exhaust pipe assembly maintenance ..............................................................................36-37
Changing muer fibres ........................................................................................................ 38
Engine parts section __________________________________________________________39
Changing the piston ................................................................................. 40-41-42-43-44-45
Verifying piston and cylinder................................................................................................. 46
Ignition ...........................................................................................................................47-48
Clutch discs ........................................................................................................................ 49
Start routine.............................................................................................................. 50-51-52
Gear selector ..................................................................................................................53-54
Gears and crankshaft .....................................................................................55-56-57-58-59
Water pump ........................................................................................................................ 60
124
124 ST SERIES
PROLOGUE
All the information contained in this manual has been prepared to provide the most information on possible operations on a Sherco
motorcycle within ST trial line. Bearing in mind that many of the specific operations must be performed in a specialised workshop,
this manual is intended as a very useful guide for operators carrying out these tasks, bearing in mind that, in many cases, they are
exceptional, infrequent tasks, this manual will help you to follow an order of assembly and action upon elements to be verified or
substituted. It also seeks to help any operator or technician to become familiarised with the processes and resolve any doubts.
Sherco is committed to providing its technical centres with maximum information in order to perform maintenance and repair work
on its motorcycles with maximum guarantees. It must be taken into account that all the processes described in this manual, as well
as the measurements, refer to standard procedures, always using original Sherco parts.
Neatness and the correct execution of all verification or changing of parts, maintaining rigour in developing all processes, and en-
suring perfect dynamic operation is Sherco's objective, in order for ST owners to be able to enjoy their qualities.
Sherco's commitment to continual research and development ensures that its motorcycles are constantly evolving. On account of
the informative nature of this manual, Sherco Motorcycles reserves the right to make changes without prior notice.
ENGLISH
125
LIST OF SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS
126 ST SERIES
TECHNICAL FEATURES OF THE ENGINE
ENGINE
80 ST 125 ST 250 ST 290 ST 305 ST
ENGLISH
Lubrication 2 % oil mixture
Fuel 98 oct. unleaded gasoline
Carburettor DellOrto PHBL26BS Keihin 28 mm DellOrto PHBL26BS Keihin 28 mm Keihin 28 mm
Carburettor adjustment Main jet 105 Main jet 122 Main jet 122 Main jet 125 Main jet 128
Edle jet 45 Edle jet 50 Edle jet 33 Edle jet 42 Edle jet 42
Needle position P3 P5 P2 +0.5 P4+0.5 P4+0.5
Refrigeration Forced-circulation liquid cooled
Starter Cog system with retracting pedal
Exhaust Stainless steel tube with aluminium muer
Primary transmission 5 sp. sequential selection with neutral selector.
1st 13:33
2nd 15:35
3rd 18:33
4th 24:26
5th 31:20
Final transmission 9:54 9:48 10:42 10:42 10:42
Clutch Wet hydraulic multi-plate
Oil capacity 450c.c 10W50W Minerva
127
TECHNICAL FEATURES OF THE FRAME
CHASSIS
80 ST 125 ST 250 ST 290 ST 305 ST
128 ST SERIES
CYCLE PART
ENGLISH
129
CHANGING WHEEL BEARING
130 ST SERIES
CHANGING FRONT FLEXIBLE BRAKE HOSE
FORMULA
ENGLISH
- Once the flexible brake hose has been
changed, fill up the tank with DOT4
Minerva brake fluid.
- Loosen the grasper bleeder and purge
the flexible brake hose by pressing
successively until the brake lever limit is
reached. Repeat this operation until the
lever at pressure feels to have reached
maximum hardness.
- Fluid level must be checked once
bleeding has been completed.
AJP
- Dismantle the flexible brake hose.
131
CHANGING FRONT FLEXIBLE BRAKE HOSE
BRAKTEC
- Dismantle the flexible brake hose.
- Once the flexible brake hose has been
changed, fill tank half way with new
brake fluid.
- Loosen the grasper bleeder and purge
the flexible brake hose by pressing
successively until the brake lever limit is
reached. Repeat this operation until the
lever at pressure feels to have reached
maximum hardness.
- Fluid level must be checked once
bleeding has been completed.
132 ST SERIES
FRONT BRAKE MAINTENANCE
FORMULA
ENGLISH
- Measure the depth of the sheathing. The
inner groove measurement should be
no less than 1mm.
133
FRONT BRAKE MAINTENANCE
BRAKTEC
PARTS BREAKDOWN
BRAKTEC
FORMULA
134 ST SERIES
CHANGING FRONT FLEXIBLE BRAKE HOSE
ENGLISH
- When assembling the discs, apply
Loctite 243 to the screws in order to
ensure greater adherence.
PARTS BREAKDOWN
135
STEERING SHAFT
136 ST SERIES
FRONT SUSPENSION
ENGLISH
- Cut the securing flange of the headlight
bracket.
- Slide the bar along the underside.
137
CHANGING RIGHT SUSPENSION BAR SEAL
138 ST SERIES
CHANGING RIGHT SUSPENSION BAR SEAL
ENGLISH
- Apply grease to the bottle mouth to
make assembly easier.
PARTS BREAKDOWN
139
CHANGING LEFT SUSPENSION BAR SEAL
140 ST SERIES
CHANGING LEFT SUSPENSION BAR SEAL
ENGLISH
screw and slide the bottle until it is fully
removed.
- Slide all parts indicated from the tube
and replace part A.
141
CHANGING LEFT SUSPENSION BAR SEAL
142 ST SERIES
CHANGING LEFT SUSPENSION BAR SEAL
PARTS BREAKDOWN
ENGLISH
143
CARBURETTOR AND REED BLOCK
144 ST SERIES
CARBURETTOR AND REED BLOCK
ENGLISH
the float chamber by rotating it slightly.
In an inverted position, test the
height of the floats. (See float height
measures in the specific instructions).
Reassemble the carburettor, inverting
the dismantling process.
145
CARBURETTOR AND REED BLOCK
146 ST SERIES
CARBURETTOR AND REED BLOCK
Dellorto Keihin
80c.c. 125 c.c. 250 c.c. 290 c.c. 300 c.c. P4
P5
P4
P3 P3
P2 P2
Carburettor float height 18.5 19 19 20 20 P1 P1
Idle jet 45 50 33 42 42
Main jet 110 122 122 125 128
Needle position P3 P5 P2 +0.5(*) P4+0.5(*) P4+0.5(*)
(*)
0.5mm
PARTS BREAKDOWN
ENGLISH
Dellorto Keihin
147
CLUTCH PUMP
PARTS BREAKDOWN
148 ST SERIES
RADIATOR
ENGLISH
- Replace and close the draining screw.
- Release the sleeves.
PARTS BREAKDOWN
149
FOOTRESTS / ENGINE PROTECTOR
PARTS BREAKDOWN
PARTS BREAKDOWN
150 ST SERIES
ELECTRICAL SYSTEM
ENGLISH
- High coil connections
- CDI connector
- Regulator and rectifier connections
PARTS BREAKDOWN
151
CHANGING HEADLIGHT LEDs
PARTS BREAKDOWN
152 ST SERIES
TILTING AXLE
ENGLISH
PARTS BREAKDOWN
153
REAR SUSPENSION
PARTS BREAKDOWN
154 ST SERIES
REAR BRAKE AND TRANSMISSION MAINTENANCE
ENGLISH
- Carry out maintenance operations on the
rear brake, dismantling the brake pads
and checking the height of the friction
lining with the help of a calliper gauge.
155
REAR BRAKE AND TRANSMISSION MAINTENANCE
PARTS BREAKDOWN
156 ST SERIES
FUEL TANK
ENGLISH
PARTS BREAKDOWN
157
EXHAUST PIPE ASSEMBLY MAINTENANCE
158 ST SERIES
EXHAUST PIPE ASSEMBLY MAINTENANCE
ENGLISH
PARTS BREAKDOWN
159
CHANGING MUFFLER FIBRES
160 ST SERIES
ENGINE PART
ENGLISH
161
CHANGING THE PISTON
-
Loosen and remove the filter box's
fastening screws as well as those of
the rear mudguard.
162 ST SERIES
CHANGING THE PISTON
ENGLISH
- Loosen the screws from the joining
beam between the cylinder head to the
- chassis.
Disconnect the coil.
-
Loosen and remove the coil bracket.
-
Loosen the screws that secure the
exhaust pipe to the cylinder.
163
CHANGING THE PISTON
-
Loosen the screws and lift the cylinder
head, paying attention not to damage
the small o-ring seals.
-
Loosen the screws that hold the
cylinder and lift it.
-
Remove the clips that fasten the bolt to
the piston using pointed pliers.
-
Remove the bolt by pushing with a
- special tool.
Check the condition of the connecting
- rod ball bearing.
Replace the gasket between the en-
164 ST SERIES
CHANGING THE PISTON
ENGLISH
- insert the bolt into the piston without
reaching the connecting rod's
anchoring area.
- Align with the connecting rod and
press the piston fully.
- Place the piston's securing clips,
making sure they are correctly placed.
Finish placing the cylinder in its final
- position and tighten the cylinder's
fastening screws with a dynamometer
at 22NM. Check the height of the
cylinder, piston and transfers.
Prepare the cylinder head and its
- corresponding o-ring seals, making
sure they are correctly located in the
grooves.
- Place the 6 small o-ring seals.
165
CHANGING THE PISTON
-
Apply lubricant to the area where the
exhaust pipe joins the muer in
- order to facilitate the connection.
- Place the exhaust pipe gasket and
make sure it fits correctly.
166 ST SERIES
CHANGING THE PISTON
ENGLISH
PARTS BREAKDOWN
167
VERIFYING PISTON AND CYLINDER
PARTS BREAKDOWN
168 ST SERIES
IGNITION
ENGLISH
- Loosen and remove the ignition cover.
Check and gauge the pick-up distance
using a
0.7-1mm gauge.
169
IGNITION
PARTS BREAKDOWN
170 ST SERIES
CLUTCH DISCS
ENGLISH
- Using a calliper gauge, check the wear
and tear of the disc lining, max 2.6mm,
min 2.4mm.
- Pay attention to how the discs are placed
when reassembling and tightening the
disc assembly.
PARTS BREAKDOWN
171
START ROUTINE
172 ST SERIES
START ROUTINE
ENGLISH
- Place the spring and washer in position.
173
START ROUTINE
PARTS BREAKDOWN
174 ST SERIES
GEAR SELECTOR
ENGLISH
- Loosen and remove the gear-shift lever.
- Empty the oil from the engine carter.
175
GEAR SELECTOR
PARTS BREAKDOWN
176 ST SERIES
GEARS AND CRANKSHAFT
ENGLISH
- Dismantle the inlet nozzle.
177
GEARS AND CRANKSHAFT
178 ST SERIES
GEARS AND CRANKSHAFT
ENGLISH
- Loosen the primary transmission pinion.
Remove the nut and washer.
179
GEARS AND CRANKSHAFT
180 ST SERIES
GEARS AND CRANKSHAFT
axle.
- Keep the parts in the same order to
make reassembly easier.
PARTS BREAKDOWN
ENGLISH
181
WATER PUMP
PARTS BREAKDOWN
182 ST SERIES