sherco motorcycle assembly instructions
TRANSCRIPT
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Sherco Motorcycle
Assembly InstructionsThis manual is intended to be used as an
assembly guide for the Sherco 1.25 – 2.9 TrialsMotorcycles. The motorcycle shown in the
pictures is a new 2002, 2.9, the one that you are
assembling may be slightly different but the
principles shown will apply to all of the models
indicated.
The technician shown in the photographs isDavid Chaves who received his training at the
Sherco factory in Spain. David is also a member
of Team Sherco and is competing in the NATC
national series as a Champ rider.
The pictures start out showing the bike in the
crate and progress through the complete
assembly process.
If you have any question or are not certain
about any procedure call Ryan Young Products
on 1-800-607-8742.
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Set the crate upright asshown.
These pictures
show how the bike
is packaged and
shipped from the
factory.
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Remove both of the
straps.
Preparation for
assembly.
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Lift the box off of the bike and set aside.
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These pictures
show the bike in
it’s shipping
configuration.
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This picture shows how the axle bolt is usedto retain the bike to the crate.
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Set the front wheel and the package containing
the plastic parts aside.
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Carefully remove all of the protective plastic wrap.
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The bike is now ready to be assembled.
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David removes the 2 rear
bolts and loosens the
front 2, This allows him to
install the handlebars
without having to
completely remove theclamps.
Handlebar Installation
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The handlebar adjustment is unique to each rider,
David usually rolls them forward. These 4 bolts
should be tightened to 15 ft lbs.
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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 leg.
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Carefully remove the front axle, If it is in a bind you
may have to loosen the fork brace bolts.
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David now sets the bike on a stand so that he can install
the front wheel.
Front Wheel Installation
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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.
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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 brace bolts in order to
properly install the axle.
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Make sure that there is enough clearance between the
brake pads to install the brake disc. In this case the pads
were touching.
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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 will fit.
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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 DAMAGE THEM.
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Carefully slide the disc between the brake pads
Install the axle.
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Install the spacer.
Tighten the
axle to 44 ft lbs
Tighten the
pinch bolts
to 8 ft lbs
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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 and Fenders Installed.
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Open the package that contains the plastic parts and
lay them out in preparation for installation.
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Remove the lower brake
caliper fixing bolt.
Remove the small bolt
from the bottom of the
fork leg.
Front Brake Caliper Guard
Installation
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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 snugly, do not strip it out.
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The next step is to install the front fender. Remove the 2
fender mounting bolts from the fender mounting
bracket.
Front Fender Installation
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Set the fender in
place on the
bracket.
Install the fender
bolts.
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Attach the headlight
wire to the chassis
wiring harness.
Fasten the headlight
to the fork tubes
using the 2 zip ties.
Headlight Installation
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Tighten and then
cut the loose
ends off of the
zip ties.
Push the cut
ends in towards
the back of the
headlight.
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You could continue with assembly 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 together.
The first step is to remove the rear fuel tank
mounting bolt.
Checking Coolant Level
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Remove the front
mounting bolt and
disconnect the fuel
tank overflow line.
Disconnect the
fuel line from thefuel valve.
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Remove the fuel tank.
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Carefully remove
the radiator cap,
you can remove it
without removing
the ignition coil.
Check the coolant
level. It should cove
the fins and not be
up in the filler neck
of the radiator.
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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.
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Carefully
reinstall
the radiator
cap.
David uses a
screw driver
as a lever to
tighten the
radiator cap.
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Reinstall the fuel
tank.
Install and tighten
the front mountingbolt.
Reattach the fueltank overflow hose.
Fuel Tank Installation
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Reconnect the fuel line.
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Rear Fender Installation
Remove the 2
fender mounting
screws.
Route the tail light
harness as shown.
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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.
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This picture shows the installed fender, note how the
lip on the fender fits over the lip on the air box.
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Install and
tighten the front
fender (rear fuel
tank) bolt.
Install and tighten the 2 rear fender mounting bolts
Rear Fender Installation Continued.
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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 foot pegs to move freely.
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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 for competition.
The Finished Product!
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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 rear
brake caliper bolts.
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Here he is
tightening the front
brake caliper bolts.
Tighten the fork
brace bolts.
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Here we see David tightening the triple clamp bolts.
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David also tightens the exhaust flange bolts.
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The bike is now ready to be filled with fuel, 93 octane
80:1 gas oil mixture 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 of anti seize
on all bolts that are threaded into aluminum.