Sherco Setup And Lubrication Guide

3y ago
23 Views
2 Downloads
1.71 MB
36 Pages
Last View : 2m ago
Last Download : 2m ago
Upload by : Pierre Damon
Transcription

www.shercousa.comSherco Setup and Lubrication GuideThis guide is designed to provide the Sherco owner withinstructions on how to: Set up a new bike Clean and re-oil the air filter Change the transmission oil Change the fork oil Repack the suspension dog bone bearings Repack the headset bearings Repack the wheel bearings Tighten the spokes and true the wheelsNote: The bikes shown in the following photos are in-service2002 2.9 models. They may not be exactly like the bike youare working on but the principles shown are applicable.If you have any questions about the procedures, please callRyan Young Products at 1-800-607-8742.3/11/2004Sherco Setup andLubrication Guide1

www.shercousa.comNew Bike Set upHere are some suggestions that we believe will help ensure a long service life foryour new Sherco. Take the time to check the tightness of these fasteners.Front axle37 ft lbs.Handlebarmounting bolts15 ft lbs.Front axle pinchbolts8 ft lbs.Suspensionlinkage bolts30 ft lbs.Triple clamppinch bolts8 ft lbs.Swing arm bolt37 ft lbs.Front brakecaliper bolts15 ft lbs.Rear axle bolt44 ft lbs.37 ft lbs.Fork bracemounting bolts(we suggest thatyou loctite thesebolts)6 ft lbs.Steering tubenutFront and rearbrake rotor bolts(we suggest thatyou loctite thesebolts)8 ft lbs. Tighten the spokes initially, then tighten them after the first ride and check them for propertightness after every ride. (see pages 34 – 36 for details on how to properly tighten thespokes) Tighten the rear sprocket fasteners initially and after the first ride then continue to checkthese bolts for tightness on a regular basis. (20 ft lbs) Use at least 93 octane fuel mixed at 80:1 ratio. This means, for example, 8 ounces of highquality 2 stroke oil should be mixed with 5 gallons of gasoline (1.6 ounces (46 cc) per gallon).We recommend Maxima Formula K2 Racing 2-cycle oil (available from RYP) During the first 10 hours of operation, do not run the engine at a constant speed for anextended period of time. Instead, vary the speed. Section riding is a very good way to break-inthe engine. Check the Spark Plug Gap initially and then check it every 3 months. The gap should be .020(.5mm) The recommended Spark Plug is the NGK BP5ES.3/11/2004Sherco Setup andLubrication Guide2

www.shercousa.comRecommended Lubrication IntervalsType of LubricationClean / inspect and re-oilthe air filterIntervalRecommended ProductEvery dusty ride / everytime the bike is pressurewashedMaxima FAB air filtercleaner.Maxima FFT air filter oilChange the transmissionoilPages 10 - 12Every 20 hours ofoperationMaxima MTL 2-cycletransmission lube(450 cc)Change the fork oil2 times per yearMaxima 5w or 10w forkfluid (270cc oil change,330cc complete rebuild)Clean / inspect andrepack the suspensiondog bone bearingsPages 18 - 262 times per year unlessyou have been riding invery wet / muddyconditionsMaxima water proofgrease mixed 50/50 witha good quality anti seizelubricantClean / inspect andrepack the headsetbearingsPages 27 - 322 times per yearMaxima water proofgrease mixed 50/50 witha good quality anti seizelubricantClean / inspect andrepack the wheelbearingsPage 332 times per year unlessyou have been riding invery wet / muddyconditionsMaxima water proofgrease mixed 50/50 witha good quality anti seizelubricantLubricate all movingjoints. (front brake lever,clutch lever, throttletube, foot pegs, rearbrake pivots, kick standpivot, chain tensionerpivot etc.)After each time the bikeis washedMaxima multi-purposelubePages 4 - 9Pages 13 - 17Maxima products are available from Ryan Young Products1-800-607-87423/11/2004Sherco Setup andLubrication Guide3

www.shercousa.comAir Filter Cleaning and Re-oilingAir filter maintenance is critical, the filter must be kept clean if youexpect to receive long life from your engine.The first step is to remove the rear fender.Using a 4mm Allen wrench remove the 3fasteners and set the fender aside.This fastener (fender / fuel tank mounting)2 fasteners, 1 on the R.H. sideand 1 on the L.H. side.Remove the filter retainer and the filter.Newer models have a clip retained by a boltthat also must be removed. Use a 3mm Allenwrench to remove this bolt.Place the filter and retainer in a suitablecontainer.Clean the filter and retainer using a goodquality air filter cleaner, we recommendMaxima FAB air filter cleaner.Once the filter is cleaned set it aside sothat it can dry.3/11/2004Sherco Setup andLubrication Guide4

www.shercousa.comWhile you are waiting for thefilter to dry, it is goodmaintenance practice to alsoremove the airbox and clean itwith warm soapy water andthen blow it dry withcompressed air.To remove the air box use a4mm Allen wrench and removethe 3 fasteners shown here.Next loosen the rear clamp byloosening the Phillips screw,which leaves the rubber hoseconnected to the carburetorRemove the fender mountingnut from the subframe inorder to make removing theair box easier.Reinstall the airbox in reverseorder.3/11/2004Sherco Setup andLubrication Guide5

www.shercousa.comAirbox ModificationIf your bike is equipped with the round rubber seal that attaches to the filterbox, you may want to perform this modification to help retain an airtight sealbetween the airbox and the silencer. This is important for keeping the air filterclean.Carefully drill a series of1/8” holes along theedge of the air box asshown. Be very carefulthat you do not drill intothe air box.Drill 5-7 evenly spacedholes.Install zip ties asshown, using themto retain the rubberseal against theairbox.3/11/2004Sherco Setup andLubrication Guide6

www.shercousa.comThe finished product is shown above with the zip ties tightened and their unusedends cut off.For extra protection, it is optional to apply a bead of black silicone sealant to thejoint between the rubber seal and the airbox.3/11/2004Sherco Setup andLubrication Guide7

www.shercousa.comReinstall the air box, tighten allof the fasteners including thehose clamp on the carburetormanifold.Apply the filter oil to the dryfilter element. We recommendMaxima FFT filter oil. Followthe manufacturers instructionson how to apply the oil. Coatthe entire filter inside andoutside surfaces with oil andsqueeze out the waste.Note that the tapered end ofthe filter retainer should beinstalled towards the front ofthe bike.Tapered end3/11/2004Sherco Setup andLubrication Guide8

www.shercousa.comInstall the clean and oiled filter backin the air box. Note that the elementedges are evenly and flatlydisplaced by the air filter retainer.Do not allow the filter edges to bebunched up, allowing dirty air tobypass the filter and enter themotor.Reinstall the rear fender and it’sthree bolts. This job is finished.3/11/2004Sherco Setup andLubrication Guide9

www.shercousa.comChanging the Transmission OilLocate the bolt that must beremoved in order to drain thetransmission oil, it is located asshown.Bolt to be removed.Use a 5mm Allen wrench andremove the bolt. Lean the bike tothe left and let the oil completelydrain out of the transmission.While you have the drain boltremoved examine the sealingwasher and make sure that it isstill serviceable.New washers are available fromRYP.Washer to be examined.3/11/2004Sherco Setup andLubrication Guide10

www.shercousa.comReinstall and tighten the drainbolt.Locate the transmission oil fillerplug. Use a 5mm Allen wrenchand remove this plug.The filler plug seal should also beexamined and replaced if it is notserviceable.New seals are available from RYP.3/11/2004Sherco Setup andLubrication Guide11

www.shercousa.comMeasure 450cc ofTransmission oil in asuitable container.We recommend MaximaMTL transmission oil.Maxima products areavailable from RYP.Use an appropriatefunnel and carefullypour the oil into thetransmission.Leaning the bike tothe left facilitates thisjob. Do not lay thebike on it’s side toperform thisoperation.Reinstall the filler plugand the job is finished.3/11/2004Sherco Setup andLubrication Guide12

www.shercousa.comChanging the Fork OilSupport the bike so that the front wheel is off of the ground.With a 10mm socket or box endwrench loosen the axle pinchbolts. They do not have to beremoved.Use a 10mm Allen wrench andremove the front axle. Removethe front wheel.Note: You do not have to removethe front wheel to change the forkoil however with the front wheelremoved you can be assured thatyou do not get any new or usedoil on the brake rotor.3/11/2004Sherco Setup andLubrication Guide13

www.shercousa.comThis is how the bottom of thefork looks with the front wheelremoved.Caution: Do not activate thefront brake lever with the wheelremoved as this could cause airto be introduced into the system.Remove the LH and RH forkblue plastic fork caps.Use a 3mm Allen wrench andremove the rotor guard fixingbolt. (The guard had beenremoved earlier)3/11/2004Sherco Setup andLubrication Guide14

www.shercousa.comUse an 8mm Allen wrenchand remove the RH and LHfork drain bolts, these boltsalso retain the internaldamping rods and can bedifficult to remove.You may have to use animpact tool to remove thetwo bolts, a small airimpact tool was used inthis illustration.Once the bolts areremoved examine thesealing washers and makesure they are serviceable.New washers are availablefrom RYP.Once the oil is drainedreinstall the bolts, torquethem to 18 ft lbs.3/11/2004Sherco Setup andLubrication Guide15

www.shercousa.comCarefully measure 270cc of fork oil for eachleg for a normal oilchange. If you havetaken the fork apartand cleaned all of thecomponents then use330 cc per leg.We recommendMaxima Fork Fluideither 5W or 10W.Use an appropriate sizefunnel and pour the oilinto each leg. Once theoil is in the fork legs theblue plastic fork capscan be reinstalled.3/11/2004Sherco Setup andLubrication Guide16

www.shercousa.comReinstall the frontwheel. Installation isthe reverse of theremoval.Tighten the axle boltto 37 ft lbs. Tightenthe pinch bolts to 8 ftlbs.Note: It isrecommended thatyou coat the axle andpinch bolts with antiseize lubricant.Pinch bolts(8 ft lbs.)Axle bolt (37 ft lbs.)Note the location of thewheel spacer.3/11/2004Sherco Setup andLubrication Guide17

www.shercousa.comCleaning and Lubricating the Suspension “Dog Bone” BearingsThe first step is tosupport the bike on asuitable stand so thatthe rear wheel is offof the ground. Thenext step is toremove the rearfender and theairbox. (for details onhow to do this, seepages 4 & 5)In order to provideclearance for removal ofthe rear dog bone boltremove the nut from thefoot peg bolt and tap it upout or the way as shown.(use a 13mm wrench and a6mm Allen wrench)3/11/2004Sherco Setup andLubrication Guide18

www.shercousa.comParts Book Page Showing the Suspension LinkageThis Page Can be Downloaded from the Sherco USA Web Page13/11/2004Sherco Setup andLubrication Guide19

www.shercousa.comRemove the top shockmounting bolt, nut andwasher. (part numbers 810,8.48 and 8.41) 17mm wrenchand 8mm Allen wrench.Remove the dog bone bolt,nut and washers. (partnumbers 16.22, 8.41 and8.53) 17mm wrench and8mm Allen wrench.3/11/2004Sherco Setup andLubrication Guide20

www.shercousa.comRemove thebottom shock bolt.(part number 16.23)8mm Allen wrench.With the upperand lower shockbolts removedyou can nowremove the shockunit from the bike.3/11/2004Sherco Setup andLubrication Guide21

www.shercousa.comWith the shock unitremoved you canaccess the bolts andnuts that retain thedog bones to thechassis. Removethese bolts using 2 13mm wrenches. (partnumbers 16.25 and8.42)3/11/2004Sherco Setup andLubrication Guide22

www.shercousa.comHere are the parts that need to be cleaned and lubricated, examine the needlebearings and the bushings carefully and replace if required. Clean all of the partsthoroughly and allow to dry.Liberally apply a mixture of Maxima waterproof grease and anti seize lubricant tothe bearings and the bushings.The dog bones are identical and can be used on either side of the bike.3/11/2004Sherco Setup andLubrication Guide23

www.shercousa.comReinstall the dog bones and the shock unit in reverse order.Tighten these bolts to 18 ft lbs.Tighten the bottomshock bolt to 37 ftlbs.3/11/2004Tighten the upper shock bolt to 30 ft lbs.Sherco Setup andLubrication Guide24

www.shercousa.comIf you will place thewasher as shownyou can install therear dog bone boltwithout having toremove the chain.Tighten this bolt to30 ft lbs.This is how thefinished productshould look whenviewed from underthe bike. (RH side)3/11/2004Sherco Setup andLubrication Guide25

www.shercousa.comReinstall the foot peg mounting nut, the airbox and the rearfinder and you are ready to ride.3mm locking screwWhile you have the shock removed it is recommended that you rotate the shockadjustment ring so that the 3mm allen head locking screw faces the rear of thebike. This will make adjusting the suspension “sag” easier to perform.3/11/2004Sherco Setup andLubrication Guide26

www.shercousa.comCleaning, Inspecting and Repacking the Headset BearingsSet the bike on a suitable stand so that the frontwheel is at least 3 inches off of the ground.In order to reinstall thehandlebars in the samelocation it is a good idea touse a marking pen andmark the handlebars andhandlebar clamp as shown.Use a 6mm Allen wrench andremove the 4 handlebarmounting bolts.3/11/2004Sherco Setup andLubrication Guide27

www.shercousa.comIt is a good idea to use a zip tieto attach the handlebars to thefork so that they stay out ofthe way while you work on thebearings.In order to get to thebearings you must removethe top triple clamp.Use a 5mm Allen wrenchand remove the 2 RH and 2LH triple clamp pinch bolts.Use a 24mm socket orbox end wrench andremove the steering tubenut.3/11/2004You should now be able toremove the triple clamp, it mayrequire a few gentle taps with aplastic hammer.Sherco Setup andLubrication Guide28

www.shercousa.comUse a spanner wrenchand remove the bearingretaining nut.Carefully lower thefork assemble so thatthe bottom bearing isexposed.Placing a piece of wood in frontof the wheel will keep the forkfrom falling off of the bike.3/11/2004Sherco Setup andLubrication Guide29

www.shercousa.comLift the upper bearing out of the race, clean and inspect both bearings and bothraces, make sure the bearings turn freely and that the races are smooth. It is notnecessary to remove the lower bearing in order to clean and inspect it.We suggest that you pack the bearings with a mixture of Maxima waterproofgrease and anti seize lubricant.Upper bearing ready to be repacked.Upper bearing packed and reinstalledin the race.3/11/2004Lower bearing ready to be repacked.Lower bearing packed and ready forreassemblySherco Setup andLubrication Guide30

www.shercousa.comReinstall the fork in reverse order.Reinstall the bearing retainer nut,tighten it up such that the fork turnsfreely from side to side. You shouldnot be able to feel any free play in theunit. Do not over tighten.Reinstall the triple clamp, you mayhave to gently tap it to get it to on thefork tubes.Reinstall the Steering tube nut,(apply loctite to this nut) tightenit to 37 ft lbs. Check and makesure the fork still turns freelyside to side. If it is tight you willhave to loosen this nut andthen loosen the bearing retainernut. Take your time and makesure that this is properlyadjusted.3/11/2004Sherco Setup andLubrication Guide31

www.shercousa.comOnce you are satisfied that theyou have the headset bearingsadjusted and tightened properlythen reinstall the pinch bolts.Tighten them to 8 ft lbs.Reinstall the handlebars, tightenthe mounting bolts to 15 ft lbs.This job is finished and you are ready for a test ride.3/11/2004Sherco Setup andLubrication Guide32

www.shercousa.comCleaning, Inspecting and Repacking the Wheel BearingsFor the purpose of this guide we are justshowing packing the front wheel bearings,packing the rear wheel bearings follows thesame basic procedure.Remove the front wheel as shown on page 13.Place the wheel as shown above, agarbage can with a towel placedover it makes a good work area.Remove the spacer, then with a sharptool very carefully remove the seal.With the seal removed inspect andclean the bearing with a good qualitycleaning solvent. If the bearing isserviceable repack it with a mixture ofMaxima waterproof grease and antiseize lubricant. Replace the seal.Repeat on the opposite side bearing.Replace the wheel and the job isfinished.3/11/2004Sherco Setup andLubrication Guide33

www.shercousa.comSpoke Tightening TechniqueNew Wheel The first thing to emphasize is to “Take your Time” The next thing is to get a good quality spoke wrench, thefront spoke nipples on the 2002, 2.9 require a 5.7mm wrenchand the rear nipples require a 6.4mm wrench. The one shownbelow is a good quality wrench that has replaceable tips.Another excellent wrench is one made by the FASSTcompany that is actually a spoke torque wrench. RYP willhave this wrench available. A quick way to check the spokes for tightness is to lightly tapthem with a metal object, the spokes will emit a dull sound ifthey are loose. This is only a quick and dirty method but it is agood indicator, after you do it for a while you will quickly beable to locate loose spokes. The simplest way to check the spokes for tightness is to startat the valve stem and move from spoke to spoke, only tighteneach spoke ½ revolution at a time, this should keep the wheelin proper alignment.3/11/2004Sherco Setup andLubrication Guide34

www.shercousa.com Continue around the wheel until you have finished one fullrevolution, start over and follow this process until all of thespokes are tight. Do not over tighten the spokes. Once you have tightened the spokes you will want to checkthe wheel for trueness. Shown below is a simple way to add agage to the fork to use to determine if the wheel is true.2 zip ties and a piece of wood can be used to make a pointer todetermine if the wheel is true. ( / - 2mm run out) If the wheel is out of true you will need to loosen thespokes on the side of the wheel that is opposite to the sidethat must be tightened in order to bring the wheel intocorrect alignment. Do not get in a hurry, this process cantake some time. It is recommended that you apply a good quality oil toeach spoke nipple in order to prevent corrosion betweenthe spoke and the nipple.3/11/2004Sherco Setup andLubrication Guide35

www.shercousa.comSpoke Tightening TechniqueIn Service WheelUse all of the same principles that were used on the new wheelexcept that the in service wheel will require some additionalsteps.1. Lubricate the joint between the spoke and nipple with agood quality penetrating oil.2. Start at the valve stem and LOOSEN the nipple ½ turnbefore you tighten it this should loosen any corrosionthat may have developed. As in the case of the newwheel only tighten each spoke ½ turn.3. Follow this same procedure around the wheel until youare satisfied that the spokes are tightened properly, youmay have to go around the wheel several times.4. When you are finished tightening the spokes you shouldcheck the wheel for trueness as you did with the newwheel, follow the same procedure as you did with thenew wheel to true it.As stated before, if you have any questions about this or anyprocedure contact Ryan Young Products at 1-800-607-8742.3/11/2004Sherco Setup andLubrication Guide36

Lubrication Guide 1 www.shercousa.com Sherco Setup and Lubrication Guide This guide is designed to provide the Sherco owner with instructions on how to: Set up a new bike Clean and re-oil the air filter Change the transmission oil Change the fork oil Repack the suspension dog bone bearings Repack the headset bearings Repack the wheel bearings Tighten the spokes .

Related Documents:

and an LCD unit. The oil mist lubrication sensor IP receives data input from eight oil mist lubrication sensors. The communication IP transmits oil mist lubrication sensor data and pump control data to the master computer. C. Oil Mist Lubrication Sensor . In An ATMEGA8 [6] was used as a processor for the oil mist lubrication sensor.Author: Cheol-Hong Moon

Notes on lubrication All specifications on lubrication are based on experimental values and field experience are recommendations by Bosch Rexroth. The service life of the ball rail system crucially depends on the lubrication. For this purpose, the documentation, especially the chapter on lubrication, must be read and understood completely.

protect against bearing contamination or lubrication loss. Yoke Roller Lubrication Hole with Annular groove McGill CAMROL Yoke roller bearings include a lubrication hole to provide a passage for lubrication to the rolling elements from the yoke roller bore. The customer supplied shaft must provide axial lubrication path to supply bearing.

Understanding proper bearing lubrication procedures is critical to ensuring long-term, trouble-free performance. Klüber Lubrication has prepared this explanation as a general guide. If a more detailed explanation is required, please contact your nearest Klüber Lubrication representative or the manufacturer of the lubricant you are using.

6 Gilman Precision Solutions for Linear and Rotary Motion 3. Lubrication Dovetail & Hardened Way Lubrication Use these charts and formulas as a guide to determine the lube area or the amount of lubrication required for the slide . Lubrication requirements may vary depend

consistent lubrication management systems and activities. 11. Q: What are the 12 interrelated areas incorporated into any sustainable lubrication program plan, as per ICML 55? A: 1. SKILLS: Job Task, Training and Competency 2. MACHINE: Machine Lubrication and Condition Monitoring Readiness 3. LUBRICANT: Lubricant System Design and Selection 4.

Lubrication is also used to reduce oxidation and prevent rust; to provide insulation in transformer applications; to transmit mechanical power in hydraulic fluid power applications; and to seal against dust, dirt, and water. 1.1.1. The lubrication regimes The modern period of lubrication began with the work of Osborne Reynolds (1842-1912).

ANATOMI & FISIOLOGI SISTEM LIMFATIK DAN KONSEP IMUN Atika Dalili Akhmad, M. Sc., Apt . PENDAHULUAN 20 L cairan plasma difiltrasi keluar menuju bagian interstisial, 17 L direabsorpsi oleh pembuluh darah, BAGAIMANA 3 L SISANYA ? Sistem Limfatik sistem yang terdiri dari pembuluh, sel, dan organ yang membawa kelebihan cairan insterstisial ke dalam aliran darah dan filter patogen dari darah. FUNGSI .