diagnosis

The caliper seems to be in good shape, and the exposed piston (2mm or so) looks to be in good condition, and there isn’t any noticeable damage or corrosion. Kinda stumped as to why they wouldn’t pop under air pressure.

I had a chance to play around with the Sherco in the parking lot behind my shop this week, and was able to cycle through all 5 gears, but it takes the most delicate touch for it to shift into 4th without skipping past into 5th. From searching and reading through other posts available on shifting issues, I'm leaning towards a bad or weak index spring? I placed an order through SplatShop, and added a new index, gear selector and return spring, as well as the index roller to the list. When it all arrives, I plan on replacing the whole lot when I do the main bearings. Another task this week was cleaning the carb thoroughly, and replaced the carb seals with a genuine Dellorto kit, and plastic cap. The choke tube and choke o-rings were both dried out and cracked, and the o-rings from the Idle and Mixing screw were missing. As well as the carb issues, the original Domino throttle tube was cracked, and missing half of the top cap, so replaced that as well, along with a new Apico cable, to replace the kinked OG...... I think there was an improvement in how it ran afterwards, but it may just be me, justifying all the work and money going into this bike. lol! I tried addressing the front brake drag with an attempt at removing the caliper, and popping out the pistons... unsuccessfully. I tried compressed air, working them out with a socket inside the hollow of the piston, and rebleeding to pop them out with brake fluid..... I eventually gave up, pressed them all the way in with a vise and blocks, and put them back on the bike. Re-bled them again, and now they work perfectly.... hopefully they stay this way for a while, but plan on ordering a rebuild kit for when they inevitably p*** fluid all over my new pads! Are there any tricks or tools available to aid in pulling the old 4 pot AJP pistons? Hopefully there won't be any more surprises, but I need to remember this bike is close to 20 years old, and this is probably some of the first routine maintenance it's ever received. It's amazing it still works as well as it does!

Thanks for the reply Faussy, that’s exactly what I’m experiencing with the popping, and glad to hear I shouldn’t be too concerned. I’ll see if I can figure out the shifting issue either way, but is completely rideable as is. I’ll try to document anything I do find and post it here for future reference, as it would be nice to give back to the forum, as it’s helped me out a lot so far. Also, thanks for the heads up with the rear disc. I realized I was dragging my rear brake caused by poor foot position, and it discoloured from the excess heat. I’ll take a good look at it, and replace if necessary. I really appreciate the feedback! 🍻

Hello all! I purchased an ‘05 Sherco 80 last May for $1k Cad. thinking it would be a ‘cheap’ project while I put the majority of my effort into a ‘75 TY175 resto. I’ve since put a bit more money and a whole lot of effort into sorting some of the cosmetics, and routine maintenance that had been ignored for the past 18 years. I was given the option of taking last Friday off, and was cleared of any duties by my wife, so loaded up the bike, and headed North. The weather worked in my favour, and was able to get about 50kms in over two rides, along a seasonal access road between my cottage and a nearby town. There are a number of trails and roadside obstacles to play around on along the way, but kept the risk to a minimum being alone, and no cell service. I managed to snap a few pics along the way, as the scenery was incredible it was a good opportunity to shake the bike down after doing some of the basic seals, bushings and bearings, exhaust repack, brake bleed and new pads, water pump seals, sprockets, chain, etc. The excessive smoking finally stopped, the bike felt great, and was surprisingly quick for such a small bore. issues that need to be addressed: - engine noise: I have the replacement main bearings, and gaskets, just need to pull the motor apart and investigate further. - front brake is dragging: I’m guessing a rebuild of both caliper and master is in order? - exhaust popping while riding at a consistent speed: I have no other similar 2 stroke bikes to compare it to, power seems fine, but not sure if this is normal, or maybe a timing issue? - rear shock leaking: easy fix, take it to Langs for a rebuild 😂 - 4th gear seems to be missing: I never really had it past third on my street while testing, and noticed my bike was only a 4sp on the last ride I’m assuming it’s 4th, as it bogs from 3rd when shifting up, but the final gear seems really long. Edit: while shifting it manually not running, while on the centre stand, I can shift into 4th, and it won’t engage a gear, just spins as if in neutral. Thinking back, while riding it seems to shift from 3rd completely past 4th into 5th, and down from 5th into 3rd, without hesitation or a false neutral. 🤔 …. I’ll have to investigate a little further when replacing the mains. Could this be a bent fork, or detent issue? Even though it’s had some frustrations, this little Sherco has been a ton of fun and a great learning experience (with a few more lessons to go!) 🍻 Graham How it all began: As of April 21, 2023

Thanks! That’s my intention with it for now, along with displaying it at a couple of shows this summer, before I drop it on a rock or two. I may add a set of new rear shocks, 6” Renthals and Sammy Miller style pegs when the time comes, but for now, I’m really happy with it!

Hello all! I've recently 'finished' my 1975 TY175 build, that I have been working on for the past year. Initially I was going to sort it out to ride at the cottage, but with too much time on my hands, and polishing gear handy, this beater turned out pretty well! I appreciate all the info that is available on the Trials Central forums, as I have referenced it constantly during the build. Cheers! The before and after.

I hate bringing back a thread that's what, 18 years old now? I really appreciate the detailed pics to give me the confidence to cut this piece of unobtanium in half. Cheers Chris! Here's my attempt on a 2005 0.8 exhaust. I drew a dotted line in Sharpie where I should have cut, as I managed to catch the flanged lip of the baffle, separating the two halves. I tacked the baffle back in place before welding the two halves back together. I honestly thought I took more pics, for those who still own these old Sherco's, but suffered a bit of a brake cleaner induced brain fart while in the process. I used some high temp. ceramic insulation for the repack, and it seems to have quieted the exhaust a little. It is a definite improvement over the oil soaked remains of the old insulation.