SHERCO 2013 SE 250i-R, 2013 SE 300i-R, 2011 SE 2.5i-F, 2011 SE 3.0i-F Shop Manual
Shop manual
2013
SE 250i-
R
SE 300i-
R
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CONTENTS
Forward ................................................................................................................................................... 2
Motor tools SE25i-F ............................................................................................................................... 3
Technical specification - Motor ............................................................................................................. 4
Technical specification - Frame ............................................................................................................ 5
Standard adjustement – Fork ............................................................................................................... 6
Standard adjustment - Fork Sachs USD Gold Series Ø48MM.......................................................... 6
Standard adjustment - Fork WP USD Gold Series Ø48MM .............................................................. 6
Standard adjustement – Shock absorber ............................................................................................ 7
Standard adjustment - WP Shock absorber ........................................................................................ 7
Operations requiring demounting or not engine ................................................................................. 8
Removing the motor .............................................................................................................................. 9
Removing the motor: ............................................................................................................................ 9
Motor top end ....................................................................................................................................... 11
Disassembling the right side ............................................................................................................... 23
Disassembling the left side ................................................................................................................. 26
Crankcase / Transmission / Central crankcases .............................................................................. 29
Tightening torques ............................................................................................................................... 36
Clean injector body .............................................................................................................................. 38
SHERCO diagnostic tools ................................................................................................................... 41
Software installation ........................................................................................................................... 42
Software presentation (the various interfaces) : ................................................................................... 42
Connecting the diagnostic kit wiring ................................................................................................... 43
Performing diagnostic ......................................................................................................................... 43
Synchronizing the ECU / with the butterfly openning sensor (TPS) .................................................... 45
Electrical installation checking ........................................................................................................... 47
Regulator ............................................................................................................................................ 47
Cable diagram (Injection / light) .......................................................................................................... 48
Injection beam .................................................................................................................................... 48
Light beam ......................................................................................................................................... 50
Racing lighting cable diagram : ........................................................................................................... 52
Flasher installation cable diagram : ..................................................................................................... 53
Fan cable diagram : ............................................................................................................................. 54
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Forward
This manual is designed primarily for skilled mechanics working in a properly equipped
workshop. The execution of the operations in this manual requires a strong mechanical
knowledge and specific SHERCO tools designed for the SE 250i-R and SE 300i-R engine.
This workshop manual is a supplement to the SHERCO SE 250i-R and SE 300i-R owner’s
manual.
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Motor tools SE25i-F
Tool
ref
Designation
1819
Dead point
1814
Clutch holder tool
1815
Ignition tool
2067
Swingarm tool
2068
Freewheel tool
2069
Oil seal tool (Gear box exit)
2070
Oil level gauge tool
2071
Bearing tool 6905 (Gear selector
drum)
2072
Bearing tool 6222 (Clutch shaft)
2079
Bearing tool 6203 left ( Balancer)
2080
Oil seal tool 8x18x5
1822
Bearing tool (Water pump shaft)
2078
Oil seal 36x57x7,5 Right
(Crankshaft)
2077
Bearing tool 4905 Right (Balancer)
2074
Bearing tool 6003 (Gear shaft)
1968
Oil seal tool (Water pump)
2075
Piston tool
2076
Bearing tool (Crankshaft)
1816
Ring tool
1821
Engine support tool 250
1817
Pinion tool
1818
Piston support
2073
Resort tool
R462
Flywheel puller
R464
Ring extractor
R450
Gear selector oil seal tool
3785
Spark key
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Technical specification - Motor
Type Liquid cooled single cylinder 4 strokes engine
Displacement 249.4 CC 303.7 CC
Bore/Stroke 78/52mm 84/54.8mm
Compression ratio 12.6 :1 12.8:1
Fuel Without lead 95 or 98
Valve timing 4 valves, DOHC driven by tooth type chain
Admission valve diameter 29mm
Exhaust admission valve 25mm
Thickness admission valve 0.15-0.2mm
Thickness exhaust valve 0.2-0.25mm
Crankshat bearing 2 roller bearing
Piston Aluminium forge
Lubrification Lubrication under pressure with 2 trochoidal pumps
Motor oil 1 L SAE 10W60
Primary reduction ratio 21 :70
Gear box :
1ère
2ème
3ème
4ème
5 ème
6 ème
6 speed
14 : 33
17 : 30
19 : 28
21 : 26
23 : 24
25 : 22
Final transmission 13 X48 13 X 48
Clutch Multi-disk in oil bath. Hydraulic command
Ignition system / Batterie Electric start/12V 6.5Ah
Electronic injection Magneti Marelli
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Technical specification - Frame
Frame
Semi-perimeter CrMo steel with aluminum subframe
Fork
SACHS USD Gold Series 48mm dia. (standard) & WP USD 48mm dia.
(racing)
Rear suspension
WP Suspension with separate cylinder
Travel Front/rear 300/300mm
Front brake
270mm (standard), 256mm (racing)
Rear brake
220mm
Brake disc
2.7mm front and 3.6mm rear
Front tire
90/90-21”
Rear tire
140/80-18”
Pressure TT
0.9 bar
Fuel tank capacity
8.51 with 1l of reserve
Angle of the steering column 27.3°
Wheel base 1470mm
Weight (with fuel) 102 kg
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Standard adjustement – Fork
Standard adjustment - Fork Sachs USD Gold Series Ø48MM
Compression
Turn clockwise to the stop, then back of 12
clicks
Rebound
Turn clockwise to the stop, then back off
12 clicks
Spring
4.5N/mm
Fork oil
SAE 5
Oil capacity
600cm3
Oil level
130mm
Standard adjustment - Fork WP USD Gold Series Ø48MM
Compression Comfort 20 clicks back
Standard 13 clicks back
Sport 8 clicks back
Rebound Comfort 18 clicks back
Standard 13 clicks back
Sport 10 clicks back
Preload Comfort 2 turns
Standard 4 turns
Sport 6 turns
Spring stiffness Rider weight: 143 -165 lbs 4.0N/mm
Rider weight: 165- 187 lbs 4.2 N/mm
(original)
Rider weight: 187- 210 lbs 4.4N/mm
Type of oil SAE 4
Oil level 110mm
7/54
Standard adjustement – Shock absorber
Standard adjustment - WP Shock absorber
Low-speed
compression
Comfort 20 clicks back
Standard 15 clicks back
Sport 12 clicks back
High-speed
compression
Comfort 2.5 clicks back
Standard 2 clicks back
Sport 1.5 clicks back
Rebound Comfort 15 clicks back
Standard 13 clics en arrière
Sport 11 clics en arrière
Spring stiffness Rider weight: 143 -165
lbs
48N/mm
Rider weight: 165- 187
lbs
51N/mm (origine)
Rider weight: 187- 210
lbs
54N/mm
8/54
Operations requiring demounting or not engine
Removing engine Not demounting engine
Crankshaft •
Gear box •
Crankshaft bearing •
Gear Box bearing •
Piston •
Cylinder •
Cylinder head •
Valve timing •
Ignition •
Pinion of ignition system •
Freewheel •
Clutch •
Water pump •
Oil pump •
Gear selection •
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Removing the motor
Removing the motor:
To remove the engine, you must remove
the swing arm axle, the swing arm and the rear
wheel. To keep the bike from falling, remember
to support the chassis with an appropriate jack.
• Drain (refer to the owners manual)
- the engine oil
- the engine coolant
• Remove the seat.
• Disconnect the battery.
• Remove the fuel tank and its covers.
• Disconnect all the electrical wiring
connectors from the engine. (Starter, TPS
sensor, water temperature sensor, coil, fuel
injector).
• Remove the exhaust.
• Remove the ignition coil.
• Remove the fuel injector body.
• Remove the chain.
• Remove the chain guard.
• Remove the clutch actuating cylinder.
When the clutch actuating cylinder is
removed the piston is loose. Hold the piston it
in place using a plastic strap.
• Remove all of the water hoses
connected to the motor.
• Remove the left radiator.
• Loosen all of the engine bolts [A].
• Loosen the swing arm bolt.
• Remove the brackets that attach the
cylinder head to the chassis.
• Remove the motor mounting bolts.
• Remove the swing arm bolt.
• Remove the motor.
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Reinstalling the motor:
• The motor should be reinstalled in the
frame in the reverse order of how it was
removed. The following torque values should
be utilized.
Tightening torques :
Motor mounting bolts: 60Nm
Swing arm axle nut: 100 Nm
Clutch receiver screws: 10 Nm
Cylinder head bracket bolts: 23Nm
Exhaust mounting bolts: 10Nm
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Motor top end
For additional details refer to the parts catalog SE 250i_SE 300i..
Removing the cylinder head:
• Remove the spark plug.
• Remove the valve cover.
• Remove the three valve cover screws.
These three screws are equipped with orings ref: 0900.
• Remove the cap from the ignition cover.
[A].
• Remove the timing control plug [A]
• Turn the engine counterclockwise in
order to align the timing marks on the
crankshaft with the marks on the timing gear.
Install the special tool that locks the engine at
Top Dead Center [A] (ref 1819)
A
A
A
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• Remove the screws from the cam chain
tensioner as shown in the photo.
• Remove the cam chain tensioner.
• Remove the spark plug well.
• Remove the camshaft bearing journal.
Starting on the inside, remove the screws
In a criss cross manner (see the numbers on
the photo).
• Remove the exhaust camshaft retaining
clip.
• Remove the exhaust camshaft.
• Remove the intake camshaft retaining
clip.
• Remove the intake camshaft.
• Remove the two nuts M6 and the
washer.
2
3
1
2
3
4 5
7
6
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Standard
SE 250i
-R:
Cylinder diameter (A) = 77.982±0.01 mm
Cylinder diameter (B) = 77.982~77.995 mm
Taper limit 0.05 mm
Out of round limit 0.05 mm
Standard
SE 300i
-R:
Cylinder diameter (A) = 83.982±0.01 mm
Cylinder diameter (B) = 83.982~83.995 mm
Taper limit 0.05 mm
Out of round limit 0.05 mm
• Remove the cylinder head bolts (Be sure
to loosen them in the correct direction).
Black bolt N°1 on the picture is longer , 3
bolts are identical .
• Remove the cylinder head.
• Remove the head gasket and the
cylinder.
Motor top end:
Inspection of the cylinder for wear:
Measure the inside diameter of the cylinder
when it is cold.
• Inspect the inside of the cylinder for any
scratches or other evidence of abnormal wear.
If the cylinder is badly damaged or worn it
should be replaced.
• Since the cylinder does not wear in a
uniform manner measure in from side to side
and up and down as shown.
If the inside measurement of the cylinder
exceeds the tolerance limit it must be replaced.
(A)=10 mm
(B)=25 mm
Piston / cylinder clearance
To determine the piston / cylinder clearance as
accurately as possible it is sufficient to measure
the piston and the cylinder, and then calculate
the difference between the two values.
Measure the diameters as shown.
Piston / cylinder clearances
Standard 0.03 – 0.05 mm
Limit 0.10 mm
1 4
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Piston wear:
• Using a micrometer measure the outside
diameter of the piston [A] 10mm [B] above the
bottom of the piston and at right angles to the
axis of the piston.
If the outer diameter of the piston is below the
tolerance it must be replaced.
Piston 250i-R= 77.950±0.005 mm
Piston 300i-R= 83.950±0.005 mm
Ring groove / piston ring:
• Using a feeler gauge measure the
clearance between the piston ring and the ring
groove.
• Check in several places to determine the
actual clearance if the clearance is greater than
the maximum, replace the piston ring and if
necessary the piston.
Ring groove / piston ring
Standard
Compression ring: 0.030-0.065 mm
Limit 0.13 mm
Oil control ring: 0.020-0.055 mm
Limit 0.13 mm
Ring end gap
Compression ring: 0.3-0.4 Limit 0.7 mm
Oil control ring: 0.3-0.5 mm
Inspect the connecting rod, the piston pin and
the piston for wear:
• Visually inspect the circlips in place.
If they appear worn or distorted replace them. If
the hole for the circlips appears worn replace
the piston.
• Measure the piston pin with a
micrometer.
If at any place on the pin the diameter is below
the limit replace the piston pin.
• Measure the diameter of the piston pin
holes in the piston and the hole in the
connecting rod. If the one or more holes in the
piston are incorrect replace the piston.
If the diameter of the hole in the connecting rod
is incorrect, replace the connecting rod.
Piston pin diameter
15.997-16.000 mm
Piston pin hole diameter in the piston
16.004-16.009 mm
Connecting rod hole diameter
16.000-16.011 mm
15/54
Check the camshafts for wear:
• Remove the camshafts.
• Measure the heights [A] of the camshaft
lobes with a micrometer.
If the cams are worn beyond the limits, replace
the cams.
Camshaft height limit 250
Exhaust: 31.245 mm
Intake: 32.145 mm
Camshaft height limit 300
Exhaust: 31.977 mm
Intake: 32.145 mm
Checking the camshafts and camshaft journals
for wear:
• Measure the clearance between the
camshaft and the camshaft journals using
plastigage [A].
Lubricate the fixing bolts with engine oil and
tighten to the proper torque.
Tightening torque
Camshaft journal mounting bolts: 10 Nm
If any of the measurements are over the limit,
then measure the diameter of each journal.
Camshaft / journal clearance
Standard: 0.020 – 0.062 mm
Limit: 0.15 mm
If the diameter of the journal is below the limit
replace the camshaft and measure again.
Camshaft journal diameter
Standard: 23.05 – 23.25 mm
Limit 23.02 mm
If the clearance is outside of the tolerance
limits, replace the entire cylinder head.
Eccentricity of the camshaft:
Measure the camshaft runout.
If it is out of tolerance, replace the camshaft.
Runout: Less than 0.03 mm
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fezf
Inspect the cylinder head for flatness:
• Place the cylinder head on the
workbench
• Using a precision straight edge [A] and a
feeler gauge check the head for warpage;
check in several places as shown in the photo.
If the warpage is above the limit, repair if
possible. If the damage is severe replace the
head.
Cylinder head warpage:
Limit = 0.05 mm
Visually inspect the timing chain for damage:
Inspect the timing chain by flexing it to
determine if there are any tight spots. If tight
spots are found it should be replaced.
Check the automatic chain adjuster and make
sure that it is not in the last ratchet notch.
Visually inspect the cam tensioner guides:
Visually inspect all of the cam chain tensioner
channel guides and pads including the ones on
the cylinder head cover.
Change as necessary.
Valve - Guide clearance :
Intake :
Mini clearance : 0.02 mm
Maxi clearance : 0.045 mm
Escape:
Mini clearance : 0.04 mm
Maxi clearance : 0.065 mm
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