SHERCO 2014 250 SEF-R, 2014300 SEF-R Workshop Manual

Workshop manual
250 SEF-R 300 SEF-R
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CONTENTS
Forward ......................................................................................................................................................... 3
Motor tools 250 SEF-R and 300 SEF-R .................................................................................................. 4
Technical specification - Motor ................................................................................................................. 5
Technical specification - Frame ................................................................................................................ 6
Standard adjustement – Fork .................................................................................................................... 7
Standard adjustment - Fork Sachs USD Gold Series Ø48MM ............................................................ 7
Standard adjustment - Fork WP USD Gold Series Ø48MM ................................................................ 7
Standard adjustement – Shock absorber ................................................................................................ 8
Standard adjustment - WP Shock absorber ........................................................................................... 8
Operations requiring demounting or not engine ..................................................................................... 9
Removing the motor ................................................................................................................................. 10
Motor top end ............................................................................................................................................. 12
Disassembling the right side ................................................................................................................... 24
Crankcase / Transmission / Central crankcases ................................................................................. 31
Tightening torques .................................................................................................................................... 38
Clean injector body ................................................................................................................................... 40
SYNERJECT )
Injection system instruction manual ............................................................................ 43
1- SYNERJECT ) injection system presentation .................................................................................... 43
2-Software presentation ........................................................................................................................... 50
3- Using the software: .............................................................................................................................. 54
Electrical installation checking ................................................................................................................ 66
Cable diagram ........................................................................................................................................... 68
Injection beam ( 250 SEF-R, see 2013 workshop manual) .................................................................... 68
250 SEF 2014 light system cable diagram .............................................................................................. 70
300 SEF 2014 light system cable diagram .............................................................................................. 71
250 SEF-R 2014 Racing light system cable diagram .............................................................................. 72
300 SEF-R 2014 Racing light system cable diagram .............................................................................. 73
Flasher installation cable diagram ........................................................................................................... 74
Fan cable diagram .................................................................................................................................... 75
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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 250 SEF-R and 300 SEF-R engine.
This workshop manual is a supplement to the SHERCO 250 SEF-R and 300 SEF-R owner’s manual.
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Motor tools 250 SEF-R and 300 SEF-R
Tool ref
Designation
1819
Dead point
1814
Clutch holder tool
4753
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 248.6 CC 303.7 CC Bore/Stroke 76/54.8mm 84/54.8mm Compression ratio 13.2 :1 12.85:1 Fuel Without lead 95 or 98 Valve timing 4 valves, DOHC driven by tooth type chain Admission valve diameter 29mm 30mm 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 10W40 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 X49 13 X 48 Clutch Multi-disk in oil bath. Hydraulic command Ignition system / Batterie Electric start/12V 4Ah Electronic injection Magneti Marelli Synerject
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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 (without fuel) 110 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
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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
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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
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 cool
ant
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
connected to the motor.
Remove the left radiator.
Loosen all of the engine bolts
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.
water hoses
[A].
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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
Motor top end
For additional details refer to the parts catalog
Removing the cylinder head:
Remove the spark plug.
Remove the valve cover
.
Remove the three valve cover screws.
These three screw
s are equipped with
rings ref: 0900.
Remove the cap from the
[A].
Remove the timing control plug
Turn the engine counterclockwise in
order to align the timing marks on the
crankshaft with the marks on the timing gear.
Install the sp
ecial tool that locks the engine at
Top Dead Center [A] (ref 1819)
250 SEF-R _ 300 SEF-R
.
o-
ignition cover.
[A]
A
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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
3
7
5 2
4
6
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 c
ylinder 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
Standard
250 SEF
-
Cylinder diameter (A)
Cylinder diameter (B)
Taper limit
0.05 mm
Out of round limit
Standard
300 SEF
-
Cylinder diameter (A) = 83
Cylinder diameter (B) = 83.982~83
Taper lim
it 0.05 mm
Out of round limit 0.05 mm
4
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R:
= 75.982±0.01 mm = 75.982~77.995 mm
0.05 mm
R:
.982±0.01 mm
.995 mm
1
3
2
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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 250 SEF-R= 75.950±0.005 mm Piston 300 SEF-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
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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
Reassembling the top end of the motor:
Reassemble the piston
Install the piston rings on the piston with
the
end gaps as shown in the photo, the
compression ring goes in the top groove and
the oil control ring goes in the bottom groove.
A Lower expander end gap B Lower piston ring end gap C Upper expander end gap D Upper piston ring gap
The expander rings do n
bottom; however the oil control ring and the
compression ring must be installed with the
« N » mark facing up.
Apply engine oil to the wrist pin internal
bore in the piston.
Carefully
note the piston orientation (the
small cut outs are on
the exhaust side)
Install the locat
ing pins [B].
Install the base gasket [C].
Use special tool number 1821 to
maintain the piston in the correct location [A].
Place one of the cir clips in the special
tool number 2075 as shown in the photo; install
the
clip close to one end of the tool.
Use the tool to set up the clip for
installation on the wrist pin.
Install the cir clip on the wrist pin.
ot have a top or
C
B D
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A
A
C
Install the wrist pin into the piston and
connecting rod using the tool and lightly tapping
with a hammer.
Install the opposite circlip
special tool.
Install the cylinder over the piston using
an appropriate ring compressor.
Install the two cylinder head locating pins
[A].
Install the head gasket [B].
Install the cylinder head.
Install the head bolts noting the different
lengths; tighten them using two passes in the
order shown in the photo.
Install and tighten the two M6 nuts.
Cylinder head torque: Studs 1st pass: 30 Nm 2nd pass: 45 Nm Nuts M6: 10 Nm
The tw
o internal bolts are of different
length and are equipped with washers.
, using the
A
4
2
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B
1
3
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Valve timing:
Verify that tool number 1819 is still properly installed.
Install the intake cam.
Install the exhaust cam.
(see the photo for how to set the timing marks)
Install the camshaft retaining clips.
Apply moly disulfide grease to the
camshafts.
The timing marks should align with the joint
EX (Echappement) IN (Admission)
Install the
camshaft retaining cover. (pay
careful attention to the tightening order).
Camshaft retaining cover torque
10Nm
Install the camshaft chain tensioner
using a new gasket.
Torque the two fixing bolts to:
10Nm
Install the cam tensioner adjusting bolt
(pay attention to the o-ring).
Torque the tensioner adjusting screw to:
10Nm
Remove the special tool number 1819.
Rotate the engine a few times to make
sure that the valve timing is correct.
Finally check the valve timing using the
timing marks.
Replace the cap
that was removed to
install tool number 1819.
Torque the cap to: 8Nm
Replace the spark plug well.
Make sure that the o-
rings are installed on
the spark plug well.
2
6
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1
3
7
5
4
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Apply a thin coat of silicone to the camshaft end cap bores.
Replace the valve cover.
Install the valve cover installation bolts.
Torque the bolts to: 8Nm
Checking the valve clearance:
The valve clearance must be checked when the engine is cold.
Remove the spark plug and the valve cover.
Remove the timing plug from the crankcase.
Install special tool number 1819.
With a feeler gauge measure the
clearance between the bucket and the cam.
Valve clearance Intake 0.15 – 0.20 mm Exhaust 0.20 – 0.25 mm
If the clearance is not correct then change the discs in order to obtain the correct gap.
Remove the discs with a magnet.
Measure the thickness of the disc and
replace with one of the correct thickness.
Select the appropriate disc from the existing parts catalog.
Côté Droit
Replacing the cam chain:
Remove the camshafts (see the cha
on the motor top end).
Remove the clutch cover (see the
chapter on « Right side
» removing the clutch).
Remove the chain tensioner adjuster.
Remove the cam chain.
Inspect the cam chain (see «
inspecting the cam chain »).
Install the cam chain
in the opposite
manner in which it was removed
Reinstall the cam tensioner bolt and
tighten to the correct torque.
Torque the cam tensioner bolt to:
10Nm.
pter
visually
.
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