Sherco 250-se workshop manual

TECHNICAL SPECIFICATION

FOREWORD ........................................................ 2

TOOLS LIST 250-300 SE ........................................ 3

TECHNICAL SPECIFICATION ............................. 4

ENGINE ............................................................... 4

CARBURETOR .................................................. 4

CYCLE PART ....................................................... 5

STANDARD ADJUSTMENT ................................. 6

FORK .................................................................. 6

SHOCK ABSORBER ............................................. 7

OPERATIONS REQUIRING DISASSEMBLY OR NOT

ENGINE ............................................................... 8

REMOVING THE ENGINE ................................. 9

REASSEMBLING THE ENGINE IN THE FRAME

........................................................................ 9

DISMANTLING THE ENGINE .......................... 10

❱❘ Gear box drainage ................................................. 10

❱❘ Removing the pinion and selector .......................... 10

❱❘ Removing the cylinder head / the cylinder / the

piston ......................................................................... 11

❱❘ Removing the clutch housing ................................. 12

❱❘ Removing the pressure plate and discs ................. 13

❱❘ Remove the electric starter .................................... 13

❱❘ Removing the primary transmission ....................... 14

❱❘ Removing the primary transmission ....................... 15

❱❘ Removing the torque limiter and the starter drive .. 15

❱❘ Removing the ignition ............................................. 16

❱❘ Intake pipe and valve box ...................................... 16

❱❘ Remove the gear selection .................................... 17

❱❘ Removing the connecting rod assembly ................ 18

❱❘ Connecting rod assembly ....................................... 18

CHECKING ENGINE COMPONENTS ............. 19

❱❘ Balance weight, checking the external dimensions 19

❱❘ Radial play of the connecting rod head .................. 19

❱❘ Checking the crankshaft run out ............................ 19

❱❘ Piston ..................................................................... 20

❱❘ Gap spacing ........................................................... 20

❱❘ Piston pin check ..................................................... 20

❱❘ Checking the wear condition of the cylinder .......... 20

❱❘ Functional check .................................................... 21

❱❘ Valve stop learning after cylinder reassembly ....... 24

❱❘ Valve box intake pipe sleeve .................................. 24

❱❘ Clutch ..................................................................... 25

❱❘ Gearbox .................................................................. 25

❱❘ Valve box and intake pipe ...................................... 33

❱❘ Gearbox output pinion............................................ 33

❱❘ Starter drive assembly ........................................... 33

❱❘ Mounting the ignition and its cover ........................ 34

❱❘ Mounting the electric starter .................................. 34

SYNERJECT) INJECTION SYSTEM

INSTRUCTION MANUAL .................................... 35

INTRODUCTION SYNERJECT SYSTEM ......... 35

1.1- Synerject system .............................................. 35

1.2- Description Exxodiag diagnostic .................. 35

1.3- Diagnostic tool kit contents. ........................... 36

1.4- Installation of the diagnostic tool ................... 36

PRESENTATION OF THE SOFWARE ............. 40

2.1- Connection with Keyless system ................... 40

2.2-

Software settings: configuration menu

2.3- Update menu and synchronization ................ 43

3 - Using

3.1- Identification ..................................................... 45

3.2- Reading the default codes .............................. 46

3.3- Erasing default codes ...................................... 48

3.4- Test the actuators ............................................ 49

3.5- Updating the ECU ............................................. 51

3.6- Screen printing function.................................. 53

TORQUES TABLE ........................................... 54

CARBURETOR ADJUSTEMENT TABLE ........ 55

❱❘ SE 250-Carburetor adjustments table ................... 55

❱❘ SE 300-Carburetor adjustments table ................... 56

CHECKING THE LOAD CIRCUIT .................... 57

❱❘ Static control value ................................................. 57

❱❘ Dynamic control values .......................................... 57

the software

.............................................. 45

.................... 42

T° SENSOR, ENGINE RPM SENSOR, HIGH

VOLTAGE COIL ............................................... 58

WIRING DIAGRAM .......................................... 59

❱❘ Main harness .......................................................... 59

❱❘ Standard lights harness .......................................... 60

❱❘ Racing lights harness .............................................. 61

❱❘ Accessories harness ................................................ 62

REASSEMBLING THE ENGINE ...................... 27

❱❘ Assembling the half crankcases ............................. 27

REASSEMBLING THE ENGINE ...................... 28

❱❘ Gear selection mechanism ..................................... 28

❱❘ Primary transmission and clutch ............................ 29

❱❘ Clutch discs, pressure plate ................................... 30

❱❘ Clutch housing........................................................ 30

❱❘ Piston and cylinder ................................................. 31

❱❘ Squish table ............................................................ 32

❱❘ Cylinder head ......................................................... 32

FOREWORD

This manual is primarily intended for qualified mechanics working in a properly equipped workshop.

A solid knowledge of mechanics and the specific SHERCO tools for the 250 SE-R and 300 SE-R engines are required to perform the various operations.

This workshop manual complements the SHERCO 250 SE-R and 300 SE-R user manual

TOOLS LIST 250-300 SE

Tool reference Designation

5749 Clutch block

4753 Ignition block

2067 Swing-arm pin tool

R467 Right crankcase primary shaft bearing tool

R465 Secondary shaft bearing tool

5397 Gearbox output shaft bearing tool

R446 Gearbox output spi tool

5398 Barrel selection bearing tool

5399

R469 Right crankcase crankshaft bearing tool

Left crankcase crankshaft bearing tool

5400

5401

5402

1968

1821

5206

2073

R462

R464

R453

R444

Clutch side crankshaft spi tool

Ignition side crankshaft spi tool

HK0808 needle cage tool (water pump, starter drive double pinion, starter drive)

Water pump spi seal tool

Engine support

Primary pinion block tool

Spring block (pin selection)

Magnetic flywheel puller

Crankshaft ring extractor

Selector axis bearing assembly tool

Selector spi seal tool

6267

4967

Diagnostic Key less tool

Diagnostic briefcase

250/300 SE

TECHNICAL SPECIFICATION

ENGINE

Type Capacity Bore/Stroke

Petrol

Cooling Ignition system

Spark plug

Distance between spark plug electrodes

Piston

Engine oil Primary transmission Gearbox : 6 speeds 1st 14 : 32 2nd 15 : 26 3rd 29 : 27 4th 21 : 24 5th 23 : 22 6th 25 : 21 Final transmission Clutch Starter Battery

249.32 CC

66.4/72 mm

Cast aluminum

750 ml SAE 10W40

27 : 75

Oil bathed multi disks, hydraulic control

Electric starter

12V 4Ah

Unleaded with an octane rating of at least 98 mixed with 2-

250 300

Single cylinder 2 stroke liquid cooling

stroke oil (2 %)

Liquid with forced circulation

Synerject electronic ignition

NGK BR7ES/DENSO W22ESRU

0.7 mm

14 X 49

293.14 CC

72/72 mm

Alternator

220W

CARBURETOR

Carburetor type Needle position Jet needle Main jet Idle jet Choke jet Air regulating screw

opening Valve spacing

KEA 162 (KEA 115) KEA 172 (KEA 115)

KEP 40 (KEA38) KEP 42 (KEA 38)

85 (50) 85 (50)

3rd position from the top

N°7 N°7

KEIHIN PWK 36S AG KEIHIN PWK 36S AG

250 300

3rd position from the top

N1EG (N84K) N8RE (N84K)

1T 1/4 1T 1/2

TECHNICAL SPECIFICATION

Frame

Semi

perimeter CrMo

steel with aluminum sub frame

Angle of the steering column

CYCLE PART

Fork

Rear suspension

Travel Front/Rear FACTORY 330/330mm

Front brake rotor Ø 260mm

Rear brake rotor Ø 220mm

Brake disc Limit : 2.7mm front et 3.6mm rear

Front tire 90/90-21’’

Rear tyre 140/80-18’’

Pressure front / Rear 0.9 bar

Fuel tank capacity 10.4Ll with1 liter of reserve

Wheel base 1480mm

KAYABA USD Ø48mm Closed cartridge(FACTORY)

WP XPLOR USD Ø48mm (RACING)

KAYABA suspension with separate cylinder (FACTORY)

WP suspension with separate cylinder (RACING)

Aluminum swing arm

RACING 300/330mm

27.3°

Weight (without fuel) 119 kg

250/300 SE

STANDARD ADJUSTMENT

Compression

Rebound

Spring

Fork oil

Compression

Rebound

Preload

Spring stiffness

Type of oil

Spring length with preload spacer

Quantity of oil

FORK

Factory settings

Racing settings

– Fork KAYABA USD Ø48 mm

Comfort 20 clicks back

Standard 13 clicks back

Sport 8 clicks back

Comfort 18 clicks back

Standard 13 clicks back

Sport 10 clicks back Rider weight Rider weight

Rider weight

01M 345 CC

– Fork WP XPLOR suspension USD Ø48mm

Comfort 18 clicks back

Standard 15 clicks back

Sport 12 clicks back

Comfort 18 clicks back

: 65-75 kg 4.0N/mm (Original) : 75-85 kg 4.2N/m

: 85-95 4.4N/m

Standard 15 clicks back

Sport 12 clicks back

Comfort +0 tours

Standard +0 tours

Sport +6 tours

Rider weight

Oil level measurement (fork compressed and spring removed) from the top of the fork tube

: 65 - 75 kg 4.2N/mm

: 75 - 85 kg 4.4N/mm (Original)

: 85 - 95 kg 4.6N/mm

SAE 4

474 mm

606ml

100mm (min30-max 120 mm)

Low

speed compression

High

speed compression

Rebound

Spring stiffness

Low

speed compression

High

speed compression

Rebound

Spring stiffness

STANDARD ADJUSTMENT

SHOCK ABSORBER

Factory Settings

– KAYABA shock absorber

Comfort 20 clicks back

Standard 14 clicks back

Sport 12 clicks back

Comfort 2,5 turns back

Standard 1.5 turns back

Sport 1 turn back

Comfort 15 clicks back

Standard 13 clicks back

Sport 11 clicks back

Type of oil

Racing Settings

Rider weight : 65-75 kg

Rider weight : 75-85 kg

Rider weight : 85-95 kg

K2C

– WP suspension shock absorber

Comfort 17 clicks back

Standard 12 clicks back

Sport 9 clicks back

Comfort 2 turns back

Standard 1.5 turns back

Sport 1 turn back

Comfort 16 clicks back

Standard 14 clicks back

50N/mm

46N/mm

48N/mm (original)

Sport 12 clicks back

Rider weight : 65-75 kg

Rider weight : 75-85 kg

Rider weight : 85-95 kg

250/300 SE

51N/mm

54N/mm (original)

57N/mm

OPERATIONS REQUIRING DISASSEMBLY OR NOT ENGINE

Operation requiring engine

Operation not requiring engine

Crankshaft

(including

the crank

Complete gearbox

Crankshaft bearing

Gearbox bearing

Piston

Cylinder

Cylinder head

Ignition

Starter gear set

Complete clutch

Water pump

Speed selection assembly

kit)

removal

•

removal

•

REMOVING / REISTALLING THE ENGINE

WARNING

REMOVING THE ENGINE

To remove the engine, you must remove the swing arm's pivot bolt to detach the rear wheel/swing arm assembly. Secure the chassis with a jack to prevent the motorcycle

from overturning.

• Drain (refer to the owner’s 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 carburetor.

• Remove the chain.

• Remove the chain guard.

• Remove the clutch slave cylinder.

When the clutch slave cylinder is removed, the piston is no longer held in place. Secure

the piston with a plastic collar.

• Remove all of the water hoses connected to the engine.

• 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 engine mounting bolts.

• Remove the swing arm bolt.

• Remove the motor.

REASSEMBLING THE ENGINE IN THE FRAME

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:

Engine mounting bolts: 60Nm Swing arm axle nut: 100 Nm Clutch receiver screws: 10 Nm Cylinder head bracket bolts: 23Nm Exhaust mounting bolts: 10Nm

250/300 SE

DISMANTLING THE ENGINE

❱❘ Gear box drainage

• Remove drainage plugs

oil

flow out.

[1]

and

[2],

let the

❱❘ Removing the pinion and

selector

•

Unfold the safety washer tab device.

•

Remove the gearbox output pinion

•

Remove the screw first the selector.

•

Release the clutch control rod.

[3]

using a punch

[5]

first and then

[4].

DISMANTLING THE ENGINE

❱❘ Removing the cylinder head / the cylinder / the piston

•

Remove the shoulder screws cashers, remove two O-rings

the cylinder head and the

[1]

the copper

•

Remove the exhaust valve actuator

• Remove the exhaust chamber cover.

• Remove the 4 screws

• The cylinder and remove it.

• Mask the cover.

[4]

on the base of

[2]

250/300 SE

DISMANTLING THE ENGINE

• Remove the piston pin clips.

• Remove the piston pin.

• Remove the piston and extract the needle

bearing from the connecting rod.

•

Remove the gasket

❱❘ Removing the clutch housing

•

Remove the screws and the water pump cover.

•

Remove the gasket

• Remove the screws and extract the clutch housing.

• Remove the gasket

DISMANTLNG THE ENGINE

3 2

❱❘ Removing the pressure plate and discs

• Loosen the pressure plate screws

• Remove the screws, springs and springs

cups.

• Remove the pressure plate and discs from housing.

• Remove the support part shaft

[1]

on the primary

❱❘ Remove the electric starter

• Remove the 2 screws

[2]

250/300 SE

DISMANTLING THE ENGINE

WARNING

housing ring

❱❘ Removing the primary transmission

• Lock the pinion at the end of the crankshaft with the 5206 tool

[3]

• Unscrew the primary transmission nut and then remove it with its conical washer

• Open the clutch boss lock washer

• Apply the 5749 tool

hold the boss, then loosen the nut.

• Remove the tool.

• Remove the boss the crenellated washer,

the housing with 2 needle cages

[6]

which is designed to

[5]

[4]

• Removing the primary transmission pinion and the spacer

crankshaft

To the pin and the o-ring.The primary

transmission pinion and the clutch

are paired, which is why they can not be

changed separately. Always replace them

[1]

together.

at the end of the

DISMANTLING THE ENGINE

❱❘ Removing the primary transmission

• Remove the screws and extract the ignition housing with its gasket

❱❘ Removing the torque limiter and the starter drive

• Remove the 3 shoulder screws [1]

• Remove the torque limiter lug [2]

• Remove the starter drive [3]

• Remove the torque limiter [4]

250/300 SE

DISMANTLING THE ENGINE

2 1

❱❘ Removing the ignition

•

Hold the flywheel with the 4753 tool unscrew the shoulder nut.

•

Position the R462 puller magnetic wheel

[3]

[2]

and extract the

[1]

and

❱❘ Intake pipe and valve box

• Remove the 4 THEP screws

• Remove the pipe, the valve box, and their

respective gasket.

[4]

DISMANTLING THE ENGINE

WARNING

1 2

WARNING

•

Separate the half crankcases.

•

Tilt the engine so that the ignition side is facing you.

•

Remove all the fixing screws.

•

Remove the seal ring and its o-ring from the gearbox output shaft.

•

Lift the left half crankcase by lightly tapping the gearbox output shaft with a plastic mallet to separate it from the other half.

•

Remove the half crankcase and the central gasket

between the half housings to separate

them should be avoided as much as

possible. You may damage the gasket

Prizing a screwdriver or other tool

surfaces.

Pay attention to the gearbox shafts' set

rings. They can remain stuck inside the

housing

❱❘ Remove the gear selection

• Remove the gearbox lubrication tube ,

• Remove the set ring from the primary shaft

[2]

• Remove the two pin from the shift forks [3] and push the shift forks to the side to release tem from the cylinder

• Remove the selection cylinder from its bearing

• Remove the shift forks

• Remove the primary and secondary shaft

from their bearing together.

When dismantling, take care not to lose

the small rollers

identify which is the corresponding fork

for each roller to facilitate reassembly

[4]

on the fork studs

250/300 SE

+ 46 hidden pages