SHERCO 250 SEF-R Workshop Manual
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SHERCO 250 SEF-R Workshop Manual

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Summary of Contents for SHERCO 250 SEF-R

  • Page 2: Table Of Contents

    CONTENTS FORWARD ..............................3 MOTOR TOOLS 250 SEF-R and 300 SEF-R ...................... 4 TECHNICAL SPECIFICATION ........................5 THE MOTOR ........................5 THE FRAME ........................6 STANDARD ADJUSTMENT .......................... 7 THE FORK ........................7 SHOCK ABSORBER ......................8 OPERATIONS REQUIRING DEMOUNTING OR NOT ENGINE ................9 REMOVING / REINSTALLING THE MOTOR ....................
  • Page 3 250 SEF light system cable diagram ......................... 71 300 SEF light system cable diagram ......................... 72 250 SEF-R Racing light system cable diagram ....................73 300 SEF-R Racing light system cable diagram ....................74 Flasher installation cable diagram ........................75...

  • Page 4: Forward

    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.

  • Page 5: Motor Tools 250 Sef-R And 300 Sef-R

    MOTOR TOOLS 250 SEF-R and 300 SEF-R TOOL 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)

  • Page 6: Technical Specification

    TECHNICAL SPECIFICATION THE MOTOR 250 SEF-R 300 SEF-R 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...

  • Page 7: The Frame

    TECHNICAL SPECIFICATION THE FRAME Frame Semi-perimeter CrMo steel with aluminum subframe SACHS USD Gold Series 48mm dia. (standard) & WP USD Fork 48mm dia. (racing) Rear suspension WP Suspension with separate cylinder Travel Front/Rear 300/330mm Front brake disc Ø 270mm (standard), Ø 256mm (racing) Rear brake disc Ø...

  • Page 8: Standard Adjustment

    STANDARD ADJUSTMENT THE FORK Standard adjustment - Fork Sachs USD Gold Series Ø48MM Turn clockwise to the stop, then Compression back of 12 clicks Turn clockwise to the stop, then Rebound back off 12 clicks Spring 4.5N/mm Fork oil SAE 5 Oil capacity 600cm3 Oil level...

  • Page 9: Shock Absorber

    STANDARD ADJUSTMENT 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...

  • Page 10: Operations Requiring Demounting Or Not Engine

    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 •...

  • Page 11: Removing / Reinstalling The Motor

    REMOVING / REINSTALLING THE MOTOR REMOVING THE MOTOR ATTENTION 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. ...

  • Page 12: Motor

    MOTOR For additional details refer to the parts catalog 250 SEF-R _ 300 SEF-R REMOVING THE CYLINDER HEAD  Remove the spark plug.  Remove the valve cover.  Remove the three valve cover screws. ATTENTION : These three screws are equipped with o-rings ref: 0900.
  • Page 13  Remove the screws from the cam chain tensioner as shown in the photo.  Remove the cam chain tensioner.  Remove the spark plug well.  Remove camshaft bearing journal. Starting inside, remove the screws In a criss cross manner (see the numbers on the photo).

  • Page 14: Motor Top End Controls

     Remove the cylinder head bolts (Be sure to loosen them in the correct direction). ATTENTION : Black bolt N°1 on the picture is longer, 3 bolts are identical.  Remove the cylinder head.  Remove the head gasket and the cylinder.

  • Page 15: Piston Wear

    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...

  • Page 16: Check The Camshafts For Wear

    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...

  • Page 17: Inspect The Cylinder Head For Flatness

    Inspect cylinder head 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.

  • Page 18: Reassembling The Top End Of The Motor

    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.
  • Page 19  Install the wrist pin into the piston and connecting rod using the tool and lightly tapping with a hammer.  Install the opposite circlip, using the special tool.  Install the cylinder over the piston using an appropriate ring compressor. ...

  • Page 20: Valve Timing

    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...
  • Page 21  Install the camshaft retaining cover. (pay careful attention to the tightening order). Camshaft retaining cover torque 10Nm ATTENTION : The screw n°1 is a M6 X 35  Install the camshaft chain tensioner using a new gasket. Torque the two fixing bolts to: 10Nm ...

  • Page 22: Checking The Valve Clearance

    Checking the valve clearance  The valve clearance must be checked when the engine is cold.  Remove the spark plug and the valve cover.  Remove timing plug from crankcase.  Install special tool number 1819.  With a feeler gauge measure the clearance between the bucket and the cam.

  • Page 23: Disassembling The Right Side

    DISASSEMBLING THE RIGHT SIDE For additional details see the parts catalog 250 SEF-R and 300 SEF-R. Clutch dismanting  Install special tool number 1819. ATTENTION : Only this tool disassembling the clutch, do not use it to remove the hub fixing nut.

  • Page 24: Disassembling And Inspecting The Water Pump

     Reinstall the clutch cover, inspect the o-ring and replace if it is damaged. Disassembling and inspecting the water pump  Drain the coolant by removing screw [A].  Remove the screws from the water pump housing.  Remove the water pump impeller using a 10 mm socket.

  • Page 25: Removing The Clutch Hub And The Clutch Basket

    Removing the clutch hub and the clutch basket  Drain the engine oil and the engine coolant.  Remove clutch housing. (see disassembling the right side paragraph)  Remove the clutch. (see clutch removal paragraph)  Remove the clutch release bearing assembly. ...

  • Page 26: Disassembling The Left Side

    10Nm. DISASSEMBLING THE LEFT SIDE For additional details refer to the parts catalog 250 SEF-R and 300 SEF-R. Disassembling the ignition case  Drain the engine oil.  Remove the 10 screws that retain the ignition case.

  • Page 27: Removing The Rotor

    Removing the rotor  Utilize the special rotor holding tool number 4753.  Remove the rotor fixing nut.  Remove the flywheel using special tool number R462.  Remove the two starter shafts along with the starter gears.  Remove the oil centrifuge (anti blowby). ATTENTION : the threads this screw are LH, do not turn the wrong direction ...

  • Page 28: Reassembling The Ignition Case

    Reassembling the ignition case  Install the free wheel gear.  Reinstall the two starter shafts and their gears.  Visually inspect the oil seal on the oil centrifuge.  Use special tool number 1818 to screw the oil centrifuge. Apply thread locker (blue) to the oil centrifuge thread.

  • Page 29: Crankcase / Transmission / Central Crankcases

    CRANKCASE / TRANSMISSION / CENTRAL CRANKCASES Disassembling the transmission and the crankshaft  Remove the engine from the frame (see the engine removal chapter).  Remove the top end (see the top end chapter).  Remove the ignition components (see the ignition chapter).

  • Page 30: Checking The Transmission Components

     Remove the Right side crankcase.  Remove the crankshaft.  Remove the counter balancer assembly.  Remove the shifting fork shafts.  Remove the gear selector drum.  Remove the shift forks.  Remove remaining transmission components. Checking transmission components ...

  • Page 31: Checking The Crankshaft

    Checking the crankshaft Radial play of the big end bearing :  Place the crankshaft in a set of V blocks and install a dial indicator as shown [A].  Push the rod [B] in the direction of the indicator and then push it in the opposite direction.

  • Page 32: Checking The Center Crankcases

    Checking the center crankcases  Inspect the general condition of the center crankcases for wear and cracks. Replace the center crankcase if necessary.  Inspect the condition of all the bearings. Replace the bearings if necessary.  Inspect the condition of the crankshaft bearings.

  • Page 33: Reassembling The Central Crankcase Assembly

    Reassembling central crankcase assembly ATTENTION : During the rebuild, replace all seals (paper, seal, o-ring…).  Install the crankshaft and counter balancer assembly in the left case, align the marks as shown.  Install the transmission gear along with their corresponding shafts.
  • Page 34  On the right hand case make sure the breather jet is in place.  Place the right case on the left case previously fabricated.  Install the 13 screws that retain the two halves together. Torque the 13 center crankcase screws to: 10 Nm.
  • Page 35  Install the special tool that locks the engine at top dead center (ref 1819).  Use tool 1817 to block the transmission ant to tighten balancer nut. Torque balancer threadlocker.  Install the oil pump drive roll pin, the intern rotor and fixing nut to the cover.

  • Page 36: Tightening Torques

    TIGHTENING TORQUES STANDARD TORQUE THREADLOCKER 6 Nm 10 Nm 24 Nm 40 Nm MOTOR TIGHTENING TORQUES THREADLOCKER Magnetic drain plug 15 Nm Drain plug with prefilter 15 Nm Oil filter cover 15 Nm Spark plug (with copper grease) 15 Nm Bolt for bleeding cooling system 6 Nm •...
  • Page 37 FRAME TIGHTENING TORQUES THREADLOCKER Rear wheel axle nut 100 Nm • Aluminium sub frame bolts 24 Nm Front wheel axle nut 40 Nm Front fork / axle boltes / axle M6 15 Nm • Brake pad bolt 8 Nm WP 12 Nm Botton plat fork bolts Sachs 15 Nm WP 17 Nm...

  • Page 38: Clean Injector Body

    CLEAN INJECTOR BODY Material  Minerva Net Carbu or carbu cleaner  Allen keys of 2.5  Screwdriver with 7mm dowel  Wrench of 8 Put down the injector body  Remove the seat  Remove the fuel tank  Remove the injector body clamps ...
  • Page 39  Disconnect each connector  Inspect  Clean with carbu cleaner or universal product cleaner  Blow...

  • Page 40: Clean Of Injector Body

    Clean of injector body  Clean the injector body with Net Carbu  Make sure you clean perfectly the edge of the mixture throttle on each side by opening it completely  Clean the injector Soufflez  Blow Replace the injector body ...

  • Page 41: Synerject ) Injection System Instruction Manual

    INJECTION SYSTEM PRESENTATION 1.1- Your Sherco 300 SEF-R (for 250 SEF-R, refer to the 2013 manual) is equipped with a Synerject injection system that is composed of a M3C computer, a Ø 42mm throttle body, a special ignition system and a special harness.
  • Page 42 Photo 1 : Synerject M3C Computer Photo 2 : Synerject injector body Ø42mm N° DESIGNATION Stepper motor (Idle management and engine braking) Injector TMAP sensor (Air temperature/air pressure) TPS: Butterfly position sensor 1.2- Description- Exxodiag diagnostic tool reference #4967 The diagnostic tool allows you to perform diagnostic operations, make updates to the injection mapping and to determine certain information (serial number of the motorcycle, number of hours of operation, etc.).
  • Page 43 1.4- Installation of the diagnostic too In case of problem during the installation, please contact EXXOTEST at +33 (0)4 50 02 34 34 or by mail to courrier@exxotest.com. A- Installing the software and drivers :  Open the installation CD on your computer ...
  • Page 44  Click « Next »  Click « Install »  Installation is in progress...
  • Page 45  Select « Start installing drivers » and « Finish »  The following window opens. Read the terms of the licence agreement. Select « I accept the terms of the license agreement » and « Install ».  Installation in progress...
  • Page 46  The following window opens. Click « Finish » The installation is complete. B- Connect one end of the "MUXDIAG II" interface cable to a USB port on your computer. Connect the other end to the diagnostic connector on the motorcycle. Check to make sure that the "MUXDIAG II"...

  • Page 47: Software Presentation

    2.1- Connection with Keyless system Sherco had a Keyless system on its motorcycles which allows the bike to switch on without any key and switch off automatically after 30secondes of non-use. This last point blocks the diagnostic, this is why it is necessary to follow the steps down below before doing it.
  • Page 48 Note: In order to establish connection with the bike it must be turned on (ON). To navigate through the various menus only the USB cable with the "MUXDIAG II" box must be connected to the computer. Start the software by using this icon. Go to the following menu: Diagnostic Menu Setup Menu...

  • Page 49: Software Setup : Configuration Menu

    2.2- Software setup : configuration menu In this menu you can change the following:  Taking a diagnostic reading. You can refresh the list by clicking on this button. Le n° doit correspondre au n° du boîtier "MUXDIAG II".  The languages included on the software include: French, English, Spanish, Portuguese, German and Italian (If the CD that you have does not include these languages.

  • Page 50: Menu Update And Synchronization

    2.3- Menu update and synchronization A- With this menu you can update the diagnostic software tool :  To determine if a software update is available, make sure that you have an internet connection and then click this icon.  If an update is available, the following window will appear : ...
  • Page 51  Click on in order to start the download of the update.  The following message will appear:  Click on to start the installation.  Repeat the setup steps -> page 42. It is not necessary to reinstall the drivers.

  • Page 52: Using The Software

     Click on this icon  Complete the following settings if necessary  Click on in order to save your changes USING THE SOFTWARE Diagnostic menu and updating the injection mapping General : Click on « Sherco » Click on « M3C »...
  • Page 53 You get the following menu : A-Identification : You can check the identification of the following (serial number, hours of operation, calibration number) B-Parameter measurements : general parameters (speed, pressure, stepper, etc)
  • Page 54 1-Engine information : Displayed below are the main system values : Details : - Stepper Position: The air valve (stepper) opening value -> 35 < < 75 If the value is too low: there could be an air leak at the engine air intake If the value is too high: there could be dirt in the injector butterfly area Note : The correct air valve motor value should be 15mm and 2mm with the motor idling and at 80°C.
  • Page 55 2-Other less frequently used values appear in the windows : Throttle position : - The adjustment value for the minimum throttle butterfly opening should be (in V): 0.4<0.5V<0.6 Miscellaneous : - Manifold Pressure (mb): pressure at the injector nozzle body measured by the TMAP sensor -Engine synchronization status: engine cycle recognition.
  • Page 56 If a default appears : You can get the details of the default by clicking on the default display : -Record the defaults and exit the menu by clicking on this icon...
  • Page 57 Note : 1- Transient default/permanent default : a transient default becomes permanent after a certain number of engine cycles of the following components (injector, fuel pump, etc). For a permanent default to disappear it takes 40 cycles without the engine default reappearing. 2- Fan Default : If there is no fan installed on the bike, there will always be a rise in the fan default code (P0485) D-Erasing default codes...
  • Page 58 The following screen will appear : Confirm by clicking on this icon 2-Return to the menu « reading default codes » : Check and make sure that the defaults are the same as before. Check/replace the defective parts. Check all of the connections.
  • Page 59 E-Test the actuators In addition to reading default codes you can also check some of the system components : 1-Ignition coil When you launch the ignition coil test, the following message will appear :...
  • Page 60 The system is not able to detect an ignition coil failure with the engine stopped. The test results will be the same if the coil is faulty or not. Therefore, when testing the ignition coil make sure that the engine makes the correct sound for a properly functioning ignition coil. 2-Injector This is the same type of test as with ignition coil.
  • Page 61 Example of a functioning stepper : Stepper default : In the event of a reoccurring default, check/change the defective parts. Note : The fan test is meaningless if the bike is not equipped with a fan.
  • Page 62 F- Updating the computer : By using the diagnostic tool it is possible to make updates to the injection mapping (calibration). An example would be the fitting of a racing silencer or there is an update from the factory. These files will be freely available on sherconetwork (end 2013): You must pay attention to the model, the displacement, the type of silencer, etc.
  • Page 63 5- At the end of the download the fuel pump will start and the following message will appear : INFORMATION : Download was successful Confirm by clicking on this icon 6-Check to make sure that the correct calibration file was allocated by clicking on «...
  • Page 64 G- Screen printing function If you are communicating with technical support and need help identifying potential problems you can perform a screen print operation by pressing F10 on your keyboard. This will allow you to attach these files to your inquiry. The "identification"...

  • Page 65: Electrical Installation Checking

    ELECTRICAL INSTALLATION CHECKING 1- Static values (engine off) Tension battery > 12.5V Stator resistance : 0.44Ω±15% Y1-Y2 Y2-Y3 Y1-Y3 Pick up sensor : 120 Ω±10% Check there is no continuity between stator and the ground of the motorcycle 2- Dynamic values : Pick up sensor : 1.7V MIN/300 tr/min 120V MAX/10000 tr/min...
  • Page 66 Generator : Tolerance on typical values= -5% /+10% VOLTAGE (AC) CURRENT (IB) (DC) 2000 25.0V 2500 15,0 3000 15,6 4000 16,2 5000 16,4 DC 13,5V 6000 16,8A 7000 16,6A 8000 101V 16,7A 9000 114V 16,8A 10000 125V...

  • Page 67: Controls Of The Sensors

    CONTROLS OF THE SENSORS CONTROL TPS SENSOR 1. Remove the injector body from the bike. 2. Control the resistance of the TPS as done below. 3. Values (in kΩ). Butterfly closed : Between + (red) and – (black) : 5 +/- 0.5 Between signal (blue) and –...

  • Page 68: Values Of Temperature Sensor

    VALUES OF TEMPERATURE SENSOR RESIST (K Ω) TEMP (°C) 100.950 53.100 29.121 16.599 9.750 5.970 3.747 3.000 2.547 1.598 1.150 0.746 0.565 0.377 0.275 +100 0.204 +110 0.153 +125 0.102...

  • Page 69: Cable Diagram

    CABLE DIAGRAM Injection beam FONCTION Light harness connector 1010 Electrical starter 1020A Pick up sensor 1020B Generator 1020C Regulator 1042 General Relay 1135 Bobine HT 1211A Fuel pump 1211B Dashboard 1225 Stepper motor 1290 TPS sensor 1303 ECU relay 1310 TMAP sensor 1320 1330...
  • Page 70 Diagram :...
  • Page 71 Geometry :...

  • Page 72: 250 Sef Light System Cable Diagram

    250 SEF light system cable diagram...

  • Page 73: 300 Sef Light System Cable Diagram

    300 SEF light system cable diagram...

  • Page 74: 250 Sef-R Racing Light System Cable Diagram

    250 SEF-R Racing light system cable diagram...

  • Page 75: 300 Sef-R Racing Light System Cable Diagram

    300 SEF-R Racing light system cable diagram...

  • Page 76: Flasher Installation Cable Diagram

    Flasher installation cable diagram...

  • Page 77: Fan Cable Diagram

    Fan cable diagram...

This manual is also suitable for:

300 sef-r

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