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Related Manuals for SHERCO 250 SE-R 2017
Summary of Contents for SHERCO 250 SE-R 2017
- Page 1 MANUEL D’ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER...
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Page 2: Table Of Contents
SUMMARY FOREWORD ................................ 4 ENGINE TOOL LIST FOR USE ............................5 ENGINE SPECIFICATIONS ............................6 ❱❘ Engine ............................6 ❱❘ Chassis ............................7 FACTORY SETTINGS..............................8 ❱❘ Front fork ............................. 8 ❱❘ Rear fork ............................9 OPERATIONS PERFORMED WITH THE ENGINE IN AND OUT OF THE FRAME ..................... 10 REMOVING/INSTALLING THE ENGINE .......................... - Page 3 ❱❘ Disassembly of the exhaust valve system ....................27 ❱❘ Checking the operation of the exhaust valve and the boosters ............... 31 ❱❘ Adjusting the tension of the valve cables ....................33 ❱❘ Reed valves, intake manifold ......................35 ❱❘ Clutch ............................35 REASSEMBLING THE ENGINE .............................
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Page 4: Foreword
This manual is intended primarily for use by trained mechanics in a properly equipped workshop. The various operations require strong mechanical skills and specifi c tools to work on the SHERCO 250 SE-R and SE-R 300 engines. This workshop manual complements the SHERCO 250 SE-R and SE-R 300 manual. 250-300 SE-R... -
Page 5: Engine Tool List For Use
ENGINE TOOL LIST FOR USE ❱❘ On the 250 SE-R and 300 SE-R Tool reference Description Clutch block 5749 5207 Flywheel block 2067 Swingarm tool R467 Tool for the oscillating input shaft bearing housing R465 Secondary shaft bearing tool 5397 Gearbox bearing output shaft tool R446 Gearbox output shaft tool... -
Page 6: Engine Specifications
ENGINE SPECIFICATIONS ❱❘ Engine Type Single cylinder, 2-stroke, liquid cooled Displacement 249,32 CC 293,14 CC Bore/Stroke 66,4/72 mm 72/72 mm Fuel Unleaded gasoline with an octane rating of at least 95 with a (2%) mix of 2-stroke oil Cooling Liquid with forced circulation Ignition system DC-CDI system with digital advance Spark plug... -
Page 7: Chassis
CHASSIS SPECIFICATIONS ❱❘ Chassis Frame Semi-perimeter Cr-Mo steel with an aluminium subframe Fork SACHS USD Série Or Ø48 mm (standard) WP suspension USD Ø48 mm (racing) Rear suspension WP shock with remote cylinder and aluminium control rods Travel Front/Rear 300/330 mm Front brake disc Ø... -
Page 8: Factory Settings
FACTORY SETTINGS ❱❘ Front fork Front fork factory settings – SACHS 48mmØ USD Series Compression 12 clicks back Rebound 12 clicks back Spring stiffness 4.5N/mm Fork oil SAE 5 Quantity of oil per leg 600 cm (20.3 fluid ounces) Oil level (with the fork compressed, and the spring 130 mm (5.12 inches) removed. -
Page 9: Rear Fork
FACTORY SETTINGS ❱❘ Rear fork Factory settings – WP rear suspension unit Low speed Compression Comfort 20 clicks back Standard 15 clicks back Sport 12 clicks back High speed Compression Comfort 2,5 turns back Standard 2 turns back Sport 1,5 turns back Rebound damping Comfort 15 clicks back... -
Page 10: Operations Performed With The Engine In And Out Of The Frame
OPERATIONS PERFORMED WITH THE ENGINE IN AND OUT OF THE FRAME Operations requiring engine Operations that do not require removal engine removal • Crankshaft (including connecting rod) • Transmission - Complete • Crankshaft bearings • Transmission bearings • Piston • Cylinder •... -
Page 11: Removing/Installing The Engine
REMOVING/INSTALLING THE ENGINE ❱❘ Removing the engine CAUTION In order to remove the engine, the swing arm pivot bolt must be removed. This allows the swing arm and the rear wheel assembly to be separated from the bike. To insure that the bike does not fall, support it with a jack. - Drain (See the owner’s manual) •... -
Page 12: Reinstalling The Engine
REMOVING/INSTALLING THE ENGINE ❱❘ Reinstalling the engine The installation of the engine back into the frame should follow in reverse order the way it was removed. Note the torque value of all of the mounting bolts: Engine mounting bolts: 60Nm (44 lb-ft) Swingarm nut: 100 Nm (74 lb-ft) Clutch save cylinder bolts: 10 Nm (7.4 lb-ft) Cylinder head bracket bolts: 23 Nm (17 lb-ft) - Page 13 REMOVING/INSTALLING THE ENGINE - This position of pulley corresponds to valves 100% closed. You can use a wrench 10 to controle. - Tighten the 10 nut. - Start adjusting the lower cable tensioner by unscrewing the 8 nut until it comes against the sleeve stop.
- Page 14 REMOVING/INSTALLING THE ENGINE - Tighten by 1 full turn the 8 nut (1full turn = 1mm). - The measurement between the tensioning cable crimping sleeve and bottom of the cylinder sheath should be 0.5mm minimum, maximum when pulling (WITH STRENGTH) on the cable to the rear of the bike.
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Page 15: Disassembly Of The Engine
DISASSEMBLY OF THE ENGINE Refer to the exploded view in the parts catalog for the 250 SE-R / 300 SE-R ❱❘ Draining the transmission oil - Remove the drain plugs [1] and [2], let the oil drain. ❱❘ Removing the sprocket and the gear selector - Straighten the security tab [3] using a suitable punch. -
Page 16: Removing The Cylinder Head, Cylinder And Piston
DISASSEMBLY OF THE ENGINE ❱❘ Removing the cylinder head, cylinder and piston - Remove the cylinder head mounting bolts [1] the cylinder head and the two o-rings. - Remove the four socket head bolts [3] and the four washers [2] located on the base of the cylinder. -
Page 17: Removing The Clutch
DISASSEMBLY OF THE ENGINE ❱❘ Removing the clutch - Remove the waterpump cover screws and the cover. Remove the seal. - Remove the clutch cover screws and the cover. Remove the seal. ❱❘ Removing the pressure plate and discs - Carefully loosen all of the screws [1] on the pressure plate. - Remove the screws, the springs and the spring cups. -
Page 18: Removing The Electric Starter
DISASSEMBLY OF THE ENGINE - Remove the pressure plate and the discs. - Remove the clutch release bearing assembly [1] located in the primary shaft. ❱❘ Removing the electric starter - Remove the 2 screws [2]. ❱❘ Removing the primary drive gear - Secure the end of the crankshaft gear with the special tool 5206 [3]. -
Page 19: Removing The Interlock Mechanism
DISASSEMBLY OF THE ENGINE - Remove the primary gear and spacer [1] from the crankshaft. CAUTION Note the pin and the seal. The primary drive gear and the clutch hub are matched so they can not be changed separately. They must be replaced as a set. -
Page 20: Removing The Ignition Cover
DISASSEMBLY OF THE ENGINE ❱❘ Removing the ignition cover - Remove the retaining screws, and then remove the ignition cover along with the gasket. ❱❘ Removing the electric starter double gear and the starter drive - Remove the three shoulder bolts [1]. - Remove the double gear retaining bracket [2]. -
Page 21: Removing The Flywheel
DISASSEMBLY OF THE ENGINE ❱❘ Removing the flywheel - Hold the flywheel with special tool #5207 [1] and remove the retaining nut [2]. - Use the extracting tool 5208 [3] and remove the flywheel [4]. ❱❘ Intake manifold and reeds - Remove the four bolts [5]. -
Page 22: Separating The Housing Halves
DISASSEMBLY OF THE ENGINE ❱❘ Separating the housing halves - Turn the engine so that the ignition side is facing you. - Remove all of the screws. - Remove the sealing ring from the output shaft along with the o-ring. - Lift the engine by the left crankcase half and use a small plastic mallet to tap on the gearbox output shaft in order to separate the two... -
Page 23: Removing The Crankshaft
DISASSEMBLY OF THE ENGINE - Remove the primary and secondary gear assemblies from the bearings. ❱❘ Removing the crankshaft - Pull the crankshaft out of the bearing (use a plastic mallet if necessary). - Clean all of the parts and inspect for wear, replace if required. CAUTION In a complete reassembly of the engine, it is best to replace all gaskets, oil seals, o-rings and bearings. -
Page 24: Engine Components
ENGINE COMPONENTS ❱❘ Crankshaft - If you replace the roller bearing it is also necessary to replace the inner ring which is located next to the counterweight. - Heat special tool R464 to approximately 150°C, place it immediately on the inner ring. Allow the heat to penetrate the ring and then carefully remove it. -
Page 25: Lateral Play Of The Connecting Rod
ENGINE COMPONENTS ❱❘ Lateral play of the connecting rod - Measure the side clearance of the connecting rod [A]. Side clearance of the connecting rod: Standard: 0.8 mm - 1 mm Permissible limit: 1.25 mm If the clearance exceeds the permissible limit, replace the crankshaft. -
Page 26: Remanufactured Cylinder
ENGINE COMPONENTS CAUTION If the end gap is greater than the permissible limit, then check the condition of the piston and cylinder. If the piston and cylinder are within the permissible limits, then replace the piston rings. ❱❘ Checking the cylinder for wear - To check the cylinder for wear, use a micrometer to measure the bore. -
Page 27: Disassembly Of The Exhaust Valve System
ENGINE COMPONENTS ❱❘ Disassembly of the exhaust valve system Disassemble all of the parts, clean them and check for wear. To remove the cables, follow the disassembly and reassembly procedure. - Remove the control mechanism protective cover. - Remove the screw from the tab, use a pair of pliers to hold the tab if necessary. - Page 28 ENGINE COMPONENTS - Remove the tab. - Remove the spring. - Remove the control valve. - Remove the other spring. - Remove the control cap and the center screw. 250-300 SE-R...
- Page 29 ENGINE COMPONENTS - Remove the clip and then remove the cap. - Remove the clip from the center shaft. - Remove the booster controls. - Remove the center shaft. Inspect all of the parts (bearings, selas, O-rings), replace if necessary. - Remove the two boosters.
- Page 30 ENGINE COMPONENTS - Slide the ring back and forth. Make sure that the locking mechanism allows the guillotine to move freely. - Clean and remove the scale from all of the parts that have been removed. - Systematically replace the bearings, seals and Orings with new ones.
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Page 31: Checking The Operation Of The Exhaust Valve And The Boosters
ENGINE COMPONENTS ❱❘ Checking the operation of the exhaust valve and the boosters - Rotate the control in a counterclockwise direction as far as it will go. - The guillotine and the two booster valves should be down. - Rotate the control valve clockwise so that the latch is in contact with the cable. - Page 32 ENGINE COMPONENTS - Continue to rotate the control valve clockwise, the second guillotine must begin to return and the boosters must begin to rise. - Complete the rotation of the control valve, both guillotines should be returned and both boosters should be raised. - If the timing is not perfect, loosen the screw.
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Page 33: Adjusting The Tension Of The Valve Cables
ENGINE COMPONENTS ❱❘ Adjusting the tension of the valve cables - Install the tool 4810 on the boosters machining hole. - Install the boosters ont the cylinder machining holes. - Install the main valves and the boosters with the cover (check the good engagement) tighten the M5 screw to 6 Nm. - Page 34 ENGINE COMPONENTS - Loosen the M4 screw of the main valve actuator. - Apply a torque with a 2.5 key counter clockwise sense on the M4 screw, check if the main valves are stop (Full main valves opening), at this moment block the screw at 3 - Check if the boosters are in interaction with the tool spacer (Don’t apply any rotation to the pulley valve).
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Page 35: Reed Valves, Intake Manifold
ENGINE COMPONENTS ❱❘ Reed valves, intake manifold - Over time the carbon reeds can lose their elasticity which will cause a loss of power. - Replace worn or damaged reeds. - Check the condition of the intake manifold; make sure that it is not cracked. ❱❘... -
Page 36: Reassembling The Engine
REASSEMBLING THE ENGINE Refer to the exploded view in the parts catalog for the 250 SE-R / 300 SE-R ❱❘ Crankshaft - Carefully insert the crankshaft assembly into the ball bearing in the RH crankcase until it stops. CAUTION The connecting rod should be in the middle of the cylinder bore. -
Page 37: Assembling The Crankcase Halves
REASSEMBLY THE ENGINE ❱❘ Assembling the crankcase halves - Install the transmission lubrification tube in the right crankcase half. CAUTION Install the tube with the flat side towards the oil filler cap rivet. Install the O-ring on the transmission lubrication tube. - Make sure the locating dowels are in place in the RH case and that the shim washers are installed on the transmission shafts. -
Page 38: Selector Mechanism
REASSEMBLY THE ENGINE ❱❘ Selector mechanism - Place the spring in the housing with the bent portion facing up. - Install the spacer, the locking pin and the washer, apply blue thread locker to the M6X20 bolt and assemble everything. - Hook the spring on the lever. -
Page 39: Clutch And Primary Drive
REASSEMBLY THE ENGINE ❱❘ Clutch and primary drive - Lubricate the seal on the crankshaft. - Install the O-ring seal on the crankshaft and then install the steel spacer with the groove towards the crank. - Insert the half moon key into the crank. - Install the primary gear with the shoulder facing down. -
Page 40: Clutch Discs, Pressure Plate
REASSEMBLY THE ENGINE ❱❘ Clutch discs, pressure plate - Apply oil to the clutch release bearing assembly [1] and install in the primary shaft. - Prior to installation lubricate the friction discs. - Install a friction disc and then alternate, friction/steel until 8 friction and 7 steel discs are installed. -
Page 41: Piston And Cylinder
REASSEMBLY THE ENGINE M6X… ❱❘ Piston and cylinder - Well lubricate all of the parts prior to reassembly. - Install the needle bearing in the connecting rod, install the piston and the piston pin (arrow on top of piston should face forward). - Install the clip with the opening down. -
Page 42: Reed Valves And Intake Manifold
REASSEMBLY THE ENGINE ❱❘ Reed valves and intake manifold - Install a new gasket between the reed valve block and the intake manifold. - Install the reed block on the intake manifold. - Install a new gasket on the intake manifold assembly. -
Page 43: Installing The Flywheel And The Ignition Cover
REASSEMBLY THE ENGINE ❱❘ Installing the flywheel and the ignition cover - Install the half moon in the slot in the crankshaft. - Slide the fl ywheel on the crankshaft. - Apply blue thread locker to the crankshaft threads. - Install the nut and then install special tool 5207, tighten the nut to 60Nm. - Install the two locating dowels. -
Page 44: Tightening Torque Table
TIGHTENING TORQUE TABLE Standard torques Loctite 6 Nm 10 Nm 24 Nm Chassis torques Loctite Rear axle nut 100 Nm • Sub-frame mounting bolts 24 Nm Front axle 40 Nm Front axle pinch bolts 15 Nm • Brake pad mounting bolts 8 Nm Fork triple tree lower pinch bolts WP 12 Nm Sachs 15 Nm... - Page 45 TIGHTENING TORQUE TABLE Engine torques Loctite • Speed sensor screw 8 Nm Coolant drain screw 10 Nm Oil level screw 6 Nm Clutch slave cylinder mounting screws 9 Nm Cylinder head (using a crossing pattern) 25 Nm Crankcase drain plug 8 Nm Clutch pressure plate screws 10 Nm...
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Page 46: Carburetor Setting Table
CARBURETOR SETTING TABLE ❱❘ Carburetor setting table for the SE-R 250: -20°C … -7°C -6°C … 5°C 6°C … 15°C 16°C … 24°C 25°C … 36°C 37°C … 49°C Sea level Temperature 3 000 m Air screw 1T1/2 1T1/2 2T1/2 Pilot jet 2 301 m Needle... -
Page 47: Carburetor Setting Table
CARBURETOR SETTING TABLE ❱❘ Carburetor setting table for the SE-R 300: -20°C … -7°C -6°C … 5°C 6°C … 15°C 16°C … 24°C 25°C … 36°C 37°C … 49°C Sea level Temperature 3 000 m Air screw 1T1/2 1T1/2 2T1/2 Pilot jet 2 301 m Needle... -
Page 48: Checking The Charging System
CHECKING THE CHARGING SYSTEM ❱❘ Static control values (engine off) 250 SE-R/300 SE-R - Battery voltage > 12.5V - Resistance value of the stator windings: Measure the resistance between each winding. 0.46Ω±20% (à 20°C) Y1-Y2 Y2-Y3 Y1-Y3 Check to make sure that there is no continuity between the windings and the mass of the bike. - Resistance at the Pick UP sensor (Speed sensor): Red ~ Green 100 Ω±20% (at 20°C) - High tension coil... -
Page 49: Wiring Diagrams
WIRING DIAGRAMS ❱❘ Main harness 6517... - Page 50 WIRING DIAGRAMS 250-300 SE-R...
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Page 51: Lighting Harness 250 Se-R/300 Se-R
WIRING DIAGRAMS ❱❘ Lighting harness 250 SE-R/300 SE-R... -
Page 52: Lighting Harness - Racing 250 Se-R/300 Se-R
WIRING DIAGRAMS ❱❘ Lighting harness - Racing 250 SE-R/300 SE-R 250-300 SE-R... -
Page 53: Wiring Harness - Accessories
WIRING DIAGRAMS ❱❘ Wiring harness - accessories...