SHERCO 250 SE-R Workshop Manual
  1. Manuals
  2. Brands
  3. SHERCO Manuals
  4. Motorcycle
  5. 250 SE-R
  6. Workshop manual

SHERCO 250 SE-R Workshop Manual

Hide thumbs Also See for 250 SE-R:
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for SHERCO 250 SE-R

Summary of Contents for SHERCO 250 SE-R

  • Page 5: Table Of Contents

    TECHNICAL SPECIFICATION FOREWORD ............2 ❱❘ Valve box and intake pipe ........33 ❱❘ Gearbox output pinion..........33 TOOLS LIST 250-300 SE ........3 ❱❘ Starter drive assembly ........... 33 TECHNICAL SPECIFICATION ......4 ❱❘ Mounting the ignition and its cover ......34 ENGINE ...............

  • Page 6: 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...

  • Page 7: Tools List 250-300 Se

    TOOLS LIST 250-300 SE Tool reference Designation Clutch block 5749 4753 Ignition block 2067 Swing-arm pin tool Right crankcase primary shaft bearing tool R467 R465 Secondary shaft bearing tool 5397 Gearbox output shaft bearing tool R446 Gearbox output spi tool 5398 Barrel selection bearing tool Left crankcase crankshaft bearing tool...

  • Page 8: Technical Specification Engine

    TECHNICAL SPECIFICATION ENGINE Single cylinder 2 stroke liquid cooling Type 249.32 CC 293.14 CC Capacity 72/72 mm Bore/Stroke 66.4/72 mm Unleaded with an octane rating of at least 98 mixed with 2- Petrol stroke oil (2 %) Liquid with forced circulation Cooling Synerject electronic ignition Ignition system...

  • Page 9: Cycle Part

    TECHNICAL SPECIFICATION CYCLE PART Semi-perimeter CrMo steel with aluminum sub frame Frame KAYABA USD Ø48mm Closed cartridge(FACTORY) Fork WP XPLOR USD Ø48mm (RACING) KAYABA suspension with separate cylinder (FACTORY) Rear suspension WP suspension with separate cylinder (RACING) Aluminum swing arm FACTORY 330/330mm Travel Front/Rear RACING 300/330mm...

  • Page 10: Standard Adjustment Fork

    STANDARD ADJUSTMENT FORK Factory settings – Fork KAYABA USD Ø48 mm Comfort 20 clicks back Compression Standard 13 clicks back Sport 8 clicks back Rebound Comfort 18 clicks back Standard 13 clicks back Sport 10 clicks back Spring Rider weight: 65-75 kg 4.0N/mm (Original) Rider weight: 75-85 kg 4.2N/m...

  • Page 11: Shock Absorber

    STANDARD ADJUSTMENT SHOCK ABSORBER Factory Settings – KAYABA shock absorber Low-speed compression Comfort 20 clicks back Standard 14 clicks back Sport 12 clicks back High-speed compression Comfort 2,5 turns back Standard 1.5 turns back Sport 1 turn back Rebound Comfort 15 clicks back Standard 13 clicks back...

  • Page 12: Operations Requiring Disassembly Or Not Engine

    OPERATIONS REQUIRING DISASSEMBLY OR NOT ENGINE Operation requiring engine Operation not requiring engine removal removal Crankshaft (including the crank • kit) Complete gearbox • • Crankshaft bearing • Gearbox bearing Piston • Cylinder • • Cylinder head • Ignition Starter gear set •...

  • Page 13: Removing The Engine

    REMOVING / REISTALLING THE ENGINE REMOVING THE ENGINE WARNING 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) •...

  • Page 14: Dismantling The Engine

    DISMANTLING THE ENGINE ❱❘ Gear box drainage [2], • Remove drainage plugs let the oil flow out. ❱❘ Removing the pinion and selector • Unfold the safety washer tab using a punch device. [4]. • Remove the gearbox output pinion •...

  • Page 15: Removing The Cylinder Head / The Cylinder / The Piston

    DISMANTLING THE ENGINE ❱❘ Removing the cylinder head / the cylinder / the piston • Remove the shoulder screws the copper cashers, remove the cylinder head and the two O-rings • Remove the exhaust valve actuator Remove the exhaust chamber cover. •...

  • Page 16: Removing The Clutch Housing

    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 •...

  • Page 17: Removing The Pressure Plate And Discs

    DISMANTLNG THE ENGINE ❱❘ 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 on the primary shaft ❱❘...

  • Page 18: Removing The Primary Transmission

    DISMANTLING THE ENGINE ❱❘ Removing the primary transmission • Lock the pinion at the end of the crankshaft with the 5206 tool • Unscrew the primary transmission nut and then remove it with its conical washer • Open the clutch boss lock washer •...

  • Page 19: Removing The Primary Transmission

    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] •...

  • Page 20: Removing The Ignition

    DISMANTLING THE ENGINE ❱❘ Removing the ignition Hold the flywheel with the 4753 tool • unscrew the shoulder nut. Position the R462 puller and extract the • magnetic wheel ❱❘ Intake pipe and valve box • Remove the 4 THEP screws •...

  • Page 21: Remove The Gear Selection

    DISMANTLING THE ENGINE 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 •...

  • Page 22: Removing The Connecting Rod Assembly

    DISMANTLING THE ENGINE ❱❘ Removing the connecting rod assembly Remove the connecting rod assembly from its bearing (if necessary by tapping lightly with a plastic mallet • on the end of the crankshaft). Clean all parts and check for wear. Replace if necessary. •...

  • Page 23: Checking Engine Components

    CHECKING ENGINE COMPONENTS ❱❘ Balance weight, checking the external dimensions • Use a caliper to measure the external distance of the balance weights: External value : 64.3mm +0 / -0.2 64.3 ❱❘ Radial play of the connecting rod head • Position the crankshaft on the V and place a dial gauge [A] against the connecting rod head.

  • Page 24: Piston

    CHECKING ENGINE COMPONENTS ❱❘ Piston • If you want to install a used piston, check the following points : • Skirt : look for any marks (tightening). Light marks can be removed with a soft stone. • Segment grooves : Segments must not get stuck in their groove. These can be cleaned with an old segment or emery cloth (400 grit).

  • Page 25: Functional Check

    CHECKING ENGINE COMPONENTS [6]. Remove the valve cover • [12]. Remove the actuator support • [10] Remove the stop screw with the • [9]. copper sealing washer Remove the bore circlip with circlip pliers • [29]. Remove the valve mechanism assembly •...
  • Page 26 CHECKING ENGINE COMPONENTS WARNING When reassembling the actuator support [12], be careful that the 2 screws are not the same lengt After reassembly, check the lateral play of • the central valve minimum 0.1 mm Check that the pin stops against the valve •...
  • Page 27 CHECKING ENGINE COMPONENTS WARNING In the following cases the valve must not reach the stopper during opening and closing • Check the lateral play of all the mechanics minimum 0.1 mm 250/300 SE...

  • Page 28: Valve Stop Learning After Cylinder Reassembly

    ❱❘ Valve stop learning after cylinder reassembly WARNING After any maintenance operation on the internal parts of the cylinder and/or after changing the cylinder, the Sherco diagnostic tool's machine learning application must be run (see p63 diagnostic tool chapter). ❱❘ Valve box intake pipe sleeve Over time the carbon tabs gradually lose •...

  • Page 29: Clutch

    The 7 smooth disks must be in good condition with a maximum deformation limit of 0.05 mm. • Refer to the 250 SE-R/300 SE-R spare parts catalogue for exploded views ❱❘ Gearbox Apply grease to the shift fork studs and •...
  • Page 30 CHECKING ENGINE COMPONENTS WARNING A used fork must have its original pinion and its rollers Attach the forks in the grooves of the sliding • gears and push the barrel into its ball bearing. Oil the fork shafts and thread them into the •...

  • Page 31: Reassembling The Engine

    REASSEMBLING THE ENGINE ❱❘ Assembling the half crankcases Assemble the gearbox lubrication tube on the right half crankcase • WARNING Pay attention to the tube indexing, flat section near oil cap rivet. • Fit the o-ring onto the gearbox lubrication tube. •...

  • Page 32: Reassembling The Engine

    REASSEMBLING THE ENGINE ❱❘ Gear selection mechanism Put the spring in the crankcase with the • strand bent upwards. Thread the spacer, the locking pin the • washer, coat the CHC M6X20 screw with blue threadlock and assemble all parts. Attach the spring to the lever.

  • Page 33: Primary Transmission And Clutch

    REASSEMBLING THE ENGINE ❱❘ Primary transmission and clutch Grease the connecting rod assembly seal. • Thread the previously oiled o-ring onto the • connecting rod assembly, then fit the steel spacer with the groove on the same side as the balance weight. Install the half-moon pin in its housing.

  • Page 34: Clutch Discs, Pressure Plate

    REASSEMBLING THE ENGINE ❱❘ Clutch discs, pressure plate • Oil the push pin [1] and thread it onto the primary shaft. • Before assembly oil the clutch plates. • Start with clutch plate. The 8 clutch discs and the 7 smooth discs are alternated. •...

  • Page 35: Piston And Cylinder

    REASSEMBLING THE ENGINE ❱❘ Piston and cylinder Oil the parts thoroughly before reassembling. • Thread the needle bearing into the small • end, position the piston (the arrow on the top of the piston in the direction of the exhaust). Position the shaft and the clips with the open •...

  • Page 36: Squish Table

    REASSEMBLING THE ENGINE ❱❘ Squish table Squish, Standard = 1.7±0.1 mm (Set back of piston = -0.05mm) Measurement of piston's overrun Squish 1st Thickness of Sherco or set back (-) (X mm) measurement gasket to have reference 0.5 mm gasket a 1.7 mm...

  • Page 37: Valve Box And Intake Pipe

    REASSEMBLING THE ENGINE ❱❘ Valve box and intake pipe Place a new valve box gasket. • Put the complete valve box in the intake • duct. Install a new intake pipe gasket. • Assemble the intake pipe with the 4M6 •...

  • Page 38: Mounting The Ignition And Its Cover

    REASSEMBLING THE ENGINE ❱❘ Mounting the ignition and its cover Put the half moon pin in its housing on the crankshaft. • Thread the rotor onto the crankshaft. • Put blue threadlock on the thread. • Using the 5207 tool, put on the nut and tighten to 60Nm. •...

  • Page 39: Synerject ) Injection System Instruction Manual

    1.2- Description Exxodiag diagnostic Tools référence 4967 Your Sherco 250 SE-R and 300 SE-R is equipped with a Synerject electronic management system consisting of an M3C controller, an ignition, an engine actuator, a high voltage coil, a water temperature sensor and a specific electrical harness...

  • Page 40: Diagnostic Tool Kit Contents

    INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT 1.3- Diagnostic tool kit contents. The case consists of a USB to MUX output cable, a MUX peripheral device, a MUX to motorcycle diagnostic connector cable, an installation CD (or the link below), a user manual 1.4- Installation of the diagnostic tool In case of problem during the installation please contact EXWOTEST at +33 (0)4 50 02 34 34 or by...
  • Page 41 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT • Click on « Next ». • Click on « Install ». • Installation in progress. 250/300 SE...
  • Page 42 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT • Check the box « Start the driver installation » and click on « Finish ». • The following window will open. Read the terms of the license agreement. Check the box « I accept the terms of the license agreement » and click on «...
  • Page 43 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT • The following window will open. Click on « Finish ». The installation is complete B- Connect the « MUXDIAG II » cable and its interface to a USB port on your computer Connect the cable to the diagnostic connector of the motorcycle. Make sure the «...

  • Page 44: Presentation Of The Sofware

    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 45 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT Information: To set up the connection with the motorcycle, the motorcycle must be switched on (On). To navigate through the different menus, the USB cable with the «MUXDIAG II» device only may be connected to the computer. Run the software using the icon The following menu will come up Update and...

  • Page 46: Software Settings: Configuration Menu

    INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT Software settings: configuration menu 2.2- In this menu, you can modify: The diagnostic plug. You can refresh the list by hitting the button. • The number must match the number of the « MUXDIAG II » device.

  • Page 47: Update Menu And Synchronization

    INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT 2.3- Update menu and synchronization A- In this menu, you can update the diagnostic software tool • To determine whether an update is available, check that you have an Internet connection, and then click on the following icon •...
  • Page 48 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT • Click on to start downloading the update. • The following message will come up • Click on to start installation • Resume the installation process -> page 41. It is not necessary to restart the installation of the drivers B- Configuration of Internet access parameters It may be necessary to set up a proxy server to access the Internet •...

  • Page 49: Using The Software

    SYNERJECT Using the software Diagnostic menu and injection mapping update General • Click on « Sherco ». • Click on « M3C ». • You get the following menu Identification You can check the identification of the following (serial number, hours of operation,...

  • Page 50: Reading The Default Codes

    INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT A. Parameter measurements General parameters B. Engine information Displayed below are the main system values Reading the default codes When you click on "read default codes” the system starts checking. • If no default appears exit the menu by clicking on this icon:...
  • Page 51 SYNERJECT INJECTION SYSTEM INSTRUCTION MANUAL 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 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).

  • Page 52: Erasing Default Codes

    SYNERJECT INJECTION SYSTEM INSTRUCTION MANUAL Erasing default codes If a default appears: go to the menu « Erasing default codes » Click this icon in order to erase all of the default codes The following screen will appear: Confirm by clicking on this icon...

  • Page 53: Test The Actuators

    SYNERJECT INJECTION SYSTEM INSTRUCTION MANUAL 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. 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 250/300 SE...
  • Page 54 SYNERJECT INJECTION SYSTEM INSTRUCTION MANUAL 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.

  • Page 55: Updating The Ecu

    SYNERJECT INJECTION SYSTEM INSTRUCTION MANUAL Updating the ECU 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: You must pay attention to the model, the displacement, the type of silencer, etc In case of doubt, contact technical support.
  • Page 56 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT Confirm by clicking on this icon Select the calibration file (.mot) that was previously downloaded and click open. 4. The file is being downloaded WARNING DO NOT TURN OFF THE MOTORCYCLE DURING THE DOWNLOAD OPERATION (FLASH) DO NOT ABRUPTLY STOP THE FLASH DOWNLOAD PROCESS THERE IS A RISK OF IRREPAIRABLE DAMAGE TO THE COMPUTER 5.

  • Page 57: Screen Printing Function

    INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT Information: the information on serial number and operating hours are not reset during a calibration update. 7. Put back the “shunt” on the connector in the air filter box to switch back on “keyless” mode. 8.

  • Page 58: Torques Table

    TORQUES TABLE Standard tightening torque Threadlock 7 Nm 10 Nm 25 Nm Chassis tightening torque Threadlock Rear wheel nut 100 Nm Rear cradle fixing screw 24 Nm • Front wheel nut 40 Nm Fork end pinch screw 15 Nm Brake pad pin screw 8 Nm •...

  • Page 59: Carburetor Adjustement Table

    CARBURETOR ADJUSTEMENT TABLE ❱❘ SE 250-Carburetor adjustments table Sea level Temperature -20°C -6°C 6°C 16°C 25°C 37°C 15°C 24°C 36°C 49°C -7°C 5°C 3.000 m Air screw 1T1/4 1T3/4 1T3/4 2T1/4 2T1/4 adjustment 2.301 m Idle jet N1EG N1EG N1EH N1EH N1EI Needle...

  • Page 60: Se 300-Carburetor Adjustments Table

    CABURETOR ADJUSTEMENT TABLE ❱❘ SE 300-Carburetor adjustments table Sea level Temperature -20°C -6°C 6°C … 16°C 25°C 37°C … … 5°C 15°C … … … 49°C 24°C 36°C -7°C 3.000 m Air screw 1T1/2 1T/1/2 2T1/2 adjustment 2.301 m Idle jet N8RE N8RE N8RF...

  • Page 61: Checking The Load Circuit

    CHECKING THE LOAD CIRCUIT ❱❘ Static control value For this control please make sure the bike is off Battery voltage > 12.5V. • Resistance values of stator windings : Measurement of the resistance between each winding. • Y1-Y2 0.44Ω±20 % (at Y2-Y3 20°C) Y1-Y3...

  • Page 62: T° Sensor, Engine Rpm Sensor, High Voltage Coil

    T° SENSOR, ENGINE RPM SENSOR, HIGH VOLTAGE COIL Water temperature sensor resistance (on cylinder head) • TEMP (°C) RESIST (K Ω) 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 Pick UP sensor resistance (RPM sensor) : Red ~...

  • Page 63: Wiring Diagram

    WIRING DIAGRAM ❱❘ Main harness 250/300 SE...

  • Page 64: Standard Lights Harness

    WIRING DIAGRAM ❱❘ Standard lights harness...

  • Page 65: Racing Lights Harness

    WIRING DIAGRAM ❱❘ Racing lights harness 250/300 SE...

  • Page 66: Accessories Harness

    WIRING DIAGRAM ❱❘ Accessories harness...

This manual is also suitable for:

250 se factory300 se-r300 se factory

Table of Contents