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

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Workshop manual
Workshop manual
Workshop manual
2014
250 SEF-R
300 SEF-R

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Summary of Contents for SHERCO 2014 250 SEF-R

  • Page 1 250 SEF-R 300 SEF-R Workshop manual Workshop manual Workshop manual 2014...

  • Page 2: Table Of Contents

    2/75 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 ..............

  • Page 3: 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 4: Motor Tools 250 Sef-R And 300 Sef-R

    4/75 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 Bearing tool 6905 (Gear selector 2071 drum) 2072...

  • Page 5: Technical Specification - Motor

    5/75 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...

  • Page 6: Technical Specification - Frame

    6/75 Technical specification - Frame Frame Semi-perimeter CrMo steel with aluminum subframe SACHS USD Gold Series 48mm dia. (standard) & WP USD 48mm Fork 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...

  • Page 7: Standard Adjustement - Fork

    7/75 Standard adjustement – Fork Standard adjustment - Fork Sachs USD Gold Series Ø48MM Compression Turn clockwise to the stop, then back of 12 clicks Turn clockwise to the stop, then back off Rebound 12 clicks 4.5N/mm Spring SAE 5 Fork oil 600cm3 Oil capacity...

  • Page 8: Standard Adjustement - Shock Absorber

    8/75 Standard adjustement – Shock absorber Standard adjustment - WP Shock absorber Low-speed Comfort 20 clicks back compression Standard 15 clicks back Sport 12 clicks back High-speed Comfort 2.5 clicks back compression Standard 2 clicks back Sport 1.5 clicks back Rebound Comfort 15 clicks back...

  • Page 9: Operations Requiring Demounting Or Not Engine

    9/75 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 10: Removing The Motor

    10/75 Removing the motor Removing the motor Removing the motor: To remove the engine, you must remove To remove the engine, you must remove the swing arm axle, the swing arm and the rear the swing arm axle, the swing arm and the rear wheel.
  • Page 11 11/75 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...

  • Page 12: Motor Top End

    12/75 Motor top end For additional details refer to the parts catalog 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.
  • Page 13 13/75 • 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).
  • Page 14 14/75 • Remove the cylinder head bolts (Be sure Remove the cylinder head bolts (Be sure to loosen them in the correct direction). to loosen them in the correct direction). Black bolt N° 1 on the picture is longer , 3 Black bolt N°...
  • Page 15 15/75 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.
  • Page 16 16/75 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...
  • Page 17 17/75 Inspect the cylinder head for flatness: • Place cylinder head fezf 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 18/75 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 Install the piston rings on the piston with the end gaps as shown in the photo, the end gaps as shown in the photo, the compression ring goes in the top groove and compression ring goes in the top groove and...
  • Page 19 19/75 • Install the wrist pin into the piston and Install the wrist pin into the piston and connecting rod using the tool and lightly tapping connecting rod using the tool and lightly tapping with a hammer. • Install the opposite circlip Install the opposite circlip, using the special tool.
  • Page 20 20/75 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) IN (Admission) EX (Echappement) The timing marks should align with the joint •...
  • Page 21 21/75 • Install the camshaft retaining cover. (pay camshaft retaining cover. (pay careful attention to the tightening order). careful attention to the tightening order). Camshaft retaining cover torque Camshaft retaining cover torque 10Nm • Install the camshaft chain tensioner Install the camshaft chain tensioner using a new gasket.
  • Page 22 22/75 • 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: Checking the valve clearance: • The valve clearance must be checked when the engine is cold.
  • Page 23 23/75 Replacing the cam chain: • Remove the camshafts (see the cha Remove the camshafts (see the chapter on the motor top end). • Remove the clutch cover (see the Remove the clutch cover (see the chapter on « Right side » removing the clutch). »...

  • Page 24: Disassembling The Right Side

    24/75 Disassembling the right side g the right side For additional details see the parts catalog For additional details see the parts catalog 250 SEF-R and 300 SEF-R. Clutch dismantling: • Install special tool number 1819. Install special tool number 1819. Only use this tool for disassembling the for disassembling the clutch, do not use it to remove the hub fixing...
  • Page 25 25/75 • Reinstall the clutch cover, inspect the o Reinstall the clutch cover, inspect the o- ring and replace if it is damaged. replace if it is damaged. Disassembling and inspecting the water pump: Disassembling and inspecting the water pump: •...
  • Page 26 26/75 Removing the clutch hub and the clutch basket: Removing the clutch hub and the clutch basket: • Drain the engine oil and the engine Drain the engine oil and the engine coolant. • Remove clutch housing. housing. (see (see disassembling the right side paragraph) disassembling the right side paragraph) •...
  • Page 27 27/75 • Install the judder spring ATTENTION ! with the sense of with the sense of this part • Install the special friction disc. Install the special friction disc. • Install all the metal and friction discs. Install all the metal and friction discs. •...
  • Page 28 28/75 Disassembling the left side Disassembling the left side For additional details refer to the parts catalog For additional details refer to the parts catalog 250 SEF-R and 300 SEF-R Disassembling the ignition case: Disassembling the ignition case: • Drain the engine oil. •...
  • Page 29 29/75 Removing the rotor: • Utilize the special ro l rotor holding tool number 4753. • Remove the rotor fixing nut. Remove the rotor fixing nut. • Remove the flywheel using special tool wheel using special tool number R462. • Remove the two starter shafts along with Remove the two starter shafts along with the starter gears.
  • Page 30 30/75 Reassembling the ignition case: Reassembling the ignition case: • Install the free wheel gear. Install the free wheel gear. • Reinstall the two starter shafts and their Reinstall the two starter shafts and their gears. • Visually inspect the oil seal on the oil Visually inspect the oil seal on the oil centrifuge.

  • Page 31: Crankcase / Transmission / Central Crankcases

    31/75 Crankcase / Transmission / Central crankcases Disassembling transmission 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 32 32/75 • 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 the remaining transmission components. Checking the transmission components: •...
  • Page 33 33/75 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 34 34/75 Checking the center crankcases: Checking the center crankcases: • Inspect the general condition of the l condition of the center crankcases for wear and cracks. center crankcases for wear and cracks. Replace the center crankcase if Replace the center crankcase if necessary. •...
  • Page 35 35/75 Reassembling the central crankcase assembly: Reassembling the central crankcase assembly: During the rebuild, replace all seals ring the rebuild, replace all seals (paper, seal, o-ring…). • Install Install crankshaft crankshaft counter counter balancer assembly in the left case, align the balancer assembly in the left case, align the marks as shown.
  • Page 36 36/75 • 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 37 37/75 • Install the special tool that locks the Install the special tool that locks the engine at top dead center (ref 1819). engine at top dead center (ref 1819). • Use tool 1817 to block the transmission Use tool 1817 to block the transmission ant to tighten balancer nut.

  • Page 38: Tightening Torques

    38/75 Tightening torques Standard torque Threadlocker 6 Nm 10 Nm 24 Nm 40 Nm 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 bolts / axle M6 15 Nm Brake pad bolt 8 Nm...
  • Page 39 39/75 Motor tightening torques Threadlocker Ignition sensor screw 8 Nm • Bolt for bleeding cooling system 6 Nm Clutch slave cylinder screw 9 Nm Exhaust bolt 10Nm Cylinder head pass 30 Nm 2nd pass 45 Nm Hexagon nut M6 10 Nm Camshaft cap 10 Nm Chain tensioner screw (x2)

  • Page 40: Clean Injector Body

    40/75 Clean injector body Clean injector body Material : - Minerva Net Carbu or carbu cleaner 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 -Remove the throttle body cover...
  • Page 41 41/75 - Disconnect each connector -Inspect -Clean with carbu cleaner or universal product cleaner -Blow...
  • Page 42 42/75 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 Replace the injector body - Put back all the parts together again, put some connector grease inside the electrical connectors (TPS plug, injector plug)

  • Page 43: Synerject )

    SYNERJECT ) ) ) ) 1.1- Your Sherco 300 SEF-R (for 250 SEF R (for 250 SEF-R, refer to the 2013 manual) i e 2013 manual) is equipped with a Synerject injection system that is composed of a injection system that is composed of a M3C computer, a Ø...
  • Page 44 44/75 Photo 1: Synerject M3C Computer Computer Photo 3: Synerject injector body Synerject injector body Ø42mm N° Designation TPS: Butterfly position sensor Butterfly position sensor TMAP sensor (Air temperature/air pressure sensor (Air temperature/air pressure) Stepper motor (Idle management and engine braking dle management and engine braking Injector...
  • Page 45 45/75 1.2 Description- Exxodiag diagnostic tool reference #4967 Exxodiag diagnostic tool reference #4967 The diagnostic tool allows you to perform diagnostic operations, make updates to the injection The diagnostic tool allows you to perform diagnostic operations, make updates to the injection The diagnostic tool allows you to perform diagnostic operations, make updates to the injection mapping and to determine certain information (serial mapping and to determine certain information (serial number of the motorcycle, number of...
  • Page 46 46/75 • Select the folder where you the folder where you want the software to be installed • Click "Next" • Click "Install"...
  • Page 47 47/75 • Installation is in progress • Select "Start installing drivers" and "Finish" Select "Start installing drivers" and "Finish"...
  • Page 48 48/75 • The following window opens. Read the terms of the license agreement. The following window opens. Read the terms of the license agreement. The following window opens. Read the terms of the license agreement. Select "I accept the terms of the license agreement the terms of the license agreement"...
  • Page 49 49/75 • The following window opens. Click "Finish" 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 one end of the "MUXDIAG II" interface cable to a USB port on your computer; Connect one end of the "MUXDIAG II"...

  • Page 50: 2-Software Presentation

    50/75 2-Software presentation Note: In order to establish connection In order to establish connection with the bike it must be turned on (ON) 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 rious menus only the USB cable with the "MUXDIAG II"...
  • Page 51 51/75 2.1 Software setup: configuration configuration menu In this menu you can change the following: In this menu you can change the following: • Taking a diagnostic reading. Taking a diagnostic reading. You can refresh the list by clicking on this button. You can refresh the list by clicking on this button.
  • Page 52 52/75 • Click on to return to the home scre to return to the home screen • Click on to validate your changes to validate your changes 2.2- Menu update and synchronization u update and synchronization: A- With this menu you can update the diagnostic software tool: With this menu you can update the diagnostic software tool: •...
  • Page 53 53/75 • If no update is available the following message appears If no update is available the following message appears : • Click on in order to start the download o in order to start the download of the update. •...

  • Page 54: 3- Using The Software

    • Click on in order to save your changes in order to save your changes 3- Using the software: Diagnostic menu and updating the injection mapping Diagnostic menu and updating the injection mapping General: Click on "Sherco" Click on "M3C"...
  • Page 55 55/75 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) 1- Engine Information: Displayed below are the main system values:...
  • Page 56 56/75 Details: - Stepper Position: The air valve (stepper) opening value Stepper Position: The air valve (stepper) opening value -> 35 < < 75 If the value is too low: there could be an air leak at the 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 value is too high: there could be dirt in the injector butterfly area Note: The correct air valve motor value should be 1...
  • Page 57 57/75 -Engine synchronization status: engine cycle recognition. Engine synchronization status: engine cycle recognition. 0: engine not in phase. 1: engine running in phase. -The full engine idling adaptation (%): The full engine idling adaptation (%):not activated function C-Reading the default codes: When you click on "read default c read default codes”...
  • Page 58 58/75 You can get the details of the default by You can get the details of the default by clicking on the default display: -Record the defaults and exit the menu by cl 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 Transient default/permanent default: a transient default becomes permanent after a certain...
  • Page 59 59/75 Click this icon in order to erase all of the default codes erase all of the default codes The following screen will appear: The following screen will appear: Confirm by clicking on this icon 2-Return to the menu "reading default codes": Return to the menu "reading default codes": Check and make sure that the defaults are the same as before.
  • Page 60 60/75 E-Test the actuators In addition to reading default codes you can also check In addition to reading default codes you can also check some of the system components: some of the system components: 1-Ignition coil When you launch the ignition coil test When you launch the ignition coil test, the following message will appear:...
  • Page 61 61/75 The system is not able to detect an ignition coil failure with the engine stopped. The system is not able to detect an ignition coil failure with the engine stopped. 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.
  • Page 62 62/75 Stepper default: In the event of a reoccurring default, check default, check/change the defective parts. /change the defective parts. Note: The fan test is meaningless if the meaningless if the bike is not equipped with a fa not equipped with a fan.
  • Page 63 63/75 F- Updating the computer: By using the diagnostic tool it is possible to make updates to the injection mapping (calibration). By using the diagnostic tool it is possible to make updates to the injection mapping (calibration). 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.
  • Page 64 64/75 ATTENTION! DO NOT TURN OFF THE MOTORCYCLE DURING THE DOWN DO NOT TURN OFF THE MOTORCYCLE DURING THE DOWNLOAD LOAD OPERATION (FLASH) DO NOT ABRUPTLY STOP THE FLASH DOWNLOAD PROCESS DO NOT ABRUPTLY STOP THE FLASH DOWNLOAD PROCESS DO NOT ABRUPTLY STOP THE FLASH DOWNLOAD PROCESS THERE IS A RISK OF IRREPAIRABLE DAMAGE TO THE COMPUTER THERE IS A RISK OF IRREPAIRABLE DAMAGE TO THE COMPUTER THERE IS A RISK OF IRREPAIRABLE DAMAGE TO THE COMPUTER...
  • Page 65 65/75 G- Screen printing function If you are communicating with technical support and n If you are communicating with technical support and need help identifying potential problems eed help identifying potential problems you can perform a screen print operation by pressing F10 on your keyboard. This will allow you you can perform a screen print operation by pressing F10 on your keyboard.

  • Page 66: Electrical Installation Checking

    66/75 Electrical installation checking 1-Static values (engine off) 300 SEF-R (for 250 SEF-R, see 2013 workshop manual) Tension battery : > 12.5V A- Stator resistance Y1-Y2 0.44 ±15% Y2-Y3 Y1-Y3 B-Pick up sensor : 120 ±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...
  • Page 67 67/75 Generator: Tolérance on typical values = -5% /+10% Voltage (AC) Current (IB) (DC) 2000 25.0V DC 13,5V 2500 15,0 3000 15,6 4000 16,2 5000 16,4 6000 16,8A 7000 16,6A 8000 101V 16,7A 9000 114V 16,8A 10000 125V...

  • Page 68: Cable Diagram

    68/75 Cable diagram Injection beam ( 250 SEF-R, see 2013 workshop manual) N° PIN Fonction Double mapping Electrical starter switch Key switch or engine switch Diagnostic connector Fan harness connector Emergency stop Dashboard Stepper motor Injector Fuel pump TCO sensor TPS sensor Engine ground Electrical starter...
  • Page 69 69/75 300 SEF-R 2014 Synerject EFI system cable diagram...

  • Page 70: 250 Sef 2014 Light System Cable Diagram

    70/75 250 SEF 2014 light system cable diagram...

  • Page 71: 300 Sef 2014 Light System Cable Diagram

    71/75 300 SEF 2014 light system cable diagram...

  • Page 72: 250 Sef-R 2014 Racing Light System Cable Diagram

    72/75 250 SEF-R 2014 Racing light system cable diagram...

  • Page 73: 300 Sef-R 2014 Racing Light System Cable Diagram

    73/75 300 SEF-R 2014 Racing light system cable diagram...

  • Page 74: Flasher Installation Cable Diagram

    74/75 Flasher installation cable diagram...

  • Page 75: Fan Cable Diagram

    75/75 Fan cable diagram...

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2014300 sef-r

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