SHERCO 250 SE/R Workshop Manual
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SHERCO 250 SE/R Workshop Manual

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WORKSHOP MANUAL

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Summary of Contents for SHERCO 250 SE/R

  • Page 1 WORKSHOP MANUAL...
  • Page 2 250-300 SE-R...

  • Page 3: Table Of Contents

    CONTENTS FOREWORD ..............4 Functional check ..............26 Valve stop learning after cylinder reassembly ....30 ENGINE TOOL LIST .............5 Valve box, intake pipe sleeve ..........30 250 SE-R and 300 SE-R ............5 Clutch ................31 TECHNICAL SPECIFICATIONS ........6 Connecting rod assembly ..........31 Engine ................6 REASSEMBLING THE ENGINE ........32 Carburettor ................7 Gearbox ................32...

  • Page 4: 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 5: Engine Tool List

    ENGINE TOOL LIST 250 SE-R and 300 SE-R 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...

  • Page 6: Technical Specifications

    TECHNICAL SPECIFICATIONS ENGINE Single cylinder 2 stroke liquid cooling Type Capacity 249.32 CC 293.14 CC Bore/Stroke 66.4/72 mm 72/72 mm Unleaded with an octane rating of at least 98 Petrol mixed with 2-stroke oil (2 %) Cooling Liquid with forced circulation Synerject electronic ignition Ignition system NGK BR7ES/DENSO W22ESRU...

  • Page 7: Carburettor

    CARBURETTOR Carburettor type KEIHIN PWK 36S AG KEIHIN PWK 36S AG Needle position 3rd position from the top 3rd position from the top N1EG (N84K) N8RE (N84K) Jet needle Main jet KEA 165 (KEA 115) KEA 172 (KEA 115) Idle jet KEP 42 (KEA38) KEP 42 (KEA 38) Choke jet...

  • Page 8: Factory Settings

    FACTORY SETTINGS FORK FACTORY SETTINGS - WP FORK USD SUSPENSION Ø48 MM Comfort 20 clicks back Compression Standard 13 clicks back Sport 8 clicks back Comfort 18 clicks back Expansion Standard 13 clicks back Sport 10 clicks back Comfort 4 turns 6 turns Pre-tension Standard...

  • Page 9: Shock Absorber

    SHOCK ABSORBER FACTORY SETTINGS - WP SUSPENSION SHOCK ABSORBER Comfort 20 clicks back Low speed compression Standard 15 clicks back Sport 12 clicks back Comfort 2.5 turns back High speed compression Standard 2 turns back Sport 1.5 turns back Comfort 15 clicks back Expansion Standard...

  • Page 10: Engine Removal/Assembly

    ENGINE REMOVAL/ASSEMBLY 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 (see user manual). •...

  • Page 11: Reassembling The Engine In The Frame

    REASSEMBLING THE ENGINE IN THE FRAME To reassemble, follow the disassembly procedure in reverse while respecting the tighte- ning torques of screws and nuts : Engine screw : 60Nm. Swivel-arm screw : 100 Nm. Clutch slave cylinder screw : 10 Nm. Head-frame screw : 23 Nm.

  • Page 12: Dismantling The Engine

    DISMANTLING THE ENGINE Refer to the 250 SE-R/300 SE-R spare parts catalogue for exploded views. DRAINING THE GEARBOX • Remove the drain plugs , let the oil drain. REMOVING THE PINION AND SELECTOR • Unfold the safety washer's tab using a punch.

  • Page 13: Removing The Cylinder Head, Cylinder And Piston

    REMOVING THE CYLINDER HEAD, CYLINDER, AND PISTON • Remove the shoulder bolts , the copper washers, remove the cylinder head and the two o-rings. • Remove the exhaust valve actuator • Remove the exhaust chamber cover • Remove the 4 screws on the base of the cylinder and remove it.

  • Page 14: Removing The Clutch Housing

    DISMANTLING THE ENGINE (next) • Remove the piston pin clips. • Remove the piston pin. • Remove the piston and extract the needle bearing from the connecting rod eye. • Remove the header gasket. REMOVING THE CLUTCH HOUSING • Remove the screws and the water pump cover.

  • Page 15: Removing The Pressure Plate And Discs

    REMOVING THE PRESSURE PLATE AND DISCS • Loosen the pressure plate screws • Remove the screws, springs and spring cups. • Remove the pressure plate and discs from the housing. • Remove the support piece on the primary shaft.

  • Page 16: Removing The Electric Starter

    DISMANTLING THE ENGINE (next) REMOVE THE ELECTRIC STARTER • Remove the 2 screws 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. •...

  • Page 17: Removing The Locking Mechanism

    • Removing the primary transmission pinion and the spacer at the end of the crankshaft. PAY ATTENTION To the pin and the o-ring. The primary transmission pinion and the clutch housing ring are paired, which is why they can not be changed separately.

  • Page 18: Removing The Ignition Housing

    DISMANTLING THE ENGINE (next) REMOVING THE IGNITION HOUSING • Remove the screws and extract the ignition housing with its gasket. REMOVING THE TORQUE LIMITER AND THE STARTER DRIVE • Remove the 3 shoulder screws • Remove the torque limiter lug •...

  • Page 19: Removing The Ignition

    REMOVING THE IGNITION • Hold the flywheel with the 4753 tool and unscrew the shoulder nut. • Position the R462 puller and extract the magnetic flywheel INTAKE PIPE AND VALVE BOX • Remove the 4 THEP screws • Remove the pipe, the valve box, and their respective gasket.

  • Page 20: Separating The Half Crankcases

    DISMANTLING THE ENGINE (next) • 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. •...

  • Page 21: Removing The Connecting Rod Assembly

    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 them if necessary. WARNING When completely dismantling the engine, it is best to replace all gaskets, spi seals, o-rings and even bearings.

  • Page 22: Checking Engine Components

    CHECKING ENGINE COMPONENTS CONNECTING ROD ASSEMBLY • If the roller bearing has been changed, the inner ring which sits against the balance weight must also be changed. • Heat the R464 tool to approximately 150°C, immediately thread it onto the inner ring.

  • Page 23: Lateral Play Of The Connecting Rod Head

    LATERAL PLAY OF THE CONNECTING ROD HEAD • Measure the lateral play of the connecting rod head Lateral play of the connecting rod head : Standard : 0.8 mm - 1 mm Tolerable limit : 1.25 mm If the play is greater than the tolerated limit, the crankshaft must be replaced.

  • Page 24: Gap Spacing

    CHECKING ENGINE COMPONENTS (next) GAP SPACING • Thread the segment into the cylinder and position it with the piston (about 10 mm from the top edge of the cylinder). • Using a spacer, the gap spacing is measured. Gap spacing : Standard 0.35-0.45 mm, Max 0.65. WARNING If the gap is greater than indicated, check the condition of the cylinder and the piston.

  • Page 25: Disassembling The Exhaust Valve System

    DISASSEMBLING THE EXHAUST VALVE SYSTEM • Remove the valve cover [6]. • Remove the actuator support [12]. • Remove the stop screw [10] with the copper sealing washer [9]. • Remove the bore circlip with circlip pliers [29]. • Remove the valve mechanism assembly.

  • Page 26: Functional Check

    CHECKING ENGINE COMPONENTS (next) FUNCTIONAL CHECK • Clean and descale all the dismantled parts. • Check with your fingernail that there are no notches on the exhaust barrels [32] and [35], visually check their seating in the cylinder. • Inspect the axis of rotation of the exhaust valve [33], replace it if there are notches that you can feel with your fingernail.
  • Page 27 • Operate the system with rotational movements. • Check that the pin stops against the valve (kidney-shaped contact) when it is 100 % open. • Check that the pin stops against the valve (kidney-shaped contact) when it is 100 % closed.
  • Page 28 CHECKING ENGINE COMPONENTS (next) 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-R...
  • Page 29 4 X M5X16 M6X20 4 X M5X16...

  • Page 30: Valve Stop Learning After Cylinder Reassembly

    VALVE STOP LEARNING AFTER CYLINDER REASSEMBLYT 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 •...

  • Page 31: Clutch

    CLUTCH • Stopper [3] check wear. • Rod [8] check for wear. Minimum length : 194.7 mm. • Springs [17] Check their length. Minimum spring length 45 mm. Replace the 6 springs if necessary. • 8 clutch plates [14] Minimum thickness 2.68 mm. •...

  • Page 32: Gearbox

    CHECKING ENGINE COMPONENTS (next) GEARBOX • Apply grease to the shift fork studs and thread the rings over them. • Fix the securing washers on the primary and secondary shaft. • Position both the primary and secondary shafts and push them into their respective bearings until they stop.

  • Page 33: 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 34: Gear Selection Mechanism

    REASSEMBLING THE ENGINE (next) 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.

  • Page 35: Primary Transmission And Clutch

    • Check that the return spring strands are against the pin on each side of the housing. • Position the selector and try changing all the gears. You will have to turn the gearbox output shaft to change the different gears. Remove the selector again. PRIMARY TRANSMISSION AND CLUTCH •...

  • Page 36: Clutch Discs, Pressure Plate

    REASSEMBLING THE ENGINE (next) • Mount the clutch boss on the primary shaft, coat its nut with red threadlock and a new safety washer. • Employ the 5749 tool and tighten the nut to 100Nm. • Remove the tool and brake the nut by folding the edge of the lock washer.

  • Page 37: Clutch Housing

    CLUTCH HOUSING • Check that the two centring bushings are in place in the clutch housing. • Fit the housing gasket and hold it in place with a little grease. • Glue the water pump set ring with a little grease. •...

  • Page 38: Piston And Cylinder

    REASSEMBLING THE ENGINE (next) 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). •...

  • Page 39: Cylinder Head

    • 250-300 header gasket adjustment table. Squish, Standard = 1.7±0.1 mm (Set back of piston = -0.05mm) Measurement of pis- Squish 1st measure- Thickness of gasket Sherco reference ton's overrun or set ment 0.5 mm gasket to put to have a gasket(s) to be back (-) (X mm) 1.7 mm Squish...

  • Page 40: Valve Box And Intake Pipe

    REASSEMBLING THE ENGINE (next) 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 screws.

  • Page 41: Mounting The Ignition And Its Cover

    MOUNTING THE IGNITION AND ITS COVER • Put the half moon pinin 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 42: Diagnostic Tool

    PRESENTATION OF THE IGNITION MANAGEMENT SYSTEM AND EXHAUST VALVE OPENING MANAGEMENT SYSTEM • 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 43: Description Of Exxodiag Diagnostic Tool Reference 4967

    COMPOSITION OF THE DIAGNOSTIC TOOL • 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. http ://download.annecyelectronique.com/Exxodiag/Sherco/ShercoDiag_Setup.exe INSTALLING THE DIAGNOSTIC TOOL WARNING If you experience any problems during installation, please contact EXXOTEST at +33 (0) 4 50 02 34 34 or by mail at courrier@exxotest.com.
  • Page 44 DIAGNOSTIC TOOL (next) • Click "next". • Select the folder where you want the software installed. • Click "next". • Click on "Install". 250-300 SE-R...
  • Page 45 • Installation in progress. • Tick "Start installing drivers" and "Finish". • The following window opens. Read the terms of the licence agreement. Tick "I accept the terms of the licence agreement" and "Install". • Installation in progress.
  • Page 46 DIAGNOSTIC TOOL (next) • The following window opens. Click "Finish". • The installation is complete. B - Connect the cable and its "MUXDIAG II" interface to a USB port on your computer • Connect the cord to the motorcycle's diagnostic connector. •...

  • Page 47: Connection With Keyless System

    CONNECTION WITH KEYLESS SYSTEM • Sherco has equipped its motorcycles with a keyless system that allows keyless use and which automatically cuts the motorcycle's ignition after 30 seconds of inactivity. • This last feature can prevent the diagnosis operation, which is why it is important to respect the following steps before any operation.

  • Page 48: Software Setup : Setup Menu

    DIAGNOSTIC TOOL (next) • You will access the following menu : SOFTWARE SETUP : SETUP MENU 250-300 SE-R...

  • Page 49: Update And Synchronisation Menu

    In this menu you can change : • The diagnostic connector. You can refresh the list of connectors by clicking on the button . The number must match the "MUXDIAG II" unit number. • The software user language : French, English, Spanish, Portuguese, German, Italian (it is possible that the installation CD does not include all languages.
  • Page 50 DIAGNOSTIC TOOL (next) • If no update is available, the following message appears : • Click to start downloading the update. • The following message appears : • Click to start the installation. • Repeat the steps of the installation. You do not have to restart driver installation.

  • Page 51: Using The Software

    • Enter the following settings if necessary. USING THE SOFTWARE Diagnostic menu and calibration update General • Click on "Sherco". • Click on M3C - 2-stroke carburettor. • You will access the following menu :...
  • Page 52 DIAGNOSTIC TOOL (next) A - Identification : identification verification (serial number, vehicle operating hours, calibration number) B - Settings measurement : general settings (speed, pressure, engine status, etc.) 1 - Engine information : The main system values appear : 250-300 SE-R...
  • Page 53 Details : • Stepper position : Not used. • Throttle valve position : Not used. • Stop button status : status of the emergency stop button. 0 : deactivated, 1 : activated. • Engine status : ES (engine ready to start), ST (engine starts), IS (idle speed), PL (acceleration), PU (deceleration).
  • Page 54 DIAGNOSTIC TOOL (next) • By clicking on the displayed fault you can access its details : Note the faults and exit the menu with the icon Info : 1 - Transient fault/permanent fault : a transient fault becomes permanent after a variable num- ber of engine cycles, depending on the components (injector, fuel pump, etc.).
  • Page 55 D - Deleting fault codes 1 - If faults appear, go to the menu "Delete fault codes" • Confirm that the fault codes are deleted with the icon • The following tab appears : • Confirm with the icon 2 - Return to the "Reading fault codes" menu Check that the displayed faults are identical.
  • Page 56 DIAGNOSTIC TOOL (next) E - Updating the controller It is possible to update the injection mapping (calibration) with the diagnostic tool. This could be for a Racing muffler, for example, or because an update is proposed by the factory. These files will be freely available on sherconetwork (from the end of 2013). Pay attention to the vintage, the engine capacity, the type of silencer, etc.
  • Page 57 5 - At the end of the download the fuel pump starts-up and the following message appears : INFORMATION : the download was successful Confirm with the icon 6 - Check the correct assignment of the calibration file by selecting "Identification" Check that the file name matches the downloaded file.
  • Page 58 DIAGNOSTIC TOOL (next) F - Actuator testing In addition to reading fault codes, you can also test certain system components. 1 - Ignition coil At the start of the ignition coil test, the following message appears : 250-300 SE-R...
  • Page 59 The system is not able to detect a coil fault when the engine is stopped. Whether the coil is defective or not, the test result will be identical. During the test, it is therefore important to check that the coil produces a sound that is characteristic of correct operation. 2 - Injector : not used 3 - Fuel pump : not used 4 - Fan...
  • Page 60 DIAGNOSEWERKZEUG (next) This learning sequence is mandatory after any maintenance work on the engine (Exhaust valve system cleaning and checking, replacement of cylinder parts, replacement of cylinder, disas- sembly or replacement of the electronic valve actuator…). G - Screen printing function When communicating with technical support and for the quick identification of potential pro- blems, you can attach screen print files to your message using the F10 key of your keyboard.

  • Page 61: Tightening Torques Table

    TIGHTENING 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 62: Carburettor Adjustment Table

    CARBURETTOR ADJUSTMENT TABLE SE-R 250 CARBURETTOR ADJUSTMENT TABLE Sea level Temperature -20°C -6°C 6°C … 16°C 25°C 37°C … … 5°C 15°C … … … -7°C 24°C 36°C 49°C 3.000 m Air screw 1T1/4 1T3/4 1T3/4 2T1/4 2T1/4 adjustment Idle jet 2.301 m N1EG N1EG...

  • Page 63: Carburettor Adjustment Table

    SE-R 300 CARBURETTOR ADJUSTMENT TABLE Sea level Temperature -20°C -6°C 6°C … 16°C 25°C 37°C … … 5°C 15°C … … … -7°C 24°C 36°C 49°C 3.000 m Air screw 1T1/2 1T1/2 2T1/2 adjustment Idle jet 2.301 m N8RE N8RE N8RF N8RF N8RG...

  • Page 64: Checking The Load Circuit

    CHECKING THE LOAD CIRCUIT STATIC CONTROL VALUES (ENGINE OFF) 250 SE-R/300 SE-R • Battery voltage > 12.5V. • Resistance values of stator windings : Measurement of the resistance between each winding. Y1-Y2 0.44Ω±20 % (at 20°C) Y2-Y3 Y1-Y3 DYNAMIC CONTROL VALUES •...

  • Page 65: T° Sensor, Engine Rpm Sensor, Hv Coil Check

    T° SENSOR, ENGINE RPM SENSOR, HV COIL CHECK • 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 •...

  • Page 66: Main Harness

    WIRING DIAGRAM MAIN HARNESS 250-300 SE-R...

  • Page 67: Standard Lights Harness

    STANDARD LIGHTS HARNESS...

  • Page 68: Racing Lights Harness

    WIRING DIAGRAM (next) RACING LIGHTS HARNESS 250-300 SE-R...

  • Page 69: Accessories Harness

    ACCESSORIES HARNESS...

This manual is also suitable for:

300 se/r

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