Table Of Contents - SHERCO 250 SE/R Workshop Manual

FOREWORD ................................................................4
ENGINE TOOL LIST .....................................................5
250 SE-R and 300 SE-R ....................................................5
TECHNICAL SPECIFICATIONS .....................................6
Engine ...............................................................................6
Carburettor ........................................................................7
Cycle part ..........................................................................7
FACTORY SETTINGS ...................................................8
Fork ..................................................................................8
Shock absorber .................................................................9
OPERATIONS REQUIRING REMOVAL OF THE ENGINE OR
NOT ...........................................................................9
ENGINE REMOVAL/ASSEMBLY .................................10
Removing the engine .......................................................10
Reassembling the engine in the frame ..............................11
DISMANTLING THE ENGINE ......................................12
Draining the gearbox ........................................................12
Removing the pinion and selector .....................................12
Removing the cylinder head, cylinder and piston ................13
Removing the clutch housing ............................................14
Removing the pressure plate and discs .............................15
Removing the electric starter ............................................16
Removing the primary transmission ..................................16
Removing the locking mechanism .....................................17
Removing the ignition housing ..........................................18
Removing the torque limiter and the starter drive...............18
Removing the ignition .......................................................19
Intake pipe and valve box .................................................19
Separating the half crankcases .........................................20
Removing the gear selection.............................................20
Removing the connecting rod assembly ............................21
CHECKING ENGINE COMPONENTS ............................22
Connecting rod assembly .................................................22
Balance weights, checking the external dimensions ...........22
Radial play of the connecting rod head .............................22
Lateral play of the connecting rod head ............................23
Checking the crankshaft's run out ....................................23
Piston..............................................................................23
Gap spacing ....................................................................24
Piston pin check ..............................................................24
Checking the wear condition of the cylinder ......................24
Standard cylinder replacement .........................................24
Disassembling the exhaust valve system ...........................25
CONTENTS
Functional check ..............................................................26
Valve stop learning after cylinder reassembly ....................30
Valve box, intake pipe sleeve ............................................30
Clutch .............................................................................31
Connecting rod assembly .................................................31
REASSEMBLING THE ENGINE ...................................32
Gearbox ..........................................................................32
Assembling the half crankcases........................................33
Gear selection mechanism ...............................................34
Primary transmission and clutch .......................................35
Clutch discs, pressure plate..............................................36
Clutch housing .................................................................37
Piston and cylinder ..........................................................38
Cylinder head ..................................................................39
Valve box and intake pipe .................................................40
Gearbox output pinion ......................................................40
Mounting the ignition and its cover ...................................41
Mounting the electric starter .............................................41
DIAGNOSTIC TOOL ...................................................42
Presentation of the ignition management system and exhaust
valve opening management system ..................................42
Description of Exxodiag diagnostic tool reference 4967 .....43
Composition of the diagnostic tool ....................................43
Installing the diagnostic tool .............................................43
Connection with Keyless system .......................................47
Software setup : setup menu ............................................48
Update and synchronisation menu ....................................49
Using the software ...........................................................51
TIGHTENING TORQUES TABLE ..................................61
CARBURETTOR ADJUSTMENT TABLE .......................62
SE-R 250 carburettor adjustment table .............................62
CARBURETTOR ADJUSTMENT TABLE .......................63
SE-R 300 carburettor adjustment table .............................63
CHECKING THE LOAD CIRCUIT..................................64
Static control values (engine off) 250 SE-R/300 SE-R ........64
Dynamic control values ....................................................64
T° SENSOR, ENGINE RPM SENSOR, HV COIL CHECK . 65
Main harness...................................................................66
Standard lights harness ....................................................67
Racing lights harness .......................................................68
Accessories harness ........................................................69
3