Related Manuals for SHERCO 250 SEF RACING
Summary of Contents for SHERCO 250 SEF RACING
- Page 1 WORKSHOP MANUAL | MANUEL D’ATELIER | MANUAL DE TALLER 250 SEF RACING 250 SEF FACTORY 300 SEF RACING 300 SEF FACTORY...
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Page 2: Table Of Contents
❱❘ Reassembling the central crankcase assembly30 Table of contents TIGHTENING TORQUES .........34 FORWARD ............2 INJECTOR BODY ..........36 TOOL LIST ............3 Clean injector body ........36 TECHNICAL SPECIFICATION......4 ❱❘ Material ..............36 ENGINE .............. 4 ❱❘ Put down the injector body ........ 36 FRAME ............... -
Page 3: Forward
SHERCO tools designed for the 250 SEF and 300 SEF engine. This workshop manual is a supplement to the SHERCO 250 SEF and 300 SEF owner’s manual. -
Page 4: Tool List
TOOL LIST TOOL 250/300 4T Owner manual Fuel pressure Clutch tool 1814 Support piston tool 8700 tool 8691 1818 Container / Support Tool ignition Pinion clutch Ring extractor R464 Engine Tool R481/R455 4753 shaft tool 1817 Tools 0726 Top dead point Diagnostic Flying 1819... -
Page 5: Technical Specification
TECHNICAL SPECIFICATION ENGINE 250 SEF 300 SEF Type Liquid cooled single cylinder 4 strokes engine Displacement 249.4 CC 303.7 CC Bore / Stroke 78/52,2mm 84 / 54.8mm Compression ratio 13 :1 12.4:1 Fuel Without lead 95 or 98 4 valves, DOHC driven by tooth type chain Valve timing Admission valve diameter 31mm... -
Page 6: Frame
TECHNICAL SPECIFICATION FRAME Semi-perimeter CrMo steel with aluminum subframe Frame KAYABA USD Ø48mm Closed cartridge(FACTORY) Fork WP XPLOR USD Ø48mm (RACING) KAYABA suspension with separate cylinder Rear suspension WP suspension with separate cylinder, Aluminium swing arm Travel Front/Rear FACTORY 330/330mm RACING 300/330mm Front brake disque Ø... -
Page 7: Standard Adjustment Fork
STANDARD ADJUSTMENT FORK Original settings – Fork KAYABA USD Ø48 mm Compression Comfort 20 clicks back Standard 12 clicks back Sport 8 clicks back Rebound Comfort 18 clicks back Standard 12 clicks back Sport 10 clicks back Spring Rider weight : 65-75 kg 4.0N/mm Rider weight : 75-85 kg 4.2N/m... -
Page 8: Shock Absorber
STANDARD ADJUSTMENT SHOCK ABSORBER Racing 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 9: Operations Requiring Demounting Or Not Engine
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 • Freewheel •... -
Page 10: Removing / Reistalling The Engine
REMOVING / REISTALLING THE ENGINE REMOVING THE ENGINE WARNING To remove the engine, you must remove the swing arm axle, the swing arm and the rear wheel. To keep the bike from falling, remember to support the chassis with an appropriate jack. Drain (refer to the owner’s manual) •... -
Page 11: Engine
ENGINE For additional details refer to the parts catalog 250 SEF _ 300 SEF REMOVING THE CYLINDER HEAD Remove the spark plug. • Remove the valve cover. • Remove the three valve cover screws. • WARNING These three screws are equipped with o-rings. Ref: 0900 ❱❘... -
Page 12: Removing The Camshafts
ENGINE ❱❘ Removing the camshafts • Unscrew the eight screws from the shaft bearing cap cam following the order shown in the picture. • Remove the bearing cap. • Remove the exhaust camshaft retaining clip. • Remove the exhaust camshaft. •... -
Page 13: Individual Parts Inspection Engine Top End Controls
INDIVIDUAL PARTS INSPECTION ENGINE TOP END CONTROLS ❱❘ Inspection of the cylinder for wear Measure the inside diameter of the cylinder when it is cold. Inspect the inside of the cylinder for any scratches or other evidence of abnormal wear. If the cylinder is badly damaged or worn it should be replaced. -
Page 14: Piston Wear
INDIVIDUAL PARTS INSPECTION ❱❘ 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 15 INDIVIDUAL PARTS INSPECTION 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: 32.10 mm Intake: 32.40 mm Camshaft height limit 300 Exhaust: 32,10 mm...
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Page 16: Cylinder Head Inspection
INDIVIDUAL PARTS INSPECTION ❱❘ Cylinder head inspection Inspect the cylinder head for flatness • Place the cylinder head on the 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. -
Page 17: Reassembling The Top End Of The Engine ❱❘ Reassemble The Piston
REASSEMBLING THE TOP END OF THE ENGINE ❱❘ Reassemble the piston • Install the piston rings on the piston with the end gaps as shown in the photo, the compression ring goes in the top groove and the oil control ring goes in the bottom groove. A Lower expander end gap B Lower piston ring end gap C Upper expander end gap... -
Page 18: Reassemble The Cylinder Head
REASSEMBLING THE TOP END OF THE ENGINE • Install the wrist pin into the piston and connecting rod using the tool and lightly tapping with a hammer. • Install the opposite circlip, using the special tool. • Install the cylinder over the piston using an appropriate ring compressor •... -
Page 19: Valve Timing
REASSEMBLING THE TOP END OF THE ENGINE ❱❘ Valve timing • Beware if the tool number 1819 is still properly installed. • Install the intake cam. • Install the exhaust cam. (see the picture for how to set the timing marks) •... - Page 20 REASSEMBLING THE TOP END OF THE ENGINE Install the camshaft retaining cover. (pay • careful attention to the tightening order). Camshaft retaining cover torque 10Nm WARNING The screw n°1 is a M6 X 35 • Install the camshaft chain tensioner using a new gasket.
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Page 21: Valve Clearance
REASSEMBLING THE TOP END OF THE ENGINE ❱❘ Valve clearance • The valve clearance must be checked when the engine is cold. • Remove the spark plug and the valve cover. • Remove the timing plug from the crankcase. • Install special tool number 1819. •... -
Page 22: Disassembling Cover Disassembling The Right Side
DISASSEMBLING COVER DISASSEMBLING THE RIGHT SIDE ❱❘ Clutch dismantling Install special tool number 1819. • WARNING Only use this tool for disassembling the clutch, do not use it to remove the hub fixing nut. • Remove the 4 screws that retain the clutch cover. -
Page 23: Disassembling And Inspecting The Water Pump22
DISASSEMBLING COVER ❱❘ Disassembling and inspecting the water pump • Drain the coolant by removing screw [A]. • Remove the screws from the water pump housing. • Remove the water pump impeller using a 10 mm socket. WARNING If the seal is leaking, coolant will come out of the weep hole (see picture). -
Page 24: Removing The Clutch Hub And The Clutch Basket23
DISASSEMBLING COVER ❱❘ Removing the clutch hub and the clutch basket • Drain the engine oil and the engine coolant. • Remove the clutch housing. (see disassembling the right side paragraph) • Remove the clutch. (see clutch removal paragraph) • Remove the clutch release bearing assembly. -
Page 25: Disassembling The Left Side
DISASSEMBLING COVER WARNING There is a sense • Install the special friction disc. • Install all the metal and friction discs. • Reinstall the clutch release bearing assembly, the clutch spring holder in the reverse order of their removal. Torque the clutch screws to: 10Nm •... -
Page 26: Removing The Rotor
DISASSEMBLING COVER ❱❘ Removing the rotor • Use the special rotor holding tool number 4753. • Remove the rotor fixing nut. • Remove the flywheel using special tool number R462. • Remove the two starter shafts along with the starter gears. •... -
Page 27: Reassembling The Ignition Case
DISASSEMBLING COVER ❱❘ Reassembling the ignition case • Install the free wheel gear. • Reinstall the two starter shafts and their gears. • Visually inspect the oil seal on the oil centrifuge. • Use special tool number 1818 to screw the oil centrifuge. -
Page 28: Disassembling Crankcases Crankshaft - Transmission - Central Crankcases
DISASSEMBLING CRANKCASES CRANKSHAFT - TRANSMISSION - CENTRAL CRANKCASES ❱❘ Disassembling the transmission and the 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 29: Checking The Transmission Components
DISASSEMBLING CRANKCASES • 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. ❱❘... -
Page 30: Checking The Crankshaft
DISASSEMBLING CRANKCASES ❱❘ 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 31: Checking The Crankcase
DISASSEMBLING CRANKCASES ❱❘ Checking the crankcase • Inspect the general condition of the center WARNING During the rebuild, replace all seals (paper, seal, o-ring…). crankcases for wear and cracks. Replace the center crankcase if necessary. • Inspect the condition of all the bearings. Replace the bearings if necessary. - Page 32 CARTERS CENTRAUX / VILEBREQUIN / TRANSMISSION • Install the 2 centering pins and the wash on the secondary shaft. WARNING: During the replacement of the gearbox or the crankcase on the 250-300 4t engines, it is necessary to check the side play of the primary shaft and adjust it if it is necessary INSPECTION OF THE PRIMARY SHAFT SIDE...
- Page 33 REASSEMBLING CRANKCASES • 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 •...
- Page 34 REASSEMBLING CRANKCASES • Install the fixing nuts on the crankshaft and the transmission input shaft. • Apply the proper torque these fixing nuts. • Install special tool number 1817 and torque the crankshaft fixing nut. Torque the crankshaft fixing nut to: 120 Nm. •...
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Page 35: Reassembling The Central Crankcase Assembly30
TIGHTENING TORQUES STANDARD TORQUE THREADLOCKER 6 Nm 10 Nm 24 Nm 40 Nm MOTOR TIGHTENING TORQUES THREADLOCKER Magnetic drain plug 15 Nm Drain plug with prefilter 15 Nm Oil filter cover 15 Nm Spark plug (with copper grease) 15 Nm Bolt for bleeding cooling system 6 Nm Ignition sensor screw... - Page 36 TIGHTENING TORQUES 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 boltes / axle M6 15 Nm • Brake pad bolt 8 Nm 12 Nm Botton plat fork bolts 17 Nm...
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Page 37: Injector Body
INJECTOR BODY Clean injector body ❱❘ Material • MOTUL Net Carb or parts 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 •... - Page 38 INJECTOR BODY • Disconnect each connector • Visually inspect the connector • Clean with carb cleaner or universal product cleaner • Blow 250/300 SEF...
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Page 39: Clean Of Injector Body
INJECTOR BODY ❱❘ Clean of injector body • Clean the injector body with Net Carburetor • Make sure you clean perfectly the edge of the mixture throttle on each side by opening it completely • Clean the injector • Blow ❱❘... -
Page 40: Electrical Installation Checking
ELECTRICAL INSTALLATION CHECKING ❱❘ 1- Fan control Disconnect the fan wiring harness. • Connect a 12V battery directly to the • fan has shown on the diagram. Make sure the fan turns correctly • without any hard point or unnatural noise. -
Page 41: 4-Fall Sensor Control
ELECTRICAL INSTALLATION CHECKING ❱❘ 4-Fall sensor control Remove the sensor from its location, • leaving me connected to the electrical harness. Using a multimeter , measure the • output voltage of the angle sensor. Positive plug on the blue wire and negative on the black wire. -
Page 42: 7-Map Sensor Control
ELECTRICAL INSTALLATION CHECKING ❱❘ 7-Map sensor control Check the output voltage of the sensor. • Connect the multimeter to the sensor • (harness side) between terminal N°3 (positive) and terminal N°4 (negative). Then, between terminal N°1 (positive) and terminal N°4 (negative). Sensor output voltage : Between 3 and 5 V ❱❘... -
Page 43: 9-Stepper Motor Control
ELECTRICAL INSTALLATION CHECKING ❱❘ 9-Stepper motor control Checking the stepeper motor coils. • Connect the multimeter to the sensor • (harness side) between terminal N°A and terminal N°D. Then, between the terminal N°B and terminal N°C. There must be continuity between the terminals ;... -
Page 44: 12-Checking The Alternator
ELECTRICAL INSTALLATION CHECKING ❱❘ 12-Checking the alternator Checking the resistance of the • alternator windings. Connect the multimeter between each phase of the alternator (yellow wire) an measure the resistance. Winding resistance: 0.44Ω +/- 15% Checking the alternator output voltage. •... -
Page 45: 14-Water Sensor Control
ELECTRICAL INSTALLATION CHECKING ❱❘ 14-Water sensor control Drain the coolant. • Remove the temperature probe. • Immerse the sensor in a container • filled with coolant Immerse a thermometer in the liquid • to check its temperature. Heat the liquid slowly and check the •... -
Page 46: Wiring Harness
WIRING HARNESS ❱❘ Homologated light wire harness (8145) 250/300 SEF... -
Page 47: Racing Light Wire Harness (6845)
WIRING HARNESS ❱❘ Racing light wire harness (6845) -
Page 48: Main Wire Harness (7314)
WIRING HARNESS ❱❘ Main wire harness (7314) 250/300 SEF... -
Page 49: Fan Wire Harness (3577)
WIRING HARNESS ❱❘ Fan wire harness (3577) -
Page 50: Synerject Injection System Instruction Manual
INJECTION SYSTEM P R E S E N T A T I O N 1.1- Injection system Your Sherco is equipped with a Synerject injection system that is composed of a M3C computer, a Ø 42mm throttle body, a special ignition system and a special harness. N°... -
Page 51: Description Exxodiag Diagnostic Tools Référence 4967
INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT Picture 1 : Synerject M3C Computer Picture 2 : Synerject injector body Ø42mm N° DESIGNATION Stepper motor (Idle management and engine braking) I Injector TMAP sensor (Air temperature/air pressure) TPS: Butterfly position sensor 1.2- Description Exxodiag diagnostic Tools référence 4967 The diagnostic tool allows you to perform diagnostic operations, make updates to the injection mapping and to determine certain information (serial number of the motorcycle, number of hours of operation, etc.). -
Page 52: Installation Of The Diagnostic Tool
INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT 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 mail to courrierxxotest.com. A- Installing the software and drivers • Open the installation CD on your computer •... - Page 53 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT • Click on « Next ». • Click on « Install ». • Installation in progress.
- Page 54 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 55 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 «...
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Page 56: Connection With Keyless System
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 57 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...
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Page 58: 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 59: 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 60 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 •...
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Page 61: Using The Sofware
SYNERJECT Using the sofware 2.4- Diagnostic menu and injection mapping update General • Click on « Sherco ». • Click on « M3C ». • You get the following menu : A- Identification You can check the identification of the following (serial number, hours of operation,... - Page 62 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT B- Parameter measurements general parameters (speed, pressure, stepper, etc) 1- Engine information Displayed below are the main system values : Details : - Stepper Position: The air valve (stepper) opening value -> 35 < < 75 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 Note : The correct air valve motor value should be 15mm and 2mm with the motor idling and at 80°C.
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Page 63: C- Reading The Default Codes
INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT 2- Other less frequently used values appear in the windows Throttle position : - The adjustment value for the minimum throttle butterfly opening should be (in V): 0.4<0.5V<0.6 Miscellaneous : - Manifold Pressure (mb): pressure at the injector nozzle body measured by the TMAP sensor -Engine synchronization status: engine cycle recognition. -
Page 64: D- Erasing Default Codes
INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT 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 : 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 65 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT The following screen will appear: Confirm by clicking on this icon 2- Return to the menu « reading default codes » Check and make sure that the defaults are the same as before. Check/replace the defective parts.
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Page 66: E- Test The Actuators
INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT E- 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 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 67 INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT 2- Injector This is the same type of test as with ignition coil. Make sure that the injector issues a snap when activated. 3- Fuel pump / fan / stepper For the fuel pump, the fan and the stepper (air valve) perform a standard test. If there is a default it twill appear as a classic default.
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Page 68: F- Updating The Computer
INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT Stepper default: In the event of a reoccurring default, check/change the defective parts. Note : The fan test is meaningless if the bike is not equipped with a fan F- Updating the computer 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 69 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...
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Page 70: G- Screen Printing Function
INJECTION SYSTEM INSTRUCTION MANUAL SYNERJECT Note: Serial number information and operating hours are not reset during a calibration update. 7- Start the motorcycle and make sure that the engine parameters are normal (idle, stepper opening, etc). G- Screen printing function If you are communicating with technical support and need help identifying potential problems you can perform a screen print operation by pressing F10 on your keyboard. - Page 71 www.sherco.com...