Table of Contents
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Table of Contents
Related Manuals for SHERCO 300 SE-R 2017
Summarization of Contents
Engine Specifications
Engine Details
Details on engine type, displacement, bore/stroke, fuel, cooling, ignition, spark plug, piston, oil, transmission, clutch, starter, battery, and alternator.
Carburetor Specifications
Specifications for carburetor type, needle position, needle jet, main jet, pilot jet, starter jet, air screw adjustment, and slide cut.
Chassis Specifications
Chassis Details
Details on frame, fork, rear suspension, travel, brake discs, tire sizes, tire pressure, fuel tank capacity, steering angle, wheelbase, and weight.
Factory Settings
Front Fork Settings
Factory settings for compression, rebound, spring stiffness, and fork oil for SACHS and WP USD series front forks.
Rear Fork Settings
Factory settings for low and high speed compression, rebound damping, and spring stiffness for WP rear suspension unit.
Engine Removal and Installation
Engine Removal Steps
Detailed steps and cautions for removing the engine from the motorcycle frame.
Engine Reinstallation Steps
Procedure for reinstalling the engine, including torque values and critical cable tension adjustments for the exhaust valve control.
Engine Disassembly
Draining Transmission Oil
Instructions for draining the transmission oil by removing the drain plugs.
Removing Sprocket and Gear Selector
Steps to remove the sprocket, gear selector, and clutch control rod.
Removing Cylinder Head, Cylinder, and Piston
Procedure for removing the cylinder head, cylinder, piston pin, and base gasket.
Removing the Clutch
Steps to remove the water pump cover, clutch cover, and their seals.
Removing Clutch Pressure Plate and Discs
Procedure for loosening screws and removing the pressure plate, springs, and spring cups.
Removing the Electric Starter
Instructions for removing the electric starter by taking out two screws.
Removing Primary Drive Gear
Steps to secure the crankshaft, loosen the nut, and remove the primary drive gear and conical washer.
Removing the Interlock Mechanism
Procedure to compress the spring, remove the retaining bolt, shifting interlock mechanism, and lever.
Removing the Ignition Cover
Steps to remove retaining screws and the ignition cover with its gasket.
Removing Starter Double Gear and Drive
Instructions for removing shoulder bolts, retaining bracket, double gear, needle bearing, and starter drive.
Removing the Flywheel
Procedure to hold the flywheel, remove the retaining nut, and use extracting tools to remove the flywheel.
Removing Intake Manifold and Reeds
Steps to remove bolts, intake manifold, reed block, and associated parts.
Separating Engine Housing Halves
Procedure for separating the engine crankcase halves, including screw removal and tapping on the output shaft.
Removing Transmission Components
Steps to remove lubrication tube, shims, shifting fork shafts, shifting drum, and shifting forks, paying attention to rollers.
Removing the Crankshaft
Procedure to pull the crankshaft out of the bearing and clean/inspect all parts for wear.
Engine Components
Crankshaft Installation and Inspection
Instructions for replacing roller bearing inner ring, heating tools, and installing new rings.
Checking Crankshaft Dimensions
Using a Vernier caliper to measure crankshaft counterweight distance and overall dimension.
Checking Big End Radial Clearance
Procedure to measure big end radial clearance using V-blocks and a dial indicator.
Checking Connecting Rod Lateral Play
Measuring side clearance of the connecting rod and checking against permissible limits.
Checking Crankshaft Runout
Procedure to measure crankshaft runout using alignment fixtures and dial indicators.
Piston Inspection
Checking piston skirt for seizing, stuck rings, ring retainers, and piston rings condition.
Checking Piston Ring End Gap
Measuring piston ring end gap using a feeler gauge after placing the ring in the cylinder.
Checking Cylinder for Wear
Using a micrometer to measure cylinder bore diameter at different locations for roundness and ovality.
Remanufactured Cylinder Guidelines
Guidelines for replacing or replating cylinders, noting piston and cylinder size stamping.
Exhaust Valve System Disassembly
Steps to disassemble exhaust valve system parts, clean them, and check for wear, including cable removal.
Checking Exhaust Valve and Booster Operation
Procedure to check the operation of the guillotine and booster valves by rotating the control valve.
Adjusting Valve Cable Tension
Instructions for installing tools, boosters, main valves, and cover, then tightening screws to specification.
Reed Valves and Intake Manifold
Checking carbon reeds for elasticity loss and intake manifold for cracks.
Clutch Component Inspection
Checking clutch release bearing assembly, rod, springs, friction discs, and steel discs for wear and thickness.
Engine Reassembly
Crankshaft Reassembly
Carefully inserting the crankshaft assembly into the crankcase bearing.
Gearbox Reassembly
Installing rollers, washers, primary and secondary shafts, and shifting forks into the crankcase.
Assembling Crankcase Halves
Procedure for installing the lubrication tube, gasket, seals, and screws to assemble the crankcase halves.
Selector Mechanism Reassembly
Steps for installing the spring, spacer, locking pin, washer, star shaped selector drum, and roller.
Clutch and Primary Drive Reassembly
Lubricating seals, installing spacer, key, primary gear, washer, bearings, clutch housing, and tightening nuts.
Clutch Discs and Pressure Plate Reassembly
Installing clutch release bearing, lubricating friction discs, alternating discs, and installing pressure plate, cups, springs, and screws.
Clutch Housing Reassembly
Checking dowels, installing housing gasket, water pump shim washers, and securing the clutch housing with screws.
Piston and Cylinder Reassembly
Lubricating parts, installing needle bearing, piston, pin, rings, and cylinder, then tightening bolts.
Cylinder Head Reassembly
Cleaning mating surfaces, installing dowels, cylinder head, and tightening bolts with copper washers.
Reed Valves and Intake Manifold Reassembly
Installing gaskets, reed block, intake manifold assembly, and inlet sleeve with metal collar.
Transmission Output Sprocket Reassembly
Lubricating O-ring, installing spacer, output sprocket, safety washer, and nut, then bending the tab.
Mounting the Starter Drive
Installing double gear, starter drive, retaining bracket, and shoulder bolts, then greasing gears.
Flywheel and Ignition Cover Installation
Installing half moon, flywheel, nut, dowels, gasket, and ignition cover.
Installing the Electric Starter
Replacing O-ring, installing starter, attaching with screws, lubricating clutch shaft, installing gear selector and drain plugs.
Tightening Torque Table
Standard Torque Specifications
Table of torque values for M5, M6, and M8 screws.
Chassis Torque Specifications
Table of torque values for chassis components like axle nuts, frame bolts, and fork pinch bolts.
Engine Torque Specifications
Table of torque values for engine components like sensor screws, drain plugs, clutch parts, flywheel, and cylinder mounting.
Checking the Charging System
Static Charging System Checks
Measuring battery voltage and stator winding resistance with the engine off.
Dynamic Charging System Checks
Checking voltage regulator and output regulator values at different RPMs.
Wiring Diagrams
Main Wiring Harness Diagram
Diagram illustrating the main wiring harness connections and components.
Lighting Harness Diagram (Standard)
Electrical diagram for the standard lighting harness for SE-R 250/300 models.
Lighting Harness Diagram (Racing)
Electrical diagram for the racing lighting harness for SE-R 250/300 models.
Wiring Harness for Accessories
Diagram for the wiring harness used for accessories, including flashers, horn, and plate light.
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