Related Manuals for SHERCO 250 SEF FACTORY
Summarization of Contents
TOOL LIST
TOOL 250/300 4T
Lists essential tools for maintenance and repair of 250/300 4T models.
FACTORY
Tools specific to the 'Factory' model variant.
SUSPENSION
Tools for suspension maintenance and adjustment.
RACING
Tools specific to the 'Racing' model variant.
STANDARD ADJUSTMENT
FORK
Original settings and adjustment procedures for the front fork suspension.
SHOCK ABSORBER
Original settings and adjustment procedures for the rear shock absorber.
REMOVING / REISTALLING THE ENGINE
REMOVING THE ENGINE
Step-by-step guide for removing the engine from the motorcycle chassis.
REINSTALLING THE ENGINE
Instructions for reinstalling the engine back into the motorcycle chassis.
ENGINE
REMOVING THE CYLINDER HEAD
Detailed steps for removing the cylinder head assembly from the engine.
Preparation
Preparatory steps before disassembling the engine's cylinder head.
Removing the cam chain tensioner
Procedure for removing the camshaft chain tensioner.
Removing the camshafts
Steps for removing the camshafts from the cylinder head.
Removing head cylinder
Procedure for removing the cylinder head from the engine block.
INDIVIDUAL PARTS INSPECTION
ENGINE TOP END CONTROLS
Checks and inspections for the engine's top-end components.
Inspection of the cylinder for wear
Procedure for inspecting the cylinder for wear and measuring its diameter.
Piston wear
Procedure for measuring piston diameter and checking for wear.
Ring groove / Piston ring
Checking clearance between piston rings and their grooves.
Ring end gap
Measurement of piston ring end gap.
Inspect the connecting rod, the piston pin and the piston for wear
Visual and dimensional inspection of connecting rod, piston pin, and piston.
Check the camshafts for wear
Procedure for measuring camshaft lobe height and checking for wear.
Checking the camshafts and camshaft journals for wear
Checking clearance and diameter of camshaft journals.
Eccentricity of the camshaft
Measuring camshaft runout to check for eccentricity.
Cylinder head inspection
Inspecting the cylinder head for flatness and warpage.
Visually inspect the timing chain for damage
Visual inspection of the timing chain and related parts for wear or damage.
Valve – Guide clearance
Measuring valve and guide clearance for intake and exhaust valves.
REASSEMBLING THE TOP END OF THE ENGINE
Reassemble the piston
Procedure for correctly installing piston rings and the wrist pin.
Reassemble the cylinder head
Steps for installing the cylinder head, including bolt tightening sequence.
Valve timing
Procedure for setting and verifying the engine's valve timing.
Camshaft retaining cover torque
Torque specifications for the camshaft retaining cover bolts.
Camshaft chain tensioner
Procedure for installing the camshaft chain tensioner.
Valve cover
Procedure for installing the valve cover, including torque values.
Valve clearance
Procedure for checking and adjusting valve clearance using shims.
Replacing the timing chain
Steps for removing and installing the engine's timing chain.
DISASSEMBLING COVER
DISASSEMBLING THE RIGHT SIDE
Procedures for disassembling the right side of the engine/transmission.
Clutch dismantling
Steps for disassembling the motorcycle's clutch assembly.
Inspection of the clutch
Inspection of clutch plates and discs for wear and deformation.
Check the clutch spring length
Procedure for measuring clutch spring length.
Disassembling and inspecting the water pump
Steps for removing and inspecting the water pump assembly.
Changing the water pump shaft seal
Procedure for replacing the water pump shaft seal.
Removing the clutch hub and the clutch basket
Steps for removing the clutch hub and basket assembly.
Reassembling the clutch hub components
Procedure for reassembling the clutch hub components.
Disassembling the ignition case
Procedures for disassembling the ignition case.
Replacing the stator and sensor system
Steps for replacing the stator and associated sensors.
Removing the rotor
Procedure for removing the rotor assembly.
Inspect the freewheel and the needle bearings
Inspection of the freewheel and needle bearings for wear.
Reassembling the ignition case
Procedure for reassembling the ignition case.
DISASSEMBLING CRANKCASES
Disassembling the transmission and the crankshaft
Steps for disassembling the transmission and crankshaft from the crankcase.
Checking the transmission components
Inspection of transmission gears, forks, and drum for wear or damage.
Checking the crankshaft
Procedures for checking crankshaft radial play, lateral movement, and run out.
Checking the crankcase
Inspection of crankcases for wear, cracks, and bearings.
Reassembling the central crankcase assembly
Procedure for reassembling the central crankcase with transmission and crankshaft.
Inspection of the primary shaft side play
Checking and adjusting the primary shaft side play using shims.
TIGHTENING TORQUES
STANDARD TORQUE
Standard torque values for common fastener sizes (M5, M6, M8, M10).
MOTOR TIGHTENING TORQUES
Specific torque values for engine components and fasteners.
FRAME TIGHTENING TORQUES
Torque values for frame and chassis related components.
INJECTOR BODY
Clean injector body
Steps for cleaning the fuel injector body.
Material
List of materials and tools required for injector body cleaning.
Put down the injector body
Procedure for removing the fuel injector body from the motorcycle.
Disconnect each connector
Steps for disconnecting electrical connectors on the injector.
Visually inspect the connector
Visual inspection of electrical connectors for damage or debris.
Clean with carb cleaner or universal product cleaner
Cleaning electrical connectors using appropriate cleaning agents.
Clean of injector body
Detailed steps for cleaning the fuel injector body.
Replace the injector body
Procedure for replacing the entire fuel injector body assembly.
ELECTRICAL INSTALLATION CHECKING
1- Fan control
Procedure for checking the operation of the cooling fan.
2-CDI
Information regarding the CDI unit and its connections.
3-Fuel pump control
Procedure for checking the fuel pump operation and pressure.
4-Fall sensor control
Checking the fall sensor (angle sensor) output voltage.
5-Checking the voltage regulator
Procedure for checking the voltage regulator's output and diode bridge.
6-Battery control
Procedure for checking the motorcycle battery voltage.
7-Map sensor control
Checking the MAP sensor output voltage.
8-TPS sensor control
Checking the TPS sensor output and input voltage, and resistance.
9-Stepper motor control
Checking the stepper motor coils for continuity.
10-Injector control
Measuring the input voltage to the injector.
11-Starter control
Procedure for testing the starter motor operation.
12-Checking the alternator
Checking alternator winding resistance and output voltage.
13-Hall sensor control (Crankshaft)
Checking the Hall sensor resistance and output voltage.
14-Water sensor control
Checking the water sensor resistance at various temperatures.
15-Ignition coil control
Checking the primary and secondary coil resistance of the ignition coil.
WIRING HARNESS
Homologated light wire harness (8145)
Wiring diagram for the homologated light wire harness.
Racing light wire harness (6845)
Wiring diagram for the racing light wire harness.
Main wire harness (7314)
Wiring diagram for the main wire harness of the motorcycle.
Fan wire harness (3577)
Wiring diagram for the fan wire harness.
SYNERJECT) INJECTION SYSTEMINSTRUCTION MANUAL
SYNERJECT) INJECTION SYSTEM PRESENTATION
Introduction to the Synerject injection system components.
1.1- Injection system
Overview of the Synerject injection system and its main parts.
1.2- Description Exxodiag diagnostic Tools référence 4967
Description of the Exxodiag diagnostic tool and its capabilities.
1.3- Diagnostic tool kit contents.
Contents of the diagnostic tool kit.
1.4- Installation of the diagnostic tool
Step-by-step guide for installing the diagnostic software and drivers.
A- Installing the software and drivers
Detailed instructions for installing the diagnostic software and drivers.
B-Connect the «MUXDIAG II » cable and its interface to a USB port on your computer
Connecting the diagnostic tool to the computer via USB.
2.1- Connection with Keyless system
Procedure for connecting the diagnostic tool to bikes with a keyless system.
2.2 Software settings : configuration menu
Configuring software settings like communication peripheral and language.
2.3- Update menu and synchronization
Updating the diagnostic software tool.
A- In this menu, you can update the diagnostic software tool
Steps for checking and downloading software updates.
B- Configuration of Internet access parameters
Configuring proxy settings for internet access.
2.4- Using the sofware
General usage of the diagnostic software.
A- Identification
Checking motorcycle identification details like VIN and serial numbers.
B- Parameter measurements
Reading general parameters like RPM, temperature, and voltage.
1- Engine information
Display of main engine system values and parameters.
2- Other less frequently used values appear in the windows
Reading less frequent values like throttle position and engine synchronization.
C- Reading the default codes
Reading stored diagnostic trouble codes from the ECU.
D- Erasing default codes
Procedure for erasing default codes after troubleshooting.
2- Return to the menu « reading default codes »
Navigating back to the 'reading default codes' menu.
E- Test the actuators
Testing system actuators like ignition coil, injector, and fan.
1-Ignition coil
Performing a test on the ignition coil actuator.
2-Injector
Performing a test on the injector actuator.
3-Fuel pump / fan / stepper
Testing fuel pump, fan, and stepper motor actuators.
F- Updating the computer
Updating the motorcycle's ECU software or calibration.
G- Screen printing function
Using the screen printing function to capture diagnostic information.
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