Related Manuals for SHERCO 250 SE RACING
Summary of Contents for SHERCO 250 SE RACING
- Page 1 WORKSHOP MANUAL | MANUEL D’ATELIER | MANUAL DE TALLER 250 SE RACING 250 SE FACTORY 300 SE RACING 300 SE FACTORY...
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Page 2: Table Of Contents
TABLE OF CONTENTS FORWARD ..............3 ❱❘ Assembly the ignition and starter assembly..... 34 ❱❘ Gear selection mechanism........35 TOOLS LIST 250-300 SE ..........4 ❱❘ Primary transmission and clutch......36 TECHNICAL SPECIFICATION ......... 5 ❱❘ Clutch housing............38 ENGINE .............. -
Page 3: Forward
The execution of the operations in this manual requires a strong mechanical knowledge and specific SHERCO tools designed for the 250 SE and 300 SE engine. This workshop manual is a supplement to the SHERCO 250 SE and 300 SE owner’s manual. -
Page 4: Tools List 250-300 Se
TOOLS LIST 250-300 SE TOOLS 250/300 2T Owner Manual Clutch Tool Crankshaft Ring Extractor Engine support / Container R464 8699 5749 R481/R455 Pinion clutch shaft tool Ignition Tool Flying extractor Tool kit 5593 4753 0726 R462 Gearbox Ring Extractor Diagnostic Tool 10092 8561 SUSPENSION... -
Page 5: Technical Specification
TECHNICAL SPECIFICATION ENGINE Mono-cylinder 2 temps liquid Type 249,32 CC 293,14 CC Displacement 72 / 72 mm Bore / Stroke 66,4 / 72 mm Compression ratio 11.5 / 1 11.9 / 1 Without lead 95 or 98 mixed with 2 stroke oil (2%) Fuel Liquid forced Cooling... -
Page 6: Bike Specification
TECHNICAL SPECIFICATION BIKE SPECIFICATION Frame Semi-perimétric CrMo steel with aluminium sub frame KAYABA USD Ø48mm Closed cartridge (FACTORY) Fork KAYABA USD Ø48mmopen cartridge (RACING) KAYABA rear shock with separate cylinder Rear shock Aluminium swing-arm FACTORY 330/330mm Travel front / rear RACING 300/330mm Rotor Ø... -
Page 7: Standard Adjustment Fork
STANDARD ADJUSTMENT FORK Setting Factory – Fork KAYABA USD Ø48 mm Compression Comfort 20 clicks back Standard 13 clicks back Sport 8 clicks back Rebound Comfort 18 clicks back Standard 13 clicks back Sport 10 clicks back Spring stiffness Rider weight : 65-75 kg 4.0N/mm (Original) Rider weight : 75-85 kg 4.2N/m... -
Page 8: Shock Absorber
STANDARD ADJUSTMENT SHOCK ABSORBER Setting Factory – Shock absorber KAYABA Comfort 20 clicks back Low-speed compression 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 THE ENGINE NOT DEMOUNTING ENGINE Crankshaft (including • connecting rod kit) • Gear box • Crankshaft bearing • Gear box bearing • Piston • Cylinder • Cylinder head • Ignition • Pinion of ignition system •... -
Page 10: Removing / Reinstalling The Engine
REMOVING / REINSTALLING 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. -
Page 11: Engine Disassembly
ENGINE DISASSEMBLY ❱❘ Draining the gearbox • Remove drain plugs & and allow the oil to drain. ❱❘ Removing the pinion and gear selector lever • Remove circlips using external pliers. • Remove the gearbox sprocket • Remove screw and remove the gear selector lever. -
Page 12: Dismantling The Engine Top End
ENGINE DISASSEMBLY ❱❘ Dismantling the engine top end : ❱❘ Removing the cylinder head, cylinder and piston • Remove the shoulder screws and the cooper washers. • Remove the cylinder head and the two toric seals. • Remove the 3 valve actuator cover screws taking care to not lose the metal spacers •... - Page 13 ENGINE DISASSEMBLY • Remove the 4 shoulder nuts at the base of the cylinder. • Remove the cylinder and place tool 5774 under the piston to hold it in place. • Cover the housing. • Remove the piston pin circlips •...
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Page 14: Disassembly Of The Right Side
ENGINE DISASSEMBLY ❱❘ Disassembly of the right side: ❱❘ Removal of the clutch cover. Remove the 4 screws • Remove the water pump housing • it’s O-ring. Remove the water pump impeller • turning it counter clockwise. Remove the 9 housing screws •... - Page 15 ENGINE DISASSEMBLY • Remove the clutch release bearing • Remove the friction discs pack and smooth disc from the clutch basket • Using tool 5206 Installed between the crown and the primary transmission gear which locks the assembly allowing the transmission nut to be removed using 28 mm socket.
- Page 16 ENGINE DISASSEMBLY • Using a magnet remove the washer from the bearing support. • Remove the pinion and its key from the crankshaft. The primary transmission pinion and clutch gear ring gear are matched, so they cannot be changed separately. Always replace them as a matched set.
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Page 17: Disassembly Of The Left Side
ENGINE DISASSEMBLY • Remove the pin from the selector cylinder. • Remove the BTR screw , remove the washer the locking tab and the spring. ❱❘ Disassembly of the left side : ❱❘ Removing the starter assembly. Remove the 8 screws from the ignition cover •... -
Page 18: Ignition Removal
ENGINE DISASSEMBLY Remove the starter motor • Be careful to not lose the washer, which is located behind the launcher. Remove the torque limiter • ❱❘ Ignition removal. • Hold the ignition flywheel with tool 4753 remove the locknut from the crankshaft. -
Page 19: Disassembly Of The Crankcases
ENGINE DISASSEMBLY ❱❘ Disassembly of the crankcases: ❱❘ Inlet pipe and reed valve box. Remove the 4 retaining screws from the • inlet pipe Remove the inlet pipe • Remove the reed valve box as well as the • seal ❱❘... -
Page 20: Removal Of The Gear Selection
ENGINE DISASSEMBLY • Remove the left crankcase half by lifting it up and lightly tapping the gearbox output shaft with a plastic hammer in order to separate the two halves. WARNING Avoid as much as possible introducing a screwdriver or any other tool between the two-crankcase halves to separate them. -
Page 21: Removal Of The Crankshaft
ENGINE DISASSEMBLY Take care to not lose the rollers • the shifter fork lugs. Remove the shift forks from the • gearbox. • Simultaneously bring out of their bearing the drive shaft and the shaft secondary. ❱❘ Removal of the crankshaft. •... -
Page 22: Replacing Engine Components
REPLACING ENGINE COMPONENTS ❱❘ Replacement of the crankshaft bearings. • Remove the crankshaft oil seal on the left end of the crankshaft. • Place a kinetic puller of 35 capacity on the roller bearing, heat the crankcase around the bearing and remove the bearing. -
Page 23: Gear Box Output Bearing
REPLACING ENGINE COMPOENTS ❱❘ Gear box output bearing. • Start by removing the ignition housing (Cf ❱❘ Disassembly of the left side). • Unscrew the bearing locking screw, and remove the retaining plate. • Install a 30mm kinetic puller in the roller bearing. -
Page 24: Inspecting The Engine Components
INSPECTING THE ENGINE COMPONENTS ❱❘ Checking the crankshaft: ❱❘ Balancing mass, External dimension control. • Using a caliper, measure the outer distance of the balancing mass. External value: 64.3mm +0 / -0.2 ❱❘ Radial clearance of the connecting rod head. •... -
Page 25: Checking The Crankshaft Runout
INSPECTING THE ENGINE COMPONENTS ❱❘ Checking the crankshaft runout. • Place the crankshaft on an alignment device or a set of V-blocks and locate the dial indicators as shown in the picture. • Then slowly rotate the crankshaft. The maximum difference between the measurements corresponds to the centring of the crankshaft. -
Page 26: Checking The Piston Pin
INSPECTING THE ENGINE COMPONENTS ❱❘ Checking the piston pin Piston pin diameter Piston pin hole diameter Standard: 17,995-17,998 mm Standard: 18.006-18.010mm Tolerated limit: 18.08mm Tolerated limit: 17,962mm ❱❘ Checking state of the cylinder wear • To determine the cylinder wear. Measure the cylinder bore with bore inspection tool. Mesure about 10mm fril the top edge of the cylinder. - Page 27 INSPECTING THE ENGINE COMPONENTS Remove the 2 screws , remove the • actuator support Remove the 4 screws from the • exhaust chamber cover. Degrease the exhaust gas chamber. • Make sure that the drain hole is not • clogged. Remove the stop screw and its •...
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Page 28: Functional Check
INSPECTING THE ENGINE COMPONENTS Use a clamp and remove the booster • valve. Using a rod push out the first valve • shaft. if it does not come out with the booster, • use a pair of pliers to remove the valve axel. -
Page 29: Assembling The Valve Mechanism
INSPECTING THE ENGINE COMPONENTS ❱❘ Assembling the valve mechanism. Systematically replace all of the top end gasket. Place the valve in its housing. • Install the booster and its circlips in the • exhaust chamber. Install the first valve shaft. •... - Page 30 INSPECTING THE ENGINE COMPONENTS • Tighten the booster stop screw at 4Nm do not forget to install is sealing washer. • Use the new gasket and install the actuator support • Tighten screws to 10Nm. Warning : screw is a 6 x 20 screw use a washer while the screw is a 6 x 16...
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Page 31: Transmission Control
WARNING After any maintenance, operation on the internal parts of the cylinder and / or after changing the cylinder it is necessary to adjust the automatic valves using the Sherco diagnostic tool. 3.4 Actuator test (Page: 66) ❱❘ Transmission control ❱❘... -
Page 32: Gearbox
INSPECTING THE ENGINE COMPONENTS ❱❘ Gearbox. Check all of the gears : • Check the coupling dogs • • Check the pinion teeth • Check the fork grooves Check the condition of the shifter lock • forks. Thickness limit value: 4.87 mm Check the selector drum;... -
Page 33: Engine Reassembly
ENGINE REASSEMBLY ❱❘ Assembling the crankshaft and the gearbox Start by cleaning the engine casings thoroughly, do not hesitate to blow into the lubrication passages and remove all impurities. Install a new O-ring at the end • of the crankshaft. Simultaneously install the two-gear •... -
Page 34: Assembly The Ignition And Starter Assembly
ENGINE REASSEMBLY Place an O-ring on the end of the • lubrication tube and install it in the crankcases as show. Install the location pins on the crankcase • housing. Install a new gasket. • You can install the ignition side •... -
Page 35: Gear Selection Mechanism
ENGINE REASSEMBLY ❱❘ Gear selection mechanism. • Install the spring in the housing with curved ends up. The other end of the spring should rest against the housing • Install the spacer, the locking finger, and the washer, apply blue threat locker to the screw tighten to 10Nm. -
Page 36: Primary Transmission And Clutch
ENGINE REASSEMBLY ❱❘ Primary transmission and clutch. • Lubricate the crankshaft seal and insert it into its housing. • Install the spacer that you have pre- oiled on the crankshaft. • Install the half-moon key on the crankshaft. • Install the conical washer and the nut •... - Page 37 ENGINE REASSEMBLY • Using the tool 5749 to hold the clutch housing tighten the nut to 100Nm. • Oil all of the clutch discs. • Install them in the clutch basket alternating a smooth disc and a disc with fiber. A disc with the fiber should be the first disc installed Warning: You must end up with a fiber disc which is housed differently from the others discs in the guide grooves.
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Page 38: Clutch Housing
ENGINE REASSEMBLY ❱❘ Clutch housing. • Check to make sure that the two locating sleeves are securely in place in the housing. • Install the clutch housing along with a new seal. • Install 5 clutch cover screws tighten to 10 Nm. •... -
Page 39: Piston Et Cylinder
ENGINE REASSEMBLY • Before you install the starter launcher, make sure that the support washer is installed. • Place the starter motor into its housing. • Installed the 2 locating pins for the limiter support. • Install the limiter support; grease the pinion with spray grease. - Page 40 ENGINE REASSEMBLY • Install the needle bearing in the connecting rod. • Position the piston (with the arrow pointing towards the exhaust). • Install the piston pin. • Using the circlips installation tool install the piston circlip with open facing down. •...
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Page 41: Cylinder Head
Protrusion measurement or withdrawal (-) piston (X mm) squish with Thickness of Sherco ref Made with 0.5 mm gasket gasket 0.5 mm gasket to obtain from gasket up Squich 1,7 mm to 1.7mm of... -
Page 42: Reed Valve And Intake Pipe
ENGINE REASSEMBLY • Install the cylinder head. • Install the shoulder bolt along with new cooper washers. • Tighten the bolts in tree passes and crosswise to 25Nm. • Coat the temperature sensor with waterproofing Loctite ® 577. • Install the temperature sensor along with a new seal and tighten to 20Nm. -
Page 43: Installation Of The Ignition Cove
ENGINE REASSEMBLY Install the clamp on the inlet pipe. • ❱❘ Installation of the ignition cove. • Install the 2 guides • Install a new gasket. • Install the cover. • Tighten the 8 cover screws and tighten to 10Nm. •... -
Page 44: Water Pump / Balnce Shaft Bearing
REPLACING ENGINE COMPONENTS ❱❘ Water pump / balnce shaft bearing. • Start by removing the clutch housing (See: Disassembly of the right side). • Remove the water pump / balancer shaft. • Use tool 8987. • The tool consists of the 6 different parts. •... - Page 45 REPLACING ENGINE COMPONENT • Screw the threaded rod into the claws. • Install nut while keeping the claws and the spacer • Heat the crankcases around the periphery of the where the bearings are installed. Warning: Do not hesitate to heat well at the risk of damaging your tool.
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Page 46: Electrical Part
ELECTRICAL PART ❱❘ Electical components Position Designation Position Designation Coil Relay Additional CDI Temperature sensor Hall sensor Starter Battery Alternator Regulators Valve motor... -
Page 47: 1- Fan Control
ELECTRICAL PART ❱❘ 1- Fan control Disconnect the fan from the harness. • Connect a 12v battery directly to the fan • as shown in the diagram. Check to make sure the fan run • smoothly without any excessive noise. ❱❘... -
Page 48: 4-Battery Check
ELECTRICAL PART ❱❘ 4-Battery check – Connect a multimeter to the battery • terminals and check its voltage la Value read: 12.8V Battery charged 12.7V or less Charge battery Less than 12V Replace battery ❱❘ 5-starter check Remove the starter and position it in a •... -
Page 49: 7-Checking The (Crankshaft) Hall Sensor
ELECTRICAL PART ❱❘ 7-Checking the (crankshaft) hall sensor Sensor resistance check. • Connect the multimeter between the red and green wire of the sensor and measure the resistance. Sensor resistance: 100 Ω +/- 20% Checking the output voltage of the •... -
Page 50: 9-Checking The Ignition Coil
ELECTRICAL PART ❱❘ 9-Checking the ignition coil Remove the ignition coil. • Using a multimeter, measure the • primary coil resistance in the following SPARK PLUG manner. Primary coil: measure the resistance • between the ground and the coils output to the CDI. -
Page 51: Diagnostic Tool Synerject
DIAGNOSTIC TOOL SYNERJECT SYNERJECT INJECTION SYSTEM PRESENTATION 1.1- Components Identification Synerject M3C : 3459 Valve motor : 6933 Ignition coil: Temperature sensor: Additional CDI : Ref 4003 Ref 0380 Ref 8456 1.2- Description Exxodiag diagnostic Tools Ref: kit 8561 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: Diagnostic Tool Kit Contents
Diagnostic tool kit contents. The diagnostic kit (Ref : 8561) consists of a USB to MUX output cable, a MUX device, a MUX to motorcycle diagnostic connector cable, a shunt and a user manual. http://download.annecyelectronique.com/Exxodiag/Sherco/ShercoDiag_Setup.exe 1.4- Installation of the diagnostic tool. - Page 53 DIAGNOSTIC TOOL SYNERJECT • Click on “Next”. • Click on « Install ». • Installation in progress. 250/300 SE...
- Page 54 DIAGNOSTIC TOOL SYNERJECT • Check the box “Start the driver installation” and click on “Finish”. • The next window opens. Read the terms of the License Agreement Check « I accept the terms of the License Agreement » and « Install » •...
- Page 55 DIAGNOSTIC TOOL SYNERJECT • The following window will open . Click on « Finish » Installation is now complete B- Connection between computer, « Muxdiag II » and motorbike Connect the cable to the diagnostic connector of the motorcycle. Make sure the “Muxdiag II “unit is properly powered by checking the LED: •...
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Page 56: Presentation Of The Software
2.1- Connection with keyless system Sherco has equipped its motorbikes with a “keyless” system that a allows keyless operation and automatically turns off the ignition after 30 seconds of inactivity. This las point prevents the diagnosis from being made; which is why it is essential to... - Page 57 DIAGNOSTIC TOOL SYNERJECT Information: To set up the connection with the motorcycle, the motorcycle must be switch on with the shunt. To navigate through the different menus, only the USB cable with the “Muxdiag II” box must be connected to the computer. Start the software using the icon on your desktop: The following menu will come up: Update and...
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Page 58: Software Settings
DIAGNOSTIC TOOL SYNERJECT Software settings 2.2- • Configuration menu: 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 your « Muxidiag II » device. The language available in the software: French, English, Spanish, Portuguese, German, Italian. -
Page 59: Update Menu And Synchronization
DIAGNOSTIC TOOL SYNERJECT 2.3- Update menu and synchronization A- in this menu, you can update the diagnostic sofware tool. • To find out if an update is available, check that you have an internet connection, then click on the following icon •... - Page 60 DIAGNOSTIC TOOL SYNERJECT • Click on to start downloading the update. • The following message fill come up. • Click on to start the installation • Repeat the installation steps. It is not necessary to repeat the driver installation. B- Configuration of internet access parameters It may be necessary to set up a proxy server to access the inter.
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Page 61: Use Of The Software
DIAGNOSTIC TOOL SYNERJECT Use of the software Diagnostic menu and injection mapping update. General • Click on « Sherco’ ». • Click on « M3C ». • You reach the following menu Identification Identification check (Serial number, Vehicle operating hours, calibration number….) -
Page 62: Reading Trouble Codes
DIAGNOSTIC TOOL SYNERJECT A. Measurement of parameters: General parameters (Speed, temperature, pressure ect….) B. Engine information The main values of the system appear: Reading trouble codes If you click on « trouble code reading » the system start checking. • If no trouble codes appears exit the menu by clicking on this icon :... - Page 63 DIAGNOSTIC TOOL SYNERJECT If trouble codes appears : • • You can get the details of the default by clicking on the default display : • Record the defaults and exit the by clicking on this icon • Record the defaults and exit the menu by clicking on : Note: 1- Fugitive/Permanent fault: A fugitive fault becomes permanent after variable number of engine cycles depending on the components (injector, fuel pump, etc.).
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Page 64: Erasing Fault Codes
DIAGNOSTIC TOOL SYNERJECT Erasing fault codes If fault code appears: go to the menu “trouble code cleaning “. Click on in order to clear all the defaults codes : • • The following window appear: • Confirm by clicking on :... -
Page 65: Actuator Test
DIAGNOSTIC TOOL SYNERJECT Return to the “trouble code reading” menu • Check and make sure that the default are the same as befor. Check / Replace the defective parts. • Check all the connections. Actuator test In addition to reading the trouble codes, you can also test certain system components 1- Ignition coil When you launch the ignition coil test, the following message will appear: 250/300 SE... - Page 66 DIAGNOSTIC TOOL SYNERJECT The system is not able to detect an ignition coil failure with the engine stopped. The test result will be the same if the coil is faulty or not. Therefore, when testing the ignition coil make sure that the engine makes the correct sound for a properly functioning ignition coil.
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Page 67: Ecu Update
DIAGNOSTIC TOOL SYNERJECT ECU update With the diagnostic tool, it is possible to update the ignition maps (calibration). For a Racing silencer, for example, or because an update is proposed by the factory. You must pay attention to the model, the displacement, the type of exhaust, ect… In case of doubt, contact the technical support: 1. - Page 69 DIAGNOSTIC TOOL SYNERJECT Confirm by clicking on this icon: Select the previously downloaded calibration “.mot” and click open 4. The file is being downloaded WARNING Do not switch off the motorbike power supply during the dowload operation. Do not switch off the sofware during the flash Risk off irremediable damage to your ECU.
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Page 70: Print Screen Function
DIAGNOSTIC TOOL SYNERJECT Information: Serial N° and operating hour’s information is not rest during a calibration update. 7. Put the “Shunt” back on the connector in the air box to switch back to “Keyless” mode. 8. The procedure of the ECU power latch will proceed during 20 seconds. 9. -
Page 71: Tightening Torques
TIGHTENING TORQUES Standard torque Thread locker 7 Nm 10 Nm 25 Nm Frame Tightening Torque Thread locker Front wheel axel nut Rear wheel axel nut 100 Nm Swing arm pivot nut 100 Nm Rear shock link nut 60 Nm Shock absorber Top / Bottom 50 Nm Top steering head screw 20 Nm... -
Page 72: Carburetor Tuning
CARBURETOR TUNING ❱❘ SE 250-Carburettor adjustment table Sea level Temp -20°C -6°C 6°C 16°C 25°C 37°C -7°C 5°C 15°C 24°C 36°C 49°C Air adjust screw 1T1/4 1T3/4 1T3/4 2T1/4 2T1/4 3.000 m (10,000f ft) Idling jet N1EG N1EG N1EH N1EH N1EI Needle 2.301 m... -
Page 73: Se 300-Carburettor Adjustment Table
CARBURETOR TUNING ❱❘ SE 300-Carburettor adjustment table Seal level Temp -20°C -6°C 6°C 16°C 25°C 37°C -7°C 5°C 15°C 24°C 36°C 49°C Air adjust screw 1T1/2 1T/1/2 2T1/2 3.000 m (10,000f ft) Idling jet Needle N8RE N8RE N8RF N8RF N8RG N8RH 2.301 m Position... - Page 78 NOTES...
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