SHERCO 2013 SE 250i-R Shop Manual
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SHERCO 2013 SE 250i-R Shop Manual

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SE 250i-R
SE 300i-R
Shop manual
2013

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Summary of Contents for SHERCO 2013 SE 250i-R

  • Page 1 SE 250i-R SE 300i-R Shop manual 2013...

  • Page 2: Table Of Contents

    Crankcase / Transmission / Central crankcases ................29 Tightening torques ..........................36 Clean injector body ..........................38 SHERCO diagnostic tools ........................41 Software installation ........................... 42 Software presentation (the various interfaces) : ................... 42 Connecting the diagnostic kit wiring ....................43 Performing diagnostic .........................

  • Page 3: Forward

    The execution of the operations in this manual requires a strong mechanical knowledge and specific SHERCO tools designed for the SE 250i-R and SE 300i-R engine. This workshop manual is a supplement to the SHERCO SE 250i-R and SE 300i-R owner’s manual.

  • Page 4: Motor Tools Se25I-F

    3/54 Motor tools SE25i-F Tool Designation 1819 Dead point 1814 Clutch holder tool 1815 Ignition tool 2067 Swingarm tool 2068 Freewheel tool 2069 Oil seal tool (Gear box exit) 2070 Oil level gauge tool Bearing tool 6905 (Gear selector 2071 drum) 2072 Bearing tool 6222 (Clutch shaft)

  • Page 5: Technical Specification - Motor

    4/54 Technical specification - Motor Type Liquid cooled single cylinder 4 strokes engine Displacement 249.4 CC 303.7 CC Bore/Stroke 78/52mm 84/54.8mm Compression ratio 12.6 :1 12.8:1 Fuel Without lead 95 or 98 Valve timing 4 valves, DOHC driven by tooth type chain Admission valve diameter 29mm Exhaust admission valve...

  • Page 6: Technical Specification - Frame

    5/54 Technical specification - Frame Frame Semi-perimeter CrMo steel with aluminum subframe SACHS USD Gold Series 48mm dia. (standard) & WP USD 48mm dia. Fork (racing) Rear suspension WP Suspension with separate cylinder Travel Front/rear 300/300mm Front brake 270mm (standard), 256mm (racing) Rear brake 220mm Brake disc...

  • Page 7: Standard Adjustement - Fork

    6/54 Standard adjustement – Fork Standard adjustment - Fork Sachs USD Gold Series Ø48MM Compression Turn clockwise to the stop, then back of 12 clicks Turn clockwise to the stop, then back off Rebound 12 clicks 4.5N/mm Spring SAE 5 Fork oil 600cm3 Oil capacity...

  • Page 8: Standard Adjustement - Shock Absorber

    7/54 Standard adjustement – Shock absorber Standard adjustment - WP Shock absorber Low-speed Comfort 20 clicks back compression Standard 15 clicks back Sport 12 clicks back High-speed Comfort 2.5 clicks back compression Standard 2 clicks back Sport 1.5 clicks back Rebound Comfort 15 clicks back...

  • Page 9: Operations Requiring Demounting Or Not Engine

    8/54 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 •...

  • Page 10: Removing The Motor

    9/54 Removing the motor Removing the motor: 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 10/54 Reinstalling the motor: • The motor should be reinstalled in the frame in the reverse order of how it was removed. The following torque values should be utilized. Tightening torques : Motor mounting bolts: 60Nm Swing arm axle nut: 100 Nm Clutch receiver screws: 10 Nm Cylinder head bracket bolts: 23Nm Exhaust mounting bolts: 10Nm...

  • Page 12: Motor Top End

    11/54 Motor top end For additional details refer to the parts catalog SE 250i_SE 300i.. Removing the cylinder head: • Remove the spark plug. • Remove the valve cover. • Remove the three valve cover screws. These three screws are equipped with o- rings ref: 0900.
  • Page 13 12/54 • Remove the screws from the cam chain tensioner as shown in the photo. • Remove the cam chain tensioner. • Remove the spark plug well. • Remove the camshaft bearing journal. Starting on the inside, remove the screws In a criss cross manner (see the numbers on the photo).
  • Page 14 13/54 • Remove the cylinder head bolts (Be sure to loosen them in the correct direction). Black bolt N° 1 on the picture is longer , 3 bolts are identical . • Remove the cylinder head. • Remove the head gasket and the cylinder.
  • Page 15 14/54 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 16 15/54 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: 31.245 mm Intake: 32.145 mm Camshaft height limit 300 Exhaust: 31.977 mm...
  • Page 17 16/54 Inspect the cylinder head for flatness: • Place cylinder head fezf 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. If the warpage is above the limit, repair if possible.
  • Page 18 17/54 Reassembling the top end of the motor: 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 19 18/54 • 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 20 19/54 Valve timing: • Verify that tool number 1819 is still properly installed. • Install the intake cam. • Install the exhaust cam. (see the photo for how to set the timing marks) IN (Admission) EX (Echappement) The timing marks should align with the joint •...
  • Page 21 20/54 • Install the camshaft retaining cover. (pay careful attention to the tightening order). Camshaft retaining cover torque 10Nm • Install the camshaft chain tensioner using a new gasket. Torque the two fixing bolts to: 10Nm • Install the cam tensioner adjusting bolt (pay attention to the o-ring).
  • Page 22 21/54 • Apply a thin coat of silicone to the camshaft end cap bores. • Replace the valve cover. • Install the valve cover installation bolts. Torque the bolts to: Checking the valve clearance: • The valve clearance must be checked when the engine is cold.
  • Page 23 22/54 Replacing the cam chain: • Remove the camshafts (see the chapter on the motor top end). • Remove the clutch cover (see the chapter on « Right side » removing the clutch). • Remove the chain tensioner adjuster. • Remove the cam chain.

  • Page 24: Disassembling The Right Side

    23/54 Disassembling the right side For additional details see the parts catalog 250i and 300i. Clutch dismantling: • Install special tool number 1819. Only use this tool for disassembling the clutch, do not use it to remove the hub fixing nut.
  • Page 25 24/54 • Reinstall the clutch cover, inspect the o- ring and replace if it is damaged. 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.
  • Page 26 25/54 Removing the clutch hub and the clutch basket: • Drain the engine oil and the engine coolant. • Remove clutch housing. (see disassembling the right side paragraph) • Remove the clutch. (see clutch removal paragraph) • Remove the clutch release bearing assembly.

  • Page 27: Disassembling The Left Side

    26/54 Disassembling the left side For additional details refer to the parts catalog 250i and 300i. Disassembling the ignition case: • Drain the engine oil. • Remove the 10 screws that retain the ignition case. • Visually inspect the inner surfaces of the rotor [A] and the outer surfaces of the stator [B].
  • Page 28 27/54 • Remove the flywheel using special tool number R462. • Remove the two starter shafts along with the starter gears. • Remove the oil centrifuge (anti blowby) Attention the threads this screw are LH, do not turn the wrong direction. •...
  • Page 29 28/54 Reassembling the ignition case: • Apply grease to the caged needle bearing and reinstall it. • Reinstall the two starter shafts and their gears. • Visually inspect the oil seal on the oil centrifuge. • Use special tool number 1818 to install the oil centrifuge.

  • Page 30: Crankcase / Transmission / Central Crankcases

    29/54 Crankcase / Transmission / Central crankcases Disassembling transmission 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 31 30/54 • 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. Checking the transmission components: •...
  • Page 32 31/54 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 33 32/54 Checking the center crankcases: • Inspect the general condition of the center crankcases for wear and cracks. Replace the center crankcase if necessary. • Inspect the condition of all the bearings. Replace the bearings if necessary. • Inspect the condition of the crankshaft bearings.
  • Page 34 33/54 Reassembling the central crankcase assembly: During the rebuild, replace all seals (paper, seal, o-ring…). • Install crankshaft counter balancer assembly in the left case, align the marks as shown. • Install the transmission gear along with their corresponding shafts. •...
  • Page 35 34/54 • 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 Nm.
  • Page 36 35/54 • Install the special tool that locks the engine at top dead center (ref 1819). • Use tool 1817 to block the transmission ant to tighten balancer nut. Torque balancer threadlocker. • Install the oil pump drive roll pin, the intern rotor and fixing nut to the cover.

  • Page 37: Tightening Torques

    36/54 Tightening torques Standard torque Threadlocker 6 Nm 10 Nm 24 Nm 40 Nm 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 bolts / axle M6 15 Nm Brake pad bolt 8 Nm...
  • Page 38 37/54 Motor tightening torques Threadlocker Ignition sensor screw 8 Nm • Bolt for bleeding cooling system 6 Nm Clutch slave cylinder screw 9 Nm Exhaust bolt 10Nm Cylinder head pass 30 Nm 2nd pass 50 Nm Hexagon nut M6 10 Nm Camshaft cap 10 Nm Chain tensioner screw (x2)

  • Page 39: Clean Injector Body

    38/54 Clean injector body Material : - Minerva Net Carbu - Allen keys of 4 - Screwdriver - Wrench of 8 Put down the injector body - Remove the seat - Remove the fuel tank - Remove the injector body cover...
  • Page 40 39/54 - Disconnect the injector connector - Disconnect the TPS plug - Remove the throttle cable - Unscrew the hose clamps - Remove the injector body Throttle cable Hose clamp...
  • Page 41 40/54 Clean of injector body - Clean the injector body with Net Carbu - Make sure you clean perfectly the edge of the mixture throttle on each side by opening it completely - Clean the injector - In order to keep the air screw adjustment, screw it completely and count the number of turns - Remove the air screw, clean it and clean the location.

  • Page 42: Sherco Diagnostic Tools

    To perform the diagnosis you must install the Sherco Vehicle Diagnostic Scan Tool Software (VDSTS). SHERCO reference R471. This software does not change the fuel injection map. This is only a diagnostic tool.

  • Page 43: Software Installation

    42/54 Contents of the diagnostic kit : The diagnostic kit consists of an RS232 cable, battery cables and theVDSTS software. Software installation Insert the CD-ROM "Scan-Vehicle Diagnostic Software Tool" in your computer drive. Run Setup setup.exe Then follow the instructions on the screen. Restart the computer.

  • Page 44: Connecting The Diagnostic Kit Wiring

    43/54 ► Connectcion : Allows you to connect to the vehicle. ► Disconnect : Allows you to disconnect from the vehicle. ► Ecu choice menu : When you connect to the vehicle, the software automatically recognizes the type of ECU. Connecting the diagnostic kit wiring Connect the serial cable RS232 to the serial port of your computer (laptop or desktop).
  • Page 45 44/54 To establish communications, use the "Connection menu" by clicking on the icon or selecting the menu command in the software. When you start the motorcycle, if there is a default, a message will appear on the screen. Errors code : Air temperature: “O.C/High V.”...

  • Page 46: Synchronizing The Ecu / With The Butterfly Openning Sensor (Tps)

    45/54 The diagnostic operations are carried out in the menu Function, Test / Active test you can test various components of the injection system. When you test a component, a green light will appear. You can test the following components: fuel injector, fuel pump, ignition coil voltage and the various engine sensors (the bike should be at its operating temperature and running for these tests).
  • Page 47 46/54 Value butterfly angle position should <3.1 <3.5 Check that the painting has not accidentally removed from the butterfly stop screw. Never touch the butterfly stop screw. The bike must be in perfect working condition (valves adjusted properly, fresh air filter, etc.). Check that air by-pass air screw at the injector body is not unscrewed over two TURNS out (factory value:...

  • Page 48: Electrical Installation Checking

    47/54 Electrical installation checking Static values (engine off) Tension battery : > 12.5V Stator resistance : 1.5/1.6 Ohms Pick up sensor : 170 Ohms Check there is no continuity between stator and the ground of the motorcycle Regulator Dynamic values Alternative 200V alternative caliber) Low rpm: 22V +-2V A 6000 rpm : 77V+-3V...

  • Page 49: Cable Diagram (Injection / Light)

    48/54 Cable diagram (Injection / light) Injection beam ECU connections : N° PIN Fonction 5 volts RPM (information) Water temperaturel Ventilator RPM sensor - Diagnostique connector Dignostique connector TPS sensor RPM sensor + Injector GND for double ignition mapping +V_BATT +12v Water temperature Fuel relay Ignition spark plug...
  • Page 50 49/54 Cable diagram :...

  • Page 51: Light Beam

    50/54 Light beam Dashborad connection : Dashboard reference 3522 Dashbord connector ref 3522 Rear view N° PIN Fonction V_BATT (+batt 12v) Fuel + Après contact High beam VCC_Hall Sens_In Neutral Right indicator Left indicator Reserved...
  • Page 52 51/54 Cable diagram :...

  • Page 53: Racing Lighting Cable Diagram

    52/54 Racing lighting cable diagram :...

  • Page 54: Flasher Installation Cable Diagram

    53/54 Flasher installation cable diagram :...

  • Page 55: Fan Cable Diagram

    54/54 Fan cable diagram :...

This manual is also suitable for:

2013 se 300i-r2011 se 2.5i-f2011 se 3.0i-f

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