SHERCO 250 SE-R Instruction manual

1

1
TECHNICAL SPECIFICATION
FOREWORD ........................................................ 2
TOOLS LIST 250-300 SE ........................................ 3
TECHNICAL SPECIFICATION ............................. 4
ENGINE ............................................................... 4
CARBURETOR .................................................. 4
CYCLE PART ....................................................... 5
STANDARD ADJUSTMENT ................................. 6
FORK .................................................................. 6
SHOCK ABSORBER ............................................. 7
OPERATIONS REQUIRING DISASSEMBLY OR NOT
ENGINE ...............................................................
REMOVING THE ENGINE ................................. 9
REASSEMBLING THE ENGINE IN THE FRAME
........................................................................ 9
DISMANTLING THE ENGINE .......................... 10
❱❘ Gear box drainage ................................................. 10
❱❘ Removing t e pinion and selector .......................... 10
❱❘ Removing t e cylinder ead / t e cylinder / t e
piston ......................................................................... 11
❱❘ Removing t e clutc ousing ................................. 12
❱❘ Removing t e pressure plate and discs ................. 13
❱❘ Remove t e electric starter .................................... 13
❱❘ Removing t e primary transmission ....................... 14
❱❘ Removing t e primary transmission ....................... 15
❱❘ Removing t e torque limiter and t e starter drive .. 15
❱❘ Removing t e ignition ............................................. 16
❱❘ Intake pipe and valve box ...................................... 16
❱❘ Remove t e gear selection .................................... 17
❱❘ Removing t e connecting rod assembly ................ 18
❱❘ Connecting rod assembly ....................................... 18
CHECKING ENGINE COMPONENTS ............. 19
❱❘ Balance weig t, c ecking t e external dimensions 19
❱❘ Radial play of t e connecting rod ead .................. 19
❱❘ C ecking t e cranks aft run out ............................ 19
❱❘ Piston ..................................................................... 20
❱❘ Gap spacing ........................................................... 20
❱❘ Piston pin c eck ..................................................... 20
❱❘ C ecking t e wear condition of t e cylinder .......... 20
❱❘ Functional c eck .................................................... 21
❱❘ Valve stop learning after cylinder reassembly ....... 24
❱❘ Valve box intake pipe sleeve .................................. 24
❱❘ Clutc ..................................................................... 25
❱❘ Gearbox .................................................................. 25
REASSEMBLING THE ENGINE ...................... 27
❱❘ Assembling t e alf crankcases ............................. 27
REASSEMBLING THE ENGINE ...................... 2
❱❘ Gear selection mec anism ..................................... 28
❱❘ Primary transmission and clutc ............................ 29
❱❘ Clutc discs, pressure plate ................................... 30
❱❘ Clutc ousing........................................................ 30
❱❘ Piston and cylinder ................................................. 31
❱❘ Squis table ............................................................ 32
❱❘ Cylinder ead ......................................................... 32
❱❘ Valve box and intake pipe ...................................... 33
❱❘ Gearbox output pinion............................................ 33
❱❘ Starter drive assembly ........................................... 33
❱❘ Mounting t e ignition and its cover ........................ 34
❱❘ Mounting t e electric starter .................................. 34
SYNERJECT
)
INJECTION SYSTEM
INSTRUCTION MANUAL .................................... 35
INTRODUCTION SYNERJECT SYSTEM ......... 35
1.1- Synerject system .............................................. 35
1.2- Description Exxodiag diagnostic .................. 35
1.3- Diagnostic tool kit contents. ........................... 36
1.4- Installation of the diagnostic tool ................... 36
PRESENTATION OF THE SOFWARE ............. 4
2.1- Connection with Keyless system ................... 40
2.2- Software settings: configuration menu .................... 42
2.3- Update menu and synchronization ................ 43
3 - Using the software .............................................. 45
3.1- Identification ..................................................... 45
3.2- Reading the default codes .............................. 46
3.3- Erasing default codes ...................................... 48
3.4- Test the actuators ............................................ 49
3.5- Updating the ECU ............................................. 51
3.6- Screen printing function.................................. 53
TORQUES TABLE ........................................... 54
CARBURETOR ADJUSTEMENT TABLE ........ 55
❱❘ SE 250-Carburetor adjustments table ................... 55
❱❘ SE 300-Carburetor adjustments table ................... 56
CHECKING THE LOAD CIRCUIT .................... 57
❱❘ Static control value ................................................. 57
❱❘ Dynamic control values .......................................... 57
T° SENSOR, ENGINE RPM SENSOR, HIGH
VOLTAGE COIL ............................................... 5
WIRING DIAGRAM .......................................... 59
❱❘ Main harness .......................................................... 59
❱❘ Standard lights harness .......................................... 60
❱❘ Racing lights harness .............................................. 61
❱❘ Accessories harness ................................................ 62

FOREWORD
T is manual is primarily intended for qualified mec anics working in a properly equipped
works op.
A solid knowledge of mec anics and t e specific SHERCO tools for t e 250 SE-R and
300 SE-R engines are required to perform t e various operations.
T is works op manual complements t e SHERCO 250 SE-R and 300 SE-R user manual

3
250/300 SE
TOOLS LIST 250-300 SE
Tool reference Designation
5749 Clutc block
4753 Ignition block
2067 Swing-arm pin tool
R467 Rig t crankcase primary s aft bearing tool
R465 Secondary s aft bearing tool
5397 Gearbox output s aft bearing tool
R446 Gearbox output spi tool
539 Barrel selection bearing tool
5399 Left crankcase cranks aft bearing tool
R469 Rig t crankcase cranks aft bearing tool
5400 Clutc side cranks aft spi tool
5401 Ignition side cranks aft spi tool
5402 HK0808 needle cage tool
(water pump, starter drive double pinion, starter drive)
196 Water pump spi seal tool
1 21 Engine support
5206 Primary pinion block tool
2073 Spring block (pin selection)
R462 Magnetic flyw eel puller
R464 Cranks aft ring extractor
R453 Selector axis bearing assembly tool
R444 Selector spi seal tool
6267 Diagnostic Key less tool
4967 Diagnostic briefcase

4
TECHNICAL SPECIFICATION
ENGINE
CARBURETOR
250 300
Carburetor type KEIHIN PWK 36S AG KEIHIN PWK 36S AG
Needle position 3rd position from t e top 3rd position from t e top
Jet needle N1EG (N84K) N8RE (N84K)
Main jet KEA 162 (KEA 115) KEA 172 (KEA 115)
Idle jet KEP 40 (KEA38) KEP 42 (KEA 38)
Choke jet 85 (50) 85 (50)
Air regulating screw
opening 1T 1/4 1T 1/2
Valve spacing N°7 N°7
250 300
Type Single cylinder 2 stroke liquid cooling
Capacity 249.32 CC 293.14 CC
Bore/Stroke 66.4/72 mm 72/72 mm
Petrol Unleaded wit an octane rating of at least 98 mixed wit 2-
stroke oil (2 %)
Cooling Liquid wit forced circulation
Ignition system Synerject electronic ignition
Spark plug NGK BR7ES/DENSO W22ESRU
Distance between spark
plug electrodes
0.7 mm
Piston Cast aluminum
Engine oil 750 ml SAE 10W40
Primary transmission 27 : 75
Gearbox : 6 speeds
1st 14 : 32
2nd 15 : 26
3rd 29 : 27
4th 21 : 24
5th 23 : 22
6th 25 : 21
Final transmission 14 X 49
Clutch Oil bat ed multi disks, ydraulic control
Starter Electric starter
Battery 12V 4A
Alternator 220W

5
250/300 SE
TECHNICAL SPECIFICATION
CYCLE PART
Frame
Semi
-
perimeter CrMo
steel wit aluminum sub frame
Fork KAYABA USD Ø48mm Closed cartridge(FACTORY)
WP XPLOR USD Ø48mm (RACING)
Rear suspension
KAYABA suspension wit separate cylinder (FACTORY)
WP suspension wit separate cylinder (RACING)
Aluminum swing arm
Travel Front/Rear FACTORY 330/330mm
RACING 300/330mm
Front brake rotor Ø 260mm
Rear brake rotor Ø 220mm
Brake disc Limit : 2.7mm front et 3.6mm rear
Front tire 90/90-21’’
Rear tyre 140/80-18’’
Pressure front / Rear 0.9 bar
Fuel tank capacity 10.4Ll wit 1 liter of reserve
Angle of the steering column
27.3°
Wheel base 1480mm
Weight (without fuel) 119 kg

6
STANDARD ADJUSTMENT
FORK
Factory settings – 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
Rider weig t : 65-75 kg 4.0N/mm (Original)
Rider weig t : 75-85 kg 4.2N/m
Rider weig t : 85-95 4.4N/m
Fork oil
01M 345 CC
Racing settings – Fork WP XPLOR suspension USD Ø48mm
Compression
Comfort 18 clicks back
Standard 15 clicks back
Sport 12 clicks back
Rebound
Comfort 18 clicks back
Standard 15 clicks back
Sport 12 clicks back
Preload
Comfort +0 tours
Standard +0 tours
Sport +6 tours
Spring stiffness
Rider weig t : 65 - 75 kg 4.2N/mm
Rider weig t : 75 - 85 kg 4.4N/mm (Original)
Rider weig t : 85 - 95 kg 4.6N/mm
Type of oil
SAE 4
Spring length with preload spacer
474 mm
Quantity of oil
606ml
Oil level measurement (fork compressed and spring
removed) from the top of the fork tube
100mm (min30-max 120 mm)

7
250/300 SE
STANDARD ADJUSTMENT
SHOCK ABSORBER
Factory Settings – KAYABA s ock 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
Sport 11 clicks back
Spring stiffness
Rider weig t : 65-75 kg 46N/mm
Rider weig t : 75-85 kg 48N/mm (original)
Rider weig t : 85-95 kg 50N/mm
Type of oil K2C
Racing Settings – WP suspension s ock absorber
Low
-
speed compression
Comfort 17 clicks back
Standard 12 clicks back
Sport 9 clicks back
High
-
speed compression
Comfort 2 turns back
Standard 1.5 turns back
Sport 1 turn back
Rebound
Comfort 16 clicks back
Standard 14 clicks back
Sport 12 clicks back
Spring stiffness
Rider weig t : 65-75 kg 51N/mm
Rider weig t : 75-85 kg 54N/mm (original)
Rider weig t : 85-95 kg 57N/mm

8
OPERATIONS REQUIRING DISASSEMBLY OR NOT ENGINE
Operation requiring engine
removal
Operation not requiring engine
removal
Crankshaft
(including
the
crank
kit)
•
Complete gearbox
•
Crankshaft bearing
•
Gearbox bearing
•
Piston
•
Cylinder
•
Cylinder head
•
Ignition
•
Starter gear set
•
Complete clutch
•
Water pump
•
Speed selection assembly
•

9
250/300 SE
REMOVING / REISTALLING THE ENGINE
REMOVING THE ENGINE
• Drain (refer to t e owner’s manual)
- t e engine oil
- t e engine coolant
• Remove t e seat.
• Disconnect t e battery.
• Remove t e fuel tank and its covers.
• Disconnect all t e electrical wiring connectors from t e engine.
(Starter, TPS sensor, water temperature sensor, coil, fuel injector)
• Remove t e ex aust.
• Remove t e ignition coil.
• Remove t e carburetor.
• Remove t e c ain.
• Remove t e c ain guard.
• Remove t e clutc slave cylinder.
• Remove all of t e water oses connected to t e engine.
• Remove t e left radiator.
• Loosen all of t e engine bolts.
• Loosen t e swing arm bolt.
• Remove t e brackets t at attac t e cylinder ead to t e c assis.
• Remove t e engine mounting bolts.
• Remove t e swing arm bolt.
• Remove t e motor.
REASSEMBLING THE ENGINE IN THE FRAME
T e motor s ould be reinstalled in t e frame in t e reverse order of ow it was removed. T e following
torque values s ould be utilized.
Tightening torques:
Engine mounting bolts: 60Nm
Swing arm axle nut: 100 Nm
Clutch receiver screws: 10 Nm
Cylinder head bracket bolts: 23Nm
Exhaust mounting bolts: 10Nm
WARNING
To remove t e engine, you must remove t e swing arm's pivot bolt to detac t e rear
w eel/swing arm assembly. Secure t e c assis wit a jack to prevent t e motorcycle
from overturning.
WARNING
W en t e clutc slave cylinder is removed, t e piston is no longer eld in place. Secure
t e piston wit a plastic collar.

10
DISMANTLING THE ENGINE
❱❘ Gear box drainage
• Remove drainage plugs [1] and [2], let t e
oil
flow out.
❱❘ Removing t e pinion and
selector
• Unfold t e safety was er tab [3] using a punc
device.
•
Remove t e gearbox output pinion [4].
•
Remove t e screw first [5] first and t en
t e selector.
•
Release t e clutc control rod.
1
2
3
4
5
1

11
250/300 SE
DISMANTLING THE ENGINE
❱❘ Removing t e cylinder ead / t e cylinder / t e piston
• Remove t e s oulder screws [1] t e copper
cas ers, remove
t e cylinder ead and t e
two O-rings
• Remove t e ex aust valve actuator [2]
• Remove t e ex aust c amber cover .
• Remove t e 4 screws
[4] on t e base of
• T e cylinder and remove it
.
• Mask t e cover.
1
2
3
4

12
DISMANTLING THE ENGINE
• Remove t e piston pin clips.
• Remove t e piston pin.
• Remove t e piston and extract t e needle
bearing from t e connecting rod.
• Remove t e gasket
❱❘ Removing t e clutc ousing
• Remove t e screws and t e water pump
cover.
•
Remove t e gasket .
• Remove t e screws and extract t e clutc
ousing.
• Remove t e gasket

13
250/300 SE
DISMANTLNG THE ENGINE
❱❘ Removing t e pressure plate and discs
• Loosen t e pressure plate screws
• Remove t e screws, springs and springs
cups.
• Remove t e pressure plate and discs from
ousing.
• Remove t e support part
[1] on t e primary
s aft
❱❘ Remove t e electric starter
• Remove t e 2 screws [2]
3
2

14
DISMANTLING THE ENGINE
❱❘ Removing t e primary transmission
• Lock t e pinion at t e end of t e cranks aft
wit t e 5206 tool
[3]
• Unscrew t e primary transmission nut
[4]
and t en remove it wit its conical was er
• Open t e clutc boss lock was er [5]
• Apply t e 5749 tool
[6] w ic is designed to
old t e boss, t en loosen t e nut.
• Remove t e tool.
• Remove t e boss t e crenellated was er,
t e ousing wit 2 needle cages
• Removing t e primary transmission pinion
and t e spacer
[1] at t e end of t e
cranks aft
..
WARNING
To t e pin and t e o-ring.T e primary
transmission pinion and t e clutc
ousing ring
are paired, w ic is w y t ey can not be
c anged separately. Always replace t em
toget er.
4
3
6
6
1
3
2

15
250/300 SE
DISMANTLING THE ENGINE
❱❘ Removing t e primary transmission
• Remove t e screws and extract t e ignition
ousing wit its gasket
❱❘ Removing t e torque limiter and t e starter drive
• Remove t e 3 s oulder screws [1]
• Remove t e torque limiter lug [2]
• Remove t e starter drive [3]
• Remove t e torque limiter [4]
2
1
2
2

16
DISMANTLING THE ENGINE
❱❘ Removing t e ignition
• Hold t e flyw eel wit t e 4753 tool [1] and
unscrew t e s oulder nut.
• Position t e R462 puller [2] and extract t e
magnetic w eel
[3]
❱❘ Intake pipe and valve box
• Remove t e 4 THEP screws [4]
• Remove t e pipe, t e valve box, and t eir
respective gasket.
2
1
3
2
4