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SHERCO 2012 SE 250i-R, Shop Manual, Page: 2 / 55

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CONTENTS 

 
 
 

Forward

 ......................................................................................................................................................... 2

 

Motor tools SE25i-F

 .................................................................................................................................... 3

 

Technical specification - Motor

 ................................................................................................................. 4

 

Technical specification - Frame

 ................................................................................................................ 5

 

Standard adjustement – Fork

 .................................................................................................................... 6

 

Standard adjustment - Fork Sachs USD Gold Series Ø48MM

 ............................................................ 6

 

Standard adjustment - Fork WP USD Gold Series Ø48MM

 ................................................................ 6

 

Standard adjustement – Shock absorber

 ................................................................................................ 7

 

Standard adjustment - WP Shock absorber

 ........................................................................................... 7

 

Operations requiring demounting or not engine

 ..................................................................................... 8

 

Removing the motor

 ................................................................................................................................... 9

 

Removing the motor: ................................................................................................................................. 9

 

Motor top end

 ............................................................................................................................................. 11

 

Disassembling the right side

 ................................................................................................................... 23

 

Disassembling the left side

 ...................................................................................................................... 26

 

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 .............................................................................................................................. 43

 

Synchronizing the ECU / with the butterfly openning sensor (TPS) ....................................................... 45

 

Electrical installation checking ................................................................................................................ 47

 

Regulator .................................................................................................................................................. 47

 

Cable diagram (Injection / light)

 .............................................................................................................. 48

 

Injection beam ......................................................................................................................................... 48

 

Light beam ............................................................................................................................................... 50

 

Racing lighting cable diagram : ............................................................................................................... 52

 

Flasher installation cable diagram : ......................................................................................................... 53

 

Fan cable diagram : .................................................................................................................................. 54

 

 

Summary of Contents for 2012 SE 250i-R

Page 1: ...Shop manual 2012 SE 250i R SE 300i R...

Page 2: ...9 Motor top end 11 Disassembling the right side 23 Disassembling the left side 26 Crankcase Transmission Central crankcases 29 Tightening torques 36 Clean injector body 38 SHERCO diagnostic tools 41...

Page 3: ...a properly equipped workshop 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 works...

Page 4: ...aft 2079 Bearing tool 6203 left Balancer 2080 Oil seal tool 8x18x5 1822 Bearing tool Water pump shaft 2078 Oil seal 36x57x7 5 Right Crankshaft 2077 Bearing tool 4905 Right Balancer 2074 Bearing tool 6...

Page 5: ...ve 25mm Thickness admission valve 0 15 0 2mm Thickness exhaust valve 0 2 0 25mm Crankshat bearing 2 roller bearing Piston Aluminium forge Lubrification Lubrication under pressure with 2 trochoidal pum...

Page 6: ...g Rear suspension WP Suspension with separate cylinder Travel Front rear 300 300mm Front brake 270mm standard 256mm racing Rear brake 220mm Brake disc 2 7mm front and 3 6mm rear Front tire 90 90 21 Re...

Page 7: ...y 600cm3 Oil level 130mm Standard adjustment Fork WP USD Gold Series 48MM Compression Comfort 22 clicks back Standard 15 clicks back Sport 10 clicks back Rebound Comfort 20 clicks back Standard 15 cli...

Page 8: ...5 clicks back Sport 12 clicks back High speed compression Comfort 2 5 clicks back Standard 2 clicks back Sport 1 5 clicks back Rebound Comfort 15 clicks back Standard 13 clics en arri re Sport 11 clic...

Page 9: ...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 Freewheel Clut...

Page 10: ...emove the left radiator Loosen all of the engine bolts Loosen the swing arm bolt Remove the brackets that attach the cylinder head to the chassis Remove the motor mounting bolts Remove the swing arm b...

Page 11: ...n the frame in the reverse order of how it was removed The following torque values should be utilized Tightening torques Motor mounting bolts 40Nm Swing arm axle nut 100 Nm Clutch receiver screws 10 N...

Page 12: ...ing marks on the crankshaft with the marks on the timing gear Install the special tool that locks the engine at Top Dead Center A ref 1819 details refer to the parts catalog SE 250i_SE 300i Remove the...

Page 13: ...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 Remove the exhaust camshaft retaining clip Remove the exhaus...

Page 14: ...linder diameter A Cylinder diameter B Taper limit 0 05 mm Out of round limit Standard SE 300i R Cylinder diameter A 83 Cylinder diameter B 83 982 83 Taper limit 0 05 mm Out of round limit 0 05 mm Remo...

Page 15: ...l control ring 0 020 0 055 mm Limit 0 13 mm Ring end gap Compression ring 0 3 0 4 Limit 0 7 mm Oil control ring 0 3 0 5 mm Inspect the connecting rod the piston pin and the piston for wear Visually in...

Page 16: ...and tighten to the proper torque Tightening torque Camshaft journal mounting bolts 10 Nm If any of the measurements are over the limit then measure the diameter of each journal Camshaft journal clear...

Page 17: ...ect the timing chain for damage Inspect the timing chain by flexing it to determine if there are any tight spots If tight spots are found it should be replaced Check the automatic chain adjuster and m...

Page 18: ...ect location A Place one of the cir clips in the special tool number 2075 as shown in the photo install the clip close to one end of the tool Use the tool to set up the clip for installation on the wr...

Page 19: ...s Cylinder head torque Studs 1st pass 30 Nm 2nd pass 50 Nm Nuts M6 10 Nm The two internal bolts are of different length and are equipped with washers Install the wrist pin into the piston and connecti...

Page 20: ...the intake cam Install the exhaust cam see the photo for how to set the timing marks Install the camshaft retaining clips Apply moly disulfide grease to the camshafts The timing marks should align wit...

Page 21: ...Replace the cap that was removed to install tool number 1819 Torque the cap to 8Nm Replace the spark plug well Make sure that the o rings are installed on the spark plug well Install the camshaft ret...

Page 22: ...valve cover Remove the timing plug from the crankcase Install special tool number 1819 With a feeler gauge measure the clearance between the bucket and the cam Valve clearance Intake 0 15 0 20 mm Exha...

Page 23: ...am chain Install the cam chain in the opposite manner in which it was removed Reinstall the cam tensioner bolt and tighten to the correct torque Torque the cam tensioner bolt to 10Nm Remove the camsha...

Page 24: ...Soak the friction discs in engine oil Replace the discs on the hub by starting with a friction disc and then a steel disc ending with a friction disc Replace the pressure plate Install the 5 springs...

Page 25: ...h housing locating pins always install a new paper gasket and if necessary install ring seal on the water pump housing Tighten the water pump housing screws to 11Nm Tighten the coolant drain plug to 6...

Page 26: ...e fixing nut to 80Nm Check for free rotation of the clutch hub Reinstall the clutch release bearing assembly the clutch and the clutch housing in the reverse order of their removal Removing the clutch...

Page 27: ...otor A and the outer surfaces of the stator B Check the pulse generator sensor Replace if necessary Replacing the stator and sensor system Remove the two screws that retain the sensor C and the two sc...

Page 28: ...ary Finally check the rollers on the freewheel Replace if necessary If the freewheel must be replaced then the rest of the gears must be replaced and vice versa wheel using special tool Remove the two...

Page 29: ...o 80 medium threadlocker Install the remaining shafts and gears Install the two case locating pins Install a new gasket Install the ignition crankcase cover and tighten the 10 screws Torque the igniti...

Page 30: ...unter balancer weight Remove the freewheel crankshaft spacer using a two armed gear puller see photo Remove the engine oil pump cover Block the transmission primary gear with special tool number 1817...

Page 31: ...mponents Check the condition of all the gears Inspect the engagement dogs A look at all of the gear teeth B and the fork shifting groove on each gear C If any of the parts are damaged or badly worn th...

Page 32: ...must be replaced Lateral movement of the big end Measure the lateral movement of the big end A Lateral movement of the big end Standard 0 2 mm 0 3mm Tolerance limit 0 55 mm If the lateral movement of...

Page 33: ...r R464 heat the tool and the bearing Remove the bearing The radial play in the roller bearings must be practically zero Checking the center crankcases Inspect the general condition of the center crank...

Page 34: ...n diameter Do not forget to lubricate all of the rotating and sliding parts Replace the two locating dowels in the case and install the washer on the secondary shaft Reassembling the central crankcase...

Page 35: ...pump cover and tighten the cover screws to the appropriate torque Torque the oil pump cover screws to 5 Nm Install the oil pump drive roll pin the drive gear and the cir clip Install the primary drive...

Page 36: ...utch see the paragraph on disassembling the right side Install the clutch cover Install the spark plug Torque the spark plug to 15 Nm Apply threadlocker to all of the internal engine threads except th...

Page 37: ...s 24 Nm Front wheel axle nut 40 Nm Front fork axle bolts axle M6 15 Nm Brake pad bolt 8 Nm Triple clamp bolts 17 Nm Motor screw 40 Nm Swing arm nut 100 Nm Cylinder head frame srews 23 Nm Motor tighten...

Page 38: ...ass Hexagon nut M6 30 Nm 50 Nm 10 Nm Camshaft cap 10 Nm Chain tensioner screw x2 10 Nm Chain tensioner screw x1 10 Nm Timing control plug 8 Nm Chain guide screw 10 Nm Clutch pression screw 10 Nm Water...

Page 39: ...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 body 38 54...

Page 40: ...Disconnect the injector connector Disconnect the TPS plug Remove the throttle cable Unscrew the hose clamps Remove the injector body Throttle cable 39 54 Hose clamp...

Page 41: ...r 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 Replace the air screw with its initial adjustment Replace the...

Page 42: ...hicle Diagnostic Scan Tool Software VDSTS SHERCO reference R471 This software does not change the fuel injection map This is only a diagnostic tool Num Designation Emplacement 1 Housing ECU atmospheri...

Page 43: ...bles and theVDSTS software Vehicle Diagnostic Software Tool in your computer drive Then follow the instructions on the screen Software presentation the various interfaces Allows you to select the seri...

Page 44: ...the vehicle the software automatically recognizes ng the diagnostic kit wiring Connect the serial cable RS232 to the serial port of your computer laptop or desktop Connect the power cable to the batt...

Page 45: ...n the screen Errors code Air temperature O C High V ou S C Low V Engine Temperature O C High V ou S C Low V Pressure O C Low V ou S C High V Papillon Pos O C High V ou S C Low V Crank Pos Crank Pos Si...

Page 46: ...fuel pump ignition coil voltage and the various engine sensors the bike should be at its operating temperature and running for these Synchronizing the ECU with the butterfly openning sensor TPS A feat...

Page 47: ...t be in perfect working condition valves adjusted properly fresh air filter etc pass air screw at the injector body is not unscrewed over two TURNS out factory value 1 round Make this adjustment with...

Page 48: ...cle Regulator Dynamic values Alternative 200V alternative caliber Low rpm 22V 2V A 6000 rpm 77V 3V Continue Regulator pins out Caliber 20V continue A 4000 tr min 14 6V Red white Green Battery recharge...

Page 49: ...er temperaturel 5 Ventilator 6 NC 7 RPM sensor 8 NC 9 Diagnostique connector 10 Dignostique connector 11 TPS sensor 12 RPM sensor 13 Injector 14 NC 15 NC 16 GND for double ignition mapping 17 V_BATT 1...

Page 50: ...49 54 Cable diagram...

Page 51: ...ference 3522 N PIN Fonction 1 V_BATT batt 12v 2 Fuel 3 Rpm 4 Apr s contact 5 High beam 6 VCC_Hall 7 NC 8 Sens_In 9 Neutral 10 Oil 11 GND 12 NC 13 Right indicator 14 Left indicator 15 Reserved 16 GND 1...

Page 52: ...51 54 Cable diagram...

Page 53: ...52 54 Racing lighting cable diagram...

Page 54: ...53 54 Flasher installation cable diagram...

Page 55: ...54 54 Fan cable diagram...

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