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This  manual  is  designed  primarily  for  skilled  mechanics  working  in  a  properly  equipped
workshop.  The  execution  of  the  operations  in  this  manual  requires  a  strong  mechanical
knowledge and specific SHERCO tools designed for the 250 SEF-R and 300 SEF-R engine.

This  workshop  manual  is  a  supplement  to  the  SHERCO  250  SEF-R  and  300  SEF-R  owner’s
manual.

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Содержание 2014 250 SEF-R

Страница 1: ...Workshop manual Workshop manual 2014 250 SEF R 300 SEF R Workshop manual...

Страница 2: ...Disassembling the right side 24 Crankcase Transmission Central crankcases 31 Tightening torques 38 Clean injector body 40 SYNERJECT Injection system instruction manual 43 1 SYNERJECT injection system...

Страница 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 250 SEF R and 300 SEF R engine This works...

Страница 4: ...lutch shaft 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 Bearin...

Страница 5: ...alve 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 p...

Страница 6: ...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 Rear...

Страница 7: ...ty 600cm3 Oil level 130mm Standard adjustment Fork WP USD Gold Series 48MM Compression Comfort 20 clicks back Standard 13 clicks back Sport 8 clicks back Rebound Comfort 18 clicks back Standard 13 cli...

Страница 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...

Страница 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...

Страница 10: ...e 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 bolt...

Страница 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 60Nm Swing arm axle nut 100 Nm Clutch receiver screws 10 N...

Страница 12: ...iming 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 For additional details refer to the parts catalog 250 SEF R...

Страница 13: ...ll 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 exhaust camsh...

Страница 14: ...ard 250 SEF Cylinder diameter A Cylinder diameter B Taper limit 0 05 mm Out of round limit Standard 300 SEF Cylinder diameter A 83 Cylinder diameter B 83 982 83 Taper limit 0 05 mm Out of round limit...

Страница 15: ...Oil 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...

Страница 16: ...te the fixing bolts with engine oil 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...

Страница 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...

Страница 18: ...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 wrist pin Install the cir clip on...

Страница 19: ...uts Cylinder head torque Studs 1st pass 30 Nm 2nd pass 45 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 connec...

Страница 20: ...rly installed Install 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...

Страница 21: ...ming marks 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 camshaft retai...

Страница 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...

Страница 23: ...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 camshaft...

Страница 24: ...e friction discs in engine oil Replace the discs on the hub by starting with a friction disc and then a steel di with a friction disc Replace the pressure plate Install the 5 springs Install the 5 scr...

Страница 25: ...ch housing locating pins always install a new paper gasket and if necessary ins ring seal on the water pump housing Tighten the water pump housing screws to 10Nm Tighten the coolant drain plug to 6Nm...

Страница 26: ...the nut thread Install the fixing nut Torque the fixing nut to 80Nm Check for free rotation of the clutch hub Blend the special washer over the nut Install the seat judder spring Removing the clutch h...

Страница 27: ...he reverse order of their removal Torque the clutch screws to 10Nm Install the clutch cover dowels a new clutch cover gasket and tighten to 10Nm with the sense of Install the special friction disc Ins...

Страница 28: ...the proper torque with strong Loctite red Do not forget the AET washers below the stator screws Torque the stator and sensor screws to 8Nm Disassembling the left side For additional details refer to t...

Страница 29: ...he free wheel housing Replace if necessary 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...

Страница 30: ...he rotor and the oil centrifuge Install the remaining shafts and gears Install the two case locating pins Install a new gasket Install the ignition crankcase cover an tighten the 10 screws Torque the...

Страница 31: ...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...

Страница 32: ...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...

Страница 33: ...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...

Страница 34: ...install tool number 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 l condition of the center crank...

Страница 35: ...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 transmission secondary shaft Reassembling the central crankca...

Страница 36: ...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...

Страница 37: ...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 the five cl...

Страница 38: ...Nm Front fork axle bolts axle M6 15 Nm Brake pad bolt 8 Nm Botton plat fork bolts Wp 12 Nm Sachs 15 Nm Upper plat fork bolts Wp 17 Nm Sachs 17 Nm Motor screw 60 Nm Swing arm nut 100 Nm Cylinder head...

Страница 39: ...ass Hexagon nut M6 30 Nm 45 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...

Страница 40: ...eys of 2 5 Screwdriver with 7mm dowel Wrench of 8 Put down the injector body Remove the seat Remove the fuel tank Remove the injector body clamps Remove the throttle body cover Remove the throttle cab...

Страница 41: ...41 75 Disconnect each connector Inspect Clean with carbu cleaner or universal product cleaner Blow...

Страница 42: ...he injector body Put back all the parts together again put some connector grease inside the electrical connectors TPS plug injector plug If you dismount the throttle body manifold be careful with the...

Страница 43: ...R refer to the 2013 manual i injection system that is composed of a M3C computer a special ignition system and a special harness D signation Location Computer Left side of the frame injection unit 42m...

Страница 44: ...y position sensor 2 TMAP sensor Air temperature air pressure 3 Stepper motor Idle management and engine braking 4 Injector Computer Synerject injector body 42mm 2 3 Designation Butterfly position sens...

Страница 45: ...Open the installation CD Run Sherco_Setup Select the disired language Click Next Exxodiag diagnostic tool reference 4967 The diagnostic tool allows you to perform diagnostic operations make updates t...

Страница 46: ...Select the folder where you Click Next Click Install the folder where you want the software to be installed 46 75...

Страница 47: ...Installation is in progress Select Start installing drivers and Finish Select Start installing drivers and Finish 47 75...

Страница 48: ...nt the terms of the license agreement Installation in progress The following window opens Read the terms of the license agreement the terms of the license agreement and Install 48 75 The following win...

Страница 49: ...ged in it is in standby The following window opens Click Finish Connect one end of the MUXDIAG II interface cable to a USB port on your computer connect the other end to the diagnostic connector on th...

Страница 50: ...s mapping etc Setup Menu language selection units etc In order to establish connection with the bike it must be turned on ON rious menus only the USB cable with the MUXDIAG II box must be connected St...

Страница 51: ...ation menu In this menu you can change the following Taking a diagnostic reading You can refresh the list by clicking on this button oit correspondre au n du bo tier MUXDIAG II The languages included...

Страница 52: ...ick this icon If an update is available the following window will appear to return to the home screen to validate your changes u update and synchronization With this menu you can update the diagnostic...

Страница 53: ...tart the installation Repeat the setup steps see page If no update is available the following message appears in order to start the download of the update The following message will appear to start th...

Страница 54: ...n in order to save your changes 3 Using the software Diagnostic menu and updating the injection mapping General Click on Sherco Click on M3C e the internet access settings xy server in order to access...

Страница 55: ...cation You can check the identification of the following serial number hours of operation calibration number B Parameter measurements general parameters speed pressure stepper etc 1 Engine Information...

Страница 56: ...is too high there could be dirt in the injector butterfly area The correct air valve motor value should be 15mm and 2mm with the motor idling and at Butterfly position With the engine stopped it shoul...

Страница 57: ...efault codes When you click on read default c If no default appears exit the menu by clicking on this icon If a default appears Engine synchronization status engine cycle recognition The full engine i...

Страница 58: ...rd the defaults and exit the menu by clicking on this icon Transient default permanent default a transient default becomes permanent after a certain number of engine cycles of the following components...

Страница 59: ...fault codes Check and make sure that the defaults are the same as before parts Check all of the connections erase all of the default codes The following screen will appear Return to the menu reading d...

Страница 60: ...an also check 1 Ignition coil When you launch the ignition coil test In addition to reading default codes you can also check some of the system components When you launch the ignition coil test the fo...

Страница 61: ...ne stopped The test results 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...

Страница 62: ...vent of a reoccurring default check Note The fan test is meaningless if the default check change the defective parts meaningless if the bike is not equipped with a fa 62 75 change the defective parts...

Страница 63: ...nloaded and click 4 The file is being downloaded By using the diagnostic tool it is possible to make updates to the injection mapping calibration An example would be the fitting of a racing silencer o...

Страница 64: ...ROCESS THERE IS A RISK OF IRREPAIRABLE DAMAGE TO THE COMPUTER At the end of the download the fuel pump will start and the following message will appear INFORMATION Download was successful Check to mak...

Страница 65: ...ith technical support and need help identifying potential problems you can perform a screen print operation by pressing F10 on your keyboard This will allow you to attach these files to your inquiry T...

Страница 66: ...up sensor 120 10 Check there is no continuity between stator and the ground of the motorcycle 2 Dynamic values Pick up sensor 1 7V MIN 300 tr min 120V MAX 10000 tr min Regulator Alternative 200V alte...

Страница 67: ...rance on typical values 5 10 RPM Voltage AC Current IB DC VB 2000 25 0V 14A DC 13 5V 2500 31V 15 0 3000 38V 15 6 4000 51V 16 2 5000 63V 16 4 6000 76V 16 8A 7000 92V 16 6A 8000 101V 16 7A 9000 114V 16...

Страница 68: ...onnector 7 Emergency stop 8 Dashboard 9 Stepper motor 10 Injector 11 Fuel pump 12 TCO sensor 13 TPS sensor 14 Engine ground 15 Electrical starter 16 TMAP sensor 17 Pick up sensor 18 Bobine HT 19 Light...

Страница 69: ...69 75 300 SEF R 2014 Synerject EFI system cable diagram...

Страница 70: ...70 75 250 SEF 2014 light system cable diagram...

Страница 71: ...71 75 300 SEF 2014 light system cable diagram...

Страница 72: ...72 75 250 SEF R 2014 Racing light system cable diagram...

Страница 73: ...73 75 300 SEF R 2014 Racing light system cable diagram...

Страница 74: ...74 75 Flasher installation cable diagram...

Страница 75: ...75 75 Fan cable diagram...

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