SHERCO 250 SE-R 2017, Workshop Manual

Page 1: ...MANUEL D ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER ...

Page 2: ...the clutch 17 Removing the pressure plate and discs 17 Removing the electric starter 18 Removing the primary drive gear 18 Removing the interlock mechanism 19 Removing the ignition cover 20 Removing the electric starter double gear and the starter drive 20 Removing the flywheel 21 Intake manifold and reeds 21 Separating the housing halves 22 Removing the transmission components 22 Removing the cra...

Page 3: ...ad 41 Reed valves and intake manifold 42 Transmission output sprocket 42 Mounting the starter drive 42 Installing the flywheel and the ignition cover 43 Installing the electric starter 43 TIGHTENINGTORQUETABLE 44 CARBURETORSETTINGTABLE 46 Carburetor setting table for the SE R 250 46 CARBURETORSETTINGTABLE 47 Carburetor setting table for the SE R 300 47 CHECKINGTHECHARGINGSYSTEM 48 Static control v...

Page 4: ...or use by trained mechanics in a properly equipped workshop The various operations require strong mechanical skills and specifi c tools to work on the SHERCO 250 SE R and SE R 300 engines This workshop manual complements the SHERCO 250 SE R and SE R 300 manual ...

Page 5: ...earing selection tool 5399 Left crankcase bearing tool R469 Right crankcase bearing tool 5400 Clutch side crankshaft bearing tool 5401 Ignition side crankshaft bearing tool 5402 HK0808 needle bearing tool water pump starter motor double pinion starter motor bearing 1968 Water pump seal tool 1821 Motor support 5206 Primary pinion block tool 2073 Spring block selection fi ngers 5208 Flywheel puller ...

Page 6: ... Engine oil 750 ml SAE 10W40 Transmission primary drive ratio 27 75 Transmission 1st 2nd 3rd 4th 5th 6th 6 speed 14 32 15 26 19 27 21 24 23 22 25 21 Transmission final drive 14 X 49 Clutch Hydraulically operated multi disc in oil bath Starter Electric starter Battery 12V 4Ah Alternator 220W Carburetor Type of carburator KEIHIN PWK 36S AG KEIHIN PWK 36S AG Needle position 4th position from the top ...

Page 7: ...ntrol rods Travel Front Rear 300 330 mm Front brake disc Ø 270 mm standard Ø 256 mm racing Rear brake disc Ø 220 mm Disc brake wear limit 2 7 mm front and 3 6 mm rear Front tire 90 90 21 Rear tire 140 80 18 Tire air pressure all terrain 0 9 bar 13 psi Fuel tank capacity 10 4l with1 liter of reserve 2 75 gallons 25 gallons Steering angle in both directions 27 3 Wheelbase 1480 mm 58 3 inches Weight ...

Page 8: ... Front fork factory settings WP 48mm ØUSD Series 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 Preload Comfort 4 turns Standard 6 turns Sport 8 turns Spring stiffness Rider weight 65 75 kg 143 165 pounds 4 0N mm Rider weight 75 85 kg 165 187 pounds 4 2N mm original Rider weight 85 95 kg 187...

Page 9: ...licks back High speed Compression Comfort 2 5 turns back Standard 2 turns back Sport 1 5 turns back Rebound damping Comfort 15 clicks back Standard 13 clicks back Sport 11 clicks back Spring stiffness Rider weight 65 75 kg 143 165 pounds 48N mm Rider weight 75 85 kg 165 187 pounds 51N mm original Rider weight 85 95 kg 187 210 pounds 54N mm FRANÇAIS ...

Page 10: ...g engine removal Operations that do not require engine removal Crankshaft including connecting rod Transmission Complete Crankshaft bearings Transmission bearings Piston Cylinder Cylinder head Ignition Starting motor gearing Complete clutch Water pump Transmission gear selector mechanism ...

Page 11: ...ted to the engine Remove the left radiator Loosen all of the engine mounting bolts Loosen the swing arm axle bolt Remove the mounting brackets that are attached to the cylinder head and the electric motor Remove the rear axle Remove the swing arm axle Disconnect all of the cables from the valve block Remove the motor CAUTION When the clutch slave cylinder is removed the piston is no longer contain...

Page 12: ...just the top position cable n 1 on the cable pulley and in the cable stop located on the cylinder For the lower cable n 2 put it in the cable stop without any tension Turn the bike ignition switch ON Wait until the electric motor initializes the valves and then shuts down Turn the bike ignition switch OFF Start adjusting the upper cable tensioner n 3 by unscrewing the 8 nut in order to obtain 10 2...

Page 13: ... a wrench 10 to controle Tighten the 10 nut Start adjusting the lower cable tensioner by unscrewing the 8 nut until it comes against the sleeve stop CAUTION Tighten only until the cable is not moving anymore while pulling WITH STRENGTH the sheath toward the rear of the bike Stop adjusting at this time ...

Page 14: ...ing WITH STRENGTH on the cable to the rear of the bike If this measurement is not correct correct by thightening or loosening the 8 nut Tighten the 10 nut Lubricate with grease for chain in spray the cables on the pulley the pulley groove and the steel plate to prevent oxidation Replace the protective rubber of the pulley the protective plastic cover and tighten the screw Finally replace the prote...

Page 15: ... SE R Draining the transmission oil Remove the drain plugs 1 and 2 let the oil drain Removing the sprocket and the gear selector Straighten the security tab 3 using a suitable punch Remove the nut and the sprocket 4 Remove the bolt 5 and the gear selector Remove the clutch control rod 2 1 3 4 5 ...

Page 16: ...ing bolts 1 the cylinder head and the two o rings Remove the four socket head bolts 3 and the four washers 2 located on the base of the cylinder Remove the cylinder Remove the piston pin retaining clips Remove the piston pin Remove the piston and the needle bearing from the connecting rod Remove the base gasket 3 2 1 ...

Page 17: ...terpump cover screws and the cover Remove the seal Remove the clutch cover screws and the cover Remove the seal Removing the pressure plate and discs Carefully loosen all of the screws 1 on the pressure plate Remove the screws the springs and the spring cups 1 ...

Page 18: ...2 screws 2 Removing the primary drive gear Secure the end of the crankshaft gear with the special tool 5206 3 Loosen the fi xing nut 4 and remove the nut primary drive gear and the conical washer Open the safety washer on the clutch hub nut 5 Use special tool 5749 6 to hold the clutch hub and loosen the nut Remove the tool Remove the nut the clutch hub and the two needle bearings 2 2 4 3 6 5 1 ...

Page 19: ... remove the shifting interlock mechanism 3 Remove the bolt 4 and then remove the lever along with the spring and the spacer CAUTION Note the pin and the seal The primary drive gear and the clutch hub are matched so they can not be changed separately They must be replaced as a set CAUTION Make sure that the washer stays at the bottom of the housing CAUTIONNote the location of the dowel pin that loc...

Page 20: ... screws and then remove the ignition cover along with the gasket Removing the electric starter double gear and the starter drive Remove the three shoulder bolts 1 Remove the double gear retaining bracket 2 Remove the double gear 3 and the needle bearing Remove the starter drive 4 3 4 2 1 ...

Page 21: ... the flywheel with special tool 5207 1 and remove the retaining nut 2 Use the extracting tool 5208 3 and remove the flywheel 4 Intake manifold and reeds Remove the four bolts 5 Remove the intake manifold the reed block and the associated parts 4 3 1 2 5 ...

Page 22: ...cation tube 1 Remove the main shaft shim 2 Remove the shifting fork shafts and push the shifting forks aside in order to release the shifting drum Remove the shifting drum Remove the shifting forks CAUTION Do not use a screwdriver or any other tool to attempt to separate the halves Damage to the mating surfaces can occur CAUTION Pay careful attention to the shims that are on the end of the transmi...

Page 23: ...e bearings Removing the crankshaft Pull the crankshaft out of the bearing use a plastic mallet if necessary Clean all of the parts and inspect for wear replace if required CAUTION In a complete reassembly of the engine it is best to replace all gaskets oil seals o rings and bearings ...

Page 24: ...ft Checking the crankshaft dimensions With a Vernier caliper measure the distance over the ouside of the crankshaft counterweights Overall dimension 64 3 0 0 2 mm Radial clearance of the big end Place the crankshaft in a set of V blocks and place a dial indicator A against the big end of the rod Push B the rod towards the gauge and then pull it in the opposite direction The difference between the ...

Page 25: ...mm maxi Permissible limit 0 05 mm If the runout is not correct replace the crankshaft or align it so that it falls within the permissible limits Piston If you want to use a piston that has already seen service then check the following Skirt Check for traces of seizing slight traces can be removed with a soft stone Stuck rings The rings must not be stuck in the grooves To clean the grooves you can ...

Page 26: ...Remanufactured cylinder CAUTION If the end gap is greater than the permissible limit then check the condition of the piston and cylinder If the piston and cylinder are within the permissible limits then replace the piston rings CAUTION If the diameter of the cylinder is greater that 66 412 mm for example have the Nikasil lining replaced or replace the cylinder Prior to having the cylinder replated...

Page 27: ...Disassemble all of the parts clean them and check for wear To remove the cables follow the disassembly and reassembly procedure Remove the control mechanism protective cover Remove the screw from the tab use a pair of pliers to hold the tab if necessary FRANÇAIS ...

Page 28: ...250 300 SE R 28 ENGINECOMPONENTS Remove the tab Remove the spring Remove the control valve Remove the other spring Remove the control cap and the center screw ...

Page 29: ...p from the center shaft Remove the booster controls Remove the center shaft Inspect all of the parts bearings selas O rings replace if necessary Remove the two boosters Using a 3mm Allen wrench remove the two screws that retain the valve retaining plate Remove the two valves ...

Page 30: ...bly paying careful attention to the next operation Replace the cover on the control valves making sure that the forks are in contact with the valves Check the operation of the valves refer to the section below Checking the operation of the exhaust valve and the boosters CAUTION Pay particular attention to the location of the spring catch When installing the shaft make sure that the tab is position...

Page 31: ...d the boosters Rotate the control in a counterclockwise direction as far as it will go The guillotine and the two booster valves should be down Rotate the control valve clockwise so that the latch is in contact with the cable The guillotine must be retracted FRANÇAIS ...

Page 32: ...to return and the boosters must begin to rise Complete the rotation of the control valve both guillotines should be returned and both boosters should be raised If the timing is not perfect loosen the screw Rotate the control valve to the maximum clockwise untit it stops and tighten the screw Check the timing again ...

Page 33: ...f the valve cables Install the tool 4810 on the boosters machining hole Install the boosters ont the cylinder machining holes Install the main valves and the boosters with the cover check the good engagement tighten the M5 screw to 6 Nm FRANÇAIS ...

Page 34: ...the M4 screw check if the main valves are stop Full main valves opening at this moment block the screw at 3 Nm Check if the boosters are in interaction with the tool spacer Don t apply any rotation to the pulley valve Disable the valves cover and dismount the 2 tools spacer Install the complete cylinder and check the good synchronisation ...

Page 35: ...n of the intake manifold make sure that it is not cracked Clutch Clutch release bearing assembly 3 check for wear Rod 8 check for wear Minimum length 194 7 mm Springs 17 Check their length Minimum length 45 mm All 6 must be replaced if any are out of spec 8 friction discs 14 Minimum thickness 2 68 mm The 7 steel discs must be in good condition with a maximum deformation of 0 05 mm ...

Page 36: ...heir respective bearings in the crankcase Install the shifting forks on their respective shafts as shown The fork shown as 3 should be installed on the primary shaft Install the shifting forks into the grooves in the shifting rings Lubricate the shafts and then fully insert them into their respective bores in the case as shown Install the shim washer on the shaft CAUTION The connecting rod should ...

Page 37: ...ight coat of grease on a new gasket and install it on the RH case Grease the seals in the LH case and then carefully install it Install the screws and tighten them to 10 Nm Tap on the end of the crankshaft with a plastic mallet and then make sure the transmission gears turn freely CAUTION Install the tube with the flat side towards the oil filler cap rivet Install the O ring on the transmission lu...

Page 38: ... the selector drum Apply blue thread locker on the screw and install it in the selector drum Apply grease to the gear selector shaft and install it in the needles bearings in the case remember to install the shim When the selector arm contacts the star shaped drum retract it so that the shaft can be fully inserted Check to make sure the ends of the spring are in contact with the case as shown Temp...

Page 39: ...e two needle bearings 2 Install the clutch housing and the notched washer 3 Apply blue thread locker to the threads of the main shaft Use special tool 5749 to retain the hub assembly and tighten the nut to 100Nm Remove the tool and lock the nut by bending the lock washer Apply blue thread locker to the threads on the crankshaft Install the conical washer and nut apply red thread locker on the scre...

Page 40: ...tern for tightening Clutch housing Check to make sure that the two locating dowels are in place in the housing Install the housing gasket and retain it with a little grease Install the water pump shim washers 2 use a little grease to retain them Install the clutch housing make sure that the water pump drive gear engages the crankshaft gear you may have to rotate the gear to get it to engage Instal...

Page 41: ...e piston rings making sure they are properly aligned sign on the TOP Install the previously prepared cylinder use two bolts and washers on opposite sides Install the other two bolts and washers and tighten to 40 Nm Cylinder head Clean the mating surfaces of the cylinder and the head Install the two locating dowels on the cylinder Install the cylinder head Install the M8 bolts with new copper washe...

Page 42: ...ission output sprocket Lubricate the O ring and install it on the output shaft Slide the spacer over the output shaft so that it engages the seal Install the transmission output sprocket Apply blue thread locker to the threads of the output shaft Install the safety washer Install the nut and tighten to 150Nm Bend the safety washer tab to retain the nut Mounting the starter drive Install the double...

Page 43: ...tall a new gasket and then install the ignition cover Installing the electric starter Replace the starter O ring with a new one Apply a little grease to the O ring Install the starter in the right case Attach the starter with two screws Lubricate the clutch control shaft and insert it into the main shaft Install the gear selector Install the drain plugs using new seals CAUTION Do not fill the gear...

Page 44: ...xle nut 100 Nm Sub frame mounting bolts 24 Nm Front axle 40 Nm Front axle pinch bolts 15 Nm Brake pad mounting bolts 8 Nm Fork triple tree lower pinch bolts WP 12 Nm Sachs 15 Nm Fork triple tree upper pinch bolts WP 17 Nm Sachs 17 Nm Engine mounting bolts 60 Nm Swingarm axle nut 100 Nm Cylinder head bracket bolts 24 Nm ...

Page 45: ...tern 25 Nm Crankcase drain plug 8 Nm Clutch pressure plate screws 10 Nm Water pump mounting screws 10 Nm Flywheel nut 60 Nm Clutch hub nut 100 Nm Primary drive nut 150 Nm Ignition cover screws 10 Nm Central housing screws 10 Nm Intake manifold screws 10 Nm Starter motor triangle plate mounting screws 10 Nm Starter motor bolts 10 Nm Cylinder mounting screws 40 Nm Transmission sprocket nut 150 Nm ...

Page 46: ...N8RH N8RW N8RW N8RJ N8RJ N8RK Needle position 4 4 3 3 2 2 Main jet 172 170 170 168 165 162 1 500 m Air screw 1T 1T 1T1 2 1T1 2 2T 2T to Pilot jet 42 40 40 40 40 40 751 m Needle N8RG N8RH N8RW N8RW N8RJ N8RJ Needle position 4 4 4 3 3 2 Main jet 175 172 170 170 168 165 750 m Air screw 1T 1T 1T 1T1 2 1T1 2 2T to Pilot jet 45 42 40 40 40 40 301 m Needle N8RG N8RG N8RH N8RW N8RW N8RJ Needle position 5 ...

Page 47: ...RG N8RG N8RH N8RH N8RH Needle position 3 3 2 2 2 2 Main jet 168 165 165 162 160 158 1 500 m Air screw 1T 1T 1T1 2 1T1 2 2T 2T1 2 to Pilot jet 40 40 40 40 40 40 751 m Needle N8RF N8RF N8RG N8RG N8RH N8RH Needle position 3 3 3 2 2 2 Main jet 170 168 165 165 162 160 750 m Air screw 1T 1T 1T 1T1 2 1T1 2 2T to Pilot jet 40 40 40 40 40 40 301 m Needle N8RF N8RF N8RF N8RG N8RG N8RH Needle position 4 3 3 ...

Page 48: ... no continuity between the windings and the mass of the bike Resistance at the Pick UP sensor Speed sensor Red Green 100 Ω 20 at 20 C High tension coil Primary coll 0 30 Ω 15 at 20 C Secondary coll 6 3 Ω 20 at 20 C Dynamic control values Voltage regulator Alternating AC 200V class At idle 22V 2V T 6000 RPM 77V 3V Continuous On the output regulator 20V continuous At 4000 RPM 14 6V Red White Green Y...

Page 49: ...49 WIRINGDIAGRAMS Main harness 6517 ...

Page 50: ...250 300 SE R 50 WIRINGDIAGRAMS ...

Page 51: ...51 WIRINGDIAGRAMS Lighting harness 250 SE R 300 SE R ...

Page 52: ...250 300 SE R 52 WIRINGDIAGRAMS Lighting harness Racing 250 SE R 300 SE R ...

Page 53: ...53 WIRINGDIAGRAMS Wiring harness accessories ...

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