SHERCO 250 SEF-R Workshop Manual

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CONTENTS
FORWARD.................................................................................................................................................3
MOTOR TOOLS 250 SEF-R and 300 SEF-R......................................................................................................4
TECHNICAL SPECIFICATION........................................................................................................................5
THE MOTOR ..................................................................................................................... 5
THEFRAME ...................................................................................................................... 6
STANDARD ADJUSTMENT ..........................................................................................................................7

THEFORK........................................................................................................................ 7
SHOCK ABSORBER.............................................................................................................. 8
OPERATIONS REQUIRING DEMOUNTING OR NOT ENGINE.............................................................................9
REMOVING / REINSTALLING THE MOTOR ...................................................................................................10

REMOVINGTHEMOTOR ...................................................................................................... 10
REINSTALLINGTHEMOTOR................................................................................................... 10
MOTOR ..................................................................................................................................................11
REMOVINGTHECYLINDER HEAD ............................................................................................. 11
MOTORTOPENDCONTROLS................................................................................................. 13
Inspection of the cylinder for wear .....................................................................................................................13
Piston / cylinder clearance .................................................................................................................................13
Piston wear ........................................................................................................................................................14
Ring groove / piston ring ....................................................................................................................................14
Ring end gap ......................................................................................................................................................14
Inspect the connecting rod, the piston pin and the piston for wear ...................................................................14
Check the camshafts for wear ...........................................................................................................................15
Checking the camshafts and camshaft journals for wear ..................................................................................15
Eccentricity of the camshaft ...............................................................................................................................15
Inspect the cylinder head for flatness ................................................................................................................16
Visually inspect the timing chain for damage .....................................................................................................16
Inspecter visuellement les patins de distributions ..............................................................................................16
Valve – Guide clearance ....................................................................................................................................16
REASSEMBLING THETOPEND OFTHEMOTOR .............................................................................. 17
Reassemble the piston.......................................................................................................................................17
Valve timing ........................................................................................................................................................19
Checking the valve clearance ............................................................................................................................21
Replacing the cam chain ....................................................................................................................................21
DISASSEMBLING THERIGHT SIDE............................................................................................. 22
Clutch dismanting ...............................................................................................................................................22
Inspect the clutch ...............................................................................................................................................22
Check the clutch spring length ...........................................................................................................................22
Reassembly of the clutch ...................................................................................................................................22
Disassembling and inspecting the water pump .................................................................................................23
Changing the water pump shaft seal requires removing the clutch housing .....................................................23
Removing the clutch hub and the clutch basket ................................................................................................24
Reassembling the clutch hub components ........................................................................................................24
DISASSEMBLING THE LEFT SIDE .............................................................................................. 25
Disassembling the ignition case .........................................................................................................................25
Replacing the stator and sensor system ............................................................................................................25
1
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Removing the rotor .............................................................................................................................................26
Inspect the freewheel and the needle bearings .................................................................................................26
Reassembling the ignition case .........................................................................................................................27
CRANKCASE /TRANSMISSION/ CENTRAL CRANKCASES .................................................................... 28
Disassembling the transmission and the crankshaft ..........................................................................................28
Checking the transmission components ............................................................................................................29
Checking the crankshaft.....................................................................................................................................30
Checking the center crankcases ........................................................................................................................31
Reassembling the central crankcase assembly .................................................................................................32
TIGHTENINGTORQUES ....................................................................................................... 35
CLEAN INJECTOR BODY....................................................................................................... 37
Material...............................................................................................................................................................37
Put down the injector body .................................................................................................................................37
Clean of injector body ........................................................................................................................................39
Replace the injector body...................................................................................................................................39
SYNERJECT ) INJECTION SYSTEM INSTRUCTION MANUAL .....................................................................40

SYNERJECT ) INJECTIONSYSTEM PRESENTATION ........................................................................... 40
SOFTWARE PRESENTATION.................................................................................................. 46
2.1- Connection with Keyless system ................................................................................................................46
2.2- Software setup : configuration menu ..........................................................................................................48
2.3- Menu update and synchronization ..............................................................................................................49
USINGTHESOFTWARE ....................................................................................................... 51
ELECTRICAL INSTALLATION CHECKING ....................................................................................................64
CONTROLS OF THE SENSORS ..................................................................................................................66

CONTROLTPS SENSOR....................................................................................................... 66
VALUES OFTEMPERATURE SENSOR......................................................................................... 67
CABLE DIAGRAM .....................................................................................................................................68

Injection beam ....................................................................................................................................................68
250 SEF light system cable diagram .................................................................................................................71
300 SEF light system cable diagram .................................................................................................................72
250 SEF-R Racing light system cable diagram .................................................................................................73
300 SEF-R Racing light system cable diagram .................................................................................................74
Flasher installation cable diagram .....................................................................................................................75
Fan cable diagram .............................................................................................................................................76
2
FORWARD
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.
3
MOTOR TOOLS 250 SEF-R and 300 SEF-R
TOOL DESIGNATION
REF
1819 Dead point
1814 Clutch holder tool
4753 Ignition tool
2067 Swingarm tool
2068 Freewheel tool
2069 Oil seal tool (Gear box exit)
2070 Oil level gauge tool
2071 Bearing tool 6905 (Gear selector drum)
2072 Bearing tool 6222 (Clutch 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 Bearing tool 6003 (Gear shaft)
1968 Oil seal tool (Water pump)
2075 Piston tool
2076 Bearing tool (Crankshaft)
1816 Ring tool
1821 Engine support tool 250
1817 Pinion tool
1818 Piston support
2073 Resort tool
R462 Flywheel puller
R464 Ring extractor
R450 Gear selector oil seal tool
3785 Spark key
6267 Shunt for keyless system
4
TECHNICAL SPECIFICATION
THE MOTOR
250 SEF-R 300 SEF-R

Type Liquid cooled single cylinder 4 strokes engine
Displacement 248.6 CC 303.7 CC
Bore/Stroke 76/54.8mm 84/54.8mm
Compression ratio 13.2 :1 12.85:1
Fuel Without lead 95 or 98
Valve timing 4 valves, DOHC driven by tooth type chain
Admission valve diameter 29mm 30mm
Exhaust admission valve 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 pumps
Motor oil 1 litre SAE 10W40
Primary reduction ratio 21 :70
Gear box : 6 speed
1st 14 : 33
2nd 17 : 30
3rd 19 : 28
4th 21 : 26
5th 23 : 24
6th 25 : 22
Final transmission 13 X 49 13 X 48
Clutch Multi-disk in oil bath. Hydraulic command
Ignition system / Batterie Electric start/12V 4Ah
Electronic injection Synerject
5
TECHNICAL SPECIFICATION
THE FRAME
Frame Semi-perimeter CrMo steel with aluminum subframe

SACHS USD Gold Series 48mm dia. (standard) & WP USD
Fork
48mm dia. (racing)
Rear suspension WP Suspension with separate cylinder
Travel Front/Rear 300/330mm
Front brake disc Ø 270mm (standard), Ø 256mm (racing)
Rear brake disc Ø 220mm
Brake disc 2.7mm front et 3.6mm rear
Front tire 90/90-21’’
Rear tire 140/80-18’’
Pressure TT 0.9 bar
Fuel tank capacity 9.7l with 1l of reserve
Angle of the steering column 27.3°
Wheel base 1480mm
Weight (without fuel) 102 kg
6
STANDARD ADJUSTMENT
THE FORK
Standard adjustment - Fork Sachs USD Gold Series Ø48MM
Turn clockwise to the stop, then

Compression
back of 12 clicks
Turn clockwise to the stop, then
Rebound
back off 12 clicks
Spring 4.5N/mm
Fork oil SAE 5
Oil capacity 600cm3
Oil level 130mm
Standard adjustment - Fork WP USD Gold Series Ø48MM
Compression Comfort 20 clicks back

Standard 13 clicks back
Sport 8 clicks back
Rebound Comfort 18 clicks back
Sport 10 clicks back
Preload Comfort 2 turns
Standard 4 turns
Sport 6 turns
Spring stiffness Rider weight : 143 -165 lbs 4.0N/mm
Rider weight : 165- 187 lbs 4.2 N/mm (original)
Rider weight : 187- 210 lbs 4.4N/mm
Type of oil SAE 4
Oil level measurement (fork compressed and spring 110mm
removed) from the top of the fork tube
7
STANDARD ADJUSTMENT
SHOCK ABSORBER
Standard adjustment - WP Shock absorber
Low-speed compression Comfort 20 clicks back

Sport 12 clicks back
High-speed compression Comfort 2.5 clicks back
Sport 1.5 clicks back
Rebound Comfort 15 clicks back
Standard 13 clics en arrière
Sport 11 clics en arrière
Spring stiffness Rider weight : 143 -165 lbs 48N/mm
Rider weight : 165- 187 lbs 51N/mm (origine)
Rider weight : 187- 210 lbs 54N/mm
8
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 •
Freewheel •
Clutch •
Water pump •
Oil pump •
Gear selection •
9
REMOVING / REINSTALLING THE MOTOR
REMOVING THE MOTOR
ATTENTION
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.
 Drain (refer to the owner’s manual)
- the engine oil
- the engine coolant
 Remove the seat.
 Disconnect the battery.
 Remove the fuel tank and its covers.
 Disconnect all the electrical wiring connectors from the engine. (Starter, TPS sensor,
water temperature sensor, coil, fuel injector).
 Remove the exhaust.
 Remove the ignition coil.
 Remove the fuel injector body.
 Remove the chain.
 Remove the chain guard.
 Remove the clutch actuating cylinder.
ATTENTION
When the clutch actuating cylinder is removed the piston is loose. Hold the piston it in place
using a plastic strap.
 Remove all of the water hoses connected to the motor.
 Remove the left radiator.
 Loosen all of the engine bolts [A].
 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.
 Remove the motor.
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
10
MOTOR
For additional details refer to the parts catalog 250 SEF-R _ 300 SEF-R
REMOVING THE CYLINDER HEAD

 Remove the spark plug.
 Remove the valve cover.
 Remove the three valve cover screws.
ATTENTION : These three screws are equipped with o-rings ref: 0900.
 Remove the cap from the ignition

cover [A].
 Remove the timing control plug [A]
 Turn the engine counterclockwise in

order to align the timing 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)
11
 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).
 Remove the exhaust camshaft

retaining clip.
 Remove the exhaust camshaft.
 Remove the intake camshaft
retaining clip.
 Remove the intake camshaft.
 Remove the two nuts M6 and the

washer.
12
 Remove the cylinder head bolts (Be
sure to loosen them in the correct
direction).
ATTENTION : Black bolt N°1 on the
picture is longer, 3 bolts are identical.
 Remove the cylinder head.

 Remove the head gasket and the
cylinder.
MOTOR TOP END CONTROLS

Inspection of the cylinder for wear
Measure the inside diameter of the cylinder
when it is cold.
Inspect the inside of the cylinder for any
scratches or other evidence of abnormal wear.
If the cylindecar is badly damaged or worn it
should be replaced.
Since the cylinder does not wear in a uniform
manner measure in from side to side and up
and down as shown.
If the inside measurement of the cylinder
exceeds the tolerance limit it must be
replaced.
(A)=10 mm
(B)=25 mm
Piston / cylinder clearance

To determine the piston / cylinder clearance as
accurately as possible it is sufficient to
measure the piston and the cylinder, and then
calculate the difference between the two
values. Measure the diameters as shown.
Piston / cylinder clearances
Standard 0.03 – 0.05 mm
Limit 0.10 mm
13
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.
Piston 250 SEF-R= 75.950±0.005 mm
Piston 300 SEF-R= 83.950±0.005 mm
Ring groove / piston ring

 Using a feeler gauge measure the
clearance between the piston ring and the
ring groove.
 Check in several places to determine the
actual clearance if the clearance is greater
than the maximum, replace the piston ring
and if necessary the piston.
Ring groove / piston ring
Standard
Compression ring: 0.030-0.065 mm
Limit 0.13 mm
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 inspect the circlips in place.
If they appear worn or distorted replace
them. If the hole for the circlips appears
worn replace the piston.
 Measure the piston pin with a micrometer.
If at any place on the pin the diameter is
below the limit replace the piston pin.
 Measure the diameter of the piston pin
holes in the piston and the hole in the
connecting rod. If the one or more holes in
the piston are incorrect replace the piston.
If the diameter of the hole in the connecting
rod is incorrect, replace the connecting rod.
14
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
Intake: 32.145 mm
Checking the camshafts and

camshaft journals for wear
 Measure the clearance between the
camshaft and the camshaft journals using
plastigage [A].
 Lubricate 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 each
journal.
Camshaft / journal clearance
Standard: 0.020 – 0.062 mm
Limit: 0.15 mm
If the diameter of the journal is below the
limit replace the camshaft and measure
again.
Camshaft journal diameter
Standard: 23.05 – 23.25 mm
Limit 23.02 mm
If the clearance is outside of the tolerance
limits, replace the entire cylinder head.
Eccentricity of the camshaft

 Measure the camshasft runout.
If it is out of tolerance, replace the camshaft.
Runout : Less than 0.03 mm
15
Inspect the cylinder head for
flatness
 Place the cylinder head on the 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. If the damage is severe replace the
head.
Cylinder head warpage:
Limit = 0.05 mm
Visually inspect 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
make sure that it is not in the last ratchet
notch.
Inspecter visuellement les patins de

distributions
 Visually inspect all of the cam chain
tensioner channel guides and pads
including the ones on the cylinder head
cover.
 Change as necessary.
Valve – Guide clearance

Intake :
Mini clearance : 0.02 mm
Maxi clearance : 0.045 mm
Escape :
Mini clearance : 0.04 mm
Maxi clearance : 0.065 mm
16
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
D Upper piston ring gap
ATTENTION : The expander rings do not
have a top or bottom; however the oil
control ring and the compression ring must
be installed with the « N » mark facing up.
 Apply engine oil to the wrist pin internal
bore in the piston.
 Carefully note the piston orientation (the
small cut outs are on the exhaust side)
 Install the locating pins [B].
 Install the base gasket [C].
 Use special tool number 1821 to maintain
the piston in the correct location [A].
ATTENTION : Use the same head gasket
(thickness 0.3 or 0.4mm depending on the
model).
 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 wrist pin.
Install the circlip on the wrist pin.
 Mettre le poussoir de l’outil pour mettre en

place le clip.
 Mettre l’axe de piston.
17
 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.
 Install the two cylinder head locating pins

[A].
 Install the head gasket [B].
 Install the cylinder head.
 Install the head bolts noting the different

lengths; tighten them using two passes in
the order shown in the photo.
 Install and tighten the two M6 nuts.
Cylinder head torque:
Studs 1st pass: 30 Nm
2nd pass: 45 Nm
Nuts M6: 10 Nm
ATTENTION : The two internal bolts are of

different length and are equipped with
washers.
18
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)
 Install the camshaft retaining clips.

 Apply moly disulfide grease to the
camshafts.
19
 Install the camshaft retaining cover. (pay
careful attention to the tightening order).
Camshaft retaining cover torque
10Nm
ATTENTION : The screw n°1 is a M6 X 35
 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).
Torque the tensioner adjusting screw
to: 10Nm
 Remove the special tool number 1819.
 Rotate the engine a few times to make
sure that the valve timing is correct.
 Finally check the valve timing using the
timing marks.
 Replace the cap that was removed to
install tool number 1819.
Torque the cap to:
8Nm
 Replace the spark plug well.
ATTENTION : Make sure that the o-rings

are installed on the spark plug well.
 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:
8Nm
20
Checking the valve clearance
 The valve clearance must be checked

when the engine is cold.
 Remove the spark plug and the 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
Exhaust 0.20 – 0.25 mm
 If the clearance is not correct then change

the discs in order to obtain the correct gap.
 Remove the discs with a magnet.
 Measure the thickness of the disc and
replace with one of the correct thickness.
Select the appropriate disc from the
existing parts catalog.
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.
 Inspect the cam chain (see « visually
inspecting the cam 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.
21
DISASSEMBLING THE RIGHT SIDE
For additional details see the parts catalog 250 SEF-R and 300 SEF-R.
Clutch dismanting
 Install special tool number 1819.
ATTENTION : Only use this tool for
disassembling the clutch, do not use it to
remove the hub fixing nut.
 Remove the 4 screws that retain the clutch
cover.
 Remove the 5 pressure plate screws (see the
photo).
 Sort the discs and make sure they are
trimmed and smooth.
Make sure that the clutch hub rotates freely.
Inspect the clutch

 Inspect the discs to make sure they are
trimmed and smooth.
Friction plate thickness
Standard: 2.95
Limit: 2.7
Deformation limit: 0.3mm
Steel disc thickness
Standard: 1.4
Limit: 1.3
Deformation limit: 0.3mm
Check the clutch spring length

 Measure the free length of the clutch springs.
Standard : 37.29mm
Limit : 36.5mm
Reassembly of the clutch

 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.
 Install the 5 screws and tighten in an
alternating order (see the disassembly photo).
Torque the screws to:
10Nm
22
 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.
ATTENTION : If the seal is leaking, coolant
will come out of the weep hole (see photo). In
order to change the seal the clutch housing
must be removed.
Changing the water pump shaft seal

requires removing the clutch housing
 Remove the clutch housing.
 Remove the clip from the water pump shaft.
 Remove the water pump shaft.
 Remove the roll pin.
 Heat the clutch case in an over to 70°.
 Extract the bearing.
 Put some grease like “molikote Dx” on the lips
of the oil seal.
 Change the seal using special tool number
1968.
ATTENTION : make sure the seal is installed
properly, you should see the spring when you
look at the seal. (see photo).
 Check the bearing, if it requires changing use
special tool number 1822.
 Reinstall the parts in the reverse order of their
removal. Pay careful attention to the clutch
housing locating pins, always install a new
paper gasket and if necessary install a new o-
ring seal on the water pump housing.
Tighten the water pump housing screws

to:
10Nm.
Tighten the coolant drain plug to:
6Nm.
23
Removing the clutch hub and the
clutch basket
 Drain the engine oil and the engine coolant.
 Remove the clutch housing. (see
disassembling the right side paragraph)
 Remove the clutch. (see clutch removal
paragraph)
 Remove the clutch release bearing assembly.
 Retain the clutch hub using tool 1814.
 Loosen the clutch hub nut.
ATTENTION : make sure the special timing
tool number 1819 is not installed, if it is,
severe damage could occur to the crankshaft
and crankcase.
 Remove the hub and the nut.
 Inspect the needle bearings and replace if
necessary.
 Visually inspect the hub and the housing.
Reassembling the clutch hub

components
 Install the thrust washer.
 Install the needle bearings.
 Install the clutch housing.
ATTENTION : The clutch basket wheel is
appeared with the primary gear.
 Install the spacer washer.
 Install the clutch hub.
 Install the special washer.
 Grease the threads of the shaft and the nut.
 Apply thread locker (blue) to 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.
24
 Install the judder spring
ATTENTION : There is a sense.
 Install the special friction disc.

 Install all the metal and friction discs.
 Reinstall the clutch release bearing assembly,
the clutch spring holder in the 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.
DISASSEMBLING THE LEFT SIDE

For additional details refer to the parts catalog
250 SEF-R and 300 SEF-R.
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].
 Check the pulse generator (sensor)
 Replace if necessary.
Replacing the stator and sensor

system
 Remove the 2 screws that retain the sensor
[C] and the 2 screws that retain the stator [D].
 Install the new parts.
 Reinstall the screws using 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.
25
Removing the rotor
 Utilize the special rotor holding tool number
4753.
 Remove the rotor fixing nut.
 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
 Remove the freewheel gear.
Inspect the freewheel and the needle

bearings
 Visually inspect the caged needle bearings.
 Inspect the track of the freewheel gear.
 Replace the freewheel gear if necessary.
 Dismount the free wheel from the rotor by
loosening the 8 M5 screws.
 Inspect the free wheel housing.
 Finally check the rollers on the freewheel.
ATTENTION : If the freewheel must be
replaced then the rest of the gears must be
replaced and vice versa.
26
Reassembling the ignition case
 Install the free wheel gear.
 Reinstall the two starter shafts and their
gears.
 Visually inspect the oil seal on the oil
centrifuge.
 Use special tool number 1818 to screw the oil
centrifuge.
Apply thread locker (blue) to the oil centrifuge
thread.
ATTENTION : This screw thread is reversed,
it is a LH thread.
 Screw and tighten the centrifuge.
Torque the centrifuge fixing screw to: 8
Nm.
 Inspect the rotor key, change if necessary.
 Pre assembly the rotor group
 Assembly the free wheel in its housing.
Tighten this set to the rotor with the 8 M5
screws (apply thread locker blue on the
screws).
Torque the M5 screw to: 8 Nm.
 Install the rotor (turn the rotor counter
clockwise to help facilitate the installation of
the lighting rotor).
 Apply proper tightening torque to the nut on
the rotor with strong thread locker.
 Install the conical washer.
 Using special tool number 4753 to hold the
rotor tighten the fixing nut.
Torque the fixing clutch nut to 80 Nm with
thread locker (blue).
ATTENTION : Check the clearance between
the 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 and
tighten the 10 screws.
Torque the ignition crankcase cover
screws to: 10 Nm.
27
CRANKCASE / TRANSMISSION / CENTRAL CRANKCASES
Disassembling the transmission and
the 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).
 Remove the clutch components (see the
clutch chapter).
 Remove the cam drive chain (see the top
end chapter).
 Remove the cam chain tensioner and
guides.
 Block the transmission primary gear with
 Loosen the fixing nut for the counter
balancer.
 Remove the counter 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
 Remove the transmission primary gear.
 Remove the clutch basket, the needle
bearings and the thrust washer.
 Remove the primary transmission gears.
 Remove the oil pump drive gear.
 Remove the oil pump cover.
 Remove the oil pump rotor.
 Remove the oil pump shaft.
 Remove the gear selector shaft.
 Using special tool number 2073 block the
gear selector drum and remove the gear
selector index wheel screw...
 Remove the gear selector index wheel.
 Remove special tool number 2073.
 Remove the starter motor.
 Loosen and remove the 13 central
crankcase screws.
28
 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
 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 they should be replaced.
 Check the condition of all the shifting forks.

Replace the shifting forks if necessary.
 Check the condition of the gear selector

drum, make sure it is not deformed,
damaged or badly worn.
Replace the gear selector drum if necessary.
29
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. The difference between these two
readings is the radial play.
Radial play of the big end bearing:
Standard: 0.015 mm – 0.020 mm
Tolerance limit: 0.06 mm
If the radial play exceeds the tolerance limit
the crankshaft 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
If the lateral movement of the big end
exceeds the tolerance the crankshaft must
be replaced
Checking the run out :

 Place the crankshaft in a lathe or suitable
support, place dial indicators as shown.
 Turn the crankshaft and record the readings.
The maximum difference between the
readings is the crankshaft run out.
Run out:
Standard: 0.02 mm maximum
If the run out exceeds the tolerance, replace
the crankshaft or straighten it so that it
meets the tolerance.
30
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.
Replace the crankshaft bearings if
necessary.
 To remove the bearings, install tool number
R464, heat the tool and the bearing.
 Remove the bearing.
ATTENTION : The radial play in the roller

bearings must be practically zero
31
Reassembling the central
crankcase assembly
ATTENTION : During the rebuild, replace all
seals (paper, seal, o-ring…).
 Install the crankshaft and counter balancer

assembly in the left case, align the marks as
shown.
 Install the transmission gear along with their
corresponding shafts.
 Install a new roller on each shift fork.

 Install the shift forks in the transmission in
their respective grooves.
 Install the gear selector drum.
 Place the shift fork rollers in their respective
grooves in the drum.
Install the shift fork shafts
ATTENTION : The center shift fork shaft is
the smallest in diameter.
ATTENTION : 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.
32
 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.
 Install special tool number 2073 to keep the
gear selector drum from rotating.
 Install the locating pin, the gear selector
index wheel and the fixing screw.
Torque the gear selector index wheel
fixing screw to: 10 Nm.
 Remove the special tool number 2073.
 Install the gear selector shaft.
 Install the oil pump shaft, the roll pin and the
internal oil pump rotor.
 Install the oil 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 gear.
 On the transmission input shaft install the
thrust washer, the needle bearings the clutch
basket, the spacer washer, the clutch hub
and the conical washer.
 Using an appropriate solvent clean the
crankshaft threads and the input shaft
threads.
 Install the fixing nuts on the crankshaft and
the transmission input shaft.
 Apply the proper torque these fixing nuts.
 Install special tool number 1817 and torque
the crankshaft fixing nut.
Torque the crankshaft fixing nut to: 120
Nm.
 With the special tool still installed, torque the
transmission input fixing nut.
Torque the transmission input fixing nut
to: 80 Nm.
33
 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 of balancer nut 60 Nm +
threadlocker.
 Install the oil pump drive roll pin, the intern
rotor and fixing nut to the cover.
Torque of the oil pump cover : 5 Nm.
 Heat the crankshaft spacer ring (ref 1732) to
approximately 70 degrees and install it on
the crankshaft.
 Replace the freewheel assembly and the
starter drive gear train (see the paragraph on
disassembling the left side).
 Reinstall the starter.
 Reinstall the motor top end (see the
paragraph on the top end).
 Install the cam drive chain (see the
paragraph on top end).
 Install the clutch (see the paragraph on
disassembling the right side).
 Install the clutch cover.
 Install the spark plug.
Torque the spark plug to: 15 Nm.
ATTENTION : Apply threadlocker to all of

the internal engine threads except the five
clutch pressure plate fixing screws.
34
TIGHTENING TORQUES
STANDARD TORQUE THREADLOCKER

M5 6 Nm
M6 10 Nm
M8 24 Nm
M10 40 Nm
MOTOR TIGHTENING TORQUES THREADLOCKER
Magnetic drain plug 15 Nm
Drain plug with prefilter 15 Nm
Oil filter cover 15 Nm
Spark plug (with copper grease) 15 Nm
Bolt for bleeding cooling system 6 Nm
Ignition sensor screw 8 Nm •
Bolt for draining cooling system 6 Nm
Clutch slave cylinder screw 9 Nm
Exhaust bolt 10Nm
Cylinder head :
1st pass 30 Nm
2nd pass 45 Nm
Hexagon nut M6 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 pump cover 11 Nm
Rotor nut 80 Nm •
Clutch nut 80 Nm •
Oil breather wheel 8 Nm
Ignition cover 10 Nm
Crankcase screw 10 Nm
Gear selector drum screw 10 Nm
Oil pump cover 5 Nm
Balancer nut 60 Nm •
35
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 boltes / axle M6 15 Nm
Brake pad bolt 8 Nm •
WP 12 Nm
Botton plat fork bolts
Sachs 15 Nm
WP 17 Nm
Upper plat fork bolts
Sachs 17 Nm
Motor screw 60 Nm
Swing arm nut 100 Nm
Cylinder head-frame screws 23 Nm
36
CLEAN INJECTOR BODY
Material
 Minerva Net Carbu or carbu cleaner
 Allen keys 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 cable
 Remove the injector body
37
 Disconnect each connector
 Inspect
 Clean with carbu cleaner or universal

product cleaner
 Blow
38
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 Soufflez
 Blow
Replace the 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 sense of
this part!
 Set the throttle cable
 Disconnect the ECU connector.

Inspect it
 Clean with carbu cleaner or universal
product cleaner
 Blow
 Apply connector grease

 Connect to the ECU
39
SYNERJECT ) INJECTION SYSTEM INSTRUCTION MANUAL
SYNERJECT ) INJECTION SYSTEM PRESENTATION

1.1- Your Sherco 300 SEF-R (for 250 SEF-R, refer to the 2013 manual) is equipped
with a Synerject injection system that is composed of a M3C computer, a Ø 42mm
throttle body, a special ignition system and a special harness.
Photo 1
1 2 3 4 5
N° DESIGNATION LOCATION
1 Synerject M3C Computer Left side of the frame
2 Engine speed sensor (pick-up) Upper part of the ignition cover
3 Synerject injection unit Ø 42mm
4 Water temperature sensor The rear of the cylinder head
5 Diagnostic connector with double At the right front of the bike between
water protection (labeled ECU) the radiator and the frame
40
Photo 1 : Synerject M3C Computer
Photo 2 : Synerject injector body Ø42mm
1 2 3 4
N° DESIGNATION
1 Stepper motor (Idle management and engine braking)
2 Injector
3 TMAP sensor (Air temperature/air pressure)
4 TPS: Butterfly position sensor
1.2- Description- Exxodiag diagnostic tool reference #4967

The diagnostic tool allows you to perform diagnostic operations, make updates to the injection
mapping and to determine certain information (serial number of the motorcycle, number of
hours of operation, etc.).
1.3- Diagnostic tool kit contents

The kit consists of a USB to MUX output cable, a MUX device, a MUX to motorcycle diagnostic
connector cable, an installation CD and a user manual.
41
1.4- Installation of the diagnostic tool
In case of problem during the installation, please contact EXXOTEST at +33 (0)4 50 02 34 34 or
by mail to courrier@exxotest.com.
A- Installing the software and drivers :

 Open the installation CD on your computer
 Run « Sherco_Setup »
 Select the desired language
 Click « Next »
 Select the folder where you want the

softwarer to be installed
42
 Click « Next »
 Click « Install »
 Installation is in progress
43
 Select « Start installing drivers » and
« Finish »
 The following window opens. Read the

terms of the licence agreement. Select
« I accept the terms of the license
agreement » and « Install ».
 Installation in progress
44
 The following window opens. Click
« Finish »
The installation is complete.
B- 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 the motorcycle.
Check to make sure that the "MUXDIAG II" is receiving power. The LED lights should be lit:
 Solid blue: The PC connection has been successfully established

 Flashing blue: Connected to current PC
 Blue LED off: The PC is off or in standby mode or there is a problem with the USB
connection
 Steady green: There is a problem with the software
 Flashing green (slow): The software is functioning correctly
 Flashing green (fast): Connected to current PC
 Green off: The firmware is not present
 Solid red: The card is receiving power
All LED’s off : The unit is not plugged in, it is in standby mode or there is a USB problem
45
SOFTWARE PRESENTATION
2.1- Connection with Keyless system
Sherco had a Keyless system on its motorcycles which allows the bike to switch on without any
key and switch off automatically after 30secondes of non-use.
This last point blocks the diagnostic, this is why it is necessary to follow the steps down below
before doing it.
1. Remove the plug (1) from the connector (2) (located on the rear sub frame – on the right
part of the bike).
2
1
1
2. Take the shunt (3) (reference 6267) and connect the plug (1) into it.
3. You can now do the diagnostic by following the next explanations.
46
Note: In order to establish connection with the bike it must be turned on (ON).
To navigate through the various menus only the USB cable with the "MUXDIAG II" box must be
connected to the computer.
Start the software by using this icon.
Go to the following menu:
Diagnostic Menu Setup Menu Update and sync Help

(diagnosis, updates (language selection, Menu (software
mapping, etc) units, etc) update, proxy
settings)
47
2.2- Software setup : configuration menu
In this menu you can change the following:
 Taking a diagnostic reading. You can refresh the list by clicking on this button. .
Le n° doit correspondre au n° du boîtier "MUXDIAG II".
 The languages included on the software include: French, English, Spanish, Portuguese,
German and Italian (If the CD that you have does not include these languages. Perform a
software update, -> page 49).
 Choose the desired units.
 Click on to return to the home screen
 Click on to validate your changes
48
2.3- Menu update and synchronization
A- With this menu you can update the diagnostic software tool :
 To determine if a software update is

available, make sure that you have an
internet connection and then click this
icon.
 If an update is available, the following

window will appear :
 If no update is available, the following

message appears :
49
 Click on in order to start the
download of the update.
 The following message will appear:
 Click on to start the installation.
 Repeat the setup steps -> page 42. It is not necessary to reinstall the drivers.
50
B-Configure the internet access settings
You may need to set up a Proxy server in order to access the internet.
 Click on this icon
 Complete the following settings if necessary
 Click on in order to save your changes
USING THE SOFTWARE
Diagnostic menu and updating the injection mapping
General :
Click on « Sherco »
Click on « M3C »
51
You get the following menu :
A-Identification : You can check the identification of the following (serial number, hours of
operation, calibration number)
B-Parameter measurements : general parameters (speed, pressure, stepper, etc)
52
1-Engine information :
Displayed below are the main system values :
Details :
- Stepper Position: The air valve (stepper) opening value -> 35 < 50 < 75
If the value is too low: there could be an air leak at the engine air intake
If the value is too high: there could be dirt in the injector butterfly area
Note : The correct air valve motor value should be 15mm and 2mm with the motor idling and at
80°C.
-Butterfly position: With the engine stopped it should be 0%: the maximum opening value should
be 100%. If the value is not 0% with the engine stopped it means that it needs to be adjusted.
Perform a system reset several times (Switch the ignition off. Wait until the ECU relay shuts. Put
it on the bike). The pitch should be 0.5%.
-Emergency stop button: the status of the emergency stop button. 0: off, 1: on.
-Engine status: ES (engine ready to start), ST (engine running), IS (engine is at idle), PL

(acceleration), PU (deceleration), PUC (injection cutoff deceleration)
53
2-Other less frequently used values appear in the windows :
Throttle position :
- The adjustment value for the minimum throttle butterfly opening should be (in V): 0.4<0.5V<0.6
Miscellaneous :
- Manifold Pressure (mb): pressure at the injector nozzle body measured by the TMAP sensor
-Engine synchronization status: engine cycle recognition.

0: engine not in phase.
1: engine running in phase.
-The full engine idling adaptation (%): not activated function
C-Reading the default codes :
When you click on "read default codes” the system starts checking.
If no default appears exit the menu by clicking on this icon
54
If a default appears :
You can get the details of the default by clicking on the default display :
-Record the defaults and exit the menu by clicking on this icon
55
Note :
1- Transient default/permanent default : a transient default becomes permanent after a certain

number of engine cycles of the following components (injector, fuel pump, etc). For a permanent
default to disappear it takes 40 cycles without the engine default reappearing.
2- Fan Default : If there is no fan installed on the bike, there will always be a rise in the fan
default code (P0485)
D-Erasing default codes
1-If a default appears : go to the menu « Erasing default codes »
Click this icon in order to erase all of the default codes
56
The following screen will appear :
Confirm by clicking on this icon
2-Return to the menu « reading default codes » :
Check and make sure that the defaults are the same as before. Check/replace the defective
parts. Check all of the connections.
57
E-Test the actuators
In addition to reading default codes you can also check some of the system components :
1-Ignition coil
When you launch the ignition coil test, the following message will appear :
58
The system is not able to detect an ignition coil failure with the engine 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 coil.
2-Injector
This is the same type of test as with ignition coil. Make sure that the injector issues a snap when
activated.
3-Fuel pump/fan/stepper
For the fuel pump, the fan and the stepper (air valve) perform a standard test. If there is a
default it twill appear as a classic default.
59
Example of a functioning stepper :
Stepper default :
In the event of a reoccurring default, check/change the defective parts.
Note : The fan test is meaningless if the bike is not equipped with a fan.
60
F- Updating the computer :
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 or there is an update from the factory.
These files will be freely available on sherconetwork (end 2013):
You must pay attention to the model, the displacement, the type of silencer, etc.
In case of doubt, contact technical support.
1-Download the desired update (file.mot)
2- Power up the motorcycle
3-Click on the computer update
Select the calibration file (.mot) that was previously downloaded and click open.
4- The file is being downloaded
ATTENTION !
DO NOT TURN OFF THE MOTORCYCLE DURING THE DOWNLOAD OPERATION
(FLASH)
DO NOT ABRUPTLY STOP THE FLASH DOWNLOAD PROCESS
THERE IS A RISK OF IRREPAIRABLE DAMAGE TO THE COMPUTER
61
5- At the end of the download the fuel pump will start and the following message will appear :
INFORMATION : Download was successful
6-Check to make sure that the correct calibration file was allocated by clicking on
« Identification »
Check to make sure that the file name matches the file that was downloaded
Note: Serial number information and operating hours are not reset during a calibration update.
7- Start the motorcycle and make sure that the engine parameters are normal (idle, stepper
opening, etc).
62
G- Screen printing function
If you are communicating with 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.
The "identification" screen contains all of the important information about the motorcycle (serial
number of the bike, number of hours of operation, calibration, etc).
63
ELECTRICAL INSTALLATION CHECKING
1- Static values (engine off)
Tension battery > 12.5V
Stator resistance :
Y1-Y2 0.44Ω±15%
Y2-Y3
Y1-Y3
Pick up sensor : 120 Ω±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 :
Alternatif (calibre 200V alternatif)
Idle speed 22V ±2V
A 6000 tr/min : 77V±3V
Continue
Regulator pins out (Caliber 20V continue)
A 4000 tr/min : 14.6V + Red/White, - Green
64
Generator :
Tolerance on typical values= -5% /+10%
RPM VOLTAGE (AC) CURRENT (IB) (DC) VB

2000 25.0V 14A
2500 31V 15,0
3000 38V 15,6
4000 51V 16,2
5000 63V 16,4
DC 13,5V
6000 76V 16,8A
7000 92V 16,6A
8000 101V 16,7A
9000 114V 16,8A
10000 125V 17A
65
CONTROLS OF THE SENSORS
CONTROL TPS SENSOR

1. Remove the injector body from the bike.
TPS
2. Control the resistance of the TPS as done below.
3. Values (in kΩ).

Butterfly closed :
Between + (red) and – (black) : 5 +/- 0.5
Between signal (blue) and – (black) : 1.25 à 1.55
Between signal (blue) and + (red) : 5.3 +/- 0.5
Butterfly fully open :

Between + (red) et – (black) : 5 +/- 0.5
Between signal (blue) et – (black) : 4.6 +/- 0.4
Between signal (blue) et + (red) : 2.05 +/- 0.3
66
VALUES OF TEMPERATURE SENSOR
TEMP (°C) RESIST (K Ω)

-40 100.950
-30 53.100
-20 29.121
-10 16.599
0 9.750
+10 5.970
+20 3.747
+25 3.000
+30 2.547
+40 1.598
+50 1.150
+60 0.746
+70 0.565
+80 0.377
+90 0.275
+100 0.204
+110 0.153
+125 0.102
67
CABLE DIAGRAM
Injection beam
REF FONCTION
002 Light harness connector
1010 Electrical starter
1020A Pick up sensor
1020B Generator
1020C Regulator
1042 General Relay
1135 Bobine HT
1211A Fuel pump
1211B Dashboard
1225 Stepper motor
1290 TPS sensor
1303 ECU relay
1310 TMAP sensor
1320 ECU
1330 Injector
1510 Fan harness connector
4020 TCO sensor
8235A Electrical starter relay (relay)
8235B Electrical starter relay (battery)
8235C Electrical starter relay (motor)
8235D Electrical starter relay motor
9901 Double mapping
9902 Emergency stop
C001A Diagnostic connector
C001B Diagnostic connector
C001C Diagnostic connector plug
Fusible Fuse 15A
MM01 Engine ground
BB00A + Battery
BB00B - Battery
68
Diagram :
69
Geometry :
70
250 SEF light system cable diagram
71
300 SEF light system cable diagram
72
250 SEF-R Racing light system cable diagram
73
300 SEF-R Racing light system cable diagram
74
Flasher installation cable diagram
75
Fan cable diagram
76

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MOTOR TOOLS 250 SEF-R and 300 SEF-R......................................................................................................4

STANDARD ADJUSTMENT ..........................................................................................................................7

OPERATIONS REQUIRING DEMOUNTING OR NOT ENGINE.............................................................................9

REMOVING / REINSTALLING THE MOTOR ...................................................................................................10

SYNERJECT ) INJECTION SYSTEM INSTRUCTION MANUAL .....................................................................40

ELECTRICAL INSTALLATION CHECKING ....................................................................................................64

CONTROLS OF THE SENSORS ..................................................................................................................66

CABLE DIAGRAM .....................................................................................................................................68

250 SEF-R 300 SEF-R

Frame Semi-perimeter CrMo steel with aluminum subframe

Turn clockwise to the stop, then

Standard adjustment - Fork WP USD Gold Series Ø48MM

Compression Comfort 20 clicks back

Low-speed compression Comfort 20 clicks back

Removing engine Not demounting engine

REINSTALLING THE MOTOR

REMOVING THE CYLINDER HEAD

 Remove the cap from the ignition

 Remove the timing control plug [A]

 Turn the engine counterclockwise in

 Remove the camshaft bearing

 Remove the exhaust camshaft

 Remove the two nuts M6 and the

 Remove the cylinder head.

MOTOR TOP END CONTROLS

Piston / cylinder clearance

Ring groove / piston ring

Ring end gap

Inspect the connecting rod, the

Camshaft height limit 300

Checking the camshafts and

Eccentricity of the camshaft

Visually inspect the timing chain for

Inspecter visuellement les patins de

Valve – Guide clearance

 Mettre le poussoir de l’outil pour mettre en

 Install the two cylinder head locating pins

 Install the head bolts noting the different

ATTENTION : The two internal bolts are of

 Install the camshaft retaining clips.

ATTENTION : The screw n°1 is a M6 X 35

 Install the camshaft chain tensioner using

ATTENTION : Make sure that the o-rings

 Apply a thin coat of silicone to the

 The valve clearance must be checked

 If the clearance is not correct then change

Replacing the cam chain

 Remove the camshafts (see the chapter on

Inspect the clutch

Check the clutch spring length

Reassembly of the clutch

Disassembling and inspecting the

Changing the water pump shaft seal

Tighten the water pump housing screws

Reassembling the clutch hub

 Check for free rotation of the clutch hub.

ATTENTION : There is a sense.

 Install the special friction disc.