Table of contents

FORWARD .................................................................................................................................................... 3
TOOLS LIST 250 SEF/300 SEF ....................................................................................................................... 4
TECHNICAL SPECIFICATION ....................................................................................................................... 5
ENGINE ......................................................................................................................................................... 5
FRAME.......................................................................................................................................................... 6
STANDARD ADJUSTMENT ........................................................................................................................... 7
FORK ............................................................................................................................................................ 7
SHOCK ABSORBER ....................................................................................................................................... 8
OPERATIONS REQUIRING DEMOUNTING OR NOT ENGINE........................................................................ 9
REMOVING / REISTALLING THE ENGINE ............................................................................................... 10
REMOVING THE ENGINE ......................................................................................................................... 10
REINSTALLING THE ENGINE .................................................................................................................. 10
ENGINE ..................................................................................................................................................... 11
REMOVING THE CYLINDER HEAD................................................................................................................. 11
❱❘ Preparation ............................................................................................................................................................. 11
❱❘ Removing the cam chain tensioner ..................................................................................................................... 11
❱❘Removing the camshafts ....................................................................................................................................... 12
❱❘ Removing head cylinder ....................................................................................................................................... 12
INDIVIDUAL PARTS INSPECTION ........................................................................................................... 13
ENGINE TOP END CONTROLS ................................................................................................................ 13
❱❘ Inspection of the cylinder for wear ...................................................................................................................... 13
❱❘ Piston wear ............................................................................................................................................................. 14
❱❘ Cylinder head inspection ...................................................................................................................................... 16
❱❘ Visually inspect the timing chain for damage..................................................................................................... 16
❱❘ Valve – Guide clearance ........................................................................................................................................ 16
REASSEMBLING THE TOP END OF THE ENGINE ................................................................................. 17
❱❘ Reassemble the piston .......................................................................................................................................... 17
❱❘ Reassemble the cylinder head ............................................................................................................................. 18
❱❘ Valve timing ............................................................................................................................................................ 19
❱❘ Valve clearance ...................................................................................................................................................... 21
❱❘ Replacing the timing chain ................................................................................................................................... 21
DISASSEMBLING COVER ........................................................................................................................ 22
DISASSEMBLING THE RIGHT SIDE ........................................................................................................ 22
❱❘ Clutch dismanting .................................................................................................................................................. 22
❱❘ Inspection of the clutch ......................................................................................................................................... 22
❱❘ Check the clutch spring length ............................................................................................................................ 22
❱❘ Disassembling and inspecting the water pump ................................................................................................. 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
❱❘ Removing the rotor ................................................................................................................................................ 26
❱❘ Inspect the freewheel and the needle bearings .................................................................................................. 26
❱❘ Reassembling the ignition case ........................................................................................................................... 27
DISASSEMBLING CRANKCASES ............................................................................................................ 28
CRANKSHAFT - TRANSMISSION - CENTRAL CRANKCASES .............................................................. 28
❱❘ Disassembling the transmission and the crankshaft ........................................................................................ 28
❱❘ Checking the transmission components ......................................................................................................... 29
r❱❘ Checking the crankshaft ...................................................................................................................................... 30
❱❘ Checking the crankcase ........................................................................................................................................ 31
1
REASSEMBLING CRANKCASES............................................................................................................. 32
❱❘ Reassembling the central crankcase assembly ................................................................................................. 32
TIGHTENING TORQUES ........................................................................................................................... 34
INJECTOR BODY ...................................................................................................................................... 36
Clean injector body .................................................................................................................................. 36
❱❘ Material.................................................................................................................................................................... 36
❱❘ Put down the injector body ................................................................................................................................... 36
❱❘ Clean of injector body............................................................................................................................................ 38
❱❘ Replace the injector body ..................................................................................................................................... 38
SYNERJECT) INJECTIONSYSTEMINSTRUCTION MANUAL .................................................................... 39
SYNERJECT) INJECTION SYSTEM PRESENTATION............................................................................... 39
1.1- Injection system ................................................................................................................................................. 39
1.2- Description Exxodiag diagnostic tool référence 4967 ................................................................................... 40
1.3- Diagnostic tool kit contents. ............................................................................................................................. 40
1.4- Installation of the diagnostic tool ..................................................................................................................... 41
2.1- Connection with Keyless system ..................................................................................................................... 45
2.2- Software settings : configuration menu ..................................................................................................................... 47
2.3- Update menu and synchronization .................................................................................................................. 48
2.4- Using the sofware ................................................................................................................................................. 50
C- Reading the default codes................................................................................................................................ 52
D- Erasing default codes ....................................................................................................................................... 53
E- Test the actuators ............................................................................................................................................. 55
F- Updating the computer ......................................................................................................................................... 57
G- Screen printing function ...................................................................................................................................... 59
ELECTRICAL INSTALLATION CHECKING .............................................................................................. 60
CONTROL OF THE SENSORS ................................................................................................................. 62
❱❘ Control TPS sensor ............................................................................................................................................... 62
❱❘ Value temperature sensor............................................................................................................................................. 63
CABLE DIAGRAM ..................................................................................................................................... 64
❱❘ Injection beam ........................................................................................................................................................ 64
❱❘ Diagram ................................................................................................................................................................... 65
❱❘ Geometry ................................................................................................................................................................ 66
❱❘ 250 SEF light system cable diagram .................................................................................................................... 67
❱❘ 300 SEF light system cable diagram .................................................................................................................... 68
❱❘ 250 SEF-R Racing light system cable diagram ................................................................................................... 69
❱❘ 300 SEF-R Racing light system cable diagram ................................................................................................... 70
❱❘ Flasher installation cable diagram ....................................................................................................................... 71
❱❘ Fan cable diagram ................................................................................................................................................. 72
 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 and 300 SEF engine.

This workshop manual is a supplement to the SHERCO 250 SEF and 300 SEF owner’s manual.
.
TOOLS LIST 250 SEF / 300 SEF
REF. DESIGNATION
TOOL
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 Primary rolling tool 6003

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
ENGINE

250 SEF 300 SEF

Type Liquid cooled single cylinder 4 strokes engine
Displacement 249.4 CC 303.7 CC
Bore / Stroke 78/52,2mm 84/54.8mm
Compression ratio 13 :1 12.85:1
Fuel Without lead 95 or 98
4 valves, DOHC driven by tooth type chain
Valve timing

Admission valve diameter 31mm 31mm

Exhaust admission valve 26mm
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 liter SAE 10W40
Primary reduction ratio 21 :70
Boîte : 6 speed
1st 14 : 33
2nd 17 : 30
3nd 19 : 28
4nd 21 : 26
5nd
23 : 24
6nd 25 : 22
Final transmission 13 X 49 13 X 48
Clutch Multi-disk in oil bath. Hydraulic command
Ignition system / Battery Electric 12V 4Ah / LTZ5S Lithium 12V 2Ah
Electronic injection Synerject
TECHNICAL SPECIFICATION
FRAME
Frame Semi-perimeter CrMo steel with aluminum subframe

KAYABA USD Ø48mm Closed cartridge(FACTORY)

Fork
WP XPLOR USD Ø48mm (RACING)
Rear suspension KAYABA suspension with separate cylinder
WP suspension with separate cylinder,
Aluminium swing arm
Travel Front/Rear FACTORY 330/330mm
RACING 300/330mm
Front brake disque Ø 260mm
Rear brake disque Ø 220mm
Brake disc limit : 2.7mm front et 3.6mm rear
Front tire 90/90-21’’
Rear tyre 140/80-18’’
Pressure front / Rear 0.9 bar
Fuel tank capacity 9.7l with1 liter of reserve
Angle of the steering column
27.3°

Wheel base 1480mm

Weight (without fuel) 102 kg

6
STANDARD ADJUSTMENT
FORK
Original settings – Fork KAYABA USD Ø48 mm

Compression Comfort 20 clicks back

Standard 12 clicks back
Sport 8 clicks back
Rebound Comfort 18 clicks back
Standard 12 clicks back
Sport 10 clicks back
Spring Rider weight : 65-75 kg 4.2N/mm
Rider weight : 75-85 kg 4.4N/m
Rider weight : 85-95 4.6N/m
Fork oil 01M 345 CC

Original settings – Fork WP XPLOR suspension USD Ø48mm

Compression Comfort 18 clicks back

Standard 15 clicks back
Sport 12 clicks back
Rebound Comfort 18 clicks back
Standard 15 clicks back
Sport 12 clicks back
Preload Comfort +0 tours
Standard +0 tours
Sport +6 tours
Spring stiffness Rider weight : 65 - 75 kg 4.2N/mm
Rider weight : 75 - 85 kg 4.4N/mm (original)
Rider weight : 85 - 95 kg 4.6N/mm
Type of oil SAE 4

Spring length with preload spacer 474 mm

Quantity of oil 606ml

Oil level measurement (fork compressed and spring 100mm (min30-max 120 mm)
removed) from the top of the fork tube
STANDARD ADJUSTMENT
SHOCK ABSORBER
Racing Settings – KAYABA shock absorber

Low-speed compression Comfort 20 clicks back

Standard 14 clicks back
Sport 12 clicks back
High-speed compression Comfort 2,5 turns back
Standard 1.5 turns back
Sport 1 turn back
Rebound Comfort 15 clicks back
Standard 13 clicks back
Sport 11 clicks back
Spring stiffness Rider weight : 65-75 kg 48N/mm
Rider weight : 75-85 kg 50N/mm (original)

Rider weight : 85-95 kg 57N/mm

Type of oil K2C

Racing Settings – WP suspension shock absorber

Low-speed compression Comfort 17 clicks back

Standard 12 clicks back
Sport 9 clicks back
High-speed compression Comfort 2 turns back
Standard 1.5 turns back
Sport 1 turn back
Rebound Comfort 16 clicks back
Standard 14 clicks back
Sport 12 clicks back
Spring stiffness Rider weight : 65-75 kg 51N/mm
Rider weight : 75-85 kg 54N/mm (original)
Rider weight : 85-95 kg 57N/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 •
REMOVING / REISTALLING THE ENGINE
REMOVING THE ENGINE
WARNING
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.

WARNING
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 ENGINE

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:

10
ENGINE
For additional details refer to the parts catalog 250 SEF _ 300 SEF

REMOVING THE CYLINDER HEAD

• Remove the spark plug.
• Remove the valve cover.
• Remove the three valve cover screws.

WARNING
These three screws are equipped with o-rings. Ref: 0900

❱❘ Preparation
• Place the engine on the R455 engine support tool.
• Drain the engine oil (see user manual).
• Make sure to be in a clean environment before
starting the dismantling of the engine.
• Remove the ignition cover plug [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

❱❘ Removing the cam chain tensioner

• Remove the screws from the cam
chain tensioner as shown in the photo.
• Remove the cam chain tensioner.
• Remove the spark plug well
ENGINE
❱❘ Removing the camshafts
• Unscrew the eight screws from the shaft
bearing cap cam following the order shown
in the picture.

• Remove the bearing cap.

• Remove the exhaust camshaft retaining clip.

• Remove the exhaust camshaft.
• Remove the intake camshaft retaining clip.
• Remove the intake camshaft.

❱❘ Removing head cylinder

• Remove the two nuts M6 and the washer.

• Remove the cylinder head bolts (Be

sure to loosen them in the correct direction).

WARNING
Black bolt N°1 on the picture is longer, 3 bolts are identical.

• Remove the cylinder head.

• Remove the head gasket and the cylinder

12
INDIVIDUAL PARTS INSPECTION
ENGINE 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 cylinder
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

Standard 250 SEF

Cylinder diameter (A):77.982±0.008mm
Cylinder diameter (B):77.982±0.015mm
Taper limit: 0.05mm
Out of round limit:0.05mm
Standard 300 SEF
Cylinder diameter (A):83.982±0.01mm
Cylinder diameter (B):83.982±83.995mm
Taper limit:0.05mm
Out of round limit:0.05mm

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
INDIVIDUAL PARTS INSPECTION
❱❘ 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= 77.9400±0.005 mm
Piston 300 SEF= 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 ring: 0.020-0.055 mm
Limit: 0.13 mm
Ring end gap
• Compression ring: 0.3-0.4 Limit 0.7 mm
• Oil 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
INDIVIDUAL PARTS INSPECTION
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: 32.175 mm
Intake: 32.453 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
INDIVIDUAL PARTS INSPECTION
❱❘ Cylinder head inspection
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
• Clean all parts.
• Visually inspect the drive chain : check for any
hard spot, resistance, or wear. If any, it must be
changed.
• Visually inspect the distribution drive pinion.
Change if necessary.
• Visually inspect distributions guide plates :
change them if necessary.
• Visually inspect the pinion (1) ; replace if
necessary.
• Check that the needle bearings fit tight when
the pinion (1) is mounted on its axis.

❱❘ 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 ENGINE
❱❘ 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

WARNING
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].

WARNING
Use the same head gasket. (thickness 0.3 or 0.4mm
depending on the model)

• Place one of the 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
REASSEMBLING THE TOP END OF THE ENGINE
• 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.

❱❘ Reassemble the cylinder head

WARNING
The two internal bolts are of different length
and are equipped with washers.

• 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

18
REASSEMBLING THE TOP END OF THE ENGINE
❱❘ Valve timing

• Beware if the tool number 1819 is still

properly installed.

IN (intake) EX (exhaust)
• Install the intake cam.
• Install the exhaust cam.
(see the picture for how to set the timing marks)

The timing point is in line with the gasket plan

• Install the camshaft retaining clips.

• Apply moly disulfide grease to the
camshafts
REASSEMBLING THE TOP END OF THE ENGINE
• Install the camshaft retaining cover. (pay
careful attention to the tightening order).

Camshaft retaining cover torque 10Nm

WARNING
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.

WARNING
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
REASSEMBLING THE TOP END OF THE ENGINE
❱❘ 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 timing 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.

DISASSEMBLING COVER
DISASSEMBLING THE RIGHT SIDE
❱❘ Clutch dismantling
• Install special tool number 1819.
WARNING
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
picture).
• Sort the discs and make sure they are trimmed
and smooth.
Make sure that the clutch hub rotates freely.

❱❘ Inspection of 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

• Mesurer la longueur libre des ressorts.

Standard : 37.29mm
Limite : 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
• Reinstall the clutch cover, inspect the o-ring
and replace if it is damaged

22
 DISASSEMBLING COVER
❱❘ 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.

WARNING
If the seal is leaking, coolant will come out of
the weep hole (see picture). 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.

WARNING
Make sure the seal is installed properly. You
should see the spring when you look at the
seal. (see picture)

• 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.
DISASSEMBLING COVER
❱❘ 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.

WARNING
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.

WARNING
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
DISASSEMBLING COVER
WARNING
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

❱❘ 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

WARNING
There is a sense

❱❘ 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.
DISASSEMBLING COVER
❱❘ Removing the rotor
• Use 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 (back-flow).

WARNING
The threads this screw are LH, do not turn
the wrong direction.

• Remove the free wheel gear.

❱❘ Inspect the freewheel and the

needle bearings
• Visually inspect the caged needle bearings.
• Replace if necessary.
• 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.
• Replace if necessary.
• Finally check the rollers on the freewheel.
• Replace if necessary.

WARNING
If the freewheel must be replaced then the
rest of the gears must be replaced and vice
versa.

26
DISASSEMBLING COVER
❱❘ 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.

WARNING
This screw thread is reverse this is a
LH threat.

• 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).

WARNING
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
DISASSEMBLING CRANKCASES
CRANKSHAFT - 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
special tool number 1817.
• 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
special tool number 1817.
• 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
screw.

28
DISASSEMBLING CRANKCASES
• 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
DISASSEMBLING CRANKCASES
r ❱❘ 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
Tolerance limit: 0.55 mm
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
Tolerance limit: 0.08 mm
If the run out exceeds the tolerance, replace
the crankshaft or straighten it so that it meets
the tolerance.

30
DISASSEMBLING CRANKCASES
❱❘ Checking the crankcase
• 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.
• WARNING
The radial play in the roller
bearings must be practically zero.
REASSEMBLING CRANKCASES
❱❘ Reassembling the central
crankcase assembly
WARNING
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

WARNING
The center shift fork shaft is the
smallest in diameter.

WARNING
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
REASSEMBLING CRANKCASES
• 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.
• 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 + thread locker.
• 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.

WARNING
Apply thread locker to all of the internal engine threads
except the five clutch pressure plate fixing screws.
 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 : 30 Nm
1er passe 45 Nm
2ème passe 10 Nm
Ecrous M6
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 •

34
 TIGHTENING TORQUES

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 •
12 Nm
Botton plat fork bolts
17 Nm
Upper plat fork bolts

Motor screw 60 Nm
Swing arm nut 100 Nm
Cylinder head-frame screws 23 Nm
INJECTOR BODY
Clean injector body
❱❘ Material
• Minerva Net Carb or carb 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

36
INJECTOR BODY

• Disconnect each connector

• Visually inspect the connector

• Clean with carb cleaner or universal product

cleaner
• Blow
INJECTOR BODY
❱❘ Clean of injector body
• Clean the injector body with Net Carburetor
• Make sure you clean perfectly the edge of
the mixture throttle on each side by opening
it completely
• Clean the injector

• 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 carb cleaner or universal product
cleaner
• Blow

• Apply connector grease

• Connect to the

38
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
SYNERJECT) INJECTION SYSTEM PRESENTATION
1.1- Injection system

1 5
3 4

Your Sherco 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.

N° DESIGNATION EMPLACEMENT
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 rear side panel
water protection (labeled ECU
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
Picture 1 : Synerject M3C Computer

Picture 2 : Synerject injector body Ø42mm

1 2 3 4

N° DESIGNATION
1 Stepper motor (Idle management and engine braking)
2 I Injector
3 TMAP sensor (Air temperature/air pressure)
4 TPS: Butterfly position sensor

1.2- Description Exxodiag diagnostic Tools référence 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.

40
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
1.4- Installation of the diagnostic tool
In case of problem during the installation please contact EXWOTEST
at +33 (0)4 50 02 34 34 or by mail to courrierxxotest.com.

A- Installing the software and drivers

• Open the installation CD on your computer

• Run “ sherco_setup”

• Select the language.

• Click on « Next ».

• Choose the installation folder.

SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

• Click on « Next ».

• Click on « Install ».

• Installation in progress.

42
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

• Check the box « Start the driver installation »

and click on « Finish ».

• The following window will open. Read the

terms of the license agreement. Check the box
« I accept the terms of the license agreement »
and click on « Install ».

• Installation in progress.
 SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

• The following window will open. Click on

« Finish ».

The installation is complete.

B- Connect the « MUXDIAG II » cable and its interface to a USB port on your computer
Connect the cable to the diagnostic connector of the motorcycle.

Make sure the « MUXDIAG II » unit is properly powered by checking the LED :

• Solid blue: PC connection properly established.

• Flashing blue: communication with PC in progress.
• Blue off: no connection to the PC, or device in standby; it can also indicate a problem with the USB connector.
• Solid green: firmware issue.
• Flashing green (slow): firmware correctly run.
• Flashing green (fast): communication with PC in progress.
• Green off: no firmware.
• Solid red: correct power supply to the card.

• All LEDs OFF: the outlet is not powered on, or is off or USB in on standby mode.

44
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
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.

 SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
Information : To set up the connection with the motorcycle, the motorcycle must be switched on (On). To
navigate through the different menus, the USB cable with the «MUXDIAG II» device only may be
connected to the computer..

Run the software using the icon

The following menu will come up :

Update and

update, proxy
parameters)

Diagnostics menu Setup menu

(diagnostic, map (language selection, units,
updates,etc.) etc.)

46
 SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
2.2- Software settings : configuration menu

In this menu, you can modify :

• The diagnostic plug. You can refresh the list by hitting the button.
The number must match the number of the « MUXDIAG II » device.
• The languages available in the software: English, French, Spanish, Portuguese, German, Italian (the
installation CD provided may not include all languages). Update the software-> page 53).
• Set the unit system.

• Click to return to the home screen.

• Click to save the changes.

SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
2.3- Update menu and synchronization

A- In this menu, you can update the diagnostic software tool

• To determine whether an update is available,

check that you have an Internet connection,
and then click on the following icon

• If an update is available, the following

window will come up:

• If no update is available, the following

message will come up :

48
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
• Click on to start downloading the
update.

• The following message will come up

• Click on to start installation

• Resume the installation process -> page 41. It is not necessary to restart the installation of the drivers

B- Configuration of Internet access parameters

It may be necessary to set up a proxy server to access the Internet.

• Click on

• Fill in the following settings if necessary.

• Click on to save your changes.

SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
2.4- Using the sofware

Diagnostic menu and injection mapping update

General
• Click on « Sherco ».

• Click on « M3C ».

• You get the following menu :

A- Identification
You can check the identification of the following (serial number, hours of operation,
calibration number)

50
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
B- Parameter measurements
general parameters (speed, pressure, stepper, etc)

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)
 SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
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

If a default appears :

52
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

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

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

 SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
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.

54
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL
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 :

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.
 SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

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.

Example of a functioning stepper :

56
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

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.

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
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

Confirm by clicking on this icon

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

5- At the end of the download the fuel pump will start and the following message will appear :

INFORMATION : Download was successful

Confirm by clicking on this icon

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 download

58
SYNERJECT) INJECTION SYSTEM INSTRUCTION MANUAL

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).

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).
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:
Alternative (AC 200V Caliber)
Idle speed 22V ±2V
A 6000 tr/min : 77V±3V

Continue
On regulator output (DC 20V Caliber)
A 4000 tr/min : 14.6V + Red/White, - Green

60
ELECTRICAL INSTALLATION CHECKING
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
 CONTROL 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.

62
CONTROL OF THE SENSORS
❱❘ Value 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
CABLE DIAGRAM
❱❘ Injection beam

REF FUNCTION
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

64
CABLE DIAGRAM
❱❘ Diagram
CABLE DIAGRAM
❱❘ Geometry

66
CABLE DIAGRAM
❱❘ 250 SEF light system cable diagram
CABLE DIAGRAM
❱❘ 300 SEF light system cable diagram

68
CABLE DIAGRAM
❱❘ 250 SEF-R Racing light system cable diagram
CABLE DIAGRAM
❱❘ 300 SEF-R Racing light system cable diagram

70
CABLE DIAGRAM
❱❘ Flasher installation cable diagram
CABLE DIAGRAM
❱❘ Fan cable diagram

72