SHERCO 2015 450 SEF-R Workshop Manual
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SHERCO 2015 450 SEF-R Workshop Manual

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MANUEL D'ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER

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Summary of Contents for SHERCO 2015 450 SEF-R

  • Page 1 MANUEL D’ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER...

  • Page 2: Table Of Contents

    FOREWORD ........................................4 ENGINE TOOLS LIST 450 SEF-R..................................5 TECHNICAL SPECIFICATIONS ..................................6 • ENGINE ............................................6 • CHASSIS ............................................7 FACTORY SETTINGS ...................................... 8 • FORK ............................................8 • SHOCK ABSORBER ........................................9 OPERATIONS REQUIRING THE REMOVAL, OR NOT, OF THE ENGINE ......................10 REMOVING/INSTALLING THE ENGINE ................................
  • Page 3 SUMMARY CHECKING INDIVIDUAL PARTS ................................... 21 • CHECKING THE CENTRAL CRANKCASES ..................................21 • CHECKING THE LEFT CRANKCASE ....................................21 • CHECKING THE RIGHT CRANKCASE ..................................... 21 • CHECKING THE FREEWHEEL BEARING ..................................22 • CHANGING THE CRANKSHAFT BEARINGS ..................................22 •...

  • Page 4: Foreword

    FOREWORD This manual is intended for qualified mechanics working in a properly equipped workshop. Performing the different operations requires sound knowledge of mechanics and SHERCO tools specific to 450 SEF-R engines. 450 SEF-R...

  • Page 5: Engine Tools List 450 Sef-R

    Tools List for 450 SEF-R Engine ❱❘ 450 SEF-R Tool reference Description 1819 Top dead center timing screw 5749 Clutch removal tool ADLER 4753 Fret-type ignition unit 1822 Water pump bearing axis tool 1968 Water pump oil seal tool R455 Engine support 5593 Primary drive locking tool...

  • Page 6: Technical Specifications

    Technical Specifications ❱❘ ENGINE Type Single cylinder 4 stroke liquid cooled Displacement 449.4 cc 95/63.4 mm Bore / Stroke Compression ratio 11.84: 1 Unleaded gasoline with an octane rating of at least 95 Distribution 4-valve, double overhead camshaft, chain drive Intake valve diameter 38 mm Exhaust valve diameter 30.5...

  • Page 7: Chassis

    Technical Specifications ❱❘ Chassis Frame Semi-perimeter Cr Mo steel with aluminum subframe Semi-perimeter Cr Mo steel with aluminum subframe Fork SACHS USD Gold Series Ø 48mm (standard) & WP USD Ø 48mm (racing) Rear suspension WP Suspension with separate cylinder Travel front/rear 300/300 mm Front brake Disc Ø...

  • Page 8: Factory Settings

    FACTORY SETTINGS ❱❘ FoRK Original settings - Fork SACHS USD Gold Series Ø48 mm Compression 12 clicks back Rebound 12 clicks back Spring stiffness 4.5 N/mm Type of oil SAE 5 Quantity of oil per fork leg 600 cm Oil level measurement (fork compressed and spring remo- 130mm ved) from the top of the fork tube Original settings - Fork WP Suspension USD Ø48mm...

  • Page 9: Shock Absorber

    FACTORY SETTINGS ❱❘ Shock absorber Factory 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...

  • Page 10: Operations Requiring The Removal, Or Not, Of The Engine

    Operations Requiring the removal, or not, of the engine Operations requiring Operations not requiring the removal of the engine the removal of the engine Crankshaft (including crankshaft • repair kit) Complete transmission • Crankshaft bearing • Gearbox bearing • Piston •...

  • Page 11: Removing/Installing The Engine

    removing/installing the engine ❱❘ Removing the engine WARNING To remove the engine, remove the swing arm pivot axis, which allows you to remove the whole rear wheel / swing arm set. In order to prevent the bike from tipping over, hold the frame using a jack. •...

  • Page 12: Installing The Engine In The Frame

    removing/installing the engine ❱❘ INSTALLING THE ENGINE IN THE FRAME • Position the motor within the frame. • Position the swing arm. • Set the engine axes. • Tighten the motor axes to 40 Nm. • Tighten the swing arm pivot to 100 Nm. •...

  • Page 13: Removing The Engine

    REMOVING THE ENGINE ❱❘ 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 output shaft pinion. ❱❘...

  • Page 14: Removing The Camshaft

    REMOVING THE 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 (A). • Remove the camshafts. ❱❘ Removing the distribution tensioner •...

  • Page 15: Removing The Cylinder Head

    REMOVING THE ENGINE ❱❘ Removing the cylinder head • Unscrew the cylinder head bolts following the orderindicated in the picture. • Remove the cylinder head by pulling it vertically. • Remove the cylinder head gasket with caution. ❱❘ Removing the cylinder •...

  • Page 16: Replacing The Stator And The Engine Speed Sensor

    REMOVING THE ENGINE ❱❘ Changing the stator and the engine speed sensor • Remove the 2 screws from the sensor (2) and the two screws from the stator (1). • Set up the new parts. • Reinstall the screws with red thread lock and tighten to 7 Nm, ❱❘...

  • Page 17: Removing The Clutch

    REMOVING THE ENGINE ❱❘ Removing the clutch • Remove the clutch housing cover by unscrewing the 4 screws. Beware of the O-ring located on the rim of the cover. • Set the TDC 1819 tool. WARNING Do not use this tool for tightening or loosening with a torque value higher than 10 Nm.

  • Page 18: Removingthe Water Pump Oilseal And The Bearing Seal

    REMOVING THE ENGINE ❱❘ DRemoving the water pump oil seal and the bearing • Remove the water pump turbine with a 10 soc- ket by unscrewing it while holding the drive pinion. • Remove the water pump shaft. Both oil seals have been made accessible.

  • Page 19: Removng The Freewheel Sprocket

    REMOVING THE ENGINE ❱❘ Removing the freewheel sprocket WARNING See previous paragraph for the unlocking of the balancer shaft nut. • Remove the securing clip (1) and their washers. • Remove the torque limiter (2). • Remove the oil pump intermediate pinion (3). •...

  • Page 20: Separating The Central Crankcases

    REMOVING THE ENGINE ❱❘ Separating the central crankcases • Remove the screw (A - p. 19) with an Allen key. • Remove the water pump drive pinion (B - p.19) by removing the securing clip. Beware of the needle that may fall. •...

  • Page 21: Checking Individual Parts

    Checking individual parts ❱❘ Controlling the central crankcases • Check the general condition of the central cran- kcases for any possible damage or crack. Change the defective or worn crankcase set if necessary. • Check the condition of the bearings. Change them if necessary.

  • Page 22: Checking The Freewheel Bearing

    Checking individual parts ❱❘ Checking the freewheel sprocket bearinge • Visually check the needle bearing of the freewheel sprocket. • Change it if necessary. • Check the visual aspect of the rolling raceway of the freewheel sprocket (1). • Change the pinion if necessary. •...

  • Page 23: Checking The Crankshaft

    Checking individual parts ❱❘ Checking the crankshaft Radial clearance of the connecting rod: • Place the crankshaft on V-blocks and place a dial gauge [A] against the connecting rod. • Push [B] the connecting rod to the gauge and then in the opposite direction. The difference between those two measurements is the radial clearance.

  • Page 24: Checking The Gearbox

    Checking individual parts ❱❘ Checking the earbox • Check all pinions By checking the coupling claws [A], the pinion teeth [B] and fork grooves [C]. In case of wear, damage, change the affected pinions. • Check the condition of the gearshift forks. Change the forks if necessary.

  • Page 25: Checking The Top Engine

    Checking individual parts ❱❘ Checking the tophigher engine Inspection of cylinder wear: Measure the inside diameter of the cylinder when the cylinder is cold. • Inspect the inside part of the cylinder for scratches or any other sign of abnormal wear. If the cylinder is damaged or severely worn, replace it.
  • Page 26 Checking individual parts Piston wear: • With the help of a micrometer, measure the outside diameter [A] of piston 15 mm [B] above the bottom of the piston and at a right angle in relation to the piston pin. If the outside diameter of a piston is below the limit, replace it Piston 450 SEF-R = 94.93 - 94.95 Ring/ring groove clearance:...
  • Page 27 Checking individual parts Cams wear: • Measure the height [A] of each cam by means of a micrometer. If the cams are worn beyond the limit, replace the camshaft. Cam height limit 450 Exhaust: 37.20 mm Admission: 37.62 mm Wear of the camshaft and camshaft bearings: •...

  • Page 28: Checking The Cylinder Head

    Checking individual parts ❱❘ Checking the cylinder head Cylinder head inspection for warping: • Place a ground ruler [A] on the lower surface of the cylinder head at different positions, and mea- sure the warping by inserting a thickness gauge between the straightedge and the gauge head.

  • Page 29: Engine Assembly

    ENGINE ASSEMBLY ❱❘ Installing the central crankcases WARNING During the installation process, replace all gas- kets, (Joint paper, O-ring, etc.). • Turn the crankshaft and the balancer shaft in the right crankcase by aligning the two marks. • Fit the two gearboxes shafts. •...
  • Page 30 ENGINE ASSEMBLY • Turn the crankcase over and tighten the screw (3) Torque setting: 10 Nm. • Pull the locking finger by placing back the spring properly. • Hold the speed-locking lever locked. • Do not forget the needle (2) on the drum. •...

  • Page 31: Installing The Clutch Housing

    ENGINE ASSEMBLY Put the grooved washer and the inner clutch hub. • Using the 5593 tool, block the transmission and tighten the nut. Specified torque of the crankshaft nut: 120 Nm. • Insert the safety washer and the nut. • Using the 5749 tool, block the clutch nut and tighten.

  • Page 32: Installing The Clutch

    ENGINE ASSEMBLY ❱❘ installing the clutch • Put the 8 friction discs and the 7 metal discs, starting with a friction disc. • Install the finger follower and do not forget to install the stop and the washer. • Put the pressure plate and the 6 screws fol- lowing the order shown in the picture.

  • Page 33: Setting The Piston Rings

    ENGINE ASSEMBLY ❱❘ Setting the piston rings • Place the first rail. Pay attention to the positio- ning of the opening on the exhaust side. • Place the expander on the bottom groove (the widest) The opening should be placed in the middle Please note that ripple ends must be oriented downwards.

  • Page 34: Installing The Cylinder

    ENGINE ASSEMBLY ❱❘ installing the cylinder • Seal the joint between the left and right casings with sealing dough. • Set the guide pins and a socket joint. • Lubricate the piston skirt. • Oil the cylinder. • Fit the cylinder paying attention to the rings. •...

  • Page 35: Installing The Drive Chain

    ENGINE ASSEMBLY ❱❘ Installing the drive chain • Set the 2 distribution guide plates going through the chain well. • Fit the chain on the crankshaft pinion. • Put the distribution upper pinion. WARNING Make sure that the mark is vertical to the cylin- der, or that the FLANGE mark is aligned with the cylinder head gasket plane.

  • Page 36: Installing The Camshaft And Setting The Valve Timing

    ENGINE ASSEMBLY ❱❘ Installing the camshafts and setting the valve timing • Clean and oil the bearings. • Set the two camshafts and make sure that the visual marks «FLA» or «FLANGE» are aligned with the cylinder head gasket plane. •...

  • Page 37: Completing The Engine Assembly

    ENGINE ASSEMBLY ❱❘ Completing the engine assembly • Clean the sealing surface of the cylinder head cover. • Apply silicone sealant on both semi-circles. • Fit the cylinder head cover gasket and cylinder head cover. • Screw the cylinder head cover along with the O-rings of the 3 screws.

  • Page 38: Tightening Torque Chart

    TIGHTENING TORQUE CHART Standard tightening torque Thread Lock 6 Nm 10 Nm 24 Nm 40 Nm Chassis tightening torque Thread Lock Rear wheel nuts 100 Nm 100 Nm Rear cradle screws 24 Nm • Front wheel nut 25 Nm Fork foot pinch bolt 15 Nm Brake pads axis screws 8 Nm...
  • Page 39 TIGHTENING TORQUE CHART Engine torque setting: Thread Lock Engine speed sensor screws 7 Nm • Clutch receiver screws. 10 Nm Exhaust pipe screws 10 Nm Cylinder head tightening torque Studs 1 pass 30 Nm pass 50 Nm Nuts 10 Nm Camshaft housing screws 18 Nm Chain tensioner screws...

  • Page 40: Cleaning The Throttle Body

    Cleaning the throttle body ❱❘ EQuipment • Carburetor cleaner or Minerva brand universal cleaner. • Open-end wrench 8. • Socket screwdriver 7. • Hex key 2.5. ❱❘ Removing the throttle body • Remove the seat. • Remove the fuel tank. •...
  • Page 41 Cleaning the throttle body • Unplug all connectors. • Visually inspect. • Clean with a universal cleaning solution. • Blow.

  • Page 42: Cleaning The Throttle Body

    Cleaning the throttle body ❱❘ Cleaning the throttle body • Clean the throttle body by means of a carbure- tor cleaner spray (Net Carbu). • Be sure to clean the edge of the throttle valve on each side with the throttle fully opened. •...

  • Page 43: Changing The Tps (Throttle Position Sensor)

    (see procedure below). • Click on the Diagnostics menu logo • Then click Sherco ➟ M3C ➟ Measuring parameters ➟ Throttle position • Adjust the sensor position by rotating it (see picture) until the displayed value is set to 0.5V +/- 0.05.

  • Page 44: Injection Diagnostic Tool Synerject

    Injection diagnostic tool SYNERJECT ❱❘ 1- Presentation of the SYNERJECT injection system 1.1- Your Sherco SEF-450 R is equipped with a Synerject injection system consisting of an M3C calculator, a Ø42 mm throttle body, an ignition and a spe- cific wiring harness.
  • Page 45 Injection diagnostic tool SYNERJECT Synerject M3C Calculator Synerject Ø42 mm Throttle Body N° DESCRIPTION Stepper motor (idle control and engine brake) Injector Temperature / pressure sensor (TMAP) TPS: throttle position sensor 1.2- Exxodiag diagnostic description tool reference 4967 The diagnostic tool allows you to perform diagnostic operations, to update injection mapping and to verify certain information (serial number , operating hours, etc.).
  • Page 46 Outil diagnostique injection SYNERJECT ) Injection diagnostic tool SYNERJECT 1.4- Diagnostic tool installation A- Software and drivers installation: • Open the installation CD on your computer. • Run «Sherco_Setup». • Select the language. • Click on «Next» • Choose the installation folder. 450 SEF-R...
  • Page 47 Outil diagnostique injection SYNERJECT ) Injection diagnostic tool SYNERJECT • Click on «Next». • Click on «Install». • Installation in progress.
  • Page 48 Injection diagnostic tool SYNERJECT 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».
  • Page 49 Injection diagnostic tool SYNERJECT • 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»...

  • Page 50: 2- Software Overview

    Injection diagnostic tool SYNERJECT ❱❘ 2- Software overview 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.
  • Page 51 Injection diagnostic tool SYNERJECT 2.1- 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 installa- tion CD provided may not include all languages).
  • Page 52 Injection diagnostic tool SYNERJECT 2.2- 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 •...
  • Page 53 Injection diagnostic tool SYNERJECT • Click on to start downloading the update. • The following message will come up: • Click on to start installation. • Resume the installation process -> page 44. It is not necessary to restart the installation of the drivers.

  • Page 54: 3- Using The Software

    • Click on • Fill in the following settings if necessary. • Click on to save your changes. ❱❘ 3- Using the software Diagnostic menu and injection mapping update General: • Click on «Sherco». • Click on «M3C». 450 SEF-R...
  • Page 55 Injection diagnostic tool SYNERJECT • You reach the following menu: 3.1- Identification: checking identification (serial number, vehicles operating hours, calibration number). 3.2- Measuring the parameters: general parameters (speed, pressure, stepper, etc.).
  • Page 56 Injection diagnostic tool SYNERJECT A- Engine information: • The main values of the system appear: Details: • Stepper Position: opening value of the air valve (stepper) -> 35 < 50 < 75. Too weak value: Leak Valve / engine air intake for example. Too high value: throttle body injection clogged for example.
  • Page 57 Injection diagnostic tool SYNERJECT B- Other values are displayed in the windows: Throttle position: • Adaptation value to the minimum position of the throttle valve (V): 0.45 < 0.5 (nominal value) < 0.55. Miscellaneous: • Intake pressure (mb): pressure at the nozzle body measured by the TMAP sensor. •...
  • Page 58 Injection diagnostic tool SYNERJECT If errors occur: You can get the details of the error by clicking on the error displayed: • Record errors and exit the menu via the icon 450 SEF-R...
  • Page 59 Injection diagnostic tool SYNERJECT Info : 1- Transient failure/permanent failure: a transient error becomes permanent after a variable number of engine cycles according to the component (injector, fuel pump, etc.). For a permanent error to disappear, wait 40 motor cycles without the issue reappearing. 2- Fan error: if there is no fan installed on the motorbike, there will always be a fan error alarm (P0485).
  • Page 60 Injection diagnostic tool SYNERJECT The following tab is displayed: • Confirm with the icon B - Return to the «Reading error codes» menu: • Check that the errors detected are identical. Verify/change the defective parts. Verify the connections. 450 SEF-R...
  • Page 61 Injection diagnostic tool SYNERJECT 3.5- Actuators testing In addition to reading the error codes, you can test certain components of the system: A - Ignition coil When the ignition coil test is launched, the following message appears:...
  • Page 62 Injection diagnostic tool SYNERJECT The system is not able to detect a motor coil failure when the engine is off. Whether the coil is defective or not, the test result will be the same. Therefore, verify that the coil emits a characteristic sound of a proper operation during the testing process.
  • Page 63 Injection diagnostic tool SYNERJECT Example of proper operation stepper: Stepper error: If an error is notified, check/replace defective parts. Information: the fan test makes sense only if a fan is installed on the bike.
  • Page 64 Injection diagnostic tool SYNERJECT 3.6- Updating the calculator With the diagnostic tool, it is possible to update the engine mapping (calibration). For a racing silencer for example, or because an update was proposed by the manufacturer. These files will be available for free on sherconetwork. Pay attention to the model year, the cylinder capacity, silencer type, etc.
  • Page 65 Injection diagnostic tool SYNERJECT 5 - Upon completion of the download, the fuel pump starts up and the following message appears: INFORMATION : download successfull Confirm with the icon 6-Check the correct allocation of the calibration file by selecting «Identification». Check that the file name matches the downloaded file.
  • Page 66 Injection diagnostic tool SYNERJECT 3.7- Print screen function When liaising with technical support, and in order to allow rapid identification of potential problems, you can attach to your message screen print files with the F10 key of your keyboard. The «Identification» tab is definitely important for good communication (serial number of the bike, engine hours, calibration, etc.).

  • Page 67: Checking The Charging Circuit

    Checking the charging circuit 1 - Static control values (engine off) 450 SEF-R. Battery voltage > 12.5V. A - Stator windings resistance values. Y1-Y2 Y2-Y3 0.44Ω±10% Y1-Y3 B - Resistance of the engine speed sensor: 117 Ω ± 10% Check that there is no continuity between the windings and the mass of the motorbike. 2 - Dynamic control values: Engine speed sensor 1.7 V MIN/300 RPM...
  • Page 68 Checking the charging circuit Alternator : Tolerance values = -5% / +10%. Voltage (AC) Current (IB) (DC) 2000 7.2A 2500 11.3A 3000 50.5V 13.6A 4000 15.6A 5000 75.5V 16.5A DC 13.5V 6000 16.9A 7000 99.5V 17.2A 8000 112V 17.4A 9000 125.5V 17.5A 10000...

  • Page 69: Wiring Diagram

    Wiring diagram Injection wiring harness Connectors breakdown Double mapping Starter button Ignition lock or on/off connector Diagnostic plug Fan wiring harness Engine shutdown Dashboard Stepper motor Injector Gasoline pump Temperature sensor Throttle sensor (TPS) Engine ground Starter TMAP Engine speed sensor HT coil Light wiring harness Fuse...
  • Page 70 Wiring diagram Injection wiring harness 450 SEF-R...
  • Page 71 Wiring diagram Light wiring harness 450 SEF...
  • Page 72 Wiring diagram Light wiring harness Racing 450 SEF-R 450 SEF-R...
  • Page 73 Wiring diagram Accessories wiring harness...
  • Page 74 Wiring diagram Fan wiring harness 450 SEF-R...
  • Page 75 Wiring diagram Voltage graph - TPS sensor of throttle body...

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