3
ENGLISH
SUMMARY
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 .......................................................................................................................................................... 11
• REMOVING THE ENGINE .............................................................................................................................................................................................. 11
• INSTALLING THE ENGINE IN THE FRAME ..................................................................................................................................................................... 12
REMOVING THE ENGINE .............................................................................................................................................................................. 13
• PREPARATION ............................................................................................................................................................................................................. 13
• REMOVING THE CYLINDER HEAD COVER ..................................................................................................................................................................... 13
• POSITIONING THE ENGINE AT TOP DEAD CENTER ........................................................................................................................................................ 13
• REMOVING THE CAMSHAFT ........................................................................................................................................................................................ 14
• REMOVING THE DISTRIBUTION TENSIONER ................................................................................................................................................................ 14
• REMOVING THE DRIVE CHAIN ...................................................................................................................................................................................... 14
• REMOVING THE CYLINDER HEAD ................................................................................................................................................................................. 15
• REMOVING THE CYLINDER .......................................................................................................................................................................................... 15
• REMOVING THE PISTON .............................................................................................................................................................................................. 15
• REMOVING THE IGNITION COVER ................................................................................................................................................................................. 15
• REPLACING THE STATOR AND THE ENGINE SPEED SENSOR......................................................................................................................................... 16
• REMOVING THE ROTOR ............................................................................................................................................................................................... 16
• REMOVING THE DRIVE CHAIN ...................................................................................................................................................................................... 16
• REMOVING THE ELECTRIC STARTER ............................................................................................................................................................................ 16
• REMOVING THE CLUTCH ............................................................................................................................................................................................. 17
• REMOVING THE WATER PUMP HOUSING ...................................................................................................................................................................... 17
• REMOVING THE CLUTCH HOUSING .............................................................................................................................................................................. 17
• REMOVINGTHE WATER PUMP OILSEAL AND THE BEARING SEAL .................................................................................................................................. 18
• REMOVING THE CLUTCH BELLHOUSING ...................................................................................................................................................................... 18
• REMOVNG THE FREEWHEEL SPROCKET ...................................................................................................................................................................... 19
• REMOVING THE OIL PUMP ........................................................................................................................................................................................... 19
• CHANGING THE OIL PUMP ........................................................................................................................................................................................... 19
• REMOVING THE INDEX SHIM ....................................................................................................................................................................................... 19
• SEPARATING THE CENTRAL CRANKCASES .................................................................................................................................................................. 20
• REMOVING THEGEARBOX ............................................................................................................................................................................................ 20
• REMOVING THE CRANKSHAFT ..................................................................................................................................................................................... 20
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
• CHECKING THE CRANKSHAFT ..................................................................................................................................................................................... 23
• CHECKING THE GEARBOX ............................................................................................................................................................................................ 24
• CHECKING THE CLUTCH .............................................................................................................................................................................................. 24
• CHECKING THE TOP ENGINE ........................................................................................................................................................................................ 25
• CHECKING THE CYLINDER HEAD ................................................................................................................................................................................. 28
• CHECKING THE DISTRIBUTION..................................................................................................................................................................................... 28
ENGINE ASSEMBLY ...................................................................................................................................................................................... 29
• INSTALLING THE CENTRAL CRANKCASES ................................................................................................................................................................... 29
• INSTALLING THE CLUTCH HOUSING ............................................................................................................................................................................. 31
• INSTALLING THE WATER PUMP HOUSING .................................................................................................................................................................... 31
• INSTALLING THE CLUTCH ............................................................................................................................................................................................ 32
• INSTALLING THE ELECTRIC STARTER .......................................................................................................................................................................... 32
• SETTING THE PISTON RINGS ....................................................................................................................................................................................... 33
• INSTALLING THE PISTON ............................................................................................................................................................................................. 33
• INSTALLING THE CYLINDER ......................................................................................................................................................................................... 34
• INSTALLING THE CYLINDER HEAD ............................................................................................................................................................................... 34
• INSTALLING THE DRIVE CHAIN .................................................................................................................................................................................... 35
• INSTALLING THE ROTOR ............................................................................................................................................................................................. 35
• INSTALLING THE CAMSHAFT AND SETTING THE VALVE TIMING .................................................................................................................................... 36
• CHECKING VALVE CLEARANCE ..................................................................................................................................................................................... 36
• COMPLETING THE ENGINE ASSEMBLY ......................................................................................................................................................................... 37
• INSTALLING THE IGNITION COVER ............................................................................................................................................................................... 37
TIGHTENING TORQUE CHART ...................................................................................................................................................................... 38
CLEANING THE THROTTLE BODY ................................................................................................................................................................. 40
• EQUIPMENT ................................................................................................................................................................................................................ 40
• REMOVING THE THROTTLE BODY ................................................................................................................................................................................ 40
• CLEANING THE THROTTLE BODY ................................................................................................................................................................................. 42
• INSTALLING THE THROTTLE BODY............................................................................................................................................................................... 42
CHANGING THE TPS (THROTTLE POSITION SENSOR) ................................................................................................................................. 43
INJECTION DIAGNOSTIC TOOL SYNERJECT ................................................................................................................................................ 44
• 1- PRESENTATION OF THE SYNERJECT INJECTION SYSTEM ........................................................................................................................................ 44
• 2- SOFTWARE OVERVIEW ............................................................................................................................................................................................ 50
• 3- USING THE SOFTWARE ........................................................................................................................................................................................... 54
CHECKING THE CHARGING CIRCUIT ............................................................................................................................................................ 67
WIRING DIAGRAM ....................................................................................................................................................................................... 69
Summary of Contents for 2015 450 SEF-R
Page 1: ...MANUEL D ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER 450SEf R...
Page 70: ...70 450 SEF R Wiring diagram Injection wiring harness...
Page 71: ...71 ENGLISH Wiring diagram Light wiring harness 450 SEF...
Page 72: ...72 450 SEF R Light wiring harness Racing 450 SEF R Wiring diagram...
Page 73: ...73 ENGLISH Accessories wiring harness Wiring diagram...
Page 74: ...74 450 SEF R Fan wiring harness Wiring diagram...
Page 75: ...75 ENGLISH Voltage graph TPS sensor of throttle body Wiring diagram...
Page 76: ...Edition Avril 2015...