SHERCO 2015 450 SEF-R Workshop Manual Download

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ENGLISH

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

5774

Piston support

R462

Flywheel puller

R464

Crankshaft ring extractor

R450

Oil seal selector

R472

Applying tool for oil seal selector

5773

Special 450 spark plug wrench

5028

PUSH-IN TOOL WP Ø48

4967

Synerject injection diagnostic tool

5132

Adjustable hook spanner wrench WP Ø48

5029

Joint guide tool WP Ø48

5030

Bottle-type leveling tool WP

5031

Pipe vise clamp WP 48/60

R453

Selector shaft bearing assembly tool

R444

Oil seal selector

FRANÇAIS

Summary of Contents for 2015 450 SEF-R

Page 1: ...MANUEL D ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER 450SEf R...

Page 2: ...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...

Page 3: ...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...

Page 4: ...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 eng...

Page 5: ...ary drive locking tool 5774 Piston support R462 Flywheel puller R464 Crankshaft ring extractor R450 Oil seal selector R472 Applying tool for oil seal selector 5773 Special 450 spark plug wrench 5028 P...

Page 6: ...ake valve cold clearance 0 15 0 2 mm Exhaust valve cold clearance 0 2 0 25 mm Crankshaft bearings 2 roller bearings Piston forged aluminum Lubrication full pressure lubrication with 2 trochoid pumps M...

Page 7: ...P USD 48mm racing Rear suspension WP Suspension with separate cylinder Travel front rear 300 300 mm Front brake Disc 270 mm standard 256 mm racing Rear brake Disc 220 mm Disc brakes Wear limit 2 7 mm...

Page 8: ...ork tube 130mm Original settings Fork WP Suspension USD 48mm Compression Comfort 21 clicks back Standard 14 clicks back Sport 9 clicks back Rebound Comfort 19 clicks back Standard 14 clicks back Sport...

Page 9: ...s 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...

Page 10: ...engine Operations not requiring the removal of the engine Crankshaft including crankshaft repair kit Complete transmission Crankshaft bearing Gearbox bearing Piston Cylinder Cylinder head Distribution...

Page 11: ...Remove the throttle body Remove the chain guard Remove the secondary transmission line quick release Remove the clutch receiver WARNING When the clutch receiver is removed the piston is no longer supp...

Page 12: ...he clutch receiver Tighten to 10 Nm Place the secondary chain and adjust the tension see procedure on the user manual Put the chain guard Put the throttle body Put the pencil coil Put the exhaust pipe...

Page 13: ...center Remove the ignition cover plug 1 Remove the timing control plug 2 Rotate the motor counterclockwise in order to align the center of the hole of the crankshaft with that of the crankshaft timin...

Page 14: ...g cap A Remove the camshafts Removing the distribution tensioner Unscrew the screw 1 and remove the spring Unscrew the two screws 2 Remove the tensioner along with its gasket Removing the drive chain...

Page 15: ...der head gasket with caution Removing the cylinder Remove the cylinder by it pulling vertically Remove the cylinder gasket 1 carefully Removing the piston Remove the securing clip 1 from the piston pi...

Page 16: ...e 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 Removing the drive chain Unscrew the drive chain gu...

Page 17: ...from the pressure plate Remove the friction and metal plates Make sure the inner clutch hub can freely rotate removing the water pump housing Remove the screws 1 of the water pump housing Beware of th...

Page 18: ...the clutch bellhousing WARNING If you want to dismount the freewheel or the balancer shaft further on block the primary drive with the tool 5593 Unlock the nut off the mass of the balancer shaft 2 1...

Page 19: ...age pin lubrication and lip sealing Remove the freewheel sprocket Removing the oil pump Remove the oil pump intermediate pinion Remove the 3 screws 1 Removing the index shim Keep the selection locking...

Page 20: ...t Remove the balancer shaft Remove the crankshaft 1 1 C R L 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 securi...

Page 21: ...se at about 70 C Apply blue thread lock on the bearings of the retaining screws and tighten them to 5 Nm Check that the top engine oil nozzle 5 and BV 6 is not clogged or damaged WARNING the piston no...

Page 22: ...remove the outer securing clip 2 and remove the freewheel WARNING Replacing the freewheel systematically involves replacing the freewheel sprocket and vice versa Changing the crankshaft bearings Chang...

Page 23: ...cranks haft must be replaced Lateral clearance of the connecting rod Measure lateral clearance of the connecting rod A Lateral clearance of the connecting rod Standard 0 6 mm 0 85 mm Tolerated limit 1...

Page 24: ...ary Control the selection drum check if there are distortions abnormal wear if damage is found Change the drum if necessary Checking the clutch Check metal and friction discs Standard friction plate t...

Page 25: ...one measure of the internal diameter of the cylin der exceeds the service limit replace the cylinder A 8 mm B 30 mm Standard 450 SEF R Cylinder diameter A 94 99 0 012 mm diameter cylinder B 94 982 94...

Page 26: ...pection for wear of the connecting rod piston pin and piston Visually control the installed securing clip If it seems weakened or distorted replace it If the groove of the pinhole is excessively worn...

Page 27: ...body and threading with engine oil Torque setting Camshaft housing screws 18 Nm If any clearance is above the limit measure the diameter of each camshaft trunnion by means of a micrometer If the diam...

Page 28: ...of the cylinder head Limit 0 05 mm Valve guide clearance Intake Minimum clearance 0 02 mm Maximum Clearance 0 045 mm Exhaust Minimum clearance 0 04 mm Maximum Clearance 0 065 mm Checking the distribu...

Page 29: ...spective sliding grooves Insert the selection drum Insert the forks in their respective drum grooves Place the fork spindles WARNING N oublier pas de huiler les pi ces en friction ou en rotation Set u...

Page 30: ...t and from the crankshaft threading Apply medium thread lock on the crankshaft Fit the washer and engage the nut 4 Place the oil pump intermediate gear Place the securing clip 3 and its washer Place t...

Page 31: ...housing to approximately 70 C Place the water pump on top of the clutch hou sing Check the condition of the oil pan gasket and set it back Reassemble the clutch housing and the 8 screws outside the wa...

Page 32: ...the TDC 1819 tool WARNING Do not use this tool for tightening or loosening at a torque value superior to 10 Nm Place the clutch housing cover by tightening the 4 screws The 4 screws are not the same...

Page 33: ...le ends must be oriented downwards Place the rails below and above the expander within the groove Make sure that the upper rail is on the intake side opposite the first rail Place the top ring in the...

Page 34: ...nder Fit the cylinder paying attention to the rings Place the piston at TDC and the 1819 tool installing the cylinder head Set the guide pins and the cylinder head gasket Set the washers and nuts Scre...

Page 35: ...er head gasket plane Do not forget the two needle housing of the pinion Place back the axis 2 and the O ring and tigh ten them Tightening torque of the shaft 30 Nm Apply blue thread lock on the two sc...

Page 36: ...ews 18 Nm Remove the TDC 1819 tool Using the ignition rotor give the crankshaft at least one full turn and check the valve timing Checking the valve clearance Valve clearance must be checked when the...

Page 37: ...crews cylinder head cover 10 Nm Applying copper grease on the threads of the spark plug Tightening torque of the spark plug 16 Nm Put in the TDC plug tighten it to 15 Nm Installing the ignition cover...

Page 38: ...h bolt 15 Nm Brake pads axis screws 8 Nm Fork lower clamp pinch bolts WP 12 Nm Sachs 15 Nm Fork upper clamp pinch screws WP 17 Nm Sachs 17 Nm Sachs engine axes 40 Nm Swing arm nuts 100 Nm Cylinder hea...

Page 39: ...m Camshaft housing screws 18 Nm Chain tensioner screws 10 Nm Chain tensioner rack and pinion screws 10 Nm Central timing sprocket axis 30 Nm Crankshaft inspection stopper 8 Nm Distribution guide plate...

Page 40: ...er 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 Loosen the clamps of the throttle body Remove t...

Page 41: ...41 ENGLISH Cleaning the throttle body Unplug all connectors Visually inspect Clean with a universal cleaning solution Blow...

Page 42: ...hrottle body Reassemble the parts following the reverse order of that of the removal put special connector grease inside the connections power injector GST etc If you remove the inlet sleeve pay atten...

Page 43: ...edure Unscrew the screw 1 and remove the TPS Position the new TPS and the screw 1 without tightening it Connect the motorcycle and run the Exxotest diagnostic software see procedure below Click on the...

Page 44: ...ess 4 1 5 2 3 N DESCRIPTION LOCATION 1 Synerject M3C Calculator Left side of the frame 2 Engine speed sensor pick up Upper part of the ignition cover 3 Synerject 42 mm throttle body 4 Water temperatur...

Page 45: ...you to perform diagnostic operations to update injection mapping and to verify certain information serial number operating hours etc 1 3 Composition of the diagnostic tool The case consists of a cabl...

Page 46: ...n 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 fo...

Page 47: ...47 ENGLISH Outil diagnostique injection SYNERJECT Click on Next Click on Install Installation in progress Injection diagnostic tool SYNERJECT...

Page 48: ...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 p...

Page 49: ...lid 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...

Page 50: ...e 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 Diagnostics menu diagnostic map updates...

Page 51: ...e 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 langu...

Page 52: ...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...

Page 53: ...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 Injecti...

Page 54: ...sary 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 3 Using the software Diagnostic menu and injection mapping updat...

Page 55: ...ollowing menu 3 1 Identification checking identification serial number vehicles operating hours calibration number 3 2 Measuring the parameters general parameters speed pressure stepper etc Injection...

Page 56: ...rottle position engine stopped value 0 Maximum opening 100 If the value is not equal to 0 when the engine is off it means that adaptation has not been made Reboot the system several times Switch off i...

Page 57: ...e mb pressure at the nozzle body measured by the TMAP sensor State motor synchronization recognition of the engine cycle 0 not phase motor 1 phased running motor Adaptive on the whole idle speed contr...

Page 58: ...58 450 SEF R 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 Injection diagnostic tool SYNERJECT...

Page 59: ...r 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 P...

Page 60: ...wing 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 Injection dia...

Page 61: ...tors 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 Injection diagno...

Page 62: ...il emits a characteristic sound of a proper operation during the testing process B Injector Same type of test as for the coil Check that the injector emits a clacking sound on activation C Fuel Pump F...

Page 63: ...ample 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 Injection diagnostic t...

Page 64: ...type etc In case of any doubt contact technical support En cas de doute contacter votre support technique 1 Download the needed update file mot 2 Turn the motorbike On 3 Click on Update calculator Co...

Page 65: ...correct allocation of the calibration file by selecting Identification Check that the file name matches the downloaded file Information the information on serial number and operating hours are not re...

Page 66: ...llow 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 communicatio...

Page 67: ...Resistance of the engine speed sensor 117 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 120 V M...

Page 68: ...uit Alternator Tolerance values 5 10 RPM Voltage AC Current IB DC VB 2000 35V 7 2A DC 13 5V 2500 43V 11 3A 3000 50 5V 13 6A 4000 63V 15 6A 5000 75 5V 16 5A 6000 88V 16 9A 7000 99 5V 17 2A 8000 112V 17...

Page 69: ...ng harness 7 Engine shutdown 8 Dashboard 9 Stepper motor 10 Injector 11 Gasoline pump 12 Temperature sensor 13 Throttle sensor TPS 14 Engine ground 15 Starter 16 TMAP 17 Engine speed sensor 18 HT coil...

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...

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SHERCO 2015 450 SEF-R, Workshop Manual

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