Sherco 450 Se R Workshop Manual 1
Sherco 450 Se R Workshop Manual 1
Sherco 450 Se R Workshop Manual 1
MANUELI WORKSHOP
D’ATELIER MANUAL I MANUAL
I WORKSHOP DE TALLER
MANUAL I MANUAL DE TALLER
SUMMARY
FOREWORD ............................................................................................................................................................................. 4
TOOLSLISTFOR450SEF-RENGINE...................................................................................................................................................... 5
TECHNICALSPECIFICATIONS............................................................................................................................................................ 6
❱❘ Engine .............................................................................................................................................................................................. 6
❱❘ Chassis ............................................................................................................................................................................................. 7
FACTORYSETTINGS..................................................................................................................................................................... 8
❱❘ Fork ................................................................................................................................................................................................. 8
❱❘ Shock absorber ................................................................................................................................................................................... 9
OPERATIONSREQUIRINGTHEREMOVAL,ORNOT,OFTHEENGINE................................................................................................................... 10
REMOVING/INSTALLINGTHEENGINE .................................................................................................................................................. 11
❱❘ Removing the engine ........................................................................................................................................................................... 11
❱❘ Installing the engine in the frame .............................................................................................................................................................. 12
REMOVINGTHEENGINE ............................................................................................................................................................... 13
❱❘ Preparation ...................................................................................................................................................................................... 13
❱❘ Removing the cylinder head cover ............................................................................................................................................................ 13
❱❘ Set the engine at top dead center ............................................................................................................................................................. 13
❱❘ Removing the camshafts ....................................................................................................................................................................... 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
❱❘ Changing 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
❱❘ Removing the water pump oil seal and the bearing ......................................................................................................................................... 18
❱❘ Removing the clutch bellhousing .............................................................................................................................................................. 18
❱❘ Removing 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 the gearbox ......................................................................................................................................................................... 20
❱❘ Removing the crankshaft ....................................................................................................................................................................... 20
CHECKINGINDIVIDUALPARTS......................................................................................................................................................... 21
❱❘ Controlling the central crankcases ............................................................................................................................................................ 21
❱❘ Left crankcase ................................................................................................................................................................................... 21
❱❘ Right crankcase ................................................................................................................................................................................. 21
❱❘ Checking the freewheel sprocket bearinge .................................................................................................................................................. 22
2 450 SEF-R
❱❘ 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
ENGINEASSEMBLY.................................................................................................................................................................... 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 camshafts and setting the valve timing ....................................................................................................................................... 36
❱❘ Checking the valve clearance ................................................................................................................................................................. 36
❱❘ Completing the engine assembly ............................................................................................................................................................. 37
❱❘ Installing the ignition cover ..................................................................................................................................................................... 37
TIGHTENINGTORQUECHART ......................................................................................................................................................... 38
CLEANINGTHETHROTTLEBODY...................................................................................................................................................... 40
❱❘ Equipment ....................................................................................................................................................................................... 40
❱❘ Removing the throttle body .................................................................................................................................................................... 40
❱❘ Cleaning the throttle body ...................................................................................................................................................................... 42
❱❘ Installing the throttle body ...................................................................................................................................................................... 42
CHANGINGTHETPS–THROTTLEPOSITIONSENSOR.................................................................................................................................. 43
INJECTIONDIAGNOSTICTOOLSYNERJECT ........................................................................................................................................... 44
❱❘ 1- Presentation of the SYNERJECT injection system ...................................................................................................................................... 44
❱❘ 2- Software overview ........................................................................................................................................................................... 50
2.1- Connection with Keyless system ...................................................................................................................................................... 50
2.2- Software settings : configuration menu ............................................................................................................................................... 52
2.3- Update menu and synchronization .................................................................................................................................................... 53
❱❘ 3- Using the software ........................................................................................................................................................................... 55
CHECKINGTHECHARGINGCIRCUIT................................................................................................................................................... 68
CONTROLOFTHESENSORS .......................................................................................................................................................... 70
❱❘ 1- Control of the TPS sensor .................................................................................................................................................................. 70
❱❘ 2- Values of temperature sensor .............................................................................................................................................................. 71
WIRINGDIAGRAM...................................................................................................................................................................... 72
Injection wiring harness ........................................................................................................................................................................... 72
Light wiring harness 450 SEF ..................................................................................................................................................................... 75
Light wiring harness Racing 450 SEF-R .......................................................................................................................................................... 76
Accessories wiring harness ....................................................................................................................................................................... 77
Fan wiring harness ................................................................................................................................................................................. 78
3
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.
4 450 SEF-R
TOOLS LIST FOR 450 SEF-R ENGINE
SEF-R
❱❘ 450 SEF-R
FRANÇAIS
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
6267 Shunt for Keyless system
5
TECHNICAL SPECIFICATIONS
❱❘ Engine
Type Single cylinder 4 stroke liquid cooled
Displacement 449.4 CC
Bore / Stroke 95/63.4mm
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 38mm
Exhaust valve diameter 30.5
Intake valve cold clearance 0.15-0.2mm
Exhaust valve cold clearance 0.2-0.25mm
Crankshaft bearings 2 roller bearings
Piston forged aluminum
Lubrication Full pressure lubrification with 2 trochoid pumps
Motor oil 1 liter SAE 10w40
Primary drive 25 : 75
Gearbox : 6 speed
1st 13 : 32
2nd 16 : 29
3rd 19 : 27
4th 21 : 24
5th 23 : 22
6th 25 : 21
Final drive 14 X 49
Clutch multi disc clutch in oil bath, hydraulically operated
Start-up/battery Electric 12V 4Ah
Electronic injection Synerject
6 450 SEF-R
TECHNICAL SPECIFICATIONS
❱❘ Chassis
FRANÇAIS
Frame Semi-perimeter Cr Mo steel with aluminum subframe
Fork SACHS USD Golds Series Ø 48mm (standard)
WP suspension USD Ø 48mm (racing)
Rear suspension WP suspension with sparate cylinder
Travel front/rear 300/330mm
Front brake Disc Ø 270mm (standard), Ø 256mm (racing)
Rear brake Disc Ø 220mm
Disc brakes Wear limit : 2.7mm front and 3.6mm rear
Front tire 90/90-21’’
Rear tire 140/80-18’’
Pressure off-road front/rear 0.9 bar
Fuel tank capacity 9.7l with 1 liter of reserve
Steering angle 27.3°
Wheelbase 1490mm
Weight 110 kg
7
FACTORY SETTINGS
❱❘ Fork
8 450 SEF-R
FACTORY SETTINGS
❱❘ Shock absorber
FRANÇAIS
Factory Settings – WP suspension shock absorber
9
OPERATIONS REQUIRING THE REMOVAL, OR NOT, OF THE ENGINE
10 450 SEF-R
REMOVING/INSTALLING THE ENGINE
FRANÇAIS
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.
Empty (see the User Manual)
- The engine oil
WARNING
When the clutch receiver is removed, the piston is no longer supported. Hold the piston with a plastic clamp.
Remove the water radiator hoses connected to the engine.
Remove the left radiator.
Remove the cylinder head frame mounting brackets.
Remove the frame guards on both the right and left sides of the bike.
Unscrew the swing arm pivot.
Loosen the other two engine axes.
Unscrew the swing arm pivot and pull the swing arm slightly backward.
Remove the engine axes.
Remove the engine through the left side by pivoting it.
NOTE :
Vous devriez avoir une aide extérieure pour cette étape, le poids étant conséquent. Assurez-vous de ne pas
endommager les pates de fixation moteur sur le cadre.
11
REMOVING/INSTALLING THE ENGINE
Reinstall the tank along with its vents (refer to the user manual).
(starter case, TPS, water temperature sensor, pencil coil and injector).
WARNING
Before reconnecting, check that the ignition key (SEF 450 standard) or the switch (450 SEF / R racing) is in the
«OFF» position.
12 450 SEF-R
REMOVING THE ENGINE
❱❘ Preparation
Place the engine on the R455 engine support tool.
Drain the engine oil (see user manual).
FANÇAIS
Make sure to be in a clean environment before
WARNING
The screws have an o-ring.
13
REMOVING THE ENGINE
14 450 SEF-R
REMOVING THE ENGINE
❱❘ Removing the cylinder head
Unscrew the cylinder head bolts following the 6 3
4 5
2 1
2
1
15
REMOVING THE ENGINE
❱❘ Changing the stator and the
engine speed sensor
Remove the 2 screws from the sensor (2) and
2
1
16 450 SEF-R
REMOVING THE ENGINE
FRANÇAIS
• Remove the clutch housing cover by 4
unscrewing the 4 screws. Beware of the O-
2 6
ring located on the rim of the cover.
• Set the TDC 1819 tool.
1
5
WARNING 3
Do not use this tool for tightening or loosening
with a torque value higher than 10 Nm.
WARNING
You need to identify the screws, 6 are 25 mm
long, 2 are 30mm long (screw (1)). 1
17
REMOVING THE ENGINE
WARNING
The 2 seals are not identical nor interchangeable
• Disconnect the shaft from the water pump
drive pinion.
• Remove the water pump bearing.
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).
2
18 450 SEF-R
REMOVING THE ENGINE
❱❘ Removing the freewheel sprocket
FRANÇAIS
WARNING
See previous paragraph for the unlocking of the 2
balancer shaft nut.
1
• Remove the securing clip (1) and their
washers.
• Remove the torque limiter (2). 1 4
WARNING
Do not damage the end of the crankshaft: oil
passage, pin lubrication and lip sealing.
• Remove the freewheel sprocket.
WARNING
The pump to the left of the wall is 8mm thick and
the one to the right is 12mm thick.
19
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
BEWARE
Of the small fork sockets. 1
1
• Remove the forks C, L and R.
• Remove the two gearbox shafts.
20 450 SEF-R
CHECKING INDIVIDUAL PARTS
❱❘ Controlling the central crankcases
Check the general condition of the central
FRANÇAIS
Change the defective or worn crankcase set
crankcases for any possible damage or crack.
them if necessary.
❱❘ Left crankcase
The crankshaft bearings (1), primary shaft 5
(2) and secondary shaft (3) of the gearbox are 6 7
7
WARNING
The piston nozzles (7) are indexed and cannot be
replaced. If damaged, replace the carters.
❱❘ Right crankcase
The crankshaft bearings (1), primary shaft
(2) and secondary shaft (3) and selection drum
21
CHECKING INDIVIDUAL PARTS
❱❘ Checking the freewheel sprocket
bearinge
Visually check the needle bearing of the
Change it if necessary.
freewheel sprocket.
WARNING
Replacing the freewheel systematically involves
replacing the freewheel sprocket and vice versa.
WARNING
The radial clearance of the bearings must be
practically zero.
22 450 SEF-R
CHECKING INDIVIDUAL PARTS
❱❘ Checking the crankshaft
FRANÇAIS
Radial clearance of the connecting rod :
Place the crankshaft on V-blocks and place a B A
Push [B] the connecting rod to the gauge
dial gauge [A] against the connecting rod.
23
CHECKING INDIVIDUAL PARTS
❱❘ Checking the gearbox
Check all pinions
By checking the coupling claws [A], the pinion
teeth [B] and fork grooves [C]. In case of wear,
Ref. 6818
e : 1.2mm
min : 1.1mm
déf : 0.3mm Ref. 5444
e : 1.5mm
min : 1.4mm Ref. 6819
e : standard thickness déf : 0.3mm e : 2.0mm
min : thickness limit min : 1.9mm
déf : distortion limit déf : 0.3mm
24 450 SEF-R
CHECKING INDIVIDUAL PARTS
❱❘ Checking the top-engine
FRANÇAIS
Inspection of cylinder wear :
Measure the inside diameter of the cylinder A
when the cylinder is cold B
• 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.
• Since the cylinder does not wear out evenly
in every direction, measure it from one side to
the other and from bottom to top as shown.
If one measure of the internal diameter of the
cylinder exceeds the service limit, replace the
cylinder.
(A)=8 mm
(B)=30 mm
Piston/cylinder clearance
In order to define the clearance as accurately as
possible, measure the diameter of the piston
and the cylinder separately, and then calculate
the difference between these two values.
Measure the diameter of the piston according to
the « Piston Wear » procedure.
Piston/cylinder clearance :
Standard 0.034 – 0.056 mm
Limit 0.11 mm
25
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
End gap :
Top ring : 0.2-0.3 mm
Limit 0.5 mm
26 450 SEF-R
CHECKING INDIVIDUAL PARTS
Cams wear :
• Measure the height [A] of each cam by
FRANÇAIS
means of a micrometer.
If the cams are worn beyond the limit, replace
A
the camshaft.
Cam height limit 450
Exhaust : 37.20 mm
Admission : 37.62 mm
Camshaft offset :
Measure the runout of the camshaft.
If it is out of specification, change de camshaft.
Runout : Less than 0.03 mm.
27
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
measure the warping by inserting a thickness
gauge between the straightedge and the gauge
head. If the warping exceeds the tolerated limit,
repair the adjusting surface. Replace the cylinder
head if the adjusting surface is seriously damaged.
Warping 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
28 450 SEF-R
ENGINE ASSEMBLY
❱❘ Installing the central crankcases
FRANÇAIS
WARNING
During the installation process, replace all
gaskets (joint paper, O-ring, etc.).
WARNING
Do not forget to oil the parts in friction or in
rotation.
B C
B
29
ENGINE ASSEMBLY
30 450 SEF-R
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 : 120Nm.
• Insert the safety washer and the nut.
• Using the 5749 tool, block the clutch nut and
tighten.
Specified torque of 100 Nm nut clutch.
WARNING
Make sure that the lubrication raceway of
the crankshaft in the crankcase is clean.
Replace the crankshaft lip seal. 1
1
31
ENGINE ASSEMBLY
WARNING
Do not use this tool for tightening or loosening
at a torque value superior to 10 Nm.
4
• Place the clutch housing cover by tightening
2 6
the 4 screws. The 4 screws are not the same
length.
Beware of the O-ring located on the rim of the lid.
• Remove the TDC 1819 tool. 1
32 450 SEF-R
ENGINE ASSEMBLY
❱❘ Setting the piston rings
• Place the first rail. Pay attention to the
FRANÇAIS
position of the opening on the exhaust side.
33
ENGINE ASSEMBLY
❱❘ Installing the cylinder
• Seal the joint between the left and right casing
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.
• Place the piston at TDC and the 1819 tool.
gasket.
• Set the washers and nuts.
• Screw the cylinder head in the order shown in
the picture.
3 2
Pass 1
Tightening torque of nuts 1/2/3/4 : 30 Nm.
5 6
Pass 2
Tightening torque of nuts 1/2/3/4 : 50 Nm.
Tightening torque of screws 5/6 : 10 Nm.
1
1
34 450 SEF-R
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
cylinder, or that the FLANGE mark is aligned
with the cylinder head gasket plane.
2
• Put in the drive chain. 1 1
1
Tensioner tightening torque : 10 Nm.
35
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.
• Install the baring cap (A).
• Screw the eight screws of the camshaft-
bearing cap following the order shown in the
picture.
Specified torque of the shaft bearing screws:
18 Nm.
• Remove the TDC 1819 tool.
• Using the ignition rotor, give the crankshaft at
least one full turn and check the valve timing.
Valve clearance A 7
36 450 SEF-R
ENGINE ASSEMBLY
37
TIGHTENING TORQUE CHART
M6 10 Nm
M8 24 Nm
M10 40 Nm
38 450 SEF-R
TIGHTENING TORQUE CHART
Drum screws 10 Nm
39
CLEANING THE THROTTLE BODY
❱❘ Equipment
• Carburetor cleaner or Minerva brand universal
cleaner.
• Open-end wrench 8.
• Socket screwdriver 7.
• Hex key 2,5.
40 450 SEF-R
CLEANING THE THROTTLE BODY
• Unplug all connectors.
• Visually inspect.
FRANÇAIS
• Clean with an universal cleaning solution.
• Blow.
41
CLEANING THE THROTTLE BODY
❱❘ Cleaning the throttle body
• Clean the throttle body by means of a
carburetor cleaner spray (Net Carbu).
• Be sure to clean the edge of the throttle
valve on each side with the throttle fully opened.
• Clean the injector.
• Blow.
42 450 SEF-R
CHANGING THE TPS – THROTTLE POSITION SENSOR
43
INJECTION DIAGNOSTIC TOOL SYNERJECT
❱❘ 1- Presentation of the SYNERJECT injection system
1.1- Your Sherco 450 SEF-R is equipped with a Synerject injection system
consisting of an M3C calculator, a Ø42 mm throttle body, an ignition and a
specific wiring harness.
1
5
N° Description Location
1 Synerject M3C Calculator Left side of the frame
4 Water temperature sensor At the back of the cylinder head, on the right side
5
2-way sealed diagnostic connector (labeled At the front of the motorcycle, on the right side,
"ECU") between the radiator and the frame
44 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
FRANÇAIS
1
N° Description
1 Stepper motor (idle control and engine brake)
2 Injector
45
INJECTION DIAGNOSTIC TOOL SYNERJECT
1.4- Diagnostic tool installation
In case of problem during the installation, please contact EXXOTEST at +33 (0)4 50 02 34 34 or by mail to
courrier@exxotest.com.
• Click on « Next ».
46 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
• Click on « Next ».
FRANÇAIS
• Click on « Install ».
• Installation in progress.
47
INJECTION DIAGNOSTIC TOOL SYNERJECT
• Installation in progress.
48 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
• The following window will open. Click on
« Finish ».
FRANÇAIS
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 :
• All LEDs OFF: the outlet is not powered on, or is off or USB in on standby mode.
49
INJECTION DIAGNOSTIC TOOL SYNERJECT
❱❘ 2- Software overview
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
2. Take the shunt (3) (reference 6267) and connect the plug (1) into it.
50 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
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..
Update and
synchronization
menu (software
update, proxy
parameters) Help
51
INJECTION DIAGNOSTIC TOOL SYNERJECT
• 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.
52 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
53
INJECTION DIAGNOSTIC TOOL SYNERJECT
FRANÇAIS
• Click on to start downloading the
update.
• Resume the installation process -> page 46. It is not necessary to restart the installation of the drivers.
54 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
B- Configuration of Internet access parameters
• Click on
General :
• Click on « Sherco ».
• Cliquez on « M3C ».
55
INJECTION DIAGNOSTIC TOOL SYNERJECT
FRANÇAIS
3.1- Identification : checking identification (serial number, vehicles operating hours calibration number).
3.2- Measuring the parameters : general parameters (speed, pressure, stepper, etc).
56 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
A- Engine information :
Details :
• Stepper Position : valeur d’ouverture de la valve d’air (stepper)-> 35 < 50 < 75.
Too weak value : fuite aux soupapes/prise d’air moteur par exemple.
Too high value : papillon du corps d’injection encrassé par exemple.
Information : correct value of the air valve: motor at 80 °C after being operated for 15 m and idle for 2 m.
• State Stop button: state of the emergency stop button. 0: disabled, 1: enabled.
• Engine status: ES (engine ready to start), ST (engine starts), IS (idle regime), PL (acceleration), PU
(deceleration), PUC (cut injection deceleration).
57
INJECTION DIAGNOSTIC TOOL SYNERJECT
B- Other values are displayed in the windows :
FRANÇAIS
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.
• State motor synchronization: recognition of the engine cycle.
0: not phase motor.
1: phased running motor.
• Adaptive on the whole idle speed controller (%): function not activated.
58 450 SEF-R
INJECTION DIAGNOSTIC TOOL SYNERJECT
If errors occur :
You can get the details of the error by clicking on the error displayed :
59
INJECTION DIAGNOSTIC TOOL SYNERJECT
Info :
FRANÇAIS
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).
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INJECTION DIAGNOSTIC TOOL SYNERJECT
• Check that the errors detected are identical. Verify/change the defective parts. Verify the connections.
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INJECTION DIAGNOSTIC TOOL SYNERJECT
3
FRANÇAIS
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 :
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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.
B - Injector
Same type of test as for the coil. Check that the injector emits a clacking sound on activation.
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INJECTION DIAGNOSTIC TOOL SYNERJECT
FRANÇAIS
Stepper error :
Select the calibration file (.mot) previously downloaded and click on Open.
WARNING!
DO NOT TURN OFF THE MOTORCYCLE DURING THE DOWNLOAD OPERATION (FLASH),
DO NOT INTERRUPT THE SOFTWARE ABRUPTLY DURING THE FLASH.
RISK OF PERMANENT DAMAGE TO THE COMPUTER
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INJECTION DIAGNOSTIC TOOL SYNERJECT
5 - Upon completion of the download, the fuel pump starts up and the following message appears:
Information : the information on serial number and operating hours are not reset during a calibration update.
7-Switch on the bike and verify that the parameters of the motor are normal (idle, stepper opening, etc.).
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INJECTION DIAGNOSTIC TOOL SYNERJECT
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.).
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CHECKING THE CHARGING CIRCUIT
FRANÇAIS
Battery voltage > 12.5V.
Y1-Y2
Y2-Y3 0.44Ω±10%
Y1-Y3
Tension regulator :
Alternative (AC 200V caliber).
Idle : 22V ±2V.
At 6000 RPM : 77V±3V.
Direct :
On regulator output (DC 20V caliber).
At 4000 RPM : 14.6V + Red/White, - Green.
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CHECKING THE CHARGING CIRCUIT
Alternator :
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CONTROL OF THE SENSORS
❱❘ 1- Control of the TPS sensor
1. Remove the injector body from the bike.
TPS
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CONTROL OF THE SENSOR
❱❘ 2- Values of temperature sensor
TEMP (°C) RESIST (K Ω)
-40 100.950
-30 53.100
-20 29.121
-10 16.599
0 9.750
+10 5.970
+20 3.747
+25 3.000
+30 2.547
+40 1.598
+50 1.150
+60 0.746
+70 0.565
+80 0.377
+90 0.275
+100 0.204
+110 0.153
+125 0.102
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WIRING DIAGRAM
Injection wiring harness
Connectors description
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
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WIRING DIAGRAM
Diagram
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WIRING DIAGRAM
Geometry
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WIRING DIAGRAM
Light wiring harness 450 SEF
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WIRING DIAGRAM
Light wiring harness Racing 450 SEF-R
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WIRING DIAGRAM
Accessories wiring harness
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WIRING DIAGRAM
Fan wiring harness
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