Sherco 450 SEF Racing Workshop Manual

Sherco 450 SEF Racing Workshop Manual

Product Information

This is the workshop manual for the 450 SEF Racing, 450 SEF Factory, 500 SEF Racing, and 500 SEF Factory models. It provides information and instructions for maintaining and repairing these models. The manual includes a summary, foreword, tools list for the 450/500 SEF engine, factory settings for the fork and shock absorber, and instructions for removing/installing the engine.

Product Usage Instructions

Removing/Installing the Engine
To remove the engine:

1. Refer to page 11 of the manual for detailed instructions on removing the engine.
2. Follow the steps provided to safely disconnect and remove the engine from the frame.

To install the engine in the frame:

1. Refer to page 12 of the manual for detailed instructions on installing the engine.
2. Ensure you have prepared the necessary tools and equipment as mentioned on page 12.
3. Follow the steps provided to securely install the engine in the frame.

Preparing the Engine
Before installing the engine in the frame, follow these steps:

1. Refer to page 13 of the manual for detailed instructions on preparing the engine.
2. Remove the cylinder headcover as instructed on page 13.
3. Complete any other necessary preparations mentioned in the manual.

For further details and specific instructions regarding factory settings, tools list, and other maintenance procedures, please refer to the respective pages in the workshop manual.

WORKSHOP MANUAL | MANUEL D’ATELIER | MANUAL DE TALLER
450 SEF RACING 450 SEF FACTORY 500 SEF RACING 500 SEF FACTORY

450500 SEF

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 450/500 SEF engines.
5

TOOLS LIST FOR 450/500 SEF ENGINE

450/500 SEF
Tool reference 10338 5749 4753 1822 1968 R455 5593 5774 R462 10049 R450 R472 5773 5028 8561 7888 7669 7671 7670 R453 R444 6267

Description Top dead center timing screw
Clutch removal tool ADLER Fret-type ignition unit
Water pump bearing axis tool Water pump oil seal tool Engine support Primary drive locking tool Piston support Flywheel puller Crankshaft ring extractor Oil seal selector
Applying tool for oil seal selector Special 450 spark plug wrench
PUSH-IN TOOL Ø48 Synerject injection diagnostic tool TOP CAP WRENCH 49 MM BLUE
SEAL HAMMER 48 MM MEASURING CAM 500 ML INNER TUBE CLAMP 48 MM Selector shaft bearing assembly tool
Oil seal selector Shunt for Keyless system

6

450500 SEF

TECHNICAL SPECIFICATIONS

Engine
Type Displacement Bore / Stroke Compression ratio Unleaded Distribution Intake valve diameter Exhaust valve diameter Intake valve cold clearance Exhaust valve cold clearance Crankshaft bearings Piston Lubrication Motor oil Primary drive Gearbox : 1st 2nd 3rd 4th 5th 6th Final drive Clutch Start-up/battery
Electronic injection

Single cylinder 4 stroke liquid cooled

449.4 cc

478.222 cc

95X63.9 mm

98X63.4 mm

12.30 : 1

11.60 : 1

gasoline with an octane rating of at least 95

4-valve, double overhead camshaft, chain drive

38mm

30.5

0.15-0.2mm

0.2-0.25mm

2 roller bearings

forged aluminum

Full pressure lubrification with 2 trochoid pumps

1 liter SAE 5w40 (Motul® 300V 4T OffRoad)

25 : 68

6 speed 13 : 32 16 : 29 19 : 27 21 : 24 23 : 22 25 : 21

14 X 50
multi disc clutch in oil bath, hydraulically operated
Electric 12V 4Ah / BATTERY LITHIUM BSLI-02 12.8V 2Ah Synerject

7

TECHNICAL SPECIFICATIONS

Chassis
Frame Fork
Rear suspension Travel front/rear Front brake Rear brake Disc brakes Front tire Rear tire Pressure off-road front/rear Fuel tank capacity Steering angle Wheelbase

Semi-perimeter Cr Mo steel with aluminum subframe KAYABA USD closed cartridge Ø 48mm (Factory) KAYABA USD open cartridge Ø 48mm (Rracing)
KAYABA suspension with separate cylinder 330/330 mm
Disc Ø 260mm (Factory/Racing) Disc Ø 220mm (Factory/Racing) Wear limit : 2.7mm front and 3.6mm rear
90/90-21” 140/80-18”
0.9 bar 9.7l with 1 liter of reserve
27.3° 1490mm

8

450500 SEF

FACTORY SETTINGS

Fork

Original settings ­ Fork KAYABA USD Ø48 mm (FACTORY)

Compression Rebound Spring stiffness Type of oil/ Quantity of oil

Comfort Standard
Sport Comfort Standard
Sport Rider weight : 65-75 kg Rider weight : 75-85 kg Rider weight : 85-95 kg
01M

20 clicks back 12 clicks back 8 clicks back 18 clicks back 12 clicks back 10 clicks back
4.2N/mm 4.4N/mm (original)
4.6N/mm 345cc

Original settings ­ Fork KAYABA USD Ø48 mm (RACING)

Compression Rebound Spring Fork oil

Comfort Standard Sport Comfort Standard Sport Rider weight : 65-75 kg Rider weight : 75-85 kg Rider weight : 85-95
01M

18 clicks back 14 clicks back 12 clicks back 15 clicks back 12 clicks back 10 clicks back
4.2N/mm 4.2N/m 4.6N/m 670 CC

9

FACTORY SETTINGS

Shock absorber

Racing Settings ­KAYABA shock absorber

Low-speed compression High-speed compression Rebound Spring stiffness

Comfort Standard
Sport Comfort Standard
Sport Comfort Standard
Sport Rider weight : 65-75 kg

Rider weight : 75-85 kg Rider weight : 85-95 kg

Type of oil

20 clicks back 14 clicks back 12 clicks back 2.5 turns back 1.5 turns back
1 turn back 15 clicks back 13 clicks back 11 clicks back
48N/mm
50N/mm (original 57N/mm
K2c

10

450500 SEF

OPERATIONS REQUIRING THE REMOVAL, OR NOT, OF THE ENGINE

Crankshaft (including crankshaft repair kit) Complete transmission Crankshaft bearing Gearbox bearing Piston Cylinder Cylinder head Distribution Ignition Starter gears Freewheel Complete clutch Water pump Oil pump Gear selector set

Operation requiring the removal of the engine
·
· · · · · ·

Operation not requiring the removal of the engine
· · · · · · · ·

10

450/500 SEF

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. · Empty (see the User Manual)
– The engine oil – The coolant. · Place the motorcycle on a stool. · Remove the saddle. · Disconnect the battery (see usermanual). · Remove the tank along with its vents (refer to the user manual). · Disconnect the entire harness connected to the engine (starter case, TPS, water temperature sensor, pencil coil and injector). · Remove the springs of the exhaust pipe in order to remove it. · Remove the pencil coil. · 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 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 engineaxes. · 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
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. · Set the frame guards and secure them with clamps. · Put the right and left cylinder head supports. Put red thread lock and tighten to 25 Nm. · Fit the left radiator and tighten to 10 Nm. · Place the cooling hoses · Make sure the engine is clean and place back the 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 and secure it to the cylinder with its two springs. · Reconnect the entire harness connected to the engine (starter case, TPS, water temperature sensor, pencil coil and injector). · Reinstall the tank along with its vents (refer to the user manual). · Reconnect the battery (refer to the user manual).
WARNING
Before reconnecting, check that the ignition key/ the is in the «OFF» position.
· Place back the saddle. · Fill coolant and engine oil (refer to the user manual).

12

450/500 SEF

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.
Removing the cylinder head cover
· Remove the spark plug with the special spark plug tool 5773.
· Unscrew the3screws(1)andremovethecylinderhead cover.
WARNING
The screws have an o-ring. · Remove the cylinder head covergasket.
Set the engine at top dead center
· Removetheignitioncoverplug(1). · Removethetimingcontrol plug(2). · Rotate the motor counterclockwise in order to align
the center of the hole of the crankshaft with that of the crankshaft timing control, set the top dead center timing tool on (2) (Ref. 10338).
13

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
· Unscrew the screw (1) and remove the spring. · Unscrew the two screws(2). · Remove the tensioner along with its gasket.

Removing the drive chain
· Remove the cap (1) and then the shaft (2). · Hold the pinion (3) and disengage the chain. · Remove the pinion (3). · Remove the timing tool from the top dead
center position 10338.

14

450/500 SEF

REMOVING THE ENGINE
Removing the cylinder head
· Unscrew the cylinder head bolts following the order indicated in the picture.
· Remove the cylinder head by pulling it vertically. · Remove the cylinder 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 pin and remove the piston pin (2).
· Remove the piston.
Removing the ignition cover
· Remove the 4 screws (1) and remove the ignition cover.
· Remove the ignition cover gasket with caution.
15

REMOVING THE ENGINE
Changing the stator and the engine speedsensor
· 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 N.
Removing the rotor
· Use the rotor maintenance tool 4753. · Unblock the central nut. · Extract the flywheel with the flywheel extractor
R462.
Removing the drivechain
· Unscrew the drive chain guide plates (1) and (2). · Remove the drive chain.
Removing the electric starter
· Unscrew the two screws (1) and pull horizontally to the left.
Remove the oil filter, if not done yet.

16

450/500 SEF

REMOVING THE ENGINE
Removing the clutch
· Remove the clutch housing cover by unscrewing the 4 screws. Beware of the Oring located on the rim of the cover.
· Set the TDC 10338 tool.
WARNING
Do not use this tool for tightening or loosening with a torque value higher than 10 Nm. · Remove the 6 screws 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 the O-ring located on the rim.
Removing the clutch housing
· Dismount the 8 screws of the clutch housing.
WARNING
You need to identify the screws, 6 are 25 mm long, 2 are 30mm long (screw (1)). · Remove the clutch housing and remove the seal carefully.
17

REMOVING THE ENGINE
Removing the water pump oil seal and the bearing
· Remove the water pump turbine with a 10 socket by unscrewing it while holding the drive pinion.
· Remove the water pump shaft. Both oil seals have been madeaccessible.
WARNING
The 2 seals are not identical nor interchangeable
· Disconnect the shaft from the water pump drive pinion. · Remove the water pump bearing.
Removing the clutch bellhousing
· Remove the finger follower from the clutch hub
· Flatten the safety tab. · Block the clutch hub using the 5749 and
unscrew the nut. · Remove the hub, the notched washer and
the bellhousing. · Remove the drive pinion of the oil pump if it
does has not remained stuck to the bellhousing. · Check the needle bearings and change them if necessary · Visually check 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).

18

450/500 SEF

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). · Unscrew the nut and remove the freewheel
bellhousing (4) with a 2-arm puller.
WARNING
Do not damage the end of the crankshaft: oil passage, pin lubrication and lip sealing. · Remove the freewheel sprocket.
Removing the oil pump
· Remove the oil pump intermediate pinion. · Remove the 3 screws (1).
Changing the oil pump
· Remove the securing clip in pin end condition and remove it.
WARNING
The pump to the left of the wall is 8mm thick and the one to the right is 12mm thick.
Removing the index shim
· Keep the selection locking latch blocked (1) · Pull on the scorpion and remove the selector
shaft. · Unblock the index shim and the locking latch
with an Allen key (2).
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 needle that may fall · Turn the housing over and remove the 14 screws of the central crankcase: (1) length 45 mm x 10; (2) length 55 mm x 1; (3) length 75 x 3. · Separate the central crankcases.
Removing the gearbox
· Remove the two fork spindles (1). · Remove the selection drum.
BEWARE
Of the small fork sockets. · Remove the forks C, L and R. · Remove the two gearbox shafts.
Removing the crankshaft
· Remove the balancer shaft. · Remove the crankshaft.

20

450/500 SEF

CHECKING INDIVIDUAL PARTS
Controlling the central crankcases
· Check the general condition of the central crankcases 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.
Left crankcase
· The crankshaft bearings (1), primary shaft (2) and secondary shaft (3) of the gearbox are held by some screws and/or plates. · Balancer shaft bearing (4). · Check the bearings, replace them if necessary. · Remove the bearings. · Check that their housing is clean and install the new bearings, hot crankcase 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 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 (4) are secured by screws and/or plates. · Balancer shaft bearing (5). · Check the bearings, replace them if necessary. · Remove the bearings. · Check that their housing is clean and reinstall the new bearings, hot crankcase at about 70 °C. · Apply blue thread lock on the bearings of the retaining screws and tighten them to 5 Nm. · Check that the oil nozzle (6) and (7) (external side) is not clogged.
21

CHECKING INDIVIDUAL PARTS
Checking the freewheel sprocket bearing
· 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. · Check the visual aspect of the freewheel, its clearance with your hand, as well as its capacity to freely rotate. · Replace it if necessary; 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
· Change the corresponding bearings (outer rings) on the central crankcases. · Pull out the distribution drive pinions with a 2-arm puller. · Retrieve the inner rings of the crankshaft bearings by heating the R464 tool and the ring.
WARNING
The radial clearance of the bearings must be practically zero.
· To remove the drive pinion of the balancer shaft, tighten 2 screws 8×125 in the holes provided for this purpose.

22

450/500 SEF

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. Radial clearance of the connecting rod :
Standard : 0.008 mm ­ 0.012 mm Tolerated limit :0.05mm
If the radial clearance exceeds the limit, the crankshaft must bereplaced.
Lateral clearance of the connecting rod :
· Measure lateral clearance of the connecting rod [A].
Lateralclearanceoftheconnectingrod : Standard : 0.6 mm – 0.85mm Tolerated limit : 1.1 mm
If the radial clearance exceeds the tolerated limit, replace the crankshaft.
Checking the runout :
· Place the crankshaft on alignment devices or Vblocks, and place a gauge as shown in the image.
· Then slowly turn the crankshaft. The maximum difference between the measurements corresponds with the offset of the crankshaft.
Runout : Standard : 0.02 mm maxi Tolerated limit : 0.08 mm
If the offset is not correct, replace the crankshaft and align it so to be within tolerated limits.
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, damage, change the affected pinions. · Check the condition of the gearshift forks. · Change the forks if necessary. · 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:

Ref. 7835 e : 2.8mm min : 2.55mm déf : 0.3mm

Ref. 6818 e : 1.2mm min : 1.1mm déf : 0.3mm
e : standard thickness min : thickness limit déf : distortion limit
Checking the clutch springs :
Measure the free length of the springs. Standard : 50.0mm Limit : 49.0mm

Ref. 5444 e : 1.5mm min : 1.4mm déf : 0.3mm

Ref. 6819
e : 2.0mm min : 1.9mm déf : 0.3mm

24

450/500 SEF

CHECKING INDIVIDUAL PARTS
Checking the top-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. · 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
Standard 450 SEF : Cylinder diameter (A) = 94.99±0.012 mm Cylinder diameter (B) = 94.982~94.995 mm Conicity limit 0.05 mm Ovalization 0.05 mm
Standard 500 SEF : Cylinder diameter (A) = 97.990±00.8mm Cylinder diameter (B) = 97.99~98.005 mm Conicity limit 0.05 mm Ovalization 0.05 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 0.034­0.056mm 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 pistonpin. If the outside diameter of a piston is below the limit, replace it Piston 450 SEF= 94.93 – 94.95 Piston 500 SEF= 97.93-97.95

Ring/ring groove clearance :

· Check the base of the ring in order to verify

that the grooves do not show uneven wear.

· Once the rings are properly set in their

grooves, perform several measurements with a

thickness gauge to determine the ring/ring

groove clearance.

Top ring :

0.020-0.065 mm

Limit 0.13 mm

Oil scraper ring : 0.020-0.055 mm

Limit 0.13 mm

End gap :
Top ring : 0.2-0.3 mm Limit 0.5 mm

Inspection 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, replace the piston.
· Measure the diameter of the piston pin by means of a micrometer. If wherever along the line, the diameter of the piston pin happens to be inferior to the limit, replace the shaft.
· Measure the diameter of the two piston pinholes in the piston and the inner diameter of the connecting rod bushing. If one of the diameters of the holes measured on the piston is incorrect, change the piston.
If the diameter of the connecting rod bushing is incorrect, replace the connecting rod. Diameter of the piston pin : 18.995-19.000 mm Diameter of the piston pin hole : 19.004-19.009 mm Inner diameter of the connecting rod bushing : 20.007-20.013 mm

26

450/500 SEF

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:
· Measure all clearances between the camshaft trunnion and the camshaft bearings by means of a plastic gauge [A]. Tighten the camshaft housing screws after coating their 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 diameter of the camshaft pin is below the limit, replace the camshaft and measure the clearance again.
Diameter of the standard camshaft trunnion Standard : 23.980 ­ 23.993 mm Limit :23.960mm If the clearance remains outside the service limit, replace the cylinder head.
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
Checking the distribution
· Clean all parts.
· Visually inspect the drive chain : check for any hard spot, resistance, or wear. If any, it must be changed.
· Visually inspect the distribution drive pinion. Change if necessary.
· Visually inspect distributions guide plates : change them if necessary.
· Visually inspect the pinion (1) ; replace if necessary.
· Check that the needle bearings fit tight when the pinion (1) is mounted on its axis.

28

450/500 SEF

ENGINE ASSEMBLY
Installing the central crankcases
WARNING
During the installation process, replace all gaskets (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. · Put a roller on each fork. · Put the shift forks in the their respective sliding
grooves. · Insert the selection drum. · Insert the forks in their respective drum
grooves. · Place the fork spindles.
WARNING
Do not forget to oil the parts in friction or in rotation.
· Set up the two guide pins (A) and the washer (1) on the secondary shaft.
· Place the right crankcase on the preassembled parts.
· Put the 13 central crankcase screws and tighten. 10 screws (B) length 45 mm; 1 screw (C) length 55 mm; 3 screws (C) length (D) length 75 mm.
Tightening torque of the central crankcase screws : 10 Nm.
29

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. · Mount the star and apply blue thread lock on the drum screw and tighten it. Specified torque of the drum screw: 10 Nm.
· Place back the shaft selector taking good care to slide the spring back to its slot. · Fit the oil pump previously assembled and tighten the 3 retaining screws after applying medium thread lock. Tightening torque of the oil pump housing screws: 10 Nm. · Place the needle, the water pump drive pinion and its securing clip. · Set the freewheel pinion and its needle bearing. · Set up the freewheel and the assembled freewheel bellhousing (5) while properly indexing the crankshaft and its woodruff key. · Remove all grease with a solvent from the primary shaft 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 the torque limiter (2). · Place the securing clip (1) and the limiter shaft washer. · Set the two needle bearings on the primary shaft. · Place the pinion on the primary shaft and the clutch bellhousing. Be careful to align the notches on the pinion with the bellhousing.

30

450/500 SEF

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.
Installing the clutch housing
· Heat the housing to approximately 70 °C. · Place the water pump on top of the clutch housing. · Check the condition of the oil pan gasket and set it back. · Reassemble the clutch housing and the 8 screws outside the water pump housing. Tightening torque of the clutch housing: 10 Nm.
WARNING
Make sure that the lubrication raceway of the crankshaft in the crankcase is clean. Replace the crankshaft lip seal.
Installing the water pump housing
· Place the screws (1) of the water pump housing. Be careful to correctly position the O-ring located on the rim.
31

ENGINE ASSEMBLY
Installing the clutch
· Put the 8 friction discs and the 7 metal discs, starting with afriction disc. · Install the finger follower and do not forget to install the stop and the washer. · Put the pressure plate and the 6 screws following the order shown in the picture. · Place the TDC 10338 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 length. Beware of the O-ring located on the rim of the lid. · Remove the TDC 10338 tool.
Tightening torque of the plate screws : 10 Nm.
Installing the electric starter
· Lubricate the starter O-ring. · Fit the electric starter and tighten the 2 screws.
Tightening torque of the starter : 10 Nm.

32

450/500 SEF

ENGINE ASSEMBLY
Setting the piston rings
· Place the first rail. Pay attention to the position 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.
· 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 upper groove. The opening should be on the exhaust side. Make sure that the ring is oriented upwards.
Installing the piston
· Set the piston and piston rings. · Lubricate the piston pin and place it. · Set the piston pin-securing clip.
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 10338 tool.
Installing the cylinder head
· Set the guide pins and the cylinder head gasket. · Set the washers and nuts. · Screw the cylinder head in the order shown in the picture.
Pass 1 Tightening torque of nuts 1/2/3/4 : 30 Nm.
Pass 2 Tightening torque of nuts 1/2/3/4: 50Nm. Tighteningtorqueof screws 5/6:10Nm.

34

450/500 SEF

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.

· Do not forget the two-needle housing of the pinion.
· Place back the axis (2) and then the cap (1) with its O-ring. Tightening torque of the cap (1) : 20 Nm.

· Apply blue thread lock on the two screws (1). Tightening torque of the plate screws (1) : 10 Nm.

· Put in the drive chain.

2 1

Tensioner tightening torque : 10 Nm.

Installing the rotor
· Place the rotor. · Use the 4753 rotor holding tool. · Put medium Loctite and tighten the central nut. Tightening torque of the oil cap : 80 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 camshaftbearing cap following the order shown in the picture. Specified torque of the shaft bearing screws: 12 Nm. · Remove the TDC 10338 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 engine is cold. · With a shim set, measure the clearance between the bucket and the camshaft.

Valve clearance

Intake

0.15 ­ 0.20 mm

Exhaust

0.20 ­ 0.25 mm

· If clearances are not correct, change the pads after removing the distribution.
· Remove the cups.
· Measure the pad, replace it in order to obtain the needed clearance. For existing pad thickness models refer to the spare parts catalog.

36

450/500 SEF

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 ofthe 3 screws. Tightening torque for screws 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
· Set the guide pins. · Fit the ignition cover gasket. · Apply silicone dough on the wire guide. · Put the 4 screws of the clutch housing. Torque setting : 10 Nm. · On the secondary shaft, put the O-ring, the spacer, the pinion and the washer. · Apply red thread lock on the nut Tighten to 100 Nm.
37

TIGHTENING TORQUE CHART

FRAME TORQUES

Screw emergency stop button

M3

Spoke nut

M4

Battery screw

M4

Injection body cover screw

M4

Master cylinder cover screw

M4

T map sensor screw

M4

Odometer screw

M4

Rear light screws

M4

Frame protection screw

M4

Other frame screw

M5

Air filter support nut

M5

Lever return plate

M5

Actuator screw slows down

M5

Filter flap screw

M5

TPS sensor screw

M5

Gas control screw

M5

Light switch screw

M5

Brake pedal end screw

M5

Fork air bleed screw

M5

Regulator screw

M5

Brake hose support screw

M5

Injector support screw

M5

Hand guard support screw

M5

Expansion tank screw

M5

Other frame screw

M6

Starter cable nut

M6

Battery screw

M6

Screw Db killer

M6

Odometer support screw

M6

Front mudguard screw

M6

Chain guide screw

M6

Skid plate bottom screw

M6

Rear master cylinder screw

M6

Clutch master cylinder screw

M6

Front brake master cylinder screw

M6

Radiator side panel screw ( Tank)

M6

Chain slider screw

M6

Chain guard screw

M6

Fork protection screw

M6

Chain sprocket protection screw

M6

Brake pedal stop adjustment screw

M6

Brake pedal adjustment screw

M6

Starter relay terminal screw

M6

Selector screw

M6

Screw Flap holder

M6

3Nm 5Nm 7Nm 3Nm 7Nm 5Nm 5Nm Blue 1Nm Blue 2Nm 7nm 10Nm 7Nm Blue 8Nm 7Nm Blue 8Nm 10Nm 7Nm 7Nm Blue 3Nm 8Nm Blue 7Nm Blue 8Nm Blue 10Nm 10Nm Blue 10Nm 7Nm 10Nm 10Nm 10Nm Blue 12Nm Blue 12Nm Blue 8Nm Blue 8Nm 10Nm 10Nm 3Nm 8nm Blue
8Nm Blue 12Nm Blue 8Nm 8Nm 6Nm 12Nm Blue 12Nm Blue

38

450S/500EF

TIGHTENING TORQUE CHART

FRAME TORQUES

TPS sensor screw

M5

Gas control screw

M5

Light switch screw

M5

Brake pedal end screw

M5

Fork air bleed screw

M5

Regulator screw

M5

Brake hose support screw

M5

Injector support screw

M5

Hand guard support screw

M5

Expansion tank screw

M5

Other frame screw

M6

Starter cable nut

M6

Battery screw

M6

Screw Db killer

M6

Odometer support screw

M6

Front mudguard screw

M6

Chain guide screw

M6

Skid plate bottom screw

M6

Rear master cylinder screw

M6

Clutch master cylinder screw

M6

Front brake master cylinder screw

M6

Radiator side panel screw ( Tank)

M6

Chain slider screw

M6

Chain guard screw

M6

Fork protection screw

M6

Chain sprocket protection screw

M6

Brake pedal stop adjustment screw

M6

Brake pedal adjustment screw

M6

Starter relay terminal screw

M6

Selector screw

M6

Screw Flap holder

M6

Seat lock screw

M6

Other frame screw

M8

Valve nut

M8

Gripster nut

M8

Top nut rear sub frame

M8

Chain tensioner nut

M8

Handlebar flange screw

M8

Sprocket screw

M8

Steering stop screw

M8

Brake disc screw

M8

Front brake calliper screw

M8

Frame chain guide screw

M8

Bottom screw rear sub frame

M8

8Nm 10Nm 7Nm 7Nm 3Nm 8Nm 7Nm 8Nm 10Nm 10Nm 10Nm 7Nm 10Nm 10Nm 10Nm 12Nm 12Nm 8Nm 8Nm 10Nm 10Nm 3Nm 8nm

Blue Blue Blue Blue Blue
Blue Blue Blue Blue
Blue

8Nm 12Nm 8Nm 8Nm 6Nm 12Nm 12Nm 10Nm 25Nm 8Nm 12Nm 25Nm 25Nm 20Nm 30Nm 25Nm 35Nm 25Nm 25Nm 25Nm

Blue Blue
Blue Blue Blue
Cooper grease Blue Red Cooper grease Blue Blue

39

FRAME TORQUES

Fork leg screws

M8

Steering column clamp screw

M8

Front calliper bleed screw

M8

Roller chain screw

M8

Cylinder head support screw

M8

Lower triple clamp screw

M8

Upper triple clamp screw

M8

Engine axle

M10

Shock absorber foot axle

M10

Shock absorber upper axle

M10

Supporting nut

M10

Brake hose banjo screw

M10

Brake pedal screw

M10

Handlebar clamp screw

M10

Delta link axle

M12

H link axle

M12

Frame link H axle

M12

Screw Lambda sensor

M12

Swing arm axle

M16

Front wheel axle nut

M20

Screw nut steering column

M20

Rear wheel nut

M24

Hose guide screw

Parker

Headlight switch screw (Racing)

Parker

Hand protector screws

Parker

Flap support screw

Parker

Fan screw

Auto-perforate

Clamp

20Nm 25Nm 10Nm 25Nm 30Nm 12Nm 17Nm 60Nm 50Nm 50Nm 25Nm 25Nm 25Nm 40Nm 50Nm 50nm 50Nm 30Nm 100Nm 50Nm 30Nm 100Nm 2Nm 2nm 3Nm 3Nm 3nm 7Nm

Cooper grease Cooper grease Blue Blue Cooper grease Cooper grease
Red
Cooper grease Grease

40

450S/500EF

ENGINE TORQUES

Engine speed sensor screw

M5

Stator screws

M5

Decompressor screw

M5

Bearing lock plate screw

M5

Oil collecting screw

M5

Water pump impeller nut

M6

Limiter shaft screw

M6

Starter pinion shaft screw

M6

Oil pump intermediate pinion shaft screw

M6

Cylinder head cover screw

M6

Clutch slave cylinder screw

M6

Ignition casing screw

M6

Clutch housing screw

M6

Crankcase screws

M6

Water pump cover screw

M6

Electric starter screw

M6

Camshaft guide plate screws

M6

Locking finger screw selection

M6

Oil pump cover screws

M6

Selector star screw

M6

External cylinder head screw

M6

Timing tensioner shutter screw

M6

Distribution guide pad screw

M6

Timing tensioner pad screw

M6

Clutch spring screw

M6

Timing tensioner screw

M6

Coolant drain screw

M6

Exhaust pipe nut

M8

Exhaust pipe stud

M8

Selection shaft stop screw

M8

Camshaft bearing screw

M8

Top dead centre manhole cap

M10

Spark plugs

M10

Cylinder head nut

M10

Cylinder stud

M10

Ignition nut

M12

Water temperature sensor

M12

Oil pressure regulator

M16

Magnetic drain plug

M16

Crankshaft compartment strainer

M18

Clutch housing nut

M20

Primary gear/crankshaft nut

M20

7Nm Red 7Nm Red 8Nm Blue 8Nm Blue 7Nm Blue 10Nm Blue 12Nm Red 12Nm Red 10Nm Grease 10Nm Grease 10Nm Grease 10Nm Grease 10Nm Grease 10Nm Grease 10Nm Grease 10Nm Grease 10Nm Blue 10Nm Blue 10Nm Blue 10Nm Blue 10Nm Blue 7Nm 12Nm Red 12Nm Red 10Nm 10Nm Grease 7Nm Grease 25Nm 25Nm 15Nm Red 12Nm Grease 10Nm Grease 15Nm Cooper grease 1er passe
Grease 15Nm 2eme passe 30Nm 3eme passe 50 Nm 25Nm Blue 80Nm Blue 20Nm Yellow 20Nm Grease 25Nm Grease 25Nm Grease 100Nm Blue 120Nm Blue

41

Gearbox output sprocket nut Water connection Oil filter cover screw Valve shaft plug Ignition housing plug Oil suction strainer

ENGINE TORQUES M20 M20 M24 M27 M27 M32

100nm 15Nm 15Nm 15Nm 15Nm 25Nm

Yellow Grease Grease Grease Grease

42

450S/500EF

CLEANING THE THROTTLEBODY
Equipment
· Carburetor cleaner or Motul 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. · Remove the clamps of the throttle body. · Remove the cover of the spreader. · Remove the throttle cable. · Remove the body.

40

450/500 SEF

CLEANING THE THROTTLEBODY
· Unplug all connectors. · Visually inspect.
· Clean with an universal cleaning solution. · Blow.
41

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.
Installing the throttle 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 attention to the direction ! · Adjust the clearance of the throttle cable.
· Disconnect the computer connector. Visually inspect the connectors. · Clean with carburetor or universal cleaner. · Blow.

· Apply special connector grease. · Reconnect.

42

450/500SEF

ELECTRICAL PART
The TPS of the throttle body monitors the position of the throttle. Its indexing is paramount to the proper functioning of the motorcycle. If you replace it, follow this procedure. · 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 Diagnostics menulogo
· 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. Once done, tighten the screw (1) to 4 Nm +/-0.7.
43

ELECTRICAL PART
Electrical components
3 2
1

14 13

12

11

10

9

4
5 6
7 8

Position 1 2 3 4 5 6 7

Designation Fan CDI
Fuel pump Regulator Battery Map sensor TPS sensor

Position 8 9 10 11 12 13 14

Designation Stepper Motor
Injector Starter Alternator Hall sensor T° sensor Ignition coil

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450/500SEF

ELECTRICAL PART
1- Fan control
· Disconnect the fan wiring harness. · Connect a 12V battery directly to the
fan has shown on the diagram. · Make sure the fan turns correctly
without any hard point or unnatural noise.
2- CDI
3- Fuel pump control
· Disconnect the fuel pump hose an connect the pressure measuring tool ref: 8691.
· Pressurize the pump by operating the starter
· A constant pressure of 3 bars must be measured. Fuel pump supply control
· Connect a multimeter between the positive terminal of the pump (green wire) and the negative terminal of the pump (blue wire). Supply voltage 12V
45

ELECTRICAL PART
4- Voltage regulator control
· Voltage regulator : On regulator output (White wire) A 3500 Tr/min : 14.4V +/- 0.5V
· Diode bridge check : Connect a multimeter between the positive (white wire) and each of the phase (yellow wire). Resistance should be noted in a sense of measurement
5- Battery control
· Connect a multimeter to the + and the ­ terminals of the battery and check its voltage
Battery and check its voltage. Value readings: 12.8V Charged battery 12.7V or under Charge battery Under de 12V Replace battery

46

450/500SEF

ELECTRICAL PART
6-Map sensor control
· Check the output voltage of the sensor.
· Connect the multimeter to the sensor (harness side) between terminal N°3 (positive) and terminal N°4 (negative).
Then, between terminal N°1 (positive) and terminal N°4 (negative). Sensor output voltage : Between 3 and 5 V

7-TPS sensor control

TPS

CDI

· Measurement of the output voltage of the TPS sensor.

· Connect a multimeter to the output teminals of the TPS sensor (Positive [B] ­ negative [A] ) by keeping it in the fully closed position:

TPS sensor output voltage : 0.4V ­ 0.6V

· TPS sensor input voltage measurement.
Connect a multimeter to the input terminals of the TPS sensor (Positive [C] ­ negative [A]).

TPS sensor input voltage : 5V

· Measurement of the resistance TPS sensor:

· Remove the injection body and measure the resistance directly across the sensor.
· Butterfly closed : · Between + (rouge) et ­ (noir): 5 +/- 20% · Between signal (bleu) et ­ (noir): 1.25 à 1.55 · Between signal (bleu) et + (rouge): 5.3 +/- 20%
·
· Butterflu opened : · Between + (rouge) et ­ (noir) : 5 +/- 20% · Between signal (bleu) et ­ (noir) : 4.6 +/- 20% · Between signal (bleu) et + (rouge) : 2.05 +/- 20%

47

ELECTRICAL PART
8- Stepper motor control
· Checking the stepper motor coils. · Connect the multimeter to the sensor
(harness side) between terminal N°A and terminal N°D. Then, between the terminal N°B and terminal N°C. There must be continuity between the terminals ; if not, replace the motor.
9- Injector control
· Measure the input voltage of the injector.
· Connect a multimeter between the green supply wire and the earth. Injector supply voltage : 12V
10- Starter control
· Remove the starter and position it in a vice
· Connect a battery directly to the starter (positive on the starter terminal, negative on the starter body) as shown on the diagram.
· In the event of abnormal operation, open the starter body to clean the contact between the carbon brushes and the starter track.

48

450/500SEF

ELECTRICAL PART
11- Alternator control
· Checking the resistance of the alternator windings. Connect the multimeter between each phase of the alternator (yellow wire) an measure the resistance. Winding resistance: 0.44 +/- 15%
· Checking the alternator output voltage. Connect the multimeter between each phase of the alternator (yellow wire) and ground (multimeter in alternating position) Measure the output voltage. At idle speed: 22V +/- 2V At 6000 R/min: 77V +/- 3V
12- Hall sensor control (Crankshaft)
· Sensor resistance check. Connect the multimeter between the blue and green wires of the sensor and measure the resistance. Sensor resistance: 120 +/- 10%
· Check the output voltage of the sensor. Connect the multimeter between the blue and the ground, and check the voltage. At 300 R/min: 1.7V minimum At 10000 R/min: 120V maximum
49

ELECTRICAL PART
13- Water sensor control
· Drain the coolant. · Remove the temperature probe.
· Immerse the sensor 1 in a container filled with coolant 2.
· Immerse a thermometer 3 in the liquid
to check its temperature. · Heat the liquid slowly and check the
resistance of the sensor using a multimeter connected as shown in the diagram depending on the temperature of the liquid, referring to the table below.

TEMPS (°C) 25 30
40 50 60 70 80 90 100
14- Ignition coil control
· Checking the resistance of the primary coil.
Connect the multimeter as shown in the diagram and measure the resistance.
Primary winding resistance : Between 0.85 and 1.5
· Checking the resistance of the secondary coil.
Connect the multimeter as shown in the diagram and measure the resistance.
Secondary coil resistance : Between 10 and 14 K

50

450/500SEF

RESISTANCE () 3000 2415
1620 1081 748 528 379 278 206

WIRING HARNESS
Homologated light wire harness (8145)
51

WIRING HARNESS
Racing light wire harness (6845)

52

450/500SEF

WIRING HARNESS
Main wire harness (6781)
53

WIRING HARNESS

Fan wire harness (3577)

44

450/500 SEF

INJECTION DIAGNOSTIC TOOL SYNERJECT
1- Presentation of the SYNERJECT injection system
1.1- Your Sherco 450/500 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

3

5

4

2

N°

Description

1 Synerject M3C Calculator

2 Engine speed sensor (pick-up)

3 Synerject Ø42 mm throttle body

4 Water temperature sensor

Location Left side of the frame Upper part of the ignition cover
At the back of the cylinder head, on the right side

2-way sealed diagnostic connector (labeled At the rear side panel
5
“ECU”)

45

INJECTION DIAGNOSTIC TOOL SYNERJECT

SynerjectM3C Calculator

Synerject Ø42mm Throttle Body

N°

Description

1

Stepper motor (idle control and engine brake)

2

Injector

3

Temperature / pressure sensor (TMAP)

4

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.).
1.3- Composition of the diagnostic tool
The case consists of a cable with a USB connector to MUX, a MUX device, a MUX cable to the motorcycle diagnostic connector, an installation CD, and a user manual.

46

450/500 SEF

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 [email protected].
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.
47

INJECTION DIAGNOSTIC TOOL SYNERJECT
· Click on « Next ».
· Click on « Install ».
· Installation in progress.

48

450/500 SEF

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 ».
· Installation in progress.
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 » unit is properly powered by checking the LED : · Solid blue: PC connection properly established. · Flashing blue: communication with PC in progress. · Blue off: no connection to the PC, or device in standby; it can also indicate a problem with the USB connector. · Solid green: firmware issue. · Flashing green (slow): firmware correctly run. · Flashing green (fast): communication with PC in progress. · Green off: no firmware. · Solid red: correct power supply to the card. · All LEDs OFF: the outlet is not powered on, or is off or USB in on standby mode.

50

450/500 SEF

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 1

2. Take the shunt (3) (reference 6267) and connect the plug (1) into it. 3

3. You can now do the diagnostic by following the next explanations.
51

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.. Run the software using the icon
The following menu will come up :

Update and
update, proxy parameters)

Diagnostics menu (diagnostic, map updates,etc.)

Setup menu (language selection, units,
etc.)

52

450/500 SEF

INJECTION DIAGNOSTIC TOOL SYNERJECT
2.2- Software settings : configuration menu

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

· Click

to return to the home screen.

· Click

to save the changes.

53

INJECTION DIAGNOSTIC TOOL SYNERJECT
2.3- Update menu and synchronization

A- In this menu, you can update the diagnostic software tool :
· To determine whether an update is available, check that you have an Internet connection, and then click on the following icon
· If an update is available, the following window will come up:
· If no update is available, the following message will come up :

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450/500 SEF

INJECTION DIAGNOSTIC TOOL SYNERJECT

· Click on update.

to start downloading the

· The following message will come up :

· Click on

to start installation.

· Resume the installation process -> page 46. It is not necessary to restart the installation of the drivers.

55

INJECTION DIAGNOSTIC TOOL SYNERJECT
B- Configuration of Internet access parameters
It may be necessary to set up a proxy server to access the Internet. · Click on · Fill in the following settings if necessary.

· Click on

to save your changes.

3- Using the software
Diagnostic menu and injection mapping update General : · Click on « Sherco ».

· Clic on « M3C ».

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450/500 SEF

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).
57

INJECTION DIAGNOSTIC TOOL SYNERJECT
A- Engine information:
· The main values of the system appear :

Details :
· Stepper Position : valeur d’ouverture de la valve d’air (stepper)-> 35 < 50 < 75. Too weak value : for example , valve leak/engine air intake. Too high value : dirty injection body.
Information : correct value of the air valve: motor at 80 °C after being operated for 15 m and idle for 2 m.
· Throttle 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 ignition. Wait until the relay slap calculator makes a clacking sound. Switch the motorcycle back on). The step equals 0.5%.
· 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 injectiondeceleration).

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450/500 SEF

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. · 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.
3.3- Error codes :
When you click on « Read the error codes », the system starts checking.
· If no error appears, exit the menu via the icon
59

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

60

450/500 SEF

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).
3.4- Clearing error codes :
A ­ If there is errors, go to the « Clearing Error Codes » menu.
· Confirm deletion of error codes via the icon
61

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.

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450/500 SEF

INJECTION DIAGNOSTIC TOOL SYNERJECT
3
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 :
63

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.
C ­ Fuel Pump / Fan / Stepper
For the fuel pump, fan and stepper (air valve), it is a « standard » test, and the notification process of errors or proper operation is conventional.

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450/500 SEF

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.
65

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. In case of any doubt, contact technical support.
1 ­ Download the needed update (file : .mot). ShercoNetwork Information Technical Information Injection map Pay attention to the model year, the cylinder capacity, silencer type, etc.

2 ­ Turn On the motorbike . 3 ­ Click on Update calculator.

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450/500 SEF

INJECTION DIAGNOSTIC TOOL SYNERJECT
Confirm with the icon Select the calibration file (.mot) previously downloaded and click on Open. 4- The file is being updated.
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
5 – Upon completion of the download, the fuel pump starts up and the following message appears: INFORMATION : download successful
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.
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INJECTION DIAGNOSTIC TOOL SYNERJECT
Information:theinformationon serial number and operating hours are not resetduring acalibration update. 7-Put back the “shunt” on the connector in the air filter box to switch back on “keyless” mode. 8-the ECU power latch will proceed during 20 s. 9-wait 30 s until the ECU stop before starting the bike. 10-start the bike, stop it and wait 30 s before to restart the bike. 11-Switch on the bike and verify that the parameters of the motor are normal (idle, steeper opening, ect.)
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.).

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450/500 SEF

www.sherco.com

References

• SHERCO :: An Emotion is Born

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