Sherco 450 SEF Racing Workshop Manual
- June 13, 2024
- Sherco
Table of Contents
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:
- Refer to page 11 of the manual for detailed instructions on removing the engine.
- Follow the steps provided to safely disconnect and remove the engine from the frame.
To install the engine in the frame:
- Refer to page 12 of the manual for detailed instructions on installing the engine.
- Ensure you have prepared the necessary tools and equipment as mentioned on page 12.
- 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:
- Refer to page 13 of the manual for detailed instructions on preparing the engine.
- Remove the cylinder headcover as instructed on page 13.
- 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
44
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 courrier@exxotest.com.
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 :
54
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 ».
56
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).
58
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
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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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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 :
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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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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.
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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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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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www.sherco.com
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>