MANUEL D’ATELIER I WORKSHOP MANUAL I MANUAL DE TALLER

S E f - R
45 0
 FOREWORD..................................................................................................................................................................................................... 4

ENGINE TOOLS LIST 450 SEF-R..................................................................................................................................................................... 5

TECHNICAL SPECIFICATIONS......................................................................................................................................................................... 6
• ENGINE.......................................................................................................................................................................................................................... 6
• CHASSIS........................................................................................................................................................................................................................ 7

FACTORY SETTINGS....................................................................................................................................................................................... 8
• FORK............................................................................................................................................................................................................................. 8
• SHOCK ABSORBER......................................................................................................................................................................................................... 9

OPERATIONS REQUIRING THE REMOVAL, OR NOT, OF THE ENGINE............................................................................................................. 10

REMOVING/INSTALLING THE ENGINE........................................................................................................................................................... 11

• REMOVING THE ENGINE............................................................................................................................................................................................... 11
• INSTALLING THE ENGINE IN THE FRAME ...................................................................................................................................................................... 12

REMOVING THE ENGINE............................................................................................................................................................................... 13

• PREPARATION.............................................................................................................................................................................................................. 13
• REMOVING THE CYLINDER HEAD COVER...................................................................................................................................................................... 13
• POSITIONING THE ENGINE AT TOP DEAD CENTER......................................................................................................................................................... 13
• REMOVING THE CAMSHAFT......................................................................................................................................................................................... 14
• REMOVING THE DISTRIBUTION TENSIONER ................................................................................................................................................................. 14
• REMOVING THE DRIVE CHAIN....................................................................................................................................................................................... 14
• REMOVING THE CYLINDER HEAD.................................................................................................................................................................................. 15
• REMOVING THE CYLINDER........................................................................................................................................................................................... 15
• REMOVING THE PISTON............................................................................................................................................................................................... 15
• REMOVING THE IGNITION COVER.................................................................................................................................................................................. 15
• REPLACING THE STATOR AND THE ENGINE SPEED SENSOR......................................................................................................................................... 16
• REMOVING THE ROTOR................................................................................................................................................................................................ 16
• REMOVING THE DRIVE CHAIN....................................................................................................................................................................................... 16
• REMOVING THE ELECTRIC STARTER............................................................................................................................................................................. 16
• REMOVING THE CLUTCH.............................................................................................................................................................................................. 17
• REMOVING THE WATER PUMP HOUSING....................................................................................................................................................................... 17
• REMOVING THE CLUTCH HOUSING............................................................................................................................................................................... 17
• REMOVINGTHE WATER PUMP OILSEAL AND THE BEARING SEAL................................................................................................................................... 18
• REMOVING THE CLUTCH BELLHOUSING....................................................................................................................................................................... 18
• REMOVNG THE FREEWHEEL SPROCKET....................................................................................................................................................................... 19
• REMOVING THE OIL PUMP............................................................................................................................................................................................ 19
• CHANGING THE OIL PUMP............................................................................................................................................................................................ 19
• REMOVING THE INDEX SHIM........................................................................................................................................................................................ 19
• SEPARATING THE CENTRAL CRANKCASES .................................................................................................................................................................. 20
• REMOVING THEGEARBOX............................................................................................................................................................................................. 20
• REMOVING THE CRANKSHAFT...................................................................................................................................................................................... 20

2 450 SEF-R
 SUMMARY

CHECKING INDIVIDUAL PARTS .................................................................................................................................................................... 21

• CHECKING THE CENTRAL CRANKCASES ...................................................................................................................................................................... 21
• CHECKING THE LEFT CRANKCASE................................................................................................................................................................................ 21
• CHECKING THE RIGHT CRANKCASE.............................................................................................................................................................................. 21
• CHECKING THE FREEWHEEL BEARING.......................................................................................................................................................................... 22

ENGLISH
• CHANGING THE CRANKSHAFT BEARINGS..................................................................................................................................................................... 22
• CHECKING THE CRANKSHAFT...................................................................................................................................................................................... 23
• CHECKING THE GEARBOX............................................................................................................................................................................................. 24
• CHECKING THE CLUTCH............................................................................................................................................................................................... 24
• CHECKING THE TOP ENGINE......................................................................................................................................................................................... 25
• CHECKING THE CYLINDER HEAD.................................................................................................................................................................................. 28
• CHECKING THE DISTRIBUTION..................................................................................................................................................................................... 28

ENGINE ASSEMBLY....................................................................................................................................................................................... 29
• INSTALLING THE CENTRAL CRANKCASES .................................................................................................................................................................... 29
• INSTALLING THE CLUTCH HOUSING.............................................................................................................................................................................. 31
• INSTALLING THE WATER PUMP HOUSING..................................................................................................................................................................... 31
• INSTALLING THE CLUTCH............................................................................................................................................................................................. 32
• INSTALLING THE ELECTRIC STARTER........................................................................................................................................................................... 32
• SETTING THE PISTON RINGS........................................................................................................................................................................................ 33
• INSTALLING THE PISTON.............................................................................................................................................................................................. 33
• INSTALLING THE CYLINDER.......................................................................................................................................................................................... 34
• INSTALLING THE CYLINDER HEAD................................................................................................................................................................................ 34
• INSTALLING THE DRIVE CHAIN..................................................................................................................................................................................... 35
• INSTALLING THE ROTOR.............................................................................................................................................................................................. 35
• INSTALLING THE CAMSHAFT AND SETTING THE VALVE TIMING..................................................................................................................................... 36
• CHECKING VALVE CLEARANCE...................................................................................................................................................................................... 36
• COMPLETING THE ENGINE ASSEMBLY.......................................................................................................................................................................... 37
• INSTALLING THE IGNITION COVER................................................................................................................................................................................ 37

TIGHTENING TORQUE CHART....................................................................................................................................................................... 38

CLEANING THE THROTTLE BODY.................................................................................................................................................................. 40

• EQUIPMENT................................................................................................................................................................................................................. 40
• REMOVING THE THROTTLE BODY................................................................................................................................................................................. 40
• CLEANING THE THROTTLE BODY.................................................................................................................................................................................. 42
• INSTALLING THE THROTTLE BODY............................................................................................................................................................................... 42

CHANGING THE TPS (THROTTLE POSITION SENSOR).................................................................................................................................. 43

INJECTION DIAGNOSTIC TOOL SYNERJECT................................................................................................................................................. 44

• 1- PRESENTATION OF THE SYNERJECT INJECTION SYSTEM......................................................................................................................................... 44
• 2- SOFTWARE OVERVIEW............................................................................................................................................................................................. 50
• 3- USING THE SOFTWARE............................................................................................................................................................................................ 54

CHECKING THE CHARGING CIRCUIT............................................................................................................................................................. 67

WIRING DIAGRAM........................................................................................................................................................................................ 69

3
 FOREWORD

This manual is intended for qualified mechanics working in a properly equipped workshop. Performing
the different operations requires sound knowledge of mechanics and SHERCO tools specific to 450 SEF-R
engines.

4 450 SEF-R
 Tools List for 450 SEF-R Engine
❱❘ 450 SEF-R

ENGLISH FRANÇAIS
Tool reference Description
1819 Top dead center timing screw
5749 Clutch removal tool ADLER
4753 Fret-type ignition unit
1822 Water pump bearing axis tool
1968 Water pump oil seal tool
R455 Engine support
5593 Primary drive locking tool
5774 Piston support
R462 Flywheel puller
R464 Crankshaft ring extractor
R450 Oil seal selector
R472 Applying tool for oil seal selector
5773 Special 450 spark plug wrench
5028 PUSH-IN TOOL WP Ø48
4967 Synerject injection diagnostic tool
5132 Adjustable hook spanner wrench WP Ø48
5029 Joint guide tool WP Ø48
5030 Bottle-type leveling tool WP
5031 Pipe vise clamp WP 48/60
R453 Selector shaft bearing assembly tool
R444 Oil seal selector

5
 Technical Specifications
❱❘ ENGINE
Type Single cylinder 4 stroke liquid cooled
Displacement 449.4 cc
Bore / Stroke 95/63.4 mm

Compression ratio 11.84: 1

Unleaded gasoline with an octane rating of at least 95
Distribution 4-valve, double overhead camshaft, chain drive
Intake valve diameter 38 mm
Exhaust valve diameter 30.5
Intake valve cold clearance 0.15-0.2 mm
Exhaust valve cold clearance 0.2-0.25 mm
Crankshaft bearings 2 roller bearings
Piston forged aluminum
Lubrication full pressure lubrication with 2 trochoid pumps
Motor oil 1 liter SAE 10W40
Primary drive 25 : 75
Gearbox 6 speed
First gear 13 : 32
Second gear 16 : 29
Third gear 19 : 27
Fourth gear 21 : 24
Fifth gear 23 : 22
Sixth gear 25 : 21
Final drive 14 X 49
Clutch multi disc clutch in oil bath, hydraulically operated
Start-up/battery Electric 12V 4Ah
Electronic injection Synerject

6 450 SEF-R
 Technical Specifications
❱❘ Chassis
Frame Semi-perimeter Cr Mo steel with aluminum subframe
Semi-perimeter Cr Mo steel with aluminum subframe
Fork SACHS USD Gold Series Ø 48mm (standard) & WP USD Ø 48mm

ENGLISH
(racing)
Rear suspension WP Suspension with separate cylinder
Travel front/rear 300/300 mm
Front brake Disc Ø 270 mm (standard), Ø 256 mm (racing)
Rear brake Disc Ø 220 mm
Disc brakes Wear limit: 2.7 mm front and 3.6 mm rear
Front tire 90/90-21’’
Rear tire 140/80-18’’
Pressure off-road front/rear 0.9 bar
Fuel tank capacity 8.5 l with 1 l reserve
Steering angle 27.3°
Wheelbase 1480mm
Weight 120 kg

7
 FACTORY SETTINGS
❱❘ FoRK

Original settings - Fork SACHS USD Gold Series Ø48 mm

Compression 12 clicks back

Rebound 12 clicks back
Spring stiffness 4.5 N/mm
Type of oil SAE 5
Quantity of oil per fork leg 600 cm3
Oil level measurement (fork compressed and spring remo- 130mm
ved) from the top of the fork tube

Original settings - Fork WP Suspension USD Ø48mm

Compression Comfort 21 clicks back

Standard 14 clicks back
Sport 9 clicks back
Rebound Comfort 19 clicks back
Standard 14 clicks back
Sport 11 clicks back
Preload Comfort 0 turn
Standard 2 turns
Sport 4 turns
Spring stiffness Rider weight: 65-75 kg 4.2N/mm
Rider weight: 75-85kg 4.4 N/mm (original)
Rider weight: 85-95kg 4.6N/mm
Type of oil SAE 4
Oil level measurement (fork compressed 110mm
and spring removed) from the top of the
fork tube

8 450 SEF-R
 FACTORY SETTINGS
❱❘ Shock absorber

Factory Settings - WP suspension shock absorber

Low-speed compression Comfort 17 clicks back

ENGLISH
Standard 12 clicks back
Sport 9 clicks back
High-speed compression Comfort 2 turns back
Standard 1.5 turns back
Sport 1 turn back
Rebound Comfort 16 clicks back
Standard 14 clicks back
Sport 12 clicks back
Spring stiffness Rider weight: 65-75 kg 51N/mm
Rider weight: 75-85 kg 54N/mm (original)
Rider weight: 85-95 kg 57N/mm

9
 Operations Requiring the removal, or not, of the engine
Operations requiring Operations not requiring
the removal of the engine the removal 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 •

10 450 SEF-R
 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.

ENGLISH
• Empty (see the User Manual)
- The engine oil
- The coolant.
• Place the motorcycle on a stool.
• Remove the saddle.
• Disconnect the battery (see user manual).
• 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 engine axes
• Unscrew the swing arm pivot and pull the swing arm slightly backward.
• Remove the engine axes.
• Remove the engine through the left side by pivoting it.

NOTE :
You should need some help to perform this operation, as the weight is considerable. Make sure you do not
damage the engine mounting brackets on the frame.

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 (SEF 450 standard) or the switch (450 SEF / R racing) is in the «OFF» position.

• Place back the saddle.

• Fill coolant and engine oil (refer to the user manual).

12 450 SEF-R
 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.

ENGLISH
• Remove the output shaft pinion.

❱❘ Removing the cylinder head cover 1

• Remove the spark plug with the special spark plug tool 5773.
• Unscrew the 3 screws (1) and remove the cylinder head
cover.

WARNING
The screws have an O-ring.

• Remove the cylinder head cover gasket.

❱❘ Set the engine at top dead center

• Remove the ignition cover plug (1).
• Remove the timing control plug (2).
1
• 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 2
tool on (2) (Ref. 1819).

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. 4 8 6

2
A

3 7 5 1

❱❘ Removing the distribution tensioner

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

1
2

❱❘ Removing the drive chain

• Remove the shaft (1).
• Hold the pinion (2) and disengage the chain. 2
• Remove the pinion (2). 1
• Remove the timing tool from the top dead cen-
ter position 1819.

14 450 SEF-R
 REMOVING THE ENGINE
❱❘ Removing the cylinder head
6 3
• Unscrew the cylinder head bolts following the
orderindicated in the picture.
• Remove the cylinder head by pulling it vertically.
• Remove the cylinder head gasket with caution.

ENGLISH
4 5

2 1

❱❘ 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.

2
1

❱❘ Removing the ignition cover

• Remove the 4 screws (1) and remove
the ignition cover.
• Remove the ignition cover gasket with caution. 1
1

15
 REMOVING THE ENGINE

❱❘ Changing the stator and the engine 2

speed sensor 2

• Remove the 2 screws from the sensor (2) and

the two screws from the stator (1).
• Set up the new parts. 1 1
• Reinstall the screws with red thread lock
and tighten to 7 Nm,

❱❘ Removing the rotor

• Use the rotor maintenance tool 4753.
• Unblock the central nut.
• Extract the flywheel with the flywheel
extractor R462.

❱❘ Removing the drive chain

• Unscrew the drive chain guide plates (1) and (2).
• Remove the drive chain.

2
1

❱❘ 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 SEF-R
 REMOVING THE ENGINE

❱❘ Removing the clutch

4
• Remove the clutch housing cover by unscrewing
the 4 screws. Beware of the O-ring located on the 2 6
rim of the cover.

ENGLISH
• Set the TDC 1819 tool.
1
5

3
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 1 1
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,
1
6 are 25 mm long, 2 are 30mm long (screw (1)).
• Remove the clutch housing and remove 1

the seal carefully.

17
 REMOVING THE ENGINE
❱❘ D Removing the water pump oil seal
and the bearing
• Remove the water pump turbine with a 10 soc-
ket by unscrewing it while holding the drive pinion.
• Remove the water pump shaft. Both oil seals
have been made accessible.

WARNING
The 2 seals are not identical
nor are they 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
1
• Flatten the safety tab.
• Block the clutch hub using the 5749 and uns-
crew 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).
2

18 450 SEF-R
 REMOVING THE ENGINE
❱❘ Removing the freewheel sprocket

ENGLISH FRANÇAIS
WARNING
See previous paragraph for the unlocking of the 2
balancer shaft nut.
1

• Remove the securing clip (1) and their washers.

• Remove the torque limiter (2).
1 4
• Remove the oil pump intermediate pinion (3).
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.

1

❱❘ Removing the oil pump 1

• Remove the oil pump intermediate pinion.

• Remove the 3 screws (1). 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 8 mm thick and the
one to the right is 12 mm thick.

❱❘ Removing the index shim

• Keep the selection locking latch blocked (1) A B
2
• Pull on the scorpion and remove the selector
shaft.
1
• Unblock the index shim and the locking latch
with an Allen key (2) 2

19
 REMOVING THE ENGINE
❱❘ Separating the central crankcases 1

• Remove the screw (A - p. 19) with an Allen key.

• Remove the water pump drive pinion (B - p.19) 1
by removing the securing clip. Beware of the needle 3 3 1
3
that may fall.
• Turn the housing over and remove the 14 screws
1
of the central crankcase: (1) length 45 mm x 10; (2)
length 55 mm x 1; (3) length 75 x 3. 1
• Separate the central crankcases.
1 2
1

❱❘ Removing the gearbox

• Remove the two fork spindles (1).
• Remove the selection drum.

BEWARE
of the small fork sockets. 1

1
• Remove the forks C, L and R.
• Remove the two gearbox shafts.

❱❘ Removing the crankshaft

• Remove the balancer shaft.
• Remove the crankshaft.

R
C

20 450 SEF-R
 Checking individual parts
❱❘ Controlling the central crankcases
• Check the general condition of the central cran-
kcases for any possible damage or crack.
Change the defective or worn crankcase set if
necessary.
• Check the condition of the bearings. Change

ENGLISH
them if necessary.

❱❘ Left crankcase
5
• The crankshaft bearings (1), primary shaft (2)
6 7
and secondary shaft (3) of the gearbox are held by 7

some screws and/or plates.

• Balancer shaft bearing (4).
2
• Check the bearings, replace them if necessary. 3
4
1
• 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. 6
2
• Balancer shaft bearing (5).
• Check the bearings, replace them if necessary.
5
• Remove the bearings.
3
• Check that their housing is clean and reinstall
the new bearings, hot crankcase at about 70 °C. 1

• Apply blue thread lock on the bearings of the

4
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
bearinge
• Visually check the needle bearing of the
freewheel sprocket. 1
• 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. 2

❱❘ 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 x 125 in the holes provided for
this purpose.

22 450 SEF-R
 Checking individual parts
❱❘ Checking the crankshaft
Radial clearance of the connecting rod: A
• Place the crankshaft on V-blocks and place a
B
dial gauge [A] against the connecting rod.
• Push [B] the connecting rod to the gauge and

ENGLISH
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: 0.05 mm

If the radial clearance exceeds the limit, the cranks-

haft must be replaced.

A
Lateral clearance of the connecting rod:
• Measure lateral clearance of the connecting rod [A].
Lateral clearance of the connecting rod:
Standard: 0.6 mm - 0.85 mm
Tolerated limit: 1.1 mm

If the radial clearance exceeds the tolerated limit,

replace the crankshaft.

Checking the runout:

• Place the crankshaft on alignment devices or V-
blocks, and place a gauge as shown in the image.
• Then slowly turn the crankshaft. The maximum A A
difference between the measurements corresponds
with the offset of the crankshaft.

Runout:
Standard: 0.02 mm maximum
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 earbox
B
• 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. C
• Check the condition of the gearshift forks.
Change the forks if necessary.
• Control the selection drum, check if there are A
distortions, abnormal wear, if damage is found.
Change the drum if necessary.

❱❘ Checking the clutch

Check metal and friction discs.
Standard friction plate thickness: 2.95
Limit: 2.7
Distortion limit: 0.3mm
Standard steel disc thickness : 1.4
Limit: 1.3
Distortion limit: 0.3mm

Checking the clutch springs:

• Measure the free length of the springs.
Standard: 50.0 mm
Limit: 49.0mm

24 450 SEF-R
 Checking individual parts
❱❘ Checking the tophigher engine
Inspection of cylinder wear: A
Measure the inside diameter of the cylinder when
the cylinder is cold. B
• Inspect the inside part of the cylinder for

ENGLISH
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 cylin-
der exceeds the service limit, replace the cylinder.

(A)=8 mm
(B)=30 mm

Standard 450 SEF-R:

Cylinder diameter (A) = 94.99 ± 0.012 mm
diameter cylinder (B) = 94.982 ~ 94.995 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 0.034 – 0.056 mm
Limit 0.11 mm

25
 Checking individual parts
Piston wear:
• With the help of a micrometer, measure the
outside diameter [A] of piston 15 mm [B] above the
bottom of the piston and at a right angle in relation
to the piston pin.
If the outside diameter of a piston is below the limit,
replace it
B
Piston 450 SEF-R = 94.93 - 94.95
Ring/ring groove clearance: A
• 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 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 connec-
ting 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: 19.995-20.000 mm

Diameter of the piston pin hole: 20.004-20.009 mm
Inner diameter of the connecting rod bushing: 20.007-20.013 mm

26 450 SEF-R
 Checking individual parts
Cams wear:
• Measure the height [A] of each cam by means
of a micrometer. A
If the cams are worn beyond the limit, replace the
camshaft.

ENGLISH
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
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 clea-
rance again.

Diameter of the standard camshaft trunnion:

23.980 – 23.993 mm
Limit: 23.960 mm
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 the 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 mea-
sure 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.
1

• 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 neces-

sary.

• Check that the needle bearings fit tight when

the pinion (1) is mounted on its axis.

28 450 SEF-R
 ENGINE ASSEMBLY
❱❘ Installing the central crankcases

WARNING
During the installation process, replace all gas-
kets, (Joint paper, O-ring, etc.).

ENGLISH
• 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
N’oublier pas de huiler les pièces en friction ou en
rotation.

• Set up the two guide pins (A) and the washer (1) 1 A
on the secondary shaft. A
• 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) B
length 55 mm; 3 screws (C) length
(D) length 75 mm.
B
D D B
D
Tightening torque of the central crankcase
B
screws: 10 Nm.
B

B C
B

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. 3
• Hold the speed-locking lever locked.
• Do not forget the needle (2) on the drum.
• Mount the star and apply blue thread lock on
2
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 tigh-
ten the 3 retaining screws after applying medium 2 1
thread lock.
Tightening torque of the oil pump housing
6
screws: 10 Nm. 5
• Place the needle, the water pump drive pinion 3
and its securing clip. 4

• 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 SEF-R
 ENGINE ASSEMBLY
Put the grooved washer and the inner clutch hub.
• Using the 5593 tool, block the transmission and
tighten the nut.
Specified torque of the crankshaft nut: 120 Nm.
• Insert the safety washer and the nut.
• Using the 5749 tool, block the clutch nut and

ENGLISH
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 hou-
sing.
• 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.
1
1

❱❘ Installing the water pump housing

• Place the screws (1) of the water pump housing. 1
Be careful to correctly position the O-ring located 1
on the rim.

31
 ENGINE ASSEMBLY
❱❘ installing the clutch
• Put the 8 friction discs and the 7 metal discs,
starting with a friction disc.
• Install the finger follower and do not forget to
install the stop and the washer.
• Put the pressure plate and the 6 screws fol-
lowing the order shown in the picture.
• Place the TDC 1819 tool.

WARNING
Do not use this tool for tightening or loosening at
a torque value superior to 10 Nm.
4
• Place the clutch housing cover by tightening the
4 screws. The 4 screws are not the same length. 2 6
Beware of the O-ring located on the rim of the lid.
• Remove the TDC 1819 tool.
1
Tightening torque of the plate screws: 10 Nm.
5

3
❱❘ 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 SEF-R
 ENGINE ASSEMBLY
❱❘ Setting the piston rings
• Place the first rail. Pay attention to the positio-
ning of the opening on the exhaust side.

ENGLISH
• 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 ope-

ning 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 casings
with sealing dough.
• Set the guide pins and a socket joint.
• Lubricate the piston skirt.
• Oil the cylinder.
• Fit the cylinder paying attention to the rings.
• Place the piston at TDC and the 1819 tool.

❱❘ installing the cylinder head

• Set the guide pins and the cylinder head gasket.
• Set the washers and nuts. 1 4
• Screw the cylinder head in the order shown in
the picture.

Pass 1 3 2
Tightening torque of nuts 1/2/3/4: 30 Nm.

Pass 2
5 6
Tightening torque of nuts 1/2/3/4: 50 Nm.
Tightening torque of nuts 5/6: 10 Nm.

1
1

34 450 SEF-R
 ENGINE ASSEMBLY
❱❘ Installing the drive chain
• Set the 2 distribution guide plates going through
the chain well.
• Fit the chain on the crankshaft pinion.
• Put the distribution upper pinion.
2

ENGLISH
WARNING
Make sure that the mark is vertical to the cylin-
der, 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 the O-ring and tigh-
ten them.
Tightening torque of the shaft: 30 Nm.

• Apply blue thread lock on the two screws (1).

Tightening torque of the plate screws (1): 10 Nm.

• Put in the drive chain. 12

11
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 camshaft-bearing
cap following the order shown in the picture.
Specified torque of the shaft bearing screws:
18 Nm.
• Remove the TDC 1819 tool.
• Using the ignition rotor, give the crankshaft at
least one full turn and check the valve timing.

❱❘ Checking the valve clearance

• Valve clearance must be checked when the 5 1 3
engine is cold.
• With a shim set, measure the clearance
A 7
between the bucket and the camshaft.
6 2 4 8
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 SEF-R
 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.

ENGLISH
• Screw the cylinder head cover along with the
O-rings of the 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

Standard tightening torque Thread Lock

M5 6 Nm

M6 10 Nm

M8 24 Nm

M10 40 Nm

Chassis tightening torque Thread Lock

Rear wheel nuts 100 Nm 100 Nm

Rear cradle screws 24 Nm •

Front wheel nut 25 Nm

Fork foot pinch bolt 15 Nm

Brake pads axis screws 8 Nm •

Fork lower clamp pinch bolts WP 12 Nm / Sachs 15 Nm

Fork upper clamp pinch screws WP 17 Nm / Sachs 17 Nm

Sachs engine axes 40 Nm

Swing arm nuts 100 Nm

Cylinder head screws (frame) 25 Nm

Engine tightening torque Thread Lock

Magnetic drain plug 15 Nm

Drain plug with pre-filter M18 15 Nm

Drain plug with pre-filter M32 20 Nm

Oil filter lid 15 Nm

Spark plug (apply copper grease) 15 Nm

Coolant bleed screw 6 Nm

38 450 SEF-R
 TIGHTENING TORQUE CHART

Engine torque setting: Thread Lock

Engine speed sensor screws 7 Nm •

Clutch receiver screws. 10 Nm

ENGLISH
Exhaust pipe screws 10 Nm

Cylinder head tightening torque

Studs 1st pass 30 Nm
2nd pass 50 Nm
Nuts M6 10 Nm

Camshaft housing screws 18 Nm

Chain tensioner screws 10 Nm

Chain tensioner rack-and-pinion screws 10 Nm

Central timing sprocket axis 30 Nm

Crankshaft inspection stopper 8 Nm

Distribution guide plate screws 10 Nm •

Water pump housing screws 10 Nm

Ignition flywheel nuts 80 Nm •

Inner clutch hub nuts 100 Nm •

Bellhousing freewheel nuts 120 Nm •

Ignition cover screws 10 Nm

Central crankcase screws 10 Nm

Drum screws 10 Nm

Oil pump screws 10 Nm

39
 Cleaning the throttle body
❱❘ EQuipment
• Carburetor cleaner or Minerva brand universal
cleaner.
• Open-end wrench 8.
• Socket screwdriver 7.
• Hex key 2.5.

❱❘ Removing the throttle body

• Remove the seat.
• Remove the fuel tank.
• Loosen the clamps of the throttle body.
• Remove the cover of the spreader.
• Remove the throttle cable.
• Remove the body.

40 450 SEF-R
 Cleaning the throttle body
• Unplug all connectors.
• Visually inspect.

ENGLISH
• Clean with a universal cleaning solution.
• Blow.

41
 Cleaning the throttle body
❱❘ Cleaning the throttle body
• Clean the throttle body by means of a carbure-
tor 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 SEF-R
 Changing the TPS - Throttle Position Sensor
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.

ENGLISH
• 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 menu logo

• 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
 Injection diagnostic tool SYNERJECT
❱❘ 1- Presentation of the SYNERJECT injection system
1.1- Your Sherco SEF-450 R is equipped with a Synerject injection system
consisting of an M3C calculator, a Ø42 mm throttle body, an ignition and a spe-
cific wiring harness.

1
5

N° DESCRIPTION LOCATION
1 Synerject M3C Calculator Left side of the frame

2 Engine speed sensor (pick-up) Upper part of the ignition cover

3 Synerject Ø42 mm throttle body

4
Water temperature sensor At the back of the cylinder head, on the right
side

5
2-way sealed diagnostic connector (labeled "ECU") At the front of the motorcycle, on the right side,
between the radiator and the frame

44 450 SEF-R
 Injection diagnostic tool SYNERJECT

ENGLISH
3

Synerject M3C Calculator Synerject Ø42 mm 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 dia-
gnostic connector, an installation CD, and a user manual.

45
 Outil diagnostique
Injection diagnosticinjection SYNERJECT )
tool SYNERJECT
1.4- Diagnostic tool installation
A- Software and drivers installation:
• Open the installation CD on your computer.

• Run «Sherco_Setup».

• Select the language.

• Click on «Next»

• Choose the installation folder.

46 450 SEF-R
 Outil diagnostique
Injection diagnosticinjection SYNERJECT )
tool SYNERJECT
• Click on «Next».

ENGLISH
• Click on «Install».

• Installation in progress.

47
 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.

48 450 SEF-R
 Injection diagnostic tool SYNERJECT

• The following window will open. Click on

«Finish».

ENGLISH
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.

49
 Injection diagnostic tool SYNERJECT
❱❘ 2- Software overview
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
synchronization
menu (software
update,proxy
parameters) Help

Diagnostics menu Setup menu

(diagnostic, map (language selection, units,
updates, etc.) etc.)

50 450 SEF-R
 Injection diagnostic tool SYNERJECT

2.1- Software settings: configuration menu

ENGLISH
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
«MUXDIAG II» device.
• The languages available in the software: English, French, Spanish, Portuguese, German, Italian (the installa-
tion CD provided may not include all languages). Update the software-> page 52).
• Set the unit system.

• Click to return to the home screen.

• Click to save the changes.

51
 Injection diagnostic tool SYNERJECT

2.2- 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:

52 450 SEF-R
 Injection diagnostic tool SYNERJECT

• Click on to start downloading the

update.

ENGLISH
• The following message will come up:

• Click on to start installation.

• Resume the installation process -> page 44. It is not necessary to restart the installation of the drivers.

53
 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».

• Click on «M3C».

54 450 SEF-R
 Injection diagnostic tool SYNERJECT
• You reach the following menu:

ENGLISH
3.1- Identification: checking identification (serial number, vehicles operating hours, calibration number).

3.2- Measuring the parameters: general parameters (speed, pressure, stepper, etc.).

55
 Injection diagnostic tool SYNERJECT
A- Engine information:

• The main values of the system appear:

Details:

• Stepper Position: opening value of the air valve (stepper) -> 35 < 50 < 75. Too weak value: Leak Valve /
engine air intake for example.
Too high value: throttle body injection clogged for example.

Information : correct value of the air valve: motor at 80 °C after being operated for15 m and idle for2 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 (decelera-
tion), PUC (cut injection deceleration).

56 450 SEF-R
 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:

ENGLISH
• 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

57
 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

58 450 SEF-R
 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.

ENGLISH
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 errors occur, go to the «Clearing Error Codes» menu.

• Confirm deletion of error codes via the icon

59
 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.

60 450 SEF-R
 Injection diagnostic tool SYNERJECT

3.5- Actuators testing

In addition to reading the error codes, you can test certain components of the system:

ENGLISH
A - Ignition coil
When the ignition coil test is launched, the following message appears:

61
 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.

62 450 SEF-R
 Injection diagnostic tool SYNERJECT
Example of proper operation stepper:

ENGLISH
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.

63
 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. Pay attention to the model year, the cylinder capacity,
silencer type, etc. In case of any doubt, contact technical support.
En cas de doute, contacter votre support technique.
1 - Download the needed update (file: .mot).
2 - Turn the motorbike On.
3 - Click on Update calculator.

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

64 450 SEF-R
 Injection diagnostic tool SYNERJECT
5 - Upon completion of the download, the fuel pump starts up and the following message appears:

INFORMATION : download successfull

Confirm with the icon

ENGLISH
6-Check the correct allocation of the calibration file by selecting «Identification».

Check that the file name matches the downloaded file.

Information: the information on serial number and operating hours are not reset during a calibration update.

7-Démarrer la moto et vérifier que les paramètres moteurs sont normaux (ralenti, ouverture stepper, etc.).

65
 Injection diagnostic tool SYNERJECT

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.).

66 450 SEF-R
 Checking the charging circuit
1 - Static control values (engine off) 450 SEF-R.

Battery voltage > 12.5V.

A - Stator windings resistance values.

ENGLISH
Y1-Y2
Y2-Y3 0.44Ω±10%
Y1-Y3

B - Resistance of the engine speed sensor: 117 Ω ± 10%

Check that there is no continuity between the windings and the mass of the motorbike.

2 - Dynamic control values:

Engine speed sensor

1.7 V MIN/300 RPM
120 V MAX/10000 RPM

Tension regulator:
Alternative (AC 200 V caliber).
Idle: 22 V ± 2 V
At 6000 RPM 77 V ± 3 V.

Direct :
On regulator output (DC 20 V caliber).
At 4000 RPM 14.6 V + Red/White, - Green.

67
 Checking the charging circuit
Alternator :

Tolerance values = -5% / +10%.

RPM Voltage (AC) Current (IB) (DC) VB

2000 35V 7.2A
2500 43V 11.3A
3000 50.5V 13.6A
4000 63V 15.6A
5000 75.5V 16.5A
DC 13.5V
6000 88V 16.9A
7000 99.5V 17.2A
8000 112V 17.4A
9000 125.5V 17.5A
10000 137V 17.6A

68 450 SEF-R
 Wiring diagram
Injection wiring harness

Connectors breakdown
1 ECU
2 Double mapping
3 Starter button

ENGLISH
4 Ignition lock or on/off connector
5 Diagnostic plug
6 Fan wiring harness
7 Engine shutdown
8 Dashboard
9 Stepper motor
10 Injector
11 Gasoline pump
12 Temperature sensor
13 Throttle sensor (TPS)
14 Engine ground
15 Starter
16 TMAP
17 Engine speed sensor
18 HT coil
19 Light wiring harness
20 Fuse
21 Alternator
22 Starter relay (to the starter)
23 Starter relay (to the battery)
24 + battery
25 - battery
26 Relay ECU
27 Starter relay
28 Regulator

69
 Wiring diagram
Injection wiring harness

70 450 SEF-R
 Wiring diagram
Light wiring harness 450 SEF

ENGLISH

71
 Wiring diagram
Light wiring harness Racing 450 SEF-R

72 450 SEF-R
 Wiring diagram
Accessories wiring harness

ENGLISH

73
 Wiring diagram
Fan wiring harness

74 450 SEF-R
 Wiring diagram
Voltage graph - TPS sensor of throttle body

ENGLISH

75
- Edition Avril 2015