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SUMMARY

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 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

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

• CHECKING THE CENTRAL CRANKCASES ..................................................................................................................................................................... 21

• CHECKING THE LEFT CRANKCASE ............................................................................................................................................................................... 21

• CHECKING THE RIGHT CRANKCASE ............................................................................................................................................................................. 21

• CHECKING THE FREEWHEEL BEARING ......................................................................................................................................................................... 22

• 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

Brand	SHERCO
Model	2015 450 SEF-R
Category	Motorcycle
Language	English

SHERCO 2015 450 SEF-R User Manual

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