450 SEFR (2019) - Motorcycle Sherco - Free user manual and instructions

USER MANUAL 450 SEFR (2019) Sherco

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64INDEX n FRANÇAIS P. 4 n ENGLISH P. 6 6 n ESPAGNOL P. 128 ENGLISHINTRODUCTION We want to thank you for the trust that you have placed in us by purchasing this product.

You are now the owner of a SHERCO 450 SEF/R. All the pleasures of driving are promised to you if you follow the advice and instructions that SHERCO has set in this manual, and ride it in compliance with the applicable traffic laws. n This manual explains the operation, inspection, basic maintenance and focus of your SHERCO. If you have any questions about this manual or your machine, you should contact your SHERCO dealer: www.sherco.com / under «Dealers». n Be sure to carefully read this manual in its entirety before using your machine. n To keep your SHERCO in perfect condition for many years, perform all of the care and maintenance described in the manual. (The vehicle you purchased may differ slightly from the vehicle presented in this manual.) n SHERCO reserves the right to make changes without providing notice. Dealer stamp Frame number (

DIMENSIONS Overall length 2260 mm Overall width 820 mm Seat height 950 mm Wheelbase 1490 mm Ground clearance 355 mm MOTOR Type: Single cylinder 4 stroke liquid cooled Displacement : 449,4cc Bore / Stroke 95mm x 63.4mm Compression ratio 11.84:1 Distribution 4-valve DOHC chain drive Starting System electric starter Intake valve diameter 38mm Exhaust valve diameter 30,5mm Intake valve cold clearance 0.15-0.2mm Exhaust valve cold clearance 0.2-0.25mm Spark plug NGK LMAR9E-J Spark plug gap 0.7 mm Electronic injection SYNERJECT Alternator 12V, 220W Engine oil 1,1 litres SAE 10w60 TRANSMISSION Type 6 speed Clutch Multi disc clutch in oil bath, hydraulically operated Primary drive 25 : 75 Gearbox 6 speed Secondary drive 14X49 Technical Specifications 68Technical Specifications CHASSIS Frame Semi-perimeter CrMo steel with aluminum sub- frame Fork SACHS USD Gold Series 48mm dia. (standard) WP USD 48mm dia. (racing) Rear suspension WP Suspension with separate cylinder Travel front/rear 300/330mm Front brake disc 270mm (standard), 256mm (racing) Rear brake disc disque Ø 220mm Disc brakes wear limit : 2.7mm front and 3.6mm rear Front tire 90/90-21’’ Rear tire 140/80-18’’ Pressure off-road front / rear 0,9 bar Fuel tank capacity with reserve 9.7l with 1l of reserve Fuel requirement Unleaded gasoline with an octane index of at least 95

CLEANING PRODUCTS AND CONSUMABLES

Engine oil SAE 10w60 /

Description of the vehicle

Rear light (tail / brake light / plate light)

q w e r t y u Description of the vehicle (continued) Engine serial number location n Engine serial number location n Vehicle serial number location

The engine serial number is stamped on the left side of the engine housing.

The serial number of the vehicle is stamped on the right side of the steering tube.

High beam (Headlight)

Low beam (Headlight)

: All lights are on. Position OFF

: All lights are off. n Clutch lever The clutch lever

is on the left handlebar and has an adjustment screw

n Front brake lever The front brake lever

is on the right side of the handlebar and has an adjustment screw

Control devices and controls

Injection system mapping selection button n Rigth switch Available with the homologation kit. The main switch has two positions Position

The engine is off and can not be started. Position

Mode selection button n Dashboard

Off position G and D n Flasher switch (450 SEF) Control devices and controls

Control devices and controls (continued) Position

“Hard” n Injection system mapping switch n Motor emergency stop button (450 SEF/R) n KEYLESS System Two possible positions: The button is released: in this position, the bike can be ridden. The button is held down: in this position the motor is Off when released the motor can be restarted. The bike has a «keyless» system. It allows the bike to start without any key or ON/OFF switch. It automatically turns on and it turns off after 30 secondes of non use of the bike. When the motorcycle is not used for a long time or during a strong cold (<10°C) the lithium battery can go into sleep. To wake her up, press few short blows on the starter button. 761N23456

Control devices and controls (continued) FOOT CONTROLS:

GEAR SELECTOR, SIDE STAND, REAR BRAKE

n Gear selector The drawing shows the path of the gear selector for each of the 6 speeds. n Footbrake

Rear brake control n Side stand Remove the rubber safety latch

, using your foot on the shaft unfold it until it supports the weight of the bike. WARNING - The stand has a security system which automatically folds the stand when the bike is moved into an upright position. - The stand has been designed to withstand the sheer weight of the bike.

Control devices and controls (continued)

MOTORCYCLE COMPUTER INSTRUCTIONS

Button 1: Change screens 1,2,3 Hold button 1: Screen 1: DST Adjust Screen 2: DST2 Adjust Button 2: Change screens 1,2,3 Hold button 2: Screen 1: Reset DST Screen 2: Reset DST2 Screen 3: Reset MAX/AVG Hold buttons 1 et 2: Setup mode Screen 1: Speed, Clock, Distance 1 Screen 2: Speed, Clock, Distance 2Screen 3: Alternating AVG/MAX speed, Accumulated run time, ODO n Mode buttons The vehicle doesn’t need to be switched on Left button: Switch between the three display screens Enter adjustable trip distance mode ( DST and DST2) Decrement distance while in adjustable dis- tance mode Right button: Switch between the three display screens Resets Trip distance 1, Trip distance 2, maxi- mum and average speed (when pressed and held for three seconds) Increments distance while in adjustable dis- tance mode Turn indicator High beam Fuel injection (MIL): EFI problem Low fuel CAUTION In order to avoid any water ingress, keep a minimal washing dis-tance of 20cm. 78Control devices and controls (continued) SPD function Current speed (screens 1 and 2): displays the current speed of the vehicle. The speed can be displayed in km/h (default) or mph. (

p.81) MAX speed (screen 3): displays the maximum speed since the last reset was performed. The maximum speed can be displayed in km/h (default) or mph. (

p.81) Reset to 0 →MAX Function→ Hold the right Button down for 3seconds →0→ Reset to 0 done AVG function Average speed (screen 3): displays the average speed of the vehicle since the last reset was performed. The average speed is displayed in the chosen units, km/h (default) or mph (

p.81) Reset to 0 →AVG Function→ Hold the right Button down for 3seconds →0→ Reset to 0 done DST function (screen 1): displays the mileage traveled by the vehicle since the last reset was performed. The distance is displayed in the selected units, km/h (default) or mph (

p.81) Reset to 0 →DST Function→ Hold the right Button down for 3seconds →0.0→ Reset to 0 done DST2 function (screen 1): displays the mileage traveled by the vehicle since the last reset was performed. The distance is displayed in the selected units, km/h (default) or mph (

DST and DST2 can be incremented or decre- mented by the user DST set up (screen 1) → Hold the left Button down for 3seconds → «DST» icon will flash

• Hold left Button to decrement/ Hold the right Button to increment → back to screen 1 DST2 set up (screen 2) → Hold the left Button down for 3seconds → «DST2» icon will flash

• Hold left Button to decrement/ Hold the right Button to increment → back to screen 2 ODO function Odometer (screen 3): displays the total mileage traveled by the vehicle. The total distance is displayed in the selected units, km/h (default) or mph (

p.81) This information can not be reset to 0. Beyond 399 999 km (or miles), the counter goes back to 0. ART function Accumulated Ride Time (screen 3): displays the hours of operation of the vehicle. This information can not be reset to 0. Until 99h59min → displayed in one minute increments After 99h59min up to 9999h → displayed in one hour increments If the unit should reach 9999 hours of accu- mulated ride time, the display will stop incre- menting, and will remain at that number. Clock function (screens 1 et 2): displays clock information Low battery/ Low battery error function: ->When the battery voltage drops to less than 2.40V, the LO battery warning will turn on. ->When the internal battery is critically low, the unit will only display a blinking «LO» icon. Fig 6 Adjustable trip distance function Fig 7 ODO function Fig 8 ART function Fig 9 Clock function Fig 11 Low battery/ Low battery error function Control devices and controls (continued) 80Maintenance reminder: allows user to define a countdown for maintenance operations. When the maintenance countdown gets to zero, the maintenance icon will appear on the LCD. Displaying the remaining accumulated ride time : From main screen -> hold the left button down for 3 seconds -> the remaining value is displayed -> no button activation -> back to screen 3. Note : If the maintenance reminder is turned off , the information displayed on the screen will be OFF. Resetting the remaining accumulated ride time : From main screen, hold the left button down for 3 seconds -> the remaining value is displayed -> hold the right button down for 3 seconds -> the maintenance reminder is reset to zero (will begin the countdown again according to the maintenance interval already chosen in the set up menu). n Set up menu Left and right buttons pressed simultaneously for 3s activates the Set up mode Left button Right button Toggle between M/H and KM/H settings Toggle between 24 Hour et 12 Hour Decrement time of day value Decrement maintenance reminder value Increment time of day value Increment maintenance reminder value UNIT (Unit type) LIFE (Wheel circumference) Do not modify these settings PPr (Pulse per revolution) (Clock format) (Clock setup) (Maintenance reminder) The meter will automatically advance from one setting option to the next, after 5s of no button activation Miles or Km Default: km 12 or 24h Default: 24h Clock setup Maintenance reminder setting ( in hours) Default setting: 5h (first oil change) OFF: disabled Set the value Control devices and controls (continued)

Control devices and controls (continued) Riding the motorcyle n Cold engine starting

1. Make sure the gear selector is in neutral.

2. Start the engine by pressing the starter button, with the throttle closed.

3. Allow the engine to warm up for a few minutes.

n Hot engine starting Follow the instructions above without Step 3. n Shifting gears - The positions of the gear selector are shown on page 77. - To find the neutral position, press the selector down into first gear (a resistance will be felt), then move the selector up slightly. n Fuel Use only unleaded fuel with an octane index of at least 95. n Filler cap Open : Turn the cap counterclockwise. The opposite direction to the hands of a watch. Close : Turn the cap clockwise. The same direction as the hands of a watch. 82Riding the motorcycle (suite) Safety information 1.Close the throttle before changing gears.

2. Engage the lowest gear.

3. Partially open the throttle while engaging the clutch.

n Parking - Stop the bike with the stop button. The keyless system will automatically switch off the igni- tion after 30secondes of non use of the bike. Become familiar with all of the controls and their functions before using the vehicle. - Do not drive after consuming alcohol. - Wear a helmet when using the vehicle. - Keep the machine in good working order and maintain it properly so that it is reliable and safe for use. - Gasoline is flammable, refuel the motorcycle when the engine is stopped. - Exhaust fumes are toxic, you should never start the engine in a closed building. - Always park the vehicle on a flat hard surface, do not park the vehicle on a slope or on soft ground. Always control the balance of the vehicle. - Check the following every day before riding the motorcycle: Tires : Wear and pressure Engine oil : Level (

p.88) Gasoline : Check the level and make sure there are no leaks Transmission chain Properly lubed and adjusted (

p.103) Direction of travel : Make sure that your path is clear Brakes : Operation, fluid leakage, brake pad wear (

p.104) Electrical Equipment : Operation of the horn and lights (

p.74 and p.76) Components (nut, bolts ...): Verify that all components of the vehicle are properly tightened (

p.125) If you experience a problem with any of the components of the motorcycle, consult the Service and Adjustments section of this manual or contact a Sherco dealer.

WARNING - The hot liquid can cause severe injuries. - The coolant is harmful - After contact with skin or eyes, or ingestion, or injuries caused by hot liquids: Consult a physician - Use protective gloves. - Do not replace the coolant with water or other not approved fluids: it could damage your engine. - Follow these procedures carefully and always fill the engine with coolant when the engine is cold. WARNING It is important to follow this procedure. The lack of fluid, or the presence of a pocket of air left in the radiator can cause serious damage to the engine. Place the bike upright on a horizontal surface. - Remove the cap

Fill the radiator full so that there is no air in the system. Fill the coolant to the top of the radiator. Replace the cap

and check to make sure it is tight. Replace the screw

Check the fluid level in the expansion container. The liquid should reach the level on the container where it indicates “LEVEL” If the level is not correct, unscrew the cap

WARNING Make sure the bike is vertical and on a horizontal surface. -Place a container under the bike -Remove the cap

-Allow the coolant to drain.

NOTE To protect the environment deposit the drained coolant at an approved collection center.

Cooling System (continued)

located on the left side of the radiator - Pour the coolant into the radiator through the cap

- Allow the coolant to flow through the screw

until there are no bubbles, replace the screw

using a new gasket. Coolant Minerva Perma Universal D 4 -25°C Radiator bleed screw M6X8 8Nm - Continue filling. - Fill until the coolant reaches the level (approxi- mately 1.1 liters) - Put the bike on the side stand and follow the rest of the filling procedure (

Motor settings CHECKING THE PLAY IN THE THROTTLE CABLE With the handlebars facing straight ahead, check that the throttle twist grip functions properly. Throttle cable play 2....4mm If the cable play is not correct, adjust the accelerator throttle cable play. (

p.87) Start the bike and let it run at idle. Turn the hand- lebars and check that the idle speed is constant. If the speed changes, readjust the play in the throttle cable. (

p.87) n Checking the throttle cable play n Adjusting the play in the throttle cable Adjust the throttle cable play at the location shown

with the adjuster. If this is not enough, adjust the play directly on the throttle body.

- Make sure that the bike is on its two wheels, vertical and on a horizontal surface. - Check the engine oil level by viewing the sight gage located on the clutch housing

- Adjust the level according to the diagram shown below. If necessary add oil to achieve the correct oil level. - Unscrew the engine oil fil- ler cap

located on the clutch housing Level warm engine WARNING - Improper oil level can damage your engine. - Do not use your bike if the level is below the minimum. Topping up the engine oil Engine Oil SAE 10w60

Engine maintenance (continued) DRAINING THE ENGINE OIL AND REMOVING THE OIL FILTER - When draining the oil the engine should be warm

WARNING Use protective gloves - Position the motorcycle upright on a level sur- face.

Place a container under the bike to catch the old oil.

Remove the drain plug

- Remove the magnetic drain plug

- Remove the pre-filter

- Allow the oil to drain

and remove the chain guard

Engine maintenance (continued) - Remove the oil filter cover

- Use a hook to remove the oil filter

- Let the oil drain. - Clean the drain plugs

with a degreaser. - Clean and inspect the pre-filters

and change them if necessary. 90q

Engine maintenance (continued) - Install a new oil filter

, install in the direction shown in the photo. - Install the cap

using a new O-ring. Oil Filter cap M45 15Nm - Install the plug

as shown in photo n°4. Drain plug

p.88) - Fill the engine with oil Motor oil 1,1l SAE 10w60 - Install the engine guard. (

p.88) - Add additional oil if necessary.

REFILLING THE ENGINE WITH OIL

WARNING To protect the environment, oil, oil filters and used material must be deposited in a collection center and not down the drain or in the wild.

NOTE The oil filter should be replaced at each oil change.

Adjusting the chassis HANDLEBAR POSITION The triple clamps have two holes separated by a distance A. Distance between holes A 13mm The handlebar clamps are offset by a distance B Handlebar offset B 4mm The bike comes standard with the handle- bars in the rear most position. Remove the four screws

. Remove the handle- bar top clamps and remove the handlebar. Remove the two screws

. Remove the lower clamps and place them in the desired position. Handlebar lower clamp M10x35 40Nm Loctite

Replace the handlebars and top clamps. Replace the four screws

and tighten evenly. Handlebar clamps fixing screws M8x25 24Nm The handlebars can be rotated forward and rearward in the clamps.

determine the behavior of the fork when it is compressed. Turning in the screw- clockwise increases the hydraulic force (and vice versa). Remove the caps

located at the lower end the fork. Turn screw

clockwise to the stop and go back the number of clicks required. Setting compression WP suspension XPLOR Ø48mm (racing) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Setting compression KAYABA (factory) Comfort 20 clicks Standard 12 clicks Sport 8 clicks Replace the cap

Adjusting the chassis

If the weight of the rider is above or below the standard, compensate by changing the stiffness of the springs (forks and shock). The steering angle can be changed using the set screws located on the bottom of the steering column. Loosen the nut

and tighten the screw

until you have the steering angle desired. Tighten the nut and do the same operation on the other side. Steering angle lock nut M8 20Nm Standard weight of the- rider (with equipment) 75 à 85kg

Adjusting the chassis (continued)

The adjusting screws

determine the behavior of the fork when it rebounds. Turning the screws clockwise increases the hydraulic force (and vice versa). The adjustment screws

are located at the end of the upper fork legs. Turn the screw

clockwise to the stop then go back the number of clicks required. Setting rebound WP suspension XPLOR Ø48mm (racing) Comfort 18 clicks Standard 15 clicks Sport 12 clicks Setting rebound KAYABA (factory) Comfort 18 clicks Standard 12 clicks Sport 10 clicks

SETTING THE FORK SPRING PRELOAD

The adjusting nut allows the preload of the Spring to be adjusted. Turning the nut clockwise increases the preload (and vice versa). Turn the nut with a wrench counterclockwise until it stops and then turn it the number of turns required. Suspension spring preload WP XPLOR Ø48mm (racing) Comfort 0 turn Standard 0 turn Sport 2 turns 94Adjusting the chassis (continued)

SETTING The adjusting screw

determines the slow speed behavior of the rear shock (sensitivity Turning the screw clockwise increases the hydraulic force (and vice versa). Turn the screw

clockwise with a screwdriver until it stops and then turn it back the number of clicks required. Do not loosen the nut

SETTING The adjusting screw

determines the high speed behaviour of the rear shock (big hits). Turning the screw clockwise increases the hydraulic force (and vice versa). Turn the screw

clockwise with a socket wrench until it stops and then back the number of clicks required. Do not loosen the nut

96Adjusting the chassis (continued) SETTING THE DEPRESSION OF THE REAR SHOCK

With the bike on an appropriate stand Measure the dimension R1 between a fixed point on the chassis and the rear axle. With the bike setting on its wheels Measure the dimension R2 from the same fixed point on the chassis and the rear axle. The static deflection is the difference between R1-R2. Static deflection 30mm If the static deflection is not correct, adjust the preload of the shock (

With the rider on the motorcycle Measure the dimension R3 between the same fixed point on the chassis and the rear axle. The sag is the difference between R1-R3. Sag 110 mm If the sag is not correct, change the spring.

Remove and clean the rear shock unit (

Loosen / tighten the red plastic ring

depen- ding on the length required. Indications Loosening one turn Decreases the ove- rall length by 3mm. Tightening one turn Increases the overall length by 3mm. Tighten the collar

p.96) Adjusting the chassis (continued)

Remove and clean the rear shock unit (

p.106) Select and install a spring based on your weight. Spring Rate Rider Weight (with equipment) : 65-75kg 51N/mm Rider Weight (with equipment) : 75-85kg 54N/mm Rider Weight (with equipment) : 85-95kg 57N/mm Reinstall the shock. Adjust the sag (

Loosen / tighten the red plastic ring

depending on the length required.. REAR SHOCK KAYABA (FACTORY) Indications Loosening one turn Decreases the ove- rall length by 4mm. Tightening one turn Increases the overall length by 4mm. Tighten the collar

a quarter turn counterclockwise to release the saddle. Remove the seat by pulling it towards the back of the bike.

REINSTALLING OF THE SADDLE

Install the saddle by sliding it forward, making sure that the slot

in the seat pan engages the post

in the reservoir. The

notches in the saddle must pass through the tabs on the subframe

that are provided for this purpose. Lock the Dzeus fastner by turning it a quarter turn clockwise.

REMOVING THE AIR FILTER

The air filter is vital for the smooth operation of your engine. Maintenance is therefore essential. A dirty air filter reduces the performance of your bike, increases fuel consumption and, at worst, impurities can pass into the engine and cause premature wear. Remove the seat (

Remove the filter with the plastic carrier

Separate the filter from its plastic holder.

Chassis maintenance (continued)

CLEANING THE AIR FILTER

Clean the foam air filter with a special liquid cleaner and let dry. INFO Do not clean the air filter with a solvent or gasoline. Air filter cleaner Minerva air filter cleaner INFO Do not wring out the filter by twisting. Press only. Soak the air filter in an air filter oil. Air Filter oil Minerva protect Air If necessary clean the inside of the air box with a cloth.

REINSTALLING THE AIR FILTER

Reposition the filter on its support. Be sure to engage on all six tabs. Apply a film of grease on the face of the filter element. Reinstall the filter and its support by taking spe- cial care to make sure it is centered. Refit the knurled screws

Check to make sure the air filter is properly seated. Install the saddle (

p.98) Unscrew the fuel tank fixing screws

Disconnect the fuel pump electrical connector

Remove the fuel hose by pressing the connector

and pulling on the hose

WARNING Attention, there is a risk of spraying fuel. do not put your face near the fuel line exit. Prevent ingress of dirt in the gasoline fuel line. This can lead to a seizure of the injector. Unscrew the screws

don the right and left radiator grill. Remove the fuel tank by pulling upwards, provide lateral clearance by slightly moving the radiator grills. Use caution when removing the fuel tank and do not damage any of the fuel hoses or electrical connections.

Chassis maintenance (continued) Reassembly of the fuel tank. Be sure to correctly position the throttle

Locate all of the fuel hoses / electrical connec- tions under the fuel tank well. Install the tank by moving the radiator guards away from the radiator to provide clearance for the fuel tank and makesure that all of the cables, wires and hoses are free, clear and not pinched. Check the adjustment of the radiator guards in relationship to the fuel tank. Connect the fuel line

Install the fuel tank mounting screws

along with their rubber inserts. Install the radiator grill mounting screws. Chassis screws M6 10Nm Reinstall the saddle (

p.98) After some time of operation, the air accumulates under pressure in the fork. Every 5 to 10 hours (depending on the riding intensity), it should be purged. With the fork cold and fully extended, loosen and then retighten both fork caps.

102Chassis maintenance (continued) Place the motorcycle on a suitable stand. Remove the front wheel (

p.108) Remove the fork protectors. Slide the dust cover down. Clean and lubricate the dust cover and the fork tube. Lubrifiant universel Minerva F4 Reinstall the dust cover and clean off any left over oil. Reinstall the fork protection. Reinstall the front wheel (

p.108) Take the bike off of the stand. Place the motorcycle on a suitable stand. Exert a back and forth force on the fork legs. There should not be any play in the bearings in any direction in the steering bearings. If there is play and / or resistance, adjust and / or change the bearings. Adjust the bearing free play (

p.103) Take the bike off of the stand.

CLEANING THE FORK DUST SEALS

Chassis maintenance (continued) Place the motorcycle on a suitable stand. Loosen screws and Loosen or tighten the nut to adjust the steering bearing play.Steering nut M20 30NmTighten the screws SACHS top fork screwsM8x35 12NmWP top fork screws M8x35 17Nm Tighten screw Top clamping screw M8x30 17NmLoctite

Check the play of the steering head bearings.

p.102)Remove the bike from the stand.The bearings should be greased at least once a year with a good quality grease.Regularly cleaning the chain considerably increases its service life.Clean the chain and apply chain lubricant.Minerva Chain CleanerPlace the motorcycle on a suitable stand Push the chain up and measure the chain movement as shown in the diagram.Chain tension 50mm...53mmIf the chain tension is not correct, see how to adjust the chain. ( p.104) Otherwise, remove the bike from the stand.

CHECKING THE CHAIN TENSION

WARNING Improper chain tension can cause mechanical damage. Place the motorcycle on a suitable stand. Loosen nut

Loosen or tighten the screws

until you have the correct chain tension. Chain tension 50mm...53mm Monitor the symmetry of the two sides by observing the position of the marks

Rear axle nut M24 100Nm Remove the bike from the stand.

NOTE The sliding piece is designed to accommodatelonger chains by turning it 180 degrees. The position of the lever can be adjusted to meet the needs of the rider. - Turn the knob

clockwise to move the lever closer to the handlebar.

Chassis maintenance (continued) - Turn the knob

in the opposite direction to move the lever away from the handlebar.Clutch lever free play A ≥3mm WARNING- The hydraulic fluid is highly corrosive it can be dan-gerous to the skin.- Read the recommendations on the container.Position the master cylinder horizontally.- Remove the two screws , the cover

and the membrane - Check the fluid level and fill if necessary.Level of brake fluid below the top of the reservoir. 4mm Minerva brake fluid DOT 4- Reinstall the lid with the membrane and the screws. 106Chassis maintenance (continued)

Place the motorcycle on a suitable stand. Remove the right side plate. Remove the spring

from the muffler and spring

from the intermediate exhaust pipe. Remove the screw

Remove the top screw of the shock. Remove the shock from the top. Remove the screws

and the muffler along with the intermediate exhaust pipe.

WARNING Do not remove the muffler after operating the motor- cycle. It can behot and there is a risk of being burned. Remove the shaft

Chassis maintenance (continued)

REINSTALLING THE REAR SHOCK

Install the shock from the top. Install the top screw and tighten. Upper shock screw M10 40Nm Loctite

Position the rods and “H” link. Install the lower shock screw

and tighten. Lower shock screw M10 40Nm Loctite

and tighten. Lower shock shaft M12 40Nm Reassemble the intermediate exhaust and install screw

loosely. Reassemble the rear silencer and loosely tighten screws

using the nylock self-locking nuts. Chassis screws M6 10Nm Attach the intermediate pipe spring

Tighten the muffler attaching screws

Chassis screws M6 10Nm Install right side plate. Remove the bike from the stand. 108Wheels, tires

WHEEL Place the motorcycle on a suitable stand. Remove the two screws

Loosen the two screws

Pull the axle through the right side. Remove the wheel from the fork. WARNING Do not operate the front brake lever when the front wheel is removed. Check that the brake disc is not dirty or contaminated with oil or grease. If it is, clean the disc with brake cleaner. Brake cleaner Minerva brake cleaner and degreaser Install the spacer

on the left side of the wheel hub. Install the front wheel in the fork and install the axle (grease the axle prior to installation). Tighten the screws

Fork screws M8 12Nm Install and tighten the axle nut

Front axle nut M20 25Nm Tighten the screws on the right side of the bike. Fork screws M8 12Nm Operate the front brake lever several times until the pads touch the disc.Remove the bike from the stand and push down on the fork several times.

Wheels, tires (continued)

REMOVING THE REAR WHEEL

REINSTALLING THE REAR WHEEL

Place the motorcycle on a suitable stand. - Unscrew the nut

and remove the adjuster.

out using a nylon hammer. - Remove the axle. - Move the wheel as far forward as possible. - Remove the chain and wheel. WARNING Do not operate the rear brake pedal when the rear wheel is removed. Check that the brake disc is not dirty or contaminated with oil or grease. If it is, clean the disc with brake cleaner. Brake cleaner Minerva brake cleaner and degreaser Install the two spacers

and make sure they are positioned correctly. 110Wheels, tires (continued)

Regularly check the tire pressure with a precision pressure gauge. - Remove the valve cap. - Check air pressure when the tire is cold. Tire air pressure when used in rough terrain. Front 0,9bar (13 psi) Rear 0,9bar (13 psi) If the pressure does not comply with the above table : - Correct the pressure. - Replace the valve cap. Install the chain tensioner

but do not tighten. Check the chain tension (

Rear Axle nut M24 100Nm Operate the rear brake pedal several times until the pads touch the disk. Remove the bike from the stand. Install the rear wheel in the swing arm and install the axle (grease the axle prior to installation) Mount the chain.

Wheels, tires (continued)

CHECKING FOR WEAR AND DAMAGE

CHECKING SPOKE TENSION

- Regularly check the depth of the tread. Tread depth ≥3mm If the depth is less than the value shown : - Change the tire Check for cuts, cracks, nails, sharp objects and bulges on the tire. If the tire is damaged : - Change the tire - Changer le pneumatique Do not neglect the tension of the spokes. WARNING Proper tension ensures stability and secure riding. - Check the spoke tension before and after each use of the bike, especially if the spokes are new or have been recently adjusted. - Use a screwdriver to tap on each spoke. The sound must be sharp. - If it is dull, take the bike to a SHERCO dealer to get the spokes properly adjusted. Note : indicative tightening torque of 5 to 6 Nm. 112Brakes

Pull the lever toward the handlebar and check the free play

Free play of the front brake lever ≥3mm If the free play does not meet the specification, do the following. Set the free play using the adjustment screw

- Turn clockwise to decrease the free play. - Turn it counterclockwise to increase the free play. Make sure that the reservoir is in a horizontal position. Check the fluid level through the sight glass. Ensure that the level is (between the arrows) it should be closest to the up arrow. MIN If the level is below the MIN mark, top up the brake fluid according to the instructions below.

WARNING- The hydraulic fluid is highly corrosive.- It can be dangerous to the skin.- Read the recommendations on the container.- Remove the two screws

Remove the cover and the membrane

Fill the reservoir with brake fluid to the correct level

≥5mm- Replace the spring If the travel does not meet the specification, refer to the rear brake travel adjustment. ( p.114)The position of the brake pedal can be adjusted as follows: loosen the lock nut loosen or tighten the screw to obtain the desired position.Tighten the lock nut when the pedal is properly located.Brake pedal lock nut M6 10NmCheck the pedal travel ( p.113) 114Brakes (continued)

Fill with fluid to the mark as shown

Minerva brake fluid DOT 4 - Reinstall the membrane and the cover using a new O-ring. ADJUSTING THE TRAVEL OF THE REAR BRAKE PEDAL Position the motorcycle on a flat surface. Check the fluid level through the sight glass. Ensure that the level (between the arrows) is closest to the up arrow. MIN If the level is below the MIN mark, top up the brake fluid according to the instructions below.

Brakes (continued) - Remove the clip

- Remove the brake pads. Do not operate the front brake lever or rear brake pedal when the brake pads are removed. Check the pads for wear Minimum pad thickness

≥1mm If replacement is necessary, always change the pads in pairs. Check that the brake discs are not contaminated with oil or grease. In they are, clean the discs with brake cleaner. Brake cleaner Minerva brake cleaner and degreaser REMOVING THE FRONT AND REAR BRAKE PADS CHECKING THE CONDITION OF THE BRAKE PADS REINSTALLING THE FRONT AND REAR BRAKE PADS 116Brakes (continued)

Turn off all electric devices and stop the engine. WARNING Wait at least 30 secondes, bike turned off and stop- ped, so that the Keyless system turns off. If this is not done there is a significant risk of damage to the computer (ECU). - Remove the seat (

p.98). - The battery is located at the bottom of the filter housing. - Remove the two screws

that retain the battery retaining bracket. - Disconnect the negative cable from the battery

- Disconnect the battery positive cable

- Remove the battery from the top. Install the new pads. Reinstall the retaining pins

p.112 and p.113) WARNING Do not use the bike until the brake lever and the pedal are operational. «Pump» the brake lever / brake pedal up and down until the brake pads are in contact with the discs.

REMOVING THE BATTERY

Electrical system maintenance

Electrical system maintenance (continued) - Insert the battery into place. - Connect the positive cable to the battery. - Connect the negative cable to the battery. - Install the battery retaining bracket and tighten the two screws

Chassis screws M6 10Nm - Check the positioning of the battery cables to make sure that they do not interfere with the installation of the air filter. - Replace the air filter (

p.98). The battery is a maintenance-free type. If the vehicle is not used for an extended period, it is recommended that the battery be disconnected and stored in a dry place. See removing the battery (

p.116) Check the voltage of the battery with a voltmeter : Battery voltage >12.5V If the voltage is below the specification, remove the battery and recharge it using a battery charger. Battery charging (12V)

or 5A for 30 minutes Disconnect the charger after charging. Install the battery (

118Electrical system maintenance (continued)

is on a relay by the starter. Remove the defective fuse and replace with a new fuse of the same value. Main fuse 30A Put a new spare fuse in the reserve location in the fuse box. - Replace the saddle (

REPLACING THE MAIN FUSE

is located in a high location on the wiring harness on the right side of the bike. Remove the defective fuse and replace with a new fuse of the same value. Light fuse 15A - Replace the saddle (

p.98). Turn the ignition to the off position. Unclip the left and right rubber fastners

each side of the fork. Separate all of the brake hoses / cables from the meter bracket at the top and bottom. Move the top plate up to clear the housing. Disconnect the connector

and remove theheadlight housing.

Electrical system maintenance (continued) Connect the electrical connector. Engage the light plate, ensuring that the holes in the plate

Place all of the brake hoses / cables in the inte- rior of meter upper guide

Attach the rubber fastners. Check the setting of headlight beam. (

Remove the headlight housing assembly

Turn the socket a quarter turn counterclockwise to remove it from the headlight assembly. Gently press the bulb in while turning it counter- clockwise and remove it from the socket. Install a new bulb

Headlight bulb S2 12V 35/35W S2 Reinstall the socket with the bulb in the headlight assembly by turning it in a clockwise direction. Reinstall the protective rubber. To replace the pilot light

simply remove the socket from the reflector

Pilot light W5W 12V 5W Reinstall the headlight housing assembly

The headlight beam is adjusted with the motorcycle in a state of operation with its driver seated on the saddle. To set the headlight beam, tighten or loosen the screw at the base of the headlight housing. Tightening the screw

raises the headlight beam. Loosening the screw

lowers the headlight beam.

1. Remove the headlight housing (

signal flasher in order to access the motorcyle computer screws.

3. Remove the screws

and remove the com- puter to get it out of the way.

4. Disconnect the main connector from the computer.

5. Open the computer with a coin and remove the

6. Install a new battery (with the marking up).

Computer battery CR 2032 3V

7. Replace the cover, taking care not to damage

8. Plug the main connector into the computer.

9. Install it on the bike and check to make sure

10. Reinstall the computer support.

and replace the turn signal flasher.

12. Replace the headlight housing (

13. Set the computer (

SHERCO advises you to wash your 450 SEF/R as often as possible in order to main- tain it in good working order and prolong its life.

1. Cover the end of the exhaust silencer and

the air filter (plastic bag, special cover or a special cap).

2. To degrease the engine, apply a degrea-

ser, clean with a brush then rinse the engine with a water hose.

3. Wash the rest of the vehicle with hot

4. Rinse with clear water.

5. Dry with a chamois or a clean, soft cloth.

6. Clean the chain and lubricate it with a

7. When the cleaning is finished, remove the

air filter and exhaust protection, Start the engine and let it run atidle for a few minutes. Avoid using high pressure equipment which may cause water to leak into the bearings and fork seals and cause serious damage. Use an average strength detergent rather than a strong detergent. Before storing the vehicle Long-Term (more than 2 months), follow these instructions :

1. Wash the whole bike.

2. Empty the fuel tank.

3. Remove the spark plug and inject a pro-

tective spray inside the engine through the hole in the cylinder. Install the spark plug. Cycle the engine a few revolutions to apply a protective film on the cylinder walls.

4. Remove the battery (

5. Charge the battery (

6. Lubricate all cables with a spray lubricant.

7. Jack the motorcycle up so that the wheels

8. Cover the exhaust outlet with a plastic

bag to prevent moisture from entering.

9. Spray a protective oil film on all unpainted

metal surfaces of the motor and also on the electrical wiring.

10. Cover the motorcycle with a cover.

Reinstall the battery (

RECOMMISSSIONING AFTER STORAGE Washing and storage CAUTION In order to avoid any water ingress, keep a mini-mal washing distance of 20cm. Maintenance schedule 122Maintenance schedule Maintenance After 5 hours Every 20 hours ENGINE Change engine oil, filter, clean pre filter and change if necessary

Clean the magnetic drain plug

Replace spark plug (after 50 hours) Check and adjust valve clearances

Check engine mounting bolts for tightnessr

ACCESSORIES Check cooling system for leaks

Check sealing and attachment of the exhaust

Check status, flexibility and position of the cables, adjust and lubricate

Check oil level in clutch master cylinder

Clean air filter and housing

Check status and position of the electrical wiring

Check function of electric components (headlight/tail/stop turn signals, computer control unit, etc.)

BRAKES Check brake fluid level, brake pad thickness and the brake discs

Check status and sealing of the brake lines

Check status, of the foot brake pedal and hand brake lever

Check tightness of brake system fastners and discs

CHASSIS Check for leaks and function of fork and shock

Clean the dust covers

Purge air from the fork legs

Check general tightness of bolts and screws

WHEELS Check rims and spoke tension

Check condition of the tires and tire pressure

Check wheel bearing clearance

Maintenance schedule (continued) ANNUAL MAINTENANCE Major maintenance items that should be performed by the dealer 1X by year minimum Fork

Clean and grease steering head bearings and seals

Treat electric contacts and switches with an aerosol protector

Checks and major maintenance to be performed by the rider Before each use After each use Check the engine oil level

Verify operation of the lights

Verify operation of the horn

Lubricate throttle cable

Regularly purge the air from the fork legs

Regularly clean the fork dust seals

Clean air filter and box

Check tires and tire pressure

Check the coolant level

Check fuel lines for leaks

Check status of all the controls

Spray anti-corrosion protector on all non painted parts (except for the brake parts and the exhaust system)

Check tightness of nuts, screws and clamps

WARNING Check the tightening of the screws of your bike after the first ride / the first hours of use. In competition you have to perform the 20 hour maintenance schedule after each race! This should not be exceeded by more than 2 hours. The services performed by the Sherco dealer do not replace routine service and maintenance by the rider! 124Maintenance schedule (continued)

IMPORTANT CHECKS AND MAJOR MAINTENANCE ITEMS

THAT SHOULD BE PERFORMED BY THE SHERCO DEALER Competition use At 20H At 50H At 100H Recreational user At 50H At 100H Check the clutch disc wear

Check the length of the clutch springs

Check that the clutch nut is not loose

Check that the clutch housing is not loose

Check the wear of the cylinder and piston

Check the camshafts for wear (a) visually check

Check the camshaft buckets for wear

Check the wear of valve guides

Check operation of chain tensioner guide

Check the run-out at the end of the crankshaft

Check the condition of the connecting rod

Check all of the gearbox components for wear

Check ECU's errors with the Sherco diagnostic tool

Check and charge the battery

Check the fuel pressure

Check the length of the relief valve spring

Replace fiberglass packing in the muffler

Check the length of the camshaft drive chain

Magnetic Drain Plug M12 15Nm Prefilter drain plug M18 15Nm Oil filter cap M45 15Nm Sparkplug (apply grease to the copper washer) 15Nm Water pump housing screws M6X8 6Nm Radiator bleed screw M6X8 8Nm Drain plug with large pre-filter M32 20Nm