HUSQVARNA Motorcycle SM 400 SM 450 R Service Repair Workshop Manual 2003-2004

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This manual covers the SM 400 R and SM 450 R supermoto motorcycles produced between 2003 and 2004. These models represent robust engineering and performance heritage, adapted for dynamic supermoto...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 131521

Stichworte: 2003 2004 Husqvarna Motorcycle Motorcycles SM 400 SM 450 R SM Models

Produktvarianten

Beschreibung

This manual covers the SM 400 R and SM 450 R supermoto motorcycles produced between 2003 and 2004. These models represent robust engineering and performance heritage, adapted for dynamic supermoto riding. Known for their potent single-cylinder engines, agile chassis, and capable suspension, these motorcycles offer an exhilarating experience for both spirited road riding and occasional track use. The brand's long history, dating back to 1903, underpins the quality and reliability expected from these machines, which are designed to deliver exceptional performance and rider engagement. This comprehensive service repair workshop manual provides A-Z repair and maintenance information for all variants of the SM 400 R and SM 450 R for the specified model years. It includes detailed procedures for every system, from engine and transmission to suspension, brakes, and electrical components. The manual offers factory-level detail, including step-by-step instructions, crucial torque specifications, and clear wiring schematics, enabling owners and technicians to perform everything from routine servicing to complex repairs and diagnostics. Its purpose is to empower users with the knowledge needed to maintain their motorcycles in optimal condition and ensure long-term reliability.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

SM 450 R

Year:

2003-2004

Vehicle Type:

Motorcycle

Segment:

Supermoto

👋 Introduction

Market Position

Purpose:

To provide owners and technicians with the official, comprehensive repair and maintenance information for Husqvarna SM 400 R and SM 450 R models.

Competitive Analysis

Value Proposition:

Offers the same authoritative information used by dealership technicians, enabling users to perform professional-level repairs and maintenance, saving significant costs.

Key Features

Content Detail:

Vehicle/model specific, not generic. Includes step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications.

Accessibility:

Instant download, printable pages, compatible with various operating systems (Windows, Mac).

📋 Manual Details

Coverage Areas

Covered Models:

All SM 400 R and SM 450 R variants for model years 2003 and 2004.

Repair Scope:

A-Z comprehensive repairs and maintenance.

Page Count

Estimated Page Count:

N/A (Digital format, scalable)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine:

Detailed breakdown of engine components, assembly, disassembly, tuning, and troubleshooting.

Fuel System:

Carburetor specifications, adjustment, cleaning, fuel pump, and fuel lines.

Ignition System:

CDI unit, spark plug specifications, timing, and troubleshooting.

Exhaust System:

Component identification, installation, and inspection.

Cooling System:

Radiator, hoses, thermostat, coolant specifications, and flushing procedures.

Transmission:

Clutch operation, gearbox disassembly and assembly, gear selection, and lubrication.

Suspension Front:

Fork disassembly, assembly, oil type and level, seal replacement, and adjustments.

Suspension Rear:

Monoshock absorber service, linkage maintenance, and adjustments.

Brakes Front:

Brake caliper service, master cylinder overhaul, pad replacement, fluid flush, and rotor inspection.

Brakes Rear:

Brake caliper service, master cylinder overhaul, pad replacement, fluid flush, and rotor inspection.

Wheels And Tires:

Wheel bearing maintenance, spoke tensioning, tire selection, and mounting.

Electrical System:

Wiring schematics, battery maintenance, lighting system, starter motor, and charging system.

Frame And Bodywork:

Chassis inspection, fairing removal and installation, seat, and fuel tank procedures.

Controls:

Handlebar, levers, pedals, and cable adjustment.

Procedures Included

Maintenance:

Routine checks, lubrication, filter replacement, chain adjustment, and overall inspection.

Troubleshooting:

Diagnostic flowcharts and common problem identification for various systems.

Repair:

Step-by-step instructions for replacing and repairing all major and minor components.

Disassembly Assembly:

Detailed guidance on how to safely take apart and reassemble entire motorcycle systems.

Torque Specifications:

Crucial torque values for all fasteners to ensure proper assembly and safety.

Wiring Schematics:

Complete and detailed electrical diagrams for diagnostics and repairs.

Technical Depth

Depth:

Factory-level detail, covering everything from basic maintenance to complete engine rebuilds and complex electrical diagnostics.

📊 Manual Specifications

File Format

Format Details:

PDF files designed for easy viewing and printing.

Print Quality

Print Capability:

All pages are printable, with the ability to enlarge images for detailed viewing.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Format:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke (likely liquid-cooled, based on model type and era).

Bore Stroke Sm400:

Specific data to be found within the manual; typical for this era might be around 88mm x 66.2mm for a 400cc class.

Bore Stroke Sm450:

Specific data to be found within the manual; typical for this era might be around 97mm x 60.8mm for a 450cc class.

Displacement Sm400:

Approximately 398cc (actual value confirmed in manual).

Displacement Sm450:

Approximately 449cc (actual value confirmed in manual).

Performance

Horsepower Sm400:

Estimated 40-45 HP (actual figures in manual).

Horsepower Sm450:

Estimated 45-50 HP (actual figures in manual).

Torque Sm400:

Estimated 35-40 Nm (actual figures in manual).

Torque Sm450:

Estimated 40-45 Nm (actual figures in manual).

Fuel System

Carburetor Type:

Likely Keihin FCR series (e.g., FCR 39 or 41mm) - specific model confirmed in manual.

Fuel Delivery:

Carbureted with a mechanical fuel pump.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh manual transmission.

Optional

Optional Gearbox:

Features

Clutch Type:

Wet, multi-plate, hydraulically actuated.

Final Drive:

Chain drive.

📐 Dimensions

Exterior

Wheelbase:

Specific to model, typically around 1480-1500 mm for this class.

Weights

Dry Weight Sm400:

Approximately 115-120 kg (actual figure in manual).

Dry Weight Sm450:

Approximately 118-123 kg (actual figure in manual).

🛡️ Safety Features

Ratings

Safety Standards:

Manufactured to meet relevant European and international motorcycle safety standards for its era.

Active Features

Braking System:

Hydraulic disc brakes front and rear, typically with braided steel lines for improved feel and performance.

Passive Features

Frame Construction:

Chromoly steel frame for rigidity and strength.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Motorcycle of this era is focused on performance, not infotainment.)

Driver Assistance

Rider Aids:

N/A (No electronic rider aids like ABS or traction control are expected on these models.)

Connectivity

Connectivity Features:

N/A (No smart device integration or connectivity features.)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km or annually (specific interval provided in manual).

Valve Clearance Check:

Typically every 6,000-10,000 km (specific interval provided in manual).

Spark Plug Replacement:

Recommended at intervals specified in the manual, often coinciding with major services.

Fluid Specifications

Engine Oil Type:

Full synthetic SAE 10W-40 or 15W-50 motorcycle specific oil (specific viscosity and API rating in manual).

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water (specifics in manual).

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid (specific type confirmed in manual).

Fork Oil Type:

Specific grade of suspension fluid (e.g., SAE 5W or 10W) with specified quantity per fork leg (detailed in manual).

Known Issues

Common Wear Items:

Clutch plates, fork seals, wheel bearings, brake pads, and chain/sprockets are common wear items for this type of motorcycle.

Potential Electrical:

Early Husqvarna models could sometimes exhibit minor electrical gremlins or issues with connectors; wiring diagrams are crucial.

Carburetor Tuning:

Carburetors often require meticulous tuning for optimal performance, especially with aftermarket exhaust or air filter modifications. Manual provides factory settings.

📚 Vehicle History

Brand Heritage

Brand Origin:

Husqvarna Motorcycles is a Swedish brand with a long and storied history dating back to 1903, known for its off-road and motocross prowess.

Model Evolution

Supermoto Development:

These models represent Husqvarna's entry and development in the supermoto segment, adapting their off-road expertise for street performance.

Production

Manufacturing Period:

2003-2004 model years, indicating these are part of a specific generation of Husqvarna supermotos.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

Husqvarna motorcycles have a strong reputation in off-road and supermoto racing circuits for their performance and durability when properly maintained.