Husqvarna SM510R 2007 2008 Service Repair Workshop Manual

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Stichworte: 2007 2008 Husqvarna Misc Motorcycle Motorcycles SM510R

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Beschreibung

Welcome to the comprehensive guide for the SM510R, covering models from 2007 and 2008. This Supermoto, or street-legal dirt bike, represents a performance-oriented machine known for its agile handling and urban street capability, blending off-road DNA with a focus on spirited riding. As a second-generation SM Series model, the SM510R was designed for enthusiasts and owners seeking a potent and engaging riding experience. This manual provides detailed information to help you understand and maintain your motorcycle. This workshop manual offers extensive coverage for the SM510R, encompassing everything from routine preventative maintenance, such as oil changes and filter replacements, to complete engine and transmission overhauls. You will find detailed procedures for servicing the engine, transmission, chassis, brakes, fuel system, and electrical components. Furthermore, the manual includes troubleshooting guides for common issues, diagnostic procedures, and essential technical specifications, including torque values, ensuring you have the necessary knowledge for effective maintenance and repair.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

SM510R

Year:

2007, 2008

Codes

Engine Code Prefix:

Generation

Model Generation:

Second Generation SM Series

👋 Introduction

Market Position

Segment:

Supermoto (SM) / Street-Legal Dirt Bike

Target Audience:

Enthusiasts, owners, and independent mechanics seeking in-depth repair and maintenance information.

Competitive Analysis

Competitors 2007 2008:

KTM 640/690 SMC, Ducati Hypermotard, Yamaha WR250X/WR450X (though some were not street-legal). Husqvarna offered a unique blend of Italian flair and potent performance.

Key Features

Vehicle Focus:

Performance-oriented, agile handling, urban street capability with off-road styling and DNA.

Manual Value Proposition:

Empowers owners to perform advanced maintenance and repairs, saving costs and maximizing vehicle uptime.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, top-end, bottom-end, valve train, lubrication system, cooling system, fuel injection system, ignition system.

Transmission:

Clutch operation, gearbox internal components, shifting mechanisms, lubrication.

Chassis:

Frame, swingarm, steering head, suspension (front forks and rear shock absorber), wheel bearings, chain and sprockets.

Brakes:

Hydraulic brake system, front and rear brake calipers, master cylinders, brake lines, brake pads, rotor inspection and replacement.

Electrical:

Wiring diagrams, battery, starter motor, alternator, lighting system, ignition system components, fuel pump, sensors, ECU troubleshooting.

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle body, EFI system diagnostics.

Bodywork:

Fairings, seat, handlebars, fenders, minor body panel removal and installation.

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, chain adjustment and lubrication, brake fluid flush, coolant flush, spark plug inspection/replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues.

Rebuilds:

Detailed instructions for engine and gearbox disassembly, inspection, and reassembly.

Adjustments:

Carburetor (if applicable, though EFI is standard), clutch, throttle cable, suspension settings.

Specifications Torque:

Torque specifications for all critical fasteners.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to full engine and component overhauls, including diagnostic procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution scans for clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

Searchability

Searchability:

Likely text-searchable PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder

Displacement:

498cc (approximately)

Bore X Stroke:

98 mm x 82 mm (typical for this platform)

Valvetrain:

SOHC, 4 valves per cylinder

Cooling System:

Liquid-cooled

Ignition System:

Electronic ignition, likely CDI or ECU controlled.

Performance

Horsepower:

Approx. 50-55 hp (estimate based on similar models)

Torque:

Approx. 45-48 Nm (estimate based on similar models)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), typically with a single injector.

Throttle Body Size:

Likely 45-50mm

Lubrication System

Oil Type:

Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 recommended (check manual for specifics).

Oil Capacity:

Approx. 1.5 - 1.7 liters (with filter change)

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Features

Clutch Type:

Wet, multi-plate, hydraulically operated

Final Drive:

O-ring sealed chain, 520 pitch

📐 Dimensions

Exterior

Seat Height:

Approx. 35-36 inches (889-914 mm)

Weights

Dry Weight:

Approx. 120-125 kg (265-275 lbs)

Wet Weight:

Approx. 135-140 kg (298-308 lbs)

Fuel Tank Capacity:

Approx. 7-8 liters

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle, not subject to automotive crash safety ratings).

Active Features

Braking System:

Hydraulic disc brakes, front and rear.

Front Brake Rotor:

Single 320mm disc with radial-mount 4-piston caliper (common setup).

Rear Brake Rotor:

Single 240mm disc with single-piston caliper.

Passive Features

Tires:

Street-biased Supermoto tires. Typical sizes: Front 120/70-17, Rear 150/60-17.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation: speedometer, tachometer, odometer, trip meter, basic indicator lights).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like ABS or traction control typically found on this model year).

Connectivity

Connectivity Features:

Engine Management

ECU Functionality:

Engine Control Unit manages fuel injection, ignition timing, and other engine parameters.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km or annually, whichever comes first (refer to manual for exact spec).

Air Filter Cleaning:

Every 3,000-5,000 km or more frequently in dusty conditions.

Spark Plug Inspection:

Every 6,000-8,000 km.

Valve Clearance Check:

Every 10,000-12,000 km.

Fluid Specifications

Engine Oil Grade:

JASO MA/MA2 certified, SAE 10W-40 or 15W-50 recommended.

Coolant Type:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Clutch Fluid Type:

DOT 4 hydraulic brake fluid (shared system).

Known Issues

Electrical Connections:

Corrosion or poor connections in wiring harnesses can sometimes lead to intermittent electrical issues.

Fuel Injector Clogging:

Can occur with poor fuel quality, leading to rough running.

Suspension Seals:

Fork seals and rear shock seals can wear over time, requiring replacement for optimal damping and leak prevention.

Cam Chain Tensioner:

Hydraulic tensioners can sometimes fail, leading to rattling noise; replacement is critical.

📚 Vehicle History

Brand Heritage

Brand Origin:

Swedish, founded in 1689. Motorcycle production began in 1904. Known for off-road and dual-sport motorcycles.

Model Evolution

Sm510R Context:

The SM510R was part of Husqvarna's successful foray into the supermoto segment, building on their strong off-road platform. This generation featured fuel injection and a more modern chassis.

Production

Manufacturer Country:

Italy (Husqvarna was owned by the Cagiva Group during this period).

Production Period:

Mid-2000s to late 2000s for this specific platform update.

🏆 Awards & Recognition

Recognitions

Awards:

Husqvarna motorcycles have a strong history in off-road racing and have received numerous accolades in various disciplines. Specific awards for the SM510R model year are not widely publicized but it was well-regarded in the supermoto community for its performance and handling.