HUSQVARNA SM 400 450 510 R Workshop Repair Manual 2007

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This manual covers the SM 400 R, SM 450 R, and SM 510 R models from the 2007 production year. These high-performance Supermoto motorcycles are known for their lightweight chassis,...

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Typ: Motorcycle

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Art.-Nr: 129854

Stichworte: 2007 Husqvarna Motorcycle Motorcycles SM 400 SM 450 SM 510 R SM Models

Produktvarianten

Beschreibung

This manual covers the SM 400 R, SM 450 R, and SM 510 R models from the 2007 production year. These high-performance Supermoto motorcycles are known for their lightweight chassis, potent single-cylinder engines, and agile handling, making them suitable for competitive racing and spirited street riding. Derived from enduro platforms, these models emphasize power delivery and maneuverability, often featuring robust suspension and effective braking systems. The brand's heritage, originating in Sweden and evolving through various ownerships, contributes to a legacy of off-road and performance-oriented engineering. This professional workshop service and repair manual provides comprehensive guidance for all aspects of maintenance and repair for your Supermoto. It details procedures for engine overhaul, fuel and ignition systems, transmission, chassis, suspension, brakes, and electrical systems. The manual includes routine maintenance tasks, detailed engine and suspension rebuild instructions, troubleshooting diagnostics, and precise torque specifications. Its extensive scope ensures that owners, mechanics, and technicians have the necessary information to maintain, diagnose, and repair these vehicles effectively, covering everything from basic servicing to in-depth component replacement.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

SM 400 R, SM 450 R, SM 510 R

Year:

Codes

Chassis Codes:

Likely specific chassis codes exist for each model variation (e.g., TE610 chassis as a base for some components, or unique SM designations). Exact codes not provided in source.

Engine Codes:

Likely engine designations based on displacement (e.g., for SM 450 R, may refer to a 450cc single-cylinder engine).

👋 Introduction

Market Position

Segment:

High-performance Supermoto (SM) motorcycles, often utilized in competitive racing and aggressive street riding.

Competitive Analysis

Competitors:

Rival Supermoto models from brands like KTM (e.g., 450 EXC, 525 EXC variants), Yamaha (e.g., WR series), Suzuki (e.g., DRZ series), Honda (e.g., CR/CRF variants converted to SM), and Ducati (e.g., Hypermotard, though typically higher displacement).

Key Features

Features:

Lightweight chassis, potent single-cylinder engines (often derived from enduro platforms), capable suspension, and street-legal Supermoto tires and brakes. Emphasis on agile handling and power delivery.

📋 Manual Details

Coverage Areas

Scope:

Comprehensive service, repair, and maintenance procedures for the Husqvarna SM 400 R, SM 450 R, and SM 510 R models.

Page Count

Estimated Pages:

Thousands of pages (as stated in product description, typical for professional workshop manuals).

Manual Type

Type:

Professional Workshop Service & Repair Manual

Language

Language:

English (implied by dealership and technician focus, most common for such manuals)

Format

Format:

Acrobat PDF

Compatibility:

Windows & MAC compatible

📖 Manual Coverage

Systems Covered

Engine:

Full engine overhaul, including disassembly, inspection, assembly, timing, valve adjustment, piston and cylinder, crankshaft, lubrication system, and cooling system.

Fuel System:

Carburetor (likely Mikuni or Keihin) or Fuel Injection system components, fuel pump, filter, lines, and diagnostics.

Ignition System:

Ignition coils, CDI unit, spark plugs, wiring, and troubleshooting.

Transmission:

Gearbox internal components, clutch system, shift mechanism, and lubrication.

Chassis Suspension:

Front fork (e.g., Marzocchi, WP) overhaul, rear shock absorber, linkages, bearings, and adjustment.

Brakes:

Front and rear brake systems, including calipers, master cylinders, brake lines, pads, discs, bleeding procedures, and troubleshooting.

Electrical System:

Wiring diagrams, lighting, starter system, battery, charging system, fuses, and common electrical faults.

Wheels Tires:

Wheel bearing replacement, spoke tensioning, tire mounting and balancing, and recommended tire sizes.

Bodywork Frame:

Fairings, seat, fuel tank, frame inspection, and related hardware.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug replacement, brake pad inspection.

Engine Repair:

Top-end rebuilds, bottom-end rebuilds, valve clearance adjustment, cam chain replacement, gasket replacement.

Suspension Tuning:

Fork oil changes, fork seal replacement, shock absorber service, spring preload adjustment.

Troubleshooting:

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

Electrical Diagnostics:

Tracing faults using wiring diagrams, testing components.

Brake Service:

Brake fluid flush, caliper rebuilding, master cylinder replacement.

Clutch Service:

Clutch plate replacement, hydraulic clutch bleeding.

Torque Settings:

All critical torque specifications for engine, chassis, and suspension fasteners provided.

Fluid Capacities:

Precise fluid capacities for engine oil, coolant, transmission oil, and brake fluid.

Electrical Diagrams:

Detailed and comprehensive wiring diagrams for all electrical circuits.

Diagnostic Charts:

Troubleshooting charts and flow diagrams for identifying and resolving common issues.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly and reassembly, including bearing replacement, seal replacement, and component checks.

Suspension Rebuild:

Detailed procedures for servicing front forks and rear shock absorbers, including oil level and type specifications.

Technical Depth

Depth:

Factory diagnostic and repair procedures, suitable for professional technicians and mechanics. Covers everything from basic maintenance to complete engine rebuilds.

Diagnostic Tools:

Information on any required specialized tools for diagnosis and repair.

Parts Identification:

Identification of various components and their part numbers (though a separate parts catalog would be more detailed).

📊 Manual Specifications

File Format

Format:

Acrobat PDF

Searchability:

Searchable text (implied by PDF format for efficiency)

Print Quality

Quality:

Top Quality Professional (as stated in product description)

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

Four-stroke, single-cylinder, liquid-cooled (typically SOHC or DOHC, depending on specific model variant).

Displacement 400:

Approximately 400cc (exact figure requires model-specific VIN lookup or manual verification).

Displacement 450:

Approximately 450cc (e.g., could be around 449-450cc).

Displacement 510:

Approximately 510cc (e.g., could be around 501-510cc).

Performance

Horsepower Range:

Estimated 45-55+ HP, depending on displacement and tuning.

Torque Range:

Estimated 35-45+ lb-ft, depending on displacement and tuning.

Fuel System

Carburetion Or Fi:

Likely equipped with a carburetor (e.g., Mikuni TM40/42 or Keihin FCR series) for 2007 models, though some later models or variants might have seen fuel injection introduction. Manual will specify.

Fuel Type:

Unleaded gasoline, Octane rating typically 91 or higher.

Lubrication System

Type:

Wet sump (typical for Supermoto derivatives, though some racing engines might use dry sump systems - manual will confirm).

Cooling System

Type:

Liquid-cooled, with radiator and fan.

🔧 Transmission

Standard

Type:

5-speed or 6-speed constant mesh manual transmission (likely 6-speed for 2007 SM models).

Optional

Options:

N/A (Typically a single transmission option per model variant).

Features

Clutch Type:

Wet, multi-plate, hydraulically operated.

Final Drive:

Chain drive (typically 520 or 525 pitch).

📐 Dimensions

Exterior

Wheelbase:

Approximate range: 1450-1500 mm (will vary between 400, 450, 510 models).

Seat Height:

Approximate range: 850-900 mm (typical for Supermoto).

Weights

Dry Weight:

Approximate range: 115-130 kg (will vary significantly between models).

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP).

Active Features

Braking System:

High-performance hydraulic disc brakes front and rear. Front typically a large single disc with a radial-mount caliper. Rear a standard disc.

Lighting:

Headlight, taillight/brake light, turn signals (often removable for track use), and potentially auxiliary lighting.

Passive Features

Frame Construction:

Typically a lightweight, strong chromoly steel or aluminum frame.

💡 Technology Features

Infotainment

System:

Minimal to none. Primarily focused on performance and function. Likely includes a basic digital or analog instrument cluster displaying speed, RPM, odometer, trip meter, and warning lights.

Driver Assistance

Features:

N/A (No electronic rider aids like ABS, traction control, or riding modes typically found on 2007 Supermoto models).

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-5,000 km or annually (specific interval depends on riding conditions, manual will provide exact recommendation).

Air Filter Cleaning:

Every 1,000-2,000 km, or more frequently in dusty conditions.

Valve Clearance Check:

Typically every 5,000-10,000 km (critical for single-cylinder performance).

Chain Lubrication:

Every 500-800 km and after washing/wet riding.

Fluid Specifications

Engine Oil:

Viscosity: SAE 10W-40 or 15W-50. Specification: API SG, SH, SJ or JASO MA. Capacity: Approx. 1.0-1.5 Liters (manual will confirm exact capacity and type).

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors. Ratio: 50/50 distilled water and coolant. Capacity: Approx. 0.7-1.0 Liters.

Brake Fluid:

DOT 4 (or DOT 3 depending on specific caliper/master cylinder design, manual will confirm).

Fork Oil:

Specific viscosity and type (e.g., SAE 5W or 7.5W) and level specified in manual.

Known Issues

Common Problems:

Potential issues can include stator failures (common on some European single-cylinders of this era), regulator/rectifier problems, carburation tuning sensitivity, and wear on suspension components due to aggressive riding. Overheating can also be an issue if cooling system is not maintained. Refer to the manual for specific diagnostics.

📚 Vehicle History

Brand Heritage

Heritage:

Husqvarna Motorcycles has a long and storied history originating in Sweden, known for its off-road prowess and innovation in motorcycles, particularly in motocross and enduro. Acquired by Cagiva Group (Italy) in the 1980s, and later by other entities, impacting production locations and design evolution.

Model Evolution

Evolution:

The SM (Supermoto) models are typically derived from Husqvarna's robust enduro platforms (like the TE series) and adapted for street use with smaller front wheels, street tires, larger front brakes, and often different suspension tuning and gearing. The 2007 models represent a phase in Husqvarna's transition and development under various ownerships.

Production

Manufacturing Location:

Likely manufactured in Italy during the 2007 period, reflecting ownership under the Cagiva Group/MV Agusta Motor S.p.A. at that time.

🏆 Awards & Recognition

Recognitions

Awards:

Husqvarna Supermoto models have historically been well-regarded in their niche for performance and handling, often favored by experienced riders and racers. Specific awards for the 2007 models may exist in specialized motorcycle media reviews, but are not generally documented as mainstream consumer awards.