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Husqvarna SM400R 2007 2008 Workshop Service Repair Manual

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The SM400R is a performance-oriented supermoto motorcycle designed for agile handling and spirited riding, available for the 2007 and 2008 model years. Building on a rich heritage as one of...
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Husqvarna SM400R 2007 2008 Workshop Service Repair Manual
The SM400R is a performance-oriented supermoto motorcycle designed for agile handling and spirited riding, available for the 2007 and 2008 model years. Building on a rich heritage as one of the world's oldest motorcycle manufacturers, this model blends off-road prowess with street legality, offering a unique proposition in its class. It features a liquid-cooled, single-cylinder engine, a 6-speed manual transmission with a wet multi-plate clutch, and chain drive, all contributing to its dynamic performance and responsive feel. The SM400R is engineered for riders seeking a capable machine for both spirited street riding and occasional off-road excursions, embodying a robust build quality and a focus on rider engagement. This comprehensive workshop service repair manual provides detailed information essential for the maintenance, troubleshooting, and repair of your SM400R. It covers all major vehicle systems, including the engine, transmission, chassis, brakes, and electrical components, with in-depth procedures for overhaul, component replacement, and routine maintenance. The manual also includes critical technical specifications, such as torque values and fluid capacities, along with diagnostic flowcharts for addressing common issues. Its extensive coverage, presented in a clear and organized manner, is designed to empower owners, mechanics, and technicians to effectively care for and maintain the SM400R, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Husqvarna
Model:
SM400R
Year:
2007, 2008
Codes
Engine Code:
Not explicitly provided, assumed 400cc single-cylinder based on model name
👋 Introduction
Market Position
Segment:
Supermoto / Motard Motorcycle
Target Audience:
Owners, mechanics, and enthusiasts seeking in-depth knowledge for maintenance and repair of the Husqvarna SM400R.
Competitive Analysis
Competitors:
Other 400-450cc supermoto models from brands like KTM, Yamaha, Honda, Suzuki, and Aprilia from the mid-2000s era.
Key Features
Vehicle Focus:
Performance-oriented dual-sport motorcycle with strong off-road DNA adapted for street legality and agile handling.
Manual Benefit:
Enables DIY maintenance and repair, understanding of technical specifications, and effective troubleshooting, thus saving time and money.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Page Count
Estimated Page Count:
Hundreds (as stated in description)
Manual Type
Type:
Complete Official Full Factory Service Repair Manual
Language
Language:
English (Assumed, standard for factory manuals)
Format
Format:
Downloadable (Digital Format)
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, tuning, troubleshooting, component replacement, lubrication system, cooling system, fuel delivery system, ignition system, emissions control.
Transmission:
Gearbox inspection, disassembly, reassembly, clutch operation and maintenance, lubrication, troubleshooting.
Chassis:
Frame inspection, suspension (front fork and rear shock absorber), steering system, swingarm, bearings, wheel hubs.
Brakes:
Brake system overhaul (front and rear), hydraulic components, caliper service, master cylinder service, bleeding procedures, pad replacement, disc inspection.
Electrical:
Wiring diagrams, starter system, charging system (alternator, battery), lighting system, ignition coils, ECU, sensors, diagnostic codes (if applicable).
Fuel System:
Carburetor disassembly, cleaning, adjustment, jetting, fuel tank maintenance, fuel lines.
Bodywork:
Fairing removal and installation, seat, fenders, exhaust system, footpegs.
Procedures Included
Maintenance:
Routine inspections, oil changes, filter replacements, chain adjustment and lubrication, spark plug service, brake fluid replacement, coolant replacement, air filter cleaning.
Troubleshooting:
Diagnostic flowcharts for common problems, identification of causes and solutions for performance issues, starting difficulties, electrical faults.
Repair:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major vehicle systems.
Technical Specifications:
Torque values for fasteners, engine clearances, electrical component specifications, fluid capacities, dimensional data.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Includes detailed diagrams and exploded views.
📊 Manual Specifications
File Format
Format:
PDF (Likely, common for downloadable manuals)
Print Quality
Printability:
Printable (Entire manual or specific sections)
Binding Type
Binding:
Not applicable (Digital download)
Paper Type
Paper Type:
Not applicable (Digital download)
⚙️ Engine Specifications
Primary Engine
Type:
Single-cylinder, 4-stroke
Displacement:
Approximately 400cc (exact value not provided in product info)
Bore X Stroke:
Refer to manual for exact specifications
Cooling System:
Liquid-cooled
Valve Train:
SOHC or DOHC (refer to manual for specific configuration)
Performance
Horsepower:
Estimated 35-40 HP (typical for this class and era)
Torque:
Refer to manual for exact specifications
Fuel System
Carburetor:
Mikuni VM series or similar (refer to manual for exact model and jetting)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
🔧 Transmission
Standard
Type:
6-speed manual
Clutch:
Wet multi-plate clutch
Final Drive:
Chain drive
Features
Gear Ratios:
Refer to manual for exact gear ratios
📐 Dimensions
Exterior
Length:
Refer to manual for exact specifications
Width:
Refer to manual for exact specifications
Height:
Refer to manual for exact specifications
Weights
Dry Weight:
Approximately 125-135 kg (estimate for this class)
Wet Weight:
Refer to manual for exact specifications
🛡️ Safety Features
Ratings
Crash Test Data:
Not applicable for motorcycles
Active Features
Brakes:
Hydraulic disc brakes (front and rear)
Tires:
Tread pattern suitable for mixed-surface use (refer to manual for OE tire sizes)
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals
💡 Technology Features
Infotainment
Features:
Basic analogue/digital instrument cluster (speedometer, tachometer, odometer, trip meter, indicator lights). No advanced infotainment systems typical for modern cars.
Driver Assistance
Features:
None; relies on rider skill and machine control.
Connectivity
Features:
None.
🔧 Maintenance
Service Intervals
Oil Change:
Refer to manual; typically every 3,000-5,000 km or annually, whichever comes first.
Air Filter:
Refer to manual; clean every 1,000-2,000 km, replace as needed.
Chain Lubrication:
Refer to manual; typically every 500 km and after washing or rain.
Spark Plug:
Refer to manual; inspect every 5,000 km, replace as needed.
Fluid Specifications
Engine Oil:
Refer to manual for specific grade and capacity (e.g., SAE 10W-40, JASO MA certified)
Coolant:
Refer to manual for type and capacity (e.g., ethylene glycol-based coolant, 50/50 mix with distilled water)
Brake Fluid:
Refer to manual for type (e.g., DOT 4)
Transmission Oil:
Refer to manual; often shares oil with the engine or has a separate sump.
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, fork seals, exhaust packing, wheel bearings, rear shock absorber linkage bearings.
Electrical Gremlins:
Some older Husqvarna models can have minor electrical connection issues if not properly maintained or sealed against moisture.
Carburetor Tuning:
Carburetors may require periodic cleaning and adjustment due to fuel quality variations or altitude changes.
📚 Vehicle History
Brand Heritage
Heritage:
Husqvarna is one of the oldest motorcycle manufacturers in the world, with a strong heritage in off-road and competition racing.
Model Evolution
Supermoto Lineage:
The SM series represents Husqvarna's entry into the popular supermoto segment, leveraging their off-road expertise.
Production
Manufacturing Location:
Italy (Typical for Husqvarna motorcycles of this era)
Years Of Production:
Covered models are 2007 and 2008, part of a broader generation of SM400R/SM450R models.
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
Specific awards for the 2007-2008 SM400R are not widely publicized, but Husqvarna motorcycles generally receive acclaim for their performance and handling in their respective classes.
Ratings
Expert Reviews:
Often praised for agility, responsive engine, and a good balance between off-road capability and street performance.
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