Category:
Performance Supermoto Motorcycle
Target Audience:
Enthusiast owners, independent mechanics, and workshop technicians seeking in-depth repair and maintenance information.
Competition:
Competes with other European supermoto manufacturers of the era, such as KTM EXC/SMC series, Aprilia SXV, and Ducati Hypermotard.
Value Proposition:
Provides significant cost savings on service and repairs by empowering owners and technicians with professional-level information.
Usability:
Easy to use with printable procedures, eliminating wear-and-tear issues of physical manuals.
General Coverage:
Comprehensive repair, maintenance, rebuild, refurbishment, and restoration for Husqvarna SM 400, SM 450, and SM 510 models.
Specific Coverage:
Engine, transmission, chassis, suspension, brakes, electrical system, fuel system, cooling system, exhaust system, bodywork, diagnostics, and troubleshooting.
Estimated Page Count:
Over 500 pages (typical for comprehensive workshop manuals of this era and complexity)
Type:
Digital Workshop Repair Manual
Engine:
Detailed breakdown of all engine components, assembly, disassembly, tuning, diagnostics, and repair procedures for single-cylinder, four-stroke engines.
Transmission:
Complete coverage of gearbox, clutch, and shifting mechanisms including maintenance, repair, and overhaul.
Fuel System:
Carburetor (Mikuni VM series common) and fuel injection system components, adjustments, cleaning, and troubleshooting.
Cooling System:
Radiator, coolant flow, water pump, and thermostat maintenance and repair.
Electrical System:
Ignition system, lighting, charging system (stator, regulator/rectifier), starter motor, battery, wiring diagrams, and component testing.
Brakes:
Hydraulic brake system, caliper maintenance, pad replacement, fluid bleeding, master cylinder and slave cylinder servicing.
Suspension:
Front forks (e.g., Marzocchi Shiver USD), rear shock absorber (e.g., Sachs or Ohlins depending on trim), seal replacement, oil changes, and adjustments.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm, wheel bearings, and general chassis maintenance.
Bodywork And Fairings:
Removal, installation, and repair of plastic body panels, seats, and fuel tank.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks.
Troubleshooting:
Diagnostic flowcharts and procedures for identifying and resolving common and uncommon issues across all vehicle systems.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and testing.
Rebuild:
Detailed instructions for complete engine, transmission, and suspension unit overhauls.
Diagnostics:
Fault code interpretation (if applicable), electrical testing, and mechanical measurement procedures.
Depth:
Professional technician level, covering everything from routine checks to complete engine rebuilds and advanced diagnostics.
Precision:
Includes precise torque specifications, clearances, and measurement tolerances for critical components.
Format:
PDF (Portable Document Format)
Image Quality:
High Quality Photos, Illustrations, and Diagrams
Searchability:
Likely searchable text within the PDF, facilitating quick information retrieval.
Binding:
N/A (Digital Download - No physical binding)
Paper Type:
N/A (Digital Download - No physical paper)
Operating Systems:
Compatible with Microsoft Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7, and all Mac computers.
Type:
Single-cylinder, four-stroke
Displacement Sm400:
Approximately 400cc (specific bore/stroke required from manual for exact figure)
Displacement Sm450:
Approximately 450cc (specific bore/stroke required from manual for exact figure)
Displacement Sm510:
Approximately 510cc (specific bore/stroke required from manual for exact figure)
Bore Stroke Sm400:
Example: 86 mm x 68 mm (typical for this displacement range, verify with manual)
Bore Stroke Sm450:
Example: 95 mm x 63.4 mm (typical for this displacement range, verify with manual)
Bore Stroke Sm510:
Example: 97 mm x 71 mm (typical for this displacement range, verify with manual)
Valve Train:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific engine variant, 4 valves per cylinder typical.
Horsepower Sm400:
Approx. 40-45 HP (verify with manual)
Horsepower Sm450:
Approx. 45-50 HP (verify with manual)
Horsepower Sm510:
Approx. 50-55 HP (verify with manual)
Torque Sm510:
Approx. 45-50 Nm (verify with manual)
Carburetor Type:
Mikuni VM38/VM40 or Keihin FCR Flatslide (common, verify with manual)
Fuel Injection:
Some variants may have electronic fuel injection (EFI), requiring specific manual coverage.
Ignition Type:
Electronic ignition (CDI or TCI)
Crash Safety:
N/A (Motorcycle safety ratings differ from automobiles; focus is on rider protection through design and equipment, detailed in manual)
Brakes:
High-performance hydraulic disc brakes (front and rear), often Brembo calipers. Specific disc sizes and caliper types will be in the manual.
Suspension:
Quality USD (Upside Down) front forks and adjustable monoshock rear suspension contribute to stability and control.
Lighting:
Headlight, taillight, brake lights, turn signals (compliance varies by market).
Oil Change:
Typically every 3,000-5,000 km or annually, whichever comes first (refer to manual for precise interval).
Valve Clearance:
Initial check at first service, then every 6,000-10,000 km (refer to manual for precise interval and procedure).
Chain And Sprockets:
Regular cleaning, lubrication, and tension adjustment; replacement based on wear.
Engine Oil:
SAE 10W-40 or 15W-50 semi-synthetic or fully synthetic motorcycle oil, API SG or higher (verify specific viscosity and API rating in manual).
Coolant:
Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio recommended). Specific coolant type may be specified.
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid (verify specific DOT rating in manual).
Fork Oil:
Specific ISO VG viscosity grade (e.g., 5W, 7.5W, 10W) and volume per fork leg (refer to manual).
Cam Chain Tensioner:
Some Husqvarna single-cylinder engines of this era can develop noise from the automatic cam chain tensioner. Manual will detail inspection and replacement.
Carburetor Tuning:
Carburetors may require periodic cleaning, adjustment, and jetting changes depending on altitude and modifications. Manual provides tuning guides.
Electrical Connections:
As with many performance bikes, check for corrosion or loose connections in the electrical system, especially in the lighting and charging circuits. Manual includes wiring diagrams for troubleshooting.
Suspension Seals:
Fork seal leaks can occur with hard use; the manual provides procedures for seal replacement.
Manufacturer:
Husqvarna Motorcycles, a historic Swedish brand with a strong off-road racing heritage, now owned by different entities over time (e.g., Cagiva Group, BMW, Pierer Mobility Group).
Supermoto Development:
Husqvarna has a long history in motocross and enduro, and the SM series represents their dedicated supermoto offerings, blending off-road chassis with street-legal components and performance.
Manufacturing Location:
Typically manufactured in Italy during this ownership period.
