HUSQVARNA Motorcycle SM 400 SM 450 R Full Service & Repair 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 performance-oriented machines, known for their agile handling and powerful engines, are...

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Tipo: Motorcycle

Proveedor:

SKU: 151117

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

Variantes de producto

Descripción

This manual covers the SM 400 R and SM 450 R Supermoto motorcycles produced between 2003 and 2004. These performance-oriented machines, known for their agile handling and powerful engines, are built upon a rich Swedish heritage in off-road racing. They represent a blend of motocross and enduro capabilities adapted for street use, offering an exciting riding experience. The engineering quality of these models is designed for enthusiasts seeking a capable and dynamic motorcycle for both spirited riding and everyday use. This comprehensive Factory Service Repair Workshop Manual provides detailed guidance for all aspects of maintenance, servicing, and repair for your SM 400 R or SM 450 R. It includes in-depth procedures for engine overhauls, transmission servicing, chassis maintenance, suspension adjustments, brake system repairs, and electrical system diagnostics. With hundreds of detailed photos, diagrams, and step-by-step instructions, this manual is an essential resource for owners and technicians alike to ensure optimal performance, reliability, and longevity of the motorcycle.

🏷️ Basic Information

Identification

Make:

Husqvarna

Model:

SM 400 R / SM 450 R

Model Variant:

Supermoto

Product Type:

Full Service & Repair Manual

Product Name:

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

👋 Introduction

Market Position

Market Segment:

Performance Supermoto / Motard Motorcycles

Target Audience:

Husqvarna SM 400 R / SM 450 R owners, independent repair shops, motorcycle enthusiasts

Competitive Analysis

Competitors:

Models from KTM (e.g., 450 EXC/SMR), Yamaha (e.g., WR450F converted), Suzuki (e.g., DRZ400SM), Honda (e.g., CRF450R converted)

Key Features

Feature 1:

Factory-level repair and maintenance information

Feature 2:

Detailed visual aids (photos, diagrams)

Feature 3:

Comprehensive troubleshooting and diagnostic guidance

Feature 4:

Lifetime access and usability

📋 Manual Details

Coverage Areas

Coverage Years:

2003-2004

Coverage Models:

SM 400 R, SM 450 R

Page Count

Estimated Page Count:

Hundreds (Specific count not provided, but described as 'very detailed' with 'hundreds of pages')

Manual Type

Type:

Factory Service Repair Workshop Manual

Description:

Professional Manual covering all repairs, servicing, and troubleshooting procedures.

Language

Language:

English (Assumed, standard for service manuals of this nature)

Format

File Format:

Accessibility:

Instant download for computer, tablet, or smartphone

Licensing

Licensing Model:

Lifetime use, no expiry, no renewal fees, no limitations

Device Compatibility:

Unlimited computers/devices

Trial Version:

No, full version only

Printing

Print Capability:

Print single pages or entire manual

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, diagnostics, component specifics (e.g., carburetor, ignition, cooling system if applicable)

Transmission:

Clutch, gearbox operation, maintenance, repair procedures, lubrication

Chassis:

Frame inspection and repair, swingarm, linkage maintenance, bearing service

Suspension:

Front fork (USD), rear shock absorber service, adjustments, seal replacement, damping control

Brakes:

Front and rear brake system maintenance, caliper service, master cylinder rebuild, bleeding procedures, pad replacement, rotor inspection

Electrical:

Wiring diagrams, lighting system, ignition system components, battery maintenance, charging system (stator, regulator/rectifier), starter motor

Fuel System:

Fuel tank, fuel pump (if applicable), fuel lines, carburetor settings and cleaning

Exhaust System:

Muffler, header pipe maintenance and repair

Cooling System:

Radiator, coolant hoses, fan (if applicable), coolant specifications and replacement

Wheels Tires:

Wheel bearing service, tire pressure specifications, rim inspection

Bodywork:

Fairings, seat, fenders, graphics removal and installation

Procedures Included

Maintenance:

Routine servicing, oil changes, filter replacements, chain adjustment, pre-ride checks

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault finding guides

Repair:

Step-by-step instructions for component disassembly, repair, and reassembly

Rebuild:

Detailed procedures for major component overhauls (e.g., engine, gearbox, suspension)

Diagnostics:

Electrical system diagnostics, engine performance testing

Cleaning:

Specific cleaning procedures for components like carburetors, fuel injectors (if applicable), and electrical connectors

Technical Depth

Depth:

Comprehensive (Professional Mechanic/Technician level)

Visuals:

Hundreds of detailed photos & diagrams, exploded diagrams

Instructions:

Step-by-step instructions for every job

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text within PDF (standard for quality manuals)

Print Quality

Print Resolution:

High resolution for clear diagrams and text

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, 4-stroke (common for these models, specific details likely in manual)

Engine Displacement 400:

Approximately 400cc (Specific CC for SM 400 R to be confirmed in manual)

Engine Displacement 450:

Approximately 450cc (Specific CC for SM 450 R to be confirmed in manual)

Cooling System:

Liquid-cooled (Standard for these performance-oriented models)

Performance

Horsepower:

Estimated 40-50 HP range (Specific figures to be confirmed in manual)

Torque:

Torque figures to be confirmed in manual

Fuel System

Carburetor Size 400:

Likely Keihin FCR 39mm or similar for SM 400 R (specific details in manual)

Carburetor Size 450:

Likely Keihin FCR 41mm or similar for SM 450 R (specific details in manual)

Fuel Type:

Unleaded gasoline (Regular or Premium, specified in manual)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 5-speed (typical for these models)

Features

Clutch Type:

Wet multi-plate (Standard)

Gear Ratios:

Specific gear ratios for each model variant to be detailed in the manual

Final Drive:

Chain drive (Standard)

📐 Dimensions

Weights

Dry Weight:

Estimated 240-260 lbs (110-120 kg) range (Specifics for each model in manual)

Wet Weight:

To be confirmed in manual (includes fluids)

🛡️ Safety Features

Active Features

Brakes Front:

Hydraulic disc brake, multi-piston caliper (e.g., Brembo, Nissin) with specific rotor size

Brakes Rear:

Hydraulic disc brake, single-piston caliper with specific rotor size

Passive Features

Frame Type:

Steel or aluminum perimeter/trellis frame (Specific to Husqvarna design)

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrumentation: speedometer, odometer, engine warning lights)

Driver Assistance

No ABS typically offered on these models from this era

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typical 3,000-5,000 km or annually (Specific intervals and oil type in manual)

Valve Clearance Check:

Typically every 5,000-10,000 km (Critical procedure detailed in manual)

Chain Maintenance:

Regular cleaning, lubrication, and adjustment (Frequency dependent on riding conditions)

Fluid Specifications

Engine Oil Type:

Likely SAE 10W-40 or 10W-50, JASO MA certified (Specifics in manual)

Coolant Type:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water (Specifics in manual)

Brake Fluid Type:

DOT 4 (Standard for hydraulic brakes, specify in manual)

Known Issues

Issue 1:

Carburetor tuning can be sensitive to altitude and temperature changes, requiring periodic adjustment.

Issue 2:

Some owners report wear on the kickstart mechanism if not operated correctly.

Issue 3:

Regular chain and sprocket inspection/replacement is crucial for drivetrain longevity.

Issue 4:

Valve clearance checks are important for maintaining engine performance and preventing damage.

📚 Vehicle History

Brand Heritage

Brand Origin:

Swedish (Husqvarna is one of the oldest motorcycle manufacturers)

Model Evolution

Supermoto Development:

Husqvarna has a strong off-road heritage and transitioned into performance street-legal off-road conversions, including supermotos.

Production

Production Period:

Early 2000s, building on their success in motocross and enduro