Segment:
Performance off-road/motard motorcycle.
Target Audience:
Owners and mechanics seeking in-depth knowledge for maintaining and repairing the Husqvarna SM 400.
Key Competitors:
KTM EXC/SMR models, GasGas SM series, Yamaha WR/YZSM series.
Manual Value Proposition:
Provides comprehensive, factory-level technical information crucial for effective repair and maintenance of a specialized motorcycle.
Model Characteristics:
Known for potent single-cylinder engines, advanced chassis design, and agile handling, catering to performance-oriented riders.
Primary Coverage:
Mechanical Repair, Maintenance, Overhaul, Troubleshooting, Restoration
Secondary Coverage:
Electrical Systems, Chassis Components, Bodywork
Estimated Pages:
Hundreds (as stated in product description)
Type:
Service Repair Manual
Language:
English (assumed, typical for such manuals)
Engine:
Engine disassembly, assembly, tuning, lubrication, cooling, ignition, and fuel systems.
Transmission:
Gearbox components, clutch, shifting mechanisms, lubrication, and maintenance.
Chassis:
Frame, suspension (front forks, rear shock absorber), steering, wheels, and hubs.
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders, lines, pads, discs), bleeding procedures.
Electrical:
Wiring diagrams, lighting system, ignition system, battery, starter, charging system.
Fuel System:
Carburetor(s) (type and settings), fuel lines, fuel pump (if applicable), tank.
Maintenance:
Regular service checks, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance checks.
Troubleshooting:
Diagnostic procedures for common running issues, electrical faults, and mechanical problems.
Repair:
Detailed step-by-step instructions for component removal, repair, and reinstallation.
Rebuild Refurbish:
Comprehensive guidance for engine, transmission, and suspension rebuilds.
Depth:
Highly detailed, suitable for professional mechanics and experienced DIY enthusiasts. Covers complete engine teardowns, transmission overhauls, and electrical system diagnostics.
Diagnostic Focus:
Includes specific symptom-to-cause diagnostic flowcharts and troubleshooting trees.
Engine Type:
Single-cylinder, four-stroke (typical for this model era).
Displacement:
Approximately 400cc (specific exact displacement may vary slightly by sub-model or regional variant).
Bore X Stroke:
Specifics required from manual, but typical for the 400cc class.
Cooling System:
Liquid-cooled (standard for performance motorcycles of this era).
Valve Train:
SOHC or DOHC, typically with 4 valves (specific configuration to be confirmed in manual).
Horsepower:
Estimated 40-45 HP (dependent on specific tune and model year variant).
Torque:
Estimated 35-40 Nm (dependent on specific tune and model year variant).
Carburetor:
Mikuni or Keihin flat-slide carburetor (e.g., 38mm or 41mm are common).
Ignition System:
Digital CDI or electronic ignition.
Type:
6-speed constant mesh, sequential.
Options:
Not typically offered as an option; standard configuration for the model.
Clutch Type:
Wet multi-plate, hydraulically actuated.
Gear Ratios:
Specific gear ratios available in the manual for detailed analysis.
Final Drive:
Chain drive.
Seat Height:
High, typical for off-road based motorcycles; specific value to be confirmed in manual.
Wheelbase:
Approximately 1450-1470 mm (typical for this class).
Dry Weight:
Around 120-130 kg (estimated, subject to specific model configuration).
Safety Ratings:
N/A (Motorcycles are not subjected to formal crash safety ratings like cars).
Braking System:
Performance disc brakes front and rear, often Brembo components.
Suspension:
High-quality adjustable suspension (e.g., WP or Marzocchi forks, adjustable monoshock) for enhanced control and stability.
Frame Construction:
Chromoly steel or aluminum frame, designed for rigidity and impact resistance.
Infotainment System:
N/A (Motorcycle focused on performance, lacks car-style infotainment).
Assistance Features:
N/A (No electronic rider aids like ABS or traction control typically found on this model).
Instrumentation:
Digital or analog instrument cluster displaying speed, RPM, odometer, trip meter, and indicator lights.
Oil Change Interval:
Typically every 3,000-5,000 km or annually (specific recommended interval detailed in manual).
Valve Check Interval:
Around 6,000-10,000 km (critical for 4-stroke performance, detailed in manual).
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment; frequency depends on riding conditions.
Engine Oil Type:
High-quality synthetic motorcycle oil, SAE 10W-40 or 15W-50 (specific viscosity and API rating in manual).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (refer to manual for exact specification).
Transmission Oil:
Dedicated gearbox oil or engine oil depending on design; specific grade and capacity in manual.
Common Wear Items:
Clutch plates, brake pads, wheel bearings, suspension seals, chain and sprockets.
Engine Considerations:
Valve adjustment precision is key for performance and longevity; carburetor tuning can be sensitive to altitude and temperature changes.
Electrical Considerations:
Wiring loom integrity and connections can be vulnerable to vibration and environmental exposure.
Brand Origin:
Husqvarna Motorcycles, founded in Sweden in 1903, with a long history in off-road racing and innovation.
Lineage:
Part of Husqvarna's highly successful SMR (Supermoto) line, which evolved from their potent enduro and motocross platforms.
Production Period:
2004-2005 model years covered by this manual.
Manufacturing Location:
Typically Italy during this period under the Cagiva Group ownership, before acquisition by BMW.
