Segment:
High-performance Supermoto motorcycles.
Competitors 2007:
KTM (e.g., 450 SXS, 525 EXC), Aprilia (e.g., SXV450, SXV550), Yamaha (e.g., YZF-R6 conversion), Suzuki (e.g., RM-Z450 conversion).
Target Audience:
Husqvarna SM 400R, 450R, 510R owners and technicians requiring detailed repair and maintenance information.
Manual Value Proposition:
Provides all necessary technical information for performing all repairs and services, simplifying complex procedures.
Content Format:
Includes illustrations, diagrams, specifications, step-by-step instructions, and pictures.
Engine Mechanical:
Complete overhaul, disassembly, assembly, inspection, repair of all engine components.
Fuel System:
Carburetor (Mikuni TMR40 for 400/450, TMR41 for 510, or Keihin FCR for some variants), fuel pump, fuel lines, fuel tank.
Ignition System:
CDI, spark plugs, wiring, timing.
Cooling System:
Radiator, fan, hoses, coolant specifications and replacement.
Transmission Drivetrain:
Clutch operation, gearbox disassembly, assembly, gear inspection, shift mechanism.
Suspension:
Front forks (e.g., Marzocchi or Sachs), rear shock absorber, linkage system, adjustments, service.
Brakes:
Front and rear disc brakes, hydraulic systems, caliper service, master cylinders, brake fluid specifications.
Electrical System:
Wiring diagrams, battery, lighting, starter motor, charging system, instrument cluster.
Frame Chassis:
Frame inspection, steering head bearings, swingarm, footpegs, bodywork components.
Wheels Tires:
Wheel bearing service, tire pressure recommendations, wheel balancing.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug checks, brake fluid checks.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Engine Rebuild:
Detailed steps for complete engine teardown and rebuilding, including piston, ring, valve, and crankshaft service.
Suspension Servicing:
Fork seal replacement, shock absorber servicing and adjustment, linkage lubrication.
Brake System Repair:
Bleeding procedures, caliper rebuild, master cylinder service.
Electrical Diagnostics:
Wiring diagram interpretation, component testing, fault finding.
Carburetor Adjustment Overhaul:
Jetting information, float level adjustment, cleaning and rebuilding procedures.
Depth:
Comprehensive workshop level, suitable for professional technicians and experienced DIY mechanics.
Diagnostic Capabilities:
Detailed diagnostic flowcharts and procedures for identifying and resolving issues.
Rebuild Instructions:
Step-by-step instructions for complete overhauls of major components.
Engine Type:
Single-cylinder, 4-stroke, Liquid-cooled, DOHC
Displacement Sm400:
Approx. 397cc
Displacement Sm450:
Approx. 449cc
Displacement Sm510:
Approx. 501cc
Horsepower Sm400:
Typically in the range of 40-45 HP (estimated)
Horsepower Sm450:
Typically in the range of 45-50 HP (estimated)
Horsepower Sm510:
Typically in the range of 50-55 HP (estimated)
Torque:
Specific torque figures vary by model, but generally strong for displacement.
Carburetor Sm400 450:
Mikuni TMR40 or Keihin FCR (check specific model variant)
Carburetor Sm510:
Mikuni TMR41 or Keihin FCR (check specific model variant)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Safety Features Overview:
Focus on rider control and braking systems. No formal crash ratings for this type of vehicle.
Front Brake:
Hydraulic disc brake, typically with a large diameter rotor (e.g., 320mm) and multi-piston caliper.
Rear Brake:
Hydraulic disc brake, typically with a standard diameter rotor and single or dual-piston caliper.
Lighting:
Headlight, tail light, brake light, turn signals (market dependent).
Engine Oil Change:
Typically every 500-1000 km or 3-6 months (refer to specific manual for exact interval).
Air Filter Cleaning:
Regular inspection and cleaning, especially in dusty conditions. Replacement as needed.
Chain Maintenance:
Lubrication and tension adjustment every 300-500 km.
Valve Clearance Check:
Typically every 5,000 - 10,000 km or as specified in the manual. Critical for performance.
Engine Oil Type:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified.
Coolant Type:
Permanent antifreeze coolant (ethylene glycol based), mixed 50/50 with distilled water.
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, suspension seals, cam chain.
Carburetor Issues:
Can be sensitive to altitude and temperature changes; requires proper jetting and cleaning for optimal performance.
Electrical Connections:
Check for corrosion or looseness, particularly in high-vibration environments.
