Segment:
Supermoto / Dirt Bike Crossover
Target Audience:
Enthusiast owners, independent repair shops, and DIY mechanics
Competitors:
Other dual-sport or supermoto models from brands like KTM, Suzuki, Yamaha, and Honda of the same era.
Resource Value:
Essential resource for maintaining and repairing the Husqvarna SM 400, ensuring longevity and optimal performance.
Download Benefit:
Instant access to critical service information, enabling immediate work on the vehicle.
Primary Coverage:
All 2004-2005 Husqvarna SM 400 Models
Geographic Coverage:
Global (assuming standard factory service information)
Estimated Page Count:
Extensive (details expected to cover comprehensive repair procedures)
Type:
Workshop Repair Manual / Service Manual
Language:
English (typical for workshop manuals of this era and origin)
Engine:
Complete overhaul, diagnosis, tuning, and component repair
Transmission:
Disassembly, assembly, inspection, and repair of gearbox and clutch
Fuel System:
Carburetor (likely Mikuni or Keihin) tuning, cleaning, and rebuilding; fuel tank, lines, and pump (if applicable)
Ignition System:
CDI, spark plugs, wiring, and troubleshooting
Cooling System:
Radiator, hoses, thermostat, coolant specifications, and flushing procedures
Exhaust System:
Component inspection and replacement
Chassis:
Frame inspection, maintenance, and component mounting
Suspension:
Front forks (e.g., Marzocchi) and rear shock absorber (e.g., Sachs) disassembly, service, and adjustments
Brakes:
Hydraulic system (front and rear disc brakes), caliper overhaul, master cylinder service, pad replacement, fluid specifications, and bleeding procedures
Wheels And Tires:
Tire inspection, replacement, and pressure specifications; wheel bearing service
Electrical System:
Wiring diagrams, battery maintenance, lighting, horn, starter motor, and troubleshooting of electrical faults
Bodywork And Plastics:
Fairing, seat, fenders, and tank removal/installation
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, and general upkeep
Troubleshooting:
Diagnostic charts and procedures for common and uncommon issues
Repair:
Step-by-step repair instructions for all major and minor components
Disassembly Reassembly:
Detailed procedures for taking apart and putting back together all mechanical and electrical assemblies
Adjustments:
Carburetor synchronization, valve clearance adjustment, chain tension, brake lever free play, etc.
Overhaul:
Complete engine and transmission rebuild procedures
Depth:
Comprehensive: Covers everything from basic maintenance to advanced engine rebuilding and electrical diagnostics.
Diagram Quality:
High: Features exploded views and detailed diagrams for easy identification and understanding of component relationships.
Compatibility:
PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, Windows 7 & 8, etc.)
Printability:
Printable (typical for PDF manuals)
Binding:
Not Applicable (Digital Download)
Paper Type:
Not Applicable (Digital Download)
Engine Type:
Single-cylinder, Four-stroke
Displacement:
Approximately 398cc (as indicated by '400' in model name)
Bore X Stroke:
Specifics would be detailed within the manual, likely around 80mm x 79mm based on common Husqvarna single-cylinder configurations of the era.
Cooling System:
Liquid-cooled
Compression Ratio:
Specifics will be found in the manual, likely in the range of 10.5:1 to 12.0:1.
Horsepower:
Estimated 30-35 HP (typical for a 400cc class supermoto of this era)
Torque:
Specifics would be detailed within the manual, typically around 25-30 lb-ft.
Carburetor Type:
Likely a single Mikuni TM40 or Keihin FCR carb (manual will specify exact model and jetting)
Fuel Type:
Unleaded Gasoline (Premium recommended, octane rating to be specified in manual)
Actuation:
DOHC (Double Overhead Camshafts), 4 valves per cylinder
Type:
Constant Mesh, 6-speed Sequential
Optional Transmissions:
Not Applicable (Standard 6-speed for this model)
Clutch Type:
Wet Multi-plate, Cable Operated
Gear Ratios:
Specific ratios will be detailed in the manual.
Final Drive:
O-ring sealed chain, 520 pitch (typical)
Transmission Oil Type:
Specific SAE viscosity grade (e.g., SAE 10W-40 or 10W-50) and API classification will be specified in the manual.
Length:
Specifics found in manual, typical for supermoto (approx. 2200mm)
Width:
Specifics found in manual, typical for supermoto (approx. 850mm)
Height:
Specifics found in manual, typical for supermoto (approx. 1200mm)
Dry Weight:
Estimated around 120-130 kg (typical for this class)
Wet Weight:
Specifics would require fluid capacities and will be in the manual.
Cargo Capacity:
N/A (Motorcycle)
Crash Test Results:
Not Applicable (Motorcycles are not subjected to the same crash testing as passenger vehicles)
Brakes:
Hydraulic Disc Brakes (Front & Rear), braided steel lines likely standard
Lighting:
Headlight, Taillight, Brake Lights, Turn Signals
Frame Construction:
Steel or Aluminum perimeter frame (specifics in manual)
Handlebar:
Fat bar design for improved impact absorption and control
Infotainment System:
N/A (Basic instrumentation typical for this era and style of motorcycle)
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights.
Driver Assistance Features:
N/A (No electronic rider aids typical for this model year)
Connectivity Features:
N/A
Oil Change Interval:
Typically every 3,000-5,000 km or annually (specific interval detailed in manual)
Air Filter Cleaning:
Recommended every 1,000-2,000 km or as needed based on riding conditions.
Valve Clearance Check:
Typically every 6,000-10,000 km (critical for engine health).
Chain Lubrication Adjustment:
Recommended every 500 km or after riding in wet conditions.
Engine Oil Type:
Specific SAE viscosity and API rating (e.g., JASO MA approved motorcycle oil, SAE 10W-50) will be listed in the manual.
Brake Fluid Type:
DOT 4 specified (common for hydraulic disc brakes, confirm in manual).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (specified mix ratio and type in manual).
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment.
Electrical Connections:
Corrosion or loose connections can occur on older models, requiring inspection and cleaning.
Suspension Seals:
Fork seals and rear shock seals can degrade over time and require replacement.
Starter Motor Relay:
Occasional failure of the starter relay can prevent starting.
