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Husqvarna SM400R 2007 2008 Service Repair Manual

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The SM400R, produced for the 2007 and 2008 model years, is a performance-oriented supermoto motorcycle designed to blend off-road capability with agile street handling. Building on a rich heritage in...
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Husqvarna SM400R 2007 2008 Service Repair Manual
The SM400R, produced for the 2007 and 2008 model years, is a performance-oriented supermoto motorcycle designed to blend off-road capability with agile street handling. Building on a rich heritage in off-road racing, this model offers a potent four-stroke, single-cylinder engine with an estimated displacement of 398 cc, delivering an estimated 35-45 horsepower. Its construction emphasizes a lightweight chassis, robust suspension, and powerful braking systems, making it a capable machine for both spirited riding and everyday use. The SM400R stands out for its focused design, prioritizing rider engagement and performance characteristics often compared to competitors like the DR-Z400SM. This comprehensive Service Repair Manual is your definitive guide to maintaining and repairing your SM400R. Covering a wide array of systems, including detailed procedures for the engine, transmission, chassis, and electrical components, this manual ensures you have the knowledge to keep your motorcycle in peak condition. It provides step-by-step instructions for routine maintenance, such as oil changes and filter replacements, as well as in-depth repair guidance for complex issues. Furthermore, this manual includes essential troubleshooting information, diagnostic procedures, and details on specialized tools, empowering owners and technicians to effectively service and preserve the integrity of the SM400R.
🏷️ Basic Information
Identification
Make:
Husqvarna
Model:
SM400R
Year:
2007, 2008
Codes
Chassis Code:
Likely specific to model variant, requires manual inspection for precise designation.
👋 Introduction
Market Position
Category:
Supermoto motorcycle.
Target Audience:
Husqvarna SM400R owners seeking to perform their own maintenance and repairs.
Competitive Analysis
Competitors:
Suzuki DR-Z400SM, Yamaha WR450F (SM conversions), KTM 640/650 Duke II/SMC.
Key Features
Vehicle Purpose:
Performance-oriented supermoto, blending off-road capability with street agility.
📋 Manual Details
Coverage Areas
Primary Focus:
Service and Repair
Scope:
Comprehensive repair and maintenance procedures.
Page Count
Estimated Pages:
Likely 200-400 pages, typical for a comprehensive service manual of this era.
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF
File Format
File Type:
PDF
Print Quality
Resolution:
High resolution for clear text and diagrams, suitable for printing.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
📖 Manual Coverage
Systems Covered
Engine:
Engine disassembly, assembly, tuning, diagnostics, lubrication system, cooling system, fuel system, ignition system.
Transmission:
Clutch, gearbox inspection and repair, gear shift mechanism.
Chassis:
Frame inspection, suspension system (front and rear), steering system, wheels and tires, braking system (front and rear).
Electrical:
Wiring diagrams, battery, lighting system, ignition system components, starter motor, alternator, instrumentation, diagnostic connectors.
Bodywork:
Fairings, seat, fuel tank, fenders, body panel removal and installation.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, valve clearance checks, brake pad replacement.
Diagnostics:
Troubleshooting common problems, symptom-based diagnostics, error code interpretation (if applicable).
Repair:
Detailed step-by-step repair procedures for all major components, including engine rebuilds, suspension overhauls, and electrical system repairs.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance tasks.
Technical Depth
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission overhauls.
Diagnostic Capabilities:
Advanced diagnostic procedures and troubleshooting guides.
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, single-cylinder, liquid-cooled.
Displacement:
398 cc (likely, based on model name).
Bore X Stroke:
Requires manual verification; typically around 85mm x 70mm for this displacement.
Compression Ratio:
Typically 11.0:1 to 12.5:1, requires manual verification.
Performance
Horsepower:
Estimated 35-45 HP, depends on specific tuning and regulations. Manual will provide exact figures.
Torque:
Estimated 30-35 Nm, requires manual verification.
Fuel System
Carburetion:
Mikuni VM38SS or similar, or fuel injection on later/specific variants. Manual will specify.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2 (AKI).
Lubrication System
Oil Type:
SAE 10W-40 or 20W-50 motorcycle-specific oil, JASO MA certified. Manual will confirm exact specification.
Oil Capacity:
Approximately 1.5-1.8 liters (with filter change). Manual will provide precise figure.
Cooling System
Type:
Liquid-cooled.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors. Manual will specify brand/type and mixture ratio.
🔧 Transmission
Standard
Type:
5-speed constant mesh.
Optional
Optional Transmissions:
None typically offered for this model.
Features
Clutch Type:
Wet, multi-plate.
Final Drive:
O-ring sealed chain drive.
Gear Ratios:
Specific ratios will be detailed in the manual. Typical for this class.
📐 Dimensions
Exterior
Length:
Approx. 2200 mm. Manual will provide exact.
Width:
Approx. 850 mm (handlebar width). Manual will provide exact.
Height:
Approx. 1250 mm (seat height). Manual will provide exact.
Wheelbase:
Approx. 1470 mm. Manual will provide exact.
Ground Clearance:
Approx. 250-300 mm. Manual will provide exact.
Weights
Dry Weight:
Approx. 130-135 kg. Manual will provide exact specification.
Wet Weight:
Approx. 145-150 kg (fully fueled). Manual will provide exact specification.
Fuel Capacity:
Approx. 8-10 liters. Manual will provide exact figure.
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not typically assigned official safety ratings like cars; however, the manual will cover braking system safety checks and maintenance.
Active Features
Braking System:
Hydraulic disc brakes front and rear. Manual details caliper, rotor, and fluid specifications.
Tires:
Dual-sport or street-biased supermoto tires. Manual will specify recommended sizes and pressures.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals. Manual covers bulb types and replacement.
Instrumentation:
Digital speedometer, tachometer, odometer, trip meter, indicator lights. Manual covers functionality and troubleshooting.
💡 Technology Features
Infotainment
Infotainment System:
None typically featured on this model; focus is on performance and mechanicals.
Driver Assistance
Driver Assistance Features:
None.
Connectivity
Connectivity Features:
None.
Diagnostics Technology
Diagnostic Port:
May feature a basic diagnostic connector for fault code reading, though less sophisticated than modern vehicles. Manual will detail its location and use.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually. Manual will provide precise interval.
Air Filter Cleaning:
Every 1,000-2,000 km or as needed depending on conditions. Manual will specify.
Valve Clearance Check:
Every 6,000-10,000 km. Manual will provide precise interval and adjustment procedure.
Spark Plug Replacement:
Every 5,000-8,000 km. Manual will specify correct plug type and gap.
Fluid Specifications
Brake Fluid:
DOT 4. Manual will confirm specific recommendation.
Coolant Mixture:
50/50 mix of antifreeze and distilled water. Manual will confirm.
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, wheel bearings, fork seals.
Potential Problems:
Carburetor tuning can be sensitive to altitude and temperature changes. Overheating can occur in heavy traffic without adequate airflow. Manual addresses troubleshooting these.
Part Numbers
Oil Filter Part Number:
Likely HUSQVARNA 800080037 or equivalent. Manual will list exact OEM part numbers.
Air Filter Part Number:
Likely HUSQVARNA 800085265 or equivalent. Manual will list exact OEM part numbers.
📚 Vehicle History
Brand Heritage
Brand Origin:
Husqvarna Motorcycles, founded in Sweden in 1903, with a strong history in off-road and enduro racing.
Model Evolution
Model Lineage:
The SM400R is part of Husqvarna's Supermoto line, derived from their enduro platforms, offering a street-focused iteration.
Production
Production Years:
2007-2008 (as covered by this manual). Specific production numbers are not widely published but were a niche offering.
Manufacturing Location:
Typically Italy during this period under Cagiva Group ownership.
🏆 Awards & Recognition
Recognitions
Brand Awards:
Husqvarna has numerous accolades in enduro and motocross racing, contributing to the performance reputation of its street models.
Ratings
Model Reviews:
Generally well-received for its agile handling and powerful engine in the supermoto segment. Specific contemporary reviews would provide comparative ratings.
Certifications
Certifications:
The manual will adhere to industry standards for technical documentation.
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