🏷️ Basic Information

Make:

Husqvarna

Model:

SM 400, SM 450, SM 510

Model Variants Covered:

SM400R, SM450R, SM510R, SM510 SMR

Year Range:

2005, 2006

👋 Introduction

Category:

Performance Supermoto Motorcycle

Target Audience:

Enthusiast owners, independent mechanics, and workshop technicians seeking in-depth repair and maintenance information.

Competition:

Competes with other European supermoto manufacturers of the era, such as KTM EXC/SMC series, Aprilia SXV, and Ducati Hypermotard.

Value Proposition:

Provides significant cost savings on service and repairs by empowering owners and technicians with professional-level information.

Usability:

Easy to use with printable procedures, eliminating wear-and-tear issues of physical manuals.

📋 Manual Details

General Coverage:

Comprehensive repair, maintenance, rebuild, refurbishment, and restoration for Husqvarna SM 400, SM 450, and SM 510 models.

Specific Coverage:

Engine, transmission, chassis, suspension, brakes, electrical system, fuel system, cooling system, exhaust system, bodywork, diagnostics, and troubleshooting.

Estimated Page Count:

Over 500 pages (typical for comprehensive workshop manuals of this era and complexity)

Type:

Digital Workshop Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed breakdown of all engine components, assembly, disassembly, tuning, diagnostics, and repair procedures for single-cylinder, four-stroke engines.

Transmission:

Complete coverage of gearbox, clutch, and shifting mechanisms including maintenance, repair, and overhaul.

Fuel System:

Carburetor (Mikuni VM series common) and fuel injection system components, adjustments, cleaning, and troubleshooting.

Cooling System:

Radiator, coolant flow, water pump, and thermostat maintenance and repair.

Electrical System:

Ignition system, lighting, charging system (stator, regulator/rectifier), starter motor, battery, wiring diagrams, and component testing.

Brakes:

Hydraulic brake system, caliper maintenance, pad replacement, fluid bleeding, master cylinder and slave cylinder servicing.

Suspension:

Front forks (e.g., Marzocchi Shiver USD), rear shock absorber (e.g., Sachs or Ohlins depending on trim), seal replacement, oil changes, and adjustments.

Chassis And Frame:

Frame inspection, steering head bearings, swingarm, wheel bearings, and general chassis maintenance.

Bodywork And Fairings:

Removal, installation, and repair of plastic body panels, seats, and fuel tank.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance checks.

Troubleshooting:

Diagnostic flowcharts and procedures for identifying and resolving common and uncommon issues across all vehicle systems.

Repair:

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

Rebuild:

Detailed instructions for complete engine, transmission, and suspension unit overhauls.

Diagnostics:

Fault code interpretation (if applicable), electrical testing, and mechanical measurement procedures.

Depth:

Professional technician level, covering everything from routine checks to complete engine rebuilds and advanced diagnostics.

Precision:

Includes precise torque specifications, clearances, and measurement tolerances for critical components.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Image Quality:

High Quality Photos, Illustrations, and Diagrams

Searchability:

Likely searchable text within the PDF, facilitating quick information retrieval.

Binding:

N/A (Digital Download - No physical binding)

Paper Type:

N/A (Digital Download - No physical paper)

Operating Systems:

Compatible with Microsoft Windows 95, 98, 98SE, 2000, NT, ME, XP, Vista, Windows 7, and all Mac computers.

⚙️ Engine Specifications

Type:

Single-cylinder, four-stroke

Displacement Sm400:

Approximately 400cc (specific bore/stroke required from manual for exact figure)

Displacement Sm450:

Approximately 450cc (specific bore/stroke required from manual for exact figure)

Displacement Sm510:

Approximately 510cc (specific bore/stroke required from manual for exact figure)

Bore Stroke Sm400:

Example: 86 mm x 68 mm (typical for this displacement range, verify with manual)

Bore Stroke Sm450:

Example: 95 mm x 63.4 mm (typical for this displacement range, verify with manual)

Bore Stroke Sm510:

Example: 97 mm x 71 mm (typical for this displacement range, verify with manual)

Cooling:

Liquid-cooled

Valve Train:

SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on specific engine variant, 4 valves per cylinder typical.

Horsepower Sm400:

Approx. 40-45 HP (verify with manual)

Horsepower Sm450:

Approx. 45-50 HP (verify with manual)

Horsepower Sm510:

Approx. 50-55 HP (verify with manual)

Torque Sm510:

Approx. 45-50 Nm (verify with manual)

Carburetor Type:

Mikuni VM38/VM40 or Keihin FCR Flatslide (common, verify with manual)

Fuel Injection:

Some variants may have electronic fuel injection (EFI), requiring specific manual coverage.

Ignition Type:

Electronic ignition (CDI or TCI)

🔧 Transmission

Type:

Constant mesh, 6-speed sequential gearbox

Type:

N/A (6-speed is standard across these models)

Clutch:

Hydraulically operated wet multi-plate clutch

Gear Ratios:

Specific gear ratios will be detailed within the manual for each model variant.

Final Drive:

Chain drive

📐 Dimensions

Wheelbase:

Approx. 1470 mm - 1490 mm (verify with manual)

Seat Height:

Approx. 890 mm - 920 mm (verify with manual)

Dry Weight:

Approx. 120-135 kg (verify with manual)

🛡️ Safety Features

Crash Safety:

N/A (Motorcycle safety ratings differ from automobiles; focus is on rider protection through design and equipment, detailed in manual)

Brakes:

High-performance hydraulic disc brakes (front and rear), often Brembo calipers. Specific disc sizes and caliper types will be in the manual.

Suspension:

Quality USD (Upside Down) front forks and adjustable monoshock rear suspension contribute to stability and control.

Lighting:

Headlight, taillight, brake lights, turn signals (compliance varies by market).

💡 Technology Features

Display:

Basic digital or analog instrument cluster displaying speed, RPM, odometer, trip meter, and essential warning lights. No advanced infotainment typically.

ABS:

ABS was generally not a standard or common option on supermoto models of this era.

Bluetooth Wifi:

N/A (No connectivity features typically found on motorcycles of this vintage).

🔧 Maintenance

Oil Change:

Typically every 3,000-5,000 km or annually, whichever comes first (refer to manual for precise interval).

Valve Clearance:

Initial check at first service, then every 6,000-10,000 km (refer to manual for precise interval and procedure).

Chain And Sprockets:

Regular cleaning, lubrication, and tension adjustment; replacement based on wear.

Engine Oil:

SAE 10W-40 or 15W-50 semi-synthetic or fully synthetic motorcycle oil, API SG or higher (verify specific viscosity and API rating in manual).

Coolant:

Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio recommended). Specific coolant type may be specified.

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid (verify specific DOT rating in manual).

Fork Oil:

Specific ISO VG viscosity grade (e.g., 5W, 7.5W, 10W) and volume per fork leg (refer to manual).

Cam Chain Tensioner:

Some Husqvarna single-cylinder engines of this era can develop noise from the automatic cam chain tensioner. Manual will detail inspection and replacement.

Carburetor Tuning:

Carburetors may require periodic cleaning, adjustment, and jetting changes depending on altitude and modifications. Manual provides tuning guides.

Electrical Connections:

As with many performance bikes, check for corrosion or loose connections in the electrical system, especially in the lighting and charging circuits. Manual includes wiring diagrams for troubleshooting.

Suspension Seals:

Fork seal leaks can occur with hard use; the manual provides procedures for seal replacement.

📚 Vehicle History

Manufacturer:

Husqvarna Motorcycles, a historic Swedish brand with a strong off-road racing heritage, now owned by different entities over time (e.g., Cagiva Group, BMW, Pierer Mobility Group).

Supermoto Development:

Husqvarna has a long history in motocross and enduro, and the SM series represents their dedicated supermoto offerings, blending off-road chassis with street-legal components and performance.

Manufacturing Location:

Typically manufactured in Italy during this ownership period.

🏆 Awards & Recognition

Performance Awards:

Husqvarna motorcycles, including the SM series, have historically been recognized in motorsport publications and by riders for their performance and off-road capabilities adapted to the street.