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HUSQVARNA SM 400 450 510 R Workshop Repair Manual Download All 2006-2007 ModelS COVERED PDF

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🏷️ Basic Information Identification Make: Husqvarna Model: SM 400R, SM 450R, SM 510R Model Variant: Supermoto Year: 2006, 2007 Engine Displacement: 400cc, 450cc, 510cc Codes Engine Code Indicator: Various based on specific model and year Chassis Code Indicator: Various based on specific model and year 👋 Introduction Market Position Category: High-performance Supermoto motorcycle. Target Audience: Enthusiasts, home mechanics, professional technicians working on Husqvarna Supermoto motorcycles. Competitive Analysis Competitors 2006 2007: KTM (e.g., 525 EXC/SMC), Yamaha (e.g., YZ450F converted to supermoto), Honda (e.g., CRF450X converted), Suzuki (e.g., RM-Z450 converted), Aprilia SXV series. Key Features Engine Type: Liquid-cooled, four-stroke single-cylinder. Chassis Type: Steel trellis frame (typical for Husqvarna of this era). Suspension Type: Upside-down telescopic front forks, monoshock rear suspension with linkage. Braking System: High-performance hydraulic disc brakes front and rear, often with larger diameter rotors for supermoto use. Wheel Size: Typically 17-inch front and rear wheels for supermoto configuration. 📋 Manual Details Coverage Areas Vehicle Coverage: Husqvarna SM 400R, SM 450R, SM 510R models for the 2006 and 2007 model years. Page Count Estimated Page Count: Comprehensive (exact count not specified, but described as 'huge amount of detailed repair information') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, tuning, troubleshooting, component identification, specifications. Transmission: Gearbox disassembly, assembly, troubleshooting, lubrication, specifications. Clutch: Clutch operation, adjustment, service, component specifications. Fuel System: Carburetor (likely Keihin FCR or similar for these models) tuning, cleaning, troubleshooting, fuel pump, fuel lines. Ignition System: Ignition timing, components (CDI, coil, spark plug), troubleshooting, specifications. Cooling System: Radiator, hoses, coolant specifications, fan operation, bleeding. Electrical System: Wiring diagrams, battery, charging system (stator/generator), lighting, starter motor, fuses, relays, troubleshooting. Chassis And Frame: Frame inspection, reinforcement, steering head bearing service. Suspension: Front fork (upside-down, likely Marzocchi or Sachs) service, adjustments, oil types, damping settings. Rear shock absorber service, adjustments, linkage maintenance. Brakes: Brake system service (hydraulic), caliper maintenance, master cylinder service, bleeding procedures, pad replacement, rotor specifications. Wheels And Tires: Tire pressures, wheel bearing service, spoke tensioning (if applicable), rim specifications. Exhaust System: Exhaust system inspection, component replacement, tuning considerations. Bodywork And Fairings: Fairing removal and installation, seat, fuel tank, fender service. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain maintenance, spark plug service, air filter cleaning/replacement, brake fluid flush. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon issues. Repair And Rebuild: Complete disassembly and reassembly guides for major components. Adjustments: Carburetor synchronization, valve clearance adjustments, suspension adjustments, chain slack adjustment. Torque Specifications: Detailed torque values for critical fasteners. Wiring Diagrams: Comprehensive electrical system schematics. Technical Depth Depth: Complete workshop level, covering everything from basic maintenance to full engine and transmission rebuilds. Diagrams And Illustrations: Features exploded views, diagrams, and step-by-step illustrations to aid in understanding. 📊 Manual Specifications File Format Format: PDF Compatibility: PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.) Print Quality Quality: High-quality, suitable for printing. Binding Type Type: N/A (Digital download) Paper Type Type: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 4-stroke, DOHC, single-cylinder Bore X Stroke 400: Approximately 84 mm x 72 mm (est. for 400cc class) Bore X Stroke 450: Approximately 93 mm x 63.4 mm (est. for 450cc class) Bore X Stroke 510: Approximately 97 mm x 70.5 mm (est. for 510cc class) Compression Ratio: Varies by model, typically around 11.0:1 to 12.5:1 Horsepower 400: Approx. 40-45 HP (est.) Horsepower 450: Approx. 45-50 HP (est.) Horsepower 510: Approx. 50-55 HP (est.) Torque: Specific figures vary, but expected to be robust for their displacement. Fuel System Carburetor Type: High-performance flat-slide carburetor (e.g., Keihin FCR MX 39mm or 41mm likely) Fuel Type: Unleaded gasoline (Octane rating specified in manual, likely 91+) Fuel Tank Capacity: Typically around 7-10 liters (1.8-2.6 gallons) 🔧 Transmission Standard Type: Constant-mesh, 5-speed or 6-speed sequential manual transmission. Optional Type: N/A (Manual transmission only) Features Clutch Type: Wet multi-plate clutch, hydraulically operated. Final Drive: Chain drive 📐 Dimensions Exterior Length: Varies by model, typical supermoto dimensions apply. Width: Varies by model, typical supermoto dimensions apply. Height: Varies by model, typical supermoto dimensions apply. Weights Dry Weight: Approx. 115-125 kg (253-275 lbs) depending on model and exact configuration. Wet Weight: Approx. 125-135 kg (275-298 lbs) depending on model and fluid levels. 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycles are not typically subject to automotive crash testing standards) Active Features Braking: High-performance hydraulic disc brakes front and rear, radial-mount calipers on some models for improved stopping power. Suspension Tuning: Adjustable suspension for optimal handling and rider control. Passive Features Lighting: Headlight, taillight, brake lights, turn signals (as per street-legal requirements in most markets). Frame Design: Robust chassis providing stability and rider feedback. 💡 Technology Features Infotainment System: N/A (Basic motorcycle instrumentation - speedometer, tachometer, odometer, neutral indicator, etc.) Driver...
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HUSQVARNA SM 400 450 510 R Workshop Repair Manual Download All 2006-2007 ModelS COVERED PDFHUSQVARNA SM 400 450 510 R Workshop Repair Manual Download All 2006-2007 ModelS COVERED PDFHUSQVARNA SM 400 450 510 R Workshop Repair Manual Download All 2006-2007 ModelS COVERED PDFHUSQVARNA SM 400 450 510 R Workshop Repair Manual Download All 2006-2007 ModelS COVERED PDF
🏷️ Basic Information
Identification
Make:
Husqvarna
Model:
SM 400R, SM 450R, SM 510R
Model Variant:
Supermoto
Year:
2006, 2007
Engine Displacement:
400cc, 450cc, 510cc
Codes
Engine Code Indicator:
Various based on specific model and year
Chassis Code Indicator:
Various based on specific model and year
👋 Introduction
Market Position
Category:
High-performance Supermoto motorcycle.
Target Audience:
Enthusiasts, home mechanics, professional technicians working on Husqvarna Supermoto motorcycles.
Competitive Analysis
Competitors 2006 2007:
KTM (e.g., 525 EXC/SMC), Yamaha (e.g., YZ450F converted to supermoto), Honda (e.g., CRF450X converted), Suzuki (e.g., RM-Z450 converted), Aprilia SXV series.
Key Features
Engine Type:
Liquid-cooled, four-stroke single-cylinder.
Chassis Type:
Steel trellis frame (typical for Husqvarna of this era).
Suspension Type:
Upside-down telescopic front forks, monoshock rear suspension with linkage.
Braking System:
High-performance hydraulic disc brakes front and rear, often with larger diameter rotors for supermoto use.
Wheel Size:
Typically 17-inch front and rear wheels for supermoto configuration.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
Husqvarna SM 400R, SM 450R, SM 510R models for the 2006 and 2007 model years.
Page Count
Estimated Page Count:
Comprehensive (exact count not specified, but described as 'huge amount of detailed repair information')
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine:
Engine disassembly, assembly, tuning, troubleshooting, component identification, specifications.
Transmission:
Gearbox disassembly, assembly, troubleshooting, lubrication, specifications.
Clutch:
Clutch operation, adjustment, service, component specifications.
Fuel System:
Carburetor (likely Keihin FCR or similar for these models) tuning, cleaning, troubleshooting, fuel pump, fuel lines.
Ignition System:
Ignition timing, components (CDI, coil, spark plug), troubleshooting, specifications.
Cooling System:
Radiator, hoses, coolant specifications, fan operation, bleeding.
Electrical System:
Wiring diagrams, battery, charging system (stator/generator), lighting, starter motor, fuses, relays, troubleshooting.
Chassis And Frame:
Frame inspection, reinforcement, steering head bearing service.
Suspension:
Front fork (upside-down, likely Marzocchi or Sachs) service, adjustments, oil types, damping settings. Rear shock absorber service, adjustments, linkage maintenance.
Brakes:
Brake system service (hydraulic), caliper maintenance, master cylinder service, bleeding procedures, pad replacement, rotor specifications.
Wheels And Tires:
Tire pressures, wheel bearing service, spoke tensioning (if applicable), rim specifications.
Exhaust System:
Exhaust system inspection, component replacement, tuning considerations.
Bodywork And Fairings:
Fairing removal and installation, seat, fuel tank, fender service.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain maintenance, spark plug service, air filter cleaning/replacement, brake fluid flush.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues.
Repair And Rebuild:
Complete disassembly and reassembly guides for major components.
Adjustments:
Carburetor synchronization, valve clearance adjustments, suspension adjustments, chain slack adjustment.
Torque Specifications:
Detailed torque values for critical fasteners.
Wiring Diagrams:
Comprehensive electrical system schematics.
Technical Depth
Depth:
Complete workshop level, covering everything from basic maintenance to full engine and transmission rebuilds.
Diagrams And Illustrations:
Features exploded views, diagrams, and step-by-step illustrations to aid in understanding.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.)
Print Quality
Quality:
High-quality, suitable for printing.
Binding Type
Type:
N/A (Digital download)
Paper Type
Type:
N/A (Digital download)
⚙️ Engine Specifications
Primary Engine
Type:
Liquid-cooled, 4-stroke, DOHC, single-cylinder
Bore X Stroke 400:
Approximately 84 mm x 72 mm (est. for 400cc class)
Bore X Stroke 450:
Approximately 93 mm x 63.4 mm (est. for 450cc class)
Bore X Stroke 510:
Approximately 97 mm x 70.5 mm (est. for 510cc class)
Compression Ratio:
Varies by model, typically around 11.0:1 to 12.5:1
Horsepower 400:
Approx. 40-45 HP (est.)
Horsepower 450:
Approx. 45-50 HP (est.)
Horsepower 510:
Approx. 50-55 HP (est.)
Torque:
Specific figures vary, but expected to be robust for their displacement.
Fuel System
Carburetor Type:
High-performance flat-slide carburetor (e.g., Keihin FCR MX 39mm or 41mm likely)
Fuel Type:
Unleaded gasoline (Octane rating specified in manual, likely 91+)
Fuel Tank Capacity:
Typically around 7-10 liters (1.8-2.6 gallons)
🔧 Transmission
Standard
Type:
Constant-mesh, 5-speed or 6-speed sequential manual transmission.
Optional
Type:
N/A (Manual transmission only)
Features
Clutch Type:
Wet multi-plate clutch, hydraulically operated.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Varies by model, typical supermoto dimensions apply.
Width:
Varies by model, typical supermoto dimensions apply.
Height:
Varies by model, typical supermoto dimensions apply.
Weights
Dry Weight:
Approx. 115-125 kg (253-275 lbs) depending on model and exact configuration.
Wet Weight:
Approx. 125-135 kg (275-298 lbs) depending on model and fluid levels.
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycles are not typically subject to automotive crash testing standards)
Active Features
Braking:
High-performance hydraulic disc brakes front and rear, radial-mount calipers on some models for improved stopping power.
Suspension Tuning:
Adjustable suspension for optimal handling and rider control.
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals (as per street-legal requirements in most markets).
Frame Design:
Robust chassis providing stability and rider feedback.
💡 Technology Features
Infotainment
System:
N/A (Basic motorcycle instrumentation - speedometer, tachometer, odometer, neutral indicator, etc.)
Driver Assistance
Features:
N/A (Focus on rider control and mechanical performance)
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 50-100 operating hours or annually, check manual for specifics. (e.g., 3,000 km / 1,800 miles if street ridden frequently)
Air Filter Cleaning:
Regularly, especially in dusty conditions. (e.g., every 10-20 operating hours)
Spark Plug Replacement:
Approximately every 100-150 operating hours or as per manual recommendation.
Valve Clearance Check:
Typically every 100-200 operating hours or annually.
Brake Fluid Change:
Annually or as needed.
Fluid Specifications
Engine Oil Type:
Motorcycle specific 4-stroke engine oil, SAE 10W-40 or 15W-50 recommended (check manual for precise viscosity and API/JASO rating, e.g., JASO MA)
Engine Oil Capacity:
Approx. 1.0-1.5 liters (check manual for exact capacity)
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Motorex M3.0 or equivalent).
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid.
Fork Oil Type:
Specific fork oil viscosity (e.g., SAE 5W or 7.5W, check manual for exact type and level).
Transmission Oil:
Often shares oil with the engine, or requires a separate transmission oil if so specified (check manual).
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals.
Engine Performance Tuning:
Carburetor tuning can be sensitive to altitude and temperature changes; proper jetting is crucial.
Electrical Connections:
Ensure all electrical connectors are clean and secure to prevent intermittent issues.
Suspension Maintenance:
Regular fork oil changes and seal inspection are important for optimal performance and longevity.
📚 Vehicle History
Brand Heritage
Origin:
Husqvarna Motorcycles, founded in Sweden in 1903, is one of the oldest motorcycle manufacturers.
Specialty:
Known for off-road and motocross motorcycles, later expanding into enduro and supermoto.
Model Evolution
Supermoto Lineage:
Husqvarna has a strong presence in the supermoto segment, building on their off-road prowess.
Technical Advancements 2006 2007:
These models represent a period of refinement for Husqvarna's single-cylinder platform, with robust engines and advanced chassis components.
Production
Manufacturing Location:
Primarily Italy during this period (under BMW ownership before the KTM acquisition).
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
While specific awards for these exact model years aren't commonly cited, Husqvarna's supermoto models of this era were generally well-regarded for their performance and handling capabilities within the segment.
Ratings
Performance Index:
High performance for their class, competitive with other European supermoto offerings.
Certifications
Emissions Standards:
Compliant with relevant emissions standards for model year of manufacture (varies by region).
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