2007 Husqvarna SM400 450 510 R Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Husqvarna Model: SM400R / SM450R / SM510R Model Variant: Supermoto Generation Model Generation: First Generation (Post-BMW Acquisition) Codes Model Year: 2007 Engine Code Variants: SM400R, SM450R, SM510R (specific engine codes may apply, manual will clarify). 👋 Introduction Market Position Vehicle Type: Performance Supermoto Motorcycle Target Audience: Enthusiasts, owners, and independent workshops specializing in off-road and supermoto motorcycles. Competitive Analysis Competitors: KTM EXC/SMC series, Yamaha WR/YZF-R series, Honda CRF/CRF-R series, Suzuki DR-Z/RM-Z series, Kawasaki KLX/KX-R series. Key Features Manual Uniqueness: Make, model, and year specific, ensuring accuracy and relevance for the 2007 Husqvarna SM400/450/510R models. Manual Benefit: Enables owners to perform in-depth maintenance, diagnostics, and repairs, saving on dealership service costs and empowering self-sufficiency. Diagrams Illustrations: Contains detailed step-by-step diagrams and illustrations for clarity and ease of understanding. 📋 Manual Details Coverage Areas Manual Coverage: Full Workshop Service and Repair Page Count Estimated Page Count: Refer to manual for exact count (typically 500+ pages for comprehensive manuals of this type) Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, inspection, lubrication, fuel system, cooling system (if applicable, though typically air-cooled for these models), cylinder head, cylinder, piston, crankshaft, clutch, gearbox, ignition system, starter system. Chassis Systems: Front suspension (forks), rear suspension (shock absorber, linkage), frame, steering system, wheels, tires, hydraulic braking system (front and rear). Electrical Systems: Battery, charging system (stator, regulator/rectifier), ignition system, starter motor, switches, wiring diagrams. Bodywork Plastics: Procedures for fairing removal, installation, and potential repair. Procedures Included Maintenance Procedures: Routine maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, brake pad inspection and replacement, fluid checks and top-offs. Repair Procedures: Engine rebuilds (top end and bottom end), transmission overhaul, clutch replacement, suspension component service, brake system bleeding and repair, electrical component diagnosis and replacement. Diagnostic Procedures: Troubleshooting guides for common problems, fault diagnosis for engine, electrical, and mechanical systems. Troubleshooting Methodology: Systematic approach to diagnosing problems based on symptoms. Wheel Bearing Service: Instructions for wheel bearing inspection, cleaning, lubrication, and replacement. Technical Depth Depth Of Coverage: Comprehensive; covers basic maintenance, intermediate repairs, and complete engine/component overhauls with detailed step-by-step instructions and diagrams. Engine Rebuild Details: Includes specifications for piston ring gap, bearing clearances, torque values for all critical fasteners, valve timing, and more. Suspension Service Details: Detailed procedures for fork seal replacement, damping adjustment, spring preload, and rear shock service, including oil types and quantities. Electrical Schematics Quality: Comprehensive, color-coded wiring diagrams for easy diagnosis of electrical circuits. Torque Specifications: Complete listing of all critical torque specifications for engine, chassis, and suspension fasteners. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Compatibility: Universally compatible with operating systems that support PDF readers. Print Quality Printability: Printable pages, allowing users to print specific sections or the entire manual. Binding Type Binding Type: N/A (Digital Product) Paper Type Paper Type: N/A (Digital Product) Accessibility Digital Features: Instant download, PC/MAC compatible, zoom in/out functionality, searchable text (dependent on PDF optimization). Searchability: PDF format often allows for text searching of keywords within the manual. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Engine Displacement 400: Approximately 400cc (specific model varies) Engine Displacement 450: Approximately 450cc (specific model varies) Engine Displacement 510: Approximately 510cc (specific model varies) Cooling System: Likely Liquid-Cooled (common for this era's performance models, manual will specify) Bore Stroke Spec: Specific bore and stroke dimensions for each engine displacement are detailed in the manual. Performance Horsepower Estimate: Varies by displacement, but typically in the 40-60 HP range for performance supermotos of this era. Torque Estimate: Varies by displacement, generally robust for its class. Compression Ratio: Specific compression ratio for each model variant will be detailed in the manual. Fuel System Fuel Delivery: Carburetor (e.g., Keihin FCR series likely, manual will confirm specific model). Carburetor Model: Manual will identify the exact carburetor model and size (e.g., Keihin FCR MX 39/41). 🔧 Transmission Standard Transmission Type: Constant mesh, sequential manual transmission Gear Count: Typically 5 or 6 speeds (manual will confirm) Features Clutch Type: Wet multi-plate (manual will specify details) Primary Drive: Gears (manual will specify ratios) Gear Ratios: Individual gear ratios for each speed and final drive ratio are provided. 📐 Dimensions Exterior Wheelbase: Refer to manual for precise specifications, typically around 1450-1500 mm. Seat Height: Refer to manual for precise specifications, typically high for a supermoto. Weights Dry Weight: Refer to manual for precise specifications, often in the 110-130 kg range. Curb Weight: Manual will detail curb weight including all necessary fluids. 🛡️ Safety Features Ratings Safety Certification: N/A (Motorcycle; not subject to automotive crash ratings) Active Features Braking System: Hydraulic disc brakes, front and rear. Specific caliper and rotor sizes detailed in manual. Suspension System: Adjustable USD (Upside-Down) front forks and adjustable rear...
Procedures for fairing removal, installation, and potential repair.
Procedures Included
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, chain adjustment, spark plug replacement, brake pad inspection and replacement, fluid checks and top-offs.
Repair Procedures:
Engine rebuilds (top end and bottom end), transmission overhaul, clutch replacement, suspension component service, brake system bleeding and repair, electrical component diagnosis and replacement.
Diagnostic Procedures:
Troubleshooting guides for common problems, fault diagnosis for engine, electrical, and mechanical systems.
Troubleshooting Methodology:
Systematic approach to diagnosing problems based on symptoms.
Wheel Bearing Service:
Instructions for wheel bearing inspection, cleaning, lubrication, and replacement.
Technical Depth
Depth Of Coverage:
Comprehensive; covers basic maintenance, intermediate repairs, and complete engine/component overhauls with detailed step-by-step instructions and diagrams.
Engine Rebuild Details:
Includes specifications for piston ring gap, bearing clearances, torque values for all critical fasteners, valve timing, and more.
Suspension Service Details:
Detailed procedures for fork seal replacement, damping adjustment, spring preload, and rear shock service, including oil types and quantities.
Electrical Schematics Quality:
Comprehensive, color-coded wiring diagrams for easy diagnosis of electrical circuits.
Torque Specifications:
Complete listing of all critical torque specifications for engine, chassis, and suspension fasteners.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Compatibility:
Universally compatible with operating systems that support PDF readers.
Print Quality
Printability:
Printable pages, allowing users to print specific sections or the entire manual.
Binding Type
Binding Type:
N/A (Digital Product)
Paper Type
Paper Type:
N/A (Digital Product)
Accessibility
Digital Features:
Instant download, PC/MAC compatible, zoom in/out functionality, searchable text (dependent on PDF optimization).
Searchability:
PDF format often allows for text searching of keywords within the manual.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke
Engine Displacement 400:
Approximately 400cc (specific model varies)
Engine Displacement 450:
Approximately 450cc (specific model varies)
Engine Displacement 510:
Approximately 510cc (specific model varies)
Cooling System:
Likely Liquid-Cooled (common for this era's performance models, manual will specify)
Bore Stroke Spec:
Specific bore and stroke dimensions for each engine displacement are detailed in the manual.
Performance
Horsepower Estimate:
Varies by displacement, but typically in the 40-60 HP range for performance supermotos of this era.
Torque Estimate:
Varies by displacement, generally robust for its class.
Compression Ratio:
Specific compression ratio for each model variant will be detailed in the manual.
Fuel System
Fuel Delivery:
Carburetor (e.g., Keihin FCR series likely, manual will confirm specific model).
Carburetor Model:
Manual will identify the exact carburetor model and size (e.g., Keihin FCR MX 39/41).
🔧 Transmission
Standard
Transmission Type:
Constant mesh, sequential manual transmission
Gear Count:
Typically 5 or 6 speeds (manual will confirm)
Features
Clutch Type:
Wet multi-plate (manual will specify details)
Primary Drive:
Gears (manual will specify ratios)
Gear Ratios:
Individual gear ratios for each speed and final drive ratio are provided.
📐 Dimensions
Exterior
Wheelbase:
Refer to manual for precise specifications, typically around 1450-1500 mm.
Seat Height:
Refer to manual for precise specifications, typically high for a supermoto.
Weights
Dry Weight:
Refer to manual for precise specifications, often in the 110-130 kg range.
Curb Weight:
Manual will detail curb weight including all necessary fluids.
🛡️ Safety Features
Ratings
Safety Certification:
N/A (Motorcycle; not subject to automotive crash ratings)
Active Features
Braking System:
Hydraulic disc brakes, front and rear. Specific caliper and rotor sizes detailed in manual.
Suspension System:
Adjustable USD (Upside-Down) front forks and adjustable rear monoshock suspension for dynamic handling and rider control.
No electronic rider aids like ABS or traction control typically found on these performance-oriented models of that era. Focus is on rider skill and machine feedback.
Connectivity
Connectivity Features:
None (Analog and basic digital systems).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for exact intervals (typically every 3,000-5,000 km or annually).
Valve Clearance Check:
Refer to manual for intervals (critical for engine performance, often around 5,000-10,000 km).
Air Filter Maintenance:
Recommended intervals and procedures for cleaning/replacing the air filter.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific SAE viscosity grade and API rating (e.g., 10W-40, JASO MA).
Brake Fluid Type:
Refer to manual for specific DOT rating (e.g., DOT 4).
Coolant Type:
Refer to manual for type and mixture if liquid-cooled (e.g., ethylene glycol based).
Transmission Oil Type:
Refer to manual for specific transmission oil type and capacity.
Older European motorcycles can sometimes have electrical connector issues; manual will guide troubleshooting.
📚 Vehicle History
Brand Heritage
Brand Origin:
Husqvarna Motorcycles is a Swedish brand, historically known for off-road motorcycles, acquired by Cagiva Group (Italy), then BMW Motorrad, and later KTM.
Model Evolution
Supermoto Development:
Husqvarna's supermoto line evolved from their successful enduro platforms, adapting them for street use with smaller wheels, street tires, and upgraded braking systems.
Production
Manufacturing Location:
Likely Italy during the BMW ownership period (2007 models).
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Husqvarna models of this era were generally praised for their performance, handling, and aggressive styling, often reviewed in specialist motorcycle publications.
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