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SM 450 R/ 2003-2004
Husqvarna SM 450 R/ 2003-2004 User Manual
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BOZZA-DRAFT
Manuale d’of
ficina
W
orkshop Manual
Manuel d’Atelier
W
erkst
atthandbuch
Manual de oficina
TE 250-450, TC 250-450,
SM 450 R/ 2003-2004
SM 400, TE 510-TE 510
Centennial/ 2004
Part. N. 8000
A2925
2
Table of Contents
Workshop Manual
3
Useful Suggestions
5
General Instructions for Repair Work
5
Index
11
Important Notices
18
General
27
Maintenance
59
Troubles and Remedies
97
Table of Contents
118
Regolazione Gioco Valvole
122
Adjustment of Valves Play
123
Regolazione Decompressione Avviamento
127
Regolazione Cavo Comando Gas
127
Registrazione Carburatore
129
Registrazione Minimo
130
Sostituzione Dischi Frizione
132
Registrazione Leva DI Comando E Controllo Livello Fluido Frizione Idraulica
133
Regolazione Leva Comando Freno Anteriore (TE, TC) E Controllo del Livello del Fluido (TE, TC, SMR)
135
Registrazione Posizione Pedale Comando Freno Posteriore
137
Registrazione Corsa a Vuoto Freno Posteriore
138
Controllo Livello Fluido Freno Posteriore
138
Controllo Livello Olio Motore
140
Sostituzione Olio Motore E Pulizia-Sostituzione Filtri Metallici Ed a Cartuccia
141
Controllo Livello Liquido DI Raffreddamento
143
Sostituzione Liquido DI Raffreddamento
143
Controllo Filtro Aria
146
Air Filter Check
147
Air Filter and Cleaning
147
Assembly
147
Registrazione Catena Trasmissione Secondaria
151
Lubrificazione Catena Trasmissione
154
Regolazione Delle Sospensioni in Base alle Particolari Condizioni Della Pista
159
Adjusting the Shock Absorber
164
Registrazione Ammortizzatore
164
Adjusting the Shock Absorber Spring Preload
166
Registrazione Precarico Molla Ammortizzatore
166
Shock Absorber Hydraulic Brake Adjustment
167
Registrazione Freno Idraulico Ammortizzatore
167
Shock Absorber Springs
170
Molle Ammortizzatore
170
Regolazione Forcella Anteriore
171
Adjusting the Front Fork
171
Front Fork Springs
173
Steering Ball Bearing Play Adjustment
174
Handlebar Position Change
176
Checking the Fuel Hose
177
Replacing the Muffler Deadening Material
178
Checking the Exhaust Pipe
179
General Operations
181
Foreword
182
Introduction
182
Premessa
182
Premisa
182
Vorwort
182
Démontage Moteur du Motocycle
183
Removal of Engine from Motorcycle
183
Stacco Motore Dal Motociclo
183
Ausbau des Motors von Motorrad
184
Remoción del Motor del Motociclo
184
Démontage Selle Et Batterie
195
Removal of Saddle and Battery
195
Stacco Sella E Batteria
195
Ausbau des Sattels und Batterie
196
Remoción del Sillín y de la Battería
196
Ausbau der Seitlichen Bleche
197
Démontage Panneaux Latéraux
197
Remoción de Los Paneles Laterales
197
Removal of Side Panels
197
Stacco Pannelli Laterali
197
Stacco Telaietto Posteriore Completo DI Parafango (TE- SMR: con Fanale Posteriore) E Scatola Filtro Aria Completa
197
Démontage Cadre Arrière Avec Pare- Boue (TE- SMR: Avec Feu Arrière) Et Filtre À Air Complet
198
Removal of Rear Frame with Fender (TE- SMR: with Tail Light) and Air Filter Box Assy
198
Ausbau des Hinteren Fahrgestells, des Hinteren Kotflügels (TE- SMR: mit Hinteren Scheinwerfer) und des Luftfilters
199
Remoción del Bastidor Trasero con el Guardabarros (TE- SMR: y con el Faro Trasero) y Caja Filtro del Aire
199
Ausbau der Auspuffanlage
201
Démontage Installation D'échappement
201
Remoción de la Instalación de Escape
201
Removal of Exhaust System
201
Stacco Impianto DI Scarico
201
Removal of Fuel Tank and Conveyors
202
Stacco Serbatoio Carburante E Convogliatori
202
Démontage Réservoir D'essence Et Convoyeurs
203
Leitblechen
203
Remoción del Deposito Carburante y Los Conductores
204
Démontage du Central Électronique, Bobine Électronique, Régulateur de Tension Et Tuyau Embrayage Hydraulique
205
Removal of Electronic Power Unit, Electronic Coil, Voltage Regulator and Hydraulic Clutch Hose
205
Stacco Centralina Elettronica, Bobina Elettronica, Regolatore DI Tensione E Tubazione Frizione a Comando Idraulico
205
Ausbau der Elektronischer Steuerinheit, der Elektronischer Spule, des Reglers Spannung und Kupplungsrohr
206
Remoción de la Central Electrónica, Bobina Electrónica , Regulador de Tension y Tubo Embrague Hydraulico
206
Démontage du Chaîne Transmission Secondaire
207
Removal of Secondary Drive Chain
207
Ausbau der Vergelegekette
208
Remoción de la Cadena de Transmisión Secondaria
208
Engine Disassembly
210
Camshaft Disassembly
214
Cylinder Head Cover Disassembly
214
Smontaggio Alberi a Camme
214
Smontaggio Coperchio Testa Cilindro
214
Stacco Catena Trasmissione Secondaria
215
Rimozione Corpo Pompa Acqua
216
Water Pump Body Disassembly
216
Cylinder Head Disassembly
217
Smontaggio Testa Cilindro
217
Smontaggio Valvole
218
Valve Disassembly
218
Using a Magnet, Remove the Valve Pads
219
Cylinder Disassembly
221
Piston Disassembly
221
Smontaggio Cilindro
221
Smontaggio Coperchio Trasmissione
221
Smontaggio Pistone
221
Clutch Disassembly
222
Smontaggio Frizione
222
Remove the Clutch Control Rod
223
Smontaggio Gruppo Avviamento
224
Starting System Disassembly
224
Oil Pump Disassembly
225
Smontaggio Pompa Olio
225
Gear Control Pedal and Gear Shifter Disassembly
226
Flywheel Disassembly
227
Primary Trasmission Driving Gear Disassembly
229
Crankcase Disassembly
230
Gearbox Disassembly
231
Crankshaft and Counter Balancing Shaft Disassembly
233
Engine Overhauling
237
Accoppiamenti
240
Assemblies
240
Cleaning of Components
240
Pulizia Dei Particolari
240
Cylinder Head
241
Ripresa Sede Valvola
241
Testa Cilindro
241
Recutting the Valve Seats
242
Guidavalvola
245
Valve Guides
245
Replacement of Valve Guides
246
Sostituzione Guidavalvole
246
Valve
247
Molla Valvola
248
Installation of Valves
250
Controllo del Bilanciere
251
Inspection of Rocker Arm
251
Camma Decompressore Avviamento
252
Starter Decompressor Cam
252
Albero a Camme
253
Camshaft
253
Camshaft Chain and Gearing
255
Catena E Ingranaggi Distribuzione
255
Camchain Tensioner
256
Tendicatena Distribuzione
256
Cilindro
257
Cylinder
257
Accoppiamento Cilindro-Pistone
259
Cylinder Piston Fitting
259
Piston
259
Gudgeon Pin
261
Piston Diameter
261
Spinotto
261
Accoppiamento Segmenti-Cilindro
262
Piston Rings
262
Piston Rings/Cylinder Clearance
262
Segmenti
262
Accoppiamento Segmenti-Cave Sul Pistone
263
Piston Ring/Piston Rings Groove Clearance
263
Accoppiamento Spinotto-Piede DI Biella
264
Gioco Radiale Testa DI Biella
264
Albero Motore
265
Crankshaft
265
Crankshaft Out-Of-Axis
265
Gioco Assiale Testa DI Biella
265
Contralbero DI Equilibratura
266
Counter Balance Shaft
266
Biella
267
Connecting Rod
267
Connecting Rod Small End Bush Replacement
267
Sostituzione Bussola Piede DI Biella
267
Clutch Unit
269
Clutch Housing-Friction Disc Clearance
270
Clutch Spring
270
Oil Pump
273
Gear Selector Fork and Gearing
274
Selector Drum
277
Carburetor Overhauling
278
Engine Reassembly
288
General Directions
291
Norme Generali
291
Instructions for Assembly
292
Lubricating Points
303
Reassembly of Crankshaft
304
Rimontaggio Albero Motore
304
Reassembly of Counter Balancing Shaft Driving Gear
306
Rimontaggio Ingranaggio Rinvio Contralbero
306
Auxiliary Shaft
308
Main Shaft
308
Reassembly of Transmission
308
Rimontaggio Cambio (TE-SMR)
308
Reassembly of Crankcase
314
Rimontaggio del Carter
314
Reassembly of Gearshift Mechanism
318
Rimontaggio Gruppo Comando Cambio
318
Reassembly of Oil Pump and Starting System
319
Rimontaggio Pompa Olio E Gruppo Avviamento
319
Reassembly of Clutch
320
Rimontaggio Frizione
320
Reassembly of Gear Shaft
322
Reassembly of Transmission Cover
322
Rimontaggio Albero Leva Cambio
322
Rimontaggio Coperchio Trasmissione
322
Rimontaggio Ingranaggio Distribuzione E Catena Trasmissione
324
Reassembly of Flywheel
325
Rimontaggio Volano
325
Reassembly of Piston and Cylinder
326
Rimontaggio Pistone E Cilindro
326
Reassembly of Cylinder Head
327
Rimontaggio Testa Cilindro
327
Reassembly of Cam-Chain Tensioner
330
Reassembly of Valve Lifter
330
Rimontaggio Dispositivo Alzavalvole
330
Rimontaggio Tendicatena Distribuzione
330
Reassembly of Cylinder Head Cover
335
Reassembly of the Gear Shift Position Sensor
335
Rimontaggio Coperchio Testa Cilindro
335
Rimontaggio Segnalatore del Folle
335
Cylinder Head Gasket Selection Chart
336
Frame, Suspensions and Wheels
339
Cold Tire Pressure
345
Front Wheel
345
Tire Make, Type and Dimension
345
Removing the Front Wheel
349
Removing the Front Fork
351
Front Suspension
353
Spring Table
365
Fork Working
366
General Rules for a Proper Overhauling
367
Troubleshooting Guide
367
Maintenance Recommendations
368
Routine Maintenance
368
Oil Drain
369
Oil Filling
370
Slider Disassembly
372
Stanchion Disassembly
372
Compression Setting Change
373
Slider Plug Disassembly
373
Damping Unit Reassembly
374
Foot Valve and Damping Unit Reassembly
374
Slider and Stanchion Reassembly
374
Rear Suspension
416
Removal of Rear Shock Absorber
418
Overhauling the Spring
419
Checks on the Piston Unit
425
Replacing the Gasket
426
Checking the Adjustment
427
Reservoir Replacement
429
Disassembling the Air/Oil Diaphragm of the Reservoir
431
Reassembling the Shock Absorber
432
Disassembling and Overhauling the Rear Swing Arm
445
Overhauling the Rear Swing Arm Axle
447
Overhauling the Rocking Lever and the Rear Suspension Tie Rod
448
Wheels Overhauling
450
Wheel Axle Bending
453
Wheel Spokes
454
Rims Warpage
455
Checking the Wear of Chain, Pinion and Sprocket
457
Brakes
460
Braking System
461
Impianto Frenante
461
Disc Brake
462
Disco Freno
462
Controllo Usura E Sostituzione Pastiglie Freno
464
Spurgo Impianto Frenante Anteriore
468
Front Braking System Bleeding (TE, TC)
470
Front Braking System Bleeding (SMR)
471
Spurgo Impianto Frenante Posteriore
478
Vidange Installation Freinante Arrière
478
Entleerung der Hinteren Bremsanlage
479
Purga Instalación Frenante Trasera
479
Substitución del Fluido
482
Engine Cooling System
486
Checking the Cooling Fluid Level
488
Cooling System
491
Engine Cooling System Overhauling
493
Hydraulic Control Clutch
495
Discharge of Hydraulic System Fluid
499
Overhaul of the Control Pump for Clutch Release
500
Bleeding of the Hydraulic System
501
Optional Parts List
505
Specific Tools
519
Torque Wrench Settings
520
Tampering Warning
531
Warning Statement
531
5
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Husqvarna SM 450 R/ 2003-2004 Specifications
General
Brand
Husqvarna
Model
SM 450 R/ 2003-2004
Category
Motorcycle
Language
English
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