Yamaha SR400 2022 Owner'S Manual Download

Page: 61 / 96

Perio

ic maintenance an

justment

7-20

EAU48444

justin

the

rake lever free

play

Measure the brake lever free play as
shown.

Periodically check the brake lever free
play and, if necessary, adjust it as fol-
lows.

1. Slide the rubber cover back at the

brake lever.

2. Loosen the locknut.

3. To increase the brake lever free

play, turn the brake lever free play
adjusting screw in direction (a). To
decrease the brake lever free play,
turn the adjusting screw in direc-
tion (b).

4. Tighten the locknut, and then slide

the rubber cover back to its origi-
nal position.

WARNING

EWA10631



After a

justin

the

rake lever

free play, check the free play
an

make sure that the

rake is

workin

properly.



A soft or spon

y feelin

in the

rake lever can in

icate the

presence of air in the hy

raulic

system. If there is air in the hy-

raulic system, have a Yamaha

ealer

lee

the system

efore

operatin

the motorcycle. Air in

the hy

raulic system will

imin-

ish the

rakin

performance,

which may result in loss of con-
trol an

an acci

ent.

EAU22199

justin

the

rake pe

hei

ht an

free play

WARNING

EWA10671

It is a

visa

le to have a Yamaha

ealer make these a

justments.

Brake pe

al hei

The top of the brake pedal should be
positioned at the specified distance
below the top of the footrest as shown.

Brake lever free play:

5.0–8.0 mm (0.20–0.31 in)

1. Locknut
2. Brake lever free play adjusting screw
3. Rubber cover
4. Brake lever free play

(a)

(b)

Brake pe

al hei

ht:

20.0 mm (0.79 in)

1. Brake pedal height

UB9FEYE0.book Page 20 Monday, July 12, 2021 5:47 PM

Summary of Contents for SR400 2022

Page 1: ...OTORCYCLE OWNER S MANUAL Specifications Consumer information Motorcycle care and storage Periodic maintenance and adjustment For your safety pre operation checks Instrument and control functions Descr...

Page 2: ...EAU93780 Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold UB9FEYE0 book Page 1 Monday July 12 2021 5 47 PM...

Page 3: ...n addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer The Yamaha t...

Page 4: ...ntial personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a hazardous situation which if not avoided could result in death or...

Page 5: ...NUAL 2022 by Yamaha Motor Co Ltd 1st edition June 2021 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in J...

Page 6: ...5 Periodic maintenance and adjustment 7 1 Tool kit 7 2 Periodic maintenance chart for the emission control system 7 3 General maintenance and lubrication chart 7 5 Removing and installing panels 7 9 C...

Page 7: ...the headlight bulb 7 34 Replacing the brake tail light bulb 7 35 Replacing a turn signal light bulb 7 36 Front wheel 7 37 Rear wheel 7 39 Troubleshooting 7 40 Troubleshooting chart 7 42 Motorcycle ca...

Page 8: ...vehicle They contain important information for safe and proper operation of your vehicle Never remove any labels from your vehicle If a label becomes difficult to read or comes off a replacement label...

Page 9: ...Location of important labels 1 2 1 B27 2117B 03 B27 21668 01 2 1 UB9FEYE0 book Page 2 Monday July 12 2021 5 47 PM...

Page 10: ...ou Safe Riding Perform the pre operation checks each time you use the vehicle to make sure it is in safe operating condition Failure to inspect or maintain the vehi cle properly increases the possibil...

Page 11: ...o main tain control of the motorcycle The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests Never carr...

Page 12: ...cycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accesso...

Page 13: ...change any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Kee...

Page 14: ...that are attached to solid parts of the mo torcycle such as the frame or up per front fork triple clamp and not for example to rubber mounted handlebars or turn signals or parts that could break Choos...

Page 15: ...and their usage Half type use only for riding at low speeds Full type use only for riding at low to mid range speeds Full face type use for riding at mid range to high speeds ZAUU0003 ZAUU0007 ZAUU000...

Page 16: ...2 2 Engine oil filler cap page 7 12 3 Fuel tank cap page 4 8 4 Fuel cock page 4 10 5 Battery page 7 31 6 Fuses page 7 32 7 Helmet holder page 4 12 8 Luggage strap holder page 4 13 9 Spring preload adj...

Page 17: ...gage strap holder page 4 13 2 Air filter element page 7 15 3 Kickstarter page 4 11 4 Kick indicator page 6 2 5 Headlight page 7 34 6 Brake pedal page 4 7 7 Tool kit page 7 2 8 Spring preload adjuster...

Page 18: ...switches page 4 5 3 Speedometer unit page 4 4 4 Main switch steering lock page 4 2 5 Tachometer page 4 5 6 Front brake fluid reservoir page 7 23 7 Right handlebar switches page 4 5 8 Brake lever page...

Page 19: ...standard keys as well as keys of other immobilizer systems away from the code re registering key Keep other immobilizer system keys away from the main switch as they may cause signal interfer ence NO...

Page 20: ...nnot be removed TIP To prevent battery discharge do not leave the key in the ON posi tion without the engine running The headlight comes on automat ically when the engine is started EAU10662 OFF All e...

Page 21: ...evel drops below approximately 2 2 L 0 58 US gal 0 48 Imp gal When this occurs refuel as soon as possible TIP When the vehicle is turned on the light should come on for a few seconds and then go off O...

Page 22: ...y the following 1 Make sure there are no other im mobilizer keys close to the main switch 2 Use the code re registering key to start the engine 3 If the engine starts turn it off and try starting the...

Page 23: ...U1234R Handlebar switches Left Right EAU12352 Pass switch Press this switch to flash the headlight TIP When the dimmer switch is set to the passing switch has no ef fect EAU12402 Dimmer switch Set thi...

Page 24: ...FF The hazard lights simultaneous flash ing of all turn signal lights are used in case of an emergency such as to warn other drivers when your vehicle is stopped where it might be a traffic haz ard Se...

Page 25: ...gear move the shift pedal down See page 6 3 EAU12892 Brake lever The brake lever is located on the right side of the handlebar To apply the front brake pull the lever toward the throttle grip EAU12944...

Page 26: ...is a fire hazard EAU13222 Fuel Make sure there is sufficient gasoline in the tank WARNING EWA10882 Gasoline and gasoline vapors are extremely flammable To avoid fires and explosions and to reduce the...

Page 27: ...research octane number of 90 or higher If en gine knocking or pinging occurs use a gasoline of a different brand or higher octane rating Gasohol There are two types of gasohol gaso hol containing eth...

Page 28: ...Make sure that the exhaust sys tem has cooled down before doing any maintenance work Do not allow the engine to idle more than a few minutes Long idling can cause a build up of heat EAU59492 Fuel coc...

Page 29: ...n into the neutral position before starting is recommended EAU13701 Decompression lever When this lever is pulled the exhaust valve is forced open so that the com pression pressure can be reduced This...

Page 30: ...AU14885 Adjusting the shock absorber assemblies WARNING EWA10211 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may re sult Each shock absorber asse...

Page 31: ...tion of the ignition circuit cut off system WARNING EWA10242 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the s...

Page 32: ...ne starts unless the clutch lever is pulled and the sidestand is up Also it will stop the running engine should the sidestand be lowered while the trans mission is in gear Periodically check the syste...

Page 33: ...the sidestand up 12 Pull the clutch lever 13 Push the kickstarter lever down Does the engine start The system is OK The motorcycle can be ridden The sidestand switch may not be working The motorcycle...

Page 34: ...Yamaha dealer Before using this vehicle check the following points ITEM CHECKS PAGE Fuel Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage 4 8 Engine oil Check oil level in...

Page 35: ...tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary 7 17 7 19 Shift pedal Make sure that operation is smooth Correct if necessary 7 22 Brake pedal Make...

Page 36: ...tion checks 5 3 5 Sidestand switch Check operation of ignition circuit cut off system If system is not working correctly have Yamaha dealer check vehicle 4 13 ITEM CHECKS PAGE UB9FEYE0 book Page 3 Mon...

Page 37: ...t 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might resul...

Page 38: ...nd apply the decompression lever 5 Slowly push the kickstarter lever down until the starting mark shows on the kick indicator 6 Release the decompression lever release the kickstarter lever and then p...

Page 39: ...ly push the kick starter lever down to restart the engine EAUN0073 NOTICE ECAN0072 Do not ride through deep water oth erwise the engine may be damaged Avoid puddles because they may be deeper than exp...

Page 40: ...t the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear EAU85380 To decelera...

Page 41: ...ng it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU17214 Parking When parking stop the engine and then remove the key from the main switch WAR...

Page 42: ...performing maintenance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires Running the engine whil...

Page 43: ...is manual and the tools provided in the tool kit are intended to assist you in the perfor mance of preventive maintenance and minor repairs However a torque wrench and other tools are necessary to per...

Page 44: ...maintenance chart for the emission control system No ITEM ROUTINE INITIAL ODOMETER READINGS ANNUAL CHECK 1000 km or 1 month 7000 km or 6 months 13000 km or 12 months 19000 km or 18 months 25000 km or...

Page 45: ...000 mi and thereafter every 12000 km 8000 mi 8 Air induction sys tem Check the air cut off valve reed valve and hose for damage Replace any damaged parts if necessary At 19000 km 12000 mi and thereaft...

Page 46: ...eck operation Adjust or replace cable 4 Timing chain Check timing chain tensioner Adjust if necessary 5 Decompression system Check operation Adjust or replace cable 6 Front brake Check operation fluid...

Page 47: ...ly Every 500 km 300 mi and after washing the motorcycle riding in the rain or riding in wet areas 15 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based...

Page 48: ...d vehicle for oil leakage 25 Engine oil filter ele ment Replace 26 Front and rear brake switches Check operation 27 Control cables Apply Yamaha cable lubricant or other suitable cable lubricant thorou...

Page 49: ...ced more frequently when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinder and caliper always change the fluid Regularly check the brake flui...

Page 50: ...this chapter Refer to this section each time a panel needs to be removed and installed EAU85681 Panel A To remove the panel Remove the bolt and then pull the panel off as shown To install the panel P...

Page 51: ...s an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accordance with the periodic ma...

Page 52: ...ness gauge and if nec essary adjust the gap to specifi cation To install the spark plug 1 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark...

Page 53: ...a level surface and then wait a few minutes for the oil level to settle for an accurate reading 3 Remove the engine oil filler cap wipe the dipstick clean insert it back into the oil filler hole witho...

Page 54: ...l tank drain bolt and gasket to drain the oil from the oil tank TIP Perform steps 6 8 when replacing the oil filter element 6 Remove the oil filter element cover by removing the bolts 7 Remove the use...

Page 55: ...on of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 13 Start the engine and...

Page 56: ...oil clears our performance standards Thus Yamalube mineral semisynthetic and synthetic oils have their own distinct characters and value Yamaha s expe rience gained over many years of re search and d...

Page 57: ...filter case cover by installing the screws 6 Install the panel EAU44735 Checking the engine idling speed Check the engine idling speed and if necessary have it corrected by a Yamaha dealer EAU21386 C...

Page 58: ...es Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride WARNING EWA10504 Operation of this vehicle with im proper tire pressure may cause se vere injury...

Page 59: ...since the tire surface must first be broken in for it to develop its optimal characteristics Tire information This model is equipped with tube tires Tires age even if they have not been used or have...

Page 60: ...with tubeless tires Do not attempt to use tubeless tires on this model EAU48293 Adjusting the clutch lever free play Measure the clutch lever free play as shown Periodically check the clutch lever fre...

Page 61: ...ng properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before o...

Page 62: ...ust it as fol lows To increase the brake pedal free play turn the brake pedal free play adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn the adjusting nut in di...

Page 63: ...t comes on just before braking takes ef fect If necessary adjust the rear brake light switch as follows Turn the rear brake light switch adjust ing nut while holding the rear brake light switch in pla...

Page 64: ...hich allows you to check the brake shoe wear without having to disassemble the brake To check the brake shoe wear check the position of the wear indicator while applying the brake If a brake shoe has...

Page 65: ...ces or plastic parts Always clean up spilled fluid immediately As the brake pads wear it is normal for the brake fluid level to gradually go down A low brake fluid level may indi cate worn brake pads...

Page 66: ...its ECA10572 EAU59643 To adjust the drive chain slack Consult a Yamaha dealer before ad justing the drive chain slack 1 Take the motorcycle off the cen terstand and then put the side stand down 2 Loos...

Page 67: ...at the intervals specified in the periodic maintenance and lubrica tion chart otherwise it will quickly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE...

Page 68: ...ealer check or re place it WARNING Damage to the outer housing of cables may result in internal rusting and cause inter ference with cable movement Re place damaged cables as soon as possible to preve...

Page 69: ...be lu bricated if necessary Brake lever Clutch lever EAU23185 Checking and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be...

Page 70: ...s not move up and down smoothly have a Yamaha dealer check or re pair it Otherwise the centerstand or sidestand could contact the ground and distract the operator resulting in a possible loss of contr...

Page 71: ...al times to check if the front fork compresses and re bounds smoothly NOTICE ECA10591 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU455...

Page 72: ...poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of cont...

Page 73: ...more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation NOTICE When install ing the battery be sure the key is turned to OF...

Page 74: ...causing extensive damage to the electrical system and possi bly a fire EWA15132 6 Connect the battery coupler 7 Install the battery and the battery band 8 Install the seat 9 Turn the main switch on a...

Page 75: ...adlight bulb burns out replace it as follows NOTICE ECA26690 Do not touch the glass part of the headlight bulb Otherwise the luminosity and the life of the bulb may be adversely affected Thoroughly cl...

Page 76: ...bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU70550 Replacing the brake tail light bu...

Page 77: ...by removing the screws 2 Remove the burnt out bulb by pushing it in and turning it coun terclockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Instal...

Page 78: ...here is no danger of it falling over 1 Loosen the wheel axle nut 2 Loosen the wheel axle holder nuts 3 Place the motorcycle on the cen terstand 4 Disconnect the speedometer ca ble from the speedometer...

Page 79: ...the slot in the speedometer gear unit fits over the retainer on the fork leg 4 Insert the wheel axle from the left side and then install the washer and axle nut 5 Take the motorcycle off the cen terst...

Page 80: ...haft lever 5 Loosen the drive chain puller lock nut and the drive chain slack ad justing bolt on both ends of the swingarm 6 Remove the axle nut and washer 7 While supporting the rear wheel pull the w...

Page 81: ...operation of the brake light EAU25853 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur during operation Any problem in the f...

Page 82: ...iodic maintenance and adjustment 7 41 7 heaters or furnaces Gasoline or gasoline vapors can ignite or ex plode causing severe injury or prop erty damage UB9FEYE0 book Page 41 Monday July 12 2021 5 47...

Page 83: ...move the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug s Have a Yamaha dealer check the vehicle The engine does not...

Page 84: ...in tenance products are sold under the YAMALUBE brand in many markets worldwide See your Yamaha dealer for addi tional cleaning tips NOTICE ECA26280 Improper cleaning can cause cos metic and mechanica...

Page 85: ...ield with a soft towel or sponge dampened with water and a pH neutral detergent If necessary use a high quality windshield cleaner or polish for motorcycles NOTICE Never use any strong chemicals to cl...

Page 86: ...rakes or tires If necessary wash the tires with warm water and a mild deter gent If necessary clean the brake discs and pads with brake cleaner or acetone Before riding at higher speeds test the vehic...

Page 87: ...his will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil WARNING To prevent dam age or injury from sparking make su...

Page 88: ...tity Oil change 2 00 L 2 11 US qt 1 76 Imp qt With oil filter removal 2 10 L 2 22 US qt 1 85 Imp qt Fuel Recommended fuel Unleaded gasoline E10 acceptable Octane number RON 90 Fuel tank capacity 12 L...

Page 89: ...l system System voltage 12 V Battery Model GT4B 5 Voltage capacity 12 V 2 5 Ah 10 HR Headlight Bulb type Halogen bulb Bulb wattage Headlight H4 60 0 W 55 0 W Brake tail light 21 0 W 5 0 W Front turn s...

Page 90: ...IAL NUMBER MODEL LABEL INFORMATION EAU26401 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided TIP The veh...

Page 91: ...urpos es Although the sensors and recorded data will vary by model the main data points are Vehicle status and engine perfor mance data Fuel injection and emission relat ed data This data will be uplo...

Page 92: ...e provided and Yamaha will appropriate ly manage the data With the consent of the vehicle owner Where obligated by law For use by Yamaha in litigation When the data is not related to an individual veh...

Page 93: ...el 4 8 Fuel cock 4 10 Fuel consumption tips for reducing 6 5 Fuel level warning light 4 3 Fuel tank cap 4 8 Fuses replacing 7 32 H Handlebar switches 4 5 Hazard lights switch 4 6 Headlight bulb replac...

Page 94: ...leshooting 7 40 Troubleshooting chart 7 42 Turn signal indicator light 4 3 Turn signal light bulb replacing 7 36 Turn signal switch 4 6 V Valve clearance 7 17 Vehicle identification number 10 1 W Whee...

Page 95: ...UB9FEYE0 book Page 3 Monday July 12 2021 5 47 PM...

Page 96: ...DIC183 PRINTED IN JAPAN 2021 08 0 3 1 CR E...

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