Yamaha SR400 Owner'S Manual Download

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10-1

Index

Air filter element, replacing ................... 6-13
Auxiliary light bulb, replacing ................ 6-36

Battery................................................... 6-31
Brake and clutch levers, checking and

lubricating ........................................... 6-28

Brake fluid, changing ............................ 6-24
Brake fluid level, checking .................... 6-23
Brake lever.............................................. 3-7
Brake lever free play, adjusting............. 6-19
Brake light switches .............................. 6-22
Brake pads and shoes, checking .......... 6-22
Brake pedal............................................. 3-7
Brake pedal, checking and

lubricating ........................................... 6-28

Brake pedal height and free play,

adjusting ............................................. 6-20

Cables, checking and lubricating .......... 6-27
Care ........................................................ 7-1
Catalytic converter ................................ 3-11
Centerstand and sidestand, checking

and lubricating .................................... 6-29

Clutch lever ............................................. 3-6
Clutch lever free play, adjusting............ 6-18

Decompression lever ............................ 3-12
Dimmer switch ........................................ 3-5
Drive chain, cleaning and lubricating .... 6-26
Drive chain slack................................... 6-25

Engine break-in....................................... 5-5
Engine idling speed, checking .............. 6-14
Engine oil and oil filter element ............... 6-9
Engine serial number .............................. 9-1
Engine stop switch .................................. 3-5
Engine trouble warning light.................... 3-3

Front fork, checking .............................. 6-30
Fuel ......................................................... 3-9
Fuel cock............................................... 3-11
Fuel consumption, tips for reducing ........ 5-5
Fuel level warning light ........................... 3-2
Fuel tank breather/overflow hose.......... 3-10
Fuel tank cap .......................................... 3-8
Fuses, replacing.................................... 6-33

Handlebar switches................................. 3-4
Hazard switch ......................................... 3-5

Headlight bulb, replacing ...................... 6-35
High beam indicator light ........................ 3-2
Horn switch............................................. 3-5

Identification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-15
Indicator lights and warning lights .......... 3-2

Kickstarter ............................................ 3-12

Main switch/steering lock ....................... 3-1
Maintenance and lubrication, periodic .... 6-4
Maintenance, emission control system... 6-3
Matte color, caution ................................ 7-1
Model label ............................................. 9-2

Neutral indicator light.............................. 3-2

Panel, removing and installing ............... 6-7
Parking ................................................... 5-6
Part locations.......................................... 2-1
Pass switch ............................................ 3-5

Safety information .................................. 1-1
Seat ...................................................... 3-13
Shifting ................................................... 5-3
Shift pedal .............................................. 3-6
Shift pedal, checking ............................ 6-21
Shock absorber assemblies,

adjusting............................................. 3-13

Tachometer ............................................ 3-4
Tail/brake light bulb, replacing.............. 6-37
Throttle grip and cable, checking and

lubricating........................................... 6-27

Throttle grip free play, checking ........... 6-14
Tires ..................................................... 6-15
Tool kit .................................................... 6-2
Troubleshooting.................................... 6-42
Troubleshooting chart........................... 6-43
Turn signal indicator light ....................... 3-2

2RD-28199-E1.book 1 ページ２０１５年９月３日　木曜日　午後３時４２分

Summary of Contents for SR400

Page 1: ...SR400 MOTORCYCLE 2RD 28199 E1 OWNER S MANUAL Read this manual carefully before oper ating this vehicle SR400 2RD 9 E1_hyoshi indd 1 2015 09 16 13 46 32 ...

Page 2: ...Q Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold EAU46091 2RD 9 E1_hyoshi indd 2 2015 09 16 13 46 32 ...

Page 3: ...In 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 con tact your Yamaha dealer The Yamaha team wishes you many safe and pleasant rides So remember to put safety first Yamaha continually seeks advancements in product design and quality There fore while this manual contains the most current...

Page 4: ...r death A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key information to make proce dures easier or clearer SR400 OWNER S MANUAL 2015 by Yamaha Motor Co Ltd 1st edition August 2015 All rights reserved Any reprinting or un...

Page 5: ...the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing the panel 6 7 Checking the spark plug 6 8 Engine oil and oil filter element 6 9 Replacing the air filter element 6 13 Checking the engine idling speed 6 14 Checking the throttle grip free play 6 14 Valve clearance 6 15 Tires 6 15 Spoke wheels 6 17 Adjusting the clutch lever free play 6 18 Adjustin...

Page 6: ...ht bulb 6 36 Replacing the tail brake light bulb 6 37 Replacing a turn signal light bulb 6 38 Front wheel 6 39 Rear wheel 6 40 Troubleshooting 6 42 Troubleshooting chart 6 43 Motorcycle care and storage 7 1 Matte color caution 7 1 Care 7 1 Storage 7 4 Specifications 8 1 Consumer information 9 1 Identification numbers 9 1 Index 10 1 2RD 28199 E1 book 2 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 7: ...ect or maintain the vehicle properly increases the possibility of an accident or equipment damage See page 4 1 for a list of pre operation checks This motorcycle is designed to car ry the operator and a passenger The failure of motorists to detect and recognize motorcycles in traf fic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile dri...

Page 8: ...nly It is not suitable for off road use Protective Apparel The majority of fatalities from motorcy cle accidents are the result of head in juries The use of a safety helmet is the single most critical factor in the preven tion or reduction of head injuries Always wear an approved helmet Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that cou...

Page 9: ...he maximum load limit Operation of an overloaded vehicle could cause an accident When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Se curely pack your heaviest items as close to the center of the vehicle as possible and make sure to distrib ute the weight as evenly as possi ble on both sides of ...

Page 10: ...sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the handle bar or the front fork area can cre ate instability due to improper weight distribution or aerody namic changes If accessories are added to the handlebar or front fork area they must be as light...

Page 11: ... truck bed and choke it in a rail to pre vent movement Shift the transmission in gear for models with a manual transmis sion Secure the motorcycle with tie downs or suitable straps 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 Choose the lo cation for...

Page 12: ...ipstick page 6 9 2 Engine oil filler cap page 6 9 3 Fuel tank cap page 3 8 4 Fuel cock page 3 11 5 Battery page 6 31 6 Fuse page 6 33 7 Shock absorber assembly spring preload adjusting ring page 3 13 8 Shift pedal page 3 6 1 2 4 5 6 3 7 8 2RD 28199 E1 book 1 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 13: ...r filter element page 6 13 2 Kickstarter page 3 12 3 Kick indicator page 5 2 4 Headlight page 6 35 5 Brake pedal page 3 7 6 Owner s tool kit page 6 2 7 Shock absorber assembly spring preload adjusting ring page 3 13 1 2 4 5 6 3 7 2RD 28199 E1 book 2 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 14: ...itches page 3 4 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Tachometer page 3 4 6 Front brake fluid reservoir page 6 23 7 Right handlebar switches page 3 4 8 Brake lever page 3 7 9 Throttle grip page 6 14 10 Decompression lever page 3 12 1 2 3 4 5 7 8 9 6 10 2RD 28199 E1 book 3 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 15: ...n if the engine stalls EAU10662 OFF All electrical systems are off The key can be removed WARNING EWA10062 Never turn the key to OFF or LOCK while the vehicle is moving Otherwise the electrical systems will be switched off which may result in loss of control or an accident EAU10687 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn th...

Page 16: ...en a turn signal light is flashing EAU11061 Neutral indicator light This indicator light comes on when the transmission is in the neutral position EAU11081 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU11354 Fuel level warning light This warning light comes on when the fuel level drops below approximately 2 2 L 0 58 US gal 0 48 Imp ga...

Page 17: ... on for a few seconds and then go off If the warning light does not come on initially when the key is turned to ON or if the warning light remains on have a Yamaha dealer check the electrical circuit EAU11631 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows rid ing speed The odometer shows the to tal distance traveled The tripme...

Page 18: ...in the ideal power range NOTICE ECA10032 Do not operate the engine in the ta chometer red zone Red zone 7000 r min and above EAU1234H Handlebar switches Left Left Right 1 Tachometer 2 Tachometer red zone 1 2 1 Dimmer switch 2 Pass switch 1 Turn signal switch 2 Horn switch 1 Engine stop switch 2 Hazard switch 1 2 1 2 1 2 2RD 28199 E1 book 4 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 19: ... position EAU12501 Horn switch Press this switch to sound the horn EAU12661 Engine stop switch Set this switch to before starting the engine Set this switch to to stop the engine in case of an emergen cy such as when the vehicle overturns or when the throttle cable is stuck EAU12735 Hazard switch With the key in the ON or posi tion use this switch to turn on the haz ard lights simultaneous flashin...

Page 20: ...led rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 15 EAU12872 Shift pedal The shift pedal is located on the left side of the motorcycle and is used in combination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorc...

Page 21: ...d on the right side of the handlebar To apply the front brake pull the lever toward the throttle grip EAU12944 Brake pedal The brake pedal is located on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 1 1 Brake pedal 1 2RD 28199 E1 book 7 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 22: ...ing with the key inserted in the lock and with the mark facing forward 2 Turn the key counterclockwise to the original position remove it and then close the lock cover TIP The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARNING EWA10132 Make sure that the fuel tank cap is properly installed be...

Page 23: ... dry soft cloth since fuel may deteri orate painted surfaces or plastic parts ECA10072 4 Be sure to securely close the fuel tank cap WARNING EWA15152 Gasoline is poisonous and can cause injury or death Handle gaso line with care Never siphon gaso line by mouth If you should swallow some gasoline or inhale a lot of gas oline vapor or get some gasoline in your eyes see your doctor immedi ately If ga...

Page 24: ...ent does not exceed 10 E10 Gas ohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems EAU39453 Fuel tank breather overflow hose Before operating the motorcycle Check the fuel tank breather over flow hose connection Check the fuel tank breather over flow hose for cracks or damage and replace it if necessary Make sure that...

Page 25: ... not allow the engine to idle more than a few minutes Long idling can cause a build up of heat NOTICE ECA10702 Use only unleaded gasoline The use of leaded gasoline will cause unre pairable damage to the catalytic converter EAU59491 Fuel cock The fuel cock regulates and filters the fuel supply from the fuel tank The fuel cock has two positions ON With the lever in this position fuel will be suppli...

Page 26: ...arter allowing the engine to be started in any gear if the clutch is disengaged However shifting the transmission 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 allows the piston to be moved just past the compression stroke before kick starting See...

Page 27: ...ay result Each shock absorber assembly is equipped with a spring preload adjust ing ring NOTICE ECA10102 To avoid damaging the mechanism do not attempt to turn beyond the maximum or minimum settings Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring pre...

Page 28: ...em WARNING EWA10242 The vehicle must not be ridden with the sidestand down or if the sides tand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility of raising the sidestand ...

Page 29: ...g when the trans mission is in gear and the sides tand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the fol...

Page 30: ...and up 11 Keep the clutch lever pulled 12 Push the kick starter lever down Does the engine start The system is OK The motorcycle can be ridden The neutral switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may not be working correctly The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may...

Page 31: ...s cracks or damage and check hose connection 3 9 3 10 Engine oil Check oil level in oil tank If necessary add recommended oil to specified level Check vehicle for oil leakage 6 9 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary ...

Page 32: ...ate pedal pivoting point if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 29 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operati...

Page 33: ...ich could cause an accident or injury EAU59360 TIP This model is equipped with a lean angle sensor to stop the en gine in case of a turnover In this case turn the key to OFF and then to ON Failing to do so will prevent the engine from starting even though the engine will crank when pushing the kick starter lever down an engine auto stop system The engine stops automatically if left idling for 20 m...

Page 34: ...ght does not come on initially when the key is turned to ON or if a warning light remains on see page 3 2 for the correspond ing warning light circuit check 3 Shift the transmission into the neu tral position The neutral indicator light should come on If not ask a Yamaha dealer to check the elec trical circuit 4 Completely close the throttle and apply the decompression lever 5 Slowly push the kick...

Page 35: ...e gear positions are shown in the il lustration TIP To shift the transmission into the neu tral position press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it NOTICE ECA10261 Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission...

Page 36: ...r gear TIP When shifting gears in normal operat ing conditions use the recommended shift points EAU16701 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission into first gear when the motorcycle reaches 20 km h 12 mph If the engine is about to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle 3 Shift the...

Page 37: ... ing material carefully Since the engine is brand new do not put an excessive load on it for the first 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 result in engine overheating must be avoided EAU17094 0 1000 km 0 600 mi Avoid prolonged operation above...

Page 38: ...ince the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them and be burned Do not park on a slope or on soft ground otherwise the vehicle may overturn increasing the risk of a fuel leak and fire Do not park near grass or other flammable materials which might catch fire 2RD 28199 E1 book 6 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 39: ...ilure to properly maintain the ve hicle or performing maintenance ac tivities incorrectly may increase your risk of injury or death during service or while using the vehicle If you are not familiar with vehicle ser vice have a Yamaha dealer perform service WARNING EWA15123 Turn off the engine when performing maintenance unless otherwise specified A running engine has moving parts that can catch on...

Page 40: ... are trained and equipped to perform these particular services EAU59370 Owner s tool kit The owner s tool kit is located inside the tool box To access the owner s tool kit slide the lock cover open insert the key into the lock and then turn it 1 4 turn clockwise The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performa...

Page 41: ...s data and technical skills EAU63321 Periodic maintenance chart for the emission control system NO ITEM 1 Fuel line Check fuel hoses for cracks or damage 2 Spark plug Check condition Clean and regap Replace 3 Valves Check valve clearance Adjust 4 Fuel injection Check engine idle speed 5 Muffler and exhaust pipe Check the screw clamp s for looseness 6 Air induction system Check the air cut off valv...

Page 42: ...nd adjust brake pedal free play Replace brake shoes Whenever worn to the limit 7 Brake hose Check for cracks or damage Check for correct routing and clamping Replace Every 4 years 8 Brake fluid Change Every 2 years 9 Wheels Check runout spoke tightness and for damage Tighten spokes if necessary 10 Tires Check tread depth and for damage Replace if necessary Check air pressure Correct if necessary 1...

Page 43: ...e with silicone grease 17 Brake pedal pivot shaft Lubricate with lithium soap based grease 18 Clutch lever pivot shaft Lubricate with lithium soap based grease 19 Sidestand centerstand Check operation Lubricate with lithium soap based grease 20 Sidestand switch Check operation 21 Front fork Check operation and for oil leakage 22 Shock absorber assemblies Check operation and shock absorbers for oil...

Page 44: ...and caliper always change the fluid Regularly check the brake fluid level and fill the reservoir as re quired Every two years replace the internal components of the brake master cylin der and caliper and change the brake fluid Replace the brake hose every four years and if cracked or damaged 27 Throttle grip Check operation Check throttle grip free play and adjust if necessary Lubricate cable and ...

Page 45: ...nel needs to be removed and installed TIP The panel on the left side is removable using the key However there is no need to remove this panel for mainte nance jobs described in this chapter EAU19152 Panel A To remove the panel Remove the bolt and then pull the pan el off as shown To install the panel Place the panel in the original position and then install the bolt 1 Panel A 1 1 Panel A 2 Bolt 3 ...

Page 46: ...f the spark plug is a medium to light tan the ideal color when the vehicle is ridden normally TIP If the spark plug shows a distinctly dif ferent color the engine could be oper ating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicle 2 Check the spark plug for electrode erosion and excessive carbon or other deposits and replace it if necess...

Page 47: ...ance and lubri cation chart To check the engine oil level 1 Start the engine warm it up for several minutes and then turn it off 2 On a level surface place the vehi cle on the centerstand 3 Wait a few minutes until the oil set tles Remove the engine oil filler cap wipe the dipstick clean insert it back into the oil filler hole with out screwing it in and then re move it again to check the oil leve...

Page 48: ...used oil 3 Remove the oil filter element cover bleed bolt and its gasket and the oil filter element drain bolt to drain the oil from the oil filter element chamber 4 Remove the engine oil drain bolt and its gasket to drain the oil from the crankcase 5 Remove the engine oil filler cap the engine oil tank drain bolt and its gasket to drain the oil from the oil tank 1 Engine oil filler cap 2 Dipstick...

Page 49: ...en the bolt to the specified torque 10 Install the oil filter element cover bleed bolt and its gasket and then tighten the bolt to the specified torque 11 Install the engine oil drain bolts and their new gasket and then tighten the bolts to the specified torques 1 Engine oil drain bolt oil tank 2 Gasket 1 Oil filter element cover bolt 2 1 1 1 Oil filter element cover 2 O ring 3 Oil filter element ...

Page 50: ...leaking im mediately turn the engine off and check for the cause 14 Turn the engine off and then check the oil level and correct it if necessary NOTICE ECA11232 After changing the engine oil make sure to check the oil pressure as de scribed below Loosen the bleed bolt Start the engine and keep it idling until oil flows out If no oil comes out after one minute turn the engine off immediately so it ...

Page 51: ...page 6 7 2 Remove the air filter case cover by removing the screws 3 Pull the air filter element out 4 Insert a new air filter element into the air filter case NOTICE Make sure that the air filter element is properly seated in the air filter case The engine should never be operated without the air filter element installed otherwise the piston s and or cylinder s may become excessively worn ECA1048...

Page 52: ...corrected by a Yamaha dealer EAU21386 Checking the throttle grip free play Measure the throttle grip free play as shown Periodically check the throttle grip free play and if necessary have a Yamaha dealer adjust it Engine idling speed 1200 1400 r min 1 Throttle grip free play Throttle grip free play 3 0 5 0 mm 0 12 0 20 in 1 2RD 28199 E1 book 14 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 53: ...Therefore it is essential to maintain the tires in good condition at all times and replace them at the appropriate time with the speci fied tires 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 or death from loss of control The tire air pressure must...

Page 54: ...as the necessary professional knowl edge and experience It is not recommended to patch a punctured tube If unavoid able however patch the tube very carefully and replace it as soon as possible with a high quality product Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tire information This model is equipped ...

Page 55: ...el To maximize the performance durabil ity and safe operation of your motorcy cle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warpage or oth er damage and the spokes for looseness or damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A de formed or ...

Page 56: ...tch lever free play adjusting bolt in direction a To decrease the clutch lever free play turn the adjusting bolt in direction b 4 Tighten the locknut and then slide the rubber cover to its original po sition TIP If the specified free play cannot be ob tained as described above or if the clutch does not operate correctly have a Yamaha dealer check the internal clutch mechanism 1 Clutch lever free p...

Page 57: ...ut and then slide the rubber cover back to its original position WARNING EWA10631 After adjusting the brake lever free play check the free play and make sure that the brake is working 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 operating the motorc...

Page 58: ...ng bolt in direction a To lower the brake pedal turn the adjusting bolt in di rection b 3 Tighten the locknut WARNING EWA11232 After adjusting the brake pedal height the brake pedal free play must be adjusted Brake pedal free play Measure the brake pedal free play as shown Periodically check the brake pedal free play and if necessary adjust it as fol lows To increase the brake pedal free play turn...

Page 59: ...e brake pedal free play If proper adjustment cannot be obtained as described have a Yamaha dealer make this ad justment After adjusting the brake pedal free play check the operation of the brake light EAU44821 Checking the shift pedal The operation of the shift pedal should be checked before each ride If opera tion is not smooth have a Yamaha dealer check the vehicle 1 Brake pedal free play adjust...

Page 60: ...ting nut in direction b EAU22382 Checking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic main tenance and lubrication chart EAU22432 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the b...

Page 61: ...id level with the top of the reservoir level Replenish the brake fluid if necessary WARNING EWA15991 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may al low air to enter the brake sys tem reducing braking performance Clean the filler cap before re moving Use only DOT 4 brake fluid from a sealed container Use only the specified brake ...

Page 62: ...s tem leakage therefore be sure to check the brake pads for wear and the brake system for leakage If the brake fluid level goes down suddenly have a Yamaha dealer check the cause before further riding EAU22724 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the periodic maintenance and lubrica tion chart In addition have the oil seals of the brake...

Page 63: ...the drive chain puller lock nut at each end of the swingarm 4 Place the motorcycle on the cen terstand 5 To tighten the drive chain turn the drive chain slack adjusting bolt at each end of the swingarm in direc tion a To loosen the drive chain turn the adjusting bolt at each end of the swingarm in direction b and then push the rear wheel for ward NOTICE Improper drive chain slack will overload the...

Page 64: ...ckly wear out especially when riding in dusty or wet areas Service the drive chain as follows NOTICE ECA10584 The drive chain must be lubricated after washing the motorcycle riding in the rain or riding in wet areas 1 Clean the drive chain with kero sene and a small soft brush NOTICE To prevent damaging the O rings do not clean the drive chain with steam cleaners high pressure washers or inap prop...

Page 65: ...ndi tions EWA10712 EAU23115 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated by a Yamaha dealer at the intervals speci fied in the periodic maintenance chart The throttle cable is equipped with a rubber cover Make sure that the cover is securely installed Even though the cover is i...

Page 66: ...ver pivots should 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 lubricat ed if necessary Recommended lubricants Brake lever Silicone grease Clutch lever Lithium soap based grease Recommended lubricant Lithium soap based grease 2RD 28199 E1 book ...

Page 67: ...nd or sidestand does 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 control EAUM1653 Lubricating the swingarm pivots The swingarm pivots must be lubricat ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart R...

Page 68: ...he handlebars several times to check if the front fork compresses and rebounds 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 EAU45512 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe rio...

Page 69: ...the electro lyte or to add distilled water However the battery coupler connection needs to be checked to make sure that it is se curely connected WARNING EWA10761 Electrolyte is 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 contact administer the fol...

Page 70: ...ge battery charger is re quired Using a conventional battery charger will damage the battery To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place NOTICE When removing the battery be sure the key is turned to OFF before discon necting the coupler ECA16323 2 If the battery will be stored for more than ...

Page 71: ...pecified amperage WARNING Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive dam age to the electrical system and possibly a fire EWA15132 6 Connect the battery coupler 7 Install the battery by installing the battery band 8 Install the seat 9 Turn the key to ON 10 If the fuse immediately blows again have a Yamaha dealer check the electrical system The fuse bo...

Page 72: ...electrical system and possibly a fire EWA15132 4 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 5 If a fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Backup fuse 5 Fuel injection system fuse 6 Parking lighting fuse 7 Spare fuse 1 1 2 3 4 5 7 6 Spec...

Page 73: ...ife will be adversely affected Thor oughly clean off any dirt and fin gerprints on the headlight bulb using a cloth moistened with al cohol or thinner Headlight lens Do not affix any type of tinted film or stickers to the headlight lens Do not use a headlight bulb of a wattage higher than specified 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remo...

Page 74: ... ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU33417 Replacing the auxiliary light bulb If the auxiliary light bulb burns out re place it as follows 1 Remove the headlight unit by re moving the screws 2 Remove the socket together with the bulb by pushing it in and turn ing it counterclockwise 1 Headlight bulb holder 1 1 Screw 1 Screw 1 Auxiliary light bulb socket ...

Page 75: ...nstall ing the screws EAU24135 Replacing the tail brake light bulb 1 Remove the tail brake light lens by removing the screws 2 Remove the burnt out bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws NOTICE Do not over tighten the screws otherwise the lens may br...

Page 76: ...urning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the gasket rim and lens by installing the screws with the notch on the rim and lens facing to in ward as shown NOTICE Do not overtighten the screws other wise the lens may break ECA10682 1 Turn signal light lens 2 Screw 1 Turn signal light lens 2 Turn signal light rim 3 G...

Page 77: ...he wheel axle nut and the washer 6 Pull the wheel axle out and then remove the collar and wheel NOTICE Do not apply the brake after the wheel and brake disc have been removed otherwise the brake pads will be forced shut ECA11073 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Install the collar into the right side of ...

Page 78: ...speedometer cable EAU25081 Rear wheel EAU59614 To remove the rear wheel WARNING EWA10822 To avoid injury securely support the vehicle so there is no danger of it falling over 1 Loosen the axle nut and the brake torque rod nut at the brake shoe plate 2 Disconnect the brake torque rod from the brake shoe plate by re moving the nut washer and the bolt 3 Place the motorcycle on the cen terstand 4 Remo...

Page 79: ... chain onto the rear sprocket 4 Install the washer and axle nut 5 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 6 Connect the brake torque rod to the brake shoe plate by installing the bolt washer and nut 7 Adjust the drive chain slack See page 6 25 8 Take the motorcycle off the center stand so that the rear wheel is...

Page 80: ... your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi or have a shorter service life and can lead to expensive repair bills WARNING EWA15142 When checking the fuel syste...

Page 81: ...harge the battery if necessary Operate the kickstarter If the engine does not start check the ignition 2 Battery The battery is good 3 Ignition Wet Dry There is compression There is no compression Operate the kickstarter The engine does not start Have a Yamaha dealer check the vehicle Have a Yamaha dealer check the vehicle The engine does not start Check the compression Have a Yamaha dealer check ...

Page 82: ...cts from the overall appearance of a motor cycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your mo torcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlet with a plastic bag after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connec...

Page 83: ...nts For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning com pounds for plastic may leave scratches on the windshield Test the product on a small hid den part of the windshield to make sure that it does not leave any marks If the windshield is scratched use a quality plastic polishing compound after washing Aft...

Page 84: ...fore storing or covering it WARNING EWA11132 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and...

Page 85: ... spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This 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 sure to ground the spark plug electrodes while turning the engine over EWA10952 e Remove the spark plu...

Page 86: ...Motorcycle care and storage 7 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 storing the motorcycle 2RD 28199 E1 book 5 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 87: ...r higher JASO stan dard MA Engine oil quantity 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 Air filter Air filter element Oil coated paper element Fuel Recommended fuel Regular unleaded gasoline Gasohol E10 acceptable Fuel tank capacity 12 L 3 2 US gal 2 6 Imp gal Fuel reserve amount 2 2 L 0 58 US gal 0 48 Imp gal Fuel injection Throttle body ID ma...

Page 88: ...e 18 x 2 15 Front brake Type Hydraulic disc brake Specified brake fluid DOT 4 Rear brake Type Mechanical leading trailing drum brake Front suspension Type Telescopic fork Spring Coil spring Shock absorber Hydraulic damper Wheel travel 150 mm 5 9 in Rear suspension Type Swingarm Spring Coil spring Shock absorber Hydraulic damper Wheel travel 105 mm 4 1 in Electrical system System voltage 12 V Ignit...

Page 89: ...Fuel level warning light 3 0 W 1 Engine trouble warning light 1 7 W 1 Fuse s Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Parking lighting fuse 7 5 A Fuel injection system fuse 7 5 A Backup fuse 7 5 A 2RD 28199 E1 book 3 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 90: ...LE IDENTIFICATION NUM BER ENGINE SERIAL 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 vehicle identification number is used to identify your motorcycle and may be used to register your motorcy cle with the licensing authority in your area EAU26442 Engin...

Page 91: ...label The model label is affixed to the frame under the seat See page 3 13 Re cord the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label 1 2RD 28199 E1 book 2 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 92: ...warning light 3 2 Fuel tank breather overflow hose 3 10 Fuel tank cap 3 8 Fuses replacing 6 33 H Handlebar switches 3 4 Hazard switch 3 5 Headlight bulb replacing 6 35 High beam indicator light 3 2 Horn switch 3 5 I Identification numbers 9 1 Ignition circuit cut off system 3 15 Indicator lights and warning lights 3 2 K Kickstarter 3 12 M Main switch steering lock 3 1 Maintenance and lubrication p...

Page 93: ...14 Turn signal light bulb replacing 6 38 Turn signal switch 3 5 V Valve clearance 6 15 Vehicle identification number 9 1 W Wheel bearings checking 6 31 Wheel front 6 39 Wheel rear 6 40 Wheels 6 17 2RD 28199 E1 book 2 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 94: ...2RD 28199 E1 book 3 ページ２０１５年９月３日木曜日午後３時４２分 ...

Page 95: ...2RD 9 E1_hyoshi indd 3 2015 09 16 13 46 32 ...

Page 96: ...PRINTED IN JAPAN 2015 10 0 1 1 E PRINTED ON RECYCLED PAPER Original instructions 2RD 9 E1_hyoshi indd 4 2015 09 16 13 46 32 ...

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Yamaha SR400, Owner'S Manual

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