2014 YAMAHA SR400 brake

PERIODIC MAINTENANCE AND ADJUSTMENT
6-21
1
2
3
4
56
7
8
9
10
11
12 performance.

Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.

Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.

Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.

Be careful that water does not
enter the brake fluid reservoir
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vaporlock.
NOTICE
ECA17641
Brake fluid may damage painted sur-
faces or plastic parts. Always cleanup 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 and/or brake sys-
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 master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.
Oil seals: Replace every two
years.

Brake hose: Replace every four
years.
2RD-9-E0.book 21 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-22
1
2
3
4
567
8
9
10
11
12
EAU22762
Drive chain slackThe drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU59591
To check the drive chain slack 1. Place the motorcycle on the cen- terstand.
2. Shift the transmission into the neu- tral position.
3. Push on the drive chain at the cen- ter point between the drive axle
and the rear wheel axle with a
force of 50 N (5.0 kgf, 11 lbf).
4. Measure drive chain slack as shown. 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU59641
To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack.1. Take the motorcycle off the center- stand, and then put the sidestand
down.
2. Loosen the brake pedal free play adjusting nut, brake torque rod nut,
and axle nut. 3. Loosen 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 en-
Drive chain slack: 30.0–40.0 mm (1.18–1.57 in)
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Drive chain slack adjusting bolt
3. Drive chain puller locknut
4. Axle nut
5. Brake torque rod nut
6. Brake torque rod
6
12
3
4
5
2RD-9-E0.book 22 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-23
1
2
3
4
56
7
8
9
10
11
12 gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10572]
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the sameposition for proper wheel alignment.
6. Take the motorcycle off the center- stand, and then put the sidestand down.
7. Tighten both drive chain puller locknuts, and then tighten the axle
nut and brake torque rod nut to
their specified torques.
8. Adjust the brake pedal free play. (See page 6-18.)
WARNING
EWA10661
After adjusting the brake pedal free
play, check the operation of thebrake light.
9. Make sure that the drive chain pull- ers are in the same position, the
drive chain slack is correct, and
the drive chain moves smoothly.
EAU23026
Cleaning and lubricating the
drive chainThe drive chain must be cleaned and
lubricated 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
ECA10584
The drive chain must be lubricated
after washing the motorcycle, ridingin 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-
propriate solvents.
[ECA11122]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as they
1. Axle nut
2. Drive chain puller locknut
3. Drive chain slack adjusting bolt
4. Alignment marks
1
2
(a) (b)
3
4
Tightening torques:
Drive chain puller locknut:16 Nm (1.6 m·kgf, 12 ft·lbf)
Axle nut: 129 Nm (12.9 m·kgf, 92 ft·lbf)
Brake torque rod nut:
19 Nm (1.9 m·kgf, 14 ft·lbf)
2RD-9-E0.book 23 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-25
1
2
3
4
56
7
8
9
10
11
12
EAU23144
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Brake lever Clutch lever
EAU23184
Checking and lubricating the
brake pedalThe 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-9-E0.book 25 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-27
1
2
3
4
56
7
8
9
10
11
12
EAU51951
Checking the front forkThe condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the front fork for damage and ex-
cessive oil leakage.
To check the operation 1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. While applying the front brake, push down hard on the 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 steeringWorn 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-
riodic maintenance and lubrication
chart.1. Place the vehicle on the center- stand. WARNING! To avoid inju-
ry, securely support the vehicle
so there is no danger of it falling
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
2RD-9-E0.book 27 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-32
1
2
3
4
567
8
9
10
11
12
2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
3. Unhook the headlight bulb holder, and then remove the burnt-out bulb.
4. Place a new headlight bulb into po- sition, and then secure it with the
bulb holder.
5. Install the 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.
EAU24134
Replacing the ta il/brake light
bulb1. 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.
1. Screw
1. Headlight coupler
2. Headlight bulb cover
1
1
2
1. Headlight bulb holder
1
1. Screw
2. Tail/brake light lens
1 2
2RD-9-E0.book 32 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-33
1
2
3
4
56
7
8
9
10
11
12 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 break.
[ECA10682] EAU60010
Replacing a turn
signal light
bulb1. Remove the turn signal light lens,
turn signal light rim and gasket by
removing the screws.
2. Remove the burnt-out bulb bypushing 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 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. Tail/brake light bulb
1
1. Turn signal light lens
2. Screw
1
2
1. Turn signal light lens
2. Turn signal light rim
3. Gasket
3
2
1
2RD-9-E0.book 33 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
1
2
3
4
567
8
9
10
11
12
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 the wheel hub.
3. Lift the wheel up between the fork legs.
TIPMake sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over theretainer on the fork leg.
4. Insert the wheel axle from the left-hand side, and then install the
washer and axle nut.
5. Take the motorcycle off the center- stand so that the front wheel is on
the ground, and then put the side-
stand down.
6. Tighten the axle nut and the wheel axle holder nuts to their specified
torques
7. While applying the front brake, push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
8. Connect the speedometer cable.
1. Slot
2. Speedometer gear unit
3. Projection
2
3
1
1. Retainer
2. Slot
1
2
Tightening torques:
Axle nut:104 Nm (10.4 m·kgf, 74 ft·lbf)
Wheel axle holder nut: 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
2RD-9-E0.book 36 ページ ２０１３年１１月２８日　木曜日　午後４時１８分