2014 YAMAHA SR400 light

PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU59350
TIP
Air filter
This model’s air intake system is equipped with a disposable oil-coated paper element. The air filter element cannot
be cleaned with compressed air, it must be replaced.
The air filter element needs to be replaced more fr equently 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 fluid
level and fill the reservoir as required.
Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. Replace the brake hose every four years and if cracked or damaged.
23 Engine oil Change.
Check oil level and vehicle for oil
leakage. 
24 Engine oil filter
element Replace.

25 *Front and rear brake
switches Check operation.

26 Moving parts and
cables Lubricate.

27 *Throttle grip Check operation.
Check throttle grip free play, and
adjust if necessary.
Lubricate cable and grip housing. 
28 *Lights, signals and
switches Check operation.
Adjust headlight beam.

NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU19605
Checking the spark plugThe spark plug is 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 mainte-
nance and lubrication chart. In addition,
the condition of the spark plug can re-
veal the condition of the engine.
To remove the spark plug 1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the spark plug wrench includ-
ed in the owner’s tool kit. To check the spark plug
1. Check that the porcelain insulator around the center electrode of the
spark plug is a medium-to-light tan
(the ideal color when the vehicle is
ridden normally).
TIPIf 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 checkthe vehicle.
2. Check the spark plug for electrode erosion and excessive carbon or
other deposits, and replace it if necessary.
3. Measure the spark plug gap with a wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
To install the spark plug 1. Clean the surface of the spark plug gasket and its mating surface, and
then wipe off any grime from the
spark plug threads.
2. Install the spark plug with the
1. Spark plug cap
1
1. Spark plug wrench
1
Specified spark plug: NGK/BPR6ES1. Spark plug gapSpark plug gap:0.7–0.8 mm (0.028–0.031 in)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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WARNING
EWA10681

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
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 ofthe brake light.
EAU44821
Checking the shift pedalThe operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
EAU22274
Brake light switchesThe brake light, which is activated by
the brake pedal and brake lever, should
come on just before braking takes ef-
fect. If necessary, adjust the rear brake
light switch as follows, but the front
brake light switch should be adjusted
by a Yamaha dealer.
Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
switch in place. To make the brake light
come on earlier, turn the adjusting nut
in direction (a). To make the brake light
come on later, turn the adjusting nut in
direction (b).
1. Brake pedal free play adjusting nut
(b)
(a)
1
1. Rear brake light switch adjusting nut
2. Rear brake light switch
2
1 (a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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4. Disconnect the battery coupler.
5. Remove the blown fuse, and then
install a new fuse of the specified
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 box, which contains the fuses
for the individual circuits, is located un-
der the seat. (See page 3-11.) If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off the electrical circuit in question.
2. Remove the seat. (See page 3-11.)
3. Remove the blown fuse, and then install a new fuse of the specified
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
1. Battery
2. Battery band
1. Battery coupler
12
1
Specified fuse: 30.0 A1. Fuse box
1
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
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3 4
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6
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PERIODIC MAINTENANCE AND ADJUSTMENT
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12 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.
EAU23799
Replacing the headlight bulbThis model is equipped with a halogen
bulb headlight. If the headlight bulb
burns out, replace it as follows.NOTICE
ECA10651
Take care not to damage the follow-
ing parts:
Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life 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 awattage higher than specified. 1. Remove the headlight unit by re-
moving the screws.
Specified fuses:Main fuse:30.0 A
Signaling system fuse: 15.0 A
Headlight fuse:
15.0 A
Ignition fuse: 10.0 A
Backup fuse: 7.5 A
Fuel injection system fuse:
7.5 A
Parking lighting fuse: 7.5 A
1. Do not touch the glass part of the bulb.
1. Screw1
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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
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