2014 YAMAHA SR400 maintenance

PERIODIC MAINTENANCE AND ADJUSTMENT
6-35
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2
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56
7
8
9
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12 4. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
5. Install the socket (together with the bulb) by pushing it in and turning it
clockwise until it stops.
6. Install the headlight unit by install- ing the screws.
EAU24361
Front wheel
EAU59600
To remove the front wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no danger of itfalling 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 front wheel.
5. Remove the wheel axle nut and the washer.1. Wheel axle nut
1
1. Axle holder nut
1. Speedometer cable
1
1
2RD-9-E0.book 35 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-36
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567
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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

PERIODIC MAINTENANCE AND ADJUSTMENT
6-37
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56
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EAU25081
Rear wheel
EAU59611
To remove the rear wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no danger of itfalling 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. Remove the brake pedal free play adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft 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 wheel axle out.
8. Remove the chain puller assem- blies and the spacer.
1. Brake rod
2. Brake camshaft lever
3. Brake pedal free play adjusting nut
4. Drive chain slack adjusting bolt
5. Drive chain puller locknut
6. Drive chain puller
7. Washer
8. Axle nut
9. Brake torque rod nut
10.Brake torque rod1 10
34
5
6
7
8
9
7
2
1. Drive chain slack adjusting bolt
2. Drive chain puller locknut
3. Axle nut
4. Washer
3
2
1
4
2RD-9-E0.book 37 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-38
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567
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9. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
TIPThe drive chain does not need to be
disassembled in order to remove andinstall the wheel.
To install the rear wheel1. Install the spacer into left side of the wheel hub.
2. Install the chain pullers and the wheel by inserting the wheel axle
from the left-hand side.
3. Install the drive 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 6-22.)
8. Take the motorcycle off the center- stand so that the rear wheel is on
the ground, and then put the side-
stand down.
9. Tighten the brake torque rod nut and axle nut to the specified
torques.
10. Adjust the brake pedal free play. (See page 6-18.)
WARNING
EWA10661
After adjusting the brake pedal free
play, check the operation of the
brake light.
1. Drive chain
1
Tightening torques:Brake torque rod nut:19 Nm (1.9 m·kgf, 14 ft·lbf)
Axle nut: 129 Nm (12.9 m·kgf, 92 ft·lbf)
2RD-9-E0.book 38 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-39
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EAU25852
TroubleshootingAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should 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 system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
2RD-9-E0.book 39 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
6-40
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EAU60030
Troubleshooting chart
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the battery.
Supply fuel.
The engine does not start.
Check the battery.
Operate the kickstarter.4. Compression
There is compression.
There is no compression.
Have a Yamaha dealer check the vehicle.The engine does not start.
Have a Yamaha dealer check the vehicle.
Remove 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. Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the compression.
Operate the kickstarter.
If the engine does not
start, check the ignition.
With the key in the on
position, operate the turn
signal switch.2. Battery
The turn signal flashes
brightly.
The turn signal does
not flash or is weak.
The battery is good.Check the battery lead connections,
and have a Yamaha dealer charge
the battery if necessary.
DryWet
Operate the kickstarter.
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10-1
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91011
12
INDEX
AAir filter element, replacing ...................... 6-12
Auxiliary light bulb, replacing ................... 6-34BBattery ..................................................... 6-28
Brake and clutch levers, checking and lubricating .............................................. 6-25
Brake fluid, changing ............................... 6-21
Brake fluid level, checking ....................... 6-20
Brake lever ................................................ 3-6
Brake lever free play, adjusting ............... 6-17
Brake light switches ................................. 6-19
Brake pads and shoes, checking............. 6-20
Brake pedal ............................................... 3-6
Brake pedal, checking and lubricating ..... 6-25
Brake pedal height and free play, adjusting ................................................ 6-18CCables, checking and lubricating ............. 6-24
Care ........................................................... 7-1
Catalytic converter ..................................... 3-9
Centerstand and sidestand, checking and lubricating ....................................... 6-26
Clutch lever................................................ 3-5
Clutch lever free play, adjusting .............. 6-16DDecompression lever ............................... 3-11
Dimmer switch ........................................... 3-4
Drive chain, cleaning and lubricating ....... 6-23
Drive chain slack ..................................... 6-22EEngine break-in ......................................... 5-3
Engine idling speed, checking ................. 6-13
Engine oil and oil filter element.................. 6-9 Engine serial number ................................ 9-1
Engine stop switch .................................... 3-5
Engine trouble warning light ...................... 3-3
FFront fork, checking................................. 6-27
Fuel ........................................................... 3-7
Fuel cock ................................................. 3-10
Fuel consumption, tips for reducing .......... 5-3
Fuel level warning light .............................. 3-3
Fuel tank breather/overflow hose .............. 3-9
Fuel tank cap............................................. 3-7
Fuses, replacing ...................................... 6-29HHandlebar switches ................................... 3-4
Hazard switch............................................ 3-5
Headlight bulb, replacing......................... 6-31
High beam indicator light ........................... 3-3
Horn switch ............................................... 3-5IIdentification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-13
Indicator lights and warning lights ............. 3-2KKickstarter ............................................... 3-10MMain switch/steering lock .......................... 3-1
Maintenance and lubricatio
n, periodic....... 6-4
Maintenance, emission control system ..... 6-3
Matte color, caution ................................... 7-1
Model label ................................................ 9-2NNeutral indicator light ................................ 3-2PPanel, removing and installing .................. 6-7 Parking.......................................................5-4
Part locations .............................................2-1
Pass switch ................................................3-4
SSafety information ......................................1-1
Seat ......................................................... 3-11
Shifting .......................................................5-2
Shift pedal ..................................................3-6
Shift pedal, checking................................ 6-19
Shock absorber assemblies, adjusting ....3-12
Sidestand .................................................3-12
Spark plug, checking .................................6-8
Specifications.............................................8-1
Speedometer unit ......................................3-3
Starting the engine.....................................5-1
Starting the engine, trouble........................5-2
Steering, checking ................................... 6-27
Storage ......................................................7-3
Swingarm pivots, lubricating .................... 6-26TTachometer................................................3-4
Tail/brake light bulb, replacing ................. 6-32
Throttle grip and cable, checking and
lubricating ..............................................6-24
Throttle grip free play, checking............... 6-13
Tires ......................................................... 6-14
Tool kit .......................................................6-2
Troubleshooting ....................................... 6-39
Troubleshooting chart ..............................6-40
Turn signal indicator light ...........................3-2
Turn signal light bul b, replacing ............... 6-33
Turn signal switch ......................................3-4VValve clearance ....................................... 6-13
2RD-9-E0.book 1 ページ ２０１３年１１月２８日　木曜日　午後４時１８分