2014 YAMAHA SR400 clutch

TABLE OF CONTENTSSAFETY INFORMATION................... 1-1
DESCRIPTION ................................... 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instrument s................. 2-3
INSTRUMENT AND CONTROL
FUNCTIONS ....................................... 3-1
Main switch/steering lock................. 3-1
Indicator lights and warning lights ... 3-2
Speedometer unit ............................ 3-3
Tachometer ..................................... 3-4
Handlebar switches ......................... 3-4
Clutch lever...................................... 3-5
Shift pedal....... ............................. .... 3-6
Brake lever ...................................... 3-6
Brake pedal ..................................... 3-6
Fuel tank cap ................................... 3-7
Fuel.................................................. 3-7
Fuel tank breather/o verflow hose .... 3-9
Catalytic converter ........................... 3-9
Fuel cock ....................................... 3-10
Kickstarter....... ............................. .. 3-10
Decompression lever ... .................. 3-11
Seat ............................................... 3-11
Adjusting the shock absorber assemblies ................................. 3-12
Sidestand....................................... 3-12
Ignition circuit cut-of f system ......... 3-13 FOR YOUR SAFETY –
PRE-OPERATION CHECKS
............. 4-1
OPERATION AND IMPORTANT
RIDING POINTS ................................. 5-1
Starting the engine .......................... 5-1
Starting trouble ................................ 5-2
Shifting ............................................ 5-2
Tips for reducing fuel consumption ................................ 5-3
Engine break-in ............................... 5-3
Parking ............................................ 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT ................................... 6-1
Owner’s tool kit................................ 6-2
Periodic maintenance chart for 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...... 6-12
Checking the engine idling speed ......................................... 6-13
Checking the throttle grip free
play ............................................ 6-13
Valve clearance............................. 6-13
Tires .............................................. 6-14 Spoke wheels ................................ 6-16
Adjusting the clutch lever free
play ............................................. 6-16
Adjusting the brake lever free play ............................................. 6-17
Adjusting the brake pedal height and free play............................... 6-18
Checking the shift pedal ................ 6-19
Brake light switches ....................... 6-19
Checking the front brake pads and rear brake shoes ................ 6-20
Checking the brake fluid level ........ 6-20
Changing the brake fluid ............... 6-21
Drive chain slack............................ 6-22
Cleaning and lubricating the drive chain ........................................... 6-23
Checking and lubricating the
cables ......................................... 6-24
Checking and lubricating the throttle grip and cable ................. 6-24
Checking and lubricating the brake and clutch levers .............. 6-25
Checking and lubricating the
brake pedal................................. 6-25
Checking and lubricating the
centerstand and sidestand ......... 6-26
Lubricating the swingarm pivots .... 6-26
Checking the front fork................... 6-27
Checking the steering .................... 6-27
Checking the wheel bearings......... 6-28
Battery ........................................... 6-282RD-9-E0.book 1 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

DESCRIPTION
2-3
123
4
5
6
7
8
9
10
11
12
EAU10431
Controls and instruments
12 345 78
9
6
10
1. Clutch lever (page 3-5)
2. Left handlebar switches (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 6-20)
7. Right handlebar switches (page 3-4)
8. Brake lever (page 3-6) 9. Throttle grip (page 6-13)
10.Decompression lever (page 3-11)
2RD-9-E0.book 3 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

INSTRUMENT AND CONTROL FUNCTIONS
3-5
1
23
4
5
6
7
8
9
10
11
12 lights, push the switch in after it has re-
turned to the center 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.
EAU12766
Hazard switch “ ”
With the key in the “ON” position, use
this switch to turn on the hazard lights
(simultaneous flashing of all turn signal
lights).
The hazard lights are used in case of
an emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.NOTICE
ECA10062
Do not use the hazard lights for an
extended length of time with the en-
gine not running, otherwise the bat-
tery may discharge.
EAU12821
Clutch leverThe clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
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 3-13.)1. Clutch lever
1
2RD-9-E0.book 5 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

INSTRUMENT AND CONTROL FUNCTIONS
3-6
1
234
5
6
7
8
9
10
11
12
EAU12872
Shift pedalThe 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 motorcycle.
EAU12892
Brake leverThe brake lever is located on the right
side of the handlebar. To apply the front
brake, pull the lever toward the throttle
grip.
EAU12942
Brake pedalThe brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
1. Shift pedal
1
1. Brake lever
1
1. Brake pedal
1
2RD-9-E0.book 6 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

INSTRUMENT AND CONTROL FUNCTIONS
3-10
1
234
5
6
7
8
9
10
11
12
EAU59490
Fuel cockThe fuel cock regulates and filters the
fuel supply from the fuel pump to the
fuel injector.
The fuel cock has two positions:
ON
With the lever in this position, fuel will
be supplied to the engine. Normal oper-
ation is done with the lever in this posi-
tion. OFF
With the lever in this position, fuel will
not flow. Use this lever position when
performing certain maintenance work
or when storing the vehicle for a pro-
longed time.
EAU13651
KickstarterTo start the engine, fold out the kick-
starter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but force-
fully. This model is equipped with a pri-
mary kickstarter, 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.
1. Arrow mark positioned over “ON”
1
1. Arrow mark positioned over “OFF”
1
1. Kickstarter
1
2RD-9-E0.book 10 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

INSTRUMENT AND CONTROL FUNCTIONS
3-13
1
23
4
5
6
7
8
9
10
11
12 Yamaha dealer repair it if it does not
function properly.
EAU59340
Ignition circuit cut-off systemThe ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.
It prevents starting 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 following procedure.
2RD-9-E0.book 13 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

INSTRUMENT AND CONTROL FUNCTIONS
3-14
1
234
5
6
7
8
9
10
11
12
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the kick starter lever down.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand 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.
YES NO YES NO YES NO
The neutral switch may not be working correctly.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
The clutch 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 vehicle must be placed on the center-
stand during this inspection. If a malfunction is noted, have a Yamaha
dealer check the system before riding.
WARNING
”.
2RD-9-E0.book 14 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
1
2
345
6
7
8
9
10
11
12
Clutch Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary. 6-16
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust th
rottle grip free play and lubricate cable
and grip housing. 6-13, 6-24
Control cables Make sure that operation is smooth.
Lubricate if necessary. 6-24
Drive chain Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary. 6-22, 6-23
Wheels and tires Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary. 6-14, 6-16
Shift pedal Make sure that operation is smooth.
Correct if necessary. 6-19
Brake pedal Make sure that operation is smooth.
Lubricate pedal pivoting point if necessary. 6-25
Brake and clutch levers Make sure that operation is smooth.
Lubricate lever pivoting points if necessary. 6-25
Centerstand, sidestand Make sure that operation is smooth.
Lubricate pivots if necessary. 6-26
Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.
Tighten if necessary. —
Instruments, lights, signals
and switches Check operation.
Correct if necessary.
—
Sidestand switch Check operation of ignition
circuit cut-off system.
If system is not working correctl y, have Yamaha dealer check vehicle. 3-12
ITEM CHECKS PAGE
2RD-9-E0.book 2 ページ ２０１３年１１月２８日　木曜日　午後４時１８分