2014 YAMAHA SR400 oil

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

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DESCRIPTION
EAU10411
Left view
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5, 6
3
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1. Engine oil dipstick (page 6-9)
2. Engine oil filler cap (page 6-9)
3. Fuel tank cap (page 3-7)
4. Fuel cock (page 3-10)
5. Battery (page 6-28)
6. Fuse (page 6-29)
7. Shock absorber assembly spring preload adjusting ring (page 3-12)
8. Shift pedal (page 3-6)
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4-1
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FOR YOUR SAFETY – PRE-OPERATION CHECKS
EAU15598
Inspect your vehicle each time you use it to make sure the vehi cle is in safe operating condition. Always follow the inspection
and maintenance procedures and schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility of an accident or equipment damage.
Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided inthis manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKS PAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose for
obstructions, cracks or damage, and check
hose connection. 3-7, 3-9
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, add specified brake fluid to specified level.
Check hydraulic system for leakage. 6-17, 6-20
Rear brake Check operation.
Check pedal free play.
Adjust if necessary. 6-18, 6-20
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OPERATION AND IMPORTANT RIDING POINTS
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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 is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.

Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand theshock of forced shifting.
EAU16811
Tips for reducing fuel
consumptionFuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Shift up swiftly, and avoid high en-
gine speeds during acceleration.

Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.

Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16842
Engine break-inThere is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
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 3500
r/min. NOTICE: After 1000 km (600
mi) of operation, the engine oil must
be changed and the oil filter car-
tridge or element replaced.
[ECA10303]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 4200
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PERIODIC MAINTENANCE AND ADJUSTMENT
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11 *Wheel bearings Check bearings for looseness or
damage. 
12 *Swingarm Check operation and for
excessive play. 
Lubricate with lithium-soap-based grease. Every 50000 km (30000 mi)
13 Drive chain Check chain slack, alignment and
condition.
Adjust and lubricate chain with a special O-ring chain lubricant
thoroughly. Every 500 km (300 mi) and after washing the motorcycle, riding in the rain or
riding in wet areas
14 *Steering bearings Check bearing play and steering
for roughness. 
Lubricate with lithium-soap-based grease. Every 20000 km (12000 mi)
15 *Chassis fasteners Make sure that all nuts, bolts and
screws are properly tightened. 
16 Brake lever pivot
shaft Lubricate 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 leakage. 
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)2RD-9-E0.book 5 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

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)
2RD-9-E0.book 6 ページ ２０１３年１１月２８日　木曜日　午後４時１８分

PERIODIC MAINTENANCE AND ADJUSTMENT
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12 spark plug wrench, and then tight-
en it to the specified torque.
TIPIf a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-fied torque as soon as possible.
3. Install the spark plug cap.
EAU59622
Engine oil and oil filter
elementThe engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level1. 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 level.
WARNING! Never remove the
engine oil filler cap after
high-speed operation, other-
wise hot engine oil could spout
out and cause damage or injury.
Always let the engine oil cool
down sufficiently before remov- ing the oil filler cap.
[EWA17640]
TIPThe engine oil should be between theminimum and maximum level marks.
4. If the engine oil is below the mini- mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
Tightening torque: Spark plug:25 Nm (2.5 m·kgf, 18 ft·lbf)
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
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PERIODIC MAINTENANCE AND ADJUSTMENT
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To change the engine oil (with or
without oil filter element replace-
ment)
1. Start the engine, warm it up for several minutes, and then turn it
off.
2. Place an oil pan under the engine to collect the used oil.
3. Loosen the oil filter element cover bleed bolt and oil filter element
drain bolt.
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. 6. Remove the oil filter element drain
bolt to drain the oil from the oil filter
element.
TIPSkip steps 7–9 if the oil filter element isnot being replaced.
7. Remove the oil filter element cover by removing the bolts.
8. Remove and replace the oil filter element and O-rings.TIPMake sure that the O-rings are properlyseated.
1. Oil filter element cover bleed bolt
2. Oil filter element drain bolt
1
2
1. Gasket
2. Engine oil drain bolt (crankcase)
1. Engine oil drain bolt (oil tank)
2. Gasket
21
21
1. Oil filter element drain bolt
2. Oil filter element cover bolt
2
1
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