2016 YAMAHA SR400 brake light

Table of contents
Safety information............................ 1-1
Description ........................................ 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................ 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 ..................................... 3-6
Shift pedal ....................................... 3-6
Brake lever ...................................... 3-7
Brake pedal .............. ....................... 3-7
Fuel tank cap ................................... 3-8
Fuel ................................................. 3-9
Fuel tank breather/overflow hose ........................................... 3-10
Catalytic converter......................... 3-11
Fuel cock ....................................... 3-11
Kickstarter .... ............................. .... 3-12
Decompression lever..................... 3-12
Seat ............................................... 3-13
Adjusting the shock absorber assemblies ................................. 3-13
Sidestand ...................................... 3-14
Ignition circuit cut- off system ......... 3-15
For your safety – pre-operation
checks ................................................ 4-1
Operation and im portant riding
points ................................................. 5-1
Starting the engine .......................... 5-2
Starting trouble ................................ 5-3
Shifting ............................................ 5-3
Tips for reducing fuel consumption................................. 5-5
Engine break-in ............................... 5-5
Parking ............................................ 5-6 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 ..... 6-13
Checking the engine idling
speed ......................................... 6-14
Checking the throttle grip free play ............................................ 6-14
Valve clearance ............................ 6-15
Tires .............................................. 6-15
Spoke wheels........... ..................... 6-17
Adjusting the clutch lever free play ............................................ 6-18
Adjusting the brake lever free play ............................................ 6-19
Adjusting the brake pedal height
and free play .............................. 6-20
Checking the shift pedal................ 6-21
Brake light switches ...................... 6-22
Checking the front brake pads and rear brake shoes ................ 6-22
Checking the brake fluid level ....... 6-23
Changing the brake fluid .............. 6-24
Drive chain slack ........................... 6-25
Cleaning and lubricating the drive
chain .......................................... 6-26
Checking and lubricating the cables ........................................ 6-27
Checking and lubricating the throttle grip and ca ble ................ 6-27
Checking and lubricating the
brake and clutch levers.............. 6-28
Checking and lubricating the brake pedal ................................ 6-28
Checking and lubricating the centerstand and sidestand ........ 6-29
Lubricating the swingarm pivots.... 6-29
Checking the front fork .................. 6-30
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Table of contents
Checking the steering ....................6-30
Checking the wheel bearings ........6-31
Battery ...........................................6-31
Replacing the fuses .......................6-33
Replacing the headlight bulb .........6-35
Replacing the auxiliary light bulb ...........................................6-36
Replacing the tail/brake light bulb ............................................6-37
Replacing a turn signal light
bulb ............................................6-38
Front wheel .............. ......................6-39
Rear wheel ............................ ........6-40
Troubleshooting .......... ...................6-42
Troubleshooting chart . ...................6-43
Motorcycle care and storage ...........7-1
Matte color caution ..........................7-1
Care .................................................7-1
Storage ............................................7-4
Specifications ....................................8-1
Consumer information .....................9-1
Identification numbers .....................9-1
Index .................................................10-1
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Description
2-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU63391
Right view
1. Air filter element (page 6-13)
2. Kickstarter (page 3-12)
3. Kick indicator (page 5-2)
4. Headlight (page 6-35)
5. Brake pedal (page 3-7)
6. Owner’s tool kit (page 6-2)
7. Shock absorber assembly spri ng preload adjusting ring (page 3-13)
12
4
563
7
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For your safety – pre-operation checks
4-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Drive chain Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary. 6-25,
6-26
Wheels and tires Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary. 6-15,
6-17
Shift pedal Make sure that operation is smooth.
Correct if necessary. 6-21
Brake pedal Make sure that operation is smooth.
Lubricate pedal pivoting point if necessary. 6-28
Brake and clutch
levers Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
6-28
Centerstand, sidestand Make sure that operation is smooth.
Lubricate pivots if necessary. 6-29
Chassis fasteners Make sure that all nuts, bol
ts 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 correctly, have Yamaha dealer
check vehicle. 3-14
ITEM CHECKS PAGE
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Operation and important riding points
5-4
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shock of forced shifting.
EAU16682To start out and accelerate 1. Pull the clutch lever to disengage the clutch.
2. Shift the transmission into first gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at the same time, release the clutch
lever slowly.
4. At the recommended shift points shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.
5. Shift the transmission into second gear. (Make sure not to shift the
transmission into the neutral posi-
tion.)
6. Open the throttle part way and gradually release the clutch lever.
7. Follow the same procedure when shifting to the next higher gear.
TIP
When shifting gears in normal operat-
ing conditions, use the recommended
shift points.
EAU16701To decelerate1. Apply both the front and the rear brakes to slow the motorcycle.
2. Shift the transmission into first gear when the motorcycle reaches
20 km/h (12 mph). If the engine is
about to stall or runs very roughly,
pull the clutch lever in and use the
brakes to stop the motorcycle.
3. Shift the transmission into the neu- tral position when the motorcycle
is almost completely stopped. The neutral indicator light should come
on.
EAU64120Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
Shift up points:
1st  2nd: 20 km/h (12 mph)
2nd  3rd: 30 km/h (19 mph)
3rd  4th: 40 km/h (25 mph)
4th  5th: 50 km/h (31 mph)
Shift down points: 5th  4th: 35 km/h (22 mph)
4th  3rd: 25 km/h (16 mph)
3rd  2nd: 20 km/h (12 mph)
2nd  1st: 20 km/h (12 mph)
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Periodic maintenance and adjustment
6-6
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EAU59350
TIP
Air filter This model’s air intake system is equipped with a disposable oil-coated pa- per element. The air filter element cannot be cleaned with compressed air,
it must be replaced.
The air filter element needs to be replaced more frequently 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 re-
quired.
Every two years replace the internal components of the brake master cylin- der and caliper, and change the brake fluid.
Replace the brake hose every four years and if cracked or damaged.
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
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
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Periodic maintenance and adjustment
6-21
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14
decrease the brake pedal free play,
turn the adjusting nut in direction (b).
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 of
the brake light.
EAU44821
Checking the shift pedal
The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
1. Brake pedal free play adjusting nut
(b)
(a)
1
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Periodic maintenance and adjustment
6-22
1
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3
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EAU22274
Brake light switches
The 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).
EAU22382
Checking the front brake pads
and rear brake shoes
The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU22432Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
1. Rear brake light switch adjusting nut
2. Rear brake light switch
2
1 (a)
(b)
1. Brake pad
2. Brake pad wear indicator groove
12
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