2016 YAMAHA SR400 maintenance

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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Safety information
EAU1028B
Be a Responsible Owner
As the vehicle’s owner, you are respon-
sible for the safe and proper operation
of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements before
riding this motorcycle.
He or she should:
Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
Obtain qualified training in safe
and proper riding techniques.
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
Never operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks each
time you use the vehicle to make sure it
is in safe operating condition. Failure to
inspect or maintain the vehicle properly
increases the possibility of an accident
or equipment damage. See page 4-1 for a list of pre-operation checks.
This motorcycle is designed to car-
ry the operator and a passenger.
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been caused
by an automobile driver who did
not see the motorcycle. Making
yourself conspicuous appears to
be very effective in reducing the
chance of this type of accident.
Therefore:
Wear a brightly colored jacket.
Use extra caution when you are approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
Ride where other motorists can see you. Avoid riding in another
motorist’s blind spot.
Never maintain a motorcycle without proper knowledge. Con-
tact an authorized motorcycle
dealer to inform you on basic
motorcycle maintenance. Cer-
tain maintenance can only be
carried out by certified staff.
Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license. Make sure that you are qualified and that you only lend your mo-
torcycle to other qualified opera-
tors.
Know your skills and limits. Staying within your limits may
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Instrument and control functions
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14 curs, use a gasoline of a different brand
or premium unleaded fuel. Use of un-
leaded fuel will extend spark plug life
and reduce maintenance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that contain-
ing methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
EAU39453
Fuel tank breat
her/overflow
hose
Before operating the motorcycle:
Check the fuel tank breather/over-
flow hose connection.
Check the fuel tank breather/over-
flow hose for cracks or damage,
and replace it if necessary.
Make sure that the end of the fuel
tank breather/overflow hose is not
blocked, and clean it if necessary.
1. Fuel tank breather/overflow hose
1
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Instrument and control functions
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EAU13434
Catalytic converter
This model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10863
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
Make sure that the exhaust sys-
tem has cooled down before do-
ing any maintenance work.
Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10702
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
EAU59491
Fuel cock
The fuel cock regulates and filters the
fuel supply from the fuel tank.
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.
1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “OFF”
1
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For your safety – pre-operation checks
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the in spection 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
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKSPAGE
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. 3-9, 3-10
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 brak e fluid to specified level.
Check hydraulic system for leakage. 6-19,
6-22, 6-23
Rear brake Check operation.
Check pedal free play.
Adjust if necessary. 6-20,
6-22
Clutch Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary. 6-18
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing. 6-14,
6-27
Control cables Make sure that operation is smooth.
Lubricate if necessary. 6-27
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Periodic maintenance and adjustment
EAU17246
Periodic inspection, adjustment, and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. Safety is an obl igation of the vehi-
cle owner/operator. The most important
points of vehicle inspection, adjust-
ment, and lubrication are explained on
the following pages.
The intervals given in the periodic
maintenance charts should be simply
considered as a general guide under
normal riding conditions. However, de-
pending on the weather, terrain, geo-
graphical location, and individual use,
the maintenance intervals may need to
be shortened.
WARNING
EWA10322
Failure to properly maintain the ve-
hicle or performing maintenance ac-
tivities incorrectly may increase
your risk of injury or death during
service or while using the vehicle. If
you are not familiar with vehicle ser-
vice, have a Yamaha dealer perform
service.
WARNING
EWA15123
Turn off the engine when performing
maintenance unless otherwise
specified.
A running engine has moving
parts that can catch on body
parts or clothing and electrical
parts that can cause shocks or
fires.
Running the engine while ser-
vicing can lead to eye injury,
burns, fire, or carbon monoxide
poisoning – possibly leading to death. See page 1-2 for more in-
formation about carbon monox-
ide.
WARNING
EWA15461
Brake discs, calipers, drums, and
linings can become very hot during
use. To avoid possible burns, let
brake components cool before
touching them.
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Periodic maintenance and adjustment
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EAU17303
Emission controls not only function to
ensure cleaner air, but are also vital to
proper engine operation and maximum
performance. In the following periodic
maintenance charts, the services relat-
ed to emissions control are grouped
separately. These services require
specialized data, knowledge, and
equipment. Maintenance, replacement,
or repair of the emission control devic-
es and systems may be performed by
any repair establishment or individual
that is certified (if applicable). Yamaha
dealers are trained and equipped to
perform these particular services.
EAU59370
Owner’s tool kit
The owner’s tool kit is located inside the
tool box.
To access the owner’s tool kit, slide the
lock cover open, insert the key into the
lock, and then turn it 1/4 turn clockwise.
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
TIP
If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you.
1. Unlock.
2. Lock cover
1. Owner’s tool kit
1 2
1
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Periodic maintenance and adjustment
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EAU46862
TIP
The annual checks must be performed every year, except if a kilometer-
based maintenance, or for the UK, a mileage-based maintenance, is per-
formed instead.
From 50000 km (30000 mi), repeat the maintenance intervals starting from
10000 km (6000 mi).
Items marked with an asterisk should be performed by a Yamaha dealer as
they require special tools, data and technical skills.
EAU63321
Periodic maintenance chart for the emission control system
NO. ITEM
1 *Fuel line Check fuel hoses for cracks or
damage. 
2 Spark plug Check condition.
Clean and regap.

Replace. 
3 *Valves Check valve clearance.
Adjust. 
4 *Fuel injection Check engine idle speed. 
5 *Muffler and
exhaust pipe Check the screw clamp(s) for
looseness. 
6 *Air induction
system Check the air cut-off valve, reed
valve, and hose for damage.
Replace any damaged parts if necessary. X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
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