2016 YAMAHA SR400 wheel

Periodic maintenance and adjustment
6-21
1
2
3
4
5
6
7
8
9
10
11
12
13
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
2RD-28199-E1.book 21 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-25
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU22762
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU59593To check the drive chain slack 1. Place the motorcycle on the cen- terstand.
2. Shift the transmission into the neu- tral position.
3. Push on the drive chain at the cen- ter point between the drive axle
and the rear wheel axle with a
force of 50 N (5.0 kgf, 11 lbf).
4. Measure the drive chain slack as shown.
5. If the drive chain slack is incorrect, adjust it as follows.
EAU59642To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack.1. Take the motorcycle off the center- stand, and then put the sidestand
down.
2. Loosen the brake pedal free play adjusting nut, brake torque rod nut,
and axle nut.
3. Loosen the drive chain puller lock- nut at each end of the swingarm.
4. Place the motorcycle on the cen- terstand.
5. To tighten the drive chain, turn the drive chain slack adjusting bolt at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.[ECA10572]
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.
Drive chain slack: 30.0–40.0 mm (1.18–1.57 in)
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Drive chain slack adjusting bolt
3. Drive chain puller locknut
4. Axle nut
5. Brake torque rod nut
6. Brake torque rod
6
12
3
4
5
2RD-28199-E1.book 25 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-31
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU23292
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU40447
Battery
The battery is located under the seat.
(See page 3-13.)
This model is equipped with a VRLA
(Valve Regulated Lead Acid) battery.
There is no need to check the electro-
lyte or to add distilled water. However,
the battery coupler connection needs to
be checked to make sure that it is se-
curely connected.
WARNING
EWA10761
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID. EXTERNAL: Flush with plenty of water.
INTERNAL: Drink large quan- tities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15 minutes and seek prompt
medical attention.
Batteries produce explosive hy-
drogen gas. Therefore, keep
1. Battery
1
2RD-28199-E1.book 31 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-39
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU24361
Front wheel
EAU59603
To remove the front wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no danger of it
falling 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 speedometer gear
unit. 5. Remove the wheel axle nut and
the washer.
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 wheel1. 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.
1. Wheel axle nut
1. Wheel axle holder nut
1
1
1. Speedometer cable
1. Slot
2. Speedometer gear unit
3. Projection
1
2
3
1
2RD-28199-E1.book 39 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-40
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TIP
Make 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 the
retainer on the fork leg.
4. Insert the wheel axle from the left 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.
EAU25081
Rear wheel
EAU59614
To remove the rear wheel
WARNING
EWA10822
To avoid injury, securely support the
vehicle so there is no danger of it
falling 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
1. Retainer
2. Slot
3. Wheel axle
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)
1
3 2
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 rod
1
10
34
5
6
7
8
9
7
2
2RD-28199-E1.book 40 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-41
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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 pullers and the spacer.
9. Push the wheel forward, and then remove the drive chain from the
rear sprocket.
TIP
The drive chain does not need to be
disassembled in order to remove and
install 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 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 6-25.)
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 6-20.)
WARNING
EWA10661
After adjusting the brake pedal free
play, check the operation of the
brake light.
1. Drive chain slack adjusting bolt
2. Drive chain puller locknut
3. Axle nut
4. Washer
1. Drive chain
3
2
14
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-28199-E1.book 41 ページ ２０１５年９月３日　木曜日　午後３時４２分

7-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Motorcycle care and storage
EAU37834
Matte color caution
NOTICE
ECA15193
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be-
fore cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored fin-
ished parts.
EAU26005
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning 1. Cover the muffler outlet with a plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt, like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
NOTICE
ECA10773
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
2RD-28199-E1.book 1 ページ ２０１５年９月３日　木曜日　午後３時４２分

Motorcycle care and storage
7-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.
Improper cleaning can damage
plastic parts (such as cowlings,
panels, windshields, headlight
lenses, meter lenses, etc.) and
the mufflers. Use only a soft,
clean cloth or sponge with wa-
ter to clean plastic. However, if
the plastic parts cannot be thor-
oughly cleaned with water, di-
luted mild detergent with water
may be used. Be sure to rinse
off any detergent residue using
plenty of water, as it is harmful
to plastic parts.
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave
any marks. If the windshield is
scratched, use a quality plastic
polishing compound after
washing.
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
TIP
Salt sprayed on roads in the winter may
remain well into spring. 1. Clean the motorcycle with cold wa- ter and a mild detergent, after the
engine has cooled down.
NOTICE: Do not use warm water
since it increases the corrosive
action of the salt.
[ECA10792]
2. Apply a corrosion protection sprayon all metal, including chrome- and
nickel-plated, surfaces to prevent
2RD-28199-E1.book 2 ページ ２０１５年９月３日　木曜日　午後３時４２分