2016 YAMAHA SR400 light

Periodic maintenance and adjustment
6-38
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EAU60010
Replacing a turn signal light
bulb
1. Remove the turn signal light lens, turn signal light rim and gasket by
removing the screws.
2. Remove the burnt-out bulb by pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket, push it in, and then turn it clock-
wise until it stops.
4. Install the gasket, rim and lens by installing the screws with the notch
on the rim and lens facing to in-
ward as shown. NOTICE: Do not
overtighten the screws, other-
wise the lens may break.
[ECA10682]
1. Turn signal light lens
2. Screw
1. Turn signal light lens
2. Turn signal light rim
3. Gasket
1
2
3
2
1
2RD-28199-E1.book 38 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-41
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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

Periodic maintenance and adjustment
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EAU25852
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look like
Yamaha parts, but they are often inferi-
or, have a shorter service life and can
lead to expensive repair bills.
WARNING
EWA15142
When checking the fuel system, do
not smoke, and make sure there are
no open flames or sparks in the ar-
ea, including pilot lights from water
heaters or furnaces. Gasoline or
gasoline vapors can ignite or ex-
plode, causing severe injury or
property damage.
2RD-28199-E1.book 42 ページ ２０１５年９月３日　木曜日　午後３時４２分

Motorcycle care and storage
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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

Motorcycle care and storage
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14 corrosion.
After cleaning 1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean- er to remove any remaining dirt.
6. Touch up minor paint damage caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before storing or covering it.
WARNING
EWA11132
Contaminants on the brakes or tires
can cause loss of control.
Make sure that there is no oil or
wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
NOTICE
ECA10801
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
Consult a Yamaha dealer for ad-
vice on what products to use.
Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
2RD-28199-E1.book 3 ページ ２０１５年９月３日　木曜日　午後３時４２分

Specifications
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Front tire:
Type: With tube
Size: 90/100-18M/C 54S
Manufacturer/model:
BRIDGESTONE/BT-45F
Rear tire:
Type:With tube
Size:
110/90-18M/C 61S
Manufacturer/model: BRIDGESTONE/BT-45R
Loading:
Maximum load:
150 kg (331 lb)
* (Total weight of rider, passenger, cargo and accessories)
Tire air pressure (measured on cold
tires):
Up to 90 kg (198 lb) load:Front:
175 kPa (1.75 kgf/cm
2, 25 psi)
Rear: 200 kPa (2.00 kgf/cm
2, 29 psi)
90 kg (198 lb) lo ad - maximum load:
Front: 200 kPa (2.00 kgf/cm
2, 29 psi)
Rear: 225 kPa (2.25 kgf/cm
2, 33 psi)
Front wheel:
Wheel type:Spoke wheel
Rim size: 18 x 1.85
Rear wheel:
Wheel type:Spoke wheel
Rim size: 18 x 2.15
Front brake:
Type:Hydraulic disc brake
Specified brake fluid:
DOT 4
Rear brake:
Type:Mechanical leading tr ailing drum brake
Front suspension:
Type:
Telescopic fork
Spring: Coil spring
Shock absorber:
Hydraulic damper
Wheel travel: 150 mm (5.9 in)
Rear suspension:
Type:
Swingarm
Spring: Coil spring
Shock absorber: Hydraulic damper
Wheel travel:
105 mm (4.1 in)
Electrical system:
System voltage:12 V
Ignition system:
TCI
Charging system: AC magneto
Battery:
Model:
GT4B-5
Voltage, capacity: 12 V, 2.5 Ah (10 HR)
Headlight:
Bulb type:
Halogen bulb
Bulb wattage  quantity:
Headlight:
H4, 60.0 W/55.0 W x 1
Brake/tail light:
21.0 W/5.0 W  1
Front turn signal light: 21.0 W  2
Rear turn signal light:
21.0 W  2
Auxiliary light: 4.0 W  1
Meter lighting: 1.7 W  4
Neutral indicator light:
1.7 W  1
High beam indicator light: 1.7 W  1
2RD-28199-E1.book 2 ページ ２０１５年９月３日　木曜日　午後３時４２分

Specifications
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Turn signal indicator light: 1.7 W  1
Fuel level warning light: 3.0 W  1
Engine trouble warning light: 1.7 W  1
Fuse(s):
Main fuse:
30.0 A
Headlight fuse: 15.0 A
Signaling system fuse:
15.0 A
Ignition fuse: 10.0 A
Parking lighting fuse: 7.5 A
Fuel injection system fuse:
7.5 A
Backup fuse: 7.5 A
2RD-28199-E1.book 3 ページ ２０１５年９月３日　木曜日　午後３時４２分

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Index
A
Air filter element, replacing ................... 6-13
Auxiliary light bulb, replacing ................ 6-36
B
Battery................................................... 6-31
Brake and clutch levers, checking and lubricating ........................................... 6-28
Brake fluid, changing ............................ 6-24
Brake fluid level, checking .................... 6-23
Brake lever .............................................. 3-7
Brake lever free play, adjusting............. 6-19
Brake light switches .............................. 6-22
Brake pads and shoes, checking .......... 6-22
Brake pedal ............................................. 3-7
Brake pedal, checking and
lubricating ........................................... 6-28
Brake pedal height and free play,
adjusting ............................................. 6-20
C
Cables, checking and lubricating .......... 6-27
Care ........................................................ 7-1
Catalytic converter ................................ 3-11
Centerstand and sidestand, checking and lubricating .................................... 6-29
Clutch lever ............................................. 3-6
Clutch lever free play, adjusting ............ 6-18
D
Decompression lever ............................ 3-12
Dimmer switch ........................................ 3-5
Drive chain, cleaning and lubricating .... 6-26
Drive chain slack ................................... 6-25
E
Engine break-in ....................................... 5-5
Engine idling speed, checking .............. 6-14
Engine oil and oil filter element ............... 6-9
Engine serial number .............................. 9-1
Engine stop switch .................................. 3-5
Engine trouble warning light.................... 3-3
F
Front fork, checking .............................. 6-30
Fuel ......................................................... 3-9
Fuel cock............................................... 3-11
Fuel consumption, tips for reducing ........ 5-5
Fuel level warning light ........................... 3-2
Fuel tank breather/overflow hose.......... 3-10
Fuel tank cap .......................................... 3-8
Fuses, replacing.................................... 6-33
H
Handlebar switches................................. 3-4
Hazard switch ......................................... 3-5 Headlight bulb, replacing ...................... 6-35
High beam indicator light ........................ 3-2
Horn switch ............................................. 3-5
I
Identification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-15
Indicator lights and warning lights .......... 3-2
K
Kickstarter ............................................ 3-12
M
Main switch/steering lock ....................... 3-1
Maintenance and lubrication, periodic .... 6-4
Maintenance, emission control system... 6-3
Matte color, caution ................................ 7-1
Model label ............................................. 9-2
N
Neutral indicator light .............................. 3-2
P
Panel, removing and installing ............... 6-7
Parking ................................................... 5-6
Part locations .......................................... 2-1
Pass switch ............................................ 3-5
S
Safety information .................................. 1-1
Seat ...................................................... 3-13
Shifting ................................................... 5-3
Shift pedal .............................................. 3-6
Shift pedal, chec
king ............................ 6-21
Shock absorber assemblies, adjusting ............................................. 3-13
Sidestand ............................................. 3-14
Spark plug, checking .............................. 6-8
Specifications ......................................... 8-1
Speedometer unit ................................... 3-3
Starting the engine ................................. 5-2
Starting the engine, trouble .................... 5-3
Steering, checking ................................ 6-30
Storage ................................................... 7-4
Swingarm pivots, lubricating ................. 6-29
T
Tachometer ............................................ 3-4
Tail/brake light bulb, replacing .............. 6-37
Throttle grip and cable, checking and
lubricating ........................................... 6-27
Throttle grip free play, checking ........... 6-14
Tires ..................................................... 6-15
Tool kit .................................................... 6-2
Troubleshooting .................................... 6-42
Troubleshooting chart ........................... 6-43
Turn signal indicator light ....................... 3-2
2RD-28199-E1.book 1 ページ ２０１５年９月３日　木曜日　午後３時４２分