2016 YAMAHA SR400 ECU

Safety information
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hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabili-
ty and handling if the weight distribution
of the motorcycle is changed. To avoid
the possibility of an accident, use ex-
treme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident. When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle as
possible and make sure to distrib-
ute the weight as evenly as possi-
ble on both sides of the motorcycle
to minimize imbalance or instabili-
ty.
Shifting weights can create a sud-
den imbalance. Make sure that ac-
cessories and cargo are securely
attached to the motorcycle before
riding. Check accessory mounts
and cargo restraints frequently.
Properly adjust the suspension for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
Never attach any large or heavy items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
tents, can create unstable han-
dling or a slow steering re-
sponse.
This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Maximum load: 150 kg (331 lb)
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Safety information
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appropriate. Refer to page 6-15 for tire
specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
Remove all loose items from the
motorcycle.
Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
cation for the straps carefully so
the straps will not rub against
painted surfaces during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce excessive-
ly during transport.
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Instrument and control functions
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EAU13222
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING
EWA10882
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions. 1. Before refueling, turn off the en- gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vicin-
ity of sparks, open flames, or other
sources of ignition such as the pilot
lights of water heaters and clothes
dryers.
2. Do not overfill the fuel tank. When refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.
3. Wipe up any spilled fuel immedi- ately. NOTICE: Immediately wipe off spilled fuel with a clean, dry,
soft cloth, since fuel may deteri-
orate painted surfaces or plastic
parts.
[ECA10072]
4. Be sure to securely close the fuel
tank cap.
WARNING
EWA15152
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gaso-
line by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
your eyes, see your doctor immedi-
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU57691
NOTICE
ECA11401
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
Your Yamaha engine has been de-
signed to use regular unleaded gaso-
line with a research octane number of
95 or higher. If knocking (or pinging) oc-
1. Maximum fuel level
2. Fuel tank filler tube
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Recommended fuel:
Regular unleaded gasoline (Gasohol
[E10] acceptable)
Fuel tank capacity:
12 L (3.2 US gal, 2.6 Imp.gal)
Fuel reserve amount (when the fuel
level warning light comes on): 2.2 L (0.58 US gal, 0.48 Imp.gal)
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Periodic maintenance and adjustment
6-27
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EAU23098
Checking and l ubricating the
cables
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
WARNING! Damage to the outer
housing of cables may result in in-
ternal rusting and cause interfer-
ence with cable movement. Replace
damaged cables as soon as possi-
ble to prevent unsafe condi-
tions.
[EWA10712] EAU23115
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated by a
Yamaha dealer at the intervals speci-
fied in the periodic maintenance chart.
The throttle cable is equipped with a
rubber cover. Make sure that the cover
is securely installed. Even though the
cover is installed correctly, it does not
completely protect the cable from water
entry. Therefore, use care not to pour
water directly onto the cover or cable
when washing the vehicle. If the cable
or cover becomes dirty, wipe clean with
a moist cloth.
Recommended lubricant:
Yamaha cable lubricant or other suit-
able cable lubricant
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Periodic maintenance and adjustment
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EAU51951
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the front fork for damage and ex-
cessive oil leakage.
To check the operation 1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. While applying the front brake, push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE
ECA10591
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU45512
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.1. Place the vehicle on the center- stand. WARNING! To avoid inju-
ry, securely support the vehicle
so there is no danger of it falling
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
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Periodic maintenance and adjustment
6-36
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14 4. Place a new headlight bulb into po-
sition, and then secure it with the
bulb holder.
5. Install the bulb cover, and then connect the coupler.
6. Install the headlight unit by install- ing the screws.
7. Have a Yamaha dealer adjust the headlight beam if necessary.
EAU33417
Replacing the auxiliary light
bulb
If the auxiliary light bulb burns out, re-
place it as follows.1. Remove the headlight unit by re- moving the screws.
2. Remove the socket (together with the bulb) by pushing it in and turn-
ing it counterclockwise.
1. Headlight bulb holder
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1. Screw
1. Screw
1. Auxiliary light bulb socket
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1
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Periodic maintenance and adjustment
6-39
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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
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1. Speedometer cable
1. Slot
2. Speedometer gear unit
3. Projection
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Periodic maintenance and adjustment
6-40
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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)
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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
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