2016 YAMAHA SR400 brake fluid

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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Description
2-3
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EAU63401
Controls and instruments
1. Clutch lever (page 3-6)
2. Left handlebar switches (page 3-4)
3. Speedometer unit (page 3-3)
4. Main switch/steering lock (page 3-1)
5. Tachometer (page 3-4)
6. Front brake fluid reservoir (page 6-23)
7. Right handlebar switches (page 3-4)
8. Brake lever (page 3-7)
9. Throttle grip (page 6-14)
10.Decompression lever (page 3-12)
12 345 78
9
6
10
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4-1
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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
6-4
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EAU64031
General maintenance and lubrication chart
NO. ITEM
1 Air filter element Replace. Every 20000 km (12500 mi)
2Clutch Check operation.
Adjust. 
3 *Timing chain Check timing chain tensioner.
Adjust if necessary. 
4 *Decompression
system Check operation.
Adjust or replace cable.

5 *Front brake Check operation, fluid level and
vehicle for fluid leakage.
Adjust brake lever free play. 
Replace brake pads. Whenever worn to the limit
6 *Rear brake Check operation and adjust
brake pedal free play. 
Replace brake shoes. Whenever worn to the limit
7 *Brake hose Check for cracks or damage.
Check for correct routing and
clamping. 
Replace. Every 4 years
8 *Brake fluid Change. Every 2 years
9 *Wheels Check runout, spoke tightness
and for damage.
Tighten spokes if necessary. 
10 *Tires Check tread depth and for
damage.
Replace if necessary.
Check air pressure.
Correct if necessary. 
11 *Wheel bearings Check bearings for looseness
or damage. 
12 *Swingarm Check operation and for
excessive play. 
Lubricate with lithium-soap- based grease. Every 50000 km (30000 mi)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
6-6
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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
6-23
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EAU22541Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.EAU32346
Checking the brake fluid level
Before riding, check that the brake fluid
is above the minimum level mark.
Check the brake fluid level with the top
of the reservoir level. Replenish the
brake fluid if necessary.
WARNING
EWA15991
Improper maintenance can result in
loss of braking ability. Observe
these precautions:
Insufficient brake fluid may al-
low air to enter the brake sys-
tem, reducing braking
performance.
Clean the filler cap before re-
moving. Use only DOT 4 brake
fluid from a sealed container.
Use only the specified brake flu-
id; otherwise, the rubber seals
may deteriorate, causing leak-
age.
Refill with the same type of
brake fluid. Adding a brake fluid
other than DOT 4 may result in a
harmful chemical reaction.
Be careful that water does not
enter the brake fluid reservoir
1. Brake shoe wear indicator
2. Brake shoe wear limit line
1 2
1. Minimum level mark
Specified brake fluid:
DOT 4
1
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Periodic maintenance and adjustment
6-24
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14 when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
NOTICE
ECA17641
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up spilled fluid immediately.
As the brake pads wear, it is normal for
the brake fluid level to gradually go
down. A low brake fluid level may indi-
cate worn brake pads and/or brake sys-
tem leakage; therefore, be sure to
check the brake pads for wear and the
brake system for leakage. If the brake
fluid level goes down suddenly, have a
Yamaha dealer check the cause before
further riding.
EAU22724
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever
they are damaged or leaking.
Oil seals: Replace every two
years.
Brake hose: Replace every four
years.
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Specifications
8-2
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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
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