2016 YAMAHA SR400 oil

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
2RD-28199-E1.book 1 ページ ２０１５年９月３日　木曜日　午後３時４２分

2-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
EAU63371
Left view
1. Engine oil dipstick (page 6-9)
2. Engine oil filler cap (page 6-9)
3. Fuel tank cap (page 3-8)
4. Fuel cock (page 3-11)
5. Battery (page 6-31)
6. Fuse (page 6-33)
7. Shock absorber assembly spring preload adjusting ring (page 3-13)
8. Shift pedal (page 3-6)
1, 2 4
5, 63
7
8
2RD-28199-E1.book 1 ページ ２０１５年９月３日　木曜日　午後３時４２分

4-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
2RD-28199-E1.book 1 ページ ２０１５年９月３日　木曜日　午後３時４２分

Operation and important riding points
5-5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU16811
Tips for reducing fuel
consumption
Fuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
Do not rev the engine while shifting
down, and avoid high engine
speeds with no load on the engine.
Turn the engine off instead of let-
ting it idle for an extended length of
time (e.g., in traffic jams, at traffic
lights or at railroad crossings).
EAU16842
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1600 km (1000 mi). For
this reason, you should read the follow-
ing material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1600 km (1000 mi). The various parts in
the engine wear and polish themselves
to the correct operating clearances.
During this period, prolonged full-throt-
tle operation or any condition that might
result in engine overheating must be
avoided.
EAU17094
0–1000 km (0–600 mi)
Avoid prolonged operation above 3500
r/min. NOTICE: After 1000 km (600
mi) of operation, the engine oil must
be changed and the oil filter car-
tridge or element replaced.
[ECA10303]
1000–1600 km (600–1000 mi)
Avoid prolonged operation above 4200
r/min.
1600 km (1000 mi) and beyond
The vehicle can now be operated nor-
mally.
NOTICE
ECA10311
Keep the engine speed out of
the tachometer red zone.
If any engine trouble should oc-
cur during the engine break-in
period, immediately have a
Yamaha dealer check the vehi-
cle.
2RD-28199-E1.book 5 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
13 Drive chain Check chain slack, alignment
and condition.
Adjust and lubricate chain with a special O-ring chain lubricant
thoroughly. Every 500 km (300 mi) and after
washing the motorcycle, riding
in the rain or riding in wet areas
14 *Steering bearings Check bearing play and
steering for roughness. 
Lubricate with lithium-soap- based grease. Every 20000 km (12000 mi)
15 *Chassis fasteners Make sure that all nuts, bolts
and screws are properly
tightened. 
16 Brake lever pivot
shaft Lubricate with silicone grease.

17 Brake pedal pivot
shaft Lubricate with lithium-soap-
based grease. 
18 Clutch lever pivot
shaft Lubricate with lithium-soap-
based grease. 
19 Sidestand,
centerstand Check operation.
Lubricate with lithium-soap-
based grease. 
20 *Sidestand switch Check operation. 
21 *Front fork Check operation and for oil
leakage. 
22 *Shock absorber
assemblies Check operation and shock
absorbers for oil leakage. 
23 Engine oil Change.
Check oil level and vehicle for
oil leakage. 
24 Engine oil filter
element Replace.

25 *Front and rear
brake switches Check operation.

26 Moving parts and
cables Lubricate.

NO. ITEM
X 1000 km
CHECK OR
MAINTENANCE JOB
X 1000 mi
ODOMETER READINGS
ANNUAL CHECK
110203040
0.66121824
2RD-28199-E1.book 5 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
2RD-28199-E1.book 6 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
plug wrench, and then tighten it to
the specified torque.
TIP
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible.
3. Install the spark plug cap.
EAU59626
Engine oil and oil filter
element
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level1. Start the engine, warm it up for several minutes, and then turn it
off.
2. On a level surface, place the vehi- cle on the centerstand.
3. Wait a few minutes until the oil set- tles. Remove the engine oil filler
cap, wipe the dipstick clean, insert
it back into the oil filler hole (with-
out screwing it in), and then re-
move it again to check the oil level.
WARNING! Never remove the
engine oil filler cap after high-
speed operation, otherwise hot
engine oil could spout out and
cause damage or injury. Always
let the engine oil cool down suf-
ficiently before removing the oil
filler cap.
[EWA17640]
TIP
The engine oil should be between the
minimum and maximum level marks.
Tightening torque:Spark plug:25 Nm (2.5 m·kgf, 18 ft·lbf)
2RD-28199-E1.book 9 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-10
1
2
3
4
5
6
7
8
9
10
11
12
13
14 4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Install the oil filler cap.
To change the engine oil (with or
without oil filter element replace-
ment) 1. Start the engine, warm it up for several minutes, and then turn it
off.
2. Place an oil pan under the engine to collect the used oil.
3. Remove the oil filter element cover bleed bolt and its gasket, and the
oil filter element drain bolt to drain
the oil from the oil filter element
chamber. 4. Remove the engine oil drain bolt
and its gasket to drain the oil from
the crankcase.
5. Remove the engine oil filler cap, the engine oil tank drain bolt and
its gasket to drain the oil from the
oil tank.
1. Engine oil filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
3
4
1
2
1. Oil filter element cover bleed bolt
2. Gasket
3. Oil filter element drain bolt
1. Gasket
2. Engine oil drain bolt (crankcase)
1
2
3
21
2RD-28199-E1.book 10 ページ ２０１５年９月３日　木曜日　午後３時４２分