2016 YAMAHA SR400 seat adjustment

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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Periodic maintenance and adjustment
6-11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
TIP
Skip steps 6–8 if the oil filter element is
not being replaced. 6. Remove the oil filter element cover by removing the bolts.
7. Remove and replace the oil filter element and O-rings.
TIP
Make sure that the O-rings are properly
seated. 8. Install the oil filter element cover by
installing the bolts, and then tight-
en the bolts to the specified torque.
9. Install the oil filter element drain bolt, and then tighten the bolt to the
specified torque.
10. Install the oil filter element cover bleed bolt and its gasket, and then
tighten the bolt to the specified
torque.
11. Install the engine oil drain bolts and their new gasket, and then
tighten the bolts to the specified
torques.
1. Engine oil drain bolt (oil tank)
2. Gasket
1. Oil filter element cover bolt
21
1
1. Oil filter element cover
2. O-ring
3. Oil filter element
Tightening torque:Oil filter element cover bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque: Oil filter element drain bolt: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tightening torque: Oil filter element cover bleed bolt: 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
2
1
3
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Periodic maintenance and adjustment
6-13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU52031
Replacing the air filter element
The air filter element should be re-
placed at the intervals specified in the
periodic maintenance and lubrication
chart. Replace the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
To replace the air filter element 1. Remove panel A. (See page 6-7.)
2. Remove the air filter case cover by removing the screws.
3. Pull the air filter element out.
4. Insert a new air filter element into the air filter case. NOTICE: Make
sure that the air filter element is
properly seated in the air filter
case. The engine should never
be operated without the air filter element installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.[ECA10482]
5. Install the air filter case cover by in-
stalling the screws.
6. Install the panel.
1. Screw
2. Air filter case cover
1. Air filter element
1
2
1
1
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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
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Periodic maintenance and adjustment
6-33
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU59443
Replacing the fuses
The main fuse is located inside the bat-
tery coupler. (See page 6-31.)
If the main fuse is blown, replace it as
follows. 1. Turn the key to “OFF” and turn off all electrical circuits.
2. Remove the seat. (See page 3-13.)
3. Remove the battery by removing the battery band.
4. Disconnect the battery coupler. 5. Remove the blown fuse, and then
install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher amperage
rating than recommended to
avoid causing extensive dam-
age to the electrical system and
possibly a fire.
[EWA15132]
6. Connect the battery coupler.
7. Install the battery by installing the battery band.
8. Install the seat.
9. Turn the key to “ON”.
10. If the fuse immediately blows again, have a Yamaha dealer
check the electrical system.
The fuse box, which contains the fuses
for the individual circ uits, is located un-
der the seat.
1. Battery coupler
2. Main fuse
3. Spare main fuse
1. Battery
2. Battery band
3
1
2
12
1. Battery coupler
Specified fuse: 30.0 A
1
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Periodic maintenance and adjustment
6-34
1
2
3
4
5
6
7
8
9
10
11
12
13
14 If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off the electrical circuit in question.
2. Remove the seat. (See page 3-13.)
3. Remove the blown fuse, and then install a new fuse of the specified
amperage. WARNING! Do not
use a fuse of a higher amperage
rating than recommended to
avoid causing extensive dam-
age to the electrical system and
possibly a fire.
[EWA15132]
4. Turn the key to “ON” and turn on the electrical circuit in question to
check if the device operates.
5. If a fuse immediately blows again, have a Yamaha dealer check the
electrical system.
1. Fuse box
1. Headlight fuse
2. Signaling system fuse
3. Ignition fuse
4. Backup fuse
5. Fuel injection system fuse
6. Parking lighting fuse
7. Spare fuse
1
12
3 4
5
7
6
Specified fuses: Signaling system fuse:
15.0 A
Headlight fuse: 15.0 A
Ignition fuse: 10.0 A
Backup fuse:
7.5 A
Fuel injection system fuse: 7.5 A
Parking lighting fuse: 7.5 A
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