clutch YAMAHA SR400 2014 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2014, Model line: SR400, Model: YAMAHA SR400 2014Pages: 88, PDF Size: 2.51 MB
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU1770K
General maintenance an d lubrication chartNO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)
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 Replace. 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.
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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)
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.
NO. ITEM CHECK OR MAINTENANCE JOB
ODOMETER READING
ANNUAL
CHECK
1000 km
(600 mi) 10000 km
(6000 mi) 20000 km
(12000 mi) 30000 km
(18000 mi) 40000 km
(24000 mi)2RD-9-E0.book 5 ページ ２０１３年１１月２８日 木曜日 午後４時１８分
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PERIODIC MAINTENANCE AND ADJUSTMENT
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12 9. Install the oil filter element cover by
installing the bolts.
10. Install the oil filter element drain bolt.
11. Tighten the oil filter element cover bolts and the oil filter element drain
bolt to their specified torques.
12. Tighten the oil filter element cover bleed bolt to the specified torque. 13. Install the engine oil drain bolts
and their new gasket, and then
tighten the bolts to the specified
torques.
14. Add the specified amount of the recommended engine oil, and then
install and tighten the oil filler cap.
TIPBe sure to wipe off spilled oil on any
parts after the engine and exhaust sys-
tem have cooled down.NOTICE
ECA11621
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel speci-
fication of “CD” or oils of a high-
er quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
Make sure that no foreign mate-rial enters the crankcase.
15. Start the engine, and then let it idle for several minutes while checking
it for oil leakage. If oil is leaking, im-
mediately turn the engine off and
check for the cause.
16. Turn the engine off, and then check the oil level and correct it if
necessary.
NOTICE
ECA11232
After changing the engine oil, make
sure to check the oil pressure as de-
scribed below.
1. Oil filter element cover
2. O-ring
3. Oil filter elementTightening torques:Oil filter element cover bolt:10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
2
1
3
Tightening torque:Oil filter element cover bleed bolt:5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Tightening torques: Engine oil drain bolt (crankcase):30 Nm (3.0 m·kgf, 22 ft·lbf)
Engine oil drain bolt (oil tank):
16 Nm (1.6 m·kgf, 12 ft·lbf)
Recommended engine oil: See page 8-1.
Oil quantity:
Without oil filter element replace-
ment:2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter element replacement: 2.10 L (2.22 US qt, 1.85 Imp.qt)
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EAU21944
Spoke wheels
WARNING
EWA10611
The wheels on this model are not de-
signed for use with tubeless tires.
Do not attempt to use tubeless tireson this model.
To maximize the performance, durabil-
ity, and safe operation of your motorcy-
cle, note the following points regarding
the specified wheels.
The wheel rims should be checked
for cracks, bends, warpage or oth-
er damage, and the spokes for
looseness or damage before each
ride. If any damage is found, have
a Yamaha dealer replace the
wheel. Do not attempt even the
smallest repair to the wheel. A de-
formed or cracked wheel must be
replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short- ened tire life.
EAU48291
Adjusting the cl
utch lever free
playThe clutch lever free play should mea-
sure 5.0–10.0 mm (0.20–0.39 in) as
shown. Periodically check the clutch le-
ver free play and, if necessary, adjust it
as follows.
1. Slide the rubber cover back at the clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free play, turn the adjusting bolt in di-
rection (a). To decrease the clutch1. Clutch lever free play
2. Rubber cover
3. Locknut (clutch lever)
4. Clutch lever free play adjusting bolt
32
4(a)
(b)
1
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12 lever free play, turn the adjusting
bolt in direction (b).
4. Tighten the locknut and then slide the rubber cover to its original po-
sition.
TIPIf the specified free play cannot be ob-
tained as described above or if the
clutch does not operate correctly, have
a Yamaha dealer check the internalclutch mechanism.
EAU48443
Adjusting the brake lever free
playThe brake lever free play should mea-
sure 5.0–8.0 mm (0.20–0.31 in) as
shown. Periodically check the brake le-
ver free play and, if necessary, adjust it
as follows.
1. Slide the rubber cover back at the brake lever.
2. Loosen the locknut.
3. To increase the brake lever free play, turn the brake lever free play
adjusting screw in direction (a). To decrease the brake lever free play,
turn the adjusting screw in direc-
tion (b).
4. Tighten the locknut, and then slide the rubber cover back to its original
position.
WARNING
EWA10631
After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
A soft or spongy feeling in the
brake lever can indicate the
presence of air in the hydraulic
system. If there is air in the hy-
draulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will dimin-
ish the braking performance,
which may result in loss of con-trol and an accident.
1. Locknut
2. Brake lever free play adjusting screw
3. Rubber cover
4. Brake lever free play
2 3
1
(a)
(b)
4
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EAU23144
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
Brake lever Clutch lever
EAU23184
Checking and lubricating the
brake pedalThe operation of the brake pedal
should be checked before each ride,
and the pedal pivot should be lubricat-
ed if necessary.
Recommended lubricants:
Brake lever:Silicone grease
Clutch lever: Lithium-soap-based grease
Recommended lubricant: Lithium-soap-based grease
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SPECIFICATIONS
EAU5091H
Dimensions:Overall length: 2085 mm (82.1 in)
Overall width: 750 mm (29.5 in)
Overall height: 1095 mm (43.1 in)
Seat height:
785 mm (30.9 in)
Wheelbase: 1410 mm (55.5 in)
Ground clearance: 130 mm (5.1 in)
Minimum turning radius:
2400 mm (94.5 in)Weight:Curb weight:174 kg (384 lb)Engine:Engine type:Air cooled 4-stroke, SOHC
Cylinder arrangement: Single cylinder
Displacement:
399 cm
3
Bore stroke:
87.0 67.2 mm (3.43 2.65 in)
Compression ratio: 8.50 : 1
Starting system:
Kickstarter
Lubrication system: Dry sump
Engine oil:Recommended brand:
YAMALUBE
Type: SAE 10W-30, 10W-40, 10W-50, 15W-40,
20W-40 or 20W-50
Recommended engine oil grade: API service SG type or higher, JASO stan-
dard MA
Engine oil quantity: Without oil filter element replacement:
2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter element replacement: 2.10 L (2.22 US qt, 1.85 Imp.qt)Air filter:Air filter element:
Oil-coated paper elementFuel:Recommended fuel:Regular unleaded gasoline (Gasohol (E10)
acceptable) Fuel tank capacity:
12.0 L (3.17 US gal, 2.64 Imp.gal)
Fuel reserve amount:
2.2 L (0.58 US gal, 0.48 Imp.gal)
Fuel injection:Throttle body:ID mark: 2RD1 00Spark plug(s):Manufacturer/model:
NGK/BPR6ES
Spark plug gap: 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-discTransmission:Primary reduction ratio:2.567 (77/30)
Final drive: Chain
Secondary reduction ratio:
2.947 (56/19)
Transmission type: Constant mesh 5-speed
Operation: Left foot operation
Gear ratio:
1st: 2.357 (33/14)
2nd:
1.556 (28/18)
3rd: 1.190 (25/21)
–20 –10 0 1020 30 40 50 C
10 30 50 70 90 110
0 130 F
SAE 10W-30
SAE 15W-40SAE 20W-40SAE 20W-50
SAE 10W-40SAE 10W-50
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INDEX
AAir filter element, replacing ...................... 6-12
Auxiliary light bulb, replacing ................... 6-34BBattery ..................................................... 6-28
Brake and clutch levers, checking and lubricating .............................................. 6-25
Brake fluid, changing ............................... 6-21
Brake fluid level, checking ....................... 6-20
Brake lever ................................................ 3-6
Brake lever free play, adjusting ............... 6-17
Brake light switches ................................. 6-19
Brake pads and shoes, checking............. 6-20
Brake pedal ............................................... 3-6
Brake pedal, checking and lubricating ..... 6-25
Brake pedal height and free play, adjusting ................................................ 6-18CCables, checking and lubricating ............. 6-24
Care ........................................................... 7-1
Catalytic converter ..................................... 3-9
Centerstand and sidestand, checking and lubricating ....................................... 6-26
Clutch lever................................................ 3-5
Clutch lever free play, adjusting .............. 6-16DDecompression lever ............................... 3-11
Dimmer switch ........................................... 3-4
Drive chain, cleaning and lubricating ....... 6-23
Drive chain slack ..................................... 6-22EEngine break-in ......................................... 5-3
Engine idling speed, checking ................. 6-13
Engine oil and oil filter element.................. 6-9 Engine serial number ................................ 9-1
Engine stop switch .................................... 3-5
Engine trouble warning light ...................... 3-3
FFront fork, checking................................. 6-27
Fuel ........................................................... 3-7
Fuel cock ................................................. 3-10
Fuel consumption, tips for reducing .......... 5-3
Fuel level warning light .............................. 3-3
Fuel tank breather/overflow hose .............. 3-9
Fuel tank cap............................................. 3-7
Fuses, replacing ...................................... 6-29HHandlebar switches ................................... 3-4
Hazard switch............................................ 3-5
Headlight bulb, replacing......................... 6-31
High beam indicator light ........................... 3-3
Horn switch ............................................... 3-5IIdentification numbers ............................... 9-1
Ignition circuit cut-off system ................... 3-13
Indicator lights and warning lights ............. 3-2KKickstarter ............................................... 3-10MMain switch/steering lock .......................... 3-1
Maintenance and lubricatio
n, periodic....... 6-4
Maintenance, emission control system ..... 6-3
Matte color, caution ................................... 7-1
Model label ................................................ 9-2NNeutral indicator light ................................ 3-2PPanel, removing and installing .................. 6-7 Parking.......................................................5-4
Part locations .............................................2-1
Pass switch ................................................3-4
SSafety information ......................................1-1
Seat ......................................................... 3-11
Shifting .......................................................5-2
Shift pedal ..................................................3-6
Shift pedal, checking................................ 6-19
Shock absorber assemblies, adjusting ....3-12
Sidestand .................................................3-12
Spark plug, checking .................................6-8
Specifications.............................................8-1
Speedometer unit ......................................3-3
Starting the engine.....................................5-1
Starting the engine, trouble........................5-2
Steering, checking ................................... 6-27
Storage ......................................................7-3
Swingarm pivots, lubricating .................... 6-26TTachometer................................................3-4
Tail/brake light bulb, replacing ................. 6-32
Throttle grip and cable, checking and
lubricating ..............................................6-24
Throttle grip free play, checking............... 6-13
Tires ......................................................... 6-14
Tool kit .......................................................6-2
Troubleshooting ....................................... 6-39
Troubleshooting chart ..............................6-40
Turn signal indicator light ...........................3-2
Turn signal light bul b, replacing ............... 6-33
Turn signal switch ......................................3-4VValve clearance ....................................... 6-13
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