YAMAHA SR400 2014 Workshop Manual

PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
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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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PERIODIC MAINTENANCE AND ADJUSTMENT
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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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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU60900
Adjusting the brake pedal
height and free play
WARNING
EWA10671
It is advisable to have a Yamahadealer make these adjustments.
Brake pedal height
The top of the brake pedal should be
positioned approximately 20.0 mm
(0.79 in) below the top of the footrest.
Periodically check the brake pedal
height and, if necessary, adjust it as fol-
lows. 1. Loosen the locknut at the frame.
2. To raise the brake pedal, turn the brake pedal height adjusting bolt in
direction (a). To lower the brake
pedal, turn the adjusting bolt in di-
rection (b).
3. Tighten the locknut.
WARNING
EWA11232
After adjusting the brake pedal
height, the brake pedal free playmust be adjusted. Brake pedal free play
The brake pedal free play should mea-
sure 20.0–30.0 mm (0.79–1.18 in) as
shown. Periodically check the brake
pedal free play and, if necessary, adjust
it as follows.
To increase the brake pedal free play,
turn the brake pedal free play adjusting
nut at the brake rod in direction (a). To
decrease the brake pedal free play,
turn the adjusting nut in direction (b).
1. Brake pedal height
1
1. Locknut
2. Brake pedal height adjusting bolt
1
2
(b)
(a)
1. Brake pedal free play
1
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PERIODIC MAINTENANCE AND ADJUSTMENT
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WARNING
EWA10681

After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.

If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-
justment.

After adjusting the brake pedal
free play, check the operation ofthe brake light.
EAU44821
Checking the shift pedalThe operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
EAU22274
Brake light switchesThe brake light, which is activated by
the brake pedal and brake lever, should
come on just before braking takes ef-
fect. If necessary, adjust the rear brake
light switch as follows, but the front
brake light switch should be adjusted
by a Yamaha dealer.
Turn the rear brake light switch adjust-
ing nut while holding the rear brake light
switch in place. To make the brake light
come on earlier, turn the adjusting nut
in direction (a). To make the brake light
come on later, turn the adjusting nut in
direction (b).
1. Brake pedal free play adjusting nut
(b)
(a)
1
1. Rear brake light switch adjusting nut
2. Rear brake light switch
2
1 (a)
(b)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU22382
Checking the front brake pads
and rear brake shoes The front brake pads and the rear brake
shoes must be checked for wear at the
intervals specified in the periodic main-
tenance and lubrication chart.
EAU22432
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear indicator grooves have almost disap-
peared, have a Yamaha dealer replace
the brake pads as a set.
EAU22541
Rear 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 levelBefore 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
1. Brake pad
2. Brake pad wear indicator groove1
2
1. Brake shoe wear indicator
2. Brake shoe wear limit line
12
1. Minimum level markSpecified brake fluid:
DOT 41
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PERIODIC MAINTENANCE AND ADJUSTMENT
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12 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
when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vaporlock.
NOTICE
ECA17641
Brake fluid may damage painted sur-
faces or plastic parts. Always cleanup 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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PERIODIC MAINTENANCE AND ADJUSTMENT
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EAU22762
Drive chain slackThe drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU59591
To check the drive chain slack 1. Place the motorcycle on the cen- terstand.
2. Shift the transmission into the neu- tral position.
3. Push on the drive chain at the cen- ter point between the drive axle
and the rear wheel axle with a
force of 50 N (5.0 kgf, 11 lbf).
4. Measure drive chain slack as shown. 5. If the drive chain slack is incorrect,
adjust it as follows.
EAU59641
To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack.1. Take the motorcycle off the center- stand, and then put the sidestand
down.
2. Loosen the brake pedal free play adjusting nut, brake torque rod nut,
and axle nut. 3. Loosen the drive chain puller lock-
nut at each end of the swingarm.
4. Place the motorcycle on the cen- terstand.
5. To tighten the drive chain, turn the drive chain slack adjusting bolt at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
Drive chain slack: 30.0–40.0 mm (1.18–1.57 in)
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Drive chain slack adjusting bolt
3. Drive chain puller locknut
4. Axle nut
5. Brake torque rod nut
6. Brake torque rod
6
12
3
4
5
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PERIODIC MAINTENANCE AND ADJUSTMENT
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12 gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10572]
TIPUsing the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the sameposition for proper wheel alignment.
6. Take the motorcycle off the center- stand, and then put the sidestand down.
7. Tighten both drive chain puller locknuts, and then tighten the axle
nut and brake torque rod nut to
their specified torques.
8. Adjust the brake pedal free play. (See page 6-18.)
WARNING
EWA10661
After adjusting the brake pedal free
play, check the operation of thebrake light.
9. Make sure that the drive chain pull- ers are in the same position, the
drive chain slack is correct, and
the drive chain moves smoothly.
EAU23026
Cleaning and lubricating the
drive chainThe drive chain must be cleaned and
lubricated at the intervals specified in
the periodic maintenance and lubrica-
tion chart, otherwise it will quickly wear
out, especially when riding in dusty or
wet areas. Service the drive chain as
follows.NOTICE
ECA10584
The drive chain must be lubricated
after washing the motorcycle, ridingin the rain or riding in wet areas.
1. Clean the drive chain with kero- sene and a small soft brush.
NOTICE: To prevent damaging
the O-rings, do not clean the
drive chain with steam cleaners,
high-pressure washers or inap-
propriate solvents.
[ECA11122]
2. Wipe the drive chain dry.
3. Thoroughly lubricate the drive chain with a special O-ring chain
lubricant. NOTICE: Do not use
engine oil or any other lubri-
cants for the drive chain, as they
1. Axle nut
2. Drive chain puller locknut
3. Drive chain slack adjusting bolt
4. Alignment marks
1
2
(a) (b)
3
4
Tightening torques:
Drive chain puller locknut:16 Nm (1.6 m·kgf, 12 ft·lbf)
Axle nut: 129 Nm (12.9 m·kgf, 92 ft·lbf)
Brake torque rod nut:
19 Nm (1.9 m·kgf, 14 ft·lbf)
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PERIODIC MAINTENANCE AND ADJUSTMENT
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may contain substances that
could damage the O-rings.
[ECA11112]
EAU23098
Checking and lubr
icating the
cablesThe 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 cableThe 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 lubric ant or other suit-
able cable lubricant
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PERIODIC MAINTENANCE AND ADJUSTMENT
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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
2RD-9-E0.book 25 ページ ２０１３年１１月２８日　木曜日　午後４時１８分