Clutch YAMAHA SR400 2016 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2016, Model line: SR400, Model: YAMAHA SR400 2016Pages: 96, PDF Size: 2.52 MB
Page 36 of 96
Operation and important riding points
5-4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
shock of forced shifting.
EAU16682To start out and accelerate 1. Pull the clutch lever to disengage the clutch.
2. Shift the transmission into first gear. The neutral indicator light
should go out.
3. Open the throttle gradually, and at the same time, release the clutch
lever slowly.
4. At the recommended shift points shown in the following table, close
the throttle, and at the same time,
quickly pull the clutch lever in.
5. Shift the transmission into second gear. (Make sure not to shift the
transmission into the neutral posi-
tion.)
6. Open the throttle part way and gradually release the clutch lever.
7. Follow the same procedure when shifting to the next higher gear.
TIP
When shifting gears in normal operat-
ing conditions, use the recommended
shift points.
EAU16701To decelerate1. Apply both the front and the rear brakes to slow the motorcycle.
2. Shift the transmission into first gear when the motorcycle reaches
20 km/h (12 mph). If the engine is
about to stall or runs very roughly,
pull the clutch lever in and use the
brakes to stop the motorcycle.
3. Shift the transmission into the neu- tral position when the motorcycle
is almost completely stopped. The neutral indicator light should come
on.
EAU64120Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
Shift up points:
1st 2nd: 20 km/h (12 mph)
2nd 3rd: 30 km/h (19 mph)
3rd 4th: 40 km/h (25 mph)
4th 5th: 50 km/h (31 mph)
Shift down points: 5th 4th: 35 km/h (22 mph)
4th 3rd: 25 km/h (16 mph)
3rd 2nd: 20 km/h (12 mph)
2nd 1st: 20 km/h (12 mph)
2RD-28199-E1.book 4 ページ ２０１５年９月３日 木曜日 午後３時４２分
Page 42 of 96
Periodic maintenance and adjustment
6-4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
2RD-28199-E1.book 4 ページ ２０１５年９月３日 木曜日 午後３時４２分
Page 43 of 96
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
Page 50 of 96
Periodic maintenance and adjustment
6-12
1
2
3
4
5
6
7
8
9
10
11
12
13
14 12. Add the specified amount of the
recommended engine oil, and then
install and tighten the oil filler cap.
TIP
Be 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.
13. 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.
14. 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.
Loosen the bleed bolt.
Start the engine and keep it
idling until oil flows out. If no oil
comes out after one minute,
turn the engine off immediately
so it will not seize. If this occurs,
have a Yamaha dealer repair the
vehicle.
After checking the oil pressure,
tighten the bleed bolt to the
specified torque.
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:
Oil change:2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter removal:
2.10 L (2.22 US qt, 1.85 Imp.qt)
1. Bleed bolt
Tightening torque:Bleed bolt:
18 Nm (1.8 m·kgf, 13 ft·lbf)
1
2RD-28199-E1.book 12 ページ ２０１５年９月３日 木曜日 午後３時４２分
Page 56 of 96
Periodic maintenance and adjustment
6-18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU48293
Adjusting the clutch lever free
play
Measure the clutch lever free play as
shown.
Periodically check the clutch lever free
play and, if necessary, adjust it as fol-
lows. 1. Slide the rubber cover back at the clutch lever.
2. Loosen the locknut.
3. To increase the clutch lever free play, turn the clutch lever free play
adjusting bolt in direction (a). To
decrease the clutch 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.
TIP
If 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 internal
clutch mechanism.
1. Clutch lever free play
2. Rubber cover
3. Locknut
4. Clutch lever free play adjusting bolt
Clutch lever free play:5.0–10.0 mm (0.20–0.39 in)
324
(a)
(b)
1
2RD-28199-E1.book 18 ページ ２０１５年９月３日 木曜日 午後３時４２分
Page 66 of 96
Periodic maintenance and adjustment
6-28
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU23144
Checking and lubricating the
brake and clutch levers
The 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
EAU23185
Checking and l ubricating the
brake pedal
The 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-28199-E1.book 28 ページ ２０１５年９月３日 木曜日 午後３時４２分
Page 87 of 96
8-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Specifications
EAU69993Dimensions:
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 (5.12 in)
Minimum turning radius: 2.4 m (7.87 ft)
Weight:
Curb weight:
174 kg (384 lb)
Engine:
Combustion cycle:4-stroke
Cooling system:
Air cooled
Valve train: SOHC
Number of cylinders: Single cylinder
Displacement:
399 cm
3
Bore stroke:
87.0 67.2 mm (3.43 2.65 in)
Compression ratio: 8.5 : 1
Starting system:
Kickstarter
Lubrication system: Dry sump
Engine oil:
Recommended brand:
YAMALUBE
SAE viscosity grades: 10W-40
Recommended engine oil grade:
API service SG type or higher, JASO stan-
dard MA
Engine oil quantity:
Oil change:2.00 L (2.11 US qt, 1.76 Imp.qt)
With oil filter removal:
2.10 L (2.22 US qt, 1.85 Imp.qt)
Air filter:
Air filter element:Oil-coated paper element
Fuel:
Recommended fuel:
Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity:
12 L (3.2 US gal, 2.6 Imp.gal)
Fuel reserve amount: 2.2 L (0.58 US gal, 0.48 Imp.gal)
Fuel injection:
Throttle body:
ID mark: 2RD1 00
Spark plug(s):
Manufacturer/model:NGK/BPR6ES
Spark plug gap: 0.7–0.8 mm (0.028–0.031 in)
Clutch:
Clutch type:Wet, multiple-disc
Drivetrain:
Primary reduction ratio:
2.567 (77/30)
Final drive: Chain
Secondary reduction ratio: 2.947 (56/19)
Transmission type:
Constant mesh 5-speed
Gear ratio: 1st:
2.357 (33/14)
2nd: 1.556 (28/18)
3rd: 1.190 (25/21)
4th: 0.917 (22/24)
5th: 0.778 (21/27)
Chassis:
Frame type:Semi double cradle
Caster angle: 27.7
Trail:
111 mm (4.4 in)
2RD-28199-E1.book 1 ページ ２０１５年９月３日 木曜日 午後３時４２分
Page 92 of 96
10-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Index
A
Air filter element, replacing ................... 6-13
Auxiliary light bulb, replacing ................ 6-36
B
Battery................................................... 6-31
Brake and clutch levers, checking and lubricating ........................................... 6-28
Brake fluid, changing ............................ 6-24
Brake fluid level, checking .................... 6-23
Brake lever .............................................. 3-7
Brake lever free play, adjusting............. 6-19
Brake light switches .............................. 6-22
Brake pads and shoes, checking .......... 6-22
Brake pedal ............................................. 3-7
Brake pedal, checking and
lubricating ........................................... 6-28
Brake pedal height and free play,
adjusting ............................................. 6-20
C
Cables, checking and lubricating .......... 6-27
Care ........................................................ 7-1
Catalytic converter ................................ 3-11
Centerstand and sidestand, checking and lubricating .................................... 6-29
Clutch lever ............................................. 3-6
Clutch lever free play, adjusting ............ 6-18
D
Decompression lever ............................ 3-12
Dimmer switch ........................................ 3-5
Drive chain, cleaning and lubricating .... 6-26
Drive chain slack ................................... 6-25
E
Engine break-in ....................................... 5-5
Engine idling speed, checking .............. 6-14
Engine oil and oil filter element ............... 6-9
Engine serial number .............................. 9-1
Engine stop switch .................................. 3-5
Engine trouble warning light.................... 3-3
F
Front fork, checking .............................. 6-30
Fuel ......................................................... 3-9
Fuel cock............................................... 3-11
Fuel consumption, tips for reducing ........ 5-5
Fuel level warning light ........................... 3-2
Fuel tank breather/overflow hose.......... 3-10
Fuel tank cap .......................................... 3-8
Fuses, replacing.................................... 6-33
H
Handlebar switches................................. 3-4
Hazard switch ......................................... 3-5 Headlight bulb, replacing ...................... 6-35
High beam indicator light ........................ 3-2
Horn switch ............................................. 3-5
I
Identification numbers ............................ 9-1
Ignition circuit cut-off system ................ 3-15
Indicator lights and warning lights .......... 3-2
K
Kickstarter ............................................ 3-12
M
Main switch/steering lock ....................... 3-1
Maintenance and lubrication, periodic .... 6-4
Maintenance, emission control system... 6-3
Matte color, caution ................................ 7-1
Model label ............................................. 9-2
N
Neutral indicator light .............................. 3-2
P
Panel, removing and installing ............... 6-7
Parking ................................................... 5-6
Part locations .......................................... 2-1
Pass switch ............................................ 3-5
S
Safety information .................................. 1-1
Seat ...................................................... 3-13
Shifting ................................................... 5-3
Shift pedal .............................................. 3-6
Shift pedal, chec
king ............................ 6-21
Shock absorber assemblies, adjusting ............................................. 3-13
Sidestand ............................................. 3-14
Spark plug, checking .............................. 6-8
Specifications ......................................... 8-1
Speedometer unit ................................... 3-3
Starting the engine ................................. 5-2
Starting the engine, trouble .................... 5-3
Steering, checking ................................ 6-30
Storage ................................................... 7-4
Swingarm pivots, lubricating ................. 6-29
T
Tachometer ............................................ 3-4
Tail/brake light bulb, replacing .............. 6-37
Throttle grip and cable, checking and
lubricating ........................................... 6-27
Throttle grip free play, checking ........... 6-14
Tires ..................................................... 6-15
Tool kit .................................................... 6-2
Troubleshooting .................................... 6-42
Troubleshooting chart ........................... 6-43
Turn signal indicator light ....................... 3-2
2RD-28199-E1.book 1 ページ ２０１５年９月３日 木曜日 午後３時４２分