oil YAMAHA SR400 2016 User Guide

Periodic maintenance and adjustment
6-24
1
2
3
4
5
6
7
8
9
10
11
12
13
14 when refilling. Water will signifi-
cantly lower the boiling point of
the fluid and may result in vapor
lock.
NOTICE
ECA17641
Brake fluid may damage painted sur-
faces or plastic parts. Always clean
up 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.
2RD-28199-E1.book 24 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-26
1
2
3
4
5
6
7
8
9
10
11
12
13
14 6. Take the motorcycle off the center-
stand, and then put the sidestand
down.
7. Tighten both drive chain puller locknuts to the specified torque,
and then tighten the axle nut and
brake torque rod nut to their speci-
fied torques.
8. Adjust the brake pedal free play. (See page 6-20.)
WARNING
EWA10661
After adjusting the brake pedal free
play, check the operation of the
brake 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 chain
The 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, riding
in 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
may contain substances that
could damage the O-rings.
[ECA11112]
1. Axle nut
2. Drive chain puller locknut
3. Drive chain slack adjusting bolt
4. Alignment marks
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)
1
2
(a) (b)
3
4
2RD-28199-E1.book 26 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU51951
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
Check the front fork for damage and ex-
cessive oil leakage.
To check the operation 1. Place the vehicle on a level sur- face and hold it in an upright posi-
tion. WARNING! To avoid injury,
securely support the vehicle so
there is no danger of it falling
over.
[EWA10752]
2. While applying the front brake, push down hard on the handlebars
several times to check if the front
fork compresses and rebounds
smoothly.
NOTICE
ECA10591
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU45512
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.1. Place the vehicle on the center- stand. WARNING! To avoid inju-
ry, securely support the vehicle
so there is no danger of it falling
over.
[EWA10752]
2. Hold the lower ends of the front fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
2RD-28199-E1.book 30 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-35
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU23799
Replacing the headlight bulb
This model is equipped with a halogen
bulb headlight. If the headlight bulb
burns out, replace it as follows.
NOTICE
ECA10651
Take care not to damage the follow-
ing parts:
Headlight bulb
Do not touch the glass part of
the headlight bulb to keep it free
from oil, otherwise the transpar-
ency of the glass, the luminosity
of the bulb, and the bulb life will
be adversely affected. Thor-
oughly clean off any dirt and fin-
gerprints on the headlight bulb
using a cloth moistened with al-
cohol or thinner.
Headlight lens
Do not affix any type of tinted
film or stickers to the headlight
lens.
Do not use a headlight bulb of a
wattage higher than specified.
1. Remove the headlight unit by re- moving the screws. 2. Disconnect the headlight coupler,
and then remove the headlight
bulb cover.
3. Unhook the headlight bulb holder, and then remove the burnt-out
bulb.
1. Do not touch the glass part of the bulb.
1. Screw
1. Screw
1. Headlight coupler
2. Headlight bulb cover
1
1
1
2
2RD-28199-E1.book 35 ページ ２０１５年９月３日　木曜日　午後３時４２分

7-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Motorcycle care and storage
EAU37834
Matte color caution
NOTICE
ECA15193
Some models are equipped with
matte colored finished parts. Be
sure to consult a Yamaha dealer for
advice on what products to use be-
fore cleaning the vehicle. Using a
brush, harsh chemical products or
cleaning compounds when cleaning
these parts will scratch or damage
their surface. Wax also should not
be applied to any matte colored fin-
ished parts.
EAU26005
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning 1. Cover the muffler outlet with a plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt, like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
NOTICE
ECA10773
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
2RD-28199-E1.book 1 ページ ２０１５年９月３日　木曜日　午後３時４２分

Motorcycle care and storage
7-3
1
2
3
4
5
6
7
8
9
10
11
12
13
14 corrosion.
After cleaning 1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Immediately dry the drive chain and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom- mended to apply a corrosion pro-
tection spray on all metal,
including chrome- and nickel-plat-
ed, surfaces.
5. Use spray oil as a universal clean- er to remove any remaining dirt.
6. Touch up minor paint damage caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before storing or covering it.
WARNING
EWA11132
Contaminants on the brakes or tires
can cause loss of control.
Make sure that there is no oil or
wax on the brakes or tires.
If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or ac-
etone, and wash the tires with
warm water and a mild deter-
gent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cor-
nering behavior.
NOTICE
ECA10801
Apply spray oil and wax spar-
ingly and make sure to wipe off
any excess.
Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
Avoid using abrasive polishing
compounds as they will wear
away the paint.
TIP
Consult a Yamaha dealer for ad-
vice on what products to use.
Washing, rainy weather or humid
climates can cause the headlight
lens to fog. Turning the headlight
on for a short period of time will
help remove the moisture from the
lens.
2RD-28199-E1.book 3 ページ ２０１５年９月３日　木曜日　午後３時４２分

Motorcycle care and storage
7-4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU43204
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover. Be
sure the engine and the exhaust sys-
tem are cool before covering the motor-
cycle.
NOTICE
ECA10811
Storing the motorcycle in a
poorly ventilated room or cover-
ing it with a tarp, while it is still
wet, will allow water and humid-
ity to seep in and cause rust.
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your motorcycle for sev-
eral months: 1. Follow all the instructions in the “Care” section of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
3. Perform the following steps to pro- tect the cylinder, piston rings, etc.
from corrosion.
a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place
the spark plug on the cylinder head so that the electrodes are
grounded. (This will limit spark-
ing during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder wall with oil.)
WARNING! To prevent dam-
age or injury from sparking,
make sure to ground the
spark plug electrodes while
turning the engine
over.
[EWA10952]
e. Remove the spark plug capfrom the spark plug, and then
install the spark plug and the
spark plug cap.
4. Lubricate all control cables and the pivoting points of all levers and
pedals as well as of the sides-
tand/centerstand.
5. Check and, if necessary, correct the tire air pressure, and then lift
the motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
6. Cover the muffler outlet with a plastic bag to prevent moisture
from entering it.
7. Remove the battery and fully charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place [less
than 0  C (30 F) or more than 30
 C (90 F)]. For more information
on storing the battery, see page
6-31.
TIP
Make any necessary repairs before
2RD-28199-E1.book 4 ページ ２０１５年９月３日　木曜日　午後３時４２分

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

Specifications
8-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Front tire:
Type: With tube
Size: 90/100-18M/C 54S
Manufacturer/model:
BRIDGESTONE/BT-45F
Rear tire:
Type:With tube
Size:
110/90-18M/C 61S
Manufacturer/model: BRIDGESTONE/BT-45R
Loading:
Maximum load:
150 kg (331 lb)
* (Total weight of rider, passenger, cargo and accessories)
Tire air pressure (measured on cold
tires):
Up to 90 kg (198 lb) load:Front:
175 kPa (1.75 kgf/cm
2, 25 psi)
Rear: 200 kPa (2.00 kgf/cm
2, 29 psi)
90 kg (198 lb) lo ad - maximum load:
Front: 200 kPa (2.00 kgf/cm
2, 29 psi)
Rear: 225 kPa (2.25 kgf/cm
2, 33 psi)
Front wheel:
Wheel type:Spoke wheel
Rim size: 18 x 1.85
Rear wheel:
Wheel type:Spoke wheel
Rim size: 18 x 2.15
Front brake:
Type:Hydraulic disc brake
Specified brake fluid:
DOT 4
Rear brake:
Type:Mechanical leading tr ailing drum brake
Front suspension:
Type:
Telescopic fork
Spring: Coil spring
Shock absorber:
Hydraulic damper
Wheel travel: 150 mm (5.9 in)
Rear suspension:
Type:
Swingarm
Spring: Coil spring
Shock absorber: Hydraulic damper
Wheel travel:
105 mm (4.1 in)
Electrical system:
System voltage:12 V
Ignition system:
TCI
Charging system: AC magneto
Battery:
Model:
GT4B-5
Voltage, capacity: 12 V, 2.5 Ah (10 HR)
Headlight:
Bulb type:
Halogen bulb
Bulb wattage  quantity:
Headlight:
H4, 60.0 W/55.0 W x 1
Brake/tail light:
21.0 W/5.0 W  1
Front turn signal light: 21.0 W  2
Rear turn signal light:
21.0 W  2
Auxiliary light: 4.0 W  1
Meter lighting: 1.7 W  4
Neutral indicator light:
1.7 W  1
High beam indicator light: 1.7 W  1
2RD-28199-E1.book 2 ページ ２０１５年９月３日　木曜日　午後３時４２分

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