warning YAMAHA SR400 2016 Owner's Manual

Periodic maintenance and adjustment
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WARNING
EWA10512
Never overload your vehicle. Opera-
tion of an overloaded vehicle could
cause an accident.
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.
TIP
The tire tread depth limit may differ
from country to country. Always comply
with the local regulations.
WARNING
EWA10572
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the mo-
torcycle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-
quality product.
Ride at moderate speeds after
changing a tire since the tire
surface must first be “broken
in” for it to develop its optimal
characteristics.
Tire information
This model is equipped with tube tires.
Tires age, even if they have not been
used or have only been used occasion-
ally. Cracking of the tread and sidewall
rubber, sometimes accompanied by
carcass deformation, is an evidence of
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) to maximum load:
Front:200 kPa (2.00 kgf/cm
2, 29 psi)
Rear:
225 kPa (2.25 kgf/cm
2, 33 psi)
Maximum load*: 150 kg (331 lb)
* Total weight of rider, passenger, car- go and accessories
1. Tire sidewall
2. Tire tread depth
Minimum tire tread depth (front and
rear): 1.6 mm (0.06 in)
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Periodic maintenance and adjustment
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ageing. Old and aged tires shall be
checked by tire specialists to ascertain
their suitability for further use.
WARNING
EWA10462
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, which
could lead to an accident.
After extensive tests,
only the tires list-
ed below have been approved for this
model by Yamaha.
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 tires
on 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.
Front tire: Size:90/100-18M/C 54S
Manufacturer/model:
BRIDGESTONE/BT-45F
Rear tire: Size:
110/90-18M/C 61S
Manufacturer/model: BRIDGESTONE/BT-45R
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Periodic maintenance and adjustment
6-19
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EAU48444
Adjusting the brake lever free
play
Measure the brake lever free play as
shown.
Periodically check the brake lever free
play and, if necessary, adjust it as fol-
lows.
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.
Brake lever free play:
5.0–8.0 mm (0.20–0.31 in)
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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EAU22199
Adjusting the brake pedal
height and free play
WARNING
EWA10671
It is advisable to have a Yamaha
dealer make these adjustments.
Brake pedal height
The top of the brake pedal should be
positioned at the specified distance be-
low the top of the footrest as shown.
Periodically check the brake pedal
height and, if necessary, adjust it as fol-
lows. 1. Loosen the brake pedal height locknut.
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 play
must be adjusted.
Brake pedal free play
Measure the brake pedal free play as
shown.
Periodically check the brake pedal free
play and, if necessary, adjust it as fol-
lows.
To increase the brake pedal free play,
turn the brake pedal free play adjusting
nut at the brake rod in direction (a). To
Brake pedal height:
20.0 mm (0.79 in)
1. Brake pedal height
1
1. Brake pedal height locknut
2. Brake pedal height adjusting bolt
1. Brake pedal free play
Brake pedal free play:20.0–30.0 mm (0.79–1.18 in)
1
2
(b)
(a)
1
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Periodic maintenance and adjustment
6-21
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decrease the brake pedal free play,
turn the adjusting nut in direction (b).
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 of
the brake light.
EAU44821
Checking the shift pedal
The operation of the shift pedal should
be checked before each ride. If opera-
tion is not smooth, have a Yamaha
dealer check the vehicle.
1. Brake pedal free play adjusting nut
(b)
(a)
1
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Periodic maintenance and adjustment
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EAU22541Rear 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 level
Before 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
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
1. Brake shoe wear indicator
2. Brake shoe wear limit line
1 2
1. Minimum level mark
Specified brake fluid:
DOT 4
1
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Periodic maintenance and adjustment
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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
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Periodic maintenance and adjustment
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EAU23098
Checking and l ubricating the
cables
The 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 cable
The 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 lubricant or other suit-
able cable lubricant
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Periodic maintenance and adjustment
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EAU23215
Checking and l ubricating the
centerstand and sidestand
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-to-
metal contact surfaces should be lubri-
cated if necessary.
WARNING
EWA10742
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it. Otherwise, the centerstand or
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
EAUM1653
Lubricating the swingarm
pivots
The swingarm pivots must be lubricat-
ed by a Yamaha dealer at the intervals
specified in the periodic maintenance
and lubrication chart.
Recommended lubricant: Lithium-soap-based grease
Recommended lubricant:
Lithium-soap-based grease
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Periodic maintenance and adjustment
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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.
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