All YAMAHA SR400 2016 Repair Manual

Motorcycle care and storage
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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.
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Motorcycle care and storage
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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
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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)
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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
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