clutch YAMAHA SR400 2016 Owners Manual

Table of contents
Safety information............................ 1-1
Description ........................................ 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................ 2-3
Instrument and control functions ... 3-1
Main switch/steering lock ................ 3-1
Indicator lights and warning lights ... 3-2
Speedometer unit ..... ....................... 3-3
Tachometer ..................................... 3-4
Handlebar switches ......................... 3-4
Clutch lever ..................................... 3-6
Shift pedal ....................................... 3-6
Brake lever ...................................... 3-7
Brake pedal .............. ....................... 3-7
Fuel tank cap ................................... 3-8
Fuel ................................................. 3-9
Fuel tank breather/overflow hose ........................................... 3-10
Catalytic converter......................... 3-11
Fuel cock ....................................... 3-11
Kickstarter .... ............................. .... 3-12
Decompression lever..................... 3-12
Seat ............................................... 3-13
Adjusting the shock absorber assemblies ................................. 3-13
Sidestand ...................................... 3-14
Ignition circuit cut- off system ......... 3-15
For your safety – pre-operation
checks ................................................ 4-1
Operation and im portant riding
points ................................................. 5-1
Starting the engine .......................... 5-2
Starting trouble ................................ 5-3
Shifting ............................................ 5-3
Tips for reducing fuel consumption................................. 5-5
Engine break-in ............................... 5-5
Parking ............................................ 5-6 Periodic maintenance and
adjustment
........................................ 6-1
Owner’s tool kit ............................... 6-2
Periodic maintenance chart for the
emission control system .............. 6-3
General maintenance and lubrication chart ........................... 6-4
Removing and installing the panel ............................................ 6-7
Checking the spark plug ................. 6-8
Engine oil and oil filter element ....... 6-9
Replacing the air filter element ..... 6-13
Checking the engine idling
speed ......................................... 6-14
Checking the throttle grip free play ............................................ 6-14
Valve clearance ............................ 6-15
Tires .............................................. 6-15
Spoke wheels........... ..................... 6-17
Adjusting the clutch lever free play ............................................ 6-18
Adjusting the brake lever free play ............................................ 6-19
Adjusting the brake pedal height
and free play .............................. 6-20
Checking the shift pedal................ 6-21
Brake light switches ...................... 6-22
Checking the front brake pads and rear brake shoes ................ 6-22
Checking the brake fluid level ....... 6-23
Changing the brake fluid .............. 6-24
Drive chain slack ........................... 6-25
Cleaning and lubricating the drive
chain .......................................... 6-26
Checking and lubricating the cables ........................................ 6-27
Checking and lubricating the throttle grip and ca ble ................ 6-27
Checking and lubricating the
brake and clutch levers.............. 6-28
Checking and lubricating the brake pedal ................................ 6-28
Checking and lubricating the centerstand and sidestand ........ 6-29
Lubricating the swingarm pivots.... 6-29
Checking the front fork .................. 6-30
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Description
2-3
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5
6
7
8
9
10
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13
14
EAU63401
Controls and instruments
1. Clutch lever (page 3-6)
2. Left handlebar switches (page 3-4)
3. Speedometer unit (page 3-3)
4. Main switch/steering lock (page 3-1)
5. Tachometer (page 3-4)
6. Front brake fluid reservoir (page 6-23)
7. Right handlebar switches (page 3-4)
8. Brake lever (page 3-7)
9. Throttle grip (page 6-14)
10.Decompression lever (page 3-12)
12 345 78
9
6
10
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Instrument and control functions
3-6
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6
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8
9
10
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12
13
14
EAU12822
Clutch lever
The clutch lever is located on the left
side of the handlebar. To disengage the
clutch, pull the lever toward the handle-
bar grip. To engage the clutch, release
the lever. The lever should be pulled
rapidly and released slowly for smooth
clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-15.)
EAU12872
Shift pedal
The shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever when
shifting the gears of the 5-speed con-
stant-mesh transmission equipped on
this motorcycle.
1. Clutch lever
1
1. Shift pedal
1
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Instrument and control functions
3-12
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6
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9
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EAU13651
Kickstarter
To start the engine, fold out the kick-
starter lever, move it down lightly with
your foot until the gears engage, and
then push it down smoothly but force-
fully. This model is equipped with a pri-
mary kickstarter, allowing the engine to
be started in any gear if the clutch is
disengaged. However, shifting the
transmission into the neutral position
before starting is recommended.
EAU13701
Decompression lever
When this lever is pulled, the exhaust
valve is forced open so that the com-
pression pressure can be reduced.
This allows the piston to be moved just
past the compression stroke before
kick starting. (See page 5-2.)
1. Kickstarter
1
1. Decompression lever
1
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Instrument and control functions
3-15
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14
EAU66820
Ignition circuit cut-off system
The ignition circuit cut-off system (com-
prising the sidestand switch, clutch
switch and neutral switch) has the fol-
lowing functions.
It prevents starting when the trans-
mission is in gear and the sides-
tand is up, but the clutch lever is
not pulled.
It prevents starting when the trans-
mission is in gear and the clutch le-
ver is pulled, but the sidestand is
still down.
It cuts the running engine when the
transmission is in gear and the sid-
estand is moved down.
Periodically check the operation of the
ignition circuit cut-of f system according
to the following procedure.
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Instrument and control functions
3-16
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14
With the engine turned off:
1. Move the sidestand down.
2.
Make sure that the engine stop switch
is set to “ ”.
3. Turn the key on.
4. Shift the transmission into the neutral position.
5. Push the kick starter lever down.
Does the engine start?
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
After the engine has stalled:
10. Move the sidestand up.
11. Keep the clutch lever pulled.
12. Push the kick starter lever down.
Does the engine start?
The system is OK. The motorcycle can
be ridden.
The neutral switch may not be working
correctly.
The motorcycle should not be ridden
until checked by a Yamaha dealer.
The sidestand switch may not be
working correctly.
The motorcycle should not be ridden
until checked by a Yamaha dealer.
The clutch switch may not be working
correctly.
The motorcycle should not be ridden
until checked by a Yamaha dealer.
WARNING
The vehicle must be placed on the centerstand during this inspection.
If a malfunction is noted, have a Yamaha dealer check the system
before riding.
YES NO
YESNO
YESNO
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4-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
For your safety – pre-operation checks
EAU63440
Inspect your vehicle each time you use it to make sure the vehicle is in safe oper-
ating condition. Always follow the in spection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
EWA11152
Failure to inspect or maintain the vehicle properly increases the possibility
of an accident or equipment damage. Do not operate the vehicle if you find
any problem. If a problem cannot be corrected by the procedures provided
in this manual, have the vehicle inspected by a Yamaha dealer.
Before using this vehicle, check the following points:
ITEM CHECKSPAGE
Fuel Check fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.
Check fuel tank breather hose
for obstructions, cracks or
damage, and check hose connection. 3-9, 3-10
Engine oil Check oil level in oil tank.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage. 6-9
Front brake Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic
system.
Check lever free play.
Adjust if necessary.
Check brake pads for wear.
Replace if necessary.
Check fluid level in reservoir.
If necessary, add specified brak e fluid to specified level.
Check hydraulic system for leakage. 6-19,
6-22, 6-23
Rear brake Check operation.
Check pedal free play.
Adjust if necessary. 6-20,
6-22
Clutch Check operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary. 6-18
Throttle grip Make sure that operation is smooth.
Check throttle grip free play.
If necessary, have Yamaha dealer adjust throttle grip
free play and lubricate cable and grip housing. 6-14,
6-27
Control cables Make sure that operation is smooth.
Lubricate if necessary. 6-27
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For your safety – pre-operation checks
4-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Drive chain Check chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary. 6-25,
6-26
Wheels and tires Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary. 6-15,
6-17
Shift pedal Make sure that operation is smooth.
Correct if necessary. 6-21
Brake pedal Make sure that operation is smooth.
Lubricate pedal pivoting point if necessary. 6-28
Brake and clutch
levers Make sure that operation is smooth.
Lubricate lever pivoting points if necessary.
6-28
Centerstand, sidestand Make sure that operation is smooth.
Lubricate pivots if necessary. 6-29
Chassis fasteners Make sure that all nuts, bol
ts and screws are properly
tightened.
Tighten if necessary. —
Instruments, lights,
signals and switches Check operation.
Correct if necessary.
—
Sidestand switch Check operation of ignition circuit cut-off system.
If system is not working correctly, have Yamaha dealer
check vehicle. 3-14
ITEM CHECKS PAGE
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Operation and important riding points
5-2
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8
9
10
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14
EAU59532
Starting the engine
In order for the ignition circuit cut-off
system (page 3-15) to enable starting,
one of the following conditions must be
met:
The transmission is in the neutral
position.
The transmission is in gear with
the clutch lever pulled and the sid-
estand up.
1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and set the engine stop switch to “ ”.
The engine trouble warning light
and fuel level warning light should
come on for a few seconds, then
go off.
NOTICE
ECA23270
If a warning light does not come on
initially when the key is turned to
“ON”, or if a warning light remains
on, see page 3-2 for the correspond-
ing warning light circuit check.
3. Shift the transmission into the neu- tral position. The neutral indicator
light should come on. If not, ask a
Yamaha dealer to check the elec-
trical circuit.
4. Completely close the throttle and apply the decompression lever.
5. Slowly push the kickstarter lever down until the starting mark shows
on the kick indicator. 6. Release the decompression lever,
release the kickstarter lever, and
then push the kickstarter lever
down forcefully to start the engine.
NOTICE
ECA11043
For maximum engine life, never ac-
celerate hard when the engine is
cold!
1. Starting mark
2. Kick indicator
21
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Operation and important riding points
5-3
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2
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4
5
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7
8
9
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EAU59470
Starting trouble
If the engine fails to start after 4 to 5
kicks, clear out the combustion cham-
ber with the following procedure. 1. Turn the key to “OFF”.
2. While applying the decompression lever, fully open the throttle grip
and push the kickstarter lever
down 4 to 5 times.
3. Turn the key to “ON” and retry starting the engine.
EAU16673
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the il-
lustration.
TIP
To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
NOTICE
ECA10261
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
Always use the clutch while
changing gears to avoid damag-
ing the engine, transmission,
and drive train, which are not
designed to withstand the
1. Shift pedal
2. Neutral position
1
2
1 3 4 5
N
2
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