wheel 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
2RD-28199-E1.book 1 ページ ２０１５年９月３日　木曜日　午後３時４２分

Table of contents
Checking the steering ....................6-30
Checking the wheel bearings ........6-31
Battery ...........................................6-31
Replacing the fuses .......................6-33
Replacing the headlight bulb .........6-35
Replacing the auxiliary light bulb ...........................................6-36
Replacing the tail/brake light bulb ............................................6-37
Replacing a turn signal light
bulb ............................................6-38
Front wheel .............. ......................6-39
Rear wheel ............................ ........6-40
Troubleshooting .......... ...................6-42
Troubleshooting chart . ...................6-43
Motorcycle care and storage ...........7-1
Matte color caution ..........................7-1
Care .................................................7-1
Storage ............................................7-4
Specifications ....................................8-1
Consumer information .....................9-1
Identification numbers .....................9-1
Index .................................................10-1
2RD-28199-E1.book 2 ページ ２０１５年９月３日　木曜日　午後３時４２分

Safety information
1-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14 help you to avoid an accident.
We recommend that you prac- tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn due
to excessive speed or undercor-
nering (insufficient lean angle for
the speed). Always obey the speed limit and never travel faster than warrant-
ed by road and traffic conditions.
Always signal before turning or changing lanes. Make sure that
other motorists can see you.
The posture of the operator and
passenger is important for proper
control. The operator should keep both hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
The passenger should always hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
Never ride under the influence of
alcohol or other drugs.
This motorcycle is designed for on-
road use only. It is not suitable for
off-road use. Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the preven-
tion or reduction of head injuries.
Always wear an approved helmet.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.
A passenger should also observe
the above precautions.
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
2RD-28199-E1.book 2 ページ ２０１５年９月３日　木曜日　午後３時４２分

Safety information
1-5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
appropriate. Refer to page 6-15 for tire
specifications and more information on
replacing your tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
Remove all loose items from the
motorcycle.
Check that the fuel cock (if
equipped) is in the “OFF” position
and that there are no fuel leaks.
Point the front wheel straight
ahead on the trailer or in the truck
bed, and choke it in a rail to pre-
vent movement.
Shift the transmission in gear (for
models with a manual transmis-
sion).
Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or parts
that could break). Choose the lo-
cation for the straps carefully so
the straps will not rub against
painted surfaces during transport.
The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce excessive-
ly during transport.
2RD-28199-E1.book 5 ページ ２０１５年９月３日　木曜日　午後３時４２分

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
2RD-28199-E1.book 2 ページ ２０１５年９月３日　木曜日　午後３時４２分

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

Periodic maintenance and adjustment
6-16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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)
2RD-28199-E1.book 16 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-17
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
2RD-28199-E1.book 17 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
2RD-28199-E1.book 21 ページ ２０１５年９月３日　木曜日　午後３時４２分

Periodic maintenance and adjustment
6-25
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EAU22762
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU59593To check the drive chain slack 1. Place the motorcycle on the cen- terstand.
2. Shift the transmission into the neu- tral position.
3. Push on the drive chain at the cen- ter point between the drive axle
and the rear wheel axle with a
force of 50 N (5.0 kgf, 11 lbf).
4. Measure the drive chain slack as shown.
5. If the drive chain slack is incorrect, adjust it as follows.
EAU59642To adjust the drive chain slack
Consult a Yamaha dealer before ad-
justing the drive chain slack.1. Take the motorcycle off the center- stand, and then put the sidestand
down.
2. Loosen the brake pedal free play adjusting nut, brake torque rod nut,
and axle nut.
3. Loosen the drive chain puller lock- nut at each end of the swingarm.
4. Place the motorcycle on the cen- terstand.
5. To tighten the drive chain, turn the drive chain slack adjusting bolt at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting bolt at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.[ECA10572]
TIP
Using the alignment marks on each
side of the swingarm, make sure that
both drive chain pullers are in the same
position for proper wheel alignment.
Drive chain slack: 30.0–40.0 mm (1.18–1.57 in)
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Drive chain slack adjusting bolt
3. Drive chain puller locknut
4. Axle nut
5. Brake torque rod nut
6. Brake torque rod
6
12
3
4
5
2RD-28199-E1.book 25 ページ ２０１５年９月３日　木曜日　午後３時４２分