Yamaha SR400 2014 Manuals

Yamaha SR400 2014 Manuals

Manuals and User Guides for Yamaha SR400 2014. We have 1 Yamaha SR400 2014 manual available for free PDF download: Service Manual

Yamaha SR400 2014 Service Manual

Yamaha SR400 2014 Service Manual (342 pages)

Brand: Yamaha | Category: Motorcycle | Size: 11.44 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- Symbols
  6
- General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    Fuel Line Chart
    13
  - Important Information
    14
    
    Preparation for Removal and Disassembly
    14
    
    Replacement Parts
    14
    
    Gaskets, Oil Seals and O-Rings
    14
    
    Lock Washers/Plates and Cotter Pins
    14
    
    Bearings and Oil Seals
    14
    
    Circlips
    15
    
    Rubber Parts
    15
  - Basic Service Information
    16
    
    Quick Fasteners
    16
    
    Electrical System
    16
  - Special Tools
    26
Specifications

27
- General Specifications
  28
- Engine Specifications
  29
- Chassis Specifications
  34
- Electrical Specifications
  37
- Tightening Torques
  39
- Lubrication Points and Lubricant Types
  47
  - Engine
    47
  - Chassis
    48
- Lubrication System Chart and Diagrams
  50
  - Engine Oil Lubrication Chart
    50
  - Lubrication Diagrams
    52
- Cable Routing
  60
Periodic Checks and Adjustments

85
- General Maintenance and Lubrication Chart
  87
- Introduction
  87
- Periodic Maintenance
  87
- Periodic Maintenance Chart for the Emission Control System
  87
- Checking the Fuel Line
  90
- Adjusting the Valve Clearance
  91
- Checking the Spark Plug
  91
- Adjusting the Exhaust Gas Volume
  93
- Checking the Engine Idling Speed
  93
- Checking the Throttle Body Joint
  93
- Checking the Exhaust System
  94
- Checking the Air Induction System
  95
- Checking the Oil Separator
  95
- Replacing the Air Filter Element
  95
- Adjusting the Clutch Lever Free Play
  96
- Checking the Timing Chain Tensioner
  96
- Adjusting the Decompression Lever Free Play
  97
- Checking the Brake Fluid Level
  97
- Checking the Brake Operation
  97
- Adjusting the Front Disc Brake
  98
- Checking the Front Brake Pads
  98
- Adjusting the Rear Drum Brake
  99
- Bleeding the Hydraulic Brake System
  100
- Checking the Front Brake Hose
  100
- Checking the Rear Brake Shoes
  100
- Checking and Tightening the Spokes
  101
- Checking the Wheels
  101
- Checking the Tires
  102
- Checking the Swingarm Operation
  103
- Checking the Wheel Bearings
  103
- Lubricating the Swingarm
  103
- Adjusting the Drive Chain Slack
  104
- Lubricating the Drive Chain
  104
- Checking and Adjusting the Steering Head
  105
- Checking the Centerstand
  106
- Checking the Chassis Fasteners
  106
- Checking the Front Fork
  106
- Checking the Sidestand
  106
- Checking the Sidestand Switch
  106
- Lubricating the Centerstand
  106
- Lubricating the Levers
  106
- Lubricating the Pedal
  106
- Lubricating the Sidestand
  106
- Lubricating the Steering Head
  106
- Adjusting the Rear Shock Absorber Assembly
  107
- Checking the Engine Oil Level
  107
- Checking the Rear Shock Absorber Assembly
  107
- Changing the Engine Oil
  108
- Adjusting the Rear Brake Light Switch
  110
- Checking and Lubricating the Cables
  110
- Checking the Front Brake Light Switch
  110
- Checking the Throttle Grip
  110
- Checking and Charging the Battery
  111
- Checking the Fuses
  111
- Replacing the Headlight Bulb
  111
- Adjusting the Headlight Beam
  112
Chassis

115
- General Chassis
  
  117
  - Installing the Side Covers
    120
  - Removing the Side Covers
    120
- Front Wheel
  
  123
  - Removing the Front Wheel
    123
  - Checking the Front Wheel
    123
  - Checking the Speedometer Gear Unit
    124
  - Adjusting the Front Wheel Static Balance
    124
  - Installing the Front Wheel
    125
- Rear Wheel
  
  127
- Front Brake
  
  133
  - Introduction
    138
    
    Checking the Front Brake Disc
    138
    
    Replacing the Front Brake Pads
    139
    
    Removing the Front Brake Caliper
    140
    
    Disassembling the Front Brake Caliper
    140
    
    Checking the Front Brake Caliper
    141
    
    Assembling the Front Brake Caliper
    141
    
    Installing the Front Brake Caliper
    142
    
    Removing the Front Brake Master Cylinder
    143
    
    Checking the Front Brake Master Cylinder
    143
    
    Assembling the Front Brake Master Cylinder
    144
    
    Installing the Front Brake Master Cylinder
    144
- Rear Brake
  
  146
- Handlebar
  
  149
  - Removing the Handlebar
    151
  - Checking the Handlebar
    151
  - Installing the Handlebar
    151
- Front Fork
  
  153
  - Removing the Front Fork Legs
    155
  - Disassembling the Front Fork Legs
    155
  - Checking the Front Fork Legs
    156
  - Assembling the Front Fork Legs
    156
  - Installing the Front Fork Legs
    158
- Steering Head
  
  160
  - Removing the Lower Bracket
    162
  - Checking the Steering Head
    162
  - Installing the Steering Head
    163
- Rear Shock Absorber Assembly and Swingarm
  
  164
  - Removing the Rear Shock Absorber Assemblies
    165
  - Checking the Rear Shock Absorber Assembly
    165
  - Installing the Rear Shock Absorber Assembly
    165
  - Removing the Swingarm
    165
  - Checking the Swingarm
    166
  - Adjusting the Thrust Clearance
    166
  - Installing the Swingarm
    167
- Chain Drive
  
  169
  - Removing the Drive Chain
    169
  - Checking the Drive Chain
    169
  - Checking the Drive Sprocket
    170
  - Checking the Rear Wheel Sprocket
    170
  - Checking the Rear Wheel Drive Hub
    170
  - Installing the Drive Chain
    170
Engine

173
- Engine Inspection
  
  175
  - Measuring the Compression Pressure
    175
- Engine Removal
  
  176
  - Removing the Engine
    178
  - Installing the Engine
    179
- Cylinder Head
  
  180
  - Removing the Cylinder Head
    181
  - Checking the Cylinder Head
    182
  - Checking the Camshaft
    182
  - Checking the Timing Chain and Camshaft Sprocket
    183
  - Checking the Timing Chain Tensioner
    183
  - Installing the Cylinder Head
    183
- Rocker Arms
  
  187
- Valves and Valve Springs
  
  191
  - Removing the Valves
    191
  - Checking the Valves and Valve Guides
    191
  - Checking the Valve Seats
    193
  - Checking the Valve Springs
    194
  - Installing the Valves
    195
- Cylinder and Piston
  
  197
  - Removing the Piston
    198
  - Checking the Cylinder and Piston
    198
  - Checking the Piston Rings
    199
  - Checking the Piston Pin
    200
  - Checking the Timing Chain Guides
    200
  - Installing the Piston and Cylinder
    200
- Clutch
  
  202
  - Removing the Clutch
    205
  - Checking the Friction Plates
    205
  - Checking the Clutch Plates
    205
  - Checking the Clutch Springs
    206
  - Checking the Clutch Housing
    206
  - Checking the Clutch Boss
    206
  - Checking the Pressure Plate
    206
  - Checking the Clutch Push Rods
    206
  - Checking the Primary Drive Gear
    207
  - Checking the Primary Driven Gear
    207
  - Installing the Clutch
    207
- Kickstarter
  
  210
  - Checking the Kickstarter
    212
  - Installing the Kickstarter
    212
- Oil Pump
  
  213
  - Removing the Oil Pump
    215
  - Checking the Oil Pump
    215
  - Assembling the Oil Pump
    215
  - Installing the Oil Pump
    216
- Shift Shaft
  
  217
  - Removing the Shift Shaft
    218
  - Checking the Shift Shaft
    218
  - Checking the Stopper Lever
    218
  - Installing the Shift Shaft
    218
- Generator
  
  220
  - Removing the Generator
    221
  - Installing the Generator
    221
- Crankcase
  
  222
  - Disassembling the Crankcase
    224
  - Checking the Crankcase
    224
  - Checking the Timing Chain and Crankshaft Sprocket
    224
  - Checking the Bearing
    224
  - Checking the Oil Strainer
    224
  - Assembling the Crankcase
    224
- Crankshaft Assembly
  
  226
- Transmission
  
  229
  - Removing the Transmission
    231
  - Checking the Shift Forks
    231
  - Shift Drum Assembly
    231
  - Checking the Transmission
    232
  - Assembling the Main Axle and Drive Axle
    232
  - Installing the Shift Forks and Shift Drum Assembly
    233
Fuel System

235
- Fuel Tank
  
  237
  - Removing the Fuel Tank
    239
  - Removing the Fuel Pump Case
    240
  - Checking the Fuel Cock
    241
  - Removing the Fuel Pump
    241
  - Checking the Fuel Pump Body
    242
  - Checking the Fuel Pump Operation
    242
  - Checking the Rollover Valve
    242
  - Installing the Fuel Pump
    242
  - Installing the Fuel Tank
    242
  - Installing the Fuel Pump Case
    243
- Throttle Body
  
  244
- Air Induction System
  
  250
  - Checking the Air Induction System
    253
  - Installing the Air Induction System
    253
Electrical System

255
- Ignition System
  
  258
  - Circuit Diagram
    258
  - Engine Stopping Due to Sidestand Operation
    260
  - Troubleshooting
    262
- Charging System
  
  264
  - Circuit Diagram
    264
  - Troubleshooting
    266
- Lighting System
  
  268
  - Circuit Diagram
    268
  - Troubleshooting
    270
- Signaling System
  
  272
  - Circuit Diagram
    272
  - Troubleshooting
    274
- Fuel Injection System
  
  278
  - Circuit Diagram
    278
  - Ecu Self-Diagnostic Function
    280
  - Troubleshooting Method
    282
  - Diagnostic Mode
    282
  - Troubleshooting Details
    285
  - Diagnostic Code Table
    299
- Fuel Pump System
  
  304
  - Circuit Diagram
    304
  - Troubleshooting
    306
- Electrical Components
  
  308
  - Checking the Switches
    312
  - Checking the Bulbs and Bulb Sockets
    315
  - Checking the Fuses
    316
  - Checking and Charging the Battery
    317
  - Checking the Relays
    320
  - Checking the Turn Signal/Hazard Relay
    320
  - Checking the Diode
    321
  - Checking the Spark Plug Cap
    322
  - Checking the Ignition Coil
    322
  - Checking the Ignition Spark Gap
    323
  - Checking the Crankshaft Position Sensor
    324
  - Checking the Lean Angle Sensor
    324
  - Checking the Stator Coil
    325
  - Checking the Rectifier/Regulator
    325
  - Checking the Horn
    325
  - Checking the Engine Temperature Sensor
    326
  - Checking the Fuel Sender
    326
  - Checking the Speed Sensor
    327
  - Checking the Throttle Position Sensor
    327
  - Checking the Air Induction System Solenoid
    328
  - Checking the Intake Air Pressure Sensor
    328
  - Checking the Intake Air Temperature Sensor
    329
  - Checking the Fuel Injector
    329
Troubleshooting

331
- General Information
  331
- General Information
  332
- Incorrect Engine Idling Speed
  332
  - Adjustments
    332
- Starting Failures
  332
- Troubleshooting
  332
- Faulty Clutch
  333
- Faulty Gear Shifting
  333
- Jumps out of Gear
  333
- Overheating
  333
- Poor Medium-And-High-Speed Performance
  333
- Shift Pedal Does Not Move
  333
- Faulty Front Fork Legs
  334
- Faulty Lighting or Signaling System
  334
- Poor Braking Performance
  334
- Unstable Handling
  334

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