OWNER’S MANUAL SR400 MOTORCYCLE Read this manual carefully before oper- ating this vehicle. SR400 2RD-28199-E1...
EAU46091 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your SR400. The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.
Table of contents Safety information ......1-1 Periodic maintenance and adjustment ........6-1 Description ........2-1 Owner’s tool kit ....... 6-2 Left view .......... 2-1 Periodic maintenance chart for the Right view........2-2 emission control system ....6-3 Controls and instruments ....2-3 General maintenance and lubrication chart ......
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...
Safety information EAU1028B for a list of pre-operation checks. This motorcycle is designed to car- ry the operator and a passenger. Be a Responsible Owner The failure of motorists to detect As the vehicle’s owner, you are respon- and recognize motorcycles in traf- sible for the safe and proper operation fic is the predominating cause of...
Safety information Protective Apparel help you to avoid an accident. • We recommend that you prac- The majority of fatalities from motorcy- tice riding your motorcycle cle accidents are the result of head in- where there is no traffic until you juries.
Operation of an overloaded vehicle is an important decision. Genuine could cause an accident. Yamaha accessories, which are avail- able only from a Yamaha dealer, have Maximum load: been designed, tested, and approved 150 kg (331 lb) by Yamaha for use on your vehicle.
Yamaha vehicles. Yamaha is not in a weight distribution or aerody- position to test the products that these namic changes. If accessories...
Safety information 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.
Instrument and control functions EAU10462 EAU10687 Main switch/steering lock LOCK The steering is locked and all electrical systems are off. The key can be re- moved. To lock the steering LOCK The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering.
Instrument and control functions 1. Insert the key. EAU49398 Indicator lights and warning 2. With the key in the “LOCK” posi- lights tion, push the key in and turn it to “OFF”. EAU59680 (Parking) The hazard lights and turn signal lights can be turned on, but all other electrical systems are off.
” This warning light comes on if a prob- lem is detected in the electrical circuit monitoring the engine. If this occurs, have a Yamaha dealer check the vehi- 1. Reset knob cle. 2. Speedometer The electrical circuit of the warning light 3.
Instrument and control functions EAU11882 EAU1234H Tachometer Handlebar switches Left 1. Tachometer 2. Tachometer red zone 1. Dimmer switch “ ” 2. Pass switch “ ” The tachometer allows the rider to monitor the engine speed and keep it Left within the ideal power range.
Instrument and control functions EAU12352 ECA10062 Pass switch “ ” NOTICE Press this switch to flash the headlight. Do not use the hazard lights for an extended length of time with the en- gine not running, otherwise the bat- When the dimmer switch is set to “ ”, tery may discharge.
Instrument and control functions EAU12822 EAU12872 Clutch lever Shift pedal 1. Clutch lever 1. Shift pedal The clutch lever is located on the left The shift pedal is located on the left side of the handlebar. To disengage the side of the motorcycle and is used in clutch, pull the lever toward the handle- combination with the clutch lever when bar grip.
Instrument and control functions EAU12892 EAU12944 Brake lever Brake pedal 1. Brake lever 1. Brake pedal The brake lever is located on the right The brake pedal is located on the right side of the handlebar. To apply the front side of the motorcycle.
Instrument and control functions EAU13125 Fuel tank cap The fuel tank cap cannot be installed unless the key is in the lock. In addition, To remove the fuel tank cap the key cannot be removed if the cap is not properly installed and locked. EWA10132 WARNING Make sure that the fuel tank cap is...
10% (E10). Gas- ohol containing methanol recommended by Yamaha because it 1. Fuel tank breather/overflow hose can cause damage to the fuel system Before operating the motorcycle: or vehicle performance problems.
Instrument and control functions EAU13434 EAU59491 Catalytic converter Fuel cock This model is equipped with a catalytic The fuel cock regulates and filters the converter in the exhaust system. fuel supply from the fuel tank. The fuel cock has two positions: EWA10863 WARNING The exhaust system is hot after op-...
Instrument and control functions EAU13651 EAU13701 Kickstarter Decompression lever 1. Kickstarter 1. Decompression lever To start the engine, fold out the kick- When this lever is pulled, the exhaust starter lever, move it down lightly with valve is forced open so that the com- your foot until the gears engage, and pression pressure can be reduced.
Instrument and control functions EAU13962 EAU14883 Seat Adjusting the shock absorber assemblies To remove the seat EWA10211 WARNING Remove the bolts, and then pull the seat off. Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result.
Instrument and control functions 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.
Does the engine start? The neutral switch may not be working correctly. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
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:...
• Tighten if necessary. Instruments, lights, • Check operation. — signals and switches • Correct if necessary. • Check operation of ignition circuit cut-off system. Sidestand switch • If system is not working correctly, have Yamaha dealer 3-14 check vehicle.
This model is equipped with: there is a control or function you do not a lean angle sensor to stop the en- understand, ask your Yamaha dealer. gine in case of a turnover. In this EWA10272 case, turn the key to “OFF” and WARNING then to “ON”.
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.
Operation and important riding points EAU59470 EAU16673 Starting trouble Shifting 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.
Operation and important riding points shock of forced shifting. neutral indicator light should come EAU16682 To start out and accelerate EAU64120 Recommended shift points 1. Pull the clutch lever to disengage The recommended shift points during the clutch. acceleration deceleration 2.
The vehicle can now be operated nor- mally. ECA10311 NOTICE Keep the engine speed out of the tachometer red zone. If any engine trouble should oc- cur during the engine break-in period, immediately have a Yamaha dealer check the vehi- cle.
Operation and important riding points EAU17214 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10312 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned.
From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EAU63321 Periodic maintenance chart for the emission control system...
Periodic maintenance and adjustment EAU64031 General maintenance and lubrication chart ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi Air filter element • Replace. Every 20000 km (12500 mi) • Check operation. Clutch ...
Periodic maintenance and adjustment ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi • Check chain slack, alignment and condition. Every 500 km (300 mi) and after Drive chain • Adjust and lubricate chain with washing the motorcycle, riding a special O-ring chain lubricant in the rain or riding in wet areas thoroughly.
Periodic maintenance and adjustment ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi • Check operation. • Check throttle grip free play, 27 * Throttle grip and adjust if necessary. • Lubricate cable and grip housing.
Periodic maintenance and adjustment EAU59460 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. 1.
Do not attempt to in accordance with the periodic mainte- diagnose such problems yourself. In- nance and lubrication chart. In addition, stead, have a Yamaha dealer check the condition of the spark plug can re- the vehicle. veal the condition of the engine.
Periodic maintenance and adjustment plug wrench, and then tighten it to EAU59626 Engine oil and oil filter the specified torque. element Tightening torque: The engine oil level should be checked Spark plug: before each ride. In addition, the oil 25 Nm (2.5 m·kgf, 18 ft·lbf) must be changed and the oil filter ele- ment replaced at the intervals specified in the periodic maintenance and lubri-...
Periodic maintenance and adjustment 1. Engine oil filler cap 1. Oil filter element cover bleed bolt 2. Dipstick 2. Gasket 3. Maximum level mark 3. Oil filter element drain bolt 4. Minimum level mark 4. Remove the engine oil drain bolt 4.
Periodic maintenance and adjustment 1. Engine oil drain bolt (oil tank) 1. Oil filter element cover 2. Gasket 2. O-ring 3. Oil filter element 8. Install the oil filter element cover by Skip steps 6–8 if the oil filter element is installing the bolts, and then tight- not being replaced.
See page 8-1. Oil quantity: so it will not seize. If this occurs, Oil change: have a Yamaha dealer repair the 2.00 L (2.11 US qt, 1.76 Imp.qt) vehicle. With oil filter removal: After checking the oil pressure, ...
Periodic maintenance and adjustment element installed, otherwise the EAU52031 Replacing the air filter element piston(s) and/or cylinder(s) may The air filter element should be re- become excessively worn. [ECA10482] placed at the intervals specified in the 5. Install the air filter case cover by in- periodic maintenance and lubrication stalling the screws.
Yamaha dealer. Engine idling speed: 1200–1400 r/min 1. Throttle grip free play Throttle grip free play: 3.0–5.0 mm (0.12–0.20 in) Periodically check the throttle grip free play and, if necessary, have a Yamaha dealer adjust it. 6-14...
Therefore, it must be adjusted by a Yamaha dealer is essential to maintain the tires in good at the intervals specified in the periodic condition at all times and replace them maintenance and lubrication chart.
This model is equipped with tube tires. glass fragments in it, or if the sidewall is Tires age, even if they have not been cracked, have a Yamaha dealer re- used or have only been used occasion- place the tire immediately.
Size: looseness or damage before each 90/100-18M/C 54S ride. If any damage is found, have Manufacturer/model: a Yamaha dealer replace the BRIDGESTONE/BT-45F wheel. Do not attempt even the Rear tire: smallest repair to the wheel. A de- Size:...
4. Tighten the locknut and then slide the rubber cover to its original po- sition. If the specified free play cannot be ob- tained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal 6-18...
Measure the brake lever free play as system. If there is air in the hy- shown. draulic system, have a Yamaha Brake lever free play: dealer bleed the system before 5.0–8.0 mm (0.20–0.31 in) operating the motorcycle.
EAU22199 Adjusting the brake pedal height and free play EWA10671 WARNING It is advisable to have a Yamaha dealer make these adjustments. Brake pedal height The top of the brake pedal should be 1. Brake pedal height locknut positioned at the specified distance be- 2.
If a brake shoe has worn to the point that the wear indicator reaches EWA15991 WARNING the wear limit line, have a Yamaha Improper maintenance can result in dealer replace the brake shoes as a loss of braking ability. Observe set.
Water will signifi- EAU22724 Changing the brake fluid cantly lower the boiling point of Have a Yamaha dealer change the the fluid and may result in vapor brake fluid at the intervals specified in lock. the periodic maintenance and lubrica- ECA17641 tion chart.
EAU59642 To adjust the drive chain slack in the specified limits. [ECA10572] Consult a Yamaha dealer before ad- justing the drive chain slack. 1. Take the motorcycle off the center- Using the alignment marks on each stand, and then put the sidestand side of the swingarm, make sure that down.
Periodic maintenance and adjustment 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.
Periodic maintenance and adjustment EAU23144 EAU23185 Checking and lubricating the Checking and lubricating the brake and clutch levers brake pedal The operation of the brake and clutch The operation of the brake pedal levers should be checked before each should be checked before each ride, ride, and the lever pivots should be lu- and the pedal pivot should be lubricat- bricated if necessary.
The operation of the centerstand and The swingarm pivots must be lubricat- sidestand should be checked before ed by a Yamaha dealer at the intervals each ride, and the pivots and metal-to- specified in the periodic maintenance metal contact surfaces should be lubri- and lubrication chart.
This model is equipped with a VRLA hub or if the wheel does not turn (Valve Regulated Lead Acid) battery. smoothly, have a Yamaha dealer check There is no need to check the electro- the wheel bearings. lyte or to add distilled water. However,...
IES OUT OF THE REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the bat- tery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.
8. Install the seat. 9. Turn the key to “ON”. 10. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. The fuse box, which contains the fuses for the individual circuits, is located un- der the seat.
4. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 5. If a fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Headlight fuse 2. Signaling system fuse 3.
Periodic maintenance and adjustment EAU23799 Replacing the headlight bulb This model is equipped with a halogen bulb headlight. If the headlight bulb burns out, replace it as follows. ECA10651 NOTICE Take care not to damage the follow- ing parts: Headlight bulb ...
6. Install the headlight unit by install- 1. Screw ing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Screw 2. Remove the socket (together with the bulb) by pushing it in and turn- ing it counterclockwise.
Periodic maintenance and adjustment 3. Remove the burnt-out bulb by EAU24135 Replacing the tail/brake light pushing it in and turning it counter- bulb clockwise. 1. Remove the tail/brake light lens by removing the screws. 1. Auxiliary light bulb socket 2. Auxiliary light bulb 1.
Periodic maintenance and adjustment EAU60010 Replacing a turn signal light bulb 1. Remove the turn signal light lens, turn signal light rim and gasket by removing the screws. 1. Turn signal light lens 2. Screw 1. Turn signal light lens 2.
Periodic maintenance and adjustment EAU24361 Front wheel EAU59603 To remove the front wheel EWA10822 WARNING To avoid injury, securely support the vehicle so there is no danger of it 1. Speedometer cable falling over. 5. Remove the wheel axle nut and 1.
Periodic maintenance and adjustment EAU25081 Rear wheel Make sure that there is enough space between the brake pads before insert- EAU59614 ing the brake disc and that the slot in the speedometer gear unit fits over the To remove the rear wheel retainer on the fork leg.
Periodic maintenance and adjustment the brake rod from the brake cam- install the wheel. shaft lever. 5. Loosen the drive chain puller lock- To install the rear wheel nut and the drive chain slack ad- 1. Install the spacer into left side of justing bolt on both ends of the the wheel hub.
Check the vehicle. compression. 4. Compression The engine does not start. There is compression. Have a Yamaha dealer check the vehicle. Operate the kickstarter. There is no Have a Yamaha dealer check the vehicle. compression. 6-43...
Be ble. Rust and corrosion can develop sure to consult a Yamaha dealer for even if high-quality components are advice on what products to use be- used. A rusty exhaust pipe may go un- fore cleaning the vehicle.
Motorcycle care and storage fected area any longer than in- scratching. Some cleaning com- structed. Also, thoroughly rinse pounds for plastic may leave the area off with water, immedi- scratches on the windshield. ately dry it, and then apply a cor- Test the product on a small hid- rosion protection spray.
Consult a Yamaha dealer for ad- 4. To prevent corrosion, it is recom- vice on what products to use. mended to apply a corrosion pro- ...
Motorcycle care and storage EAU43204 head so that the electrodes are Storage grounded. (This will limit spark- ing during the next step.) Short-term d. Turn the engine over several Always store your motorcycle in a cool, times with the starter. (This will dry place and, if necessary, protect it coat the cylinder wall with oil.) against dust with a porous cover.
Motorcycle care and storage storing the motorcycle.
Specifications Dimensions: Air filter: EAU69993 Overall length: Air filter element: 2085 mm (82.1 in) Oil-coated paper element Fuel: Overall width: 750 mm (29.5 in) Recommended fuel: Overall height: Regular unleaded gasoline (Gasohol [E10] 1095 mm (43.1 in) acceptable) Seat height: Fuel tank capacity: 785 mm (30.9 in) 12 L (3.2 US gal, 2.6 Imp.gal)
Specifications Front tire: Front suspension: Type: Type: With tube Telescopic fork Size: Spring: 90/100-18M/C 54S Coil spring Manufacturer/model: Shock absorber: BRIDGESTONE/BT-45F Hydraulic damper Rear tire: Wheel travel: 150 mm (5.9 in) Type: Rear suspension: With tube Size: Type: 110/90-18M/C 61S Swingarm Manufacturer/model: Spring:...
Specifications Turn signal indicator light: 1.7 W 1 Fuel level warning light: 3.0 W 1 Engine trouble warning light: 1.7 W 1 Fuse(s): Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 15.0 A Ignition fuse: 10.0 A Parking lighting fuse: 7.5 A...
Yamaha dealer. EAU26442 Engine serial number VEHICLE IDENTIFICATION NUM-...
1. Model label The model label is affixed to the frame under the seat. (See page 3-13.) Re- cord the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.