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OWNER’S MANUAL SR400 MOTORCYCLE Read this manual carefully before oper- ating this vehicle. SR400J SR400JC LIT-11626-31-55 2RD-28199-13...
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EAU82390 WARNING Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
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EAU10084 Congratulations on your purchase of the Yamaha SR400J/SR400JC. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields.
Table of contents Location of important labels....1-1 Periodic maintenance chart for the emission control system ....7-3 Safety information ......2-1 General maintenance and lubrication chart ......7-4 Description ........3-1 Removing and installing the Left view ..........3-1 panel ..........7-7 Right view ........3-2 Checking the spark plug....
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Matte color caution ......8-1 Care..........8-1 Storage ..........8-4 Specifications........9-1 Consumer information ....10-1 Identification numbers ....10-1 Reporting safety defects....10-3 Motorcycle noise regulation...10-4 Maintenance record.......10-5 YAMAHA MOTOR CORPORATION, U.S.A. 2015 AND LATER MODEL STREET & DUAL-PURPOSE MOTORCYCLE LIMITED WARRANTY.......10-6 YAMAHA EXTENDED SERVICE (Y.E.S.)........10-8 Index..........11-1...
Read and understand all of the labels on your vehicle. They contain important in- formation for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer.
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Location of important labels WARNING BEFORE YOU OPERATE THIS VEHICLE, READ THE OWNER’S MANUAL AND ALL LABELS. ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 1TP-2118K-A1 Cold tire normal pressure should be set as follows. Up to 90 kg (198 lbs) load : 175 kPa, {1.75 kgf/cm 25 psi...
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...
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Safety information help you to avoid an accident. Protective Apparel • 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.
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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.
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Yamaha vehicles. Yamaha is not in a weight distribution or aerody- position to test the products that these namic changes. If accessories...
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Safety information appropriate. Refer to page 7-16 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 EAU1068B 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 From the “LOCK” position, push the EAU4939B Indicator lights and warning key in and turn it to “OFF”. lights 1. Engine trouble warning light “ ” 2. Fuel level warning light “ ” 3. Neutral indicator light “ ”...
” 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 EAU1234M 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 EAU12822 Clutch lever When the dimmer switch is set to “ ”, the passing switch has no effect. EAU12401 Dimmer switch “ ” Set this switch to “ ” for the high beam and to “ ”...
Instrument and control functions EAU12872 EAU12892 Shift pedal Brake lever 1. Shift pedal 1. Brake lever The shift pedal is located on the left The brake lever is located on the right side of the motorcycle and is used in side of the handlebar.
Instrument and control functions EAU12944 EAU13125 Brake pedal Fuel tank cap To remove the fuel tank cap 1. Brake pedal The brake pedal is located on the right 1. Unlock. side of the motorcycle. To apply the 2. Fuel tank cap lock cover rear brake, press down on the brake Slide the fuel tank cap lock cover open, pedal.
Instrument and control functions EAU13222 Fuel The fuel tank cap cannot be installed Make sure there is sufficient gasoline in unless the key is in the lock. In addition, the tank. the key cannot be removed if the cap is EWA10882 not properly installed and locked.
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Your Yamaha engine has been de- signed to use regular unleaded gaso- line with a pump octane number [(R+M)/2] of 86 or higher, or a research...
Instrument and control functions EAU61900 EAU13434 Fuel tank breather hose Catalytic converter This model is equipped with a catalytic converter in the exhaust system. EWA10863 WARNING The exhaust system is hot after op- eration. To prevent a fire hazard or burns: ...
Instrument and control functions EAU59491 EAU13651 Fuel cock Kickstarter The fuel cock regulates and filters the fuel supply from the fuel tank. The fuel cock has two positions: 1. 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- 1.
Instrument and control functions EAU13701 EAU13962 Decompression lever Seat To remove the seat Remove the bolts, and then pull the seat off. 1. Decompression lever When this lever is pulled, the exhaust valve is forced open so that the com- pression pressure can be reduced.
Instrument and control functions EAU14283 EAU14883 Helmet holder Adjusting the shock absorber assemblies EWA10211 WARNING Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. Each shock absorber assembly is equipped with a spring preload adjust- 1.
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.
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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:...
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• 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 4-14 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.
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Operation and important riding points shock of forced shifting. to downshift as necessary. 4. Once the motorcycle has stopped, the transmission can be shifted EAU16682 To start out and accelerate into the neutral position. The neu- 1. Pull the clutch lever to disengage tral indicator light should come on the clutch.
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.
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If you are not familiar with vehicle ser- vice, have a Yamaha dealer perform service. EWA15123 WARNING Turn off the engine when performing...
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU63292 Periodic maintenance chart for the emission control system ROUTINE...
Periodic maintenance and adjustment EAU63453 General maintenance and lubrication chart ROUTINE INITIAL ODOMETER READINGS 1000 mi ITEM 1000 km month Air filter element • Replace. Every 12000 mi (19000 km) • Check timing chain tensioner. ...
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Front and rear 25 * • Check operation. brake switches • Apply Yamaha cable lubricant or Control and meter 26 * other suitable cable lubricant cables thoroughly.
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Periodic maintenance and adjustment ROUTINE INITIAL ODOMETER READINGS 1000 mi ITEM 1000 km month • 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 EAU19683 Canister (for California) the specified torque. Tightening torque: Spark plug: 25 N·m (2.5 kgf·m, 18 lb·ft) If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight.
Periodic maintenance and adjustment EAU59626 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter ele- ment replaced at the intervals specified in the periodic maintenance and lubri- cation chart.
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Periodic maintenance and adjustment 1. Oil filter element cover bleed bolt 1. Engine oil drain bolt (oil tank) 2. Gasket 2. Gasket 3. Oil filter element drain bolt 4. Remove the engine oil drain bolt Skip steps 6–8 if the oil filter element is and its gasket to drain the oil from not being replaced.
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Periodic maintenance and adjustment Tightening torques: Engine oil drain bolt (crankcase): 30 N·m (3.0 kgf·m, 22 lb·ft) Engine oil drain bolt (oil tank): 16 N·m (1.6 kgf·m, 12 lb·ft) 12. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap.
2. Remove the air filter case cover by so it will not seize. If this occurs, removing the screws. have a Yamaha dealer repair the vehicle. After checking the oil pressure, tighten the bleed bolt to the specified torque.
[ECA10482] Check the engine idling speed and, if 5. Install the air filter case cover by in- necessary, have it corrected by a stalling the screws. Yamaha dealer. 6. Install the panel. Engine idling speed: 1200–1400 r/min 7-14...
Measure the throttle grip free play as and/or engine noise. To prevent this shown. from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. 1. Throttle grip free play Throttle grip free play: 3.0–5.0 mm (0.12–0.20 in)
The tires must be checked before each ride. If the tire shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer replace the tire immediately. 7-16...
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It is dangerous to ride with a model by Yamaha. worn-out tire. When a tire tread begins to show crosswise lines, Front tire: have a Yamaha dealer replace Size: the tire immediately. 90/100-18M/C 54S Manufacturer/model: The replacement of all wheel...
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 7-18...
Periodic maintenance and adjustment clutch mechanism. EAU48444 Adjusting the brake lever free play Measure the brake lever free play as shown. Brake lever free play: 5.0–8.0 mm (0.20–0.31 in) Periodically check the brake lever free play and, if necessary, adjust it as fol- lows.
EWA10671 presence of air in the hydraulic WARNING system. If there is air in the hy- It is advisable to have a Yamaha draulic system, have a Yamaha dealer make these adjustments. dealer bleed the system before operating the motorcycle. Air in...
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If proper adjustment cannot be Brake pedal free play 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.
Brake light switches 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. Rear brake light switch adjusting nut 2. Rear brake light switch...
2. Brake pad wear indicator groove point that the wear indicator reaches Each front brake pad is provided with the wear limit line, have a Yamaha wear indicator grooves, which allow dealer replace the brake shoes as a you to check the brake pad wear with- set.
If the brake 1. Minimum level mark fluid level goes down suddenly, have a Specified brake fluid: Yamaha dealer check the cause before DOT 4 further riding. EWA15991 WARNING Improper maintenance can result in loss of braking ability.
Periodic maintenance and adjustment EAU22724 EAU22762 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the The drive chain slack should be brake fluid at the intervals specified in checked before each ride and adjusted the periodic maintenance and lubrica- if necessary.
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Periodic maintenance and adjustment EAU59643 position for proper wheel alignment. To 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.
If a cable is damaged wet areas. Service the drive chain as or does not move smoothly, have a follows. Yamaha dealer check or replace it. ECA10584 WARNING! Damage to the outer NOTICE housing of cables may result in in-...
In addi- levers should be checked before each tion, the cable should be lubricated by a ride, and the lever pivots should be lu- Yamaha dealer at the intervals speci- bricated if necessary. fied in the periodic maintenance chart. Brake lever The throttle cable is equipped with a rubber cover.
Lithium-soap-based grease WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or re- pair it. Otherwise, the centerstand or sidestand could contact the ground and distract the operator, resulting in a possible loss of control.
1. Place the vehicle on a level sur- The swingarm pivots must be lubricat- face and hold it in an upright posi- ed by a Yamaha dealer at the intervals tion. WARNING! To avoid injury, specified in the periodic maintenance securely support the vehicle so and lubrication chart.
If there is play in the wheel ward and backward. If any free hub or if the wheel does not turn play can be felt, have a Yamaha smoothly, have a Yamaha dealer check dealer check or repair the steering.
KEEP THIS AND ALL BATTER- IES OUT OF THE REACH OF CHILDREN. To charge the battery Have a Yamaha dealer charge the bat- 1. Battery tery as soon as possible if it seems to have discharged. Keep in mind that the The battery is located under the seat.
Periodic maintenance and adjustment necting the coupler. EAU59444 [ECA16931] Replacing the fuses ECA16531 The main fuse is located inside the bat- NOTICE tery coupler. (See page 7-32.) Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. 1.
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9. Turn the key to “ON”. 1. Turn the key to “OFF” and turn off 10. If the fuse immediately blows the electrical circuit in question. again, have a Yamaha dealer 2. Remove the seat. (See page check the electrical system. 4-12.) The fuse box, which contains the fuses 3.
5. If a fuse immediately blows again, of the bulb, and the bulb life will have a Yamaha dealer check the be adversely affected. Thor- electrical system. oughly clean off any dirt and fin-...
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5. Install the headlight bulb cover, and then connect the coupler. 6. Install the headlight unit by install- ing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Screw 2. Disconnect the headlight coupler, and then remove the headlight bulb cover.
Periodic maintenance and adjustment EAU24135 EAU60010 Replacing the tail/brake light Replacing a turn signal light bulb bulb 1. Remove the tail/brake light lens by 1. Remove the turn signal light lens, removing the screws. turn signal light rim and gasket by removing the screws.
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 falling over. 1. Loosen the wheel axle nut. 1. Wheel axle nut 2.
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Periodic maintenance and adjustment Make sure that there is enough space between the brake pads before insert- ing the brake disc and that the slot in the speedometer gear unit fits over the retainer on the fork leg. 1. Speedometer cable 5.
Periodic maintenance and adjustment EAU25081 the brake rod from the brake cam- Rear wheel shaft lever. 5. Loosen the drive chain puller lock- EAU59615 nut and the drive chain slack ad- justing bolt on both ends of the swingarm. To remove the rear wheel EWA10822 WARNING To avoid injury, securely support the...
5. Install the brake rod onto the brake self. However, should your motorcycle camshaft lever, and then install the require any repair, take it to a Yamaha brake pedal free play adjusting nut dealer, whose skilled technicians have onto the brake rod.
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. 7-42...
Rust and corrosion can develop matte colored finished parts. Be even if high-quality components are sure to consult a Yamaha dealer for used. A rusty exhaust pipe may go un- advice on what products to use be- noticed on a car, however, it detracts fore cleaning the vehicle.
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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.
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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.
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Motorcycle care and storage storing the motorcycle.
These identification numbers are need- ed when registering the vehicle with the authorities in your area and when or- dering spare parts from a Yamaha dealer. 1. Vehicle identification number VEHICLE IDENTIFICATION...
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This information will be illustration. This label shows specifica- needed when ordering spare parts from tions related to exhaust emissions as a Yamaha dealer. required by federal law, state law and Environment Canada. EAU26382 Key identification number 1.
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and rem- edy campaign.
Consumer information EAU26561 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, re- pair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or ele- ment of design has been removed or rendered inoperative by any person.
Consumer information EAU63481 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your ve- hicle will be required to document that maintenance has been completed in accor- dance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required.
1. Operate and maintain the motorcycle as specified in the appropriate Owner’s Manual, and 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer’s place of business.
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CUSTOMER SERVICE If your machine requires warranty service, you must take it to any authorized Yamaha motorcycle dealer within the continental United States. Be sure to bring your warranty registration card or other valid proof of the original date of purchase. If a question or problem arises regarding the warranty, first contact the owner of the dealership.
• Y.E.S. is flexible. You choose the plan that’s right for you: 12 months, 24 months, 36 months or, on certain models, even 48 months beyond your warranty period. • Y.E.S. is designed and administered by the same Yamaha people who handle your warranty – and it shows in the comprehensive coverage benefits. There are no mileage limitations.
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Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your VIN number and we’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
Index Horn switch ..........4-5 Air filter element, replacing....7-13 Identification numbers......10-1 Ignition circuit cut-off system....4-15 Battery ...........7-32 Indicator lights and warning lights... 4-2 Brake and clutch levers, checking and lubricating..........7-28 Brake fluid, changing......7-25 Key identification number...... 10-2 Brake fluid level, checking.....7-24 Kickstarter ..........
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Index Tool kit ............ 7-2 Troubleshooting ........7-41 Troubleshooting chart ......7-42 Turn signal indicator light ......4-2 Turn signal light bulb, replacing .... 7-37 Turn signal switch ........4-5 Valve clearance ........7-15 Vehicle Emission Control Information label ............ 10-2 Vehicle identification number ....
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Genuine Yamaha Accessories – Yamaha only offers accessories that meet our high standards for quality and performance. Buy with confidence, knowing your Genuine Yamaha Accessories will fit right and perform right – right out of the box. Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products.
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PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2017.09-0.2×1 !
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