Yamaha SR400 2014 User manual

2014

SERVICE MANUAL

SR400

SR400E

2RD-28197-E0

EAS20040

SR400

SR400E

SERVICE MANUAL

First edition, November 2013

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EAS20071

IMPORTANT

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-

ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles

should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-

cle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and

will appear in future editions of this manual where applicable.

TIP

Designs and specifications are subject to change without notice.

EAS20081

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential per-

sonal injury hazards. Obey all safety messages that follow this symbol

to avoid possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid

damage to the vehicle or other property.

A TIP provides key information to make procedures easier or clearer.

WARNING

NOTICE

TIP

EAS20091

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid

out with the individual steps in sequential order.

•The manual is divided into chapters and each chapter is divided into sections. The current section title

“1” is shown at the top of each page.

•Sub-section titles “2” appear in smaller print than the section title.

•To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each

removal and disassembly section.

•Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-

sembly step.

•Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

•A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation

and assembly procedure, reverse the steps.

•Jobs “7” requiring more information (such as special tools and technical data) are described sequen-

tially.

EAS20101

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool Wheel bearing grease

Tightening torque Lithium-soap-based grease

Wear limit, clearance Molybdenum disulfide grease

Engine speed Silicone grease

Electrical data YAMAHA GREASE “F”

Engine oil Apply locking agent (LOCTITE®).

Silicone fluid Replace the part with a new one.

New

GENERAL INFORMATION 1

SPECIFICATIONS 2

PERIODIC CHECKS AND

ADJUSTMENTS 3

CHASSIS 4

ENGINE 5

FUEL SYSTEM 6

ELECTRICAL SYSTEM 7

TROUBLESHOOTING 8

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

IDENTIFICATION .............................................................................................1-1

VEHICLE IDENTIFICATION NUMBER ......................................................1-1

MODEL LABEL...........................................................................................1-1

FEATURES.......................................................................................................1-2

OUTLINE OF THE FI SYSTEM..................................................................1-2

FI SYSTEM.................................................................................................1-3

FUEL LINE CHART ....................................................................................1-4

IMPORTANT INFORMATION ..........................................................................1-5

PREPARATION FOR REMOVAL AND DISASSEMBLY............................1-5

REPLACEMENT PARTS............................................................................1-5

GASKETS, OIL SEALS AND O-RINGS .....................................................1-5

LOCK WASHERS/PLATES AND COTTER PINS ......................................1-5

BEARINGS AND OIL SEALS .....................................................................1-5

CIRCLIPS ...................................................................................................1-6

RUBBER PARTS........................................................................................1-6

BASIC SERVICE INFORMATION....................................................................1-7

QUICK FASTENERS..................................................................................1-7

ELECTRICAL SYSTEM..............................................................................1-7

SPECIAL TOOLS ...........................................................................................1-12

IDENTIFICATION

1-1

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped

into the right side of the steering head pipe.

EAS20150

MODEL LABEL

The model label “1” is affixed to the frame under

the rider seat. This information will be needed to

order spare parts.

This manual suits for next models

Table of contents

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