Yamaha SR400 2022 User manual

DIC183
SR400
1
2
3
4
5
6
7
8
9
10
11
B9F-28199-EY
Read this manual carefully
before operating this vehicle.
MOTORCYCLE
OWNER’S MANUAL
Specifications
Consumer information
Motorcycle care and storage
Periodic maintenance and adjustment
For your safety – pre-operation checks
Instrument and control functions
Description
Safety information
Location of important labels
Operation and important riding points
Index
[English (E)]

EAU93780
Readthis manual carefully before operatingthis vehicle. This manual shouldstay with this vehicle if it is sold.
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Introduction
EAU10103
Welcome to the Yamaha world of motorcycling!
As the owner of the SR400, you are benefiting from Yamaha’s vast experience and newest technology regarding the design
and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
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.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and
this manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
EWA10032
Please readthis manual carefully andcompletely before operatingthis motorcycle.
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Important manual information
EAU10134
Particularly important information is distinguished in this manual by the following notations:
*Product and specifications are subject to change without notice.
This is the safety alert symbol. It is usedto alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoidpossible injury
or death.
A WARNING indicates a hazardous situation which, if not avoided, couldresult in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoiddamage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
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Important manual information
EAU10202
SR400
OWNER’S MANUAL
©2022 by Yamaha Motor Co., Ltd.
1st edition, June 2021
All rights reserved.
Any reprintingor unauthorizeduse
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printedin Japan.
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Table of contents
Location of important labels ........... 1-1
Safety information............................ 2-1
Helmets .......................................... 2-5
Description ....................................... 3-1
Left view ......................................... 3-1
Right view....................................... 3-2
Controls and instruments ............... 3-3
Instrument andcontrol functions... 4-1
Immobilizer system......................... 4-1
Main switch/steering lock............... 4-2
Indicator lights and warning
lights............................................ 4-3
Speedometer unit........................... 4-4
Tachometer .................................... 4-5
Handlebar switches........................ 4-5
Clutch lever .................................... 4-6
Shift pedal ...................................... 4-7
Brake lever...................................... 4-7
Brake pedal .................................... 4-7
Fuel tank cap.................................. 4-8
Fuel................................................. 4-8
Catalytic converter ....................... 4-10
Fuel cock ...................................... 4-10
Kickstarter .................................... 4-11
Decompression lever.................... 4-11
Seat .............................................. 4-11
Helmet holder ............................... 4-12
Adjusting the shock absorber
assemblies.................................4-12
Luggage strap holders ..................4-13
Sidestand ......................................4-13
Ignition circuit cut-off system .......4-14
For your safety – pre-operation
checks ...............................................5-1
Operation andimportant riding
points .................................................6-1
Engine break-in...............................6-1
Starting the engine..........................6-2
Starting trouble ...............................6-2
Shifting ............................................6-3
Tips for reducing fuel
consumption................................6-5
Parking ............................................6-5
Periodic maintenance and
adjustment ........................................7-1
Tool kit ............................................7-2
Periodic maintenance chart for the
emission control system..............7-3
General maintenance and
lubrication chart...........................7-5
Removing and installing panels ......7-9
Checking the spark plug...............7-10
Canister.........................................7-12
Engine oil and oil filter element .....7-12
Why Yamalube..............................7-15
Air filter element............................ 7-15
Checking the engine idling
speed ........................................ 7-16
Checking the throttle grip free
play............................................ 7-16
Valve clearance............................. 7-17
Tires .............................................. 7-17
Spoke wheels ............................... 7-19
Adjusting the clutch lever free
play............................................ 7-19
Adjusting the brake lever free
play............................................ 7-20
Adjusting the brake pedal height
and free play.............................. 7-20
Checking the shift pedal............... 7-22
Brake light switches ..................... 7-22
Checking the front brake pads
and rear brake shoes ............... 7-23
Checking the brake fluid level ...... 7-23
Changing the brake fluid ............. 7-24
Drive chain slack........................... 7-25
Cleaning and lubricating the drive
chain.......................................... 7-26
Checking and lubricating the
cables........................................ 7-27
Checking and lubricating the
throttle grip and cable............... 7-27
Checking and lubricating the
brake and clutch levers ............. 7-28
Checking and lubricating the
brake pedal ............................... 7-28
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Table of contents
Checking and lubricating the
centerstand and sidestand ........7-29
Lubricating the swingarm pivots ...7-29
Checking the front fork..................7-30
Checking the steering ...................7-30
Checking the wheel bearings ........7-31
Battery...........................................7-31
Replacing the fuses.......................7-32
Replacing the headlight bulb.........7-34
Replacing the brake/tail light
bulb ............................................7-35
Replacing a turn signal light
bulb ............................................7-36
Front wheel....................................7-37
Rear wheel.....................................7-39
Troubleshooting ............................7-40
Troubleshooting chart ...................7-42
Motorcycle care andstorage..........8-1
Matte color caution .........................8-1
Care.................................................8-1
Storage............................................8-3
Specifications....................................9-1
Consumer information ...................10-1
Identification numbers...................10-1
Diagnostic connector ....................10-2
Vehicle data recording ..................10-2
Index ................................................11-1
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Location of important labels
1-1
1
EAU10385
Read and understand all of the labels on your vehicle. They contain important information 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.
1 2
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Location of important labels
1-2
1
B27-2117B-03
B27-21668-01
21
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2-1
2
Safety information
EAU1028C
Be a Responsible Owner
As the vehicle’s owner, you are re-
sponsible for the safe and proper oper-
ation of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements be-
fore riding this motorcycle.
He or she should:
Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
Obtain qualified training in safe
and proper riding techniques.
Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
Never operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks
each time you use the vehicle to make
sure it is in safe operating condition.
Failure to inspect or maintain the vehi-
cle properly increases the possibility of
an accident or equipment damage.
See page 5-1 for a list of pre-operation
checks.
This motorcycle is designed to
carry the operator and a passen-
ger.
The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap-
pears to be very effective in reduc-
ing the chance of this type of
accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
• Never maintain a motorcycle
without proper knowledge.
Contact an authorized motorcy-
cle dealer to inform you on ba-
sic motorcycle maintenance.
Certain maintenance can only
be carried out by certified staff.
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Safety information
2-2
2
Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
• Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified oper-
ators.
• Know your skills and limits.
Staying within your limits may
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
operator. A typical error made by
the operator is veering wide on a
turn due to excessive speed or un-
dercornering (insufficient lean an-
gle for the speed).
• Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic condi-
tions.
• 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 pre-
vention 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 abra-
sions 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.
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Safety information
2-3
2
AvoidCarbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, 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
hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident, use
extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloadedvehicle
couldcause an accident.
When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle
as possible and make sure to dis-
tribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
Maximum load:
150 kg (331 lb)
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Safety information
2-4
2
tents, can create unstable han-
dling or a slow steering re-
sponse.
This vehicle is not designedto
pull a trailer or to be attachedto
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
Never install accessories or carry
cargo that would impair the per-
formance of your motorcycle.
Carefully inspect the accessory
before using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension travel,
steering travel or control opera-
tion, or obscure lights or reflec-
tors.
• Accessories fitted to the han-
dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
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Safety information
2-5
2
operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires andRims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. See page 7-17
for tire specifications and for informa-
tion on servicing and replacing your
tires.
Transportingthe 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.
Shift the transmission into gear
(for models with a manual trans-
mission).
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 location 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 exces-
sively during transport.
EAUU0033
Helmets
Operating this vehicle without an ap-
proved motorcycle helmet increases
your chances of a severe head injury or
death in the event of an accident. The
majority of fatalities from motorcycle or
scooter accidents are the result of
head injuries. The use of a safety hel-
met is the single most critical factor in
the prevention or reduction of head in-
juries.
Always select an approvedmotorcy-
cle helmet
Pay attention to the following when
choosing a motorcycle helmet.
The helmet must meet the safety
standard “TIS”.
The helmet size must match the
size of the rider’s head.
Never subject a helmet to heavy
shocks.
Wearingthe helmet correctly
Always connect the chin strap. In the
case of an accident, the helmet has a
much less chance of coming off if the
chin strap is connected.
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Safety information
2-6
2
Correct usage
Wrongusage
Types of helmets andtheir usage
Half-type: use only for riding at low
speeds
Full-type: use only for riding at low
to mid-range speeds
Full-face-type: use for riding at
mid-range to high speeds
ZAUU0003
ZAUU0007
ZAUU0004
ZAUU0005
ZAUU0006
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Description
3-1
3
EAU10411
Left view
467 8531,2
910
1. Engine oil dipstick (page 7-12)
2. Engine oil filler cap (page 7-12)
3. Fuel tank cap (page 4-8)
4. Fuel cock (page 4-10)
5. Battery (page 7-31)
6. Fuses (page 7-32)
7. Helmet holder (page 4-12)
8. Luggage strap holder (page 4-13)
9. Spring preload adjuster (page 4-12)
10.Shift pedal (page 4-7)
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Description
3-2
3
EAU10421
Right view
23 5
67
41
8
1. Luggage strap holder (page 4-13)
2. Air filter element (page 7-15)
3. Kickstarter (page 4-11)
4. Kick indicator (page 6-2)
5. Headlight (page 7-34)
6. Brake pedal (page 4-7)
7. Tool kit (page 7-2)
8. Spring preload adjuster (page 4-12)
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Description
3-3
3
EAU10431
Controls andinstruments
12 345 78
9
6
10
1. Clutch lever (page 4-6)
2. Left handlebar switches (page 4-5)
3. Speedometer unit (page 4-4)
4. Main switch/steering lock (page 4-2)
5. Tachometer (page 4-5)
6. Front brake fluid reservoir (page 7-23)
7. Right handlebar switches (page 4-5)
8. Brake lever (page 4-7)
9. Throttle grip (page 7-16)
10.Decompression lever (page 4-11)
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Instrument andcontrol functions
4-1
4
EAU1097B
Immobilizer system
This vehicle is equipped with an immo-
bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol-
lowing:
a code re-registering key
two standard keys
a transponder (in each key)
an immobilizer unit (on the vehicle)
an ECU (on the vehicle)
a system indicator light (page 4-4)
About the keys
The code re-registering key is used to
register codes in each standard key.
Store the code re-registering key in a
safe place. Use a standard key for daily
operation.
When key replacement or re-register-
ing is necessary, bring the vehicle and
the code re-registering key along with
any remaining standard keys to a
Yamaha dealer to have them re-regis-
tered.
TIP
Keep the standard keys as well as
keys of other immobilizer systems
away from the code re-registering
key.
Keep other immobilizer system
keys away from the main switch
as they may cause signal interfer-
ence.
NOTICE
ECA11823
DO NOT LOSE THE CODE RE-REG-
ISTERING KEY! CONTACT YOUR
DEALER IMMEDIATELY IF IT IS
LOST! If the code re-registeringkey
is lost, the existingstandardkeys
can still be usedto start the vehicle.
However, registeringa new stan-
dardkey is impossible. If all keys
have been lost or damaged, the en-
tire immobilizer system must be re-
placed. Therefore, handle the keys
carefully.
Do not submerse in water.
Do not expose to high tempera-
tures.
Do not place near magnets.
Do not place near items that
transmit electrical signals.
Do not handle roughly.
Do not grindor alter.
Do not disassemble.
Do not put two keys of any im-
mobilizer system on the same
key ring.
1. Code re-registering key (red bow)
2. Standard keys (black bow)
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Instrument andcontrol functions
4-2
4
EAU10474
Main switch/steeringlock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
TIP
Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-
registering.
EAU85041
ON
All electrical circuits are supplied with
power and the vehicle lights are turned
on. The engine can be started. The key
cannot be removed.
TIP
To prevent battery discharge, do
not leave the key in the “ON” posi-
tion without the engine running.
The headlight comes on automat-
ically when the engine is started.
EAU10662
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10062
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switchedoff, which may result in
loss of control or an accident.
EAU73800
LOCK
The steering is locked and all electrical
systems are off. The key can be re-
moved.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. With the key in the “OFF” position,
push the key in and turn it to
“LOCK”.
3. Remove the key.
ON
OFF
LOCK
1. Push.
2. Turn.
12
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