2014-2015 Yamaha SR400 Motorcycle Service & Repair Manual

2014-2015 SERVICE MANUAL SR400F SR400FC LIT-11616-28-01 2RD-28197-10

EAS20050 SR400F SR400FC SERVICE MANUAL ©2014 by Yamaha Motor Corporation, U.S.A. First edition, March 2014 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-28-01

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 manual. 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 vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. 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 • This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. • 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 disassembly 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. 3 6 1 5 2 7 4

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. G M BF B T R . . LS M S F E LT S 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

1 2 3 4 5 6 7 8 9 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. 1 1

2014-2015 Yamaha SR400 Motorcycle Service & Repair Manual

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