2015 SR 400 service manual

Tài liệu về kỹ thuật sữa chữa xe phân khối lớn Yamaha SR400 đời 2015. Các đời xe cũ hơn cũng có thể tham khảo. Phiên bản 2015 trở đi, SR400 được nâng cấp với phanh đĩa đơn bánh trước, hệ thống phun xăng điện tử cho động cơ 399 phân khối và được bán sang thị trường Mỹ. Tuy nhiên, xe không có nút khởi động điện mà phải khởi động bằng cần đạp truyền thống, đây cũng là nét đặc trưng “chất” riêng của SR400.

2015 SERVICE MANUAL

SR400F SR400FC

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

This manual was produced by the Yamaha Motor Company, Ltd primarily for use by Yamaha dealersand 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 vehiclesshould 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

This model has been designed and manufactured to perform within certain specifications in regard toperformance and emissions Proper service with the correct tools is necessary to ensure that the vehi-cle will operate as designed If there is any question about a service procedure, it is imperative that youcontact a Yamaha dealer for any service information changes that apply to this model This policy isintended to provide the customer with the most satisfaction from his vehicle and to conform to federalenvironmental quality objectives

Yamaha Motor Company, Ltd is continually striving to improve all of its models Modifications and nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable

sig-TIP

• This Service Manual contains information regarding periodic maintenance to the emission control

sys-tem 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 sonal injury hazards Obey all safety messages that follow this symbol

per-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

HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout 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 installationand 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

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

1 2 3 4 5 6 7 8 9

GASKETS, OIL SEALS AND O-RINGS 1-5

LOCK WASHERS/PLATES AND COTTER PINS 1-5

BEARINGS AND OIL SEALS 1-5

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

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimumair-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature Inthe conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in therespective carburetor

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating ditions, such as acceleration, deceleration, or operating under a heavy load Carburetors that meter thefuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-gine

con-As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,

it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner To modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place

accom-of the conventional carburetor system This system can achieve an optimum air-fuel ratio required bythe engine at all times by using a microprocessor that regulates the fuel injection volume according tothe engine operating conditions detected by various sensors

The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,better fuel economy, and reduced exhaust emissions

3 Engine temperature sensor

4 ISC (idle speed control) valve

5 Fuel injector

6 Throttle position sensor

7 ECU (engine control unit)

8 Battery

9 Lean angle sensor

10.Fuel pump

11.Catalytic converter

12.Intake air temperature sensor

13.Air induction system solenoid

14.Intake air pressure sensor 15.Crankshaft position sensor 16.Spark plug

Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater thevolume of fuel that is supplied Conversely, the shorter the length of time the fuel injector is energized(injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU Signals that are input from thethrottle position sensor, ISC (idle speed control) valve, engine temperature sensor, lean angle sensor,crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, speed sensor and

O2 sensor enable the ECU to determine the injection duration The injection timing is determinedthrough the signals from the crankshaft position sensor As a result, the volume of fuel that is required

by the engine can be supplied at all times in accordance with the driving conditions

Illustration is for reference only.

1

B

13 12

11

10 A

4

6 7 16

9 15

14

3

1 Fuel pump

2 Fuel injector

3 ECU (engine control unit)

4 Throttle position sensor

5 Lean angle sensor

6 ISC (idle speed control) valve

7 Speed sensor

9 Catalytic converter

10.Engine temperature sensor

11.Crankshaft position sensor

12.Intake air pressure sensor

5 6

1 Before removal and disassembly, remove all

dirt, mud, dust and foreign material

2 Use only the proper tools and cleaning

equip-ment

Refer to “SPECIAL TOOLS” on page 1-12

3 When disassembling, always keep mated

parts together This includes gears, cylinders,

pistons and other parts that have been

“mat-ed” through normal wear Mated parts must

always be reused or replaced as an

assem-bly

4 During disassembly, clean all of the parts and

place them in trays in the order of

disassem-bly This will speed up assembly and allow for

the correct installation of all parts

5 Keep all parts away from any source of fire

EAS20200

REPLACEMENT PARTS

Use only genuine Yamaha parts for all

replace-ments Use oil and grease recommended by

Yamaha for all lubrication jobs Other brands

may be similar in function and appearance, but

inferior in quality

EAS20210

GASKETS, OIL SEALS AND O-RINGS

1 When overhauling the engine, replace allgaskets, seals and O-rings All gasket surfac-

es, oil seal lips and O-rings must be cleaned

2 During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease

EAS20220

LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates

“1” and cotter pins After the bolt or nut has beentightened to specification, bend the lock tabsalong a flat of the bolt or nut

EAS20231

BEARINGS AND OIL SEALS

Install bearings “1” and oil seals “2” so that the

1 Oil

2 Lip

3 Spring

4 Grease

IMPORTANT INFORMATION

1-6

manufacturer marks or numbers are visible

When installing oil seals, lubricate the oil seal

lips with a light coat of lithium-soap-based

grease Oil bearings liberally when installing, if

appropriate

NOTICE

ECA13300

Do not spin the bearing with compressed air

because this will damage the bearing

surfac-es.

EAS20240

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips

Al-ways replace piston pin clips after one use

When installing a circlip “1”, make sure the

sharp-edged corner “2” is positioned opposite

the thrust “3” that the circlip receives

EAS32080

RUBBER PARTS

Check rubber parts for deterioration during

in-spection Some of the rubber parts are sensitive

to gasoline, flammable oil, grease, etc Do not

al-low any items other than the specified one tocontact the parts

BASIC SERVICE INFORMATION

To remove the quick fastener, push its pin with a

screwdriver, then pull the fastener out

2 Install:

• Quick fastener

TIP

To install the quick fastener, push its pin so that

it protrudes from the fastener head, then insert

the fastener into the part to be secured and push

the pin “a” in with a screwdriver Make sure that

the pin is flush with the fastener’s head

Screw type

1 Remove:

• Quick fastener

TIP

To remove the quick fastener, loosen the screw

with a screwdriver, then pull the fastener out

2 Install:

• Quick fastener TIP

To install the quick fastener, insert the fastenerinto the part to be secured and tighten the screw

“a”

EAS30401

ELECTRICAL SYSTEM Electrical parts handling

NOTICE

ECA16600

Never disconnect a battery lead while the gine is running; otherwise, the electrical components could be damaged.

en-NOTICE

ECA16750

When disconnecting the battery leads from

BASIC SERVICE INFORMATION

1-8

the battery, be sure to disconnect the

nega-tive battery lead first, then the posinega-tive

bat-tery lead If a tool or similar item contacts the

vehicle while only the negative battery lead

is connected, a spark could be generated,

which is extremely dangerous.

TIP

If a battery lead is difficult to disconnect due to

rust on the battery terminal, remove the rust

us-ing hot water

NOTICE

ECA16760

Be sure to connect the battery leads to the

correct battery terminals Reversing the

bat-tery lead connections could damage the

electrical components.

NOTICE

ECA16770

When connecting the battery leads to the

battery, be sure to connect the positive

bat-tery lead first, then the negative batbat-tery lead.

If a tool or similar item contacts the vehicle

while only the negative battery lead is nected, a spark could be generated, which is extremely dangerous.

con-NOTICE

ECA16610

Turn the main switch to “OFF” before connecting or connecting an electrical com- ponent.

dis-NOTICE

ECA16620

Handle electrical components with special care, and do not subject them to strong shocks.

NOTICE

ECA16630

Electrical components are very sensitive to and can be damaged by static electricity Therefore, never touch the terminals and be sure to keep the contacts clean.

BASIC SERVICE INFORMATION

1-9

TIP

When resetting the ECU by turning the main

switch to “OFF”, be sure to wait approximately

5 seconds before turning the main switch back

to “ON”

Checking the electrical system

TIP

Before checking the electrical system, make

sure that the battery voltage is at least 12 V

NOTICE

ECA14371

Never insert the tester probes into the

cou-pler terminal slots Always insert the probes

from the opposite end “a” of the coupler,

tak-ing care not to loosen or damage the leads.

NOTICE

ECA16640

For waterproof couplers, never insert the tester probes directly into the coupler When performing any checks using a waterproof coupler, use the specified test harness or a suitable commercially available test har- ness.

Checking the connections

Check the leads, couplers, and connectors forstains, rust, moisture, etc

• There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler.

a

BASIC SERVICE INFORMATION

1-10

NOTICE

ECA16790

When disconnecting a connector, do not pull

the leads Hold both sections of the

connec-tor securely, and then disconnect the

Moisture  Dry with an air blower

Rust/stains  Connect and disconnect

• When connecting a coupler or connector, push

both sections of the coupler or connector

to-gether until they are connected securely

• Make sure all connections are tight.

4 Check:

• Continuity

(with the pocket tester)

TIP

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3)

• As a quick remedy, use a contact revitalizer

available at most part stores

Pocket tester 90890-03112 Analog pocket tester YU-03112-C

BASIC SERVICE INFORMATION

1-11

5 Check:

• Resistance

TIP

The resistance values shown were obtained at

the standard measuring temperature of 20 C

(68 F) If the measuring temperature is not 20

C (68 F), the specified measuring conditions

• For U.S.A and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.

• For others, use part number starting with “90890-”.

Tool name/Tool No Illustration Reference

ø3 ø4 YM-A5970

1 2 3 4 5 6 7 8 9

GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-12

ENGINE TIGHTENING TORQUES 2-13

CHASSIS TIGHTENING TORQUES 2-16

LUBRICATION POINTS AND LUBRICANT TYPES 2-20

ENGINE 2-20

CHASSIS 2-21

LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23

ENGINE OIL LUBRICATION CHART 2-23

LUBRICATION DIAGRAMS 2-25

CABLE ROUTING 2-33

Weight

Standard compression pressure (at sea level) 1050 kPa/700 r/min (10.5 kgf/cm²/700 r/min,

149.3 psi/700 r/min)

r/min, 129.4–167.8 psi/700 r/min)

Fuel

ac-ceptable)

Engine oil

20W-40 or 20W-50 Recommended engine oil grade API service SG type or higher, JASO standard

MA

Engine oil quantity

Without oil filter element replacement 2.00 L (2.11 US qt, 1.76 Imp.qt)

With oil filter element replacement 2.10 L (2.22 US qt, 1.85 Imp.qt)

Oil filter

Oil pump

Inner-rotor-to-outer-rotor-tip clearance 0.070–0.120 mm (0.0028–0.0047 in)

Camshaft

ENGINE SPECIFICATIONS

2-3

Camshaft lobe dimensions

Rocker arm/rocker arm shaft

Rocker arm shaft outside diameter 11.985–11.991 mm (0.4718–0.4721 in)

Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.033 mm (0.0004–0.0013 in)

Valve, valve seat, valve guide

Valve clearance (cold)

Valve dimensions

Valve seat contact width (intake) 1.30 mm (0.0512 in)

ENGINE SPECIFICATIONS

2-4

Installed compression spring force (intake) 119.64 N (12.20 kgf, 26.90 lbf)

Installed compression spring force (exhaust) 119.64 N (12.20 kgf, 26.90 lbf)

Installed compression spring force (intake) 160.83 N (16.40 kgf, 36.15 lbf)

Installed compression spring force (exhaust) 160.83 N (16.40 kgf, 36.15 lbf)

Cylinder

Piston

Measuring point (from piston skirt bottom) 7.2 mm (0.28 in)

Piston pin bore inside diameter 20.004–20.015 mm (0.7876–0.7880 in)

2nd ring

Transmission

Shifting mechanism

Fuel line pressure at idling 310–360 kPa (3.1–3.6 kgf/cm², 45.0–52.2 psi) /

Regulated pressure 329 kPa (3.3 kgf/cm², 47.7 psi)

Air induction system

Rear wheel

Tire air pressure (measured on cold tires)

Front brake

Front disc brake

Disc outside diameter  thickness 298.0  5.0 mm (11.73  0.20 in)

Brake disc runout limit (as measured on

wheel)

0.15 mm (0.0059 in)Brake pad lining thickness (inner) 6.2 mm (0.24 in)

CHASSIS SPECIFICATIONS

2-8

Brake pad lining thickness (outer) 6.2 mm (0.24 in)

Rear brake

Rear drum brake

Front suspension

Rear suspension

Rear shock absorber assembly travel 80.0 mm (3.15 in)

Spring preload adjusting positions

CHASSIS SPECIFICATIONS

2-9

Swingarm

Swingarm end free play limit (radial) 1.0 mm (0.04 in)

Swingarm end free play limit (axial) 0.5 mm (0.02 in)

Drive chain

Engine control unit

Ignition coil

Spark plug cap

Bulb voltage, wattage  quantity

Front turn signal/position light 12 V, 27.0 W/8.0 W  2

Indicator light

Turn signal relay

Fuel sender unit

Sender unit resistance (thermistor) 1350–1900 @25 C (1350–1900 @77 F)

Fuel injection sensor

Crankshaft position sensor resistance 192–288 

Intake air pressure sensor output voltage 1.20–4.20 V

Intake air temperature sensor resistance 290–390 @80 C (290–390 @176 F) Engine temperature sensor resistance 210–220 @100 C (210–220 @212 F)

This chart specifies tightening torques for

stan-dard fasteners with a stanstan-dard ISO thread pitch

Tightening torque specifications for special

com-ponents or assemblies are provided for each

chapter of this manual To avoid warpage,

tight-en multi-fasttight-ener assemblies in a crisscross

pat-tern and progressive stages until the specified

tightening torque is reached Unless otherwise

specified, tightening torque specifications

re-quire clean, dry threads Components should be

at room temperature

A Distance between flats

B Outside thread diameter

A (nut) B

(bolt)

General tightening torques

size Q’ty Tightening torque Remarks

Exhaust tappet cover bolt (right

Cylinder head nut (cap nut) M10 1 38 Nm (3.8 m·kgf, 27 ft·lbf)

Cylinder head stud bolt (around

Height 136.8–139.3 mm (5.39–5.48 in)

Cylinder head stud bolt (right

Height 119.8–122.3 mm (4.72–4.81 in)

Cylinder head stud bolt: Short M10 1 18 Nm (1.8 m·kgf, 13 ft·lbf)

Height 39.8–42.3 mm (1.57–1.67 in)

Tighten two times.Valve clearance adjuster locknut M8 2 27 Nm (2.7 m·kgf, 20 ft·lbf)

Timing chain tensioner locknut M18 1 38 Nm (3.8 m·kgf, 27 ft·lbf)

LT

E

E

E