Yamaha 2007 R6 Service

							ENGINE
3-18
f. Repeat steps (2) and (3).
         
5. Install:
EXUP valve pulley cover
EAS21110
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
Make sure the vehicle is upright.
2. Check:
Coolant level
The coolant level should be between the 
maximum level mark “a” and minimum level 
mark “b”.
Below the minimum level mark → Remove 
the coolant reservoir cap, add the recom-
mended coolant to the proper level.
NOTE:
To access the coolant reservoir cap, remove the 
right side panel. Refer to “GENERAL CHASSIS” 
on page 4-1.
CAUTION:
ECA13470
Adding water instead of coolant lowers the 
antifreeze content of the coolant. If water is 
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
Use only distilled water. However, if dis-
tilled water is not available, soft water may 
be used.3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Check:
Coolant level
NOTE:
Before checking the coolant level, wait a few 
minutes until it settles.
EAS21120
CHECKING THE COOLING SYSTEM
1. Remove:
Side cowlings
Bottom cowlings
Refer to “GENERAL CHASSIS” on page 4-1.
Exhaust pipe assembly
Refer to “ENGINE REMOVAL” on page 5-1.
2. Check:
Radiator “1”
Radiator inlet hose “2”
Radiator inlet pipe “3”
Thermostat outlet hose “4”
Radiator outlet hose “5”
Radiator outlet pipe “6”
Oil cooler “7”
Oil cooler outlet hose “8”
Oil cooler inlet hose “9”
Water pump outlet hose “10”
Water pump inlet hose
Water pump outlet pipe “11”
Water jacket joint inlet hose “12”
Water jacket joint “13”
Cracks/damage → Replace.
Refer to “RADIATOR” on page 6-1 and “OIL 
COOLER” on page 6-4.
T R.. 
EXUP valve pulley cover bolt 
(front side)
8 Nm (0.8 m·kg, 5.8 ft·lb)
EXUP valve pulley cover bolt 
(rear side)
7 Nm (0.7 m·kg, 5.1 ft·lb)
a
b
a
b
1
3
24 c
d
a
b 
						

							ENGINE
3-19
3. Install:
Exhaust pipe assembly
Refer to “ENGINE REMOVAL” on page 5-1.
Bottom cowlings
Side cowlings
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21130
CHANGING THE COOLANT
1. Remove:
Right side panel
Right upper side cowling
Right lower side cowling
Right bottom cowling
Refer to “GENERAL CHASSIS” on page 4-1.
2. Remove:
Radiator cap “1”
WARNING
EWA13030
A hot radiator is under pressure. Therefore, 
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in-
jury. When the engine has cooled, open the 
radiator cap as follows:
Place a thick rag or a towel over the radiator 
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing 
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
3. Remove:
Coolant drain bolt (water pump) “1”
(along with the copper washer)
4. Disconnect:
Water pump inlet hose “2”
5. Drain:
Coolant
(from the engine and radiator)
6. Remove:
Coolant reservoir “1”
Coolant reservoir cap “2”
7. Drain:
Coolant
(from the coolant reservoir)
3 5
4
6
1 2
13
12
10
11
9
7 8
1
12
2
1 
						

							ENGINE
3-20
8. Install:
Coolant reservoir
9. Connect:
Water pump inlet hose
10.Install:
Coolant drain bolt (water pump)
(along with the copper washer  )
11.Fill:
Cooling system
(with the specified amount of the recom-
mended coolant)
Handling notes for coolant
Coolant is potentially harmful and should be 
handled with special care.
WARNING
EWA13040
If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
If coolant splashes on your clothes, quickly 
wash it away with water and then with soap 
and water.
If coolant is swallowed, induce vomiting 
and get immediate medical attention.
CAUTION:
ECA13480
Adding water instead of coolant lowers the 
antifreeze content of the coolant. If water is 
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
Use only distilled water. However, if dis-
tilled water is not available, soft water may 
be used.If coolant comes into contact with painted 
surfaces, immediately wash them with wa-
ter.
Do not mix different types of antifreeze.
12.Install:
Radiator cap
13.Fill:
Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)
14.Install:
Coolant reservoir cap
15.Start the engine, warm it up for several min-
utes, and then stop it.
16.Check:
Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-18.
NOTE:
Before checking the coolant level, wait a few 
minutes until the coolant has settled.
17.Install:
Right bottom cowling
Right lower side cowling
Right upper side cowling
Right side panel
Refer to “GENERAL CHASSIS” on page 4-1.
T R.. 
Coolant drain bolt (water pump)
10 Nm (1.0 m·kg, 7.2 ft·lb)
 
Recommended antifreeze
High-quality ethylene glycol anti-
freeze containing corrosion in-
hibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Radiator capacity (including all 
routes)
2.30 L (2.43 US qt) (2.02 Imp.qt)
Coolant reservoir capacity (up 
to the maximum level mark)
0.25 L (0.26 US qt) (0.22 Imp.qt)
New
a 
						

							CHASSIS
3-21
EAS21140
CHASSIS
EAS21150
ADJUSTING THE FRONT DISC BRAKE
1. Adjust:
Brake lever position
(distance “a” from the throttle grip to the brake 
lever)



 
 
 








 
 



 
 



 
 







a. Push the brake lever forward.
b. Turn the adjusting knob “1” in direction “a” or 
“b” until the brake lever is in the desired posi-
tion.
c. Align the mark “c” on the adjusting knob with 
the mark “d” on the brake lever.
WARNING
EWA13050
A soft or spongy feeling in the brake lever 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance.
CAUTION:
ECA13490
After adjusting the brake lever position, 
make sure there is no brake drag.
          
EAS21190
ADJUSTING THE REAR DISC BRAKE
1. Adjust:
Brake pedal position



 
 
 








 
 



 
 



 
 



 



a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or 
“b” until the specified brake pedal position is 
obtained.
WARNING
EWA13070
After adjusting the brake pedal position, 
check that the end of the adjusting bolt “c” is 
visible through the hole “d”.
c. Tighten the locknut “1” to specification.
WARNING
EW2C01004
A soft or spongy feeling in the brake pedal 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid-
erably reduce braking performance and 
could result in loss of control and possibly 
an accident. Therefore, check and, if neces-
sary, bleed the brake system. Direction “a”
Brake lever distance is increased.
Direction “b”
Brake lever distance is decreased.
a
1
d
ba
c
Direction “a”
Brake pedal is raised.
Direction “b”
Brake pedal is lowered.
T R.. 
Locknut
16 Nm (1.6 m·kg, 11 ft·lb)
d 1
2
c
a
b 
						

							CHASSIS
3-22
CAUTION:
EC2C01009
After adjusting the installed rear master cyl-
inder length, make sure there is no brake 
drag.
         
2. Adjust:
Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE 
LIGHT SWITCH” on page 3-23.
EAS21240
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
Make sure the vehicle is upright.
2. Check:
Brake fluid level
Below the minimum level mark “a” → Add the 
recommended brake fluid to the proper level.
WARNING
EWA13090
Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance.
Refill with the same type of brake fluid that 
is already in the system. Mixing brake fluids 
may result in a harmful chemical reaction, 
leading to poor brake performance.
When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean up 
any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the brake 
fluid level, make sure the top of the brake fluid 
reservoir is horizontal.
EAS21250
CHECKING THE FRONT BRAKE PADS
The following procedure applies to all of the 
brake pads.
1. Operate the brake.
2. Check:
Front brake pad
Wear indicators “a” almost touch the brake 
disc → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-17.
EAS21260
CHECKING THE REAR BRAKE PADS
The following procedure applies to all of the 
brake pads.
 
Front brake
Recommended fluid
DOT 4
Rear brake
Recommended fluid
DOT 4
A. Front brake
B. Rear brake
a
A
a
B
a 
						

							CHASSIS
3-23
1. Operate the brake.
2. Check:
Rear brake pad
Wear limit “a” reached → Replace the brake 
pads as a set.
Refer to “REAR BRAKE” on page 4-29.
EAS21280
CHECKING THE FRONT BRAKE HOSES
The following procedure applies to all of the 
brake hoses and brake hose holders.
1. Check:
Brake hoses “1”
Cracks/damage/wear → Replace.
2. Check:
Brake hose holders “2”
Loose → Tighten the holder bolt.
3. Hold the vehicle upright and apply the brake 
several times.
4. Check:
Brake hoses
Brake fluid leakage → Replace the damaged 
hose.
Refer to “FRONT BRAKE” on page 4-17.
EAS21290
CHECKING THE REAR BRAKE HOSES
1. Check:
Brake hoses “1”
Cracks/damage/wear → Replace.2. Check:
Brake hose holders “2”
Loose connection → Connect.
3. Hold the vehicle upright and apply the brake 
several times.
4. Check:
Brake hoses
Brake fluid leakage → Replace the damaged 
hose.
Refer to “REAR BRAKE” on page 4-29.
EAS21330
ADJUSTING THE REAR BRAKE LIGHT 
SWITCH
NOTE:
The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light 
switch is properly adjusted when the brake light 
comes on just before the braking effect starts.
1. Check:
Rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
Rear brake light operation timing



 
 
 








 
 



 
 



 
 



 



a. Hold the main body “1” of the rear brake light 
switch so that it does not rotate and turn the 
adjusting nut “2” in direction “a” or “b” until the 
rear brake light comes on at the proper time.
 
Limit
1.0 mm (0.04 in)
a
1
1
2
2
1
Direction “a”
Brake light comes on sooner.
Direction “b”
Brake light comes on later.
1
2 2 
						

							CHASSIS
3-24
         
EAS21360
BLEEDING THE HYDRAULIC BRAKE 
SYSTEM
WARNING
EWA13100
Bleed the hydraulic brake system whenever:
the system is disassembled.
a brake hose is loosened, disconnected or 
replaced.
the brake fluid level is very low.
brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow 
the brake fluid reservoir to overflow.
When bleeding the hydraulic brake system, 
make sure there is always enough brake fluid 
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic 
brake system, considerably lengthening the 
bleeding procedure.
If bleeding is difficult, it may be necessary to let 
the brake fluid settle for a few hours. Repeat 
the bleeding procedure when the tiny bubbles 
in the hose have disappeared.
1. Bleed:
Hydraulic brake system



 
 
 








 
 



 
 



 
 







a. Fill the brake fluid reservoir to the proper level 
with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose “1” tightly to the 
bleed screw “2”.
NOTE:
The bleeding order of the front hydraulic brake 
system is the following:
1. Front brake master cylinder
2. Front brake calipers
3. Front brake master cylinder
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down 
the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the 
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the 
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air bub-
bles have disappeared from the brake fluid in 
the plastic hose.
j. Tighten the bleed screw to specification.
12
a
b
2
1
A
A. Front brake master cylinder
B. Front brake caliper
C. Rear brake caliper
2
1
B
2
1
C 
						

							CHASSIS
3-25
k. Fill the brake fluid reservoir to the proper level 
with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-22.
WARNING
EWA13110
After bleeding the hydraulic brake system, 
check the brake operation.
         
EAS21380
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined by the in-
stalled shift rod length “a”.
1. Remove:
Left lower side cowling
Refer to “GENERAL CHASSIS” on page 4-1.
2. Measure:
Installed shift rod length “a”
Incorrect → Adjust.
3. Adjust:
Installed shift rod length



 
 
 








 
 



 
 



 
 







a. Loosen both locknuts “1”.
b. Turn the shift rod “2” in direction “a” or “b” until 
the specified installed shift rod length is ob-
tained.c. Tighten both locknuts to specification.
d. Make sure the installed shift rod length is 
within specification.
          
4. Install:
Left lower side cowling
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21390
ADJUSTING THE DRIVE CHAIN SLACK
CAUTION:
ECA13550
A drive chain that is too tight will overload 
the engine and other vital parts, and one that 
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep 
the drive chain slack within the specified lim-
its.
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the 
rear wheel is elevated.
2. Check:
Drive chain slack “a”
Out of specification → Adjust.
T R.. 
Bleed screw (front brake master 
cylinder)
6 Nm (0.6 m·kg, 4.3 ft·lb)
Bleed screw (front brake caliper)
5 Nm (0.5 m·kg, 3.6 ft·lb)
Bleed screw (rear brake caliper)
5 Nm (0.5 m·kg, 3.6 ft·lb)
 
Installed shift rod length
267.2–269.2 mm (10.52–10.60 in)
a
Direction “a”
Installed shift rod length increases.
Direction “b”
Installed shift rod length decreases.
T R.. 
Locknut (shift rod upper side)
7 Nm (0.7 m·kg, 5.1 ft·lb)
Locknut (shift rod lower side)
10 Nm (1.0 m·kg, 7.2 ft·lb)
a
b
12 
						

							CHASSIS
3-26
NOTE:
Measure the drive chain slack halfway between 
the drive axle and the rear wheel axle.
3. Adjust:
Drive chain slack



 
 
 








 
 



 
 



 
 







a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn both adjusting bolts “3” in direction “a” or 
“b” until the specified drive chain slack is ob-
tained.
NOTE:
Using the alignment marks “4” on each side of 
the swingarm, make sure that both chain pullers 
are in the same position for proper wheel align-
ment.
d. Tighten the wheel axle nut to specification.
e. Tighten the drive chain adjusting bolts in di-
rection “a” to specification.f. Tighten the locknuts to specification.
          
EAS21440
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting 
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive 
chain should be serviced, especially when the 
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber 
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents, 
and the use of a coarse brush can damage 
these O-rings. Therefore, use only kerosene to 
clean the drive chain. Wipe the drive chain dry 
and thoroughly lubricate it with engine oil or 
chain lubricant that is suitable for O-ring chains. 
Do not use any other lubricants on the drive 
chain since they may contain solvents that could 
damage the O-rings.
EAS21500
CHECKING AND ADJUSTING THE 
STEERING HEAD
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the 
front wheel is elevated.
2. Check:
Steering head
Grasp the bottom of the front fork legs and 
gently rock the front fork.
Binding/looseness → Adjust the steering 
head.
3. Remove:
Upper bracket
Refer to “STEERING HEAD” on page 4-55.
 
Drive chain slack
35.0–45.0 mm (1.38–1.77 in)
Direction “a”
Drive chain is tightened.
Direction “b”
Drive chain is loosened.
T R.. 
Wheel axle nut
110 Nm (11.0 m·kg, 80 ft·lb)
a
1
432
a
b
T R.. 
Drive chain adjusting bolt
2 Nm (0.2 m·kg, 1.4 ft·lb)
T R.. 
Drive chain adjusting locknut
16 Nm (1.6 m·kg, 11 ft·lb)
 
Recommended lubricant
Engine oil or chain lubricant 
suitable for O-ring chains 
						

							CHASSIS
3-27
4. Adjust:
Steering head



 
 
 








 
 



 
 



 
 







a. Remove the lock washer “1”, upper ring nut 
“2”, and rubber washer “3”.
b. Loosen the lower ring nut “4” and then tighten 
it to specification with a steering nut wrench 
“5”.
NOTE:
Set the torque wrench at a right angle to the 
steering nut wrench.
c. Loosen the lower ring nut completely, then 
tighten it to specification.
WARNING
EWA13140
Do not overtighten the lower ring nut.d. Check the steering head for looseness or 
binding by turning the front fork all the way in 
both directions. If any binding is felt, remove 
the lower bracket and check the upper and 
lower bearings.
Refer to “STEERING HEAD” on page 4-55.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, then 
align the slots of both ring nuts. If necessary, 
hold the lower ring nut and tighten the upper 
ring nut until their slots are aligned.
h. Install the lock washer “1”.
NOTE:
Make sure the lock washer tabs “a” sit correctly 
in the ring nut slots “b”.
          
5. Install:
Upper bracket
Refer to “STEERING HEAD” on page 4-55.
6. Measure:
Steering head tension



 
 
 








 
 



 
 



 
 



 



NOTE:
Make sure all of the cables and wires are prop-
erly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie “1” loosely around 
the end of the handlebar as shown.
c. Hook a spring gauge “2” onto the plastic lock-
ing tie.
 
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
T R.. 
Lower ring nut (initial tightening 
torque)
52 Nm (5.2 m·kg, 37 ft·lb)
T R.. 
Lower ring nut (final tightening 
torque)
14 Nm (1.4 m·kg, 10 ft·lb)