Yamaha 2007 R6 Service

							REAR BRAKE
4-38
EAS22700
REMOVING THE REAR BRAKE MASTER 
CYLINDER
NOTE:
Before removing the rear brake master cylinder, 
drain the brake fluid from the entire brake sys-
tem.
1. Remove:
•Rear brake hose union bolt “1”
•Copper washers “2”
•Rear brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose.
EAS22720
CHECKING THE REAR BRAKE MASTER 
CYLINDER
1. Check:
•Brake master cylinder
Damage/scratches/wear → Replace.
•Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
•Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
•Brake fluid reservoir
Cracks/damage → Replace.
•Brake fluid reservoir diaphragm
Cracks/damage → Replace.
4. Check:
•Rear brake hose
•Brake fluid reservoir hose
Cracks/damage/wear → Replace.
EAS22730
ASSEMBLING THE REAR BRAKE MASTER 
CYLINDER
WARNING
EWA13520
Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
Never use solvents on internal brake com-
ponents.
EAS22740
INSTALLING THE REAR BRAKE MASTER 
CYLINDER
1. Install:
•Rear brake hose “1”
•Copper washers “2” 
•Rear brake hose union bolt “3”
WARNING
EWA13530
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-47.
CAUTION:
ECA14160
When installing the brake hose onto the 
brake master cylinder, make sure the brake 
pipe touches the projection “a” as shown.
2. Fill:
•Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
21 3
 
Recommended fluid
DOT 4
T R.. 
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
 
Recommended fluid
DOT 4
New
23 1
a
New 
						

							REAR BRAKE
4-39
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.
3. Bleed:
•Brake system
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-24.
4. Check:
•Brake fluid level
Below the minimum level mark “a” → Add the 
recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-22.
5. Check:
•Brake pedal operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-24.
6. Adjust:
•Brake pedal position
Refer to “ADJUSTING THE REAR DISC 
BRAKE” on page 3-21.
7. Adjust:
•Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE 
LIGHT SWITCH” on page 3-23.
a 
						

							HANDLEBARS
4-40
EAS22850
HANDLEBARS
Removing the handlebars
Order Job/Parts to remove Q’ty Remarks
Left side panel/Left upper side cowlingRefer to “GENERAL CHASSIS” on page 
4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Canister (for California only) Refer to “THROTTLE BODIES” on page 7-8.
Air induction system coverRefer to “AIR INDUCTION SYSTEM” on 
page 7-15.
1 Left grip end 1
2 Handlebar grip 1
3 Clutch switch connector 2 Disconnect.
4 Left handlebar switch 1
5 Clutch cable 1 Disconnect.
6 Clutch lever assembly 1
7 Right grip end 1
8 Throttle cable housing 2
9 Throttle cable 2 Disconnect.
10 Throttle grip 1
T R..32 Nm (3.2 m • 
kg, 23 ft • Ib)
LS
T R..115 Nm (11.5 m • 
kg, 85 ft • lb)T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
LS
T R..26 Nm (2.6 m • 
kg, 19 ft • Ib)
T R..5 Nm (0.5 m • 
kg, 3.6 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..11 Nm (1.1 m • 
kg, 8.0 ft • Ib)
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
5 17
15
22
20
2316 16
15
2 3
1
1819 20
21
4
6 78
121213
11 1014
9
92422
8
LS 
						

							HANDLEBARS
4-41
11 Front brake light switch connector 2 Disconnect.
12 Right handlebar switch/Bracket 1/1
13 Front brake master cylinder holder 1
14 Front brake master cylinder assembly 1
15 Handlebar bolt 2
16 Upper bracket pinch bolt 2 Loosen.
17 Steering stem nut 1
18 Rectifier/regulator holder 1
19 Left coupler holder 1
20 Main switch coupler 2 Disconnect.
21 Upper bracket 1
22 Handlebar pinch bolt 2 Loosen.
23 Left handlebar 1
24 Right handlebar 1
For installation, reverse the removal proce-
dure.
Removing the handlebars
Order Job/Parts to remove Q’ty Remarks
T R..32 Nm (3.2 m • 
kg, 23 ft • Ib)
LS
T R..115 Nm (11.5 m • 
kg, 85 ft • lb)T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
LS
T R..26 Nm (2.6 m • 
kg, 19 ft • Ib)
T R..5 Nm (0.5 m • 
kg, 3.6 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..11 Nm (1.1 m • 
kg, 8.0 ft • Ib)
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
5 17
15
22
20
2316 16
15
2 3
1
1819 20
21
4
6 78
121213
11 1014
9
92422
8
LS 
						

							HANDLEBARS
4-42
EAS22870
REMOVING THE HANDLEBARS
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
2. Remove:
•Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar 
and the handlebar grip, and gradually push the 
grip off the handlebar.
EAS22890
CHECKING THE HANDLEBARS
1. Check:
•Left handlebar
•Right handlebar
Bends/cracks/damage → Replace.
WARNING
EWA13690
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS22900
INSTALLING THE HANDLEBARS
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is 
no danger of it falling over.
2. Install:
•Front brake master cylinder “1”
•Front brake master cylinder holder “2”
NOTE:
•Install the brake master cylinder holder with the 
“UP” mark “a” facing up.•Align the mating surfaces of the brake master 
cylinder holder with the punch mark “b” on the 
handlebar.
•First, tighten the upper bolt, then the lower bolt.
3. Install:
•Right handlebar switch “1”
•Right handlebar switch bracket “2”
NOTE:
Align the projection “a” on the right handlebar 
switch with the hole “b” on the right handlebar.
4. Install:
•Throttle grip
•Throttle cables
•Throttle cable housings “1”
NOTE:
Align the projection “a” on the throttle cable 
housing with the hole “b” in the right handlebar.
5. Install:
•Right grip end “1”
T R.. 
Front brake master cylinder hold-
er bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
1
2
a b
a
12 b 
						

							HANDLEBARS
4-43
NOTE:
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the throttle grip and the right 
grip end.
6. Install:
•Clutch lever assembly “1”
NOTE:
Align the mating surfaces of the clutch lever as-
sembly with the punch mark “a” on the left han-
dlebar.
7. Install:
•Left handlebar switch “1”
NOTE:
Align the projection “a” on the left handlebar 
switch with the hole “b” in the left handlebar.
8. Install:
•Handlebar grip “1”
•Left grip end “2”



 
 
 








 
 



 
 



 
 



 



a. Apply a thin coat of rubber adhesive onto the 
end of the left handlebar.
b. Slide the handlebar grip over the end of the 
left handlebar.
c. Wipe off any excess rubber adhesive with a 
clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
NOTE:
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the handlebar grip and the grip 
end.
          
9. Check:
•Cable routing
NOTE:
Make sure the main switch lead, brake hoses, 
throttle cables, clutch cable, and handlebar 
switch leads are routed properly. Refer to “CA-
BLE ROUTING” on page 2-47.
10.Adjust:
•Clutch cable free play
Refer to “ADJUSTING THE CLUTCH LEVER 
FREE PLAY” on page 3-13.
11.Adjust:
•Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-8.
T R.. 
Clutch lever bolt
11 Nm (1.1 m·kg, 8.0 ft·lb)
a
1
a1
 
Clutch lever free play
10.0–15.0 mm (0.39–0.59 in)
 
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in) 
						

							FRONT FORK
4-44
EAS22950
FRONT FORK
Removing the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front fork legs.
Side panelsRefer to “GENERAL CHASSIS” on page 
4-1.
Front wheel Refer to “FRONT WHEEL” on page 4-4.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Handlebar pinch bolt 1 Loosen.
4 Handlebar bolt 1 Loosen.
5 Cap bolt 1 Loosen.
6 Lower bracket pinch bolt 2 Loosen.
7 Front fork leg 1
For installation, reverse the removal proce-
dure.
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T R..32 Nm (3.2 m • 
kg, 23 ft • Ib)
T R..26 Nm (2.6 m • 
kg, 19 ft • Ib)
T R..23 Nm (2.3 m • 
kg, 17 ft • Ib)
4
5
7 13
6
2 
						

							FRONT FORK
4-45
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front fork legs.
1 Cap bolt 1
2O-ring 1
3 Washer 1
4 Damper adjusting rod 1
5Nut 1
6Spacer 1
7 Fork spring 1
8 Spring seat 1
9 Outer tube 1
10 Dust seal 1
11 Oil seal clip 1
12 Oil seal 1
13 Washer 1
14 Damper rod assembly 1
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T R..35 Nm (3.5 m • 
kg, 25 ft • Ib)
1
2
New
3
5
6
7
89
13
12
11
10
New
New
New41415 
						

							FRONT FORK
4-46
15 Inner tube 1
For assembly, reverse the disassembly pro-
cedure.
Disassembling the front fork legs
Order Job/Parts to remove Q’ty Remarks
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
T R..35 Nm (3.5 m • 
kg, 25 ft • Ib)
1
2
New
3
5
6
7
89
13
12
11
10
New
New
New41415 
						

							FRONT FORK
4-47
EAS22970
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
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. Loosen:
•Upper bracket pinch bolt “1”
•Handlebar pinch bolt “2”
•Handlebar bolt “3”
•Cap bolt “4”
•Lower bracket pinch bolts “5”
WARNING
EWA13640
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
EAS22990
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.1. Position the collar “1” as shown in the illustra-
tion by turning the spring preload adjusting 
bolt “2” counterclockwise until it stops.
2. Remove:
•Cap bolt “1”
(from the damper adjusting rod)
•Spacer “2”
•Nut “3”



 
 
 








 
 



 
 



 
 



 



a. Press down on the spacer with the fork spring 
compressor “4”.
b. Install the rod holder “5” between the nut “3” 
and the spacer “2”.
NOTE:
Use the side of the rod holder that is marked “B”.
c. Hold the spring preload adjusting bolt “6” and 
loosen the nut “3”.
CAUTION:
EC2C01011
When loosening the nut “3”, be sure not to 
break the projections “a” on the collar “7” of 
the cap bolt “1”.
123 4
5
 
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
2
1
2
41
3
5