Yamaha 2007 R6 Service
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SWINGARM 4-68 WARNING EWA13770 Do not attempt to straighten a bent pivot shaft. 3. Wash: •Pivot shaft •Dust covers •Spacers •Washers •Bearings 4. Check: •Dust covers •Spacers •Oil seals Damage/wear → Replace. •Bearings Damage/pitting → Replace. EAS23380 INSTALLING THE SWINGARM 1. Lubricate: •Bearings •Spacers •Dust covers •Pivot shaft 2. Install: •Bearing “1” •Bearing “2” •Bearings “3” •Oil seals “4”3. Install: •Swingarm pivot shaft “1”NOTE: Tighten the swingarm pivot shaft with the damp- er rod holder (24 mm) “2”. 4. Install: •Swingarm pivot shaft ring nut “1” Recommended cleaning solvent Kerosene Recommended lubricant Lithium-soap-based grease Installed depth of bearing “a” 0–1.0 mm (0–0.04 in) Installed depth of bearing “b” 4.0 mm (0.16 in) Installed depth of oil seal “c” 1.0 mm (0.04 in) 5. Swingarm 6. Swingarm pivot shaft 7. Bolt A. Left side B. Right side T R.. Swingarm pivot shaft 16 Nm (1.6 m·kg, 11 ft·lb) Damper rod holder (24 mm) 90890-01328 YM-01328 44 7c5 3 b aa562 1 bc AB AB 2 1
SWINGARM 4-69 NOTE: •Lubricate the swingarm pivot ring nut threads and mating surfaces with lithium-soap-based grease. •Tighten the swingarm pivot shaft ring nut with the ring nut wrench “2”. 5. Install: •Swingarm pivot shaft nut NOTE: Lubricate the swingarm pivot shaft nut threads and mating surfaces with lithium-soap-based grease. 6. Adjust: •Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-25. T R.. Swingarm pivot shaft ring nut 95 Nm (9.5 m·kg, 68 ft·lb) Ring nut wrench 90890-01507 YM-01507 Drive chain slack 35.0–45.0 mm (1.38–1.77 in) 2 1
CHAIN DRIVE 4-70 EAS23400 CHAIN DRIVE Removing the drive sprocket and drive chain Order Job/Parts to remove Q’ty Remarks Left lower side cowlingRefer to “GENERAL CHASSIS” on page 4-1. Left bottom cowlingRefer to “GENERAL CHASSIS” on page 4-1. Shift rod Refer to “ENGINE REMOVAL” on page 5-1. 1 Drive sprocket cover 1 2 Drive sprocket nut 1 3 Washer 1 4 Drive chain guide (drive sprocket side) 1 5 Drive sprocket 1 6 Drive chain 1 For installation, reverse the removal proce- dure. New LT LT LT LT T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..10 Nm (1.0 m • kg, 7.2 ft • Ib) T R..85 Nm (8.5 m • kg, 61 ft • Ib) 1 5 4 3 2 6
CHAIN DRIVE
4-71
EAS23410
REMOVING THE DRIVE CHAIN
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. Remove:
•Drive chain
(with the drive chain cutter)
NOTE:
Only cut the drive chain if it or the swingarm is to
be replaced.
EAS23440
CHECKING THE DRIVE CHAIN
1. Measure:
•15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.
a. Measure the length “a” between the inner
sides of the pins and the length “b” between
the outer sides of the pins on a 15-link section
of the drive chain as shown in the illustration.
b. Calculate the length “c” of the 15-link section
of the drive chain using the following formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
NOTE:
•When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
•Perform this procedure 2–3 times, at a different
location each time.
2. Check:
•Drive chain
Stiffness → Clean and lubricate or replace.
3. Clean:
•Drive chain
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
CAUTION:
EC2C01014
This vehicle has a drive chain with small
rubber O-rings “1” between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean
the drive chain. High-pressure methods
could force dirt or water into the drive
chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosene to clean the drive chain.
Do not soak the drive chain in kerosene for
more than ten minutes, otherwise the O-
rings can be damaged.
15-link length limit
239.3 mm (9.42 in)
CHAIN DRIVE
4-72
4. Check:
•O-rings “1”
Damage → Replace the drive chain.
•Drive chain rollers “2”
Damage/wear → Replace the drive chain.
•Drive chain side plates “3”
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain and make
sure the battery breather hose is properly
routed away from the drive chain and below
the swingarm.
5. Lubricate:
•Drive chain
EAS23460
CHECKING THE DRIVE SPROCKET
1. Check:
•Drive sprocket
More than 1/4 tooth “a” wear → Replace the
drive chain sprockets as a set.
Bent teeth → Replace the drive chain sprock-
ets as a set.
EAS23470
CHECKING THE REAR WHEEL SPROCKET
Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-14.
EAS23480
CHECKING THE REAR WHEEL DRIVE HUB
Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-14.
EAS28800
INSTALLING THE DRIVE CHAIN
1. Lubricate:
•Drive chain
2. Install:
•Drive sprocket “1”
•Washer “2”
•Drive sprocket nut “3”
NOTE:
•While applying the rear brake, tighten the drive
sprocket nut.
•Stake the drive sprocket nut “3” at a cutout “a”
in the drive axle.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
b. Correct
1. Drive chain roller
2. Drive chain sprocket
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
T R..
Drive sprocket nut
85 Nm (8.5 m·kg, 61 ft·lb)
LOCTITE
®
New
5 ENGINE ENGINE REMOVAL........................................................................................ 5-1 INSTALLING THE ENGINE ...................................................................... 5-6 CAMSHAFTS.................................................................................................. 5-7 REMOVING THE CAMSHAFTS ............................................................... 5-9 CHECKING THE CAMSHAFTS ................................................................ 5-9 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES ........................................................................ 5-11 CHECKING THE TIMING CHAIN TENSIONER ..................................... 5-11 INSTALLING THE CAMSHAFTS ............................................................ 5-12 CYLINDER HEAD......................................................................................... 5-15 REMOVING THE CYLINDER HEAD ...................................................... 5-16 CHECKING THE CYLINDER HEAD ....................................................... 5-16 INSTALLING THE CYLINDER HEAD ..................................................... 5-16 VALVES AND VALVE SPRINGS................................................................. 5-18 REMOVING THE VALVES ..................................................................... 5-19 CHECKING THE VALVES AND VALVE GUIDES .................................. 5-19 CHECKING THE VALVE SEATS ............................................................ 5-21 CHECKING THE VALVE SPRINGS ....................................................... 5-23 CHECKING THE VALVE LIFTERS ......................................................... 5-23 INSTALLING THE VALVES .................................................................... 5-24 GENERATOR AND STARTER CLUTCH..................................................... 5-26 REMOVING THE GENERATOR ............................................................. 5-28 CHECKING THE STARTER CLUTCH .................................................... 5-28 INSTALLING THE STARTER CLUTCH .................................................. 5-28 INSTALLING THE GENERATOR ........................................................... 5-29 PICKUP ROTOR........................................................................................... 5-30 REMOVING THE PICKUP ROTOR ........................................................ 5-31 INSTALLING THE PICKUP ROTOR ....................................................... 5-31 ELECTRIC STARTER................................................................................... 5-33 CHECKING THE STARTER MOTOR ..................................................... 5-35 ASSEMBLING THE STARTER MOTOR................................................. 5-36
CLUTCH........................................................................................................ 5-37 REMOVING THE CLUTCH ..................................................................... 5-41 CHECKING THE FRICTION PLATES .................................................... 5-41 CHECKING THE CLUTCH PLATES ....................................................... 5-41 CHECKING THE CLUTCH SPRINGS .................................................... 5-42 CHECKING THE CLUTCH HOUSING .................................................... 5-43 CHECKING THE CLUTCH BOSS........................................................... 5-43 CHECKING THE PRESSURE PLATE .................................................... 5-43 CHECKING THE PRIMARY DRIVE GEAR............................................. 5-43 CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-43 CHECKING THE PULL LEVER SHAFT AND PULL ROD ...................... 5-43 CHECKING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVE CHAIN ........................................................................................ 5-44 INSTALLING THE CLUTCH.................................................................... 5-44 SHIFT SHAFT............................................................................................... 5-47 CHECKING THE SHIFT SHAFT ............................................................. 5-49 CHECKING THE STOPPER LEVER ...................................................... 5-49 INSTALLING THE SHIFT SHAFT ........................................................... 5-49 OIL PUMP..................................................................................................... 5-50 REMOVING THE OIL PAN ..................................................................... 5-53 CHECKING THE OIL PUMP ................................................................... 5-53 CHECKING THE RELIEF VALVE ........................................................... 5-53 CHECKING THE OIL PIPES ................................................................... 5-54 CHECKING THE OIL STRAINER ........................................................... 5-54 ASSEMBLING THE OIL PUMP .............................................................. 5-54 INSTALLING THE OIL PAN .................................................................... 5-54 CRANKCASE................................................................................................ 5-55 DISASSEMBLING THE CRANKCASE ................................................... 5-57 CHECKING THE CRANKCASE .............................................................. 5-57 CHECKING THE OIL PIPE ..................................................................... 5-57 CHECKING THE TIMING CHAIN ........................................................... 5-57 ASSEMBLING THE CRANKCASE ......................................................... 5-57 CONNECTING RODS AND PISTONS.......................................................... 5-59 REMOVING THE CONNECTING RODS AND PISTONS....................... 5-60 CHECKING THE CYLINDERS AND PISTONS ...................................... 5-60 CHECKING THE PISTON RINGS .......................................................... 5-61 CHECKING THE PISTON PINS ............................................................. 5-62 CHECKING THE CONNECTING RODS................................................. 5-63 INSTALLING THE CONNECTING RODS AND PISTONS ..................... 5-64 CRANKSHAFT.............................................................................................. 5-67 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ...................... 5-68 CHECKING THE OIL NOZZLES ............................................................. 5-68 CHECKING THE CRANKSHAFT AND CONNECTING RODS............... 5-68 INSTALLING THE CRANKSHAFT .......................................................... 5-70
TRANSMISSION........................................................................................... 5-71 REMOVING THE TRANSMISSION ........................................................ 5-76 CHECKING THE SHIFT FORKS ............................................................ 5-76 CHECKING THE SHIFT DRUM ASSEMBLY.......................................... 5-76 CHECKING THE TRANSMISSION ......................................................... 5-77 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .............................. 5-77 INSTALLING THE TRANSMISSION ....................................................... 5-78
ENGINE REMOVAL 5-1 EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly Order Job/Parts to remove Q’ty Remarks Lower side cowlingsRefer to “GENERAL CHASSIS” on page 4-1. Bottom cowlingsRefer to “GENERAL CHASSIS” on page 4-1. Radiator bracket Refer to “RADIATOR” on page 6-1. 1 EXUP valve pulley cover 1 2 EXUP cable 1 Black adjusting bolt 3 EXUP cable 1 4Clamp 1 5 Muffler 1 6Gasket 1 7O 2 sensor 1 8 Exhaust pipe assembly 1 9Gasket 4 10 Exhaust pipe assembly bracket (left lower side) 1 11 Exhaust pipe assembly bracket (left upper side) 1 LSLT 12 10 1 2 35 4 6 8 (8)7 9 New LT T R..20 Nm (2.0 m • kg, 14 ft Ib) T R..20 Nm (2.0 m kg, 14 ft Ib) T R..20 Nm (2.0 m kg, 14 ft Ib) New T R..7 Nm (0.7 m kg, 5.1 ft Ib) T R..7 Nm (0.7 m kg, 5.1 ft Ib) T R..8 Nm (0.8 m kg, 5.8 ft Ib) T R..45 Nm (4.5 m kg, 32 ft Ib) T R..30 Nm (3.0 m kg, 22 ft Ib) T R..34 Nm (3.4 m kg, 24 ft Ib) LT LT T R..7 Nm (0.7 m kg, 5.1 ft Ib) 13 16 14 15 32 T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) 11 T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)