Yamaha 2007 R6 Service

							ENGINE REMOVAL
5-2
12 Exhaust pipe assembly bracket (right side) 1
13 EXUP servo motor bracket 1
14 EXUP servo motor cover 1
15 EXUP servo motor coupler 1 Disconnect.
16 EXUP servo motor 1
For installation, reverse the removal proce-
dure.
Removing the exhaust pipe assembly
Order Job/Parts to remove Q’ty Remarks
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) 
						

							ENGINE REMOVAL
5-3
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty Remarks
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.
Throttle body Refer to “THROTTLE BODIES” on page 7-8.
Air cut-off valveRefer to “AIR INDUCTION SYSTEM” on 
page 7-15.
Starter motorRefer to “ELECTRIC STARTER” on page 
5-33.
Thermostat Refer to “THERMOSTAT” on page 6-7.
Radiator Refer to “RADIATOR” on page 6-1.
Oil cooler Refer to “OIL COOLER” on page 6-4.
Water pump Refer to “WAT E R  P U M P” on page 6-9.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-70.
1 Shift rod 1
2 Shift arm 1
3 Oil filter cartridge 1
4 Oil filter cartridge bolt 1
5 Crankcase breather hose 1
5
6
7
11
1515
12 13141098
2
1
4
3
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..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
New
New
LS
T R..70 Nm (7.0 m • 
kg, 50 ft • lb)
LS
T R..17 Nm (1.7 m • 
kg, 12 ft • Ib) 
						

							ENGINE REMOVAL
5-4
6 Negative battery terminal 1 Disconnect.
7 Engine ground terminal 1 Disconnect.
8 Oil level switch coupler 1 Disconnect.
9 Crankshaft position sensor coupler 1 Disconnect.
10 Neutral switch coupler 1 Disconnect.
11 Speed sensor 1
12 Stator coil assembly coupler 1 Disconnect.
13 Clutch cable 1 Disconnect.
14 Cylinder identification sensor coupler 1 Disconnect.
15 Ignition coil coupler 4 Disconnect.
For installation, reverse the removal proce-
dure.
Disconnecting the leads and hoses
Order Job/Parts to remove Q’ty Remarks
5
6
7
11
1515
12 13141098
2
1
4
3
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..7 Nm (0.7 m • 
kg, 5.1 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
New
New
LS
T R..70 Nm (7.0 m • 
kg, 50 ft • lb)
LS
T R..17 Nm (1.7 m • 
kg, 12 ft • Ib) 
						

							ENGINE REMOVAL
5-5
Removing the engine
Order Job/Parts to remove Q’ty Remarks
NOTE:
Place a suitable stand under the engine.
1 Engine mounting bolt (front right side) 2
2 Engine mounting collar (outside) 2
3 Engine mounting collar (inside) 2
4 Engine mounting bolt (front left side) 2
5 Engine mounting nut (rear upper side) 1
6 Engine mounting collar (outside) 1
7 Engine mounting collar (inside) 1
8 Engine mounting bolt (rear upper side) 1
9 Engine mounting nut (rear lower side) 1
10 Engine mounting collar (outside) 1
11 Engine mounting collar (inside) 1
12 Engine mounting bolt (rear lower side) 1
13 Engine 1
For installation, reverse the removal proce-
dure.
123
91011 567
1
13 23
4
4 8
12
T R..45 Nm (4.5 m • 
kg, 32 ft • Ib)
T R..45 Nm (4.5 m • 
kg, 32 ft • Ib)
T R..68 Nm (6.8 m • 
kg, 49 ft • Ib)
T R..68 Nm (6.8 m • 
kg, 49 ft • Ib)
T R..45 Nm (4.5 m • 
kg, 32 ft • Ib) 
						

							ENGINE REMOVAL
5-6
EAS23720
INSTALLING THE ENGINE
1. Install:
•Engine “1”
•Engine mounting bolt (rear lower side) “2”
•Engine mounting bolt (rear upper side) “3”
•Engine mounting collars (inside) “4”
•Engine mounting collars (outside) “5”
•Engine mounting nut (rear lower side) “6”
(temporarily tighten)
•Engine mounting nut (rear upper side) “7”
(temporarily tighten)
•Engine mounting bolts (front left side) “8”
(temporarily tighten)
•Engine mounting collars (inside) “9”
•Engine mounting collars (outside) “10”
•Engine mounting bolts (front right side) “11”
(temporarily tighten)
NOTE:
•Be sure to pass the drive axle through the drive 
chain when installing the engine “1”.
•Do not fully tighten the bolts and nuts.
2. Tighten:
•Engine mounting nut (rear lower side) “6”
•Engine mounting nut (rear upper side) “7”
•Engine mounting bolts (front left side) “8”
•Engine mounting bolts (front right side) “11”3. Install:
•Shift arm “1”
NOTE:
Install the shift arm “1” with its punch mark “a” 
aligned with the notch “b” in end of the shift shaft.T R.. 
Engine mounting nut (rear lower 
side)
68 Nm (6.8 m·kg, 49 ft·lb)
Engine mounting nut (rear upper 
side)
68 Nm (6.8 m·kg, 49 ft·lb)
Engine mounting bolt (front left 
side)
45 Nm (4.5 m·kg, 32 ft·lb)
Engine mounting bolt (front right 
side)
45 Nm (4.5 m·kg, 32 ft·lb)
T R.. 
Shift arm bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
11109
654 754
11
1 109
8
8 3
2
1
b a 
						

							CAMSHAFTS
5-7
EAS23760
CAMSHAFTS
Removing the cylinder head cover
Order Job/Parts to remove Q’ty Remarks
Radiator Refer to “RADIATOR” on page 6-1.
Throttle body Refer to “THROTTLE BODIES” on page 7-8.
Air cut-off valve/Reed valve assemblyRefer to “AIR INDUCTION SYSTEM” on 
page 7-15.
1 Ignition coil 4
2 Spark plug 4
3 Cylinder identification sensor 1
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (upper side) 1
For installation, reverse the removal proce-
dure.
2
1
4
63 (6)
(6)
5
New
New
LTLT
LS
T R..8 Nm (0.8 m  
kg, 5.8 ft  Ib)
T R..13 Nm (1.3 m  
kg, 9.4 ft  Ib)
T R..12 Nm (1.2 m  
kg, 8.7 ft  Ib) 
						

							CAMSHAFTS
5-8
Removing the camshafts
Order Job/Parts to remove Q’ty Remarks
Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-30.
1 Camshaft sprocket bolt 4 Loosen.
2 Timing chain tensioner 1
3 Timing chain tensioner gasket 1
4 Intake camshaft cap 3
5 Exhaust camshaft cap 3
6 Camshaft sprocket 2
7 Intake camshaft 1
8 Exhaust camshaft 1
9Pin 2
10 Timing chain guide (intake side) 1
11 Timing chain guide (exhaust side) 1
For installation, reverse the removal proce-
dure.
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..24 Nm (2.4 m  
kg, 17 ft  Ib)
T R..12 Nm (1.2 m  
kg, 8.7 ft  Ib)
New4
16
2
3
10
97
555(10) (10)
8
6
1
11
944
M
M 
						

							CAMSHAFTS
5-9
EAS23810
REMOVING THE CAMSHAFTS
1. Remove:
•Pickup rotor cover
Refer to “PICKUP ROTOR” on page 5-30.
2. Align:
•TDC mark on the pickup rotor
(with the crankcase mating surface)



 
 
 








 
 



 
 



 
 







a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark “a” on the 
pickup rotor with the crankcase mating sur-
face “b”.
NOTE:
TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other.
         
3. Remove:
•Camshaft caps “1”
CAUTION:
ECA13720
To prevent damage to the cylinder head, 
camshafts or camshaft caps, loosen the 
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
4. Remove:
•Intake camshaft
•Exhaust camshaft
NOTE:
To prevent the timing chain from falling into the 
crankcase, fasten it with a wire “1”.
EAS23850
CHECKING THE CAMSHAFTS
1. Check:
•Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
•Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
a b
EX IN
11 
						

							CAMSHAFTS
5-10
3. Measure:
•Camshaft runout
Out of specification → Replace.4. Measure:
•Camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft 
journal diameter.



 
 
 








 
 



 
 



 
 



 



a. Install the camshaft into the cylinder head 
(without the camshaft caps).
b. Position a strip of Plastigauge
® “1” onto the 
camshaft journal as shown.
c. Install the camshaft caps.
NOTE:
•Tighten the camshaft cap bolts in stages and in 
a crisscross pattern, working from the inner 
caps out.
•Do not turn the camshaft when measuring the 
camshaft journal-to-camshaft cap clearance 
with the Plastigauge®.
d. Remove the camshaft caps and then mea-
sure the width of the Plastigauge
® “1”.
 
Camshaft lobe dimensions
Intake A
33.725–33.875 mm (1.3278–
1.3337 in)
Limit
33.675 mm (1.3258 in)
Intake B
25.225–25.325 mm (0.9931–
0.9970 in)
Limit
25.175 mm (0.9911 in)
Exhaust A
32.925–33.075 mm (1.2963–
1.3022 in)
Limit
32.875 mm (1.2943 in)
Exhaust B
25.082–25.182 mm (0.9875–
0.9914 in)
Limit
25.032 mm (0.9855 in)
 
Camshaft runout limit
0.030 mm (0.0012 in)
 
Camshaft-journal-to-camshaft-
cap clearance
0.028–0.062 mm (0.0011–0.0024 
in)
T R.. 
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							CAMSHAFTS
5-11
         
5. Measure:
•Camshaft journal diameter “a”
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder 
head and the camshaft caps as a set.
EAS23870
CHECKING THE TIMING CHAIN, CAMSHAFT 
SPROCKETS, AND TIMING CHAIN GUIDES
1. Check:
•Timing chain “1”
Damage/stiffness → Replace the timing 
chain and camshaft and camshaft sprocket 
as a set.
2. Check:
•Camshaft sprocket
More than 1/4 tooth wear “a” → Replace the 
camshaft sprocket and the timing chain as a 
set.3. Check:
•Timing chain guide (exhaust side)
•Timing chain guide (intake side)
•Timing chain guide (upper side)
Damage/wear → Replace the defective 
part(s).
EAS23970
CHECKING THE TIMING CHAIN TENSIONER
1. Remove:
•Timing chain tensioner rod “1”
•Timing chain tensioner spring seat “2”
•Timing chain tensioner inner spring “3”
•Timing chain tensioner outer spring “5”
•Timing chain tensioner housing “6”
NOTE:
Squeeze the timing chain tensioner clip “4”, and 
then remove the timing chain tensioner springs 
and timing chain tensioner rod.
2. Check:
•Timing chain tensioner housing
•Timing chain tensioner rod
•Timing chain tensioner spring seat
•Timing chain tensioner springs
Damage/wear → Replace the as a set.
3. Assemble:
•Timing chain tensioner springs
•Timing chain tensioner spring seat
•Timing chain tensioner rod
 
Camshaft journal diameter
22.459–22.472 mm (0.8842–
0.8847 in)
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket