Yamaha 2007 R6 Service

							VALVES AND VALVE SPRINGS
5-22
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and 
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted 
one another, the blueing will have been re-
moved.



 
 
 








 
 



 
 



 
 







4. Lap:
• Valve face
 Valve seat
CAUTION:
EC2C01028
This model uses titanium intake and exhaust 
valves. Titanium valves that have been used 
to lap the valve seats must not be used. Al-
ways replace lapped valves with new valves.
NOTE:
 When replacing the cylinder head, replace the 
valves without lapping the valve seats and 
valve faces.
 When replacing the valves or valve guides, use 
new valves to lap the valve seats, and then re-
place them with new valves.
         
a. Apply a coarse lapping compound “a” to the 
valve face.
CAUTION:
ECA13790
Do not let the lapping compound enter the 
gap between the valve stem and the valve 
guide.b. Apply molybdenum disulfide oil onto the 
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve 
seat are evenly polished, then clean off all of 
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve 
seat while rotating the valve back and forth be-
tween your hands.
e. Apply a fine lapping compound to the valve 
face and repeat the above steps.
f. After every lapping procedure, be sure to 
clean off all of the lapping compound from the 
valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b” 
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and 
onto the valve seat to make a clear impres-
sion. 
						

							VALVES AND VALVE SPRINGS
5-23
j. Measure the valve seat width “c” again. If the 
valve seat width is out of specification, reface 
and lap the valve seat.



 
 
 








 
 



 
 



 
 







EAS24310
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the 
valve springs.
1. Measure:
Valve spring free length “a”
Out of specification → Replace the valve 
spring.
2. Measure:
Compressed valve spring force “a”
Out of specification → Replace the valve 
spring.3. Measure:
Valve spring tilt “a”
Out of specification → Replace the valve 
spring.
EAS24320
CHECKING THE VALVE LIFTERS
The following procedure applies to all of the 
valve lifters.
1. Check:
Valve lifter
Damage/scratches → Replace the valve lift-
ers and cylinder head.
 
Free length (intake)
37.47 mm (1.48 in)
Limit
35.60 mm (1.40 in)
Free length (exhaust)
37.67 mm (1.48 in)
Limit
35.79 mm (1.42 in)
 
Installed compression spring 
force (intake)
166.00–190.00 N (37.32–42.71 lb) 
(16.93–19.37 kgf)
Installed compression spring 
force (exhaust)
165.00–189.00 N (37.09–42.49 lb) 
(16.83–19.27 kgf)
Installed length (intake)
32.80 mm (1.29 in)
Installed length (exhaust)
32.80 mm (1.29 in)
b. Installed length
 
Spring tilt (intake)
2.5°/1.6 mm
Spring tilt (exhaust)
2.5°/1.6 mm 
						

							VALVES AND VALVE SPRINGS
5-24
EAS24340
INSTALLING THE VALVES
The following procedure applies to all of the 
valves and related components.
1. Deburr:
Valve stem end
(with an oil stone)
2. Lubricate:
Valve stem “1”
Valve stem seal “2”
(with the recommended lubricant)
3. Install:
Lower spring seat “1”
Valve stem seal “2”
Valve “3”
Valve spring “4”
Upper spring seat “5”
(into the cylinder head)
NOTE:
Make sure each valve is installed in its original 
place.
Install the valve springs with the larger pitch “a” 
facing up.4. Install:
Valve cotters “1”
NOTE:
Install the valve cotters by compressing the 
valve spring with the valve spring compressor 
“1” and the valve spring compressor attachment 
“2”.
 
Recommended lubricant
Molybdenum disulfide oil
b. Smaller pitch
 
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor
90890-04109
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108 
						

							VALVES AND VALVE SPRINGS
5-25
5. To secure the valve cotters onto the valve 
stem, lightly tap the valve tip with a soft-face 
hammer.
CAUTION:
ECA13800
Hitting the valve tip with excessive force 
could damage the valve.
6. Lubricate:
Valve lifter
(with the recommended lubricant)
7. Install:
Valve pad
Valve lifter
NOTE:
The valve lifter must move smoothly when ro-
tated with a finger.
Each valve lifter and valve pad must be rein-
stalled in its original position.
 
Recommended lubricant
Engine oil 
						

							GENERATOR AND STARTER CLUTCH
5-26
EAS24480
GENERATOR AND STARTER CLUTCH
Removing the generator and starter clutch
Order Job/Parts to remove Q’ty Remarks
Left bottom cowlingRefer to “GENERAL CHASSIS” on page 
4-1.
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on 
page 3-11.
1 Stator coil assembly coupler 1 Disconnect.
2 Generator cover 1
3 Generator cover gasket 1
4 Dowel pin 2
5 Stator coil assembly lead holder 1
6 Stator coil assembly 1
7 Starter clutch idle gear shaft 1
8 Starter clutch idle gear 1
9 Generator rotor 1
10 Starter clutch 1
3
2
6 5 48
7
11
10
9 4 1
New
New
New
LT
LT
E
(9)
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..12 Nm (1.2 m  
kg, 8.7 ft  Ib)
T R..70 Nm (7.0 m  
kg, 50 ft  lb)
E
E 
						

							GENERATOR AND STARTER CLUTCH
5-27
11 Starter clutch gear 1
For installation, reverse the removal proce-
dure.
Removing the generator and starter clutch
Order Job/Parts to remove Q’ty Remarks
3
2
6 5 48
7
11
10
9 4 1
New
New
New
LT
LT
E
(9)
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..12 Nm (1.2 m  
kg, 8.7 ft  Ib)
T R..70 Nm (7.0 m  
kg, 50 ft  lb)
E
E 
						

							GENERATOR AND STARTER CLUTCH
5-29
EAS24500
INSTALLING THE GENERATOR
1. Install:
•Generator rotor
•Washer 
•Generator rotor bolt
NOTE:
•Clean the tapered portion of the crankshaft and 
the generator rotor hub.
•Lubricate the generator rotor bolt threads and 
washer mating surfaces with engine oil.
2. Tighten:
•Generator rotor bolt “1”
NOTE:
While holding the generator rotor “2” with the 
sheave holder “3”, tighten the generator rotor 
bolt.
3. Apply:
•Sealant
(onto the stator coil assembly lead grommet)
T R.. 
Generator rotor bolt
70 Nm (7.0 m·kg, 50 ft·lb)
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
a1
New
1
2 3
 
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215
®) 
						

							PICKUP ROTOR
5-30
EAS24520
PICKUP ROTOR
Removing the pickup rotor
Order Job/Parts to remove Q’ty Remarks
Right bottom cowlingRefer to “GENERAL CHASSIS” on page 
4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Generator coverRefer to “GENERATOR AND STARTER 
CLUTCH” on page 5-26.
1 Clutch cable 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Pickup rotor cover 1
4 Pickup rotor cover gasket 1
5 Crankshaft position sensor 1
6 Pickup rotor 1
For installation, reverse the removal proce-
dure.
LTLT
1 3
(3)5 42
6
LS
New
New
New
T R..10 Nm (1.0 m  
kg, 7.2 ft  Ib)
T R..15 Nm (1.5 m  
kg, 11 ft  Ib)
T R..12 Nm (1.2 m  
kg, 8.7 ft  Ib)
T R..12 Nm (1.2 m  
kg, 8.7 ft  Ib)
T R..35 Nm (3.5 m  
kg, 25 ft  Ib) 
						

							PICKUP ROTOR
5-31
EAS24530
REMOVING THE PICKUP ROTOR
1. Remove:
•Pickup rotor bolt “1”
•Washer
•Pickup rotor
NOTE:
While holding the generator rotor “2” with the ro-
tor sheave holder “3”, loosen the pickup rotor 
bolt.
EAS24540
INSTALLING THE PICKUP ROTOR
1. Install:
•Pickup rotor “1”
•Washer
•Pickup rotor bolt
NOTE:
When installing the pickup rotor, align the 
groove “a” in the crankshaft with the projection 
“b” on the pickup rotor.2. Tighten:
•Pickup rotor bolt “1”
NOTE:
While holding the generator rotor “2” with the 
sheave holder “3”, tighten the pickup rotor bolt.
3. Apply:
•Sealant
(onto the crankshaft position sensor lead 
grommet)
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
1
2 3
T R.. 
Pickup coil rotor bolt
35 Nm (3.5 m·kg, 25 ft·lb)
 
Sheave holder
90890-01701
Primary clutch holder
YS-01880-A
 
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215
®)
1
ba
1
2 3