Yamaha 2007 R6 Service

							PICKUP ROTOR
5-32 
						

							ELECTRIC STARTER
5-33
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order Job/Parts to remove Q’ty Remarks
Rider seatRefer to “GENERAL CHASSIS” on page 
4-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Canister (for California only) Refer to “THROTTLE BODIES” on page 7-8.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Thermostat Refer to “THERMOSTAT” on page 6-7.
1 Starter motor lead 1
2 Starter motor assembly 1
For installation, reverse the removal proce-
dure.
1
2
LTLT
T R..10 Nm (1.0 m  
kg, 7.2 ft  Ib) 
						

							ELECTRIC STARTER
5-34
Disassembling the starter motor
Order Job/Parts to remove Q’ty Remarks
1O-ring 1
2 Starter motor front cover 1
3 Lock washer 1
4 Oil seal 1
5 Bearing 1
6 Washer set 1
7 Starter motor yoke 1
8 Armature assembly 1
9Gasket 2
10 Washer set 2
11 Brush holder (along with the brushes) 1
12 Starter motor rear cover 1
For assembly, reverse the disassembly pro-
cedure. 
						

							ELECTRIC STARTER
5-35
EAS24790
CHECKING THE STARTER MOTOR
1. Check:
•Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
•Commutator diameter “1”
Out of specification → Replace the starter 
motor.
3. Measure:
•Mica undercut “a”
Out of specification → Scrape the mica to the 
proper measurement with a hacksaw blade 
that has been grounded to fit the commutator.
NOTE:
The mica of the commutator must be undercut to 
ensure proper operation of the commutator.
4. Measure:
•Armature assembly resistances (commutator 
and insulation)
Out of specification → Replace the starter 
motor.



 
 
 








 
 



 
 



 
 







a. Measure the armature assembly resistances 
with the pocket tester.b. If any resistance is out of specification, re-
place the starter motor.
          
5. Measure:
•Brush length “a”
Out of specification → Replace the brushes 
as a set.
6. Measure:
•Brush spring force
Out of specification → Replace the brush 
springs as a set.
 
Limit
27.0 mm (1.06 in)
 
Mica undercut (depth)
0.70 mm (0.03 in)
 
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
 
Armature coil
Commutator resistance “1”
0.0012–0.0022 Ω at 20 °C (68 °F)
Insulation resistance “2”
Above 1 MΩ at 20 °C (68 °F)
 
Limit
3.50 mm (0.14 in)
 
Brush spring force
7.16–9.52 N (25.77–34.27 oz) 
(730–971 gf) 
						

							ELECTRIC STARTER
5-36
7. Check:
•Gear teeth
Damage/wear → Replace the gear.
8. Check:
•Bearing
•Oil seal
Damage/wear → Replace the defective 
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
•Starter motor yoke “1”
NOTE:
Align the tab “a” on the brush holder with the slot 
“b” in the starter motor yoke.
2. Install:
•Starter motor yoke “1”
•Starter motor front cover “2”
•Starter motor rear cover “3”
NOTE:
Align the match marks “a” on the starter motor 
yoke with the match marks “b” on the front and 
starter motor rear covers. 
						

							CLUTCH
5-37
EAS25060
CLUTCH
Removing the clutch cover
Order Job/Parts to remove Q’ty Remarks
Right bottom cowlingRefer to “GENERAL CHASSIS” on page 
4-1.
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on 
page 3-11.
CoolantDrain.
Refer to “CHANGING THE COOLANT” on 
page 3-19.
1 Water pump breather hose 1 Disconnect.
2 Clutch cable 1 Disconnect.
3Pull lever 1
4 Pull lever spring 1
5Clutch cover 1
6 Clutch cover gasket 1
7 Dowel pin 2
For installation, reverse the removal proce-
dure.
5
2
6
71
3
4
7
LT
New
New
LT
NewLS
(7)
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..12 Nm (1.2 m • 
kg, 8.7 ft • Ib) 
						

							CLUTCH
5-38
Removing the pull lever shaft
Order Job/Parts to remove Q’ty Remarks
1 Circlip 1
2 Pull lever shaft 1
3 Oil seal 1
4 Bearing 1
5 Bearing 1
For installation, reverse the removal proce-
dure.
LS
New
New
E
5
4
3
2
LS
1 
						

							CLUTCH
5-39
Removing the clutch
Order Job/Parts to remove Q’ty Remarks
Ventilation chamber oil drain pipe Refer to “OIL PUMP” on page 5-50.
1 Clutch spring 6
2 Pressure plate 1
3Pull rod 1
4 Friction plate 1 1 brown painting
5 Clutch plate 1 1
6 Friction plate 2 7 black painting
7 Clutch plate 2 1
8 Clutch plate 3 6
9 Friction plate 3 1 purple painting
10 Clutch boss nut 1
11 Spring 3
12 Clutch boss 1
13 Clutch boss plate 1
14 Washer 1
15 Thrust washer 1 1
16 Spacer 1
1
2 3
4 5 6(6) (6)
7 89
11
10 12 1314 15 16 17 18
19 20 21
22
New
LT
LT
LTLT
LSE
(6)
E
E
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..115 Nm (11.5 m • 
kg, 85 ft • lb) 
						

							CLUTCH
5-40
17 Bearing 1
18 Clutch housing 1
19 Oil pump drive chain 1
20 Thrust washer 2 1
21 Thrust washer 3 1
22 Oil pump drive chain guide 1
For installation, reverse the removal proce-
dure.
Removing the clutch
Order Job/Parts to remove Q’ty Remarks
1
2 3
4 5 6(6) (6)
7 89
11
10 12 1314 15 16 17 18
19 20 21
22
New
LT
LT
LTLT
LSE
(6)
E
E
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..25 Nm (2.5 m • 
kg, 18 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..115 Nm (11.5 m • 
kg, 85 ft • lb) 
						

							CLUTCH
5-41
EAS25070
REMOVING THE CLUTCH
1. Remove:
•Friction plates
•Clutch plates
NOTE:
Be sure to mark the friction plates and clutch 
plates or note the position of each part so that 
they are installed in their original positions.
2. Loosen:
•Clutch boss nut “1”
NOTE:
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut.
3. Remove:
•Spacer “1”
•Bearing
•Clutch housing “2”
•Oil pump drive chain
NOTE:
Remove the spacer and bearing from the main 
axle, then remove the oil pump drive chain from 
the oil pump driven sprocket, and then remove 
the clutch housing and oil pump drive chain from 
the main axle.
EAS25100
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
•Friction plate
Damage/wear → Replace the friction plates 
as a set.
2. Measure:
•Friction plate thickness
Out of specification → Replace the friction 
plates as a set.
NOTE:
Measure the friction plate at four places.
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the 
clutch plates.
1. Check:
•Clutch plate
Damage → Replace the clutch plates as a 
set.
2. Measure:
•Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch 
plates as a set.
 
Universal clutch holder
90890-04086
YM-91042
1
2 3
21
 
Friction plate thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.80 mm (0.1102 in)
 
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
 
Clutch plate thickness
1.90–2.10 mm (0.075–0.083 in)
Warpage limit
0.10 mm (0.0039 in)