Yamaha 2007 R6 Service

							CLUTCH
5-42
NOTE:
The clutch plate thickness specification listed 
above is for the plates with the standard thick-
ness only. If a clutch plate with one of the other 
two plate thicknesses is installed, use 1.50–1.70 
mm (0.059–0.067 in) or 2.20–2.40 mm (0.086–
0.094 in) for the specification according to the 
plate.
3. Measure:
•Total width “a” of the friction plates and clutch 
plates
Out of specification → Adjust.



 
 
 








 
 



 
 



 
 







a. Adjust the total width by replacing the clutch 
plate “1” and, if necessary, clutch plate “2”.
b. Select the clutch plate from the following ta-
ble.
NOTE:
When adjusting the clutch assembly width (by 
replacing the clutch plate(s)), be sure to replace 
the clutch plate “1” first. After replacing the clutch 
plate “1”, if specifications cannot be met, replace 
the clutch plate “2”.
          
EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the 
clutch springs.
1. Check:
•Clutch spring
Damage → Replace the clutch springs as a 
set.
2. Measure:
•Clutch spring free length “a”
Out of specification → Replace the clutch 
springs as a set. 
Total width of the friction plates 
and clutch plates
42.4–43.0 mm (1.67–1.69 in)
Clutch plate “1”
Part No. Thickness
168-16325-00 1.6 mm (0.063 in)
3J2-16324-00 2.0 mm (0.079 in) STD
168-16324-00 2.3 mm (0.091 in)
a
Clutch plate “2”
Part No. Thickness
3J2-16324-00 2.0 mm (0.079 in) STD
168-16324-00 2.3 mm (0.091 in)
 
Clutch spring free length
55.00 mm (2.17 in)
Minimum length
54.00 mm (2.13 in)
12 
						

							CLUTCH
5-43
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:
•Clutch housing dogs
Damage/pitting/wear → Deburr the clutch 
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check:
•Bearing
Damage/wear → Replace the bearing and 
clutch housing.
EAS25160
CHECKING THE CLUTCH BOSS
1. Check:
•Clutch boss splines
Damage/pitting/wear → Replace the clutch 
boss.
NOTE:
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE
1. Check:
•Pressure plate “1”
Cracks/damage → Replace.
•Bearing “2”
Damage/wear → Replace.
EAS25200
CHECKING THE PRIMARY DRIVE GEAR
1. Check:
•Primary drive gear
Damage/wear → Replace the clutch housing 
and crankshaft as a set.
Excessive noise during operation → Replace 
the clutch housing and crankshaft as a set.
EAS25210
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
•Primary driven gear “1”
Damage/wear → Replace the clutch housing 
and crankshaft as a set.
Excessive noise during operation → Replace 
the clutch housing and crankshaft as a set.
EAS25220
CHECKING THE PULL LEVER SHAFT AND 
PULL ROD
1. Check:
•Pull lever shaft pinion gear teeth “1”
•Pull rod teeth “2”
Damage/wear → Replace the pull rod and 
pull lever shaft pinion gear as a set.
1
2 
						

							CLUTCH
5-44
2. Check:
•Bearing
Damage/wear → Replace.
ET2C01011
CHECKING THE OIL PUMP DRIVE 
SPROCKET AND OIL PUMP DRIVE CHAIN
1. Check:
•Oil pump drive sprocket
Cracks/damage/wear → Replace the clutch 
housing, oil pump drive chain, and oil pump 
driven sprocket as a set.
2. Check:
•Oil pump drive chain
Damage/stiffness → Replace the clutch 
housing, oil pump drive chain, and oil pump 
driven sprocket as a set.
EAS25270
INSTALLING THE CLUTCH
1. Install:
•Oil pump drive chain “1”
•Clutch housing “2”
NOTE:
•Install the oil pump drive chain onto the clutch 
housing, and then install the chain onto the oil 
pump driven sprocket while installing the clutch 
housing onto the main axle.
•Make sure that the oil pump drive chain passes 
through the oil pump drive chain guide.
2. Install:
•Clutch boss plate “1”
•Clutch boss “2”
NOTE:
Fit the projections “a” on the clutch boss into the 
grooves “b” in the clutch boss plate.
3. Install:
•Springs “1”
NOTE:
•Stack the springs on top of each other, making 
sure that the tab “a” on each spring is in a dif-
ferent position.
•Fit the tabs “a” on the springs into the grooves 
“b” in the clutch boss plate.
4. Tighten:
•Clutch boss nut “1” 
NOTE:
•While holding the clutch boss “2” with the uni-
versal clutch holder “3”, tighten the clutch boss 
nut.
12
T R.. 
Clutch boss nut
115 Nm (11.5 m·kg, 85 ft·lb)
1b
ba a
2
a
aa 1
b
a
b
1
New 
						

							CLUTCH
5-45
•Stake the clutch boss nut at a cutout “a” in the 
main axle.
5. Lubricate:
•Friction plates
•Clutch plates
(with the recommended lubricant)
6. Install:
•Friction plates
•Clutch plates
NOTE:
•First, install a friction plate and then alternate 
between a clutch plate and a friction plate.
•Install the last friction plate “1” offset from the 
other friction plates “2”, making sure to align a 
projection on the friction plate with the punch 
mark “a” on the clutch housing.
7. Install:
•Pressure plate “1”
NOTE:
Align the punch marks “a” in the pressure plate 
with one of the three punch marks “b” in the 
clutch boss.8. Install:
•Seat plate
•Clutch springs
•Clutch spring bolts
NOTE:
Tighten the clutch spring bolts in stages and in a 
crisscross pattern.
9. Install:
•Dowel pins
•Clutch cover gasket 
•Clutch cover “1”
NOTE:
•Position the pull rod so that the teeth “a” face 
towards the rear of the vehicle. Then, install the 
clutch cover.
•Apply locking agent (LOCTITE
®) to the threads 
of only the clutch cover bolts “a” shown in the 
illustration.
•Tighten the clutch cover bolts in stages and in 
a crisscross pattern.
 
Universal clutch holder
90890-04086
YM-91042
 
Recommended lubricant
Engine oil
1
2 3a
1
2
a
T R.. 
Clutch spring bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
T R.. 
Clutch cover bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
ba1
New 
						

							CLUTCH
5-46
10.Install:
•Pull lever spring “1”
•Pull lever “2”
•Washer
•Circlip 
NOTE:
•Make sure that the mark “a” on the pull lever is 
facing up.
•When installing the pull lever, push it and 
check that its punch mark “b” aligns with the 
mark “c” on the clutch cover. Make sure that 
the pull rod teeth and pull lever shaft pinion 
gear are engaged.
11.Adjust:
•Clutch cable free play
Refer to “ADJUSTING THE CLUTCH LEVER 
FREE PLAY” on page 3-13.
1
a
New
c
1
2
b a 
						

							SHIFT SHAFT
5-47
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty Remarks
Shift arm Refer to “ENGINE REMOVAL” on page 5-1.
Clutch housing Refer to “CLUTCH” on page 5-37.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Stopper lever 1
8 Stopper lever spring 1
9Spacer 1
10 Shift shaft spring 1
11 Shift shaft spring stopper 1
12 Oil seal 1
3
10
9
765413
131221 8
11
LS
New
New
New
LT
E
E
T R..22 Nm (2.2 m • 
kg, 16 ft • Ib) 
						

							SHIFT SHAFT
5-48
13 Bearing 2
For installation, reverse the removal proce-
dure.
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty Remarks
3
10
9
765413
131221 8
11
LS
New
New
New
LT
E
E
T R..22 Nm (2.2 m • 
kg, 16 ft • Ib) 
						

							SHIFT SHAFT
5-49
EAS25420
CHECKING THE SHIFT SHAFT
1. Check:
•Shift shaft
Bends/damage/wear → Replace.
•Shift shaft spring
Damage/wear → Replace.
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
•Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper 
lever.
•Stopper lever spring
Damage/wear → Replace.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
•Shift shaft spring stopper “1”
•Shift shaft assembly
•Shift shaft spring “2”
NOTE:
•Lubricate the oil seal lips with lithium-soap-
based grease.
•Hook the end of the shift shaft spring onto the 
shift shaft spring stopper.
•Hook the ends of the stopper lever spring “3” 
onto the stopper lever “4” and the crankcase 
boss “5”.
•Mesh the stopper lever with the shift drum seg-
ment assembly.
T R.. 
Shift shaft spring stopper
22 Nm (2.2 m·kg, 16 ft·lb)
LOCTITE
®
42
1
5
3 
						

							OIL PUMP
5-50
EAS24920
OIL PUMP
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on 
page 3-11.
CoolantDrain.
Refer to “CHANGING THE COOLANT” on 
page 3-19.
Exhaust pipe assembly Refer to “ENGINE REMOVAL” on page 5-1.
Water pump Refer to “WAT E R  P U M P” on page 6-9.
Clutch housing Refer to “CLUTCH” on page 5-37.
1 Oil level switch coupler 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4 Bottom cowling bracket 2
5 Oil pan 1
6 Oil pan gasket 1
7 Oil strainer 1
8 Oil strainer gasket 1
8
10
136
5
12
79
7
9 1110
4
4
2
1
3
11
454
2
3
New
New
New
New
New
New
LS
LS
LS
LS
LT
New
New
(10)
E
LT
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..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..43 Nm (4.3 m • 
kg, 31 ft • Ib) 
						

							OIL PUMP
5-51
9 Oil pipe 1
10 Ventilation chamber oil drain pipe 1
11 Oil pump assembly 1
12 Dowel pin 2
13 Relief valve assembly 1
For installation, reverse the removal proce-
dure.
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty Remarks
8
10
136
5
12
79
7
9 1110
4
4
2
1
3
11
454
2
3
New
New
New
New
New
New
LS
LS
LS
LS
LT
New
New
(10)
E
LT
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..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..43 Nm (4.3 m • 
kg, 31 ft • Ib)