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
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...

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”...

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...

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-...

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...

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 •...