Yamaha 2007 R6 Service

OIL PUMP
5-52
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks
1 Oil pump housing cover 1
2Pin 2
3 Oil pump inner rotor 1
4 Oil pump outer rotor 1
5Pin 1
6 Washer 1
7 Oil pump housing 1
8 Oil pump driven sprocket 1
For assembly, reverse the disassembly pro-
cedure. 

OIL PUMP
5-53
EAS24930
REMOVING THE OIL PAN
1. Remove:
•Oil level switch lead holder
•Bottom cowling brackets
•Oil pan
•Oil pan gasket
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the 
bolts are fully loosened, remove them.
EAS24960
CHECKING THE OIL PUMP
1. Check:
•Oil pump driven sprocket
•Oil pump housing
•Oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
•Inner-rotor-to-outer-rotor-tip clearance “a”...

OIL PUMP
5-54
EAS24980
CHECKING THE OIL PIPES
The following procedure applies to all of the oil 
delivery pipes.
1. Check:
•Ventilation chamber oil drain pipe
•Oil pipe
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
EAS24990
CHECKING THE OIL STRAINER
1. Check:
•Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS25010
ASSEMBLING THE OIL PUMP
1. Lubricate:
•Inner rotor
•Outer rotor
•Oil pump shaft
(with the recommended lubricant)
2. Install:
•Oil pump driven...

CRANKCASE
5-55
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-1.
Cylinder head Refer to “CYLINDER HEAD” on page 5-15.
Starter clutchRefer to “GENERATOR AND STARTER 
CLUTCH” on page 5-26.
Shift shaft Refer to “SHIFT SHAFT” on page 5-47.
Pickup rotor Refer to “PICKUP ROTOR” on page 5-30.
Oil pump drive chain guide Refer to “CLUTCH” on page 5-37.
Oil pump assembly Refer to “OIL PUMP” on page 5-50.
1 Timing chain 1
2 Dipstick 1
3...

CRANKCASE
5-56
9 Oil baffle plate 2 1
10 Lower crankcase 1
11 Dowel pin 3
For installation, reverse the removal proce-
dure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks
11
43 2
11
6
10
1
8
9
7
5
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..8 Nm (0.8 m • 
kg, 5.8 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..20 Nm (2.0 m • 
kg, 14 ft • Ib)
LS
New
New
New
New
New
LS
LS
LS
LT
LT
LTLT
(3)
LT
T R..12 Nm (1.2 m •...

CRANKCASE
5-57
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
• Crankcase bolts
NOTE:
 Loosen each bolt 1/4 of a turn at a time. After 
all of the bolts are fully loosened, remove them.
 Loosen the bolts in decreasing numerical order 
(refer to the numbers in the illustration).
 The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M8 × 115 mm bolts: “8”, “9”
M8 × 85 mm bolts: “1”–“7”, “10”
M8 × 65 mm bolts: “11”, “12”
M6 × 80 mm...

CRANKCASE
5-58
CAUTION:
ECA13980
Before tightening the crankcase bolts, make 
sure the transmission gears shift correctly 
when the shift drum assembly is turned by 
hand.
6. Install:
Crankcase bolts
NOTE:
Lubricate the bolts “1”–“10” thread part and 
washers with engine oil.
Lubricate the bolts “11”–“29” thread part and 
mating surfaces with engine oil.
Finger tighten the crankcase bolts.
M8 × 115 mm bolts: “8”, “9”
M8 × 85 mm bolts: “1”–“7”, “10”
M8 × 65 mm bolts: “11”, “12”
M6 × 80 mm bolt:...

CONNECTING RODS AND PISTONS
5-59
EAS24370
CONNECTING RODS AND PISTONS
Removing the connecting rods and pistons
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-55.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Piston pin clip 8
4 Piston pin 4
5Piston 4
6 Connecting rod 4
7 Big end upper bearing 4
8 Top ring 4
92nd ring 4
10 Oil ring 4
For installation, reverse the removal proce-
dure.
New
E
New
E
NewNew
New
E
M
M
T R..1st   15 Nm (1.5 m • 
kg, 11 ft • lb)
2nd...

CONNECTING RODS AND PISTONS
5-60
EAS26030
REMOVING THE CONNECTING RODS AND 
PISTONS
The following procedure applies to all of the con-
necting rods and pistons.
1. Remove:
•Connecting rod cap “1”
NOTE:
Identify the position of each connecting rod so 
that it can be reinstalled in its original place.
2. Remove:
•Big end bearings
(from the connecting rods and connecting rod 
caps)
NOTE:
Identify the position of each big end bearing so 
that it can be reinstalled in its original place.
3. Remove:
•Piston...

CONNECTING RODS AND PISTONS
5-61
NOTE:
Measure cylinder bore “C” by taking side-to-side 
and front-to-back measurements of the cylinder. 
Then, find the average of the measurements.
b. If out of specification, rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set.
c. Measure piston skirt diameter D “a” with the 
micrometer.d. If out of specification, replace the piston and 
piston rings as a set.
e. Calculate the piston-to-cylinder clearance 
with the following formula.
f. If...