Yamaha 2007 R6 Service

CONNECTING RODS AND PISTONS
5-62
NOTE:
Level the piston ring into the cylinder with the 
piston crown.
3. Measure:
•Piston ring end gap
Out of specification → Replace the piston 
ring.
NOTE:
The oil ring expander spacer’s end gap cannot 
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
EAS24440
CHECKING THE PISTON PINS
The following procedure applies to all of the pis-
ton pins.
1. Check:
•Piston pin
Blue discoloration/grooves → Replace the 
piston pin and then...

CONNECTING RODS AND PISTONS
5-63
ET2C01013
CHECKING THE CONNECTING RODS
1. Measure:
•Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end 
bearings.



 
 
 








 
 



 
 



 
 







The following procedure applies to all of the 
connecting rods.
CAUTION:
ECA13930
Do not interchange the big end bearings and 
connecting rods. To obtain the correct 
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big 
end bearings must be installed in...

CONNECTING RODS AND PISTONS
5-64
         
2. Select:
•Big end bearings (P
1–P4)
NOTE:
•The numbers stamped into the crankshaft web 
and the numbers on the connecting rods are 
used to determine the replacement big end 
bearing sizes.
•P
1–P4 refer to the bearings shown in the crank-
shaft illustration.For example, if the connecting rod P
1 and the 
crankshaft web P
1 numbers are 5 and 1 re-
spectively, then the bearing size for P
1 is:
EAS26170
INSTALLING THE CONNECTING...

CONNECTING RODS AND PISTONS
5-65
3. Offset:
•Piston ring end gaps
4. Lubricate:
•Piston
•Piston rings
•Cylinder
(with the recommended lubricant)
5. Lubricate:
•Bolt threads
•Nut seats
(with the recommended lubricant)6. Lubricate:
•Crankshaft pins
•Big end bearings
•Connecting rod inner surface
(with the recommended lubricant)
7. Install:
•Big end bearings
•Connecting rod and piston assembly
•Connecting rod cap
NOTE:
•Align the projections on the big end bearings 
with the notches in the connecting rods...

CONNECTING RODS AND PISTONS
5-66



 
 
 








 
 



 
 



 
 







WARNING
EW2C01007
Replace the connecting rod bolts and nuts 
with new ones.
NOTE:
Tighten the connecting rod nuts using the follow-
ing procedure.
a. Tighten the connecting rod nuts with a torque 
wrench.
b. Put a mark “1” on the corner of the connecting 
rod nut “2” and the connecting rod “3”.
c. Tighten the connecting rod nuts further to 
reach the specified angle 175°–185°.
WARNING
EWA13400
If the connecting rod nut is...

CRANKSHAFT
5-67
EAS25960
CRANKSHAFT
Removing the crankshaft
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-55.
Connecting rod capsRefer to “CONNECTING RODS AND PIS-
TONS” on page 5-59.
1 Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5
4 Oil nozzle 4
For installation, reverse the removal proce-
dure.
1 2
3
E
E
E
4
New
LS 

CRANKSHAFT
5-68
EAS26040
REMOVING THE CRANKSHAFT JOURNAL 
BEARINGS
1. Remove:
•Crankshaft journal lower bearings
(from the lower crankcase)
•Crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft journal 
bearing so that it can be reinstalled in its original 
place.
ET2C01018
CHECKING THE OIL NOZZLES
The following procedure applies to all of the oil 
nozzles.
1. Check:
•Oil nozzle
Damage/wear → Replace the oil nozzle.
•O-ring
Damage/wear → Replace....

CRANKSHAFT
5-69
e. Install the crankshaft journal lower bearings 
“1” into the lower crankcase and assemble 
the crankcase halves.
NOTE:
 Align the projections “a” of the crankshaft jour-
nal lower bearings with the notches “b” in the 
lower crankcase.
 Do not move the crankshaft until the clearance 
measurement has been completed.
f. Tighten the bolts to specification in the tight-
ening sequence cast on the crankcase.
Refer to “CRANKCASE” on page 5-55.
g. Remove the lower crankcase and the crank-...

CRANKSHAFT
5-70
EAS26200
INSTALLING THE CRANKSHAFT
1. Install:
•Crankshaft journal upper bearings
(into the upper crankcase)
•Crankshaft journal lower bearings
(into the lower crankcase)
NOTE:
•Align the projections “a” on the crankshaft jour-
nal bearings “1” with the notches “b” in the 
crankcases.
•Be sure to install each crankshaft journal bear-
ing in its original place. 

TRANSMISSION
5-71
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-55.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Shift drum retainer 2
6Spring 2
7 Shift fork guide bar 2
8 Shift fork-L 1
9 Shift fork-R 1
10 Shift drum assembly 1
11 Shift fork-C 1
12 Main axle assembly 1
13 Oil pipe 1
14 Bearing 1
E
E
E
E
12
11
7
13
5
676
10 5
498 12
3
15
14
LT
LT
E
E
LT
E
T...