Yamaha 2007 R6 Service

							3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................ 3-1
INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL 
SYSTEM................................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 3-1
ENGINE........................................................................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
SYNCHRONIZING THE THROTTLE BODIES ......................................... 3-6
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-8
CHECKING THE SPARK PLUGS ............................................................. 3-8
MEASURING THE COMPRESSION PRESSURE.................................... 3-9
CHECKING THE ENGINE OIL LEVEL ................................................... 3-10
CHANGING THE ENGINE OIL ............................................................... 3-11
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY................................... 3-13
REPLACING THE AIR FILTER ELEMENT ............................................. 3-14
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-15
CHECKING THE FUEL LINE .................................................................. 3-15
CHECKING THE CRANKCASE BREATHER HOSE .............................. 3-15
CHECKING THE EXHAUST SYSTEM ................................................... 3-16
CHECKING THE CANISTER (for California only)................................... 3-16
ADJUSTING THE EXUP CABLES .......................................................... 3-16
CHECKING THE COOLANT LEVEL....................................................... 3-18
CHECKING THE COOLING SYSTEM .................................................... 3-18
CHANGING THE COOLANT .................................................................. 3-19
CHASSIS....................................................................................................... 3-21
ADJUSTING THE FRONT DISC BRAKE................................................ 3-21
ADJUSTING THE REAR DISC BRAKE .................................................. 3-21
CHECKING THE BRAKE FLUID LEVEL ................................................ 3-22
CHECKING THE FRONT BRAKE PADS ................................................ 3-22
CHECKING THE REAR BRAKE PADS .................................................. 3-22
CHECKING THE FRONT BRAKE HOSES ............................................. 3-23
CHECKING THE REAR BRAKE HOSES ............................................... 3-23
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................. 3-23
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-24
ADJUSTING THE SHIFT PEDAL............................................................ 3-25
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-25
LUBRICATING THE DRIVE CHAIN ........................................................ 3-26
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-26
CHECKING THE FRONT FORK ............................................................. 3-28
ADJUSTING THE FRONT FORK LEGS ................................................. 3-28
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-30
CHECKING THE TIRES ......................................................................... 3-32
CHECKING THE WHEELS ..................................................................... 3-33
CHECKING AND LUBRICATING THE CABLES .................................... 3-34
LUBRICATING THE LEVERS ................................................................. 3-34 
						

							LUBRICATING THE PEDALS ................................................................. 3-34
LUBRICATING THE SIDESTAND .......................................................... 3-34
LUBRICATING THE REAR SUSPENSION ............................................ 3-34
ELECTRICAL SYSTEM................................................................................ 3-35
CHECKING AND CHARGING THE BATTERY....................................... 3-35
CHECKING THE FUSES ........................................................................ 3-35
REPLACING THE HEADLIGHT BULBS ................................................. 3-35
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-35 
						

							PERIODIC MAINTENANCE
3-1
EAS20450
PERIODIC MAINTENANCE
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If 
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already 
in service as well as to new vehicles that are being prepared for sale. All service technicians should be 
familiar with this entire chapter.
EAU17600
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the 
service.
EAU32183
GENERAL MAINTENANCE AND LUBRICATION CHART
No. ITEM ROUTINEINITIAL ODOMETER READINGS
600 mi 
(1000 km) 
or 
1 month4000 mi 
(7000 km) 
or 
6 months8000 mi 
(13000 
km) 
or 
12 months12000 mi 
(19000 
km) 
or 
18 months16000 mi 
(25000 
km) 
or 
24 months20000 mi 
(31000 
km) 
or 
30 months
1*Fuel lineCheck fuel hoses for cracks or 
damage.
Replace if necessary.√√√√√
2*Spark plugsCheck condition.
Adjust gap and clean.
Replace every 8000 mi 
(13000 km) or 12 months.√Replace.√Replace.√
3*Valve clearanceCheck and adjust valve clear-
ance when engine is cold.Every 26600 mi (42000 km)
4*Crankcase 
breather systemCheck breather hose for 
cracks or damage.
Replace if necessary.√√√√√
5*Fuel injectionAdjust synchronization.√√√√√
6*Exhaust systemCheck for leakage.
Tighten if necessary.
Replace gasket(s) if neces-
sary.√√√√√
7*Evaporative emis-
sion control sys-
tem (For 
California only)Check control system for 
damage.
Replace if necessary.√
8*Air induction sys-
temCheck the air cut-off valve, 
reed valve, and hose for dam-
age.
Replace any damaged parts.√√
No. ITEM ROUTINEINITIAL ODOMETER READINGS
600 mi 
(1000 km) 
or 
1 month4000 mi 
(7000 km) 
or 
6 months8000 mi 
(13000 
km) 
or 
12 months12000 mi 
(19000 
km) 
or 
18 months16000 mi 
(25000 
km) 
or 
24 months20000 mi 
(31000 
km) 
or 
30 months
1*Air filter elementCheck condition and damage.
Replace if necessary.√√√√√
2*ClutchCheck operation.
Adjust or replace cable.√√√√√√
3*Front brakeCheck operation, fluid level, 
and for fluid leakage.
Replace brake pads if neces-
sary.√√√√√√
4*Rear brakeCheck operation, fluid level, 
and for fluid leakage.
Replace brake pads if neces-
sary.√√√√√√ 
						

							PERIODIC MAINTENANCE
3-2
5*Brake hosesCheck for cracks or damage.√√√√√
Replace. Every 4 years
6*WheelsCheck runout and for dam-
age.
Replace if necessary.√√√√√
7*TiresCheck tread depth and for 
damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√√√√
8*Wheel bearingsCheck bearings for smooth 
operation.
Replace if necessary.√√√√√
9*Swingarm pivot 
bearingsCheck bearing assemblies for 
looseness.
Moderately repack with lithi-
um-soap-based grease.√Repack.
10 Drive chainCheck chain slack, alignment 
and condition.
Adjust and lubricate chain 
with a special O-ring chain lu-
bricant thoroughly.Every 500 mi (800 km) and after washing the motorcycle or riding in the 
rain
11*Steering bearingsCheck bearing assemblies for 
looseness.√√√√√√
Moderately repack with lithi-
um-soap-based grease.Every 12000 mi (19000 km)
12*Chassis fastenersCheck all chassis fitting and 
fasteners.
Correct if necessary.√√√√√
13Brake and clutch 
lever pivot shaftsApply lithium-soap-based 
grease (all-purpose grease) 
lightly.√√√√√
14Brake and shift 
pedal pivot shaftsApply lithium-soap-based 
grease (all-purpose grease) 
lightly.√√√√√
15 Sidestand pivotCheck operation.
Apply lithium-soap-based 
grease (all-purpose grease) 
lightly.√√√√√
16*Sidestand switchCheck operation and replace 
if necessary.√√√√√√
17*Front forkCheck operation and for oil 
leakage.
Replace if necessary.√√√√√
18*Shock absorber 
assemblyCheck operation and for oil 
leakage.
Replace if necessary.√√√√√
19*Rear suspension 
link pivotsCheck operation.
Correct if necessary.√√
20 Engine oilChange (warm engine before 
draining).√√√√√√
21*Engine oil filter 
cartridgeReplace.√√√
22*Cooling systemCheck hoses for cracks or 
damage.
Replace if necessary.√√√√√
Change with ethylene glycol 
anti-freeze coolant every 24 
months.Change.
23*Front and rear 
brake switchesCheck operation.√√√√√√
24*Control cablesApply Yamaha chain and ca-
ble lube or engine oil SAE 
10W-30 thoroughly.√√√√√√
25*Throttle grip 
housing and ca-
bleCheck operation and free 
play.
Adjust the throttle cable free 
play if necessary.
Lubricate the throttle grip 
housing and cable.√√√√√ No. ITEM ROUTINEINITIAL ODOMETER READINGS
600 mi 
(1000 km) 
or 
1 month4000 mi 
(7000 km) 
or 
6 months8000 mi 
(13000 
km) 
or 
12 months12000 mi 
(19000 
km) 
or 
18 months16000 mi 
(25000 
km) 
or 
24 months20000 mi 
(31000 
km) 
or 
30 months 
						

							PERIODIC MAINTENANCE
3-3
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the 
service.
NOTE:
From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi 
(13000 km) or 12 months.
EAU17650
NOTE:
Air filter
This model’s air filter is equipped with a disposable oil-coated paper element, which must not be 
cleaned with compressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty 
areas.
Hydraulic brake service
After disassembling the brake master cylinders and calipers, always change the fluid. Regularly 
check the brake fluid levels and fill the reservoirs as required.
Every two years replace the internal components of the brake master cylinders and calipers, and 
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
26*Lights, signals 
and switchesCheck operation.
Adjust headlight beam.√√√√√√ No. ITEM ROUTINEINITIAL ODOMETER READINGS
600 mi 
(1000 km) 
or 
1 month4000 mi 
(7000 km) 
or 
6 months8000 mi 
(13000 
km) 
or 
12 months12000 mi 
(19000 
km) 
or 
18 months16000 mi 
(25000 
km) 
or 
24 months20000 mi 
(31000 
km) 
or 
30 months 
						

							ENGINE
3-4
EAS20470
ENGINE
EAS20490
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the 
valves.
NOTE:
Valve clearance adjustment should be made 
on a cold engine, at room temperature.
When the valve clearance is to be measured or 
adjusted, the piston must be at top dead center 
(TDC) on the compression stroke.
1. Remove:
Rider seat
Side cowlings
Bottom cowlings
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Canister (for California only)
Refer to “THROTTLE BODIES” on page 7-8.
Throttle body
Refer to “THROTTLE BODIES” on page 7-8.
Air cut-off valve
Refer to “AIR INDUCTION SYSTEM” on 
page 7-15.
Radiator
Refer to “RADIATOR” on page 6-1.
2. Remove:
Ignition coils
Spark plugs
Cylinder head cover
Refer to “CAMSHAFTS” on page 5-7.
3. Remove:
Pickup rotor cover “1”
4. Measure:
Valve clearance
Out of specification → Adjust.



 
 
 








 
 



 
 



 
 



 



a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark “a” on the 
pickup rotor with the crankcase mating sur-
face “b”.
NOTE:
TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other.
c. Measure the valve clearance with a thickness 
gauge “1”.
NOTE:
If the valve clearance is incorrect, note the 
measured reading.
1
 
Valve clearance (cold)
Intake
0.12–0.19 mm (0.0047–0.0075 in)
Exhaust
0.16–0.23 mm (0.0063–0.0091 in)
a b
EX IN 
						

							ENGINE
3-5
Measure the valve clearance in the following 
sequence.
d. To measure the valve clearances of the other 
cylinders, starting with cylinder #1 at TDC, 
turn the crankshaft clockwise as specified in 
the following table.
         
5. Remove:
Camshafts
NOTE:
Refer to “CAMSHAFTS” on page 5-7.
When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.
6. Adjust:
Valve clearance



 
 
 








 
 



 
 



 
 



 



a. Remove the valve lifter “1” and the valve pad 
“2” with a valve lapper “3”.
NOTE:
Cover the timing chain opening with a rag to 
prevent the valve pad from falling into the 
crankcase.
Make a note of the position of each valve lifter 
“1” and valve pad “2” so that they can be in-
stalled in the correct place.
b. Calculate the difference between the speci-
fied valve clearance and the measured valve 
clearance.
Example:
Specified valve clearance = 0.11–0.20 mm 
(0.004–0.008 in)
Measured valve clearance = 0.23 mm (0.009 
in)
0.23 mm (0.009 in) – 0.20 mm (0.008 in) = 
0.03 mm (0.001 in) Valve clearance measuring sequence
Cylinder #1 → #2 → #4 → #3
A. Front
A. Degrees that the crankshaft is turned 
clockwise
B. Cylinder
C. Combustion cycle
Cylinder #2 180°
Cylinder #4 360°
Cylinder #3 540°
1
 
Valve lapper
90890-04101
Valve lapping tool
YM-A8998 
						

							ENGINE
3-6
c. Check the thickness of the current valve pad.
NOTE:
The thickness “a” of each valve pad is marked in 
hundredths of millimeters on the side that touch-
es the valve lifter.
Example:
If the valve pad is marked “155”, the pad 
thickness is 1.55 mm (0.061 in).
d. Calculate the sum of the values obtained in 
steps (b) and (c) to determine the required 
valve pad thickness and the valve pad num-
ber.
Example:
1.55 mm (0.061 in) + 0.03 mm (0.001 in) = 
1.58 mm (0.062 in)
The valve pad number is 158.
e. Round off the valve pad number according to 
the following table, and then select the suit-
able valve pad.
NOTE:
Refer to the following table for the available 
valve pads.
Example:
Valve pad number = 158
Rounded value = 160
New valve pad number = 160
f. Install the new valve pad “1” and the valve lift-
er “2”.
NOTE:
Lubricate the valve lifter with engine oil.
The valve lifter must turn smoothly when rotat-
ed by hand.
Install the valve lifter and the valve pad in the 
correct place.
g. Install the exhaust and intake camshafts, tim-
ing chain and camshaft caps.
NOTE:
Refer to “CAMSHAFTS” on page 5-7.
Lubricate the camshaft bearings, camshaft 
lobes and camshaft journals.
First, install the exhaust camshaft.
Align the camshaft marks with the camshaft 
cap marks.
Turn the crankshaft clockwise several full turns 
to seat the parts.
h. Measure the valve clearance again.
i. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is 
obtained.
          
7. Install:
All removed parts
NOTE:
For installation, reverse the removal procedure.
EAS20570
SYNCHRONIZING THE THROTTLE BODIES
NOTE:
Prior to synchronizing the throttle bodies, the 
valve clearance and the engine idling speed 
should be properly adjusted. Last digit Rounded value
0, 1, 2 0
3, 4, 5, 6 5
7, 8, 9 10
Valve pad range Nos. 150–240
Valve pad thickness1.50–2.40 mm 
(0.0591–0.0945 in)
Available valve pads25 thicknesses in 
0.05 mm (0.002 in) 
increments
T R.. 
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							ENGINE
3-7
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
2. Remove:
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
3. Remove:
Caps “1”
4. Install:
Vacuum gauge “1”
Digital tachometer
5. Install:
Fuel tank
Refer to “FUEL TANK” on page 7-1.
6. Adjust:
Throttle body synchronization



 
 
 








 
 



 
 



 
 







Basic procedure
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.b. Turn the bypass air screw “1” with a white 
paint mark out a little, and then turn it in fully.
c. Using the throttle body that has the bypass air 
screw with a white paint mark as the stan-
dard, turn the bypass air screws without white 
paint marks in or out to the adjust the other 
throttle bodies.
NOTE:
If more than one throttle body has a bypass air 
screw with a white paint mark, use the one with 
the lowest vacuum pressure as the standard.
After each step, rev the engine two or three 
times, each time for less than a second, and 
check the synchronization again.
If an air screw was removed, turn the screw 3/4 
turn in and be sure to synchronize the throttle 
body.
NOTE:
The difference in vacuum pressure between 
two throttle bodies should not exceed 1.33 kPa 
(10 mmHg).
If you are unable to adjust the throttle body 
synchronization using this procedure, use the 
following procedure instead.
          



 
 
 








 
 



 
 



 
 



 



Alternate procedure
NOTE:
Use this alternate procedure if you are unable to 
adjust the throttle body synchronization using 
the basic procedure.
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
 
Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456
 
Engine idling speed
1250–1350 r/min
11
1 
Intake vacuum
20.0 kPa (5.9 inHg) (150 mmHg)
 
Engine idling speed
1250–1350 r/min
11