Yamaha 2007 R6 Service

							ENGINE
3-8
b. Turn all of the bypass air screws in fully.
c. Using the throttle body with the lowest vacu-
um pressure as the standard, turn out the by-
pass air screws of the other throttle bodies to 
adjust them.
NOTE:
Do not turn out the bypass air screw of the 
throttle body with the lowest vacuum pressure.
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).
         
7. Stop the engine and remove the measuring 
equipment.
8. Allow the engine to cool, and then start the 
engine and check that the engine speed does 
not rise abnormally high.
9. Adjust:
Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-8.
10.Install:
Caps
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20630
ADJUSTING THE THROTTLE CABLE FREE 
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the 
engine idling speed and carburetor synchroniza-
tion should be adjusted properly.1. Check:
Throttle cable free play “a”
Out of specification → Adjust.
2. Adjust:
Throttle cable free play



 
 
 








 
 



 
 



 
 



 



a. Loosen the locknut “1”.
b. Turn the adjusting nut “2” in direction “a” or “b” 
until the specified throttle cable free play is 
obtained.
c. Tighten the locknut “1”.
WARNING
EWA12910
After adjusting the throttle cable free play, 
start the engine and turn the handlebar to the 
right and to the left to ensure that this does 
not cause the engine idling speed to change.
          
EAS20680
CHECKING THE SPARK PLUGS
The following procedure applies to all of the 
spark plugs.
 
Intake vacuum
20.0 kPa (5.9 inHg) (150 mmHg)
 
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
 
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)
Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
a
1
2
a
b 
						

							ENGINE
3-9
1. Remove:
Rider seat
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.
Air induction system solenoid
Refer to “AIR INDUCTION SYSTEM” on 
page 7-15.
2. Remove:
Ignition coils
Spark plugs
CAUTION:
ECA13320
Before removing the spark plugs, blow away 
any dirt accumulated in the spark plug wells 
with compressed air to prevent it from falling 
into the cylinders.
3. Check:
Spark plug type
Incorrect → Change.
4. Check:
Electrode “1”
Damage/wear → Replace the spark plug.
Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
Spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.7. Install:
Spark plugs
Ignition coils
NOTE:
Before installing the spark plug, clean the spark 
plug and gasket surface.
8. Install:
Air induction system solenoid
Refer to “AIR INDUCTION SYSTEM” on 
page 7-15.
Canister (for California only)
Refer to “THROTTLE BODIES” on page 7-8.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20710
MEASURING THE COMPRESSION 
PRESSURE
The following procedure applies to all of the cyl-
inders.
NOTE:
Insufficient compression pressure will result in a 
loss of performance.
1. Measure:
Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
Side cowlings
Bottom cowlings
Refer to “GENERAL CHASSIS” on page 4-1.
 
Manufacturer/model
NGK/CR10EK
 
Spark plug gap
0.6–0.7 mm (0.024–0.028 in)
T R.. 
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb) 
						

							ENGINE
3-10
Radiator
Refer to “RADIATOR” on page 6-1.
4. Remove:
Ignition coils
Spark plugs
CAUTION:
ECA13340
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumulat-
ed in the spark plug wells to prevent it from 
falling into the cylinders.
5. Install:
Compression gauge “1”
Extension “2”
6. Measure:
Compression pressure
Out of specification → Refer to steps (c) and 
(d).



 
 
 








 
 



 
 



 
 







a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine 
until the reading on the compression gauge 
stabilizes.
WARNING
EWA12940
To prevent sparking, ground all spark plug 
leads before cranking the engine.
NOTE:
The difference in compression pressure be-
tween cylinders should not exceed 100 kPa (1 
kg/cm², 14 psi).
c. If the compression pressure is above the 
maximum specification, check the cylinder 
head, valve surfaces and piston crown for 
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the min-
imum specification, pour a teaspoonful of en-
gine oil into the spark plug bore and measure 
again.
Refer to the following table.
          
7. Install:
Spark plugs
Ignition coils
8. Install:
Radiator
Refer to “RADIATOR” on page 6-1.
Bottom cowlings
Side cowlings
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20730
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface.
NOTE:
Place the vehicle on a suitable stand.
Make sure the vehicle is upright.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Remove:
Dipstick “1”
 
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
90890-04136
 
Standard compression pressure 
(at sea level)
1550 kPa/400 r/min (220.5 
psi/400 r/min) (15.5 kgf/cm²/400 
r/min)
Minimum–maximum
1300–1600 kPa (184.9–227.6 psi) 
(13.0–16.0 kgf/cm²)
1
2
Compression pressure (with oil applied into 
the cylinder)
Reading Diagnosis
Higher than without 
oilPiston ring(s) wear or 
damage → Repair.
Same as without oilPistons, valves, cylin-
der head gasket or 
piston ring(s) possi-
bly defective → Re-
pair.
T R.. 
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb) 
						

							ENGINE
3-11
4. Check:
Engine oil level
The engine oil level should be between the 
minimum level mark “a” and maximum level 
mark “b”.
Below the minimum level mark → Add the 
recommended engine oil to the proper level.
NOTE:
Before checking the engine oil level, wait a few 
minutes until the oil has settled.
Do not screw the dipstick in when inspecting 
the oil level.
5. Start the engine, warm it up for several min-
utes, and then turn it off.
6. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few 
minutes until the oil has settled.
7. Install:
Dipstick
EAS20780
CHANGING THE ENGINE OIL
1. Start the engine, warm it up for several min-
utes, and then turn it off.
2. Remove:
Left lower side cowling
Left bottom cowling
Refer to “GENERAL CHASSIS” on page 4-1.
3. Place a container under the engine oil drain 
bolt.
4. Remove:
Engine oil filler cap “1”
5. Remove:
Engine oil drain bolt “1”
(along with the gasket)
6. Drain:
Engine oil
(completely from the crankcase)
7. If the oil filter cartridge is also to be replaced, 
perform the following procedure.



 
 
 








 
 



 
 



 
 



 



a. Remove the shift arm “1”.
b. Pull the fuel tank breather hose “2” (except for 
California) and fuel tank over flow hose “3” 
upward to remove them from the guide “4”.
c. Remove the oil filter cartridge “5” with an oil 
filter wrench “6”.
 
Ty p e
YAMALUBE 4, SAE10W30 or 
SAE20W40
Recommended engine oil grade
API service SF, SG type or 
higher
ACEA standard
G4 or G5
1
a b
10˚ 30˚ 50˚ 70˚ 90˚
 110˚0˚ 
 130˚F
YAMALUBE 4 (10W30)
or SAE 10W30
YAMALUBE 4 (20W40)
or SAE 20W40
–10˚ 0˚ 10˚ 20˚ 30˚
 40˚ –20˚
 50˚C
 
Oil filter wrench
90890-01426
YU-38411
1
1 
						

							ENGINE
3-12
d. Lubricate the O-ring “1” of the new oil filter 
cartridge with a thin coat of engine oil.
CAUTION:
EC2C01006
Make sure the O-ring “1” is positioned cor-
rectly in the groove of the oil filter cartridge.
e. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
f. Insert the fuel tank breather hose (except for 
California) and fuel tank overflow hose into 
the guide and place them in their original po-
sition.
g. Install the shift arm “1” by aligning the match 
mark “a” on the shift arm with the match mark 
“b” on the shift shaft “2”.
          
8. Check:
Engine oil drain bolt gasket
Damage → Replace.
9. Install:
Engine oil drain bolt
(along with the gasket)
10.Fill:
Crankcase
(with the specified amount of the recom-
mended engine oil)
11.Install:
Engine oil filler cap
12.Start the engine, warm it up for several min-
utes, and then turn it off.
13.Check:
Engine
(for engine oil leaks)
14.Check:
Engine oil level
Refer to “CHECKING THE ENGINE OIL 
LEVEL” on page 3-10.
EAS20820
MEASURING THE ENGINE OIL PRESSURE
1. Check:
Engine oil level
Below the minimum level mark → Add the 
recommended engine oil to the proper level.
T R.. 
Oil filter cartridge
17 Nm (1.7 m·kg, 12 ft·lb)
T R.. 
Shift arm bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
1
2
4
5
3
6
T R.. 
Engine oil drain bolt
43 Nm (4.3 m·kg, 31 ft·lb)
 
Engine oil quantity
Total amount
3.40 L (3.59 US qt) (2.99 Imp.qt)
Without oil filter cartridge re-
placement
2.40 L (2.54 US qt) (2.11 Imp.qt)
With oil filter cartridge replace-
ment
2.60 L (2.75 US qt) (2.29 Imp.qt)
2
b b
1 a 
						

							ENGINE
3-13
2. Start the engine, warm it up for several min-
utes, and then turn it off.
CAUTION:
ECA13410
When the engine is cold, the engine oil will 
have a higher viscosity, causing the engine 
oil pressure to increase. Therefore, be sure 
to measure the engine oil pressure after 
warming up the engine.
3. Remove:
Left lower side cowling
Left bottom cowling
Refer to “GENERAL CHASSIS” on page 4-1.
4. Remove:
Main gallery bolt “1”
WARNING
EWA12980
The engine, muffler and engine oil are ex-
tremely hot.
5. Install:
Oil pressure gauge set “1”
Oil pressure adapter H “2”
6. Measure:
Engine oil pressure
(at the following conditions)Out of specification → Adjust.
7. Install:
Main gallery bolt
8. Install:
Left bottom cowling
Left lower side cowling
Refer to “GENERAL CHASSIS” on page 4-1.
EAS20870
ADJUSTING THE CLUTCH LEVER FREE 
PLAY
1. Check:
Clutch lever free play “a”
Out of specification → Adjust.
2. Adjust:
Clutch lever free play
 
Oil pressure gauge set
90890-03120
Oil pressure adapter H
90890-03139
1
2
1
 
Oil pressure (hot)
80.0 kPa/1300 r/min (11.6 
psi/1300 r/min) (0.80 
kgf/cm²/1300 r/min)
Oil temperature
82–92 °C (180–198 °F)
Engine oil pressure Possible causes
Below specificationFaulty oil pump
Clogged oil filter
Leaking oil passage
Broken or dam-
aged oil seal
Above specificationLeaking oil passage
Faulty oil filter
Oil viscosity too 
high
T R.. 
Main gallery bolt
8 Nm (0.8 m·kg, 5.8 ft·lb)
 
Clutch lever free play
10.0–15.0 mm (0.39–0.59 in)
a 
						

							ENGINE
3-14



 
 
 








 
 



 
 



 
 







Handlebar side
a. Turn the adjusting bolt “1” in direction “a” or 
“b” until the specified clutch lever free play is 
obtained.
NOTE:
If the specified clutch lever free play cannot be 
obtained on the handlebar side of the cable, use 
the adjusting nut on the engine side.
         



 
 
 








 
 



 
 



 
 







Engine side
a. Loosen the locknut “1”.
b. Turn the adjusting nut “2” in direction “a” or “b” 
until the specified clutch lever free play is ob-
tained.
c. Tighten the locknut “1”.
         
EAS20960
REPLACING THE AIR FILTER ELEMENT
1. Remove:
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Upper air filter case
Refer to “AIR FILTER CASE” on page 7-5.
2. Remove:
Air filter element “1”
3. Check:
Air filter element
Damage → Replace.
NOTE:
Replace the air filter element every 40000 km 
(2400 mi) of operation.
The air filter needs more frequent service if you 
are riding in unusually wet or dusty areas.
4. Install:
Air filter element
CAUTION:
EC2C01007
Never operate the engine without the air filter 
element installed. Unfiltered air will cause 
rapid wear of engine parts and may damage 
the engine. Operating the engine without the 
air filter element will also affect the throttle 
body synchronization, leading to poor en-
gine performance and possible overheating.
NOTE:
When installing the air filter element into the low-
er air filter case, make sure that the sealing sur-
faces are aligned to prevent any air leaks.
5. Install:
Upper air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1. Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
Direction “a”
Clutch lever free play is increased.
Direction “b”
Clutch lever free play is decreased.
1a
b
1
2
b
a
1 
						

							ENGINE
3-15
EAS21010
CHECKING THE THROTTLE BODY JOINTS
The following procedure applies to all of the 
throttle body joints and intake manifolds.
1. Remove:
Rider seat
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.
2. Check:
Throttle body joints “1”
Cracks/damage → Replace.
3. Install:
Throttle body
Refer to “THROTTLE BODIES” on page 7-8.
Canister (for California only)
Refer to “THROTTLE BODIES” on page 7-8.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21030
CHECKING THE FUEL LINE
The following procedure applies to all of the fuel, 
vacuum and breather hoses.
1. Remove:
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check:
Fuel hoses “1”
Vacuum hoses
Overflow hose “2”Breather hose “3” (except for California)
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
ECA14940
Make sure the fuel tank breather hose is rout-
ed correctly.
3. Install:
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21070
CHECKING THE CRANKCASE BREATHER 
HOSE
1. Remove:
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check:
Crankcase breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
CAUTION:
ECA13450
Make sure the crankcase breather hose is 
routed correctly.
3. Install:
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
1
11
2
3
1 
						

							ENGINE
3-16
EAS21080
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the ex-
haust pipe assembly and gaskets.
1. Remove:
Side cowlings
Bottom cowlings
Refer to “GENERAL CHASSIS” on page 4-1.
2. Check:
Exhaust pipe assembly “1”
Muffler “2”
Cracks/damage → Replace.
Gaskets “3”
Exhaust gas leaks → Replace.
3. Check:
Tightening torque
Exhaust pipe assembly and cylinder head 
nuts “4”
Exhaust pipe assembly and exhaust pipe as-
sembly bracket bolts “5”
Exhaust pipe assembly and muffler bolt “6”
Muffler and right rider footrest bracket bolt “7”
4. Install:
Bottom cowlings
Side cowlings
Refer to “GENERAL CHASSIS” on page 4-1.
EAS21090
CHECKING THE CANISTER (for California 
only)
1. Remove:
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
2. Check:
Canister
Canister purge hoses
3-way joint
Fuel tank breather hose (rollover valve to 
canister)
Cracks/damage → Replace.
Refer to “THROTTLE BODIES” on page 7-8.
3. Install:
Air filter case
Refer to “AIR FILTER CASE” on page 7-5.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
EAS21100
ADJUSTING THE EXUP CABLES
1. Remove:
EXUP valve pulley cover “1”
T R.. 
Exhaust pipe assembly and cylin-
der head nut
20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe assembly and ex-
haust pipe assembly bracket bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe assembly and muf-
fler bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
Muffler and right rider footrest 
bracket bolt
20 Nm (2.0 m·kg, 14 ft·lb)
2
3 1
(8)3
7
6
4
5 5 
						

							ENGINE
3-17
2. Check:
EXUP system operation



 
 
 








 
 



 
 



 
 







a. Activate the diagnostic mode and select the 
diagnostic code number “53”.
Refer to “FUEL INJECTION SYSTEM” on 
page 8-33.
b. Set the engine stop switch to “”.
c. Check that the EXUP valve operates proper-
ly.
NOTE:
Check that the projection “a” on the EXUP valve 
pulley contacts the stopper “b” (fully open posi-
tion). If the projection does not contact the stop-
per, adjust the EXUP cable free play.
         
3. Check:
EXUP cable free play (at the EXUP valve pul-
ley) “a”
Out of specification → Adjust.4. Adjust:
EXUP cable free play



 
 
 








 
 



 
 



 
 



 



a. Loosen the locknuts “1” and “2”.
b. Turn the adjusting bolt “3” in direction “a” or 
“b” until the specification.
c. Tighten the locknut “1” to specification.
d. Turn the adjusting bolt “4” in direction “a” or 
“b” until the specification.
e. Tighten the locknut “2” to specification.
 
EXUP cable free play (at the 
EXUP valve pulley)
1.5 mm (0.06 in) or less
1
ba
Direction “a”
Free play is increased.
Direction “b”
Free play is decreased.
 
EXUP cable free play (at the 
EXUP valve pulley)
c: 1.5 mm (0.06 in) or less
T R.. 
Locknut (EXUP cable adjusting 
bolt)
7 Nm (0.7 m·kg, 5.1 ft·lb)
Direction “a”
Free play is increased.
Direction “b”
Free play is decreased.
 
EXUP cable free play (at the 
EXUP valve pulley)
d: 1.5 mm (0.06 in) or less
T R.. 
Locknut (EXUP cable adjusting 
bolt)
7 Nm (0.7 m·kg, 5.1 ft·lb)
a