Yamaha 2007 R6 Service
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4 CHASSIS GENERAL CHASSIS...................................................................................... 4-1 FRONT WHEEL.............................................................................................. 4-4 REMOVING THE FRONT WHEEL ........................................................... 4-7 DISASSEMBLING THE FRONT WHEEL.................................................. 4-7 CHECKING THE FRONT WHEEL ............................................................ 4-7 ASSEMBLING THE FRONT WHEEL........................................................ 4-8 ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................... 4-8 CHECKING THE FRONT BRAKE DISCS................................................. 4-9 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ................. 4-9 REAR WHEEL............................................................................................... 4-11 REMOVING THE REAR WHEEL ............................................................ 4-14 DISASSEMBLING THE REAR WHEEL .................................................. 4-14 CHECKING THE REAR WHEEL ............................................................ 4-14 CHECKING THE REAR BRAKE CALIPER BRACKET........................... 4-14 CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-14 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ......... 4-14 ASSEMBLING THE REAR WHEEL ........................................................ 4-15 ADJUSTING THE REAR WHEEL STATIC BALANCE ........................... 4-15 CHECKING THE REAR BRAKE DISC ................................................... 4-15 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ...................... 4-15 FRONT BRAKE............................................................................................. 4-17 INTRODUCTION ..................................................................................... 4-22 CHECKING THE FRONT BRAKE DISCS............................................... 4-22 REPLACING THE FRONT BRAKE PADS .............................................. 4-23 REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-24 DISASSEMBLING THE FRONT BRAKE CALIPERS ............................. 4-24 CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-24 ASSEMBLING THE FRONT BRAKE CALIPERS ................................... 4-25 INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-25 REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-26 CHECKING THE FRONT BRAKE MASTER CYLINDER ....................... 4-26 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-26 INSTALLING THE FRONT BRAKE MASTER CYLINDER ..................... 4-27
REAR BRAKE............................................................................................... 4-29 INTRODUCTION ..................................................................................... 4-34 CHECKING THE REAR BRAKE DISC ................................................... 4-34 REPLACING THE REAR BRAKE PADS ................................................ 4-34 REMOVING THE REAR BRAKE CALIPER ............................................ 4-35 DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-35 CHECKING THE REAR BRAKE CALIPER............................................. 4-36 ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-36 INSTALLING THE REAR BRAKE CALIPER........................................... 4-37 REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-38 CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-38 ASSEMBLING THE REAR BRAKE MASTER CYLINDER ..................... 4-38 INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-38 HANDLEBARS.............................................................................................. 4-40 REMOVING THE HANDLEBARS ........................................................... 4-42 CHECKING THE HANDLEBARS ............................................................ 4-42 INSTALLING THE HANDLEBARS .......................................................... 4-42 FRONT FORK............................................................................................... 4-44 REMOVING THE FRONT FORK LEGS.................................................. 4-47 DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-47 CHECKING THE FRONT FORK LEGS .................................................. 4-48 ASSEMBLING THE FRONT FORK LEGS .............................................. 4-49 INSTALLING THE FRONT FORK LEGS ................................................ 4-53 STEERING HEAD......................................................................................... 4-55 REMOVING THE LOWER BRACKET .................................................... 4-58 CHECKING THE STEERING HEAD ....................................................... 4-58 INSTALLING THE STEERING HEAD ..................................................... 4-58 REAR SHOCK ABSORBER ASSEMBLY.................................................... 4-60 HANDLING THE REAR SHOCK ABSORBER ........................................ 4-62 DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .................. 4-62 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-62 CHECKING THE CONNECTING ARM AND RELAY ARM..................... 4-63 INSTALLING THE RELAY ARM ............................................................. 4-63 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-63 SWINGARM.................................................................................................. 4-65 REMOVING THE SWINGARM ............................................................... 4-67 CHECKING THE SWINGARM ................................................................ 4-67 INSTALLING THE SWINGARM .............................................................. 4-68
CHAIN DRIVE............................................................................................... 4-70 REMOVING THE DRIVE CHAIN ............................................................ 4-71 CHECKING THE DRIVE CHAIN ............................................................. 4-71 CHECKING THE DRIVE SPROCKET .................................................... 4-72 CHECKING THE REAR WHEEL SPROCKET........................................ 4-72 CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-72 INSTALLING THE DRIVE CHAIN ........................................................... 4-72
GENERAL CHASSIS 4-1 EAS21830 GENERAL CHASSIS Removing the seat and battery Order Job/Parts to remove Q’ty Remarks 1 Rider seat 1 2 Passenger seat 1 3 Fuel tank bracket 1 4 Negative battery lead 1 Disconnect. 5 Positive battery lead 1 Disconnect. 6 Battery band 1 7 Battery 1 For installation, reverse the removal proce- dure. T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 7 6 4 5 3 2 (4)
GENERAL CHASSIS 4-2 Removing the tail/brake light assembly Order Job/Parts to remove Q’ty Remarks Rider seat/Passenger seatRefer to “GENERAL CHASSIS” on page 4-1. 1 Owner’s tool kit 1 2 Rear upper cowling 1 3 Rear right turn signal light coupler 1 Disconnect. 4 Rear left turn signal light coupler 1 Disconnect. 5 License plate light connector 2 Disconnect. 6 License plate light assembly 1 7 Rear upper cowling damper plate 1 8 Tail/brake light coupler 1 Disconnect. 9 Tail/brake light assembly 1 10 Right passenger footrest 1 11 Left passenger footrest 1 12 Rear lower cowling 1 For installation, reverse the removal proce- dure. T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) T R..7 Nm (0.7 m • kg, 5.1 ft • Ib) T R..28 Nm (2.8 m • kg, 20 ft • Ib) 2 8 12 1 106 94 3 5 7 11 (4) (4)
GENERAL CHASSIS 4-3 Removing the side cowlings and front cowling assembly Order Job/Parts to remove Q’ty Remarks 1 Side panel 2 2 Upper side cowling 2 3 Lower side cowling 2 4 Front turn signal/position light coupler 2 Disconnect. 5 Bottom cowling 2 6 Bottom cowling inner panel 2 7 Air intake duct 2 8 Rearview mirror 2 9 Headlight sub-wire harness 1 coupler 1 Disconnect. 10 Headlight sub-wire harness 2 coupler 1 Disconnect. 11 Front cowling assembly 1 For installation, reverse the removal proce- dure. 5 4 5 47 3 R..13 Nm (1.3 m • kg, 9.4 ft • Ib) R..7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 7 2 1 6 3 8 1110 9 (4) 81 2
FRONT WHEEL 4-4 EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 1 Left reflector assembly 1 2 Right reflector assembly 1 3 Left front brake hose holder 1 4 Right front brake hose holder 1 5 Left front brake caliper 1 6 Right front brake caliper 1 7 Front wheel axle pinch bolt 4 Loosen. 8 Front wheel axle bolt 1 9 Front wheel axle 1 10 Front wheel 1 11 Collar 2 12 Dust cover 2
FRONT WHEEL 4-5 13 Front brake disc 2 For installation, reverse the removal proce- dure. Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks
FRONT WHEEL 4-6 Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3Spacer 1 For assembly, reverse the disassembly pro- cedure.
FRONT WHEEL
4-7
EAS21900
REMOVING THE FRONT WHEEL
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Remove:
Left brake caliper
Right brake caliper
NOTE:
Do not apply the brake lever when removing the
brake calipers.
EAS21910
DISASSEMBLING THE FRONT WHEEL
1. Remove:
Oil seals
Wheel bearings
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
c. Remove the wheel bearings “3” with a gener-
al bearing puller.
EAS21920
CHECKING THE FRONT WHEEL
1. Check:
Wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
EWA13460
Do not attempt to straighten a bent wheel ax-
le.
2. Check:
Tire
Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-32 and “CHECKING THE WHEELS” on
page 3-33.
3. Measure:
Radial wheel runout “1”
Lateral wheel runout “2”
Over the specified limits → Replace.
4. Check:
Wheel bearings
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
Oil seals
Damage/wear → Replace.
Radial wheel runout limit
1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)