Yamaha 2007 R6 Service

							FRONT FORK
4-48
NOTE:
Loosen the nut using a proper tool that has a 
thickness of 3 mm (0.12 in) or less.
d. Remove the cap bolt.
e. Remove the rod holder and fork spring com-
pressor.
f. Remove the nut and spacer.
         
3. Drain:
•Fork oil
NOTE:
Stroke the damper rod “1” several times while 
draining the fork oil.
4. Remove:
•Damper rod assembly
NOTE:
Remove the damper rod assembly with the 
damper rod holder “1”.5. Remove:
•Oil seal clip “1”
(with a flat-head screwdriver)
EAS23010
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Check:
•Inner tube
•Outer tube
Bends/damage/scratches → Replace.
WARNING
EWA13650
Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it.
2. Measure:
•Spring free length “a”
Out of specification → Replace.
 
Damper rod holder
90890-01506
YM-01506
1 6
7
a
3
 
Fork spring free length
247.0 mm (9.72 in)
Limit
242.1 mm (9.53 in)
1 
						

							FRONT FORK
4-49
3. Check:
• Damper rod
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
 Damper adjusting rod
Bends/damage → Replace.
CAUTION:
ECA14200
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly 
sensitive to foreign material.
 When disassembling and assembling the 
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4. Check:
 Cap bolt O-ring “1”
Damage/wear → Replace.
 Cap bolt collar projections “2”
Cracks/damage → Replace.
EAS23040
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
WARNING
EWA13660
 Make sure the oil levels in both front fork 
legs are equal.
 Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
 When assembling the front fork leg, be sure to 
replace the following parts:
– Oil seal
– Dust seal
– O-ring
 Before assembling the front fork leg, make 
sure all of the components are clean.
1. Install:
 Damper rod assembly “1”
 Inner tube “2”
CAUTION:
ECA14210
Allow the damper rod assembly to slide 
slowly down the inner tube “2” until it pro-
trudes from the bottom of the inner tube. Be 
careful not to damage the inner tube.
2. Lubricate:
 Inner tube’s outer surface
3. Tighten:
 Damper rod assembly
NOTE:
Tighten the damper rod assembly with the 
damper rod holder “1”.
4. Install:
 Dust seal “1” 
 Oil seal clip “2” 
 Oil seal “3” 
 Washer “4”
1
2
 
Recommended oil
Ohlins R & T43 (ACC-RT43F-00-
00)
T R.. 
Damper rod assembly
35 Nm (3.5 m·kg, 25 ft·lb)
 
Damper rod holder
90890-01506
YM-01506
1
2
1
New
New
New 
						

							FRONT FORK
4-50
CAUTION:
EC2C01012
Make sure the numbered side of the oil seal 
faces bottom side.
NOTE:
•Before installing the oil seal, lubricate its lips 
with lithium-soap-based grease.
•Lubricate the outer surface of the inner tube 
with fork oil.
•Before installing the oil seal, cover the top of 
the front fork leg with a plastic bag to protect 
the oil seal during installation.
5. Install:
•Outer tube
(to the inner tube)
6. Install:
•Washer
•Oil seal “1”
(with the fork seal driver “2”)7. Install:
•Oil seal clip “1”NOTE:
Adjust the oil seal clip so that it fits into the outer 
tube’s groove.
8. Install:
•Dust seal “1”
(with the fork seal driver weight “2”)
9. Install:
•Rod puller “1”
•Rod puller attachment “2”
(onto the damper rod “3”)
 
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 
mm)
YM-01442
 
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 
mm)
YM-01442
1 2 
						

							FRONT FORK
4-51
10.Fully compress the front fork leg.
11.Fill:
•Front fork leg
(with the specified amount of the recom-
mended fork oil)
CAUTION:
ECA14230
Be sure to use the recommended fork oil. 
Other oils may have an adverse effect on 
front fork performance.
When disassembling and assembling the 
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
12.After filling the front fork leg, slowly stroke the 
damper rod “1” up and down (at least ten 
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.13.Before measuring the fork oil level, wait ten 
minutes until the oil has settled and the air 
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual 
air.
14.Measure:
•Front fork leg oil level “a”
(from the top of the outer tube, with the outer 
tube fully compressed and without the fork 
spring)
Out of specification → Correct.
15.Install:
•Spring seat “1”
•Fork spring “2”
•Spacer “3”
•Nut “4”
•Damper adjusting rod “5”
•Washer “6”
•Cap bolt “7”
(with O-ring)
 
Rod puller
90890-01437
Universal damping rod bleeding 
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding 
tool set
YM-A8703
 
Quantity
465.0 cm³ (15.72 US oz) (16.37 
Imp.oz)
Recommended oil
Ohlins R & T43 (ACC-RT43F-00-
00)
 
Level
108.0 mm (4.25 in) 
						

							FRONT FORK
4-52



 
 
 








 
 



 
 



 
 







a. Remove the rod puller attachment.
b. Install the spring seat.
c. Install the fork spring.
NOTE:
Install the spring with the smaller pitch “a” facing 
up “A”.
d. Install the spacer.
e. Install the nut.
f. Reinstall the rod puller attachment.
g. Press down on the spacer with the fork spring 
compressor “8”.
h. Pull up the rod puller and install the rod holder 
“9” between the nut “4” and the spacer “3”.
NOTE:
Use the side of the rod holder that is marked “B”.
i. Remove the rod puller and rod puller attach-
ment.
j. Install the nut “4” all the way onto the damper 
rod assembly.
k. Install the damper adjusting rod.
l. Install the washer and cap bolt, and then fin-
ger tighten the cap bolt.
m. Hold the nut and tighten the spring preload 
adjusting bolt “10” into the cap bolt to specifi-
cation.
WARNING
EWA13670
Always use a new cap bolt O-ring.
CAUTION:
EC2C01013
When tightening the spring preload adjust-
ing bolt “10” into the cap bolt, be sure not to 
break the projections “c” on the collar “11”.
NOTE:
Hold the nut “4” using a proper tool that has a 
thickness of 3 mm (0.12 in) or less.
 
Rod puller
90890-01437
Universal damping rod bleeding 
tool set
YM-A8703
Rod puller attachment (M10)
90890-01436
Universal damping rod bleeding 
tool set
YM-A8703
Fork spring compressor
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
51
2 3
4
6
7
T R.. 
Nut and cap bolt
25 Nm (2.5 m·kg, 18 ft·lb)
3
84
9 
						

							FRONT FORK
4-53
n. Remove the rod holder and fork spring com-
pressor.
         
16.Install:
•Cap bolt
(to the outer tube)
NOTE:
Temporarily tighten the cap bolt.
EAS23050
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the 
front fork legs.
1. Install:
•Front fork leg
Temporarily tighten the upper and lower 
bracket pinch bolts.
WARNING
EWA13680
Make sure the brake hoses are routed prop-
erly.
NOTE:
Make sure the outer tube is flush with the top of 
the upper bracket.
2. Tighten:
•Lower bracket pinch bolts “1” and “2”
NOTE:
Tighten each bolt to 23 Nm (2.3 m·kg, 17 ft·lb) in 
the order pinch bolt “1” → pinch bolt “2” → pinch 
bolt “1”.3. Tighten:
•Cap bolt “1”
•Handlebar bolt “2”
•Handlebar pinch bolt “3”
•Upper bracket pinch bolt “4”
4. Check:
•Cable routing
NOTE:
Make sure the brake hose, throttle cables, clutch 
cable, and handlebar switch leads are routed 
properly. Refer to “CABLE ROUTING” on page 
2-47.
5. Install:
•Plastic locking tie “1”
•Plastic locking tie “2”
NOTE:
•Fasten the left handlebar switch lead to the left 
front fork leg with the plastic locking tie.
T R.. 
Lower bracket pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb)
10
11
c
4
T R.. 
Cap bolt
20 Nm (2.0 m·kg, 14 ft·lb)
T R.. 
Handlebar bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
T R.. 
Handlebar pinch bolt
32 Nm (3.2 m·kg, 23 ft·lb)
T R.. 
Upper bracket pinch bolt
26 Nm (2.6 m·kg, 19 ft·lb)
1
2
432 1 
						

							FRONT FORK
4-54
•Fasten the front brake hose to the right front 
fork leg with the plastic locking tie.
6. Adjust:
•Spring preload
•Rebound damping
•Compression damping
Refer to “ADJUSTING THE FRONT FORK 
LEGS” on page 3-28.
1 2 
						

							STEERING HEAD
4-55
EAS23090
STEERING HEAD
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks
Front cowling assemblyRefer to “GENERAL CHASSIS” on page 
4-1.
Front fork legs Refer to “FRONT FORK” on page 4-44.
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 coverRefer to “AIR INDUCTION SYSTEM” on 
page 7-15.
1 Rectifier/regulator holder 1
2 Left coupler holder 1
3 Main switch coupler 2 Disconnect.
4 Clutch cable 1 Disconnect.
5 Left handlebar assembly 1
6 Right handlebar assembly 1
7 Horn connector 2 Disconnect.
8Horn 1
9 Front brake hose joint 1
LS
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..23 Nm (2.3 m • 
kg, 17 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
LS
LS
T R..1st   52 Nm (5.2 m • 
kg, 37 ft • lb)
2nd  14 Nm (1.4 m 
• 
kg, 10 ft • Ib)
T R..115 Nm (11.5 m • 
kg, 85 ft • lb)
T R..5 Nm (0.5 m • 
kg, 3.6 ft • Ib)
12
13
14
15
16
13
2 7
2017
4 8
18
10 9
115 19
21
25
26
22
23
246 
						

							STEERING HEAD
4-56
10 Lower bracket cover 1
11 Front brake hose joint bracket 1
12 Steering stem nut 1
13 Upper bracket 1
14 Lock washer 1
15 Upper ring nut 1
16 Rubber washer 1
17 Lower ring nut 1
18 Lower bracket 1
19 Upper bearing cover 1
20 Upper bearing inner race 1
21 Upper bearing 1
22 Lower bearing 1
23 Lower bearing inner race 1
24 Lower bearing dust seal 1
25 Upper bearing outer race 1
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks
LS
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..23 Nm (2.3 m • 
kg, 17 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
LS
LS
T R..1st   52 Nm (5.2 m • 
kg, 37 ft • lb)
2nd  14 Nm (1.4 m 
• 
kg, 10 ft • Ib)
T R..115 Nm (11.5 m • 
kg, 85 ft • lb)
T R..5 Nm (0.5 m • 
kg, 3.6 ft • Ib)
12
13
14
15
16
13
2 7
2017
4 8
18
10 9
115 19
21
25
26
22
23
246 
						

							STEERING HEAD
4-57
26 Lower bearing outer race 1
For installation, reverse the removal proce-
dure.
Removing the lower bracket
Order Job/Parts to remove Q’ty Remarks
LS
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..23 Nm (2.3 m • 
kg, 17 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
LS
LS
T R..1st   52 Nm (5.2 m • 
kg, 37 ft • lb)
2nd  14 Nm (1.4 m 
• 
kg, 10 ft • Ib)
T R..115 Nm (11.5 m • 
kg, 85 ft • lb)
T R..5 Nm (0.5 m • 
kg, 3.6 ft • Ib)
12
13
14
15
16
13
2 7
2017
4 8
18
10 9
115 19
21
25
26
22
23
246