Yamaha 2007 R6 Service
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STEERING HEAD
4-58
EAS23110
REMOVING THE LOWER BRACKET
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
•Upper ring nut “1”
•Rubber washer
•Lower ring nut “2”
•Lower bracket
WARNING
EWA13730
Securely support the lower bracket so that
there is no danger of it falling.
NOTE:
Hold the lower ring nut with the ring nut wrench
“3”, and then remove the upper ring nut with the
steering nut wrench “4”.
EAS23120
CHECKING THE STEERING HEAD
1. Wash:
•Bearings
•Bearing races
2. Check:
•Bearings
•Bearing races
Damage/pitting → Replace.3. Replace:
•Bearings
•Bearing races
a. Remove the bearing race from the steering
head pipe “1” with a long rod “2” and hammer.
b. Remove the bearing race from the lower
bracket “3” with a floor chisel “4” and ham-
mer.
c. Install new bearing races.
CAUTION:
ECA14270
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearings and bearing races
as a set.
4. Check:
•Upper bracket
•Lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EAS23140
INSTALLING THE STEERING HEAD
1. Lubricate:
•Upper bearing
•Lower bearing
•Bearing races
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Spanner wrench
YU-33975
Recommended cleaning solvent
Kerosene
1
2
3
4
Recommended lubricant
Lithium-soap-based grease
STEERING HEAD 4-59 2. Install: •Lower ring nut “1” •Rubber washer “2” •Upper ring nut “3” •Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-26. 3. Install: •Upper bracket •Steering stem nut •Right handlebar assembly •Left handlebar assembly NOTE: Temporarily tighten the steering stem nut and handlebar bolts. 4. Install: •Front fork legs Refer to “FRONT FORK” on page 4-44. NOTE: Temporarily tighten the lower bracket pinch bolts. 5. Tighten: •Steering stem nut 6. Install: •Front brake hose joint bracket “1” •Lower bracket cover “2” •Front brake hose joint “3” NOTE: Make sure that the tab “a” on the front brake hose joint bracket contacts the side “b” of the front brake hose joint. 7. Check: •Cable routing NOTE: Make sure the main switch lead, brake hoses, throttle cables, clutch cable, and handlebar switch leads are routed properly. Refer to “CA- BLE ROUTING” on page 2-47. T R.. Steering stem nut 115 Nm (11.5 m·kg, 85 ft·lb) T R.. Front brake hose joint bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) T R.. Lower bracket cover bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) T R.. Front brake hose joint bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) a2b31
REAR SHOCK ABSORBER ASSEMBLY 4-60 EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Exhaust pipe assembly brackets Refer to “ENGINE REMOVAL” on page 5-1. Rear wheel Refer to “REAR WHEEL” on page 4-11. Fuel tank Refer to “FUEL TANK” on page 7-1. 1 Connecting arm nut/Washer/Bolt 2/2/2 2 Connecting arm 2 3Rear shock absorber assembly lower nut/Wash- er/Bolt1/1/1 4 Rear shock absorber assembly bracket nut 1 5 Rear shock absorber assembly upper nut/Bolt 1/1 6 Rear shock absorber assembly bracket 1 7 Rear shock absorber assembly 1 8Spacer bolt 1 9 Relay arm nut/Bolt/Spacer 1/1/1 10 Relay arm 1 11 Spacer 1 12 Spacer 1 11 11 2 9 13 15 141312 15 10 9 93 5 13 8 4 6 7 14 13 11 3 5 2 11 LS LS LSLS LS New New NewNew 133 T R..16 Nm (1.6 m • kg, 11 ft • Ib)T R..40 Nm (4.0 m • kg, 29 ft • Ib) T R..40 Nm (4.0 m • kg, 29 ft • Ib) T R..52 Nm (5.2 m • kg, 37 ft • Ib) T R..44 Nm (4.4 m • kg, 32 ft • Ib)T R..40 Nm (4.0 m • kg, 29 ft • Ib)
REAR SHOCK ABSORBER ASSEMBLY 4-61 13 Oil seal 6 14 Bearing 2 15 Bearing 2 For installation, reverse the removal proce- dure. Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks 11 11 2 9 13 15 141312 15 10 9 93 5 13 8 4 6 7 14 13 11 3 5 2 11 LS LS LSLS LS New New NewNew 133 T R..16 Nm (1.6 m • kg, 11 ft • Ib)T R..40 Nm (4.0 m • kg, 29 ft • Ib) T R..40 Nm (4.0 m • kg, 29 ft • Ib) T R..52 Nm (5.2 m • kg, 37 ft • Ib) T R..44 Nm (4.4 m • kg, 32 ft • Ib)T R..40 Nm (4.0 m • kg, 29 ft • Ib)
REAR SHOCK ABSORBER ASSEMBLY 4-62 EAS23180 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber. Do not tamper or attempt to open the rear shock absorber. Do not subject the rear shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. Do not deform or damage the rear shock absorber in any way. Rear shock absorber damage will result in poor damping perfor- mance. EAS23190 DISPOSING OF A REAR SHOCK ABSORBER 1. Gas pressure must be released before dis- posing of a rear shock absorber. To release the gas pressure, drill a 2–3 mm (0.08–0.12 in) hole through the rear shock absorber at a point 50 mm (1.97 in) from its end as shown. WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips. EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 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 rear wheel is elevated. 2. Remove: •Connecting arm bolts “1” •Connecting arms “2” •Rear shock absorber assembly lower bolt “3” NOTE: While removing the connecting arm bolts, hold the swingarm so that it does not drop down. 3. Remove: •Rear shock absorber assembly bracket nut “1” •Rear shock absorber assembly upper bolt “2” •Rear shock absorber assembly bracket “3” •Rear shock absorber assembly NOTE: Lower the swingarm, and then remove the rear shock absorber assembly from between the swingarm and frame. EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: •Rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. •Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. 1 2 3 1 2 3
REAR SHOCK ABSORBER ASSEMBLY 4-63 •Spring Damage/wear → Replace the rear shock ab- sorber assembly. •Bushing Damage/wear → Replace. •Spacer Damage/scratches → Replace. •Bolts Bends/damage/wear → Replace. EAS23260 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: •Connecting arms •Relay arm Damage/wear → Replace. 2. Check: •Bearings •Oil seals Damage/pitting → Replace. 3. Check: •Spacers Damage/scratches → Replace. EAS23270 INSTALLING THE RELAY ARM 1. Lubricate: •Spacers •Bearings 2. Install: •Bearings “1”, “2” (to the relay arm) •Oil seals “3” EAS23310 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: •Spacer 2. Tighten: •Relay arm nut 3. Install: •Spacer bolt •Rear shock absorber assembly •Rear shock absorber assembly bracket “1” NOTE: Be sure to fit the projection on either side of the rear shock absorber assembly bracket into the indentation in the frame. Recommended lubricant Lithium-soap-based grease Installed depth of bearing “a” 4.5 mm (0.18 in) Installed depth of bearing “b” 3.5 mm (0.14 in) Installed depth of oil seal “c” 1.0 mm (0.04 in) 4. Rear shock absorber 5. Relay arm 6. Connecting arms A. Left side B. Right side Recommended lubricant Lithium-soap-based grease T R.. Relay arm nut 40 Nm (4.0 m·kg, 29 ft·lb) a a 1 6 5 4 bb c c 6 3 1 3 22 AB
REAR SHOCK ABSORBER ASSEMBLY 4-64 4. Tighten: •Spacer bolt •Rear shock absorber assembly lower nut •Rear shock absorber assembly upper nut •Rear shock absorber assembly bracket nut 5. Install: •Connecting arms NOTE: When installing the connecting arms, lift up the swingarm. 6. Tighten: •Connecting arm nuts T R.. Spacer bolt 16 Nm (1.6 m·kg, 11 ft·lb) T R.. Rear shock absorber assembly lower nut 40 Nm (4.0 m·kg, 29 ft·lb) T R.. Rear shock absorber assembly upper nut 44 Nm (4.4 m·kg, 32 ft·lb) T R.. Rear shock absorber assembly bracket nut 52 Nm (5.2 m·kg, 37 ft·lb) T R.. Connecting arm nuts 40 Nm (4.0 m·kg, 29 ft·lb) 1
SWINGARM 4-65 EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-11. Rear shock absorberRefer to “REAR SHOCK ABSORBER AS- SEMBLY” on page 4-60. Drive chain guide (drive sprocket side) Refer to “CHAIN DRIVE” on page 4-70. 1 Drive chain adjusting locknut 2 2 Drive chain puller 2 3 Drive chain adjusting bolt 2 4 Rear fender 1 5 Drive chain guard 1 6 Drive chain guide (swingarm side) 1 7 Drive chain 1 8 Swingarm pivot shaft nut 1 9 Washer 1 10 Swingarm pivot shaft ring nut 1 11 Washer 1 12 Swingarm pivot shaft 1 4 16 914 14 20 13 15 19 17 65 3 10 12 832 18 11 1 12 LS LS 2019 7 LS LS NewNew LS LS 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..16 Nm (1.6 m • kg, 11 ft • Ib) T R..70 Nm (7.0 m • kg, 50 ft • lb) T R..95 Nm (9.5 m • kg, 68 ft • Ib)
SWINGARM 4-66 13 Swingarm 1 14 Dust cover 2 15 Bearing 1 16 Bearing 1 17 Spacer 1 18 Spacer 1 19 Oil seal 2 20 Bearing 2 For installation, reverse the removal proce- dure. Removing the swingarm Order Job/Parts to remove Q’ty Remarks 4 16 914 14 20 13 15 19 17 65 3 10 12 832 18 11 1 12 LS LS 2019 7 LS LS NewNew LS LS 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..16 Nm (1.6 m • kg, 11 ft • Ib) T R..70 Nm (7.0 m • kg, 50 ft • lb) T R..95 Nm (9.5 m • kg, 68 ft • Ib)
SWINGARM
4-67
EAS23350
REMOVING THE SWINGARM
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
rear wheel is elevated.
2. Measure:
•Swingarm side play
•Swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut, pivot shaft ring nut, and pivot shaft.
b. Measure the swingarm side play “A” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
d. Check the swingarm vertical movement “B”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, bear-
ings, washers, and dust covers.
3. Remove:
•Drive chain
Refer to “REMOVING THE DRIVE CHAIN”
on page 4-71.4. Remove:
•Swingarm pivot shaft ring nut “1”
NOTE:
Loosen the swingarm pivot shaft ring nut with
the ring nut wrench “2”.
5. Remove:
•Swingarm pivot shaft “1”
NOTE:
Loosen the swingarm pivot shaft with the damp-
er rod holder (24 mm) “2”.
EAS23360
CHECKING THE SWINGARM
1. Check:
•Swingarm
Bends/cracks/damage → Replace.
2. Check:
•Pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
T R..
Swingarm pivot shaft nut
70 Nm (7.0 m·kg, 50 ft·lb)
Swingarm pivot shaft ring nut
95 Nm (9.5 m·kg, 68 ft·lb)
Swingarm pivot shaft
16 Nm (1.6 m·kg, 11 ft·lb)
Swingarm side play (at the end of
the swingarm)
1.0 mm (0.04 in)
B
A
Ring nut wrench
90890-01507
YM-01507
Damper rod holder (24 mm)
90890-01328
YM-01328
21
2
1