Yamaha 2007 R6 Service

							CAMSHAFTS
5-12
NOTE:
Prior to installing the timing chain tensioner rod, 
drain the engine oil from the timing chain ten-
sioner housing.



 
 
 








 
 



 
 



 
 







a. Install the timing chain tensioner springs, tim-
ing chain tensioner spring seat, and timing 
chain tensioner rod “1”.
b. Squeeze the timing chain tensioner clip “2”, 
and then push the timing chain tensioner rod 
“3” into the timing chain tensioner housing.
NOTE:
Do not release the timing chain tensioner clip 
while pushing the rod into the housing, other-
wise the rod may be ejected.
c. Hook the clip “4” to the timing chain tensioner 
rod “3”.
NOTE:
Hook the timing chain tensioner rod pin “5” to the 
center of the clip “4”. After the installation, check 
that the clip “4” can come off by its own weight 
by pushing the timing chain tensioner rod “3” at 
the position of installation.
          
EAS24010
INSTALLING THE CAMSHAFTS
1. Align:
•TDC mark on the pickup rotor
(with the crankcase mating surface)



 
 
 








 
 



 
 



 
 



 



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”.
          
a b 
						

							CAMSHAFTS
5-13
2. Install:
•Timing chain “1”
•Exhaust camshaft “2”
•Intake camshaft “3”
(with the camshaft sprockets temporarily 
tightened)
NOTE:
•Make sure the match marks “a” on the cam-
shaft sprockets are aligned with the cylinder 
head edge “b”.
•Be sure to install the timing chain so that the 
exhaust side of the chain is taut and the intake 
side is slack.
3. Install:
•Intake camshaft caps
•Exhaust camshaft caps
NOTE:
•Make sure each camshaft cap is installed in its 
original place. Refer to the identification marks 
as follows:
“I1”, “I2”: Intake
“E1”, “E2”: Exhaust
•Make sure the arrow mark “a” on each cam-
shaft points towards the right side of the en-
gine.4. Install:
•Camshaft cap bolts
CAUTION:
ECA13730
The camshaft cap bolts must be tightened 
evenly or damage to the cylinder head, cam-
shaft caps, and camshafts will result.
NOTE:
Tighten the camshaft cap bolts in stages and in 
a crisscross pattern, working from the inner caps 
out.
5. Install:
•Timing chain tensioner gasket “1” 
•Timing chain tensioner “2”
NOTE:
•Be sure to install the timing chain tensioner 
gasket so that its section with the “L” mark “a” 
is protruding from the lower left side of the tim-
ing chain tensioner.
•The arrow mark “b” on the timing chain ten-
sioner should face up.
E2 E1
E1
I1
I2 I1
T R.. 
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T R.. 
Timing chain tensioner bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
aa
a
aa
New
2
1bL
a 
						

							CAMSHAFTS
5-14
6. Rotate the crankshaft a few times to release 
the timing chain tensioner rod.
NOTE:
If the engine is not disassembled, set the engine 
stop switch to “”, and then crank the engine a 
few times by pressing the start switch for approx-
imately 0.5–1.0 second each time.
7. Check that the timing chain is taut. If the 
chain is slack, reinstall the timing chain ten-
sioner.
NOTE:
If the engine is not disassembled, start the en-
gine and check for any abnormal noise. If any 
abnormal noise is heard, reinstall the timing 
chain tensioner.
8. Check:
•TDC mark “a”
Make sure the TDC mark on the pickup rotor 
is aligned with the crankcase mating surface 
“b”.
•Camshaft sprocket match mark “c”
Make sure the marks on the camshaft 
sprockets are aligned with the edge of the cyl-
inder head “d”.
Out of alignment → Adjust.
Refer to the installation steps above.9. Measure:
•Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
10.Install:
•Cylinder head cover gasket 
•Cylinder head cover
NOTE:
•Apply bond TB1541B “1” onto the mating sur-
faces of the cylinder head cover and cylinder 
head cover gasket.
•Apply bond TB1215B “2” onto the mating sur-
faces of the cylinder head cover gasket and 
cylinder head.
•Tighten the cylinder head cover bolts stages 
and in a crisscross pattern.
a b
T R.. 
Cylinder head cover bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
New
1
11
2 
						

							CYLINDER HEAD
5-15
EAS24100
CYLINDER HEAD
Removing the cylinder head
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-1.
Camshafts Refer to “CAMSHAFTS” on page 5-7.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
For installation, reverse the removal proce-
dure.
1
2
3
4
T R..1st   25 Nm (2.5 m • 
kg, 18 ft • lb)
2nd  42 Nm (4.2 m 
• 
kg, 30 ft • lb)T R..1st   30 Nm (3.0 m • 
kg, 22 ft • lb)
2nd  60 Nm (6.0 m 
• 
kg, 43 ft • lb)
T R..18 Nm (1.8 m • 
kg, 13 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
New
New
(8)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
E
EE 
						

							CYLINDER HEAD
5-16
EAS24120
REMOVING THE CYLINDER HEAD
1. Remove:
• Cylinder head bolts
 Cylinder head nuts
NOTE:
 Loosen the nuts, cap nuts, and bolts in de-
creasing numerical order (refer to the numbers 
in the illustration).
 Loosen each nut 1/2 of a turn at a time. After all 
of the nuts are fully loosened, remove them.
EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
 Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
 Spark plug bore threads
 Valve seats
2. Check:
 Cylinder head
Damage/scratches → Replace.
NOTE:
Replace the titanium valves with the cylinder 
head.
Refer to “CHECKING THE VALVE SEATS” 
on page 5-21.
 Cylinder head water jacket
Mineral deposits/rust → Eliminate.3. Measure:
 Cylinder head warpage
Out of specification → Resurface the cylinder 
head.



 
 
 








 
 



 
 



 
 



 



a. Place a straightedge “1” and a thickness 
gauge “2” across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder 
head as follows.
d. Place a 400–600 grit wet sandpaper on the 
surface plate and resurface the cylinder head 
using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder 
head several times.
          
EAS24240
INSTALLING THE CYLINDER HEAD
1. Install:
 Cylinder head
NOTE:
Pass the timing chain through the timing chain 
cavity.
2. Tighten:
 Cylinder head nuts “1”–“7”, “10”
862410
9
3157
12
11
 
Warpage limit
0.05 mm (0.0020 in) 
						

							CYLINDER HEAD
5-17
Cylinder head cap nuts “8”, “9”
Cylinder head bolts “11”, “12”
NOTE:
Tighten the cylinder head nuts, cap nuts, and 
bolts in the proper tightening sequence as 
shown and torque them in two stages.
T R.. 
Cylinder head nut (1st)
25 Nm (2.5 m·kg, 18 ft·lb)
Cylinder head nut (final)
42 Nm (4.2 m·kg, 30 ft·lb)
T R.. 
Cylinder head cap nut (1st)
30 Nm (3.0 m·kg, 22 ft·lb)
Cylinder head cap nut (final)
60 Nm (6.0 m·kg, 43 ft·lb)
T R.. 
Cylinder head bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
862410
9
3157
12
11 
						

							VALVES AND VALVE SPRINGS
5-18
EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
Order Job/Parts to remove Q’ty Remarks
Cylinder head Refer to “CYLINDER HEAD” on page 5-15.
1 Valve lifter 16
2 Valve pad 16
3 Valve cotter 32
4 Upper spring seat 16
5 Intake valve spring 8
6 Exhaust valve spring 8
7 Intake valve 8
8 Exhaust valve 8
9 Valve stem seal 16
10 Lower spring seat 16
11 Intake valve guide 8
12 Exhaust valve guide 8
For installation, reverse the removal proce-
dure.
1
2
33
4
59
10 1
2
3
3
4
6 9
10
78 1112
E
New
New
M
M
E
M
M
MM
M 
						

							VALVES AND VALVE SPRINGS
5-19
EAS24280
REMOVING THE VALVES
The following procedure applies to all of the 
valves and related components.
NOTE:
Before removing the internal parts of the cylinder 
head (e.g., valves, valve springs, valve seats), 
make sure the valves properly seal.
1. Remove:
•Valve lifter “1”
•Valve pad “2”
NOTE:
Make a note of the position of each valve lifter 
and valve pad so that they can be reinstalled in 
their original place.
2. Check:
•Valve sealing
Leakage at the valve seat → Check the valve 
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS” 
on page 5-21.



 
 
 








 
 



 
 



 
 







a. Pour a clean solvent “a” into the intake and 
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat “1”.
         
3. Remove:
•Valve cotters “1”
NOTE:
Remove the valve cotters by compressing the 
valve spring with the valve spring compressor 
“1” and the valve spring compressor attachment 
“2”.
4. Remove:
•Upper spring seat “1”
•Valve spring “2”
•Valve “3”
•Valve stem seal “4”
•Lower spring seat “5”
NOTE:
Identify the position of each part very carefully so 
that it can be reinstalled in its original place.
EAS24290
CHECKING THE VALVES AND VALVE 
GUIDES
The following procedure applies to all of the 
valves and valve guides.
 
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108 
						

							VALVES AND VALVE SPRINGS
5-20
1. Measure:
•Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve 
guide.
2. Replace:
•Valve guide
NOTE:
To ease valve guide removal and installation, 
and to maintain the correct fit, heat the cylinder 
head to 100 °C (212 °F) in an oven.



 
 
 








 
 



 
 



 
 







a. Remove the valve guide with the valve guide 
remover “1”.b. Install the new valve guide with the valve 
guide installer “2” and valve guide remover 
“1”.
c. After installing the valve guide, bore the valve 
guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide 
clearance.
NOTE:
After replacing the valve guide, reface the valve 
seat. •Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
 
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–0.0015 
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020 
in)
Limit
0.095 mm (0.0037 in)
 
Valve guide position
15.80 mm–16.20 mm (0.622–
0.638 in)
a. Valve guide position 
						

							VALVES AND VALVE SPRINGS
5-21
         
3. Eliminate:
•Carbon deposits
(from the valve face and valve seat)
4. Check:
•Valve face
Pitting/wear → Grind the valve face.
•Valve stem end
Mushroom shape or diameter larger than the 
body of the valve stem → Replace the valve.
5. Measure:
•Valve margin thickness D “a”
Out of specification → Replace the valve.
6. Measure:
•Valve stem runout
Out of specification → Replace the valve.
NOTE:
•When installing a new valve, always replace 
the valve guide.•If the valve is removed or replaced, always re-
place the valve stem seal.
EAS24300
CHECKING THE VALVE SEATS
The following procedure applies to all of the 
valves and valve seats.
1. Eliminate:
•Carbon deposits
(from the valve face and valve seat)
2. Check:
•Valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
•Valve seat width C “a”
Out of specification → Replace the cylinder 
head.



 
 
 








 
 



 
 



 
 



 



a. Apply Mechanic’s blueing dye (Dykem) “b” 
onto the valve face.
 
Valve guide remover (ø4.5)
90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (ø4.5)
90890-04118
Valve guide reamer (4.5 mm)
YM-04118
 
Valve margin thickness D (intake)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
0.8 mm (0.03 in)
Valve margin thickness D (ex-
haust)
1.10–1.30 mm (0.0433–0.0512 in)
Limit
1.0 mm (0.04 in)
 
Valve stem runout
0.040 mm (0.0016 in)
 
Valve seat width C (intake)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
Valve seat width C (exhaust)
1.10–1.30 mm (0.0433–0.0512 in)
Limit
1.8 mm (0.07 in)