Yamaha 2007 R6 Service

							OIL PUMP
5-52
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks
1 Oil pump housing cover 1
2Pin 2
3 Oil pump inner rotor 1
4 Oil pump outer rotor 1
5Pin 1
6 Washer 1
7 Oil pump housing 1
8 Oil pump driven sprocket 1
For assembly, reverse the disassembly pro-
cedure. 
						

							OIL PUMP
5-53
EAS24930
REMOVING THE OIL PAN
1. Remove:
•Oil level switch lead holder
•Bottom cowling brackets
•Oil pan
•Oil pan gasket
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the 
bolts are fully loosened, remove them.
EAS24960
CHECKING THE OIL PUMP
1. Check:
•Oil pump driven sprocket
•Oil pump housing
•Oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
•Inner-rotor-to-outer-rotor-tip clearance “a”
•Outer-rotor-to-oil-pump-housing clearance 
“b”
•Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification → Replace the oil pump.3. Check:
•Oil pump operation
Rough movement → Repeat steps (1) and 
(2) or replace the defective part(s).
EAS24970
CHECKING THE RELIEF VALVE
1. Check:
•Relief valve body “1”
•Relief valve “2”
•Spring “3”
•O-ring “4”
Damage/wear → Replace the defective 
part(s).
1. Inner rotor
2. Outer rotor
3. Oil pump housing
 
Inner-rotor-to-outer-rotor-tip 
clearance
Less than 0.12 mm (0.0047 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing 
clearance
0.090–0.150 mm (0.0035–0.0059 
in)
Limit
0.220 mm (0.0087 in)
Oil-pump-housing-to-inner-and-
outer-rotor clearance
0.06–0.11 mm (0.0024–0.0043 in)
Limit
0.18 mm (0.0071 in) 
						

							OIL PUMP
5-54
EAS24980
CHECKING THE OIL PIPES
The following procedure applies to all of the oil 
delivery pipes.
1. Check:
•Ventilation chamber oil drain pipe
•Oil pipe
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
EAS24990
CHECKING THE OIL STRAINER
1. Check:
•Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS25010
ASSEMBLING THE OIL PUMP
1. Lubricate:
•Inner rotor
•Outer rotor
•Oil pump shaft
(with the recommended lubricant)
2. Install:
•Oil pump driven sprocket
•Oil pump housing “1”
•Washer “2”
•Pin “3”
•Oil pump inner rotor “4”
•Oil pump outer rotor
NOTE:
When installing the inner rotor, align the pin “3” 
in the oil pump shaft with the groove “a” in the in-
ner rotor “4”.
3. Check:
•Oil pump operation
Refer to “CHECKING THE OIL PUMP” on 
page 5-53.
EAS25050
INSTALLING THE OIL PAN
1. Install:
•Oil pan gasket 
•Oil pan
•Bottom cowling brackets
•Oil level switch lead holder
NOTE:
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
 
Recommended lubricant
Engine oil
1
a
3
2 4
a
T R.. 
Oil pan bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
New 
						

							CRANKCASE
5-55
EAS25540
CRANKCASE
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-1.
Cylinder head Refer to “CYLINDER HEAD” on page 5-15.
Starter clutchRefer to “GENERATOR AND STARTER 
CLUTCH” on page 5-26.
Shift shaft Refer to “SHIFT SHAFT” on page 5-47.
Pickup rotor Refer to “PICKUP ROTOR” on page 5-30.
Oil pump drive chain guide Refer to “CLUTCH” on page 5-37.
Oil pump assembly Refer to “OIL PUMP” on page 5-50.
1 Timing chain 1
2 Dipstick 1
3 Neutral switch lead 1
4 Neutral switch 1
5 Ventilation chamber cover 1
6 Ventilation chamber cover gasket 1
7 Oil pipe 1
8 Oil baffle plate 1 1
11
43 2
11
6
10
1
8
9
7
5
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
LS
New
New
New
New
New
LS
LS
LS
LT
LT
LTLT
(3)
LT
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
(4) 
						

							CRANKCASE
5-56
9 Oil baffle plate 2 1
10 Lower crankcase 1
11 Dowel pin 3
For installation, reverse the removal proce-
dure.
Separating the crankcase
Order Job/Parts to remove Q’ty Remarks
11
43 2
11
6
10
1
8
9
7
5
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..8 Nm (0.8 m • 
kg, 5.8 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..20 Nm (2.0 m • 
kg, 14 ft • Ib)
LS
New
New
New
New
New
LS
LS
LS
LT
LT
LTLT
(3)
LT
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
(4) 
						

							CRANKCASE
5-57
EAS25550
DISASSEMBLING THE CRANKCASE
1. Place the engine upside down.
2. Remove:
• Crankcase bolts
NOTE:
 Loosen each bolt 1/4 of a turn at a time. After 
all of the bolts are fully loosened, remove them.
 Loosen the bolts in decreasing numerical order 
(refer to the numbers in the illustration).
 The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
M8 × 115 mm bolts: “8”, “9”
M8 × 85 mm bolts: “1”–“7”, “10”
M8 × 65 mm bolts: “11”, “12”
M6 × 80 mm bolt: “28”
M6 × 65 mm shoulder bolts: “13”, “14”
M6 × 65 mm bolts: “16”, “20”, “21”
M6 × 55 mm bolts: “15”, “22”–“27”
M6 × 45 mm bolts: “17”–“19”
M6 × 30 mm bolt: “29”
3. Remove:
 Lower crankcase
CAUTION:
ECA13900
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase 
mating surfaces. Work slowly and carefully 
and make sure the crankcase halves sepa-
rate evenly.
EAS25580
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a 
mild solvent.
2. Thoroughly clean all the gasket surfaces and 
crankcase mating surfaces.
3. Check:
 Crankcase
Cracks/damage → Replace.
 Oil delivery passages
Obstruction → Blow out with compressed air.
EAS25600
CHECKING THE OIL PIPE
1. Check:
 Oil pipe
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
EAS25620
CHECKING THE TIMING CHAIN
Refer to “CAMSHAFTS” on page 5-7.
EAS25640
ASSEMBLING THE CRANKCASE
1. Lubricate:
 Crankshaft journal bearings
(with the recommended lubricant)
2. Apply:
 Sealant
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2–3 mm 
(0.08–0.12 in) of the crankshaft journal bearings.
3. Install:
 Dowel pins
4. Set the shift drum assembly and transmission 
gears in the neutral position.
5. Install:
 Lower crankcase “1”
(onto the upper crankcase “2”)
26
9
8
1
43
5 7
10 13
25
26
1420
12
21
11
15
1918
16
28
27
1724232229
 
Recommended lubricant
Engine oil
 
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215
®)
1. Three Bond No.1215®
1 
						

							CRANKCASE
5-58
CAUTION:
ECA13980
Before tightening the crankcase bolts, make 
sure the transmission gears shift correctly 
when the shift drum assembly is turned by 
hand.
6. Install:
Crankcase bolts
NOTE:
Lubricate the bolts “1”–“10” thread part and 
washers with engine oil.
Lubricate the bolts “11”–“29” thread part and 
mating surfaces with engine oil.
Finger tighten the crankcase bolts.
M8 × 115 mm bolts: “8”, “9”
M8 × 85 mm bolts: “1”–“7”, “10”
M8 × 65 mm bolts: “11”, “12”
M6 × 80 mm bolt: “28”
M6 × 65 mm shoulder bolts: “13”, “14”
M6 × 65 mm bolts: “16”, “20”, “21”
M6 × 55 mm bolts: “15”, “22”–“27”
M6 × 45 mm bolts: “17”–“19”
M6 × 30 mm bolt: “29”
7. Tighten:
Crankcase bolts “1”–“10”*Loosen all bolts following the tightening or-
der and then tighten to specification torque.
NOTE:
Tighten the bolts in the tightening sequence cast 
on the crankcase.
8. Tighten:
Crankcase bolts “11”–“29”
NOTE:
Tighten the bolts in the tightening sequence cast 
on the crankcase.
T R.. 
Crankcase bolt (M8 × 115 mm, M8 
× 85 mm)
1st: 20 Nm (2.0 m·kg, 14 ft·lb)
*2nd: 25 Nm (2.5 m·kg, 18 ft·lb)
*3rd: 27 Nm (2.7 m·kg, 20 ft·lb)
1
2
26
9
8
1
43
5 7
10 13
25
26
1420
12
21
11
15
1918
16
28
27
1724232229
T R.. 
Crankcase bolt (M8 × 65 mm)
24 Nm (2.4 m·kg, 17 ft·lb)
Crankcase bolt (M6)
10 Nm (1.0 m·kg, 7.2 ft·lb)
26
9
8
1
43
5 7
10
13
25
26
1420
12
21
11
15
1918
16
28
27
1729242322 
						

							CONNECTING RODS AND PISTONS
5-59
EAS24370
CONNECTING RODS AND PISTONS
Removing the connecting rods and pistons
Order Job/Parts to remove Q’ty Remarks
CrankcaseSeparate.
Refer to “CRANKCASE” on page 5-55.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Piston pin clip 8
4 Piston pin 4
5Piston 4
6 Connecting rod 4
7 Big end upper bearing 4
8 Top ring 4
92nd ring 4
10 Oil ring 4
For installation, reverse the removal proce-
dure.
New
E
New
E
NewNew
New
E
M
M
T R..1st   15 Nm (1.5 m • 
kg, 11 ft • lb)
2nd  Specified angle 175˚-185˚
E
7
6
5
4
9
8 103 31
2
M
M
New 
						

							CONNECTING RODS AND PISTONS
5-60
EAS26030
REMOVING THE CONNECTING RODS AND 
PISTONS
The following procedure applies to all of the con-
necting rods and pistons.
1. Remove:
•Connecting rod cap “1”
NOTE:
Identify the position of each connecting rod so 
that it can be reinstalled in its original place.
2. Remove:
•Big end bearings
(from the connecting rods and connecting rod 
caps)
NOTE:
Identify the position of each big end bearing so 
that it can be reinstalled in its original place.
3. Remove:
•Piston pin clips “1”
•Piston pin “2”
•Piston “3”
•Connecting rod “4”
CAUTION:
ECA13810
Do not use a hammer to drive the piston pin 
out.
NOTE:
•For reference during installation, put an identi-
fication mark on each piston crown.
•Before removing the piston pin, deburr the pis-
ton pin clip’s groove and the piston’s pin bore 
area. If both areas are deburred and the piston 
pin is still difficult to remove, remove it with the 
piston pin puller set “5”.4. Remove:
•Top ring
•2nd ring
•Oil ring
NOTE:
When removing a piston ring, open the end gap 
with your fingers and lift the other side of the ring 
over the piston crown.
EAS24410
CHECKING THE CYLINDERS AND PISTONS
The following procedure applies to all of the cyl-
inders and pistons.
1. Check:
•Piston wall
•Cylinder wall
Vertical scratches → Rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set.
2. Measure:
•Piston-to-cylinder clearance



 
 
 








 
 



 
 



 
 



 



a. Measure cylinder bore “C” with the cylinder 
bore gauge.
 
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
4
3
2
11 
						

							CONNECTING RODS AND PISTONS
5-61
NOTE:
Measure cylinder bore “C” by taking side-to-side 
and front-to-back measurements of the cylinder. 
Then, find the average of the measurements.
b. If out of specification, rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set.
c. Measure piston skirt diameter D “a” with the 
micrometer.d. If out of specification, replace the piston and 
piston rings as a set.
e. Calculate the piston-to-cylinder clearance 
with the following formula.
f. If out of specification, rebore or replace the 
cylinder, and replace the piston and piston 
rings as a set.
          
EAS24430
CHECKING THE PISTON RINGS
1. Measure:
•Piston ring side clearance
Out of specification → Replace the piston 
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance, 
eliminate any carbon deposits from the piston 
ring grooves and piston rings.
2. Install:
•Piston ring
(into the cylinder)
 
Bore
67.000–67.010 mm (2.6378–
2.6382 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D
1–D6
“T” = maximum of D1 or D2 - maximum of D5 
or D
6
“R” = maximum of D1, D3 or D5 - minimum of 
D
2, D4 or D6
 
Piston
Diameter D
66.975–66.990 mm (2.6368–
2.6374 in)
b. 10 mm (0.39 in) from the bottom edge of the 
piston
•Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “D”
 
Piston-to-cylinder clearance
0.010–0.035 mm (0.0004–0.0014 
in)
Limit
0.05 mm (0.0022 in)
 
Piston ring
Top ring
Ring side clearance
0.030–0.065 mm (0.0012–
0.0026 in)
2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–
0.0022 in)