Yamaha 2007 R6 Service

							TRANSMISSION
5-72
15 Bearing 1
For installation, reverse the removal proce-
dure.
Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q’ty Remarks
E
E
E
E
12
11
7
13
5
676
10 5
498 12
3
15
14
LT
LT
E
E
LT
E
T R..12 Nm (1.2 m • 
kg, 8.7 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
E
New
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
(3)
New
LS
LS 
						

							TRANSMISSION
5-73
Disassembling the main axle assembly
Order Job/Parts to remove Q’ty Remarks
1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd/4th pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Bearing housing 1
14 Bearing 1
15 Main axle/1st pinion gear 1
For assembly, reverse the disassembly pro-
cedure.
M
M
M
M
E
1 2 3 4 5 8
9 6 7
10 13
14
15
12
11
New
New 
						

							TRANSMISSION
5-74
Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks
1 Washer 1
2 1st wheel gear 1
3 Collar 1
4 5th wheel gear 1
5 Circlip 1
6 Washer 1
7 3rd wheel gear 1
8 Collar 1
9 Toothed lock washer 1
10 Toothed lock washer retainer 1
11 4th wheel gear 1
12 Collar 1
13 Washer 1
14 Circlip 1
15 6th wheel gear 1
16 Circlip 1
17 Washer 1
E
M
1
2
3
4 5
68
9
10
1112
13
14
1516
1718
19
21
20
M
M
M
7
New
New
NewM
M 
						

							TRANSMISSION
5-75
18 2nd wheel gear 1
19 Collar 1
20 Bearing 1
21 Drive axle 1
For assembly, reverse the disassembly pro-
cedure.
Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks
E
M
1
2
3
4 5
68
9
10
1112
13
14
1516
1718
19
21
20
M
M
M
7
New
New
NewM
M 
						

							TRANSMISSION
5-76
ET2C01014
REMOVING THE TRANSMISSION
1. Remove:
•Main axle assembly “1”



 
 
 








 
 



 
 



 
 







a. Remove the main axle assembly bearing 
housing bolts “2”
b. Insert two bolts “3” of the proper size, as 
shown in the illustration, into the main axle 
assembly bearing housing.
c. Tighten the bolts until they contact the crank-
case surface.
d. Continue tightening the bolts until the main 
axle assembly comes free from the upper 
crankcase.
         
EAS26260
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift 
forks.
1. Check:
•Shift fork cam follower “1”
•Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the 
shift fork.2. Check:
•Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
WARNING
EWA12840
Do not attempt to straighten a bent shift fork 
guide bar.
3. Check:
•Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks 
and shift fork guide bar as a set.
EAS26270
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
•Shift drum groove
Damage/scratches/wear → Replace the shift 
drum assembly.
•Shift drum segment “1”
Damage/wear → Replace the shift drum as-
sembly.
1 2
2
2
1 mm
30 mm6 mm
3 
						

							TRANSMISSION
5-77
•Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
EAS26300
CHECKING THE TRANSMISSION
1. Measure:
•Main axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the main axle.
2. Measure:
•Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
3. Check:
•Transmission gears
Blue discoloration/pitting/wear → Replace 
the defective gear(s).•Transmission gear dogs
Cracks/damage/rounded edges → Replace 
the defective gear(s).
4. Check:
•Transmission gear engagement
(each pinion gear to its respective wheel 
gear)
Incorrect → Reassemble the transmission 
axle assemblies.
5. Check:
•Transmission gear movement
Rough movement → Replace the defective 
part(s).
6. Check:
•Circlips
Bends/damage/looseness → Replace.
ET2C01015
ASSEMBLING THE MAIN AXLE AND DRIVE 
AXLE
1. Install:
•Toothed washer “1”
•Circlip “2” 
NOTE:
•Be sure the circlip sharp-edged corner “a” is 
positioned opposite side to the toothed washer 
and gear.
•Install the circlip so that both ends “b” rest on 
the sides of a spline “c” with both axles aligned.
 
Main axle runout limit
0.02 mm (0.0008 in)
 
Drive axle runout limit
0.02 mm (0.0008 in)
New 
						

							TRANSMISSION
5-78
2. Install:
•Toothed lock washer retainer “1”
•Toothed lock washer “2”
NOTE:
•With the toothed lock washer retainer “1” in the 
groove “a” in the axle, align the projection “c” 
on the retainer with an axle spline “b”, and then 
install the toothed lock washer “2”.
•Be sure to align the projection on the toothed 
lock washer that is between the alignment 
marks “e” with the alignment mark “d” on the 
retainer.
ET2C01016
INSTALLING THE TRANSMISSION
1. Install:
•Bearing “1”
NOTE:
Face the seal side of the bearing to the outside 
and install it close to the right side end of the 
crankcase.2. Install:
•Main axle assembly “1”
NOTE:
Stake the main axle assembly bearing housing 
bolts “2” at a cutout “a” in the main axle assem-
bly bearing housing “3”.
3. Install:
•Shift fork-C “1”
•Shift drum assembly “2”
•Shift fork guide bar “3”
NOTE:
•The embossed marks on the shift forks should 
face towards the right side of the engine and be 
in the following sequence: “R”, “C”, “L”.
•Carefully position the shift forks so that they 
are installed correctly into the transmission 
gears.
•Install shift fork-C into the groove “a” in the 3rd 
and 4th pinion gear on the main axle.
4. Install:
•Shift fork-R “1”
•Shift fork-L “2”
1
22New
a
b
c
2
ee d
b
c
1
c
b
a2 1
1
1 2
a2
a
3
2
a
213 a 
						

							TRANSMISSION
5-79
•Shift fork guide bar
•Springs
•Shift drum retainers “3”
•Bearing
•Oil seal
•Circlip “4”
•Drive axle assembly “5”
NOTE:
•Install shift fork-R into the groove “a” in the 5th 
wheel gear and shift fork-L into the groove “b” 
in the 6th wheel gear on the drive axle.
•Install the shift drum retainer with its “OUT” 
mark “c” facing outward.
•Make sure that the drive axle bearing circlip “4” 
is inserted into the grooves “d” in the upper 
crankcase.
T R.. 
Shift drum retainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE
®
12d4 5 b a
33
c
c 
						

							6
COOLING SYSTEM
RADIATOR...................................................................................................... 6-1
CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR.................................................................. 6-3
OIL COOLER.................................................................................................. 6-4
CHECKING THE OIL COOLER ................................................................ 6-6
INSTALLING THE OIL COOLER .............................................................. 6-6
THERMOSTAT................................................................................................ 6-7
CHECKING THE THERMOSTAT ............................................................. 6-8
INSTALLING THE THERMOSTAT ........................................................... 6-8
WATER PUMP................................................................................................ 6-9
CHECKING THE WATER PUMP ............................................................ 6-10
INSTALLING THE WATER PUMP .......................................................... 6-10 
						

							RADIATOR
6-1
EAS26380
RADIATOR
Removing the radiator
Order Job/Parts to remove Q’ty Remarks
Lower side cowlings/Bottom cowlingsRefer to “GENERAL CHASSIS” on page 
4-1.
CoolantDrain.
Refer to “CHANGING THE COOLANT” on 
page 3-19.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Radiator fan motor coupler 2 Disconnect.
5Radiator cap 1
6Radiator 1
7Radiator fan 2
8 Radiator inlet hose 1
9 Radiator inlet pipe 1
10 Radiator outlet hose holder 1
11 Radiator outlet hose 1
12 Radiator outlet pipe 1
T R..5 Nm (0.5 m • 
kg, 3.6 ft • Ib)
T R..5 Nm (0.5 m • 
kg, 3.6 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..13 Nm (1.3 m • 
kg, 9.4 ft • Ib)
4
7 7
4
9 12 10 11
68 1
32
5
13(3) (3)