Yamaha 2007 R6 Service
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IMPORTANT INFORMATION 1-12 EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. CAUTION: ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac- es. EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Al- ways replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2” is positioned opposite the thrust “3” that the circlip receives.
CHECKING THE CONNECTIONS 1-13 EAS20250 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: Lead Coupler Connector 2. Check: Lead Coupler Connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect sev- eral times. 3. Check: All connections Loose connection → Connect properly. NOTE: If the pin “1” on the terminal is flattened, bend it up. 4. Connect: Lead Coupler Connector NOTE: Make sure all connections are tight. 5. Check: Continuity (with the pocket tester) NOTE: If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores. Pocket tester 90890-03112 Analog pocket tester YU-03112-C
SPECIAL TOOLS 1-14 EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”. For others, use part number starting with “90890-”. Tool name/Tool No. IllustrationReference pages Pocket tester 90890-03112 Analog pocket tester YU-03112-C1-13, 5-35, 8-83, 8-84, 8-85, 8-89, 8-90, 8-91, 8-92, 8-93, 8-94, 8-95, 8-96, 8-97, 8-98, 8-99, 8-100, 8-101 Valve lapper 90890-04101 Valve lapping tool YM-A89983-5 Vacuum gauge 90890-03094 Carburetor synchronizer YU-444563-7 Compression gauge 90890-03081 Engine compression tester YU-332233-10 Extension 90890-041363-10 YU-44456
SPECIAL TOOLS 1-15 Oil filter wrench 90890-01426 YU-384113-11 Oil pressure gauge set 90890-031203-13 Oil pressure adapter H 90890-031393-13 Steering nut wrench 90890-01403 Spanner wrench YU-339753-27, 4-58 Fork spring compressor 90890-01441 YM-014414-47, 4-52 Rod holder 90890-01434 Damper rod holder double ended YM-014344-47, 4-52 Damper rod holder 90890-01506 YM-015064-48, 4-49 Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 mm) YM-014424-50 Tool name/Tool No. IllustrationReference pages
SPECIAL TOOLS 1-16 Rod puller 90890-01437 Universal damping rod bleeding tool set YM-A87034-51, 4-52 Rod puller attachment (M10) 90890-01436 Universal damping rod bleeding tool set YM-A87034-51, 4-52 Ring nut wrench 90890-01268 Spanner wrench YU-012684-58 Ring nut wrench 90890-01507 YM-015074-67, 4-69 Damper rod holder (24 mm) 90890-01328 YM-013284-67, 4-68 Valve spring compressor 90890-04019 YM-040195-19, 5-24 Tool name/Tool No. IllustrationReference pages YM-A8703 YM-A8703
SPECIAL TOOLS 1-17 Valve spring compressor attachment 90890-04108 Valve spring compressor adapter 22 mm YM-041085-19, 5-24 Valve guide remover (ø4.5) 90890-04116 Valve guide remover (4.5 mm) YM-041165-21 Valve guide installer (ø4.5) 90890-04117 Valve guide installer (4.5 mm) YM-041175-21 Valve guide reamer (ø4.5) 90890-04118 Valve guide reamer (4.5 mm) YM-041185-21 Valve spring compressor 90890-041095-24 Sheave holder 90890-01701 Primary clutch holder YS-01880-A5-28, 5-29, 5-31 Flywheel puller 90890-01404 Flywheel puller YM-014045-28 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215 ®)5-29, 5-31, 5-57 Tool name/Tool No. IllustrationReference pages
SPECIAL TOOLS 1-18 Universal clutch holder 90890-04086 YM-910425-41, 5-45 Thickness gauge 90890-03180 Feeler gauge set YU-26900-95-41 Piston pin puller set 90890-01304 Piston pin puller YU-013045-60 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-016-3 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-339846-3 Tool name/Tool No. IllustrationReference pages 0.400.30 0.350.250.200.150.10 0.05 0.03 0.50 YU-01304 YU-24460-01 YU-33984
SPECIAL TOOLS 1-19 Pressure gauge 90890-03153 Pressure gauge YU-031537-12 Fuel pressure adapter 90890-03176 YM-031767-12 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A19277-13 Ignition checker 90890-06754 Opama pet-4000 spark checker YM-344878-92 Tool name/Tool No. IllustrationReference pages
2 SPECIFICATIONS GENERAL SPECIFICATIONS........................................................................ 2-1 ENGINE SPECIFICATIONS............................................................................ 2-2 CHASSIS SPECIFICATIONS........................................................................ 2-10 ELECTRICAL SPECIFICATIONS................................................................. 2-13 TIGHTENING TORQUES.............................................................................. 2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-16 ENGINE TIGHTENING TORQUES......................................................... 2-17 CHASSIS TIGHTENING TORQUES....................................................... 2-21 LUBRICATION POINTS AND LUBRICANT TYPES.................................... 2-25 ENGINE .................................................................................................. 2-25 CHASSIS ................................................................................................ 2-27 LUBRICATION SYSTEM CHART AND DIAGRAMS................................... 2-29 ENGINE OIL LUBRICATION CHART ..................................................... 2-29 LUBRICATION DIAGRAMS .................................................................... 2-31 COOLING SYSTEM DIAGRAMS.................................................................. 2-43 CABLE ROUTING......................................................................................... 2-47
GENERAL SPECIFICATIONS 2-1 EAS20280 GENERAL SPECIFICATIONS Model Model 2C05/2C08 (USA) 2C06 (California) Dimensions Overall length 2040 mm (80.3 in) Overall width 700 mm (27.6 in) Overall height 1100 mm (43.3 in) Seat height 850 mm (33.5 in) Wheelbase 1380 mm (54.3 in) Ground clearance 130 mm (5.12 in) Minimum turning radius 3600 mm (141.7 in) Weight With oil and fuel 182.0 kg (401 lb) (USA) 183.0 kg (403 lb) (California) Maximum load 193 kg (425 lb) (USA) 192 kg (423 lb) (California)