Yamaha 2007 R6 Service

							7
FUEL SYSTEM
FUEL TANK.................................................................................................... 7-1
REMOVING THE FUEL TANK .................................................................. 7-3
REMOVING THE FUEL PUMP ................................................................. 7-3
CHECKING THE FUEL PUMP BODY ...................................................... 7-3
CHECKING THE FUEL PUMP OPERATION ........................................... 7-3
INSTALLING THE FUEL PUMP................................................................ 7-3
INSTALLING THE FUEL TANK ................................................................ 7-4
AIR FILTER CASE.......................................................................................... 7-5
REMOVING THE FUEL HOSE (PRIMARY INJECTOR FUEL RAIL 
TO SECONDARY INJECTOR FUEL RAIL) ............................................. 7-7
CHECKING THE SECONDARY INJECTORS .......................................... 7-7
INSTALLING THE FUEL HOSE (PRIMARY INJECTOR FUEL RAIL 
TO SECONDARY INJECTOR FUEL RAIL) ............................................. 7-7
THROTTLE BODIES....................................................................................... 7-8
CHECKING THE PRIMARY INJECTORS .............................................. 7-12
CHECKING THE THROTTLE BODIES................................................... 7-12
CHECKING THE ROLLOVER VALVE (for California only)..................... 7-12
CHECKING THE FUEL PRESSURE ...................................................... 7-12
ADJUSTING THE THROTTLE POSITION SENSOR 
(FOR THROTTLE VALVES) .................................................................. 7-13
ADJUSTING THE THROTTLE POSITION SENSOR 
(FOR THROTTLE CABLE PULLEY) ...................................................... 7-13
INSTALLING THE THROTTLE BODY JOINTS ...................................... 7-14
AIR INDUCTION SYSTEM............................................................................ 7-15
CHECKING THE AIR INDUCTION SYSTEM ......................................... 7-19 
						

							FUEL TANK
7-1
EAS26620
FUEL TANK
Removing the fuel tank and fuel pump
Order Job/Parts to remove Q’ty Remarks
Rider seat/Fuel tank bracketRefer to “GENERAL CHASSIS” on page 
4-1.
1 Fuel tank side cover 2
2 Fuel hose (fuel tank to primary injector fuel rail) 1 Disconnect.
3 Fuel sender coupler 1 Disconnect.
4 Fuel pump coupler 1 Disconnect.
5 Fuel tank overflow hose 1 Disconnect.
6 Fuel tank breather hose 1Except for California
Disconnect.
7 Fuel tank 1
8 Fuel tank upper cover 1
9 Fuel tank overflow hose (fuel tank to hose joint) 1
10 Fuel tank breather hose (fuel tank to hose joint) 1 Except for California
11Fuel tank breather hose (fuel tank to rollover 
valve)1 For California only
12 Fuel pump 1
114(6)
12
6
3
5
29
1
8
10
7
13
1
New
T R..4 Nm (0.4 m • 
kg, 2.9 ft • Ib)
T R..9 Nm (0.9 m • 
kg, 6.5 ft • Ib)
T R..9 Nm (0.9 m • 
kg, 6.5 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib) 
						

							FUEL TANK
7-2
13 Battery cover 1
For installation, reverse the removal proce-
dure.
Removing the fuel tank and fuel pump
Order Job/Parts to remove Q’ty Remarks
114(6)
12
6
3
5
29
1
8
10
7
13
1
New
T R..4 Nm (0.4 m • 
kg, 2.9 ft • Ib)
T R..9 Nm (0.9 m • 
kg, 6.5 ft • Ib)
T R..9 Nm (0.9 m • 
kg, 6.5 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib) 
						

							FUEL TANK
7-3
EAS26630
REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the 
fuel tank cap with a pump.
2. Remove:
•Fuel hose (fuel tank to primary injector rail)
WARNING
EW2C01008
Cover fuel hose connections with a cloth 
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to 
spurt out when removing the hoses.
NOTE:
•To remove the fuel hose from the fuel pump, 
slide the fuel hose connector cover “1” on the 
end of the hose in the direction of the arrow 
shown, press the two buttons “2” on the sides 
of the connector, and then remove the hose.
•Remove the fuel hose manually without using 
any tools.
•Before removing the hose, place a few rags in 
the area under where it will be removed.
3. Remove:
•Fuel tank
NOTE:
Place the fuel tank on a level surface, resting on 
its end and the bracket “1” as shown in the illus-
tration. Make sure that the fuel pipe does not 
contact the ground; otherwise, the fuel pump 
could be damaged.
EAS26640
REMOVING THE FUEL PUMP
1. Remove:
•Fuel pump
CAUTION:
ECA14720
Do not drop the fuel pump or give it a 
strong shock.
Do not touch the base section of the fuel 
sender.
EAS26670
CHECKING THE FUEL PUMP BODY
1. Check:
•Fuel pump body
Obstruction → Clean.
Cracks/damage → Replace fuel pump as-
sembly.
2. Check:
•Diaphragms and gaskets
Tears/fatigue/cracks → Replace fuel pump 
assembly.
EAS26690
CHECKING THE FUEL PUMP OPERATION
1. Check:
•Fuel pump operation
Refer to “CHECKING THE FUEL PUMP” on 
page 8-98.
EAS26710
INSTALLING THE FUEL PUMP
1. Tighten:
•Fuel pump
NOTE:
•Do not damage the installation surfaces of the 
fuel tank when installing the fuel pump.
•Always use a new fuel pump gasket.
•Install the fuel pump as shown in the illustra-
tion.
•Align the projection “a” on the fuel pump with 
the slot in the fuel pump bracket.
•Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
12
1
1
T R.. 
Fuel pump bolt
4 Nm (0.4 m·kg, 2.9 ft·lb) 
						

							FUEL TANK
7-4
ET2C01010
INSTALLING THE FUEL TANK
1. Connect:
•Fuel tank breather hose (fuel tank to hose 
joint) “1” (except for California)
•Fuel tank overflow hose (fuel tank to hose 
joint) “2”
•Fuel tank breather hose “3” (except for Cali-
fornia)
•Fuel tank overflow hose “4”
2. Connect:
•Fuel hose (fuel tank to primary injector rail)
CAUTION:
EC2C01017
When installing the fuel hose, make sure that 
it is securely connected, and that the fuel 
hose connector cover on the fuel hose is in 
the correct position, otherwise the fuel hose 
will not be properly installed.
NOTE:
•Install the fuel hose securely onto the fuel 
pump until a distinct “click” is heard.
•To install the fuel hose onto the fuel pump, 
slide the fuel hose connector cover “1” on the 
end of the hose in the direction of the arrow 
shown.
A. Except for California
B. For California
14
56
32 a
FWD
213 4
FWD
A
24
FWD
B
1 
						

							AIR FILTER CASE
7-5
ET2C01003
AIR FILTER CASE
Removing the air filter case and secondary injectors
Order Job/Parts to remove Q’ty Remarks
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Atmospheric pressure sensor coupler 1 Disconnect.
2 Atmospheric pressure sensor 1
3 Crankcase breather hose 1 Disconnect.
4 Sub-wire harness 3 coupler 1 Disconnect.
5Fuel hose (primary injector fuel rail to second-
ary injector fuel rail)1 Disconnect.
6 Upper air filter case 1
7 Secondary injector holder 1
8 Cylinder-#1 secondary injector coupler 1 Disconnect.
9 Cylinder-#2 secondary injector coupler 1 Disconnect.
10 Cylinder-#3 secondary injector coupler 1 Disconnect.
11 Cylinder-#4 secondary injector coupler 1 Disconnect.
12 Sub-wire harness 3 1
13 Secondary injector fuel rail 1
14 Secondary injector 4
616
19
19
17
5
4
18
3
1
15 (5)
(3)(3)(9) (4)
7
98
12
1011
1314
14
14
14
2
New
New
New
New
New
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..4 Nm (0.4 m • 
kg, 2.9 ft • Ib)
LT
T R..2 Nm (0.2 m • 
kg, 1.4 ft • Ib)T R..1.5 Nm (0.15 m • 
kg, 1.08 ft • lb) 
						

							AIR FILTER CASE
7-6
15 Air filter element 1
16 Air filter case joint (upper) 2
17 Lower air filter case 1
18Air induction system hose (air filter case to air 
cut-off valve)1 Disconnect.
19 Air filter case joint (lower) 2
For installation, reverse the removal proce-
dure.
Removing the air filter case and secondary injectors
Order Job/Parts to remove Q’ty Remarks
616
19
19
17
5
4
18
3
1
15 (5)
(3)(3)(9) (4)
7
98
12
1011
1314
14
14
14
2
New
New
New
New
New
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..4 Nm (0.4 m • 
kg, 2.9 ft • Ib)
LT
T R..2 Nm (0.2 m • 
kg, 1.4 ft • Ib)T R..1.5 Nm (0.15 m • 
kg, 1.08 ft • lb) 
						

							AIR FILTER CASE
7-7
ET2C01005
REMOVING THE FUEL HOSE (PRIMARY 
INJECTOR FUEL RAIL TO SECONDARY 
INJECTOR FUEL RAIL)
1. Remove:
•Fuel hose (primary injector fuel rail to second-
ary injector fuel rail)
WARNING
EW2C01008
Cover fuel hose connections with a cloth 
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to 
spurt out when removing the hoses.
NOTE:
•To remove the fuel hose from the secondary 
injector fuel rail, slide the fuel hose connector 
cover “1” on the end of the hose in the direction 
of the arrow shown, press the two buttons “2” 
on the sides of the connector, and then remove 
the hose.
•Remove the fuel hose manually without using 
any tools.
•Before removing the hose, place a few rags in 
the area under where it will be removed.
ET2C01017
CHECKING THE SECONDARY INJECTORS
1. Check:
•Injectors
Damage → Replace.
ET2C01006
INSTALLING THE FUEL HOSE (PRIMARY 
INJECTOR FUEL RAIL TO SECONDARY 
INJECTOR FUEL RAIL)
1. Connect:
•Fuel hose (primary injector fuel rail to second-
ary injector fuel rail)
CAUTION:
EC2C01017
When installing the fuel hose, make sure that 
it is securely connected, and that the fuel 
hose connector cover on the fuel hose is in 
the correct position, otherwise the fuel hose 
will not be properly installed.
NOTE:
•Install the fuel hose securely onto the second-
ary injector fuel rail until a distinct “click” is 
heard.
•To install the fuel hose onto the secondary in-
jector fuel rail, slide the fuel hose connector 
cover “1” on the end of the hose in the direction 
of the arrow shown.
12
1 
						

							THROTTLE BODIES
7-8
EAS26970
THROTTLE BODIES
Removing the rollover valve and canister (for California only)
Order Job/Parts to remove Q’ty Remarks
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
1Canister purge hose (throttle body-#4 to 3-way 
joint)1
2Canister purge hose (throttle body-#2 to 3-way 
joint)1
3 3-way joint 1
4 Canister purge hose (3-way joint to canister) 1
5 Rollover valve 1
6Fuel tank breather hose (rollover valve to canis-
ter)1
7Canister 1
8 Canister bracket 1
For installation, reverse the removal proce-
dure.
1
7
6
5
4
8
2
3
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
T R..7 Nm (0.7 m • 
kg, 5.1 ft • Ib) 
						

							THROTTLE BODIES
7-9
Removing the throttle body assembly
Order Job/Parts to remove Q’ty Remarks
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Canister (for California only) Refer to “THROTTLE BODIES” on page 7-8.
Air induction system coverRefer to “AIR INDUCTION SYSTEM” on 
page 7-15.
1 Throttle servo motor coupler 1 Disconnect.
2Throttle position sensor (for throttle cable pulley) 
coupler1 Disconnect.
3Throttle position sensor (for throttle valves) cou-
pler1 Disconnect.
4 Sub-wire harness 2 coupler 1 Disconnect.
5 Coolant temperature sensor coupler 1 Disconnect.
6Fuel hose (primary injector fuel rail to second-
ary injector fuel rail)1
7 Fuel hose (fuel tank to primary injector fuel rail) 1
8 Throttle cable (decelerator cable) 1
9 Throttle cable (accelerator cable) 1
10 Throttle body assembly 1
11 Throttle body joint clamp 4
T R..10 Nm (1.0 m • 
kg, 7.2 ft • Ib)
7
10
3
21
5
8 (8)11
4
12
6
9
13