2004 YAMAHA YZF-R1S oil

5-78
CONNECTING RODS AND PISTONSENG
NOTE:
CAUTION:
NOTE:
NOTE:
EAS00393
REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:

connecting rod cap
1

big end bearings

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

After removing the connecting rods and con-
necting rod caps, care should be taken not to
damage the mating surfaces of the connecting
rods and connecting rod caps.
2. Remove:

Cylinder

Cylinder gasket

Cylinder stud bolts
3. Remove:

piston pin clips
1

piston pin 2

piston 3
Do not use a hammer to drive the piston pin
out.

For reference during installation, put identifica-
tion marks on the piston crown.

Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore
area. If both areas are debarred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set
4.
Piston pin puller set
90890-01304, YU-01304
4. Remove:

top ring

2nd ring

oil ring
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
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5-81
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Piston ring side clearance
Top ring
0.030
0.065 mm
(0.0012
0.0026 in)
: 0.115 mm (0.0045 in)
2nd ring
0.020
0.055 mm
(0.0008
0.002 in)
: 0.115 mm (0.0045 in)
2. Install:

piston ring
(into the cylinder)
Level the piston ring into the cylinder with the
piston crown.
a5 mm (0.20 in)
3. Measure:

piston ring end gap
Out of specification
Replace the piston
ring.
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap
Top ring
0.15
0.25 mm
(0.0059
0.0098 in)
: 0.50 mm (0.0197 in)
2nd ring
0.30
0.45 mm
(0.0118
0.0177 in)
: 0.80 mm (0.0315 in)
Oil ring
0.10
0.40 mm
(0.0039
0.0158 in)
CHECKING THE PISTON PINS
The following procedure applies to all of the pis-
ton pins.
1. Check:

piston pin
Blue discoloration / grooves
Replace the
piston pin and then check the lubrication sys-
tem.
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5-86
CONNECTING RODS AND PISTONSENG
NOTE:
r. Measure the compressed Plastigauge
width on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select re-
placement big end bearings.
2. Select:

big end bearings (P1
P4)

The numbers
A stamped into the crankshaft
web and the numbers
1 on the connecting
rods are used to determine the replacement
big end bearing sizes.

“P1”
“P4” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P
1” and the
crankshaft web “P
1” numbers are “5” and “2” re-
spectively, then the bearing size for “P1” is:
“P
1” (connecting rod) – “P1”
(crankshaft) =
5 – 2 = 3 (brown)
BIG END BEARING COLOR CODE
1Blue
2Black
3Brown
4Green
INSTALLING THE CONNECTING ROD AND
PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:

top ring
1

2nd ring 2

upper oil ring rail 3

oil ring expander 4

lower oil ring rail 5
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5-87
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers
a face up.
2. Install:

piston
1
(onto the respective connecting rod 2)

piston pin
3

piston pin clip New 4

Apply engine oil onto the piston pin.

Make sure that the “Y” mark
a on the connect-
ing rod faces left when the arrow mark
b on
the piston is pointing up. Refer to the illustra-
tion.

Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Lubricate:

piston

piston rings

cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
4. Offset:

piston ring end gaps
aTop ring
bLower oil ring rail
cUpper oil ring rail
d2nd ring
eOil ring expander
5. Lubricate:

crankshaft pins

big end bearings

connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
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5-94
CRANKSHAFTENG
NOTE:
NOTE:
NOTE:
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions of
the crankcase.
b. Place the upper crankcase upside down on a
bench.
c. Install the crankshaft journal upper bearings
1 and the crankshaft into the upper crank-
case.
Align the projections
a on the crankshaft jour-
nal upper bearings with the notches
b in the up-
per crankcase.
d. Put a piece of Plastigauge
 2 on each
crankshaft journal.
Do not put the Plastigauge
 over the oil hole in
the crankshaft journal.
e. Install the crankshaft journal lower bearings
1 into the lower crankcase and assemble
the crankcase halves.

Align the projections
a of the crankshaft jour-
nal lower bearings with the notches
b in the
lower crankcase.

Do not move the crankshaft until the clearance
measurement has been completed.
f. Tighten the bolts to specification in the tight-
ening sequence cast on the crankcase.
Crankcase bolt
Bolt
1
10
1st: 20 Nm (2.0 m
kg, 14 ft
lb)
2nd: 20 Nm (2.0 m
kg, 14 ft
lb)
3rd: +60
Bolt
11
16
24 Nm (2.4 m
kg, 17 ft
lb)
Bolt
17
26
12 Nm (1.2 m
kg, 8.7 ft
lb)
M9  105 mm (4.1 in) bolts:
1
10
M8  60 mm (2.4 in) bolt: 11 LOCTITE
M8  60 mm (2.4 in) bolts: 12, 16
M6  70 mm (2.8 in) bolts: 19, 21, 23
M6  65 mm (2.5 in) bolts: 17, 18
M6  60 mm (2.4 in) bolts: 22, 24, 25
M6  50 mm (2.0 in) bolts: 20, 26
M8  50 mm (2.0 in) bolts: 13
15
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5-95
CRANKSHAFTENG
NOTE:
NOTE:
* Following the tightening order, loosen the bolt
one by one and then retighten it to the specific
torque.
Lubricate the crankcase bolt threads with en-
gine oil.
Refer to “CRANKCASE”.
g. Remove the lower crankcase and the crank-
shaft journal lower bearings.
h. Measure the compressed Plastigauge

width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specification,
select replacement crankshaft journal bear-
ings.
2. Select:

crankshaft journal bearings (J1
J5)

The numbers
A stamped into the crankshaft
web and the numbers
1 stamped into the low-
er crankcase are used to determine the re-
placement crankshaft journal bearing sizes.

“J1
J5” refer to the bearings shown in the
crankshaft illustration.

If “J1
J5” are the same, use the same size
for all of the bearings.

If the size is the same for all “J
1 to J5” one digit
for that size is indicated. (Crankcase side only)
For example, if the crankcase “J
1” and crank-
shaft web “J
1” numbers are “6” and “2” respec-
tively, then the bearing size for “J1” is:
“J
1” (crankcase) – “J1”
(crankshaft web) – 1 =
6 – 2 – 1 = 3 (brown)
CRANKSHAFT JOURNAL BEARING
COLOR CODE
0White
1Blue
2Black
3Brown
4Green
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5-96
CRANKSHAFTENG
NOTE:
60 Nm (6.0 m
kg, 43 ft
lb)
EAS00407
INSTALLING THE CRANKSHAFT
1. Install:

crankshaft journal upper bearings
1
(into the upper crankcase)
2. Lubricate:

crankshaft journal upper bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil

Align the projections
a on the crankshaft jour-
nal upper bearings with the notches
b in the
upper crankcase.

Be sure to install each crankshaft journal up-
per bearing in its original place.
3. Install:

crankshaft
4. Install:

crankcase (lower)
Refer to “CRANKCASE”.
5. Install:

pin

pickup rotor
1

drive sprocket 2
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5-97
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12Removing the transmission, shift
drum assembly, and shift forks
Crankcase lower
Drive axle assembly
Circlip
Oil seal
Bearing
Washer
Shift drum retainer
Spring
Shift fork guide bar
Shift fork “L”
Shift fork “R”
Shift drum assembly
Shift fork “C”1
1
1
1
1
2
2
2
1
1
1
1Remove the part in the order listed.
Separate.
Refer to “CRANKCASE”.
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
TRANSMISSIONENG
EAS00419
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
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