2004 YAMAHA YZF-R1S torque

5-76
CRANKCASEENG
CAUTION:
NOTE:
3. Install:

dowel pin
4. Set the shift drum assembly and transmis-
sion gears in the neutral position.
5. Install:

lower crankcase
1
(onto the upper crankcase 2)
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
6. Install:

crankcase bolts

Lubricate the bolt threads with engine oil.

Install a washer on bolts
1
10 and 22.

Seal bolt
18

Tighten the bolts in the tightening sequence
cast on the crankcase.
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
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)
* Following the tightening order, loosen the bolt
one by one and then retighten it to the specific
torque.
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5-85
CONNECTING RODS AND PISTONSENG
WARNING
CAUTION:
l. Clean the connecting rod bolts.
m. Tighten the connecting rod bolts.
n. Put a mark
1 on the corner of the connecting
rod bolt
2 and the connecting rod 3.
o. Tighten the bolt further to reach the specified
angle (150).
p. After the installation, check that the section
shown
a is flush with each other by touching
the surface.

Side machined face
a

When the bolt is tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and per-
form the procedure again.

If they are not flush with each other, remove
the connecting rod bolt and big end bear-
ing and restart from step “e”. In this case,
make sure to replace the connecting rod
bolt.

Do not use a torque wrench to tighten the
nut to the specified angle.

Tighten the bolt until it is at the specified
angles.
q. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS”.
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5-91
CONNECTING RODS AND PISTONSENG
WARNING
CAUTION:

When the bolt is tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and per-
form the procedure again.

If they are not flush with each other, remove
the connecting rod bolt and big end bear-
ing and restart from step “9”.
In this case, make sure to replace the con-
necting rod bolt.

Do not use a torque wrench to tighten the
bolt to the specified angle.

Tighten the bolt until it is at the specified
angles.
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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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