2004 YAMAHA YZF-R1S Service Manual

5-75
CRANKCASEENG
NOTE:
EAS00399
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:

crankcase
Cracks / damage
Replace.

oil delivery passages
Obstruction
Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:

bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement
Replace.
2. Check:

oil seals
Damage / wear
Replace.
ASSEMBLING THE CRANKCASE
1. Lubricate:

crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant
Engine oil
2. Apply:

sealant
Yamaha bond No. 1215
90890-85505, ACC-1109-05-01
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2
3 mm
(0.08
0.12 in) of the crankshaft journal bear-
ings.
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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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5-77
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11
12Removing the connecting rods and
pistons
Lower crankcase
Connecting rod cap
Big end lower bearing
Big end upper bearing
Piston pin clip
Piston pin
Piston
Connecting rod
Top ring
2nd ring
Oil ring
Cylinder
Cylinder gasket4
4
4
8
4
4
4
4
4
4
1
1Remove the parts in the order listed.
Refer to “CRANKCASE”.
For installation, reverse the removal
procedure.
20 Nm (2.0 m
kg, 14 ft
lb) +150
8 Nm (0.8 m
kg, 5.8 ft
lb)
CONNECTING RODS AND PISTONSENG
EAS00252
CONNECTING RODS AND PISTONS
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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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5-79
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
EAS00387
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:

crankshaft assembly

crankshaft journal upper bearings
(from the upper crankcase)
Refer to “CRANKSHAFT”.
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.
EAS00261
CHECKING THE CYLINDER AND PISTON
1. Check:

piston wall

cylinder wall
Vertical scratches
Replace the cylinder,
and the piston and piston rings as a set.
2. Measure:

piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
bore gauge.
Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the cyl-
inder. Then, find the average of the measure-
ments.
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5-80
CONNECTING RODS AND PISTONSENG
NOTE:Cylinder bore “C”
77.00
77.01 mm
(3.0315
3.0319 in)
Wear limit77.06 mm (3.03 in)
Taper limit “T”0.005 mm (0.0002 in)
Out of round “R”0.005 mm (0.0002 in)
“C” = maximum of D1
D6
“T” = maximum of D1 or D2 – maximum
of D
5 or D6
“R” = maximum of D1 D3 or D5 –
minimum of D
2 D4 or D6
b. If out of specification, replace the cylinder,
and the pistons and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a4 mm (0.16 in) from the bottom edge of the piston
Piston size “P”
76.975
76.990 mm
(3.0305
3.0311 in)
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.010
0.035 mm
(0.0004
0.0014 in)
: 0.120 mm (0.0047 in)
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
EAS00263
CHECKING THE PISTON RINGS
1. Measure:

piston ring side clearance
Out of specification
Replace the piston
and piston rings as a set.
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
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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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5-82
CONNECTING RODS AND PISTONSENG
2. Measure:

piston pin outside diameter
a
Out of specification
Replace the piston
pin.
Piston pin outside diameter
16.991
17.000 mm
(0.6689
0.6693 in)
: 16.971 mm (0.6682 in)
3. Measure:

piston pin bore inside diameter
b
Out of specification
Replace the piston.
Piston pin bore inside diameter
17.002
17.013 mm
(0.6694
0.6698 in)
: 17.043 mm (0.6710 in)
4. Calculate:

piston-pin-to-piston clearance
Out of specification
Replace the piston pin
and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore size –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002
0.022 mm
(0.0001
0.0009 in)
: 0.072 mm (0.0028 in)
CHECKING THE BIG END BEARINGS
1. Measure:

crankshaft-pin-to-big-end-bearing clear-
ance
Out of specification
Replace the big end
bearings.
Crankshaft-pin-to-big-end-bearing
clearance
0.034
0.058 mm
(0.0013
0.0023 in)
: 0.09 mm (0.0035 in)
The following procedure applies to all of the
connecting rods.
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