2004 YAMAHA YZF-R1S Service Manual

5-83
CAUTION:
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearings must be installed in their origi-
nal positions.
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rods halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing
into the connecting rod cap.
Align the projections
a on the big end bearings
with the notches
b in the connecting rod and
connecting rod cap.
c. Put a piece of Plastigauge
 1 on the crank-
shaft pin.
d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.

Lubricate the bolt threads with molybdenum
disulfide grease.

Make sure that the “Y” mark
c on the connect-
ing rod faces towards the left side of the crank-
shaft.

Make sure that the characters
d on both the
connecting rod and connecting rod cap are
aligned.
ProCarManuals.com

5-84
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE:
NOTE:
CAUTION:
e. Tighten the connecting rod bolts.
Install by carrying out the following procedures
in order to assemble in the most suitable condi-
tion.
Connecting rod bolt
29.4 Nm (3.0 m
kg, 21 ft
lb)

First, tighten the bolts to 15 Nm (1.5 m
kg, 11
ft
lb).

Retighten the bolts to 29.4 Nm (3.0 m
kg, 21
ft
lb).
f. Replace the connecting rod bolts with new
ones.
g. Clean the connecting rod bolts.
h. After installing the big end bearing, assemble
the connecting rod and connecting rod cap
once using a single unit of the connecting
rod.
i. Tighten the connecting rod bolt while check-
ing that the sections shown
a and b are
flush with each other by touching the surface.

Side machined face
a

Thrusting faces (4 places at front and rear)
b
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.
j. Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and
install these parts to the crankshaft with the
big end bearing kept in the current condition.
k. Tighten the connecting rod bolts.
Connecting rod bolt
20 Nm (2.0 m
kg, 14 ft
lb) + 150
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
ProCarManuals.com

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”.
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com

5-88
CONNECTING RODS AND PISTONSENG
8 Nm (0.8 m
kg, 5.8 ft
lb)
NOTE:
NOTE:
29.4 Nm (3.0 m
kg, 21 ft
lb)
NOTE:
6. Check:

cylinder stud bolts
1
7. Install:

cylinder gasket
2 New
8. Install:

big end bearings
(onto the connecting rods and connecting
rod caps)

Align the projection
a on the big end bearings
with the notches
b in the connecting rods and
connecting rod caps.

Be sure to reinstall each big end bearing in its
original place.

Make sure that the characters
c on both the
connecting rod and connecting rod cap are
aligned.
9. Tighten:
Install by carrying out the following procedures
in order to assemble in the most suitable condi-
tion.

connecting rod bolts

First, tighten the bolts to 15 Nm (1.5 m
kg, 11
ft
lb).

Retighten the bolts to 29.4 Nm (3.0 m
kg, 21
ft
lb).
a. Replace the connecting rod bolts with new
ones.
ProCarManuals.com

5-89
CONNECTING RODS AND PISTONSENG
NOTE:
NOTE: b. Clean the connecting rod bolts.
c. After installing the big end bearing, assemble
the connecting rod and connecting rod cap
once using a single unit of the connecting
rod.
d. Tighten the connecting rod bolt while check-
ing that the sections shown
a and b are
flush with each other by touching the surface.

Side machined face
a

Thrusting faces (4 places at front and rear)
b
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.
e. Loosen the connecting rod bolt, remove the
connecting rod and connecting rod cap and
install these parts to the crankshaft with the
big end bearing kept in the current condition.
10. Install:

piston assemblies
1
(into the cylinder)
While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
ProCarManuals.com

5-90
CONNECTING RODS AND PISTONSENG
NOTE:
20 Nm (2.0 m
kg, 14 ft
lb) + 150
CAUTION:
11. Install:

cylinder assembly
1

connecting rod caps 2

Make sure that the “Y” marks a on the con-
necting rods face towards the left side of the
crankshaft.

Make sure that the characters on both the con-
necting rod and connecting rod cap are
aligned.
12. Tighten:

connecting rod bolts
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
a. Clean the connecting rod bolts.
b. Tighten the connecting rod bolts.
c. Put a mark
1 on the connecting rod bolts 2
and the connecting rod cap 3.
d. Tighten the bolt further to reach the specified
angle (150).
e. After the installation, check that the section
show
a is flush with each other by touching
the surface.

Side machined face
a
ProCarManuals.com