Yamaha R1 2004 ServiceManual

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:...

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...

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...

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...

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...

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...

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...

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...

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...

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...