Yamaha R1 2004 ServiceManual

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...

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...

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...

5-92
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7Removing the crankshaft
Crankcase
Connecting rod and connecting rod 
caps
Crankshaft
Crankshaft journal lower bearing
Crankshaft journal upper bearing
Washer
Crankshaft drive gear
Pin
Pickup rotor1
5
5
1
1
1
1Remove the parts in the order listed.
Separate.
Refer to “CRANKCASE”.
Refer to “CONNECTING RODS AND 
PISTONS”.
For installation, reverse the removal 
procedure.
60 Nm (6.0 m
kg, 43 ft
lb)
CRANKSHAFTENG
EAS00381
CRANKSHAFT 

5-93
CRANKSHAFTENG
CAUTION:
EAS00395
CHECKING THE CRANKSHAFT
1. Measure:

crankshaft runout
Out of specification 
 Replace the crank-
shaft.
Crankshaft runout
Less than 0.03 mm (0.0012 in)
2. Check:

crankshaft journal surfaces

crankshaft pin surfaces

bearing surfaces
Scratches / wear 
 Replace the crankshaft.
CHECKING THE CRANKSHAFT DRIVE
SPROCKET
1. Check:

crankshaft drive sprocket 
1
Cracks / damage / wear 
 Replace the de-
fective part(s).
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:...

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...

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-...

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....

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...

5-98
TRANSMISSIONENG
Order Job / Part Q’ty Remarks
13
14
15
16
17Main axle retainer
Main axle assembly
Oil pipe
O-ring
Oil baffle plate1
1
1
2
1
For installation, reverse the removal 
procedure.
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)