Yamaha 2009 YZF-R1 (Y), Service Manual, Page: 327 / 546

CONNECTING RODS AND PISTONS
5-82
EAS26190
INSTALLING THE CONNECTING ROD AND
PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:
• Big end bearings
• Connecting rod cap
(onto the connecting rod)
TIP
• Be sure to reinstall each big end bearing in
its original place.
• Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting
rods and connecting rod caps.
• Make sure that the projection “c” on the con-
necting rod cap faces the same direction as
the “Y” mark “d” on the connecting rod.
2. Tighten:
• Connecting rod bolts
ECA14B1042
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts.
TIP
Install by carrying out the following procedures
in order to assemble in the most suitable con-
dition.
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a. Replace the connecting rod bolts with new
ones.
b. Clean the connecting rod bolts and lubri-
cate the bolt threads and seats with molyb-
denum disulfide oil.
c. After installing the big end bearing, assem-
ble the connecting rod and connecting rod
cap without installing them onto the crank-
shaft.
d. Tighten the connecting rod bolt while
checking that the sections shown “a” and
“b” are flush with each other by touching
the surface.
TIP
To install the big end bearing, care should be
taken not to install it at an angle and the posi-
tion 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 condi-
tion.
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3. Install:
• Oil ring expander “1”
• Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
(into the piston)
TIP
Be sure to install the piston rings so that the
manufacturer’s marks or numbers “a” face up.
New
Connecting rod bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
a. Side machined face
b. Thrusting faces