engine YAMAHA FZR 2012 Repair Manual

Specifications
86
EJU34542
Specifications
Watercraft capacity:
Maximum people on board:
2 person
Maximum load capacity:
160 kg (353 lb)
Dimensions:
Length:
3370 mm (132.7 in)
Width:
1230 mm (48.4 in)
Height:
1160 mm (45.7 in)
Dry weight:
367 kg (809 lb)
Performance:
Maximum output (according to ISO 8665/SAE
J1228):
154.5 kW@7500 r/min
Maximum fuel consumption:
67.3 L/h (17.8 US gal/h, 14.8 Imp.gal/h)
Cruising range at full throttle:
1.04 hour
Trolling speed:
1250 ±100 r/min
Engine:
Engine type:
Liquid cooled 4-stroke, DOHC
Number of cylinders:
4
Engine displacement:
1812 cm³
Bore & stroke:
86.0 × 78.0 mm (3.39 × 3.07 in)
Compression ratio:
8.6 : 1
Valve clearance-intake (cold):
0.14–0.23 mm (0.0055–0.0091 in)
Valve clearance-exhaust (cold):
0.28–0.37 mm (0.0110–0.0146 in)
Lubrication system:
Wet sump
Cooling system:
Water
Starting system:
Electric
Ignition system:
T.C.I.Spark plug:
LFR6A
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
Battery capacity:
12 V, 19 Ah
Charging system:
Flywheel magneto
Drive unit:
Propulsion system:
Jet pump
Jet pump type:
Axial flow, single stage
Impeller rotation:
Counterclockwise
Jet thrust nozzle angle:
24.0+24.0 °
Jet thrust nozzle trim angle:
-10, -5, 0, 5, 10 °
Fuel and oil:
Recommended fuel:
Regular unleaded gasoline
Minimum octane rating (PON):
86
Minimum octane rating (RON):
90
Recommended engine oil type SAE:
SAE 10W-30, 10W-40, 20W-40, 20W-50
Recommended engine oil grade API:
API SE,SF,SG,SH,SJ,SL
Fuel tank total capacity:
70 L (18.5 US gal, 15.4 Imp.gal)
Engine oil quantity with oil filter replacement:
3.1 L (3.28 US qt, 2.73 Imp.qt)
Engine oil quantity without oil filter replacement:
3.0 L (3.17 US qt, 2.64 Imp.qt)
Engine oil total quantity:
4.3 L (4.55 US qt, 3.78 Imp.qt)
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Trouble recovery
87
EJU34561
Troubleshooting
If you have any trouble with your watercraft, use the troubleshooting chart to check for the pos-
sible cause.
If you cannot find the cause, consult a Yamaha dealer.
EJU36984Troubleshooting chart
Confirm the possible cause and remedy, and then refer to the applicable page.
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
start (Starter motor
does not turn over)Yamaha Se-
curity SystemLock mode selected Select unlock mode
26
Engine shut-
off switchClip not in place Install clip
27
Fuse Burned out Replace fuse and
check wiring91
Battery Run down Recharge 77
Poor terminal con-
nectionsTighten as required
77
Terminal corroded Clean or replace 77
Starter motor Faulty Have serviced by
Yamaha dealer—
Engine does not
start (Starter motor
turns over)Throttle lever Squeezed Release 27
Fuel Empty Refill as soon as pos-
sible47
Stale or contaminat-
edHave serviced by
Yamaha dealer—
Fuel tank Water or dirt present Have serviced by
Yamaha dealer—
Spark plug Fouled or defective Have serviced by
Yamaha dealer—
Spark plug
capNot connected or
looseHave serviced by
Yamaha dealer—
Connected to wrong
cylinderHave serviced by
Yamaha dealer—
Fuel injec-
tion systemFuel pump faulty Have serviced by
Yamaha dealer—
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88
Engine runs irregu-
larly or stallsFuel Empty Refill as soon as pos-
sible47
Stale or contaminat-
edHave serviced by
Yamaha dealer—
Fuel tank Water or dirt present Have serviced by
Yamaha dealer—
Spark plug Fouled or defective Have serviced by
Yamaha dealer—
Incorrect heat range Have serviced by
Yamaha dealer—
Gap incorrect Have serviced by
Yamaha dealer—
Spark plug
capNot connected or
looseHave serviced by
Yamaha dealer—
Cracked, torn, or
damagedHave serviced by
Yamaha dealer—
Electrical wir-
ingLoose connection Have serviced by
Yamaha dealer—
Fuel injec-
tion systemFaulty or clogged in-
jectorsHave serviced by
Yamaha dealer—
Warning light or in-
dicator blinks or
comes onFuel level Empty Refill as soon as pos-
sible47
Oil pressure
warningOil pressure dropped Have serviced by
Yamaha dealer37
Engine over-
heatedJet intake clogged Clean
90
Check engine
warningFaulty sensors Have serviced by
Yamaha dealer38 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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89
Watercraft slow or
loses powerShift lever Not completely shift-
ed into forward posi-
tionPush lever forward
until it stops 31
Watercraft
operation
modeLow RPM Mode acti-
vatedDeactivate Low RPM
Mode 33
Cavitation Jet intake clogged Clean 90
Impeller damaged or
wornHave serviced by
Yamaha dealer90
Engine over-
heat warningEngine speed reduc-
tion control activatedClean jet intake and
cool engine38
Oil pressure
warningEngine speed reduc-
tion control activatedAdd oil
37
Spark plug Fouled or defective Have serviced by
Yamaha dealer—
Incorrect heat range Have serviced by
Yamaha dealer—
Gap incorrect Have serviced by
Yamaha dealer—
Spark plug
capNot connected or
looseHave serviced by
Yamaha dealer—
Electrical wir-
ingLoose connection Have serviced by
Yamaha dealer—
Fuel Stale or contaminat-
edHave serviced by
Yamaha dealer—
Air filter Clogged Have serviced by
Yamaha dealer—
Oil buildup Have serviced by
Yamaha dealer— TROUBLE POSSIBLE CAUSE REMEDY PAGE
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Trouble recovery
90
EJU34623
Emergency procedures EJU34634Cleaning the jet intake and impeller
WARNING
EWJ00782
Before attempting to remove weeds or de-
bris from the jet intake or impeller area,
shut the engine off and remove the clip
from the engine shut-off switch. Severe in-
jury or death could result from coming in
contact with the rotating parts of the jet
pump.
If weeds or debris gets caught in the jet intake
or impeller, cavitation can occur, causing jet
thrust to decrease even though engine speed
rises. If this condition is allowed to continue,
the engine will overheat and may seize.
NOTICE: If weeds or debris gets caught in
the jet intake, do not operate the watercraft
above trolling speed until they have been
removed.
[ECJ00653]
If there is any sign that the jet intake or impel-
ler is clogged with weeds or debris, return to
shore and check the intake and impeller. Al-ways stop the engine before beaching the wa-
tercraft.
(1) Place a suitable clean cloth or carpeting
underneath the watercraft to protect it
from abrasions and scratches. Turn the
watercraft on its side as shown. NOTICE:
Always turn the watercraft over onto
its port (left) side. When turning the
watercraft on its side, support the bow
so that the handlebars are not bent or
damaged.
[ECJ00661]
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Trouble recovery
91
(2) Remove any weeds or debris from
around the jet intake, drive shaft, impel-
ler, jet pump housing, and jet thrust noz-
zle.
If debris is difficult to remove, consult a
Yamaha dealer.
EJU34641Jumping the battery
If the watercraft battery has run down, the en-
gine can be started using a 12-volt booster
battery and jumper cables.
EJU34663Connecting the jumper cables
WARNING
EWJ01250
To avoid battery explosion and serious
damage to the electrical system:

Do not reverse the polarity of the jumper
cables when connecting to the batteries.

Do not connect the negative (–) jumper
cable to the negative (–) terminal of the
watercraft battery.

Do not touch the positive (+) jumper ca-
ble to the negative (–) jumper cable.
(1) Connect the positive (+) jumper cable to
the positive (+) battery terminals of both
batteries.
(2) Connect one end of the negative (–)
jumper cable to the negative (–) battery
terminal of the booster battery.(3) Connect the other end of the negative (–)
jumper cable to an engine hanger.
(4) Start the engine, and then disconnect the
jumper cables by reversing the steps
above. (See page 27 for information on
starting the engine.)
EJU36994Replacing the fuses
If a fuse is blown, replace it with the proper
fuse.
To replace a fuse:
(1) Remove the seats. (See page 40 for seat
removal and installation procedures.)
1Negative (–) jumper cable
2Positive (+) jumper cable
3Booster battery
4Engine hanger
1Good fuse
2Blown fuse
2
3 1
4
2 1
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Trouble recovery
93
(7) Securely install the seats in their original
positions.
If the fuse immediately blows again, the elec-
trical system may be defective. If this occurs,
have a Yamaha dealer service the watercraft.
EJU41821Replacing the bilge pump fuse
If the fuse is blown, replace it with the proper
fuse.
To replace the fuse:
(1) Remove the seats and engine cover.
(See page 40 for seat removal and instal-
lation procedures and page 82 for engine
cover removal and installation proce-
dures.)
(2) Remove the plastic ties that are securing
the corrugated tube and bilge pump fuse
leads.
TIP:
Be careful not to drop the plastic ties into the
engine compartment.
(3) Pull out the bilge pump fuse holder from
the rubber cover, and then remove the
fuse cover.
(4) Replace the blown fuse with the spare
fuse of the correct amperage.
WARNING! Do not use fuses of a dif-
ferent amperage than recommended.
Substitution with a fuse that has an
improper rating can cause extensive
electrical system damage and possi-
ble fire.
[EWJ00802]
TIP:
If the fuse is difficult to remove, use the fuse
puller on the reverse side of the electrical box
1Good fuse
2Blown fuse
2 1
1Bilge pump fuse lead
2Plastic tie
3Corrugated tube
213
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94
cap. (See page 91 for information on the fuse
puller.)
(5) Securely install the fuse cover, and then
fit the bilge pump fuse holder into the rub-
ber cover.
(6) Secure the bilge pump fuse leads and
corrugated tube with the plastic ties.
(7) Securely install the engine cover and
seats in their original positions.If the fuse immediately blows again, the elec-
trical system may be defective. If this occurs,
have a Yamaha dealer service the watercraft.
EJU34715Towing the watercraft
WARNING
EWJ00811

The operator of the towing boat must
keep speed to a minimum and avoid traf-
fic or obstacles which could be a hazard
to the operator on the watercraft.

The towline should be long enough so
that the watercraft will not collide with
the towing boat when slowing down.
If the watercraft becomes inoperative in the
water, it can be towed to shore.
To tow the watercraft:
Use a towline that is three times the combined
length of the towing boat and the watercraft.
(1) Securely attach the towline to the bow
eye of the watercraft being towed.
(2) Sit astride the seat and hold on to the
handlebars in order to balance the water-
craft. NOTICE: The bow must be kept
up out of the water during towing, oth-
erwise water could flood the engine
compartment or water could flow back
into the engine, causing severe en-
gine damage.
[ECJ01330]
1Bilge pump fuse holder
2Fuse cover
3Spare fuse
4Fuse
Fuse amperage:
Bilge pump fuse:
3 A
1Bilge pump fuse lead
2Plastic tie
3Corrugated tube
4Rubber cover
21
43
213
4
1Bow eye
1
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95
Tow the watercraft at 8 km/h (5 mph) or less.
NOTICE: Tow the watercraft at 8 km/h (5
mph) or less, otherwise water could flood
the engine compartment or water could
flow back into the engine, causing severe
engine damage.
[ECJ01321]
EJU36155
Submerged watercraft
If the watercraft is submerged or flooded with
water, drain the bilge water from the engine
compartment. Then, have a Yamaha dealer
service the watercraft as soon as possible.
If the watercraft was submerged:
(1) Remove the watercraft from the water
and drain the water from the storage
compartments. (See page 42 for informa-
tion on draining the storage compart-
ments.)
(2) Drain the bilge water from the engine
compartment. (See page 50 for informa-
tion on draining the bilge water.)
(3) Have the watercraft serviced by a
Yamaha dealer as soon as possible.
NOTICE: Be sure to have a Yamaha
dealer inspect the watercraft. Other-
wise, serious engine damage could re-
sult.
[ECJ00791]
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Index
A
After removing the watercraft from the
water ..................................................... 75
B
Battery care .............................................. 77
Battery checks.......................................... 57
Battery, jumping ....................................... 91
Beaching and docking the watercraft ....... 74
Beverage holder ....................................... 45
Bilge pump fuse, replacing ....................... 93
Bilge water check ..................................... 57
Bilge water, draining................................. 50
Bilge water, draining on land .................... 50
Bilge water, draining on water .................. 51
Boarding alone ......................................... 70
Boarding and starting off from a dock ...... 73
Boarding the watercraft ............................ 69
Boarding with a passenger....................... 70
Bow eye ................................................... 42
Bow storage compartment ....................... 42
Builder’s plate............................................. 2
C
Capsized watercraft ................................. 73
Check engine warning.............................. 38
Cleaning ................................................... 80
Cleaning the watercraft ............................ 77
Cooling water pilot outlet check ............... 63
Cooling water pilot outlets ........................ 29
Craft Identification Number (CIN) ............... 1
Cruising limitations ................................... 12
D
Dual analog meter unit ............................. 35
Dual analog meter unit check................... 63
E
Emergency procedures ............................ 90
Engine break-in ........................................ 53
Engine compartment check...................... 56
Engine cover, removing and installing ..... 82
Engine idling speed check ....................... 63
Engine oil ................................................. 49
Engine oil and oil filter .............................. 85
Engine oil level check............................... 57
Engine oil requirements ........................... 49
Engine overheat warning ......................... 38
Engine serial number ................................. 1Engine shut-off cord (lanyard) check ....... 61
Engine shut-off switch .............................. 27
Engine stop switch ................................... 27
Engine unit check ..................................... 57
Enjoy your watercraft responsibly ............ 18
Equipment ................................................ 40
F
Fire extinguisher check ............................ 62
Fire extinguisher holder and cover ........... 45
Fire extinguisher holder, cover, and
band checks.......................................... 62
Flushing the cooling water passages ....... 76
Fuel .......................................................... 47
Fuel level check ....................................... 56
Fuel level meter ........................................ 37
Fuel level warning .................................... 37
Fuel requirements .................................... 47
Fuel system checks .................................. 56
Fuses, replacing ....................................... 91
G
Getting to know your watercraft ............... 64
Glossary, watercraft ................................. 20
Glove compartment .................................. 43
H
Hazard information ................................... 16
Hood check .............................................. 63
Hour meter/voltmeter ............................... 36
Hull and deck check ................................. 62
I
Identification numbers ................................ 1
Information display ................................... 36
J
Jet intake and impeller, cleaning .............. 90
Jet intake checks ...................................... 62
Jumper cables, connecting ...................... 91
L
Labels, important ........................................ 4
Labels, other .............................................. 9
Labels, warning .......................................... 5
Launching the watercraft .......................... 65
Learning to operate your watercraft ......... 64
Leaving the watercraft .............................. 66
Limitations on who may operate the
watercraft .............................................. 11
Long-term storage .................................... 80
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