engine YAMAHA FZS 2009 Workshop Manual

Maintenance and care
76
If the throttle lever does not move smoothly or
if the throttle lever free play is not within the
specified range, have a Yamaha dealer ser-
vice the watercraft.
EJU37041Cleaning and adjusting the spark
plugs
WARNING
EWJ00350
Be careful not to damage the insulator
when removing or installing a spark plug.
A damaged insulator could allow sparks to
escape, which could result in a fire or ex-
plosion.
The spark plug is an important engine compo-
nent and is easy to inspect. The condition of
the spark plug can indicate something about
the condition of the engine. For example, if
one spark plug has a distinctly different color,
the engine could require servicing. Do not at-
tempt to diagnose any problems yourself.
Have a Yamaha dealer service the watercraft.
Remove and inspect the spark plugs periodi-
cally; heat and deposits will cause the spark
plugs to slowly break down and erode. If elec-
trode erosion becomes excessive, or if carbon
and other deposits are excessive, replace the
spark plug with the specified plug.
To remove a spark plug:
(1) Remove the seats. (See page 24 for seat
removal and installation procedures.)(2) Remove the engine cover screws, and
then remove the engine cover.
(3) Remove the spark plug cap bolts, and
then remove the spark plug cap.
NOTICE: Do not use any tools to re-
move or install the spark plug cap,
otherwise the ignition coil coupler
could be damaged. The spark plug
cap may be difficult to remove be-
cause the rubber seal on the end of
the cap fits tightly. To remove the
spark plug cap, simply twist it back
and forth while pulling it up; to install
it, twist it back and forth while pushing
it down.
[ECJ00211]
Specified spark plug:
LFR6A
1Engine cover screw
2Engine cover
1 2
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Maintenance and care
77
TIP:
If removing the spark plug cap nearest the
stern, remove the plastic tie that is securing
the wiring harness before removing the cap.
(4) Remove the spark plug.
Measure the spark plug gap with a wire
thickness gauge. Replace the spark plug
or adjust the gap to specification if neces-
sary.
To install a spark plug:
(1) Clean the gasket surface.
(2) Wipe any dirt from the threads of the
spark plug.(3) Install the spark plug, and then tighten it
to the specified torque.
TIP:
If a torque wrench is not available when you
are installing a spark plug, a good estimate of
the correct torque is 1/4 turn to 1/2 turn past
finger tight using the spark plug wrench in-
cluded in the tool kit. Have the spark plug ad-
justed to the correct torque with a torque
wrench as soon as possible.
(4) Wipe off any water on the spark plug or
inside the spark plug cap, and then install
the cap. Push the spark plug cap down
until it is securely installed, and then in-
stall the spark plug cap bolts and tighten
them to the specified torque.
If the spark plug cap nearest the stern
was removed, secure the wiring harness
by installing the plastic tie after installing
the cap.
(5) Install the engine cover and engine cover
screws, and then install the seats.
EJU37490Lubrication points
To keep moving parts sliding or rotating
smoothly, coat them with water-resistant
grease.
1Spark plug cap bolt
2Spark plug cap
3Plastic tie
1Spark plug gap
Spark plug gap:
0.8–0.9 mm (0.031–0.035 in)
1
2
3
Spark plug tightening torque:
24.5 Nm (2.50 kgf-m, 18.1 ft-lb)
Spark plug cap bolt tightening torque:
7.6 Nm (0.77 kgf-m, 5.6 ft-lb)
Recommended water-resistant grease:
Yamaha Marine Grease/Yamaha
Grease A
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Maintenance and care
80
(3) Secure the battery in place. WARNING!
Fire or explosion could result if the
breather hose is damaged, obstruct-
ed, or not connected properly.
[EWJ00451]
EJU34491
Fuel injection system
If the fuel injection system is malfunctioning,
have a Yamaha dealer service the watercraft.
EJU37500Checking the trolling speed
(1) Place the watercraft in the water.
(2) Start the engine and warm it up. Use the
tachometer in the dual analog meter unit
to check the trolling speed.
If the trolling speed is out of specification,
have a Yamaha dealer service the watercraft.
1Negative (–) battery terminal: Black lead
2Positive (+) battery terminal: Red lead
3Breather hose
Trolling speed:
1250 ±100 r/min
12
3
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Specifications
81
EJU34542
Specifications
Watercraft capacity:
Maximum people on board:
3 person
Maximum load capacity:
240 kg (530 lb)
Dimensions:
Length:
3370 mm (132.7 in)
Width:
1230 mm (48.4 in)
Height:
1160 mm (45.7 in)
Dry weight:
369 kg (813 lb)
Performance:
Maximum output (according to ISO 8665/SAE
J1228):
154.50 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, 19.0 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
82
EJU34560
Troubleshooting
If you have any trouble with your watercraft, use this section to check for the possible cause.
If you cannot find the cause, or if the procedure for replacement or repair is not described in
this owner’s/operator’s manual, have a Yamaha dealer perform the necessary service.
EJU36982Troubleshooting chart
TROUBLE POSSIBLE CAUSE REMEDY PAGE
Engine does not
start (Starter motor
does not turn over)Yamaha Se-
curity SystemLock mode selected Select unlock mode
33
Engine shut-
off switchClip not in place Install clip
26
Fuse Burned out Replace fuse and
check wiring86
Battery Run down Recharge 78
Poor terminal con-
nectionsTighten as required
78
Terminal corroded Clean 70
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-
sible43
Stale or contaminat-
edHave serviced by
Yamaha dealer74
Fuel tank Water or dirt present Have serviced by
Yamaha dealer74
Spark plug Fouled or defective Clean or replace 76
Spark plug
capNot connected or
looseConnect properly
76
Connected to wrong
cylinderConnect properly
76
Fuel injec-
tion systemFuel pump faulty Have serviced by
Yamaha dealer—
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Trouble recovery
83
Engine runs irregu-
larly or stallsFuel Empty Refill as soon as pos-
sible43
Stale or contaminat-
edHave serviced by
Yamaha dealer74
Fuel tank Water or dirt present Have serviced by
Yamaha dealer74
Spark plug Fouled or defective Replace 76
Incorrect heat range Replace 76
Gap incorrect Adjust 76
Spark plug
capLoose Connect properly 76
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 blinksFuel level Empty Refill as soon as pos-
sible43
Oil pressure
warningOil pressure dropped Have serviced by
Yamaha dealer37
Engine over-
heatedJet intake clogged Clean
85
Check engine
warningFaulty sensors Have serviced by
Yamaha dealer39 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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Trouble recovery
84
Watercraft slow or
loses powerShift lever Not completely shift-
ed into forward posi-
tionPush lever forward
until it stops 29
Yamaha Se-
curity SystemLow-RPM mode se-
lectedSelect normal mode
33
Cavitation Jet intake clogged Clean 85
Impeller damaged or
wornHave serviced by
Yamaha dealer85
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 Replace 76
Incorrect heat range Replace 76
Gap incorrect Adjust 76
Spark plug
capLoose Connect properly
76
Electrical wir-
ingLoose connection Have serviced by
Yamaha dealer—
Fuel Stale or contaminat-
edHave serviced by
Yamaha dealer74
Air filter Clogged Have serviced by
Yamaha dealer74
Oil buildup Have serviced by
Yamaha dealer74 TROUBLE POSSIBLE CAUSE REMEDY PAGE
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Trouble recovery
85
EJU34620
Emergency procedures EJU34631Cleaning the jet intake and impeller
WARNING
EWJ00780
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.
[ECJ00651]
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
86
(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.
EJU34662Connecting 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. NOTICE: Never push the start
switch while the engine is running. Do
not operate the start switch for more
than 5 seconds, otherwise the battery
will be discharged and the engine will
not start. Also, the starter motor could
be damaged. If the engine does not
start in 5 seconds, release the start
switch, wait 15 seconds, and then try
again.
[ECJ00481]
EJU36991
Replacing the fuses
The fuses are located in the electrical box.
To replace a fuse:
(1) Remove the seats. (See page 24 for seat
removal and installation procedures.)
1Negative (–) jumper cable
2Positive (+) jumper cable
3Booster battery
4Engine hanger
2
3 1
4
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Trouble recovery
88
EJU34711Towing 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.
When the watercraft is towed using a towline,
the operator should hold onto the handlebars
and ride the watercraft in order to balance it.
Use a towline that is three times the combined
length of the towing boat and the watercraft.
Tow the watercraft at 5 mph (8 km/h) or less.
The bow must be kept up out of the water dur-
ing towing to prevent water from entering the
engine compartment.
EJU36151Submerged watercraft
If the watercraft is submerged or flooded with
water, follow the procedure below and consult
a Yamaha dealer as soon as possible. Failure
to do so could result in serious engine dam-
age.
(1) Beach the watercraft and remove the
stern drain plugs to drain the water fromthe engine compartment. (See page 49
for more information.)
Remove the storage compartment drain
plugs to drain the water from the storage
compartments.
(2) Install the stern drain plugs and storage
compartment drain plugs.
(3) Have the watercraft inspected 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]
1Bow eye
1
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