1986 FJ1200 Service Manual

The 1986 Yamaha FJ1200 is a high-performance sport touring motorcycle featuring a 1188cc air-cooled inline-four engine, 5-speed transmission, shaft drive, adjustable suspension, dual front disc brakes, and comprehensive instrumentation. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper servicing and operation.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine 5. Cooling System 6. Fuel System 7. Electrical System 8. Chassis 9. Troubleshooting 10. Wiring Diagrams

General Information

This manual provides detailed service information for the 1986 Yamaha FJ1200 motorcycle. Includes safety precautions, tool requirements, and general maintenance procedures.

Section	Description
Identification	Model identification and VIN locations
Safety First	Important safety precautions and warnings
Tools	Recommended service tools and equipment
Maintenance Schedule	Recommended service intervals

Specifications

Engine Type: 1188cc air-cooled DOHC inline-4
Bore x Stroke: 77.0 x 63.8mm
Compression Ratio: 9.7:1
Fuel System: Four Mikuni BS34SS carburetors
Transmission: 5-speed constant mesh
Final Drive: Shaft drive
Front Suspension: Telescopic fork, air-adjustable
Rear Suspension: Swingarm with dual shocks, adjustable preload
Front Brakes: Dual hydraulic disc, 267mm
Rear Brake: Single hydraulic disc, 267mm
Wheelbase: 1495mm (58.9 inches)
Fuel Capacity: 22 liters (5.8 gallons)

Periodic Maintenance

Regular maintenance schedule and procedures to ensure optimal performance and longevity.

Daily Checks: Tire pressure, fluid levels, controls operation
600 Miles: Oil change, valve clearance check, chain adjustment
4000 Miles: Spark plugs, air filter, brake pads inspection
8000 Miles: Carburetor synchronization, brake fluid change
16000 Miles: Valve adjustment, fork oil change, wheel bearing inspection

WARNING! Always use genuine Yamaha parts and recommended lubricants for maintenance.

Engine

Complete engine service procedures including disassembly, inspection, and reassembly.

Component	Service Procedure
Cylinder Head	Valve adjustment, camshaft service
Cylinder & Piston	Bore measurement, ring replacement
Crankshaft	Bearing clearance, runout measurement
Clutch	Plate inspection, cable adjustment
Transmission	Gear inspection, shift mechanism service

Cooling System

The FJ1200 utilizes air cooling with oil cooling assistance. Maintenance includes:

Oil cooler inspection and cleaning
Fins cleaning and straightening
Thermostat operation check
Oil temperature sensor testing

CAUTION! Ensure cooling fins are not blocked by debris or damage.

Fuel System

Carburetor service and fuel delivery system maintenance.

Carburetor disassembly and cleaning
Float level adjustment
Pilot screw setting: 2.5 turns out
Fuel filter replacement
Throttle cable adjustment and lubrication

Tip: Always use fresh fuel and stabilizer for storage periods.

Electrical System

Complete electrical system diagnosis and repair procedures.

Battery: 12V 14Ah, maintenance procedures
Charging System: Alternator output: 280W at 5000 RPM
Ignition System: Transistorized ignition, timing adjustment
Lighting: Headlight: 60/55W, brake light: 21/5W
Instruments: Speedometer, tachometer, warning lights

Chassis

Frame, suspension, brakes, and wheels service procedures.

Front Fork: Oil change, seal replacement, air pressure setting
Rear Suspension: Shock absorber service, preload adjustment
Brakes: Pad replacement, disc measurement, fluid bleeding
Wheels & Tires: Tire size: Front 110/90V18, Rear 130/90V17
Steering: Head bearing adjustment and lubrication

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Weak battery, dirty carbs	Charge battery, clean carburetors
Poor idle	Sync issue, vacuum leak	Synchronize carbs, check hoses
Overheating	Low oil, dirty fins	Check oil level, clean cooling fins
Brake fade	Old fluid, worn pads	Replace fluid and brake pads
Electrical issues	Bad connections, regulator	Check grounds, test regulator

Note: Always begin troubleshooting with simplest solutions first.

Wiring Diagrams

Complete electrical schematics for the 1986 FJ1200 including:

Main harness routing and connections
Ignition system wiring
Lighting circuit diagrams
Charging system schematic
Instrument cluster connections

CAUTION! Disconnect battery before performing electrical work.