The Yamaha FJ1200, produced between 1986 and 1993, stands as a distinguished sport-touring motorcycle renowned for its potent 1188cc inline-four engine and exceptional long-distance comfort. This model was engineered to offer a compelling blend of performance and practicality, making it a benchmark in its class. Its design philosophy prioritized rider ergonomics, a robust chassis, and effective aerodynamic fairing, ensuring a stable and fatigue-free experience for extended journeys. The FJ1200's legacy is built on its engineering quality, reliability, and its capability to deliver exhilarating performance while maintaining the comfort required for touring. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and overhaul of the Yamaha FJ1200 (1986-1993). It covers all essential systems, including the engine, fuel, ignition, electrical, chassis, and bodywork, offering step-by-step instructions, diagnostic procedures, and technical specifications. The manual is designed to assist owners, technicians, and mechanics in performing routine maintenance, troubleshooting common issues, and executing in-depth repairs to ensure the optimal performance and longevity of the vehicle. Its extensive coverage makes it an indispensable resource for anyone working on this iconic sport-touring machine. 🏷️ Basic Information Identification Make: Yamaha Model: FJ1200 Model Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993 Codes Chassis Codes: Likely 4BB, 4BR, 4BS for different market variations and evolutionary updates across the years. Specific detailed chassis codes require referencing the manual's VIN decoding section if available. 👋 Introduction Market Position Market Segment: Sport-Touring Motorcycle. Positioned as a powerful, comfortable, and capable motorcycle for long-distance touring with sporty handling characteristics. Competitive Analysis Key Competitors: Honda VFR750F/VFR700F, Kawasaki Ninja 1000 (later models), Suzuki GSX1100F Katana (though more of a sportbike), BMW K100 series. Key Features Design Philosophy: The FJ1200 was renowned for its potent 1188cc inline-four engine, comfortable riding ergonomics for touring, robust chassis, and effective fairing for wind protection, making it a benchmark in the sport-touring category of its era. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive workshop repair and service for the Yamaha FJ1200 across its 1986-1993 production run. Covers routine maintenance, diagnostics, troubleshooting, and in-depth repairs. Page Count Page Count: 457 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly and reassembly, top-end (cylinder head, valves, camshafts), bottom-end (crankshaft, connecting rods, pistons), cooling system, lubrication system (oil pump, oil cooler, oil passages). Fuel System: Carburetor systems (identification, removal, disassembly, cleaning, adjustment, synchronization), fuel lines, fuel pump, fuel filters, fuel tank. Ignition System: Ignition timing, spark plugs, ignition coils, electronic ignition control unit (CDI or similar), wiring diagrams. Exhaust System: Exhaust pipes, mufflers, heat shields, exhaust manifold gaskets. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting system (headlight, taillight, turn signals, brake light), instrumentation, switches, relays, fuses. Chassis Systems: Frame inspection, front suspension (forks, triple clamps, steering bearings), rear suspension (shock absorber, swingarm, linkages), wheel bearing maintenance, braking system (front and rear calipers, master cylinders, brake lines, brake pads, brake discs), clutch system (hydraulic or cable operation). Bodywork: Fairings, seat, fuel tank cover, fenders, and other cosmetic and structural body components, including removal and installation procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks and replacements, air filter service, chain maintenance (cleaning, lubrication, adjustment), brake fluid checks and changes, coolant checks and changes, tire pressure checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues across all vehicle systems, often with symptom-based flowcharts. Repair Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation, including torque specifications and clearances. Tune Ups: Procedures for ensuring optimal engine performance, including carburetor synchronization, ignition timing adjustments, and valve clearance checks. Special Tool Usage: Identification and guidance on the use of specialized tools required for specific maintenance and repair tasks, often referencing Yamaha's special tool part numbers. Technical Depth Depth Of Coverage: Comprehensive. Covers everything from basic fluid checks and adjustments to complete engine and transmission teardowns and rebuilds, including detailed specifications and tolerances. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Yes, printable. Designed for clear reproduction of diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, inline-four cylinder Displacement: 1188 cc (72.5 cubic inches) Bore X Stroke: 74.0 mm x 69.4 mm (approximate, variations may exist) Compression Ratio: 9.7:1 (typical, check specific year for exact) Performance Horsepower: Approximately 120-130 hp at the crankshaft (depending on year and market). Torque: Approximately 95-100 Nm (70-74 lb-ft) at 6,000 RPM (depending on year and market). Fuel System Carburetion: Mikuni BS34 Constant Velocity (CV) carburetors (typically a bank of four). Fuel Delivery: Gravity feed from fuel tank, often with a vacuum-operated fuel petcock. Lubrication System Oil Type: Yamaha recommends API SE, SF, or...