Yamaha Fj 1200 Problems

The Yamaha FJ1200. A legend. A sport-touring icon. A machine that delivered blistering performance and all-day comfort, defining an era. But even legends aren't without their quirks. Owning an FJ1200 is an experience, a relationship even, and like any relationship, it comes with its share of challenges. Knowing the common pitfalls of these magnificent machines will help you keep yours running strong for years to come.

The FJ1200: A Love Story with a Few Hiccups

The FJ1200, produced from 1986 to 1996 (depending on the market), boasts a robust air-cooled inline-four engine that's known for its reliability. However, its age means that certain components are starting to show their wear. This article isn't about scaring you away from owning an FJ1200; it's about equipping you with the knowledge to address potential issues before they become major headaches. Think of it as a pre-emptive strike against future breakdowns, allowing you to enjoy the FJ1200’s legendary performance without constant worry.

Carburetor Capers: Tuning into Smooth Riding

One of the most common issues with older FJ1200s revolves around their carburetors. These aren't fuel-injected machines; they rely on a bank of four Mikuni constant-velocity (CV) carburetors to deliver fuel and air to the engine. Over time, these carburetors can become gummed up with old fuel deposits, leading to:

Rough idling: The engine may struggle to maintain a steady idle speed, fluctuating erratically.
Hesitation upon acceleration: When you twist the throttle, the engine might stumble or hesitate before responding.
Poor fuel economy: Clogged jets and passages can disrupt the air/fuel mixture, leading to decreased fuel efficiency.
Difficulty starting: A partially clogged carburetor can make it difficult to start the engine, especially in cold weather.

The Solution: A thorough carburetor cleaning and rebuild is often the answer. This involves disassembling the carburetors, cleaning all the jets and passages with carburetor cleaner, and replacing worn O-rings and gaskets. Syncing the carburetors after reassembly is also crucial for smooth running. If you’re not comfortable tackling this yourself, a reputable motorcycle mechanic can handle the job. Consider using an ultrasonic cleaner for particularly stubborn deposits.

Cooling System Conundrums: Keeping Things Chill

While the FJ1200 is air-cooled, it still relies on an oil cooler to help regulate engine temperature. Problems in this area can lead to overheating, which can damage the engine.

Oil cooler leaks: The oil cooler itself, or the lines connecting it to the engine, can develop leaks over time. This is often due to age and vibration.
Clogged oil cooler: Debris can accumulate in the oil cooler, reducing its efficiency and hindering its ability to cool the oil.
Faulty thermostat: The thermostat controls the flow of oil to the cooler. If it fails, it can prevent the oil from being cooled properly.

The Solution: Regularly inspect the oil cooler and lines for leaks. Replace any damaged components. Consider flushing the oil cooler periodically to remove any accumulated debris. If you suspect a faulty thermostat, replace it. Using a high-quality synthetic oil can also help to improve cooling efficiency.

Electrical Enigmas: Tracing Those Pesky Shorts

Like any older motorcycle, the FJ1200 can suffer from electrical problems. Age and exposure to the elements can take their toll on the wiring harness, connectors, and other electrical components.

Wiring harness issues: The wiring harness can become brittle and cracked over time, leading to shorts and broken connections.
Connector corrosion: Corrosion can build up on electrical connectors, causing poor connections and intermittent problems.
Charging system problems: The alternator or rectifier/regulator may fail, leading to a dead battery and a non-starting motorcycle.
Faulty starter motor: The starter motor can wear out over time, making it difficult to start the engine.

The Solution: Regularly inspect the wiring harness for damage and repair any broken or frayed wires. Clean electrical connectors with contact cleaner and apply dielectric grease to prevent corrosion. Test the charging system to ensure that the alternator and rectifier/regulator are functioning properly. If the starter motor is failing, replace it. A multimeter is your best friend when diagnosing electrical issues.

Suspension Sagas: Maintaining a Smooth Ride

The FJ1200's suspension, while adequate for its time, can benefit from upgrades, especially on older models. Worn suspension components can negatively affect handling and ride quality.

Worn fork seals: Fork seals can leak, causing oil to drip down the fork tubes and reducing damping performance.
Sagging springs: The springs in the forks and rear shock can lose their spring rate over time, leading to a soft and bouncy ride.
Worn shock absorber: The rear shock absorber can lose its damping ability, resulting in a harsh and uncontrolled ride.

The Solution: Replace worn fork seals and fork oil regularly. Consider upgrading to stiffer springs in the forks and rear shock for improved handling. Aftermarket shock absorbers are also available and can significantly improve ride quality. Properly setting the sag is crucial for optimal suspension performance.

Brake Blunders: Ensuring Stopping Power

Good brakes are essential for safety, and the FJ1200's braking system can suffer from age-related problems.

Worn brake pads: Brake pads wear down over time and need to be replaced regularly.
Sticking brake calipers: The brake calipers can become corroded and sticky, leading to reduced braking performance.
Spongy brake feel: Air in the brake lines or a worn master cylinder can cause a spongy brake feel.
Warped brake rotors: Brake rotors can warp over time, causing vibration and reduced braking performance.

The Solution: Replace brake pads regularly and inspect the brake calipers for corrosion. Bleed the brake lines to remove any air. Rebuild or replace the master cylinder if it is worn. Replace warped brake rotors. Use high-quality brake fluid and flush the system regularly. Stainless steel brake lines are a worthwhile upgrade for improved brake feel.

Fuel Tank Foibles: Battling Rust and Contamination

The FJ1200's fuel tank is susceptible to rust, especially if the bike has been stored for a long period of time.

Rust in the fuel tank: Rust can form inside the fuel tank, contaminating the fuel and clogging the fuel filter and carburetors.
Fuel tank leaks: The fuel tank can develop leaks due to rust or corrosion.
Petcock problems: The petcock (fuel valve) can become clogged or leak.

The Solution: Inspect the fuel tank for rust. If rust is present, clean the tank using a rust removal product or have it professionally cleaned and sealed. Replace the fuel filter regularly. Rebuild or replace the petcock if it is leaking or clogged. Consider using a fuel stabilizer when storing the motorcycle for extended periods.

Exhaust Exasperations: Dealing with Rust and Leaks

The exhaust system can suffer from rust and leaks, especially in areas that are exposed to moisture and road salt.

Rust on the exhaust system: Rust can form on the exhaust pipes and muffler, eventually leading to holes and leaks.
Exhaust leaks: Exhaust leaks can reduce engine performance and make the motorcycle louder.
Cracked exhaust headers: The exhaust headers can crack due to heat and vibration.

The Solution: Inspect the exhaust system for rust and leaks. Repair or replace any damaged components. Consider using a high-temperature paint to protect the exhaust system from rust. Replace cracked exhaust headers.

The Dreaded Second Gear Issue

While not universally experienced, some FJ1200 owners report issues with second gear, particularly under hard acceleration. This can manifest as the gear popping out or a general unreliability in that gear.

The Solution: This often requires a transmission rebuild, a potentially costly and involved repair. Prevention is key: smooth, deliberate shifting and avoiding excessive strain on the transmission can help prolong its life.

Frequently Asked Questions

Why does my FJ1200 idle rough? Carburetor issues are the most common culprit. A thorough cleaning and synchronization are usually necessary.
My FJ1200 is overheating. What could be the problem? Check the oil level, oil cooler for blockage, and the thermostat. Low oil, a clogged cooler, or a faulty thermostat can all cause overheating.
My FJ1200's battery keeps dying. What should I check? Test the charging system (alternator and rectifier/regulator). Also, check for any parasitic draws that are draining the battery when the bike is off.
My brakes feel spongy. What should I do? Bleed the brake lines to remove any air. If the problem persists, inspect the master cylinder and brake calipers for wear.
Where can I find parts for my FJ1200? Online retailers specializing in vintage motorcycle parts are a good source. Motorcycle salvage yards can also be a treasure trove of used parts.

Keeping the Legend Alive

The Yamaha FJ1200 is a fantastic motorcycle, capable of providing years of enjoyment. By understanding its potential problems and taking preventative measures, you can ensure that your FJ1200 remains a reliable and enjoyable ride for many years to come. Regular maintenance and a proactive approach are key to keeping this legend on the road.