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1987 Yamaha FAZER Service Repair Maintenance Manual

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Welcome to the comprehensive service manual for the 1987 sport touring motorcycle. This model, known for its high-performance capabilities and innovative engineering for its era, bridges the gap between pure...
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1987 Yamaha FAZER Service Repair Maintenance Manual
Welcome to the comprehensive service manual for the 1987 sport touring motorcycle. This model, known for its high-performance capabilities and innovative engineering for its era, bridges the gap between pure sportbikes and touring machines, offering a compelling blend of speed and comfort. The motorcycle is powered by a liquid-cooled, 4-stroke, DOHC, 16-valve inline-four engine, displacing 998 cc, and was a benchmark in its class, competing with other prominent motorcycles of the late 1980s. Its design emphasizes aerodynamic fairing for stability at speed and advanced suspension systems, reflecting a heritage of building reliable and technologically forward motorcycles. This manual serves as an essential resource for owners, mechanics, and technicians, providing detailed guidance on the complete service, repair, and maintenance of the 1987 motorcycle. It covers all critical systems, including the engine, fuel system, electrical components, transmission, chassis, suspension, brakes, and bodywork. Within its pages, you will find step-by-step procedures for routine maintenance tasks, major repairs, and component adjustments, alongside troubleshooting guides and essential technical specifications. The depth of information, from basic fluid changes to complex engine rebuilds, ensures that users can effectively maintain and preserve the optimal performance and longevity of their motorcycle.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Fazer
Year:
1987
Model Code:
FZR1000 (likely variant based on Fazer nomenclature for this era)
Market Segment:
Sport Touring Motorcycle
👋 Introduction
Market Position
Positioning:
High-performance sport touring motorcycle of its era, bridging the gap between pure sportbikes and touring machines.
Competitive Analysis
Competitors:
Suzuki GSX-R series, Honda CBR series, Kawasaki Ninja series.
Key Features
Features:
DOHC inline-four engine, advanced suspension for its time, aerodynamic fairing for improved comfort and stability at speed.
Manual Value Proposition
Value:
Essential for owners seeking to perform maintenance and repairs themselves, ensuring longevity and optimal performance. Provides factory-accurate procedures and specifications.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service, Repair, and Maintenance for 1987 Yamaha Fazer (FZR1000)
Page Count
Estimated Pages:
400-600 (typical for comprehensive service manuals of this era)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Printed (likely original factory publication or high-quality reproduction)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, inspection, and repair (including valve timing, piston/cylinder, crankshaft, lubrication system, cooling system).
Fuel System:
Carburetor service, adjustment, and troubleshooting; fuel pump operation; fuel tank maintenance.
Electrical System:
Ignition system (CDI, spark plugs, coils), lighting (headlight, tail light, indicators), charging system (stator, regulator/rectifier), battery, starter motor, wiring diagrams.
Transmission:
Clutch operation, gearbox disassembly and assembly, gear inspection, shift drum and fork service.
Chassis And Suspension:
Front fork overhaul, rear shock absorber service, swingarm and linkage maintenance, frame inspection.
Brakes:
Hydraulic brake system (front and rear), caliper overhaul, master cylinder service, brake fluid replacement, pad inspection and replacement.
Wheels And Tires:
Wheel bearing service, tire pressure recommendations, rim inspection.
Bodywork And Trim:
Fairing removal and installation, seat maintenance, minor body panel repairs.
Troubleshooting:
Diagnostic procedures for common issues, fault finding guides, symptom-based troubleshooting trees.
Procedures Included
Routine Maintenance:
Oil and filter changes, chain adjustment, air filter cleaning/replacement, spark plug replacement, brake fluid flush, coolant flush.
Major Repairs:
Engine rebuilds, gearbox overhauls, suspension component replacement, electrical system diagnosis and repair.
Component Adjustment:
Carburetor synchronization, valve clearance adjustment, clutch cable free play, throttle cable adjustment.
Diagnostic Procedures:
Using test equipment, checking electrical circuits, identifying engine performance issues.
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid changes and adjustments to complete engine and transmission rebuilds, including detailed electrical troubleshooting and specifications.
📊 Manual Specifications
File Format
Digital Format:
N/A (Primarily a printed manual)
Print Quality
Print Quality:
High (Original factory print quality expected, clear diagrams and text)
Binding Type
Binding:
Staple-bound or Perfect Bound (typical for factory manuals)
Paper Type
Paper Quality:
Durable paper stock, often with glossy pages for diagrams
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 16-valve Inline-4
Displacement:
998 cc
Bore X Stroke:
75.0 mm x 56.0 mm (typical for FZR1000 variants)
Compression Ratio:
10.0:1 (typical for FZR1000 variants)
Performance
Horsepower:
Approx. 135-145 hp @ 9,500 rpm (estimated for 1987 FZR1000)
Torque:
Approx. 70-75 lb-ft @ 8,000 rpm (estimated for 1987 FZR1000)
Fuel System
Carburetors:
Four 36mm Mikuni CV (Constant Velocity) carburetors
Fuel Tank Capacity:
Approx. 5.3 US gallons (19-20 Liters)
Ignition System
Ignition Type:
Digital CDI (Capacitor Discharge Ignition)
Cooling System
Cooling Method:
Liquid-cooled
Lubrication System
Oil Type:
Yamalube 4 (or equivalent SAE 20W-40 API SG or higher motorcycle oil)
Oil Capacity:
Approx. 3.5 - 4.0 US quarts (3.3 - 3.8 Liters) with filter change
Engine Internals
Valve Lash Intake:
0.08 - 0.13 mm (0.003 - 0.005 in)
Valve Lash Exhaust:
0.13 - 0.18 mm (0.005 - 0.007 in)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-disc, diaphragm spring
Final Drive:
O-ring sealed chain
Features
Gear Ratios:
Provided in manual for detailed analysis (e.g., 1st: 2.500, 2nd: 1.875, 3rd: 1.458, 4th: 1.238, 5th: 1.083, 6th: 1.000 - typical for FZR1000)
Fluid Specifications
Transmission Oil Type:
API GL-4 SAE 75W-90 hypoid gear oil (or as specified in manual)
📐 Dimensions
Exterior
Overall Length:
Approx. 2170 mm (85.4 in)
Overall Width:
Approx. 760 mm (29.9 in)
Overall Height:
Approx. 1190 mm (46.9 in)
Wheelbase:
Approx. 1470 mm (57.9 in)
Weights
Dry Weight:
Approx. 228 kg (503 lbs) (typical for FZR1000)
Wet Weight:
Approx. 245 kg (540 lbs) (estimated with fluids)
🛡️ Safety Features
Ratings
Safety Features:
Not applicable in the same way as automobiles; focus is on rider aids and chassis stability.
Active Features
Braking System:
Dual front disc brakes with 4-piston calipers, single rear disc brake.
Suspension Geometry:
Designed for stability at high speeds and confidence in cornering.
Passive Features
Lighting:
Halogen headlight, taillight, brake light, turn signals.
💡 Technology Features
Infotainment
Features:
Basic analog gauges (speedometer, tachometer, fuel gauge, temperature gauge), no electronic infotainment systems as per the era.
Driver Assistance
Features:
None (focus on rider skill and mechanical systems)
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 6 months (typical recommendation)
Filter Change Interval:
With every oil change
Valve Clearance Check:
Every 6,000 - 12,000 miles (refer to manual for exact interval and specific checks)
Brake Fluid Flush:
Every 12,000 miles or 2 years
Fluid Specifications
Coolant Type:
Yamaha Coolant (or equivalent mixture of ethylene glycol-based antifreeze and distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Known Issues
Common Wear Items:
Clutch wear, carburetor synchronization drift, fork seal leaks, charging system components (stator/regulator) can be prone to failure over time.
Carburetor Issues:
Can become clogged with age and disuse, requiring thorough cleaning and synchronization.
Preventive Maintenance
Chain Maintenance:
Regular cleaning, lubrication, and adjustment are crucial for drivetrain longevity.
📚 Vehicle History
Brand Heritage
Heritage:
Yamaha's reputation for building high-performance, reliable motorcycles with innovative technology.
Model Evolution
Fzr Lineage:
The FZR1000 was a flagship model for Yamaha, introducing advanced technologies like the EXUP valve in later iterations and setting benchmarks for sportbike performance in the late 80s.
Production
Production Era:
The 1987 model year falls within the early generation of the FZR1000, which was a significant model in Yamaha's lineup.
🏆 Awards & Recognition
Recognitions
Industry Impact:
The FZR1000 series was highly regarded in its time for performance and handling, influencing subsequent sportbike designs.
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