Segment:
Cruiser Motorcycle
Target Audience:
Riders seeking classic styling, reliable V-twin performance, and a platform for customization. Appeals to both novice and experienced riders.
Competitors:
Honda Shadow series, Kawasaki Vulcan series, Suzuki Intruder series, Harley-Davidson Sportster (though typically higher price point).
Styling:
Retro cruiser styling with a low seat height, teardrop fuel tank, and prominent V-twin engine. Distinctive DragStar design cues.
Engine Configuration:
Air-cooled, 4-stroke, V-twin, SOHC, 2 valves per cylinder.
Reliability:
Known for Yamaha's robust engineering and durability, making it a popular choice for long-term ownership and customization.
Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
Regions Covered:
Global (USA, Europe, Japan specifications considered)
Type:
Service and Repair Manual
Format:
PDF (Digital Download)
Engine Mechanical:
Full overhaul, disassembly, inspection, assembly, torque specifications, valve adjustment, piston and cylinder analysis, crankshaft and connecting rod inspection.
Fuel System:
Carburetor tuning and rebuilding (Mikuni VM-style), fuel pump, fuel lines, fuel tank maintenance, fuel filter replacement.
Ignition System:
CDI unit, ignition coils, spark plugs, ignition timing adjustment, wiring diagrams.
Transmission:
Clutch operation, gear shifting mechanism, maintenance, lubrication, disassembly and assembly of the 5-speed gearbox.
Drivetrain:
Shaft drive system maintenance, universal joint inspection, final gear case lubrication and service.
Brake System:
Front and rear hydraulic disc brake systems, brake pad replacement, brake fluid flush and bleed, caliper maintenance, master cylinder service.
Suspension:
Front telescopic forks (including seal replacement, oil level and type specification), rear shock absorbers, swingarm maintenance.
Electrical System:
Complete wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting, starter motor, horn, fuses, and relays.
Cooling System:
Air-cooled engine cooling, emphasis on airflow and potential overheating causes.
Frame And Bodywork:
Frame inspection, fork triple clamps, handlebar mounting, body panel removal and installation, seat, fenders, fuel tank, exhaust system.
Maintenance Schedule:
Detailed recommended service intervals for oil changes, filter replacements, brake service, chain/shaft drive checks, and general inspections.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon performance issues, electrical faults, and mechanical problems.
Repair Procedures:
Step-by-step instructions for component removal, repair, replacement, and reassembly across all major vehicle systems.
Rebuild Instructions:
Comprehensive guides for engine, transmission, and carburetor rebuilds.
Technical Specifications Listing:
Detailed specifications for all components, including measurements, tolerances, fluid capacities, and recommended lubricants.
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls. Suitable for DIY enthusiasts and professional mechanics.
Engine Type:
Air-cooled, V-twin, SOHC, 4-stroke
Displacement:
649 cc (39.6 cubic inches)
Bore X Stroke:
81.0 mm x 63.0 mm (3.19 in x 2.48 in)
Valve Train:
SOHC, 2 valves per cylinder
Cooling Method:
Forced Air Cooling
Horsepower:
Approx. 45-50 HP @ 6,000 RPM (specifications vary slightly by market and year)
Torque:
Approx. 58 Nm (43 lb-ft) @ 4,000 RPM (specifications vary slightly by market and year)
Fuel Delivery:
Two Mikuni VM-type carburetors (e.g., VM22 or similar size).
Fuel Type:
Unleaded gasoline, minimum 87 octane (RON+MON)/2)
Fuel Tank Capacity:
16 Liters (4.2 US gallons)
Oil Type:
Yamalube 4 (SAE 20W-40) or equivalent API SG, SF, SE type motorcycle oil.
Oil Capacity With Filter:
3.2 Liters (3.4 US qt)
Oil Filter Part Number:
Yamaha OEM 3DM-13440-00-00 or equivalent (e.g., K&N KN-143, HiFlofiltro HF143)
Length Overall:
Approx. 2295 mm (90.4 in) for Classic, 2320 mm (91.3 in) for Custom
Width Overall:
Approx. 830 mm (32.7 in)
Height Overall:
Approx. 1140 mm (44.9 in) for Classic, 1095 mm (43.1 in) for Custom
Wheelbase:
Approx. 1605 mm (63.2 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Seat Height:
Approx. 710 mm (28.0 in)
Dry Weight:
Approx. 194 kg (428 lbs) for Classic, 192 kg (423 lbs) for Custom
Wet Weight:
Approx. 206 kg (454 lbs) for Classic, 204 kg (450 lbs) for Custom (estimated with all fluids)
Safety Ratings:
N/A (Motorcycles are not typically rated by safety organizations like NHTSA or Euro NCAP in the same way as cars).
Braking System:
Front: Hydraulic disc brake with 2-piston caliper. Rear: Hydraulic disc brake with 1-piston caliper.
Tires:
Front: 100/90-19M/C 57H. Rear: 170/80-15M/C 77H (Tire specifications may vary by original fitment).
Lighting:
Halogen headlight, LED taillight and brake light, incandescent turn signals.
Chassis Design:
Steel double-cradle frame for stability and rider feedback.
Engine Oil Change:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 4,000 km (2,500 miles) or annually with oil change.
Spark Plug Inspection And Replacement:
Inspect every 8,000 km (5,000 miles), replace as needed or every 16,000 km (10,000 miles).
Valve Clearance Check:
Every 16,000 km (10,000 miles).
Brake Fluid Change:
Every 2 years or as per manual recommendation, typically with a bleed.
Shaft Drive Oil Change:
Every 16,000 km (10,000 miles) or annually.
Fork Oil Type:
Yamaha No. 10 (10W) suspension fluid or equivalent.
Fork Oil Quantity:
Refer to manual for precise quantity per fork leg (typically around 380-400 ml).
Carburetor Issues:
Pilot jet clogging leading to hard starting or poor idle, especially after periods of inactivity. Diaphragm degradation over time.
Starter Clutch Wear:
Some owners report wear on the starter clutch mechanism, leading to grinding noises during startup.
Electrical Connections:
Corrosion on connectors, particularly in humid climates, can lead to intermittent electrical issues.
Rear Shock ABSorbers:
Stock rear shocks can be considered basic; replacement with aftermarket units is a common upgrade for improved ride quality.
Brand:
Yamaha Motor Corporation, a globally recognized manufacturer of motorcycles, marine products, and musical instruments.
Key Changes:
Minor aesthetic updates, color changes, and potential minor engine tuning adjustments across the production run. Carburetor jets and mapping may vary between early and later models.
Production Location:
Japan (Primary manufacturing location for most Yamaha models)
Discontinuation Year:
The XVS650 DragStar platform continued beyond 2008 with updates and variations, but this manual specifically covers up to the 2008 model year.
