Yamaha XVS650 V-Star 1997-2008 Workshop Service Repair Manual

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UGS: 66189

Mots clés: 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 Motorcycle Motorcycles Royal Star Venture XVS650 V-Star Yamaha

Variantes de produits

Description

This workshop service repair manual covers the XVS650 V-Star Custom and Classic models produced between 1997 and 2008. Renowned for its reliable air-cooled, 4-stroke V-twin engine and classic cruiser styling, the XVS650 offers a comfortable riding position and a smooth shaft drive. Its engineering emphasizes durability and accessible performance, making it a popular choice in the mid-size cruiser segment, competing with models from other major manufacturers. The vehicle's design focuses on fundamental motorcycle mechanics, providing a straightforward yet engaging riding experience. This comprehensive manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the XVS650 V-Star. It provides detailed step-by-step instructions for all major systems, including engine mechanical and electrical components, fuel system, suspension, brakes, and bodywork. Coverage extends to scheduled maintenance, troubleshooting common issues, and complete rebuild procedures. With its detailed illustrations, diagrams, and wiring schematics, this manual serves as an essential resource for ensuring the longevity and optimal performance of your motorcycle.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XVS650 V-Star

Model Variant:

Custom / Classic

Codes

Chassis Code:

XVS650

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Competitive Analysis

Key Competitors:

Honda Shadow 600/750, Kawasaki Vulcan 750, Suzuki Intruder 750/800, Harley-Davidson Sportster models (relative to displacement and style).

Key Features

Manual Attributes:

Detailed illustrations, diagrams, wiring schematics, specifications, step-by-step instructions, printable pages, troubleshooting guidance.

Vehicle Attributes:

Reliable V-twin engine, shaft drive, classic cruiser styling, comfortable riding position.

📋 Manual Details

Coverage Areas

Applicable Years:

1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008

Page Count

Estimated Pages:

Indicative of comprehensive coverage; typical workshop manuals of this era for motorcycles of this complexity range from 300-600+ pages.

Manual Type

Type:

Workshop Service Repair Manual (also referred to as Factory Service Repair Manual)

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete coverage including disassembly, inspection, repair, and reassembly of all engine components.

Engine Electrical:

Detailed wiring diagrams, ignition system, charging system, starting system, and troubleshooting for electrical faults.

Emission Control:

Information related to emission control systems and their servicing.

Fuel System:

Carburetor adjustment and overhaul, fuel pump, fuel lines, and tank maintenance.

Suspension System:

Front fork service (oil changes, seal replacement), rear shock absorber maintenance, and adjustments.

Clutch System:

Clutch operation, adjustment, replacement of clutch plates and springs.

Transaxle System:

Manual transaxle (gearbox) disassembly, inspection, and repair. The listing also mentions 'Automatic Transaxle System', which is unusual for this model and likely a generic descriptor or may cover specific variants if they exist, though the XVS650 is primarily known for its manual transmission.

Driveshaft And Axle:

Maintenance and repair of the shaft drive system, including universal joints and final drive components.

Steering System:

Handlebar, steering head bearing maintenance and adjustment.

Brake System:

Front and rear brake system maintenance, including disc, caliper, master cylinder, fluid replacement, and bleeding.

Body Interior Exterior:

Fairings, fenders, seat, fuel tank, and other bodywork components removal and installation.

Body Electrical System:

Lighting system, instrumentation, horn, and other electrical accessories.

Restraint System:

Likely refers to basic safety features and potentially fasteners/securing mechanisms, not passive restraint systems like airbags in cars.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, lubrication, chain adjustment (if applicable, though shaft drive), brake bleeding, coolant checks (if liquid-cooled, XVS650 is air-cooled).

Troubleshooting:

Diagnostic procedures for common problems across all major systems, with specific troubleshooting trees for electrical issues.

Repair:

Detailed step-by-step repair instructions for component removal, disassembly, repair, reassembly, and adjustment.

Rebuilds:

Comprehensive instructions for engine rebuilds, carburetor overhauls, and major component overhauls.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds. Suitable for both novice DIY enthusiasts and experienced professional mechanics.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Fully Printable

Zoom Functionality:

Yes (allows for detailed viewing of diagrams and text)

Binding Type

Binding:

N/A (Digital Download - PDF)

Paper Type

Paper Type:

N/A (Digital Download - PDF)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip (for extraction if zipped)

Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, SOHC, 4-valve, V-twin

Displacement:

649 cc (39.6 cu. in.)

Bore X Stroke:

76.0 mm x 71.0 mm (approx.)

Compression Ratio:

9.0:1 (typical)

Performance

Horsepower Approx:

Approx. 45-50 HP (at crankshaft), figures vary slightly by year and specific model tuning.

Torque Approx:

Approx. 50-55 Nm (37-40 lb-ft) at around 4500-5000 RPM.

Fuel System

Carburetion:

Dual Mikuni BSR34 carburetors (with vacuum-operated secondaries on some models/years).

Fuel Type:

Unleaded gasoline

Ignition

Ignition System:

Digital TCI (Transistor Controlled Ignition)

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multiple-disc

Final Drive:

Shaft drive

Optional

Optional Transmission:

Not applicable for this model. The manual mentions 'Automatic Transaxle System' which is likely a misstatement or generic content for this specific motorcycle.

📐 Dimensions

Exterior

Overall Length:

Varies by model (Custom vs. Classic), approximately 2295-2305 mm (90.4-90.7 in.)

Overall Width:

Approx. 830-970 mm (32.7-38.2 in.)

Overall Height:

Approx. 1100-1130 mm (43.3-44.5 in.)

Wheelbase:

Approx. 1575 mm (62.0 in.)

Weights

Dry Weight:

Approx. 181-191 kg (399-421 lbs) - varies by model configuration.

Wet Weight:

Not explicitly stated, but typically 10-15% higher than dry weight due to fluids.

Fuel Capacity:

Approx. 16.0 Liters (4.2 US gal)

🛡️ Safety Features

Ratings

Safety Ratings:

Motorcycles are not typically subjected to the same crash test ratings as cars. Safety is primarily assessed through design, braking performance, and handling characteristics.

Active Features

Braking System:

Front: Disc brake. Rear: Drum brake (earlier models) or Disc brake (later models/variants).

Tires:

Tubeless tires are standard on most modern motorcycles. Specific sizes would be detailed in the manual.

Passive Features

Lighting:

Headlight, tail light, brake light, turn signals.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a 1997-2008 motorcycle, pre-dating advanced infotainment systems. Features are purely mechanical and electrical, not digital entertainment).

Driver Assistance

Driver Assistance Features:

N/A (No electronic driver assistance systems like ABS, traction control, etc., were standard or commonly available on this model during this production run).

Connectivity

Connectivity Features:

N/A (No Bluetooth, Wi-Fi, or smartphone integration).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first. Exact interval depends on usage and specified oil type.

Spark Plug Replacement:

Refer to manual; generally around 10,000-20,000 km (6,200-12,400 miles).

Air Filter Cleaning Replacement:

Frequent checks, especially in dusty conditions. Replacement typically every 15,000-30,000 km (9,300-18,600 miles).

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent SAE 10W-40 API SG or higher, JASO MA)

Engine Oil Capacity:

Approx. 2.4 Liters (2.5 US qt) without filter change, 2.6 Liters (2.7 US qt) with filter change.

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Fork Oil Type:

Yamalube Fork Oil 10W (or equivalent)

Fork Oil Capacity:

Approx. 483 ml (16.3 US fl oz) per fork leg

Known Issues

Common Problems:

Occasional carburetor synchronization issues, potential clutch wear with high mileage, front fork seal leaks, and normal wear and tear items like brake pads and tires. Some owners report slight vibration at higher RPMs, typical for a V-twin.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Corporation has a long and distinguished history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments.

Model Evolution

V Star Lineage:

The V-Star line is Yamaha's cruiser offering, known for its accessible performance, classic styling, and V-twin engines. The XVS650 was a popular mid-size cruiser in its segment.

Production

Production Period:

The XVS650 V-Star was produced from the mid-1990s through the late 2000s, with the covered years (1997-2008) representing a significant portion of its initial and primary production run.

🏆 Awards & Recognition

Recognitions

Awards:

While specific annual awards are not listed here, the XVS650 V-Star was generally well-received for its value, styling, and reliable V-twin powertrain in the cruiser market, contributing to Yamaha's strong reputation in this segment.