🏷️ Basic Information

Make:

Yamaha

Model:

XVS650 Drag Star

Model Designation:

DragStar 650 / V-Star 650

Product Name:

Yamaha XVS-650 Drag Star Service Repair Manual - WARTUNGSANLEITUNG

Vin Code Prefix:

N/A (Motorcycle - VIN system differs)

First Generation Start Year:

1997

Covered Generation:

First Generation (1997-2008 for XVS650A Classic, 1997-2000 for XVS650)

👋 Introduction

Motorcycle Segment:

Cruiser motorcycle, targeting riders seeking classic styling and relaxed cruising comfort.

Target Audience:

DIY motorcycle enthusiasts, independent repair shops, and owners who prefer self-maintenance.

Key Competitors:

Honda Shadow 600, Kawasaki Vulcan 750, Suzuki Intruder 750/800.

Styling:

Classic cruiser design with a long, low silhouette, teardrop fuel tank, and ample chrome.

Engine Type:

Air-cooled V-twin engine, known for its characterful rumble and reliable performance.

Drivetrain:

Shaft drive (on XVS650A Classic model), offering low maintenance compared to chain drives.

📋 Manual Details

Manual Type:

Service Repair Manual

Language:

German

Format:

PDF

Bookmarked Format:

Fully bookmarked PDF

File Format:

Digital (PDF)

Estimated Page Count:

Variable, typically 300-500 pages for comprehensive service manuals of this era.

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, overhaul procedures for V-twin engine.

Fuel System:

Carburetor (CV type) tuning, cleaning, disassembly, inspection, fuel pump, fuel lines, fuel tank maintenance.

Ignition System:

CDI ignition system, ignition timing, spark plugs, ignition coils inspection and replacement.

Transmission:

Clutch operation, transmission disassembly, assembly, inspection, gear shifting mechanisms, drive shaft maintenance.

Chassis And Suspension:

Frame inspection, front fork (telescopic) overhaul, rear shock absorber replacement, swingarm maintenance.

Brakes:

Front and rear disc brake systems, brake pad replacement, caliper overhaul, brake fluid bleeding, master cylinder inspection.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), starter motor, lighting systems, instrumentation.

Cooling System:

Air-cooled engine specifications and considerations.

Exhaust System:

Exhaust pipe and muffler inspection, gasket replacement.

Wheels And Tires:

Tire pressure recommendations, wheel bearing inspection and replacement, spoke tension (if applicable).

Bodywork And Trim:

Fender, fuel tank, seat, handlebars, control levers, and cosmetic component removal/installation.

Scheduled Maintenance:

Oil changes, filter replacements, spark plug service, chain adjustment (if applicable - though shaft drive on XVS650A), brake checks, lubrication points.

Troubleshooting:

Diagnostic charts for common performance issues, electrical problems, starting difficulties.

Engine Rebuild:

Detailed steps for internal engine repairs, including piston, rings, cylinder head, crankshaft inspection and replacement.

Carburetor Rebuild:

Complete instructions for dismantling, cleaning, and reassembling carburetors.

Brake System Service:

Pad replacement, caliper service, bleeding procedures.

Suspension Adjustment:

Fork oil replacement, rear shock adjustment (if applicable).

Electrical Diagnostics:

Testing electrical components, interpreting wiring diagrams.

Torque Specifications:

Essential torque values for critical fasteners throughout the motorcycle.

Depth Level:

Comprehensive (covers routine maintenance to complete engine and component overhauls).

Diagnostic Capabilities:

Includes detailed troubleshooting flowcharts and symptom-based diagnostics.

Repair Instructions:

Step-by-step instructions with clear diagrams and explanations for most repair tasks.

Special Tools:

Lists and descriptions of required special tools for specific procedures.

📊 Manual Specifications

Print Quality:

Digital PDF format, quality depends on original scanning/digitization. Typically clear for reading and printing.

Searchability:

Likely searchable if OCR was applied during PDF creation.

Binding Type:

Not applicable (Digital PDF)

Paper Type:

Not applicable (Digital PDF)

⚙️ Engine Specifications

Engine Type:

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

Displacement:

649 cc (39.6 cu.in.)

Bore X Stroke:

76.0 mm x 71.0 mm (2.99 in x 2.80 in)

Compression Ratio:

9.0:1

Valve Train:

SOHC, 2 valves per cylinder

Horsepower:

Approx. 41.5 HP (31 kW) @ 6,000 RPM (Manufacturer's claimed)

Torque:

Approx. 52.5 Nm (38.7 lb-ft) @ 3,000 RPM (Manufacturer's claimed)

Carburetion:

2 x Mikuni BSR32 constant velocity (CV) carburetors

Fuel Tank Capacity:

16 Liters (4.2 US gal)

Oil Capacity:

3.0 Liters (3.2 US qt) with filter change

Engine Oil Type:

Yamalube 4 (or equivalent SAE 20W-40 API SG or higher, or SAE 10W-40 if ambient temperature allows per manual)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Final Drive:

Shaft drive (XVS650A Classic); Chain drive (early XVS650 models, verify specific variant)

Clutch:

Wet, multiple disc, cable operated

Gear Ratios:

Specific ratios available in manual (e.g., 1st: 2.750, 2nd: 1.895, 3rd: 1.409, 4th: 1.150, 5th: 0.962)

Transmission Oil Type:

Yamalube Gear Oil (or equivalent SAE 80 API GL-4)

Transmission Oil Capacity:

0.65 Liters (0.69 US qt)

📐 Dimensions

Length:

XVS650A Classic: 2295 mm (90.4 in); XVS650: 2245 mm (88.4 in)

Width:

XVS650A Classic: 830 mm (32.7 in); XVS650: 790 mm (31.1 in)

Height:

XVS650A Classic: 1070 mm (42.1 in); XVS650: 1105 mm (43.5 in)

Wheelbase:

XVS650A Classic: 1605 mm (63.2 in); XVS650: 1500 mm (59.1 in)

Ground Clearance:

XVS650A Classic: 130 mm (5.1 in); XVS650: 145 mm (5.7 in)

Dry Weight:

XVS650A Classic: Approx. 190 kg (419 lbs); XVS650: Approx. 180 kg (397 lbs)

Wet Weight:

XVS650A Classic: Approx. 201 kg (443 lbs); XVS650: Approx. 192 kg (423 lbs)

Load Capacity:

Refer to manual for specific load limits and payload capacity.

🛡️ Safety Features

Safety Certifications:

Meets relevant international safety standards for motorcycles (e.g., DOT, ECE standards for lighting/reflectors).

Braking System:

Front and rear disc brakes for effective stopping power.

Lighting:

Halogen headlight, taillight, turn signals, and running lights for visibility.

Chassis Design:

Steel frame designed for stability and predictable handling.

Mirrors:

Standard handlebar-mounted mirrors for rearward visibility.

💡 Technology Features

Infotainment System:

Not applicable (basic cruiser design).

Driver Assistance Features:

None typical for this era and segment (e.g., no ABS, traction control).

Connectivity Options:

None (analog instrumentation, basic electrical systems).

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 mi) or 6 months, whichever comes first.

Spark Plug Replacement:

Every 12,000 km (7,500 mi) or 12 months.

Air Filter Cleaning:

Inspect every 6,000 km (3,700 mi), clean or replace as needed.

Brake Fluid Change:

Every 2 years (recommended).

Valve Clearance Check:

Every 12,000 km (7,500 mi) or 12 months.

Engine Oil Viscosity:

SAE 20W-40 is primary, consult manual for seasonal variations (e.g., 10W-40 for colder climates).

Brake Fluid Type:

DOT 4 (FMVSS No. 116 DOT 4)

Fork Oil Type:

Yamaha Fork Oil (or equivalent SAE 10W)

Fork Oil Capacity:

Approximately 460 ml (487 cc, 15.5 US oz) per fork leg (verify exact amount in manual).

Carburetor Issues:

CV carburetors can be sensitive to air leaks or require periodic cleaning for optimal performance and idle stability.

Starter Clutch Noise:

Some models may develop a clicking or grinding noise from the starter clutch on startup. Can be related to worn components.

Rear Suspension:

Original rear shock absorbers can lose damping over time, affecting ride quality.

Throttle Cable Wear:

Throttle cables can stretch or fray with age, requiring adjustment or replacement.

📚 Vehicle History

Yamaha Heritage:

Yamaha Motor Company, established in 1955, has a rich history in motorcycle manufacturing, known for innovation and performance across various segments.

Drag Star Lineage:

The XVS650 platform was introduced as part of Yamaha's cruiser lineup, aiming to capture the classic styling market. The 'DragStar' name was used in many international markets, while in North America, it was primarily known as the 'V-Star 650'.

Xvs650 Variants:

Key variants include the XVS650 (standard cruiser with wire-spoke wheels and often a chain drive) and the XVS650A Classic (featuring longer front forks, spoked wheels, and shaft drive, emphasizing a retro aesthetic).

Production Period:

The XVS650 platform was produced from 1997 through the late 2000s, with the Classic variant continuing for a longer period.

Manufacturing Location:

Primarily manufactured in Japan by Yamaha Motor Co., Ltd.

🏆 Awards & Recognition

Market Reputation:

Praised for its reliability, classic styling, and accessible riding experience, making it a popular choice for beginners and experienced riders alike.

Owner Satisfaction:

Generally high owner satisfaction due to its robust build quality and low cost of ownership.

Emission Standards:

Meets emissions standards relevant to its production year and market (e.g., Euro I/II, EPA standards).