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Yamaha XVS650 V-Star 1997-2008 Workshop Service Manual

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The XVS650 V-Star, produced from 1997 to 2008, is a quintessential cruiser motorcycle celebrated for its classic styling, reliable air-cooled V-twin engine, and low-maintenance shaft drive. This model, available in...
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Type: Motorcycle
Vendor:
Sku: 69706
Yamaha XVS650 V-Star 1997-2008 Workshop Service ManualYamaha XVS650 V-Star 1997-2008 Workshop Service ManualYamaha XVS650 V-Star 1997-2008 Workshop Service ManualYamaha XVS650 V-Star 1997-2008 Workshop Service Manual
The XVS650 V-Star, produced from 1997 to 2008, is a quintessential cruiser motorcycle celebrated for its classic styling, reliable air-cooled V-twin engine, and low-maintenance shaft drive. This model, available in Custom and Classic variants, offers riders an accessible entry into the cruiser lifestyle, blending traditional aesthetics with renowned engineering quality. Its design philosophy prioritizes rider comfort and a distinctive V-twin character, making it a popular choice for both experienced riders and those new to motorcycling. This comprehensive workshop service manual provides detailed guidance for the maintenance, diagnosis, and repair of your XVS650 V-Star. It covers all major systems, including the engine, transmission, drivetrain, electrical components, and chassis. Within its pages, you will find step-by-step procedures for routine maintenance, in-depth troubleshooting guides for common issues, and essential technical specifications. This manual serves as an indispensable resource for owners and technicians aiming to ensure the optimal performance, longevity, and safety of their V-Star.
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
XVS650 V-Star
Model Variant:
Custom, Classic (implied by common V-Star configurations)
Codes
Chassis Code:
RP02 (for early models, specific codes may vary slightly by year)
Engine Code:
H502E (typically shared across this generation)
👋 Introduction
Market Position
Segment:
Cruiser Motorcycle
Target Audience:
Riders seeking a stylish, reliable, and accessible cruiser with V-twin character and Yamaha's engineering reputation.
Competitive Analysis
Competitors:
Honda Shadow series, Kawasaki Vulcan series, Suzuki Intruder/Boulevard series.
Key Features
Engine Configuration:
Air-cooled, 4-stroke, V-twin, SOHC, 2 valves per cylinder (total 4 valves)
Drive System:
Shaft drive (low maintenance, clean aesthetic)
Design Philosophy:
Classic cruiser styling with modern reliability and performance.
📋 Manual Details
Coverage Areas
Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008
Regions Covered:
Global (standard Yamaha workshop manual content, applicable across major markets)
Page Count
Estimated Page Count:
400-600 pages (typical for a comprehensive workshop manual)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English (standard for this product listing)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, diagnosis, and repair (including top end, bottom end, cooling system, lubrication system, fuel system, ignition system)
Transmission:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, lubrication
Drivetrain:
Final drive system (shaft drive), bevel gear unit inspection and maintenance
Electrical:
Ignition system, charging system (stator, rectifier/regulator, battery), lighting system (headlight, taillight, indicators), starting system (starter motor, solenoid), wiring diagrams, fuse/relay identification, switches, sensors
Chassis:
Frame inspection, suspension (front forks, rear shock absorber), steering system (handlebar, steering bearings), braking system (front and rear brakes, hydraulic lines, master cylinders, calipers), wheel and tire maintenance
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel tank, fuel pump (if applicable), fuel lines
Bodywork:
Fender removal/installation, seat, fuel tank removal/installation, side covers, exhaust system removal/installation
Procedures Included
Maintenance:
Routine maintenance checks, oil changes, filter replacements, chain adjustment (if applicable, though shaft drive is more common), brake fluid replacement, spark plug replacement, air filter cleaning/replacement
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting guides for engine, electrical, and chassis issues
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems
Specifications:
Detailed torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters
Assembly:
Detailed procedures for engine and transmission assembly with proper torque sequences and component alignment
Technical Depth
Depth:
Comprehensive, covering all aspects from basic scheduled maintenance to complete engine rebuilds and advanced electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchable:
Yes (typically, if produced from digital source or scanned with OCR)
Print Quality
Printability:
Printable on standard office printers
Resolution:
High resolution for clear diagrams and text
Binding Type
Binding:
N/A (Digital PDF download)
Paper Type
Paper Type:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, V-twin
Displacement:
649 cc (39.6 cubic inches)
Bore X Stroke:
76.0 mm x 71.0 mm (approximately)
Compression Ratio:
9.0:1
Valve Train:
SOHC, 2 valves per cylinder
Carburetion:
Dual Mikuni 37 mm constant-velocity carburetors (specific model may vary slightly)
Ignition System:
Digital TCI (Transistor Controlled Ignition)
Performance
Horsepower:
Approx. 44-46 hp @ 6,000-6,500 rpm (manufacturer figures)
Torque:
Approx. 50-52 lb-ft @ 3,500-4,000 rpm (manufacturer figures)
Fuel System
Fuel Tank Capacity:
16.0 Liters (4.2 US gallons)
🔧 Transmission
Standard
Type:
Constant mesh 5-speed
Clutch:
Wet, multiple-disc
Final Drive:
Shaft drive
Features
Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 2.438, 2nd: 1.632, 3rd: 1.273, 4th: 1.045, 5th: 0.864)
Transmission Fluid Type:
Yamalube 10W-40 or equivalent API SG, JASO MA
📐 Dimensions
Exterior
Overall Length:
Approx. 2,295 mm (90.4 in)
Overall Width:
Approx. 830 mm (32.7 in)
Overall Height:
Approx. 1,175 mm (46.3 in)
Wheelbase:
Approx. 1,505 mm (59.3 in)
Ground Clearance:
Approx. 140 mm (5.5 in)
Weights
Dry Weight:
Approx. 191 kg (421 lbs)
Wet Weight:
Approx. 205 kg (452 lbs) (with fluids)
Load Capacity:
Refer to owner's manual or VIN-specific data; typically rider and light cargo.
🛡️ Safety Features
Ratings
Safety Certification:
Meets applicable safety standards for its class (e.g., DOT, ECE regulations depending on market).
Active Features
Brakes Front:
Single 298 mm disc with hydraulic dual-piston caliper
Brakes Rear:
200 mm drum brake (early models) or 267 mm disc with single-piston caliper (later models, depending on market/variant)
Tires Front:
100/90-19M/C 57H (tubeless)
Tires Rear:
170/80-15M/C 77S (tubeless)
Passive Features
Lighting:
Halogen headlight, LED taillight, incandescent turn signals
💡 Technology Features
Infotainment
Display:
Analog speedometer, analog tachometer (on some models), LCD odometer and trip meter, fuel gauge (model dependent).
Audio System:
N/A (This model does not feature an integrated audio system).
Driver Assistance
ABS:
Not standard on most XVS650 V-Star models during this production period. Available as an option on some later market variants.
Connectivity
Usb Charging:
N/A (Not factory equipped)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000-6,000 km (2,500-3,750 miles) or 6 months, whichever comes first (typical recommendation, consult manual for precise interval).
Air Filter Inspection:
Inspect every 4,000-6,000 km (2,500-3,750 miles), clean or replace as needed.
Spark Plug Replacement:
Every 10,000-12,000 km (6,250-7,500 miles) (typical, consult manual for specific plug type and interval).
Brake Fluid Replacement:
Every 2 years (recommended for all hydraulic brake systems).
Shaft Drive Maintenance:
Lubricate spline joint and inspect final drive oil every 10,000-15,000 km (6,250-9,375 miles).
Fluid Specifications
Engine Oil Type:
Yamalube 10W-40 or equivalent API SG, 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
Final Drive Oil Type:
Yamalube Gear Oil 80W-90 or equivalent API GL-4
Final Drive Oil Capacity:
Approx. 0.13 Liters (4.4 US fl oz)
Known Issues
Common Wear Items:
Clutch plates, brake pads, tires, fork seals, steering head bearings.
Potential Electrical Issues:
Stator failure (charging system), rectifier/regulator failure, wiring harness wear over time leading to intermittent electrical faults. Battery terminals corrosion.
Carburetor Maintenance:
Carburetors may require periodic cleaning and synchronization due to age and fuel quality variations.
Shaft Drive Noise:
Some models may develop a slight whine from the final drive unit if not properly maintained or if spline lubrication is neglected.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Yamaha Motorcycles:
Yamaha Motor Corporation is a Japanese manufacturer known for its broad range of motorcycles, musical instruments, and other powered products. Established in 1955, Yamaha has a strong reputation for innovation and quality.
Model Evolution
V Star Lineage:
The V-Star line is Yamaha's popular cruiser segment, offering a range of displacements from 250cc up to 1300cc. The XVS650 V-Star was a core model, known for its accessible styling and manageable performance.
Production
Production Period:
1997-2008 (as specified in the manual title). Production continued with updates beyond this period.
Manufacturing Location:
Primarily manufactured in Japan, with some assembly potentially occurring in other Yamaha facilities depending on market.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific 'awards' may be difficult to pinpoint for individual model years, the V-Star 650 platform has consistently been recognized for its value, reliability, and classic styling within the cruiser market.
Ratings
Reliability Reputation:
Yamaha motorcycles, including the V-Star 650, generally hold a strong reputation for durability and reliability, contributing to their popularity and resale value.
Certifications
Emission Standards:
Designed to meet emission standards relevant to their production year and market of sale (e.g., EPA, Euro standards).
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