Yamaha XVS650 V-Star 1997-2008 Workshop Service Manual
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🏷️ 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...
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).