1998-2011 Yamaha V-Star 650 Classic XVS650, Custom XVS65 Service Manual

1998-2011 V-Star 650 Service documentation with specific diagnostic procedures. Covers Classic and Custom models. Consult this guide for technical information and repairs. Part number LIT-11616-11-16.

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Technical Safety Notice
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This official OEM document is intended for professional technicians and skilled operators. Performing service on mechanical equipment involves inherent risks. By purchasing, you acknowledge that RepairLoader provides original manufacturer data for informational purposes. Always prioritize safety: use correct tools, wear protective gear, and consult a certified professional if you are uncertain of any procedure.

Yamaha Models Covered & Key Technical Specifications

Models: XVS650, XVS650A (Classic), XVS650 Custom
Sub-models / Variants: 5BN1 (USA), 5BN2 (California), 5BN3 (Canada), Classic, Custom
Trade Names: V-Star 650
Build Years: 1998–2011
Serial Numbers: 5BN-28197-E0
Technical Data:

  • Engine: Air-cooled 4-stroke, SOHC, V-type 2-cylinder, 649 cc
  • Bore x Stroke: 81 x 63 mm
  • Compression Ratio: 9:1
  • Transmission: Constant mesh 5-speed, shaft drive
  • Carburetor: MIKUNI BDS28/2
  • Fuel System: Regular unleaded gasoline, 16 L tank capacity
  • Ignition System: T.C.I. (digital)
  • Electrical: 12V system, 12V 10AH battery (GT12B-4)
  • Suspension: Telescopic front fork, Monocross rear swingarm
Technical Specifications
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Document Number / Seller:
26548 / Robert Grant
File Size:
66.80 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Jul 1, 2025

Yamaha Manual Features & Content Preview

1998–2011 Yamaha V-Star 650 Service Manual Overview

  • Covers 1998–2011 Yamaha V-Star 650 Classic and Custom models, including 5BN1, 5BN2, and 5BN3 regional variants
  • Official Yamaha publication P/N LIT-11616-11-16, first edition August 1997
  • Includes 124 exploded-view diagrams, 8 detailed electrical wiring schematics, and extensive torque specification tables
  • Delivered as a direct download the moment payment clears
  • Full-text search finds any part number in seconds
  • Laid out for standard letter and A4 printing
  • This 1997 first edition documents the initial platform specifications used for the 1998–2011 production run of the XVS650 series

Technical Scope and Documentation

The 1998–2011 Yamaha V-Star 650 service manual provides a technical overview of the XVS650 mechanical structure, electrical systems, and chassis maintenance requirements. Detailed chapters categorize every major assembly, documenting removal and disassembly via indexed exploded diagrams and job-instruction charts. The publication structures content by system, spanning general information, specification tables, periodic inspections, engine overhaul, fuel system carburetion, chassis components, and comprehensive electrical diagrams.

Engine and Chassis Specification Highlights

This 1998–2011 Yamaha V-Star 650 documentation lists engine specifications for the 649cc V-twin power plant, including valve clearance settings and torque values for high-load components. Valve clearance for the intake is listed at 0.07–0.12 mm in the cylinder head specification table. Compression pressure at sea level is documented at 1,000 kPa (142.2 psi) minimum. The electrical section details charging system output at 14 V 20 A at 5,000 r/min. Understanding how factory workshop documentation is structured assists in navigating the diagnostic routines for the T.C.I. ignition and fuel pump systems. The 1998–2011 Yamaha V-Star 650 manual remains an essential technical reference for maintenance of the 5BN-series motorcycles, encompassing all frame, drivetrain, and electrical specifications for the long-running air-cooled V-twin cruiser platform.

Manual FAQ, Purchase & Download Details

Are lubrication points, fluid capacities, and lubricant type tables included in the document? keyboard_arrow_down

Chapter 2 contains maintenance specification tables that list lubrication points, fluid types, and related service data for the engine and chassis. These reference sections provide information on appropriate material applications.

Does the manual contain specification tables for tightening torques and general engine tolerances? keyboard_arrow_down

Chapter 2 includes comprehensive specification tables for engine, chassis, and electrical components, featuring general torque references and technical limit data.

Can the document chapters cover detailed exploded views and component arrangements for the engine and transmission systems? keyboard_arrow_down

Chapter 4 includes exploded diagrams for the engine, transmission, and clutch assemblies to assist in identifying component order and relationships. These illustrations are supplemented by job instruction charts that summarize the parts and sequences.

Is there a section that references the ignition, charging, and fuel pump electrical systems? keyboard_arrow_down

Chapter 7 lists the electrical components and includes circuit diagrams for the ignition, charging, and fuel pump systems.

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