Yamaha V-Star 650 XVS650A/XVS650 Service Manual Set, 2005–2010 (P/N LIT-11616-11-16)

The supplements provide configuration-specific changes for use with the base service manual. The October 2005 supplement requires both the base manual and the XVS650AN(C) supplement; both are included.

The XVS650K(C) supplement supplies separate chassis information for that variant. Its fork specifications and illustrations should be matched to the correct model before service.

PDF Bookmarks, Text Search and Diagram Detail

Search and diagram navigation: Embedded bookmarks provide access to all four publications and their major sections. Text search is available in portions of the first two supplements; the base manual and XVS650K(C) supplement are not text-searchable. Small wiring labels require zooming, particularly in the base-manual diagram.

One printable PDF contains 432 pages: the publications listed above plus two additional pages comprising an outer cover and a promotional page, already included in the total.

Engine Overhaul, Shaft Drive and Electrical Fault Finding

The following selected coverage highlights outline the main workshop content. Other included topics range from wheel static balancing to sealed-battery charging charts.

• Engine overhaul: Step-by-step removal, cylinder-head and valve service, piston inspection, crankcase separation, crankshaft checks, and bearing selection.

• Clutch and transmission: Clutch disassembly, friction-plate inspection, release-mechanism adjustment, shift-fork checks, and transmission reassembly.

• Shaft drive: Middle-gear and final-drive diagnosis, backlash measurement, shim selection, universal-joint service, and bearing replacement.

• Carburetion and emissions: Carburetor inspection and synchronization, fuel-level adjustment, throttle position sensor testing, fuel-cut solenoid checks, and air induction service.

• Brakes and suspension: Front pad replacement, master-cylinder and caliper repair, rear drum-brake inspection, hydraulic bleeding, fork overhaul, and steering-head service.

• Electrical diagnosis: Ignition, starting, charging, lighting, signal, fuel-pump, and carburetor-heater troubleshooting, supported by circuit diagrams and self-diagnosis charts.

• Scheduled maintenance: Emission-control and lubrication charts, valve-clearance adjustment, compression testing, control-cable checks, and brake and shift-pedal adjustments.

Yamaha prepared these manuals primarily for dealers and qualified mechanics, with basic mechanical knowledge and familiarity with repair techniques assumed.

Engine, Clutch and Shaft-Drive Repair

The base manual goes beyond external maintenance into valve-guide replacement, valve-seat inspection and lapping, piston-ring checks, oil-pump inspection, and crankshaft bearing-clearance measurement. Exploded views and job instruction charts accompany removal and assembly work.

For drivetrain diagnosis, the shaft-drive troubleshooting chart relates noises and operating symptoms to wheel bearings, gear backlash, and internal drive components. This helps distinguish a wheel-bearing problem from a final-drive fault before selecting the relevant inspection procedure.

Middle-gear service includes shim calculations and use of the YM-33222 backlash tool; final-drive measurement uses the YM-01231 backlash band. Hammering the universal joint can distort the driven-pinion collapsible collar and alter its turning torque.

Carburetor Updates and Electrical Diagnosis

The October 2005 supplement adds fuel-cut solenoid testing and expanded engine-indicator fault-code information. Code 42 identifies the speed-sensor circuit; its troubleshooting section also checks the speedometer cable, gear unit, and clutch projections.

These component-specific test paths help a technician investigate the indicated circuit rather than treating every warning-light sequence as an ignition-coil failure. The base manual separately explains TPS resistance testing and position adjustment.

Illustrations include the Lighting System Circuit Diagram, Carburetor Heater System Circuit Diagram, Starting Circuit Operation diagram, Air Induction System Diagrams, Lubrication Diagrams, and XVS650AK(C) Wiring Diagram. Cable-routing guides show lead, hose, and connector placement for reinstallation.

Brake and Chassis Differences

The XVS650AN(C) supplement revises rear-brake and shift-pedal adjustment data and documents its front-pad and caliper installation arrangement. The XVS650K(C) supplement provides its own fork disassembly, assembly, and steering-head illustrations.

The brake sections warn that solvents can swell and distort internal seals. Hydraulic brake work requires correct hose routing, proper bleeding after connections are opened, and an operational check before riding.

Examples of Solenoid and Heater Test Specifications

The October 2005 supplement specifies fuel-cut solenoid resistance at 12 Ω at 20°C (68°F), with separate identification of the two solenoid connections.

Its 20 W carburetor heater 1 is specified at 3.4–7.6 Ω, while the 15 W heater 2 is specified at 4.8–14.5 Ω, both at 20°C (68°F). The supplementary electrical specifications also list starting-circuit cut-off and fuel-pump relay coil resistance at 162–198 Ω.