2004 Yamaha DragStar 650 / V Star 650 Supplementary Factory Service Manual (P/N LIT-11616-11-1, LIT-11616-19–11)

• 440-page Yamaha XVS650 service set: The set cover is marked LIT-11616-XV-00 and contains the XVS650AK(C) base manual LIT-11616-11-16 plus supplements LIT-11616-11-21, LIT-11616-14-47, and LIT-11616-19-11; the latest supplement is the First Edition dated October 2005.
• Exact variant coverage: Identifies U.S., California, and Canadian configurations by Yamaha model code, including the cover-marked California “04 Model” XVS650SC and the later XVS650TC, XVS65V, and XVS65VC builds.
• Engine and shaft-driveline repair: Covers engine removal, cylinder heads, rocker arms and camshafts, valves, pistons, clutch, shift shaft, oil pump, starter clutch, crankshaft, transmission, middle gear, final-drive backlash, and final-gear installation.
• Chassis repair: Includes wheel and brake-disc work, front master-cylinder and caliper repair, rear brake service, hydraulic bleeding, fork overhaul, steering-head service, handlebar removal, swingarm and shock inspection, and shaft-drive repair.
• Fuel, emissions, and electrical diagnosis: Documents twin-carburetor inspection and synchronization, fuel-level and TPS checks, air-induction service, California evaporative-emission maintenance, fuel-cut solenoids, carburetor heaters, ignition, starting, charging, lighting, signals, fuel pump, and self-diagnosis.
• Workshop references: Provides exploded views, job instruction charts, cable and hose routing sheets, lubrication diagrams, wiring diagrams, circuit diagrams, troubleshooting charts, special-tool numbers, torque tables, pressure-test data, wear limits, clearances, capacities, and electrical test specifications.

Publication Scope and Model Identification

This PDF brings together the service information Yamaha says must be used as a set. The October 2005 XVS65V/XVS650SC supplement directs the technician back to the XVS650AK(C) base manual and the earlier XVS650K(C) and XVS650N(C) supplements for complete procedures. All four publications are included, so cross-references for carburetor assembly, TPS adjustment, battery service, brake bleeding, switch inspection, and other repair work lead to the required companion chapters.

The service editions are dated August 1997, December 1997, August 2000, and October 2005. Fitment can be checked against the model codes printed in the manuals: 5BN1/5BN2/5BN3 for the XVS650AK(C) U.S., California, and Canada configurations; 5FB1/5FB2/5FB3 for XVS650K(C); and 5FBD/5FBE for XVS650N(C). The later supplement identifies 5FBP for XVS650SC California, 3B62/5FBT for XVS650TC California, 3B64/5FBV for XVS65V U.S., and 3B65/5FBW for XVS65VC California. These codes should be checked before selecting model-specific procedures or replacement parts.

Repair and Overhaul Coverage

The base service manual goes well beyond periodic maintenance. Engine chapters cover removal and installation, cylinder-head and valvetrain inspection, camshaft timing, cylinder and piston service, clutch and shift mechanisms, oil-pump work, A.C. magneto and starter-clutch service, crankshaft and connecting rods, transmission inspection, and reassembly. The middle-gear and final-drive sections add backlash measurement and adjustment, drive-pinion and ring-gear work, drive-shaft inspection, and final-gear case installation—important coverage for the shaft-driven XVS650.

Chassis repair includes front and rear wheel service, brake-disc inspection, front master-cylinder and caliper disassembly, rear drum-brake work, hydraulic system bleeding, front-fork disassembly and assembly, steering-head bearings, handlebar service, rear shock absorber and swingarm inspection, and shaft-drive troubleshooting. Periodic sections cover valve-clearance adjustment, carburetor synchronization, compression checks, ignition timing, clutch and brake adjustment, final-drive oil service, steering and suspension inspection, battery checks, fuse inspection, and headlight adjustment.

The special-tool tables identify equipment used for these jobs, including pocket tester 90890-03112, fuel-level gauge YM-01312-A/90890-01312, vacuum gauge YU-08030-A/90890-03094, final-gear backlash band YM-01231/90890-01231, middle-gear backlash tool YM-33222/90890-04080, and clutch-holding tool YM-91042/90890-04086.

Fuel, Emissions, and Electrical Systems

Carburetion coverage includes the twin BDS28 carburetors, disassembly and assembly references, float and jet components, fuel-level checking, synchronization, throttle-position-sensor inspection and adjustment, air-induction-system service, and fuel-pump diagnosis. The latest supplement adds model-specific fuel-cut solenoid checks, testing for carburetor heater 1 and heater 2, heater-relay and thermo-switch diagnosis, and California emission-control maintenance.

Electrical repair is organized by system rather than presented as a single schematic. It covers TCI ignition, pickup and ignition coils, the starter circuit, charging system, lighting, turn-signal and brake-light circuits, fuel pump, carburetor heaters, switches, relays, fuses, and wiring continuity. The self-diagnosis section explains warning-light code display and fault isolation for the TPS, speed sensor, ignition coils, and both fuel-cut solenoids, including their associated fail-safe behavior.

Key visual references include the XVS65V/XVS650SC Wiring Diagram (for US and CAL), XVS650N(C) Wiring Diagram, Ignition System Circuit Diagram, Carburetor Heater System Circuit Diagram, engine lubrication chart, and self-diagnosis display-order chart. Detailed cable-routing sheets show the specified paths and clamp points for handlebar-switch leads, brake hoses, speedometer cable, TPS wiring, pickup-coil and A.C.-magneto leads, fuel hoses, and breather lines.

Manual-Specific Repair Notes

The front-fork sections warn that forcing the inner and outer tubes apart can damage the oil seal, slide metal, outer tube, or oil-lock piece; the required oil-seal orientation is also identified during assembly. Front-brake installation is routing-sensitive because the brake-hose pipe must seat correctly against the caliper stop before the hydraulic system is returned to service. Cable-routing notes keep the sidestand-switch lead away from the shift rod and prevent harnesses, relay leads, and ignition wiring from chafing against engine and cover edges.

Fuel-system, ignition, battery, and hydraulic-brake work should be performed with the motorcycle securely supported and with the manual’s fire, battery, brake-fluid, and component-protection warnings followed. The material assumes a working knowledge of motorcycle service and is written at a technical level appropriate for technicians, independent repair shops, and experienced owners.