2006-2009 Yamaha V-Star 650 XVS65, XVS650 Custom Midnight Custom Motorcycle Service & Repair Manual

XllS650 ~Service Manual Covers all 1998-2014 Yamaha V-Star 650 Custom, Classic, and Silverado models Supplementary materials begin on page 327 p 327 -- XVS65(C) & XVS65-M(C) p 367 -- XVS650N(C) p 408 -- XVS650AN(C) p 442 -- XVS650K(C) p 474 -- Additional Wiring Diagrams Page 1 of 476

YAMAHA \ LIT-11616-11-16 SBN-28197-EO Page 2 of 476

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EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor Company, ltd . is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~- Designs and specifications are subject to change without notice. IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. _A WARNING NOTE: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer. Page 4 of 476

EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the ma in categories of subjects. (See "Illustrated symbols") 1st title CD: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title®: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title @: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding i llustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram @ is provided for removal and disassembly jobs. 2. Numbers® are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a di sassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks®· The meanings of the symbol marks are given on the next page. 4. A job instruction chart <J) accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements ® are given in addition to the exploded diagram and the job instruction chart. 4 J-----11---1-- 1r---t--~--~=:;:::::-~--~~~~:::::::i~~!+;;;;;;;::~--~~~ CNlctl _ _.. "'"- ... ,... .... .,,,..."*"-. ...,,,, .... _.... , ,,, ....... ,... .. Oii ___ ,.... ""-- ~ "" - Ct---- lrifl'lll . S&Md .. ~ ......... --... ~---.--- s-.., ...,... .. __ _,,_ - ..... ~ ................... -. .W. ID .l .... NE Oil l'IE~- M(N'r .,,OW'Tlllll1 ._...... -t NG#olE tll(M()VAl •. ' l •l'0 '""" • '· •-• 1. n- ·J . ' ' \...r.. ..-.1. $$ -• 1. •$ - • •. J0 "-'1 •• 0.UTCH I ENG I'-' r=~~~====l<~w~~~~ ...... ;;;;;;-~-.=====~-t~~a 1.SU~ .lAcll ....... ,..__ .JtU!dud~<l> ~=- ... -~-=-..-= 0...,,_,...,._.,.,. _ ..... .--- 8 ..... di.lldl ... ~-- .. IMd'I ...... ...... I». """MY DfWl: GUiit lllEMOY.M. ·- .Lodi ....... ,..__ ................ ...,,<I> ~ ..... =-=..,-~.,,.... ... -~ .. ... .... _.. ........ Q) ... ........... ........................ """"'-- ·- .,~ ....... -........... .... ._... .. '"""'°" .......... ·- ·'rlcllori.._ ..... °"" .. ........ _ ... "-'- ... ~ ........ . ... .... _ ..... ~ ·- ·--- ~ .. ....... dwld\ ....... ·- .Qwd, .... ....... a.. .. ......... _ .... ._.,._._..., ,..... .. ... u...--. ........ .._. ...... ep. ~ ............... , .... ~ ... ..,_ Page 5 of 476

CD ® 1.~~~1~1 lsPEcl u-1 @ © 1·:gs1~1 ENG ~. @ @ ® lcooLI ~I lcARsl Ii' I (J) ® icHAS1~1 IELEclDI ® @) IJ~~~ ? I ~ (jJ) ~ @ E1 @ ~ @ ~ @~@B®~ @ @) ® 1 1 1 m ~ ~ @ @ @ ~ ~ ~ ® ® A l~mtl EB003000 ILLUSTRATED SYMBOLS Illustrated symbols CD to ® are printed on the top right of each page and indicate the subject of each chapter. CD General i nformation ® Specifications @ Periodic inspecti ons and adjustments © Engine @ Cooling system ® Carburetion (J) Chassis @ Electrical ® Troubleshooting Illustrated symbols ® to @ are used to identify the specifications appearing in the text . @) Can be serviced with engine mounted (jJ) Filling flu id @ Lubricant @ Special tool @ Torque @ Wear limit. clearance @ Engine speed @ Q,V,A Illustrated symbols@ to ®l in the exploded diagrams indicate the types of lubricants and lubrication points . @ Apply engine oil @)Apply gear oil @ Apply molybdenum disulfide oil @ Apply wheel bearing grease @ Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease Illustrated symbols @ to @ in the exploded diagrams indicate where to apply a locking agent@ and when to install new parts®· ® Apply locking agent (LOCTITE®) ® Replace Page 6 of 476

E8004000 CHAPTER TITLES GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL TROUBLESHOOTING ~ GEN INFO ENG CARB ~ CHAS D ELEC ? • TRBL • SHTG • Page 7 of 476

CONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ................................................................ 1-1 VEHICLE IDENTIFICATION NUMBER ................... .. ....... .. ................... 1-1 MODEL LABEL ..................................................................................... 1-1 IMPORTANT INFORMATION ...... .. .............................................................. 1-2 PREPARATION FOR REMOVAL PROCEDURES ................................. 1-2 REPLACEMENT PARTS ....................................................................... 1-2 GASKETS, OIL SEALS AND 0-RINGS ............................................. .. . 1-2 LOCK WASHERS/PLATES AND COTTER PINS .................................. 1-3 BEARINGS AND OIL SEALS ................................................................ 1-3 CIRCLIPS ................................... .. .......................................................... 1-3 CHECKING OF CONNECTIONS .. ................................................................. 1-4 SPECIAL TOOLS .......................................................................................... 1-5 CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ....................................................................... 2-1 MAINTENANCE SPECIFICATIONS ............................................................. 2-4 ENGINE ...... ... . .. ..................................................................................... 2-4 CHASSIS ............................................................................................. 2-14 ELECTRICAL ....................................................................................... 2-18 GENERAL TORQUE SPECIFICATIONS ..................................................... 2-20 LUBRICATION POINTS AND LUBRICANT TYPES ................................... 2-21 ENGINE ............................................................................................... 2-21 CHASSIS .................................................................. .......................... 2-22 LUBRICATION DIAGRAMS ................................................... .. .................. 2-23 CABLE ROUTING ....................................................................................... 2-27 ~ GEN INFO SPEC INSP ADJ "· ENG CARB D ELEC ? • TRBL SHTG Page 8 of 476

CHAPTER3. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ........................................................................................... 3-1 PERIODIC MAINTENANCE/LUBRICATION INTERVALS ........................... 3-1 GENERAL MAINTENANCE/LUBRICATION ................................................ 3-2 FUEL TANK AND SEATS ............................................................................. 3-4 ENGINE ......................................................................................................... 3-5 VALVE CLEARANCE ADJUSTMENT .................................................. 3-5 CARBURETOR SYNCHRONIZATION .................................................. 3-8 IDLING SPEED ADJUSTMENT .......................................................... 3-10 THROTILE CABLE ADJUSTMENT ................................................... 3-11 SPARK PLUG INSPECTION ........................................•...................... 3-12 IGNITION TIMING CHECK ................................................................. 3-13 COMPRESSION PRESSURE MEASUREMENT ................................ 3-15 ENGINE OIL LEVEL INSPECTION ..................................................... 3-17 ENGINE OIL REPLACEMENT ............................................................ 3-18 CLUTCH ADJUSTMENT .................................................................... 3-20 AIR FILTER CLEANING ...................................................................... 3-20 CARBURETOR JOINT INSPECTION ................................................. 3-21 FUEL LINE INSPECTION .................................................................... 3-21 BREATHER HOSE INSPECTION ........................................................ 3-22 EXHAUST SYSTEM INSPECTION .................................................... 3-22 CHASSIS ..................................................................................................... 3-23 FRONT BRAKE ADJUSTMENT ......................................................... 3-23 REAR BRAKE ADJUSTMENT ............................................................ 3-24 BRAKE FLUID LEVEL INSPECTION ................................................... 3-25 BRAKE PAD INSPECTION ................................................................. 3-26 BRAKE SHOE INSPECTION ............................................................... 3-26 BRAKE LIGHT SWITCH ADJUSTMENT ............................................ 3-26 BRAKE HOSE INSPECTION ............................................................... 3-27 AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .............................. 3-27 SHIFT PEDAL ADJUSTMENT ............................................................ 3-28 FINAL GEAR OIL LEVEL INSPECTION .............................................. 3-29 FINAL GEAR OIL REPLACEMENT ..................................................... 3-30 STEERING HEAD INSPECTION ......................................................... 3-30 FRONT FORK INSPECTION ............................................................... 3-32 REAR SHOCK ABSORBER ADJUSTMENT ....................................... 3-33 TIRE INSPECTION .............................................................................. 3-33 WHEEL INSPECTION ......................................................................... 3-36 SPOKE INSPECTION AND TIGHTENING ......................................... 3-36 CABLE INSPECTION AND LUBRICATION ........................................ 3-36 LEVER AND PEDAL LUBRICATION .................................................. 3-37 SIDESTAND LUBRICATION .............................................................. 3-37 Page 9 of 476

ELECTRICAL ............................................................................................... 3-38 BATTERY INSPECTION ..................................................................... 3-38 FUSE INSPECTION ....................................... .. ................................... 3-43 HEADLIGHT BEAM ADJUSTMENT ..... .. ........................................... 3-45 HEADLIGHT BULB REPLACEMENT .................................................. 3-45 CHAPTER 4. ENGINE ENGINE REMOVAL .. .................................................................................... 4-1 MUFFLERS, BRAKE PEDAL AND SIDE COVER ............................. .. .. 4-1 CYLINDER HEAD COVERS .................................................................. 4-3 SIDESTAND AND CRANKCASE COVER (LEFT) ........................... .. .... 4-5 ENGINE MOUNTING BOLTS .............................................................. 4-6 SHIFT PEDAL INSTALLATION ............................................................ 4-8 BRAKE PEDAL INSTALLATION ........................................................... 4-8 CYLINDER HEADS ....................................................................................... 4-9 CYLINDER HEAD REMOVAL ............................................................. 4-11 CYLINDER HEAD INSPECTION ......................................................... 4-12 CYLINDER HEAD INSTALLATION ..................................................... 4-14 ROCKER ARMS AND CAMSHAFT ............................................................ 4-17 ROCKER ARM AND CAMSHAFT REMOVAL ......... .. ......................... 4-18 ROCKER ARM AND CAMSHAFT INSPECTION ................................ 4-18 ROCKER ARM AND CAMSHAFT INSTALLATION ........................... 4-19 VALVES AND VAL VE SPRINGS ........................ .. .. ....... .. .. ........................ 4-21 VALVE AND VALVE SPRING REMOVAL .......................................... 4-22 VALVE AND VALVE SPRING INSPECTION ...................................... 4-22 VALVE AND VALVE SPRING INSTALLATION ................................. 4-26 CYLINDERS AND PISTONS ....................................................................... 4-28 PISTON REMOVAL ........................................................................ .. .. 4-29 CYLINDER AND PISTON INSPECTION .. .. ....................................... .. 4-29 PISTON RING INSPECTION .............................................................. 4-31 PISTON PIN INSPECTION ................................................................. 4-32 CYLINDER AND PISTON INSTALLATION .................. .. ............... .. ... 4-33 CLUTCH .............................. .. ...................................................................... 4-34 CRANKCASE COVER (RIGHT) ..................................... .. .................... 4-34 CLUTCH ASSEMBLY ................ .. ......................... .. .... ........................ 4-36 CLUTCH REMOVAL .................................................... .. ................. .. .. 4-38 PRIMARY DRIVE GEAR REMOVAL ................................................... 4-38 CLUTCH INSPECTION ......... .. ............................................................ 4-38 PUSH ROD INSPECTION ................................................................... 4-40 PRIMARY DRIVE GEAR INSTALLATION .......................................... 4-40 CLUTCH INSTALLATION ................................................................... 4-40 GEN INFO SPEC INSP ADJ "· ENG CARB CHAS D ELEC • TRBL SHTG Page 10 of 476

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2006-2009 Yamaha V-Star 650 XVS65, XVS650 Custom Midnight Custom Motorcycle Service & Repair Manual

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