1986-2009 Suzuki LS650 Savage / Boulevard S40 Service Manual

Suzuki LS650 Savage and Boulevard S40 Technical Documentation

• Covers 1986–2009 Suzuki LS650 Savage and Boulevard S40 motorcycles, featuring 652 cc single-cylinder engine configurations and belt-drive systems
• Official Suzuki Motor Corporation publication, 1990 copyright edition including model-specific supplements through 2009
• Contains 47 labeled exploded-view diagrams, 12 electrical specification tables, and torque value reference charts for major chassis and engine components
• Delivered as a direct download the moment payment clears
• Stored against your account so you can retrieve it after a hard-drive loss
• Full-text search finds any part number in seconds
• Laid out for standard letter and A4 printing
• This 1990 first edition is the primary OEM factory workshop documentation used for the LS650 Savage launch series, maintaining technical consistency across the Boulevard S40 production years

Component Maintenance Walkthrough

This 310-page manual is structured to guide a technician through the mechanical intricacies of the air-cooled OHC TSCC power plant and the chassis systems. Chapters are segmented into logical groups including General Information, Periodic Maintenance and Tune-up Procedures, Engine Disassembly, Fuel and Lubrication Systems, Electrical Systems, and Chassis. The content elaborates on the specific inspection parameters for the piston, cylinder bore, rocker arm shafts, and transmission gears, providing standard and service limit tolerances for each. Reassembly instructions for the crankcase, clutch assembly, and valve train are provided with clear reference to the specialized Suzuki tools required for precision adjustment.

Specification and Technical Preview

Detailed tables provide critical data for what an OEM service publication covers, including tightening torques for engine mounts and chassis bolts. Cylinder head bolt torque values are documented in a multi-stage sequence, with primary nuts specified at 29–33 Nm (21.0–24.0 lb-ft). The fuel system section lists the MIKUNI BS40SS main jet at #155 and float height at 27.95 ± 1.0 mm. Valve clearance for both intake and exhaust is documented at 0.08–0.13 mm (0.003–0.005 in) in the cold state. The transmission section details gear ratios, specifying a 2.214 low gear and a 0.875 top gear ratio. Electrical system data includes a 20A fuse rating and transistorized ignition timing set at 5° B.T.D.C. below 2000 r/min.