1986-2009 Suzuki LS650 Savage / Boulevard S40 Service Manual

Suzuki LS650 Savage & Boulevard S40 Technical Documentation

• Covers 1986–2009 Suzuki LS650 Savage and Boulevard S40 motorcycles (652 cc single-cylinder engine configurations and belt-drive systems)
• Part no. S-LS650S40
• Official Suzuki Motor Corporation publication, 1990 copyright edition including model-specific supplements through 2009
• Contains 47 exploded-view diagrams, 12 electrical specification tables, and major component torque charts
• Delivered as an instant download the moment your payment clears
• Stored securely in your account for easy retrieval after a hard-drive failure or device change
• Fully searchable PDF format—find exact part numbers and specs in seconds
• Formatted for standard US Letter and A4 shop printing
• This 1990 first edition serves as the primary OEM factory workshop documentation used for the launch series, maintaining technical consistency across all Boulevard S40 production years

Comprehensive Shop Reference

This 310-page manual delivers the exact factory data required for serious shop work on the air-cooled OHC TSCC powerplant and chassis systems. It skips the fluff and gets straight to the hard data. Chapters are logically grouped into General Information, Periodic Maintenance, Engine Disassembly, Fuel and Lubrication, Electrical, and Chassis. You get standard and service limit tolerances for critical wear items like the piston, cylinder bore, rocker arm shafts, and transmission gears. Keep in mind that working on high-compression singles requires precision; always verify your lifting points and standard shop safety protocols before tearing into the crankcase. Because this manual is an instant download, you can pull up the exact reassembly tolerances and specialized Suzuki tool requirements directly on your shop tablet right now.

Essential Specs and Clearances

Forget guessing torque values or hunting through forums. This guide offers a detailed look at what an OEM service publication covers, calling out vital fasteners from engine mounts to chassis bolts. Cylinder head bolt torques are mapped out in a strict multi-stage sequence, with primary nuts spec'd at 29–33 Nm (21.0–24.0 lb-ft).

The fuel system breakdown confirms the MIKUNI BS40SS main jet at #155 and a precise float height of 27.95 ± 1.0 mm. For the top end, cold state valve clearances for both intake and exhaust are documented at 0.08–0.13 mm (0.003–0.005 in). The transmission data specifies a 2.214 low gear and a 0.875 top gear ratio. On the electrical side, you will find the 20A fuse rating and transistorized ignition timing pinned at 5° B.T.D.C. below 2000 r/min.