1986–2009 Suzuki LS650 Savage / Boulevard S40 Service & Repair Manual (P/N S-LS650S40)

This Suzuki Motor Corporation service manual covers the 1986–2009 Suzuki LS650 Savage and Boulevard S40, with base-manual procedures and model-specific supplements through LS650K9. The publication carries a 1990 copyright and covers the air-cooled OHC TSCC single-cylinder engine and belt-drive systems.

The English-language manual is supplied as a 310-page PDF.

• Engine repair: Engine removal and installation, cylinder head overhaul, crankcase disassembly, counter balancer assembly, and camshaft and cam chain inspection.

• Clutch and transmission: Clutch inspection, transmission gear and shift fork checks, exploded-view diagrams, shaft cross-sections, and final drive belt tension adjustment.

• Fuel and lubrication: MIKUNI BS40SS carburetor disassembly, float and needle valve inspection, oil pressure testing, and lubrication system charts.

• Starting and ignition: Automatic de-compression system checks, starter motor overhaul, starter torque limiter testing, ignitor unit diagnosis, and side-stand ignition interlock tests.

• Brakes and chassis: Hydraulic brake bleeding, caliper and master cylinder overhaul, telescopic front fork service, steering stem bearings, and swingarm pivot inspection.

• Electrical diagnosis: Charging-system tests, component resistance tables, switch continuity checks, wiring diagrams, and model-specific wire and cable routing views.

Written primarily for experienced mechanics, this manual also provides a repair guide for apprentice and DIY mechanics, with specialized tools and test equipment specified for individual procedures.

Engine Clearances, Valve Timing, and Service Data

Periodic maintenance schedules and cold valve clearance specifications sit alongside standard and service limit tolerances for critical wear items like the piston, cylinder bore, rocker arm shafts, and transmission gears. Cylinder head bolt torques, engine mount fasteners, and chassis tightening data are covered in component-specific tables.

The engine chapter includes valve timing diagrams, valve guide and seat service, crankshaft inspection, and starter clutch repair. Compression testing and troubleshooting guides connect symptoms such as hard starting, poor compression, and abnormal engine noise with possible causes.

The automatic de-compression cable adjustment section warns that incorrect cable play can cause hard starting or engine damage.

Four-Speed and Five-Speed Transmission Supplements

The base manual and LS650H/J supplements cover the four-speed transmission; LS650S and later supplements cover the five-speed configuration. Separate transmission exploded views and shaft cross-sections help you select the correct assembly reference before transmission repair.

Supplements also document changes to carburetor settings, service data, wiring, fluid capacities, and chassis details. The LS650H material includes the side-stand ignition interlock system, while the LS650K5 supplement adds handlebar installation details and revised cable and hose routing drawings.

MIKUNI Carburetor and Lubrication Coverage

The fuel system chapter covers the diaphragm, transient enrichment valve, and float assembly, with model-specific main jet, pilot screw, and float height data. Carburetor identification codes distinguish the applicable specification tables, including the later 24C9 and 24CA units.

Emission control information includes California-model evaporative system hose routing between the fuel tank, canister, and associated valves. Oil pressure test information is supported by lubrication system charts and oil passage illustrations; the oil pump itself is treated as a replacement assembly rather than an internal overhaul job.

Starter Torque Limiter and Electrical Tests

The LS650T supplement adds starter torque limiter inspection using holder 09930-73130 and socket 09930-73140, plus ignitor testing with Suzuki's Digital Ignitor Checker 09931-94490.

Electrical sections cover ignition coil and pickup coil checks, regulator/rectifier resistance tables, and automatic de-compression control unit timing tests. Resistance readings are tied to the specified test equipment; service data also lists ignition timing, fuse ratings, and charging specifications.

Fork, Brake, and Chassis Repair

Front fork procedures cover the damper rod, oil seals, and oil level measurement. The fork disassembly section identifies possible damage to the antifriction bushings when separating the tubes.

Rear drum brake inspection and adjustment complement the hydraulic front brake procedures. Wire routing views and brake hose drawings show the original paths around the steering head and frame, helping prevent pinched lines during reassembly.

Engine removal, fuel system work, and brake service carry specific precautions for supporting heavy components, handling flammable fuel, and preventing brake fluid contamination.

File Format and Readability

The 310-page total comprises six introductory pages, 186 base-manual pages, and 118 supplement pages. The one-page clutch cover gasket appendix and nine blank pages are already included.

PDF bookmarks navigate the main chapters and model supplements. Existing OCR makes much of the body text searchable, but the foreword and many diagram labels are not searchable. Small wiring-diagram labels require zooming for comfortable reading.