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

• 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
• 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
• Details critical components including the automatic de-compression system, starter torque limiter, ignitor unit, steering stem bearings, swingarm pivot, engine counter balancer, starter clutch, and the telescopic front fork
• Features essential wiring diagrams, valve timing diagrams, lubrication system charts, troubleshooting guides, wire routing views, hose routing drawings, emission control schematics, and periodic maintenance schedules

Comprehensive Shop Reference

This 310-page PDF manual delivers the exact factory data required for serious shop work and troubleshooting on the air-cooled OHC TSCC powerplant and chassis systems. Chapters are logically grouped into General Information, Periodic Maintenance, Engine Disassembly, Fuel and Lubrication, Emission Control Information, Electrical, Chassis, and Servicing Information. 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, and exercise extreme caution when handling highly flammable fuel or caustic glycol-based brake fluids. Relying on precise wire and cable routing drawings directly at the workbench prevents pinched lines during engine installation and significantly speeds up electrical diagnostics.

Essential Specs, Clearances, and Service Routines

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.

For tasks that typically demand a costly trip to the dealership, this repair guide outlines the exact factory procedures. You will find step-by-step walk-throughs for overhauling the telescopic front fork, properly bleeding the hydraulic brake circuit, checking the starter torque limiter, adjusting the automatic de-compression cable play, and accurately setting the final drive belt tension.