1. Introduction
This service manual provides detailed, step-by-step instructions for servicing and rebuilding the Suzuki LS650 Savage and Boulevard S40 motorcycles produced from 1986 to 2019. It includes comprehensive information, black and white photographs, and specifications to assist with various maintenance and repair procedures.
Image 1.1: Front cover of the service manual, displaying the title and motorcycle models covered.
2. General Information
This section covers essential preliminary information for using the manual and working on the motorcycle.
- Quick Reference: Essential data and common procedures.
- Special Materials: Information on required lubricants, sealants, and other consumables.
- Special Tools: Details on specialized tools necessary for specific tasks.
- Specifications: Comprehensive technical specifications for various components.
- Torque Specifications: Critical torque values for fasteners throughout the motorcycle.
- Troubleshooting: General diagnostic procedures for common issues.
- VIN and Engine Number Location: Guidance on locating identification numbers.
3. Periodic Maintenance
Regular maintenance is crucial for the longevity and performance of your Suzuki LS650 Savage / Boulevard S40. This section outlines routine service tasks.
- Air Filter Servicing
- Automatic Decompression Cable Adjustment
- Brake Fluid Inspection and Replacement
- Brake Inspection
- Clutch Cable Adjustment
- Compression Check
- Drive Belt Inspection
- Engine Idle Speed Adjustment
- Oil and Filter Change
- Periodic Maintenance Chart
- Spark Plug Inspection and Replacement
- Steering and Suspension Inspection
- Throttle Free Play Adjustment
- Tire Inspection and Pressure Check
- Valve Clearance Adjustment
4. External Components
This section details the removal, installation, and maintenance of various external parts of the motorcycle.
- Foot Pegs
- Front Fender
- Fuel Tank
- Handlebars
- Headlight Housing
- Instruments
- Rear Fender
- Seat
- Side Covers
5. Fuel System
Instructions for servicing the carburetor and related fuel system components.
- Carburetor Assembly
- Carburetor Disassembly
- Carburetor Installation
- Carburetor Removal
6. Engine
Detailed procedures for engine repair, disassembly, and reassembly.
- Cam Chain Service
- Camshaft Installation
- Camshaft Removal
- Clutch Service
- Crankcase Bearings
- Crankcase Disassembly
- Crankcase Reassembly
- Crankshaft Service
- Cylinder Head Cover
- Cylinder Head Installation
- Cylinder Head Removal
- Engine Installation
- Engine Removal
- Gearshift Mechanism
- Left Side Engine Components
- Oil Pump Service
- Piston and Cylinder Service
- Right Side Engine Components
- Rocker Arms
- Transmission Assembly
- Transmission Disassembly
- Transmission Shafts
- Valves Service
7. Final Drive
Maintenance and service procedures for the final drive system.
- Drive Belt Inspection and Replacement
- Front Pulley Service
- Rear Pulley Service
8. Exhaust System
Instructions for the removal and installation of the exhaust system.
- Exhaust Installation
- Exhaust Removal
9. Brakes
Service procedures for both front and rear braking systems.
Front Brakes
- Brake Caliper Service
- Front Brake Rotor Inspection and Replacement
- Master Cylinder Service
Rear Brakes
- Brake Rod and Pedal Adjustment
- Drum Brake Service
10. Suspension
Maintenance and repair of the motorcycle's suspension components.
Front Suspension
- Fork Disassembly
- Fork Installation
- Fork Reassembly
- Fork Removal
Rear Suspension
- Shock Absorbers Service
- Swing Arm Service
11. Steering
Procedures for steering system maintenance and repair.
- Steering Bearing Replacement
- Steering Installation
- Steering Removal
12. Wheels
Service and inspection of the motorcycle's wheels and related components.
- Bearing Replacement
- Front Wheel Service
- Rear Wheel Service
- Wheel and Axle Inspection
13. Electrical System
Detailed information on the electrical components and wiring.
- Battery Maintenance
- Charging System Diagnostics
- Fuse Locations and Replacement
- Headlight Service
- Ignition System
- Starter Motor Service
- Starter System
- Switches (Handlebar, Ignition, etc.)
- Tail and Brake Light Service
- Turn Signals Service
- Wiring Diagrams
14. Troubleshooting Common Issues
This section addresses frequently reported problems with the Suzuki LS650 Savage / Boulevard S40, providing guidance for diagnosis.
- Carburetor Issues: Problems related to fuel delivery and engine performance.
- Electrical System: Diagnostics for electrical malfunctions.
- Rust and Corrosion: Prevention and treatment of rust.
- Starter Clutch Noise: Identifying and addressing unusual noises from the starter.
- Oil Leaks: Locating and repairing oil leaks.
- Vibration: Diagnosing sources of excessive vibration.
- Rear Shock Absorbers: Issues related to rear suspension performance.
Regular maintenance and prompt attention to any emerging issues are key to a positive ownership experience for your Suzuki LS650 Savage / Boulevard S40.
Image 14.1: Back cover of the service manual, including ISBN and barcode information.
15. Specifications
Key technical specifications for the Suzuki LS650 Savage / Boulevard S40 service manual.
| Specification | Detail |
|---|---|
| ASIN | B0DT16LKMP |
| Publisher | Independently published |
| Publication Date | January 13, 2025 |
| Language | English |
| Print Length | 347 pages |
| ISBN-13 | 979-8306829821 |
| Item Weight | 1.76 pounds |
| Dimensions | 8.5 x 0.79 x 11 inches |
16. Warranty and Support
Information regarding warranty and support for this service manual is not explicitly provided. For inquiries regarding the content or specific procedures, please refer to the publisher, Cyclepedia Press LLC, or consult an authorized Suzuki service center.
