Motorcycle Segment:
Cruiser, entry-level cruiser.
Target Audience:
Beginner riders, riders seeking a simple, reliable, and low-maintenance cruiser.
Key Competitors:
Honda Shadow VLX, Yamaha Virago 535, Kawasaki Vulcan 500.
Distinctive Features:
Long wheelbase, low seat height, torquey single-cylinder engine, distinctive styling, ease of maintenance.
Manual Value Proposition:
Provides comprehensive, detailed, and illustrated guidance for maintaining and repairing the Suzuki Boulevard S40 (LS650 Savage) across its production run, empowering both DIY enthusiasts and professional mechanics.
Applicable Years:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Region Coverage:
Global (specifications generally applicable across markets, though minor regional variations may exist)
Type:
Workshop Service Repair Manual
Delivery Method:
Instant Download
Engine:
Complete overhaul, diagnostics, tuning, fuel system (carburetor), ignition system, lubrication system, cooling system (air-cooled), exhaust system.
Transmission:
Clutch operation, gearbox disassembly and assembly, shifting mechanism, maintenance, lubrication.
Chassis And Suspension:
Front fork (telescopic) service, rear shock absorber replacement, swingarm maintenance, wheel bearing service, steering head bearing service.
Brakes:
Front disc brake system maintenance, caliper service, brake pad replacement, brake fluid bleeding, rear drum brake service.
Electrical System:
Wiring diagrams, lighting system, charging system (alternator, regulator/rectifier), starting system (starter motor, battery), ignition system troubleshooting, instrument cluster.
Fuel System:
Carburetor disassembly, cleaning, adjustment, jetting specifications, fuel tank and petcock maintenance.
Bodywork And Frame:
Frame inspection, body panel removal/installation, seat, fenders, fuel tank mounting.
General Maintenance:
Oil changes, filter replacement, spark plug inspection/replacement, chain adjustment, brake adjustments, tire pressure checks.
Troubleshooting:
Diagnostic guides for common starting issues, engine performance problems, electrical faults, and braking system malfunctions.
Disassembly And Assembly:
Detailed step-by-step instructions for removing and installing all major components and sub-assemblies.
Adjustments:
Carburetor synchronization and idle speed, ignition timing, clutch and throttle cable free play, brake lever free play.
Depth Of Coverage:
Comprehensive: Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics.
Diagnostic Capabilities:
Includes diagnostic flowcharts, fault code interpretation (if applicable), and systematic troubleshooting procedures.
Special Tools:
References specific Suzuki special service tools (SSTs) and their usage for certain procedures.
Readability:
Optimized for digital viewing and printing.
Printability:
Yes, all pages are printable.
Resolution:
High-resolution for clear text and diagrams.
Binding:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Required Software:
Adobe Reader or compatible PDF viewer.
Compatibility:
Windows, macOS, Linux operating systems.
Engine Type:
Four-stroke, SOHC, single-cylinder
Displacement:
652 cc (40.0 cu. in.)
Bore X Stroke:
94.0 mm x 9.4 mm (3.70 in x 3.70 in)
Compression Ratio:
8.5:1 (typical, check manual for specific year variations)
Cooling System:
Air-cooled
Horsepower Output:
Approx. 31-33 HP @ 5,500 RPM (estimate, specific figures vary by year and market)
Torque Output:
Approx. 38-40 lb-ft @ 3,500 RPM (estimate, specific figures vary by year and market)
Carburetor:
Mikuni VM34SS (single 34mm slide-valve carburetor)
Fuel Capacity:
9.0 L (2.4 US gal)
Fuel Type:
Unleaded gasoline, 87 octane or higher (check manual for specific recommendations)
Overall Length:
Approx. 2,280 mm (89.8 in)
Overall Width:
Approx. 800 mm (31.5 in)
Overall Height:
Approx. 1,110 mm (43.7 in)
Wheelbase:
Approx. 1,510 mm (59.4 in)
Dry Weight:
Approx. 170 kg (375 lbs)
Gross Vehicle Weight Rating:
Refer to manual; typically around 350 kg (772 lbs) for rider and passenger.
Ground Clearance:
Approx. 150 mm (5.9 in)
Crash Test Ratings:
N/A (Motorcycle safety standards differ from automotive; focus is on operational safety and rider protection.)
Braking System:
Front: Single disc brake; Rear: Drum brake.
Lighting:
Halogen headlight, LED taillight, incandescent turn signals (design may vary slightly by year).
Frame Design:
Steel double-cradle frame for rigidity and stability.
Rider Ergonomics:
Low seat height and forward-mounted footpegs contribute to a relaxed riding posture.
Manual Safety Emphasis:
The manual contains explicit DANGER, CAUTION, and NOTE sections for safe operation and to prevent damage.
Infotainment System:
N/A (This model predates modern infotainment systems; features basic analog instrumentation).
Driver Assistance Features:
N/A (Focus is on fundamental motorcycle operation and rider control).
Dashboard Features:
Speedometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators, engine oil warning lamp.
Engine Oil Change:
Every 4,000 km (2,500 miles) or 6 months. Check manual for specific interval.
Air Filter Cleaning:
Every 4,000 km (2,500 miles) or 6 months. Replace as needed.
Spark Plug Replacement:
Every 8,000 km (5,000 miles) or 12 months. Check manual for specific interval and type.
Clutch Adjustment:
As needed, typically every 4,000 km (2,500 miles). Refer to manual for procedure.
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain riding. Check manual for specific interval.
Engine Oil Type:
Refer to manual; typically SAE 10W-40 API SE, SF or SG or higher.
Engine Oil Capacity:
Approx. 2.2 L (2.3 US qt) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 compliant brake fluid.
Fork Oil Type:
Refer to manual; typically SAE 10W fork oil.
Fork Oil Capacity:
Refer to manual for precise volume per fork leg.
Carburetor Cleaning:
Common for older carburetors to require periodic cleaning and adjustment due to gumming or debris. Manual provides detailed instructions.
Rear Shock ABSorber Wear:
Over time, rear shocks can lose damping effectiveness. Manual covers replacement procedures.
Drive Shaft Maintenance:
Requires periodic lubrication of the drive shaft splines. Manual details the procedure and grease specifications.
Suzuki Motorcycle History:
Suzuki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments, known for innovation and quality.
Ls650 Savage Introduction:
Originally introduced as the LS650 Savage in 1986, it quickly gained popularity for its unique styling and accessible performance.
Boulevard Rebranding:
Renamed the Boulevard S40 in 2004 as part of Suzuki's Boulevard line-up, maintaining the core mechanicals but with some styling updates.
Engine Development:
The LS650's single-cylinder engine was a departure from multi-cylinder cruisers of the era, celebrated for its torque and simplicity.
Production Period:
1986-2009 for the model covered by this manual.
Manufacturing Location:
Japan
Industry Acclaim:
While not typically receiving specific 'awards' in the automotive sense, the LS650 Savage and Boulevard S40 were consistently praised for their reliability, ease of use, and value for money, fostering a strong enthusiast following.
Owner Satisfaction:
Generally high owner satisfaction due to its low maintenance requirements and robust engineering.
Manual Quality Certification:
This manual is described as 100% complete and intact, meeting quality standards for repair information.
