Category:
Cruiser Motorcycle
Target Audience:
Riders seeking a classic, easy-to-handle, and reliable cruiser for city riding and light touring.
Competitors:
Honda Shadow series, Yamaha V-Star series, Kawasaki Vulcan series (in similar displacement classes).
Design Philosophy:
Simple, robust design with a focus on traditional cruiser styling and user-friendliness.
Unique Selling Points:
Torque-rich single-cylinder engine, low seat height, accessible pricing, distinctive styling.
Major Components:
Engine, Fuel System, Drivetrain, Chassis, Electrical System, Bodywork
Type:
Factory Service Manual / Repair Manual
Engine Systems:
Engine overhaul, cylinder head, valve train, piston, crankshaft, lubrication system, cooling system (air-cooled design), timing system.
Fuel System:
Carburetor (Mikuni BS34) adjustment and overhaul, fuel tank, fuel lines, fuel filter replacement.
Drivetrain Systems:
Clutch operation and adjustment, gearbox inspection and repair, final drive (belt drive) maintenance and inspection.
Chassis Systems:
Front fork (suspension) disassembly and service, rear shock absorber replacement, steering system maintenance, wheel bearing service, brake system overhaul (front disc, rear drum), brake fluid specifications and bleeding procedures.
Electrical Systems:
Ignition system troubleshooting, starter motor, charging system (alternator/stator, regulator/rectifier), battery maintenance, lighting circuits, wiring diagrams, fuse specifications.
Bodywork And Frame:
Frame inspection, body panel removal and installation, seat, fenders, handlebars, control cables.
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, chain/belt adjustments, brake adjustments, cable lubrication.
Troubleshooting:
Diagnostic charts and procedures for common performance issues, electrical faults, starting problems.
Repair Overhaul:
Step-by-step instructions for engine rebuilding, transmission repair, suspension overhauls, electrical component replacement.
Technical Data Specifications:
Torque values, clearances, fluid capacities, electrical resistance values, engine timing specifications.
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
Engine Type:
4-stroke, Air-cooled, SOHC, V-twin (Note: The LS650 S40 actually features a 4-stroke, Air-cooled, SOHC, **single-cylinder** engine. This is a common point of confusion, and the manual will accurately reflect the single-cylinder configuration.)
Displacement:
652 cc (40 cubic inches)
Bore X Stroke:
94.0 mm x 94.0 mm
Horsepower:
Approx. 31 hp @ 5,200 rpm (claimed)
Torque:
Approx. 37.6 lb-ft @ 3,200 rpm (claimed)
Carburetor:
Mikuni BS34, Single Carburetor
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended)
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Capacity:
Approximately 2.7 Liters (with filter change)
Recommended Oil:
SAE 10W-40, API SE/SF/SG (or equivalent motorcycle-specific oil)
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multi-plate
Transmission Oil Capacity:
Approximately 0.7 Liters (shared with engine)
Recommended Transmission Oil:
SAE 10W-40, API SE/SF/SG (or equivalent motorcycle-specific oil)
Crash Test Ratings:
Not Applicable (Motorcycle)
Braking System:
Front: Disc brake, Rear: Drum brake
Lighting:
Halogen headlamp, LED taillight, turn signals
Frame Construction:
Steel frame for structural integrity.
Tire Design:
Tubeless tire construction (front and rear) for improved puncture resistance.
Infotainment System:
Basic, analog instrumentation: speedometer, odometer, tachometer (on some models/aftermarket), neutral indicator, high-beam indicator.
Audio System:
None (factory standard)
Rider Aids:
None (ABS, traction control not available on this model).
Connectivity Features:
None (factory standard)
Headlight Type:
Halogen bulb for optimal illumination.
Taillight Type:
LED taillight for enhanced visibility and longevity.
First Service Mileage:
600 miles (1,000 km)
Routine Maintenance Interval Miles:
Every 3,000 miles (5,000 km) or 6 months
Engine Oil Change Interval:
Every 3,000 miles (5,000 km) or 6 months, or more frequently under severe usage.
Air Filter Cleaning Replacement:
Inspect every 3,000 miles (5,000 km), clean/replace as needed.
Spark Plug Replacement:
Inspect every 3,000 miles (5,000 km), replace approx. every 6,000 miles (10,000 km).
Belt Tension Check:
Every 3,000 miles (5,000 km)
Engine Oil Grade:
SAE 10W-40
Common Wear Items:
Clutch plates, belt drive components, carburetor jets, fork seals due to mileage.
Carburetor Issues:
Potential for carburetors to become gummed up if the bike sits for extended periods without fuel stabilizer or draining. Idle mixture adjustments are common.
Belt Drive Maintenance:
Requires regular tension checks and cleaning; premature wear can occur if neglected.
Electrical Connections:
Corrosion on connectors, especially in humid environments, can lead to intermittent electrical issues.
Manufacturer:
Suzuki Motor Corporation, a Japanese multinational corporation known for a wide range of vehicles and engines.
Predecessor:
The LS650 S40 is a direct descendant of the original LS650 Savage, which debuted in 1986, sharing the same fundamental engine and chassis architecture.
Rebranding:
Renamed 'S40 Boulevard' in 2004 as part of Suzuki's initiative to consolidate its cruiser line under the 'Boulevard' name.
Production Start:
1986 (as LS650 Savage)
Production End Specific Model:
2009 (for this manual's coverage period; production continued beyond this)
Manufacturing Location:
Japan
Motorcycle Reviews:
Consistently praised for its character, ease of use, and value in motorcycle publications during its production run.
Owner Satisfaction:
Generally high owner satisfaction due to its reliability and simple maintenance.
Emissions Standards:
Meets EPA and CARB emissions standards applicable to the model years and regions of sale.
