Suzuki LS650 Savage / Boulevard S40 Motorcycle Service Manual (1986-2019)

1. Introduzione

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. Informazioni generali

This section covers essential preliminary information for using the manual and working on the motorcycle.

• Riferimento rapido: Essential data and common procedures.
• Materiali speciali: Information on required lubricants, sealants, and other consumables.
• Utensili speciali: Details on specialized tools necessary for specific tasks.
• Specifiche: Comprehensive technical specifications for various components.
• Specifiche di coppia: Critical torque values for fasteners throughout the motorcycle.
• Risoluzione dei problemi: General diagnostic procedures for common issues.
• VIN and Engine Number Location: Guidance on locating identification numbers.

3. Manutenzione periodica

Regular maintenance is crucial for the longevity and performance of your Suzuki LS650 Savage / Boulevard S40. This section outlines routine service tasks.

• Manutenzione del filtro dell'aria
• Automatic Decompression Cable Adjustment
• Ispezione e sostituzione del liquido dei freni
• Ispezione dei freni
• Regolazione del cavo della frizione
• Controllo della compressione
• Drive Belt Inspection
• Regolazione del minimo del motore
• Cambio olio e filtro
• Tabella di manutenzione periodica
• Ispezione e sostituzione delle candele
• Steering and Suspension Inspection
• Regolazione del gioco dell'acceleratore
• Ispezione e controllo della pressione degli pneumatici
• Regolazione del gioco delle valvole

4. Componenti esterni

This section details the removal, installation, and maintenance of various external parts of the motorcycle.

• Pedane
• Parafango anteriore
• Serbatoio del carburante
• Manubrio
• Headlight Housing
• Strumenti
• Parafango posteriore
• Posto a sedere
• Coperture laterali

5. Sistema di alimentazione

Instructions for servicing the carburetor and related fuel system components.

• Gruppo carburatore
• Smontaggio carburatore
• Installazione del carburatore
• Rimozione del carburatore

6. Motore

Detailed procedures for engine repair, disassembly, and reassembly.

• Cam Chain Service
• Camshaft Installation
• Rimozione dell'albero a camme
• Clutch Service
• Crankcase Bearings
• Crankcase Disassembly
• Rimontaggio del basamento
• Crankshaft Service
• Coperchio testata
• Cylinder Head Installation
• Cylinder Head Removal
• Installazione del motore
• Rimozione del motore
• Gearshift Mechanism
• Left Side Engine Components
• Oil Pump Service
• Piston and Cylinder Service
• Right Side Engine Components
• Rocker Arms
• Gruppo trasmissione
• Transmission Disassembly
• Transmission Shafts
• Valves Service

7. Trasmissione finale

Maintenance and service procedures for the final drive system.

• Drive Belt Inspection and Replacement
• Front Pulley Service
• Rear Pulley Service

8. Sistema di scarico

Instructions for the removal and installation of the exhaust system.

• Installazione dello scarico
• Rimozione dello scarico

9. Freni

Service procedures for both front and rear braking systems.

Freni anteriori

• Brake Caliper Service
• Front Brake Rotor Inspection and Replacement
• Servizio cilindro maestro

Freni posteriori

• Brake Rod and Pedal Adjustment
• Drum Brake Service

10. Sospensione

Maintenance and repair of the motorcycle's suspension components.

Sospensione anteriore

• Smontaggio della forcella
• Fork Installation
• Fork Reassembly
• Rimozione della forcella

Sospensione posteriore

• Shock Absorbers Service
• Swing Arm Service

11. Sterzo

Procedures for steering system maintenance and repair.

• Steering Bearing Replacement
• Installazione dello sterzo
• Steering Removal

12. Ruote

Service and inspection of the motorcycle's wheels and related components.

• Sostituzione dei cuscinetti
• Front Wheel Service
• Rear Wheel Service
• Wheel and Axle Inspection

13. Sistema elettrico

Detailed information on the electrical components and wiring.

• Manutenzione della batteria
• Charging System Diagnostics
• Posizione e sostituzione dei fusibili
• Headlight Service
• Sistema di accensione
• Starter Motor Service
• Sistema di avviamento
• Switches (Handlebar, Ignition, etc.)
• Tail and Brake Light Service
• Turn Signals Service
• Schemi elettrici

14. Risoluzione dei problemi comuni

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.
• Impianto elettrico: Diagnostics for electrical malfunctions.
• Ruggine e corrosione: Prevention and treatment of rust.
• Starter Clutch Noise: Identifying and addressing unusual noises from the starter.
• Perdite di olio: Locating and repairing oil leaks.
• Vibrazione: 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. Specifiche

Key technical specifications for the Suzuki LS650 Savage / Boulevard S40 service manual.

16. Garanzia e supporto

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.