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

1. Einleitung

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. Allgemeine Informationen

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

• Kurzreferenz: Essential data and common procedures.
• Special Materials: Information on required lubricants, sealants, and other consumables.
• Spezialwerkzeug: Details on specialized tools necessary for specific tasks.
• Spezifikationen: Comprehensive technical specifications for various components.
• Drehmomentspezifikationen: Critical torque values for fasteners throughout the motorcycle.
• Fehlerbehebung: General diagnostic procedures for common issues.
• Standort der Fahrzeugidentifikationsnummer (VIN) und der Motornummer: Guidance on locating identification numbers.

3. Regelmäßige Wartung

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

• Wartung des Luftfilters
• Automatic Decompression Cable Adjustment
• Brake Fluid Inspection and Replacement
• Bremseninspektion
• Kupplungszugeinstellung
• Kompressionsprüfung
• Drive Belt Inspection
• Leerlaufdrehzahlregelung
• Öl- und Filterwechsel
• Regelmäßige Wartungstabelle
• Spark Plug Inspection and Replacement
• Steering and Suspension Inspection
• Einstellung des Leerlaufspiels der Drosselklappe
• Tire Inspection and Pressure Check
• Ventilspieleinstellung

4. Externe Komponenten

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

• Fußrasten
• Vorderer Kotflügel
• Treibstofftank
• Lenker
• Scheinwerfergehäuse
• Instrumente
• Kotflügel hinten
• Sitz
• Seitenabdeckungen

5. Kraftstoffsystem

Instructions for servicing the carburetor and related fuel system components.

• Vergaser-Baugruppe
• Demontage des Vergasers
• Vergasereinbau
• Ausbau des Vergasers

6. Motor

Detailed procedures for engine repair, disassembly, and reassembly.

• Cam Chain Service
• Camshaft Installation
• Nockenwellenausbau
• Kupplungsservice
• Crankcase Bearings
• Kurbelgehäusezerlegung
• Kurbelgehäuse-Wiederzusammenbau
• Crankshaft Service
• Zylinderkopfhaube
• Zylinderkopfmontage
• Zylinderkopf-Ausbau
• Motorinstallation
• Ausbau des Motors
• Gearshift Mechanism
• Motorkomponenten der linken Seite
• Ölpumpenservice
• Piston and Cylinder Service
• Komponenten des rechten Motorteils
• Rocker Arms
• Getriebebaugruppe
• Transmission Disassembly
• Transmission Shafts
• Valves Service

7. Final Drive

Wartungs- und Serviceverfahren für das Achsantriebssystem.

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

8. Abgasanlage

Instructions for the removal and installation of the exhaust system.

• Auspuffanlage
• Auspuff entfernen

9. Bremsen

Service procedures for both front and rear braking systems.

Vorderradbremsen

• Bremszangenservice
• Front Brake Rotor Inspection and Replacement
• Hauptbremszylinder-Service

Hinterradbremsen

• Bremsstangen- und Pedaleinstellung
• Drum Brake Service

10. Aussetzung

Maintenance and repair of the motorcycle's suspension components.

Vorderradaufhängung

• Fork Disassembly
• Gabelmontage
• Gabelmontage
• Gabelentfernung

Hinterradaufhängung

• Shock Absorbers Service
• Swing Arm Service

11. Lenkung

Procedures for steering system maintenance and repair.

• Lenklagerwechsel
• Einbau der Lenkung
• Lenkungsausbau

12. Räder

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

• Lagerwechsel
• Front Wheel Service
• Rear Wheel Service
• Rad- und Achsenprüfung

13. Elektrisches System

Detailed information on the electrical components and wiring.

• Batteriewartung
• Diagnose des Ladesystems
• Fuse Locations and Replacement
• Scheinwerferservice
• Zündanlage
• Anlasser-Service
• Startersystem
• Switches (Handlebar, Ignition, etc.)
• Rück- und Bremslichtservice
• Blinkerservice
• Schaltpläne

14. Fehlerbehebung bei häufigen Problemen

This section addresses frequently reported problems with the Suzuki LS650 Savage / Boulevard S40, providing guidance for diagnosis.

• Vergaserprobleme: Problems related to fuel delivery and engine performance.
• Elektrische Anlage: Diagnostics for electrical malfunctions.
• Rost und Korrosion: Prevention and treatment of rust.
• Starter Clutch Noise: Identifying and addressing unusual noises from the starter.
• Öllecks: Locating and repairing oil leaks.
• Vibration: Diagnosing sources of excessive vibration.
• Hintere Stoßdämpfer: 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. Spezifikationen

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

16. Garantie und 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.