1986-2009 Suzuki Boulevard S40 Service & Repair Manual

FOREWORD The SUZUKI LS650 was designed to offer superior performance through lightweight design, four stroke-power (TSCC engine), engine counter balancer and electrical controlled auto- matic de-compression system. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service Suzuki Motorcycles. Apprentice mechanics and do-it- yourself mechanics will also find this manual to be an extremely useful repair guide. This manual contains up-to-date information at the time of publication. The rights are reserved to update or make corrections to this manual at any time. IMPORTANT All street-/ega/ Suzuki motorcycles with engine displacement of 50cc or greater are subject to Environmental Protection Agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service the LS650 in accordance with all EPA regulations. It is strongly recommendfJd that the chapter on Emission Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki's emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BULLETIN. SUZUKI MOTOR CORPORATION Motorcycle Service Department ©COPYRIGHT SUZUKI MOTOR CORPORATION 1990

VIEW OF LS650 RIGHT SIDE LEFT SIDE

GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND ENGINE FUEL AND LUBRICATION SYSTEM EMISSION CONTROL INFORMATION ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION

SUPPLEMENTS LS650K6 ('06 MODEL) 16 LS650K5 ('05 MODEL) 15 LS650K4 ('04 MODEL) 14 13 12 11 10 9 LS650H ('87 MODEL) LS650J ('88 MODEL) LS650S ('95 MODEL) LS650T ('96 MODEL) LS650V/W/X/Y/K1/K2/K3 ('97/'98/'99/'00/'01/'02/'03 MODELS) LS650K7 ('07 MODEL) 17 LS650K8 ('08 MODEL) 18 LS650K9 ('09 MODEL) 19

GENERAL INFORMATION CONTENTS -------~ SERIAL NUMBER LOCATIONs ............................... .. ...... .. ........ 1- 1 FUEL AND OIL RECOMMENDATIONS ............ ·························· 1- 1 BREAKING- IN PROCEDUREs ................................. .. ................. 1- 1 SPECIAL MATERIALS ···················· ······················ ···················· 1- 2 PRECAUTIONS AND GENERAL INSTRUCTIONS ··················· ···1 -4 SPEC/FICA TIONS · · · · · ·· · · · · · · · · · ·· · · · · · ·· ·· · · · · · · · · · ·· · · · · · · · ·· · · · · · ·· · · · · · · · · .. · · · · · 1- 5

1-1 GENERAL INFORMATI ON SERIAL NUMBER LOCATIONS The frame serial number or V.I.N. (Vehicle Identi- fication Number) CD is stamped on the steering head pipe. The engine serial number ® is located on the crankcase. These numbers are required especially for registering the machine and orderi ng spare parts. FUEL AND OIL RECOMMENDATIONS FUEL Use only unleaded or low-l ead type gaso li ne of at l east 85 - 95 pump octane (~method) or 89 octane or higher rated by the Research method. ENGINE OIL SU Z UK I recommends the use of SUZUKI PER- FORMA NCE 4 MOTOR O IL or an oi l which is rat ed SE or SF under the AP I (Ameri can Petro- leum Institute) classification system. The viscosity rati ng is SAE 10W/40. If an SAE 10W/40 moto r oil is not available, select an alternate according to the following cha rt. SIN G LE G RADE MULTIGRADE TEMP. . . l I • .. . .. 5W·30 FRONT FORK OIL Use fork oil # 15. BRAKE FLUID Specification and cl ass ification: WARNING : DOT 3 or DOT 4 * Since th e brake system of thi s mot orcycle is f ill ed with a glycol-based brake fluid by the ma nufacturer, do not use or mix differ- ent types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious da mage w ill result. * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake flu id left over from the previous servicing and stored for a long period. BREAKING-IN PROCEDURES During manufacture only the best possible materials are used and all mach ined parts are f inished to a very high standard but it is sti ll necessary to allow the moving parts to "B REAK-1 N" before subjecting the engine to maximum stresses. T he future perf ormance and re l iability of the engine depends on the care and restraint exercised duri ng its early li fe. The general rules are as follows. 1. Keep to this break-in throttle position. Up to 1 600 km (1 000 miles) Below 4/5 thrott le 2. After the engine has been operated for 1 600 km ( 1 000 miles) the motorcycle can be subjected to full th r ottle operation for short periods of time .

GENERAL INFORMATION 1-2 SPECIAL MATERIALS The materials listed below are needed for maintenance work on the LS650, and should be kept on hand for ready use. They supplement such standard mate ri als as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of th is manual. Material SUZUKI SUPER GREASE "A" 99000-25030 SUZUKI S'ILICONE GREASE 99000-251 00 SUZUKI MOLY PASTE 99000-25140 SUZUKI BOND No. 1207B 99104-31140 THREAD LOCK SUPER "1303" 99000-32030 Part Page • Clutch pushrod 3·38 • Oil seals 3-45 3-49 • Throttle grip • Brake pedal shaft • Gearshift lever and shaft • Speedometer cable and dust seal • Starter motor housing end 6-11 • Caliper axle 7-8 • Valve stems 3-28 • De-comp. camshaft 3-37 • Countershaft and drive- 3-41 shaft • Piston pin • Camshaft journals • Rocker arm shafts • De-comp. shaft • Mating surfaces of left and right halves of crankcase • Generator lead wire grommet 3·52 3-55 3-47 • Oil pump screw 3·37 • Starter clutch Allen bolt 3-37 • Crankcase bearing retainer 3·44 screws • Gearshift arm stopper • Generator rotor bolt • Cam sprocket bolts 3-49 3-50 3-54 Part Page • Wheel bearings 7·4, 28 • Steering stem bearings 7-21 • Pulley drum bearing 7-28 • Brake cam and pin 7-28 • Swingarm dust seals, 7-31 spacers and bearings

1 -3 GEN E RAL INFORMATIO N Material THREAD LOCK "1342" 9900(}32050 THREAD LOCK SUPER "1360" 99000-32130 SUZUKI Bond No. 1216 99104-31160 THREAD LOCK SUPER "13338" 99000-32020 Part • Engine mounting bracket bolt • Generator stator set screws • Engine oil pump mounting screws • Gearshift cam stopper bolt • Gearshift cam guide/pawl lif ter screws and nuts • Counter ba lancer bolt • Disc mounting bolts • Cylinder head cover Page 3-8 3· 36 3-47 3-48 3·48 3-50 7·4 2-4 3-55 • Muffler support stay bolt 3·7 P art Page • Throttle valve screw 4-7 • Throttle cable holder screw 4·7 • Starter motor housing screws 6-11 • Front fork damper rod bolt 7-15 • Handlebar holder bolt and 7-22 nut

1986-2009 Suzuki Boulevard S40 Service & Repair Manual

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