1986 Suzuki Savage 650 Manual

The 1986 Suzuki Savage 650 is a single-cylinder cruiser motorcycle featuring a 652cc four-stroke engine, 5-speed transmission, chain final drive, front disc brake, rear drum brake, electric start, and classic bobber styling. This manual covers safety precautions, technical specifications, maintenance procedures, troubleshooting, and operational guidelines for proper ownership and care of your motorcycle.

1. Features at a Glance 2. Safety Precautions 3. Technical Specifications 4. Controls and Instruments 5. Routine Maintenance 6. Engine Service 7. Fuel System 8. Electrical System 9. Brake System 10. Troubleshooting 11. Storage Guidelines

Features at a Glance

Key components: 652cc single-cylinder engine, 5-speed transmission, chain drive, front disc brake, rear drum brake, electric start, classic cruiser styling.

FeatureDescription
Engine Type4-stroke, air-cooled, single cylinder OHC
Displacement652cc
Transmission5-speed constant mesh
Final DriveChain
Brakes FrontHydraulic disc
Brakes RearMechanical drum
Starting SystemElectric and kick start
Fuel Capacity2.8 gallons (10.6 liters)
Seat Height27.6 inches (700mm)
Dry Weight386 lbs (175kg)

Safety Precautions

Always wear proper protective gear and inspect motorcycle before riding.

  1. Pre-ride inspection: Check tires, brakes, lights, chain tension, fluid levels.
  2. Protective gear: Always wear helmet, eye protection, gloves, jacket, and boots.
  3. Riding environment: Be aware of road conditions, weather, and traffic.
  4. Loading limits: Do not exceed maximum weight capacity of 400 lbs.

WARNING! Motorcycle operation requires skill and attention. Never operate under influence of alcohol or drugs.

Technical Specifications

Controls and Instruments

Handlebar controls: Right side - front brake lever, engine kill switch, start button. Left side - clutch lever, turn signals, horn, headlight dimmer.

Instrument Cluster: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators, oil pressure warning light.

Operation: Turn ignition key to ON position, ensure transmission in neutral (green light), pull clutch lever, press start button. Use choke when cold starting.

Routine Maintenance

Regular maintenance ensures optimal performance and longevity.

  1. Engine oil change: Every 3,000 miles or 6 months
  2. Oil filter replacement: Every other oil change
  3. Air filter cleaning: Every 6,000 miles
  4. Chain adjustment: Every 500 miles
  5. Tire pressure check: Before each ride
  6. Brake inspection: Monthly
  7. Spark plug replacement: Every 7,500 miles

Tip: Keep maintenance records for reference and resale value.

Engine Service

Engine maintenance procedures and specifications.

  1. Oil capacity: 2.0 liters with filter change
  2. Oil type: SAE 10W-40 motorcycle oil
  3. Valve clearance: Intake 0.05-0.09 mm, Exhaust 0.08-0.12 mm
  4. Compression pressure: 142-171 psi at 400 rpm
  5. Idle speed: 1,100 ± 100 rpm
  6. Spark plug: NGK DR8ES or equivalent, gap 0.7-0.8 mm

WARNING! Engine components become extremely hot during operation. Allow to cool before servicing.

Fuel System

Carburetor maintenance and fuel system specifications.

  1. Fuel type: Regular unleaded gasoline (87 octane or higher)
  2. Carburetor: Mikuni BS34SS, main jet #135, pilot jet #42.5
  3. Float level: 24.5 ± 1.0 mm
  4. Fuel filter: Replace every 12,000 miles
  5. Fuel line inspection: Check for cracks and leaks annually

CAUTION! Gasoline is highly flammable. Work in well-ventilated area away from ignition sources.

Electrical System

Battery, charging system, and electrical components.

Battery maintenance: Check electrolyte level monthly, keep terminals clean and tight.

Brake System

Front disc brake and rear drum brake maintenance.

  1. Front brake fluid: DOT 4, check level monthly
  2. Front brake pads: Replace when worn to 1mm thickness
  3. Rear brake shoes: Replace when worn to minimum thickness
  4. Brake adjustment: Rear brake pedal free play 20-30mm
  5. Brake bleeding: When fluid appears dark or contaminated

WARNING! Brakes are critical safety components. Inspect regularly and replace worn parts immediately.

Troubleshooting

SymptomPossible CauseCorrective Action
Engine won't startFuel, spark, or compression issueCheck fuel level, spark plug, battery charge, choke operation
Poor performanceClogged air filter, dirty carburetorClean/replace air filter, clean carburetor jets
Electrical failureBattery, fuse, or wiringCheck battery voltage, inspect fuses, test charging system
Brake problemsWorn pads, air in linesInspect brake components, bleed hydraulic system
Chain noiseImproper tension or lubricationAdjust chain slack to 20-30mm, lubricate regularly

Professional Service: Complex repairs should be performed by qualified Suzuki technician.

Storage Guidelines

Proper storage procedures for extended periods of non-use.

  1. Fuel system: Add fuel stabilizer and run engine for 5 minutes
  2. Battery: Remove and store with trickle charger
  3. Tires: Inflate to maximum pressure and elevate off ground
  4. Exterior: Clean thoroughly and apply protective coating
  5. Cover: Use breathable motorcycle cover in dry location

Storage Duration: Up to 6 months with proper preparation.

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