1986 Suzuki Savage Manual

The 1986 Suzuki Savage is a 650cc single-cylinder cruiser motorcycle known for its simple design, reliable performance, and easy maintenance. This manual covers safety precautions, technical specifications, routine maintenance procedures, troubleshooting guides, and repair instructions for the LS650 model. Below are key sections for operation, maintenance, and service.

Features and Specifications

Key components: 652cc four-stroke single-cylinder engine, 5-speed transmission, chain final drive, front disc brake, rear drum brake.

Safety Precautions

Always wear proper protective gear and follow safe riding practices.

1. Pre-ride inspection: Check tires, brakes, lights, and fluid levels before each ride.
2. Protective gear: Always wear helmet, eye protection, gloves, and protective clothing.
3. Load limits: Do not exceed maximum weight capacity of 397 lbs (180 kg).
4. Maintenance: Regular service ensures safe operation.

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

Operation and Controls

Familiarize yourself with all controls before riding.

1. Starting procedure: Turn fuel valve ON, ignition ON, pull choke, start engine.
2. Shifting: Use clutch lever and gear shift pedal for smooth gear changes.
3. Braking: Apply both front and rear brakes progressively.
4. Lighting: Headlight, taillight, and turn signals operation.

CAUTION! Practice in safe area before riding in traffic. Always use turn signals.

Routine Maintenance

• Oil Change: Every 3,000 miles or 6 months
• Oil Filter: Replace with every oil change
• Air Filter: Clean every 6,000 miles, replace as needed
• Spark Plug: Check/replace every 7,500 miles
• Chain Adjustment: Check every 500 miles
• Brake Fluid: Check level monthly, replace every 2 years
• Tire Pressure: Check weekly: Front 28 psi, Rear 32 psi
• Valve Clearance: Check every 7,500 miles

Engine Service

Basic engine maintenance procedures for the 652cc single-cylinder engine.

Oil Change: Drain plug located bottom of crankcase, capacity 2.5 quarts with filter change. Use SAE 10W-40 motorcycle oil.

Valve Adjustment: Intake 0.03-0.07mm, Exhaust 0.08-0.12mm. Remove valve cover and adjust with feeler gauge.

Spark Plug: NGK DR8ES or equivalent, gap 0.7-0.8mm. Replace if electrodes are worn or damaged.

Fuel System

Mikuni BS34SS carburetor maintenance and adjustment.

1. Fuel valve: Turn OFF when parked for extended periods.
2. Carburetor adjustment: Pilot screw 1.5 turns out from lightly seated.
3. Fuel filter: Clean sediment bowl periodically.
4. Idle speed: Adjust to 1,200 ± 100 rpm when engine is warm.

Tip: Use fresh gasoline and add fuel stabilizer if storing more than 30 days.

Electrical System

Battery, charging system, and lighting maintenance.

1. Battery: 12V 10Ah, check electrolyte level monthly.
2. Charging system: Output 14V at 5,000 rpm.
3. Fuses: Main fuse 20A, spare fuses in fuse box.
4. Bulb replacement: Headlight 60/55W, turn signals 21W.

WARNING! Disconnect battery before electrical work. Avoid short circuits.

Brake System

Front disc and rear drum brake maintenance.

Front Brake: Check pad thickness, replace if less than 1mm. Brake fluid DOT 4.

Rear Brake: Adjust free play at brake pedal. Replace shoes if worn.

Brake bleeding: Required when air enters system or fluid is contaminated.

Troubleshooting

Service Intervals: Follow maintenance schedule in owner's manual.

Support: Contact authorized Suzuki dealer for technical assistance.