1986 Suzuki LS 650 Savage Troubleshooting, Repair, Maintenance & Tune…

22 Jan 2015 | Author: | Comments Off on 1986 Suzuki LS 650 Savage Troubleshooting, Repair, Maintenance & Tune…
Suzuki LS 650

new battery no start no lights

I have a 1986 suzuki 650 savage the carb seems to have a problem. It started flooding gas coming out the over flow. I took it off and took the float cover off and replaced the needle needle set and float. Put it back on ran fine for about five minutes than gas started coming out the overflow again. took it to the suzuki dealer they ajusted the float and I took it home same thing

Yea these carbs can be a real pain sometimes to get right. First thing you need to do is varify the float seat is working and totally stopping all fuel flow. and all the jets, main, pilot and choke circuit are absolutely clean. Bench test the float needle valve by connecting a hose to the carb fuel line nipple and letting gas gravity feed as it would in a run position. if it tests ok, remount it on the bike.

i’m guessing you have a vacuum petcock on this year model? If you do, it needs to be inspected.

how much oil does it take?

i got a buddie with an 86 suzuki LS650 savage. he is saying the repair manual is telling hin to ground the altenator to a groove and that the rocker arms should have free play. but her isnt getting freeplay

The motor must be on TDC when checking valve clearance.

The motor must also be cold, not warm or hot.

IF you don’t know where TDC is then pull off the cap so you can see the rotor/flywheel turning and it has marks on it. turn it until you see the T mark is lined up. check clearance.

If no clearance turn the motor one complete revolution until you see the T mark is lined up again, now check the clearance. if you get clearance on TDC this is the compression stroke. this is where you want the motor when checking/adjusting the valves clearance.

You’d have to pull the rocker cover off and inspect the timing chain.

To inspect for a stuck valve, watch the valves as you turn the motor over, and see if they are moving at all.(inspect that they are moving throught the cap you removed to check adjustment).

As for the alternator, you can ground it anywhere on the frame or motor, because the frame/motor is grounded to the battery.

metal in the engine from a timing chain Just bought a Savage 650, from my friend who says there’s metal in the engine from a timing chain that broke and needs to be fixed. ‘m a handy guy (wood worker) but never worked on a motorcycle engine before. Any idea how start down the road to do this? Is there a service manual that i can buy that might help me take it apart clean it out and put it back together step by step?

Any help would be GREATLY appreciated! Thanks!

Suzuki LS 650
Suzuki LS 650

Yes, you will need a manual and they are available; The 2nd of the links below, threads to a free downloadable manual (you just have to register and put up with advert’s mailed to you whilst in the free 12 day trial period)

You can order the appropriate Service Manual from a Suzuki dealer at a high cost or seek Clymer or Haynes workshop manuals from bike accessories stores. These generally cover several years and sizes for a specific model and can be very confusing to the novice.

This fixya site has many manual ads.

Alternatively, ebay often has cheap manuals, as do some bike recyclers or wreckers, generally in a big box near sales counter.

For a total strip down you may require Special Tools to accomplish this, (at exhorbitant cost from Suzuki) generally a $25 rotor puller and a GOOD toolkit will get you there.


The first site below has exploded views of the motorcycle so you can at least familiarise yourself with the parts of the job ahead. You may also see what type of tools you may require and the gaskets, clips, spacers etc. you will encounter. And the piece of metal you’re looking for!

Nearly all work on the motor from barrel, heads and pistons and behind sidecovers of crankcases can be done with motor still in frame.

With a bit of luck, if you drain the engine oil and remove the Right side cover (clutch cover approx 12 bolts) you will see the lower camchain sprocket. The camchain runs OUTSIDE inner crankcase halves and broken piece may lie at bottom of housing. Drain oil over a magnet in a pan.

Suzuki LS 650
Suzuki LS 650
Suzuki LS 650
Suzuki LS 650
Suzuki LS 650
Suzuki LS 650
Suzuki LS 650
Suzuki LS 650
Suzuki LS 650

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