Without any detailed research, I'll throw out the first one.

The speedo changed before '92 I believe, but it is interchangeable.

Just to get all the info into the same topic, this is a repost of 2004 details.  The changes made between 2003 and 2004 were very minor and not mechanical.  Here is the list of what was new for 2004 in "Suzuki marketing speak":

FEATURE LIST: Suzuki 2004 Savage® 650 (LS650P)

New

• New rear view mirrors for more attractive appearance - similar to VL800 Volusia  
• Standard 4-way emergency flasher and and high-beam passing switch  
• Multi-reflector turn signals for improved appearance

A few random things I remember reading that need to be nailed down:

• At some point, they started painting the engine black
• Have seen people discussing whether a particular bolt requires 14 mm or 17 mm wrench...
• 4 speed to 5 speed when?

I seem to remember reading somewhere that the plug had been changed in later years which helped with the plug leak issue but am not sure.  Anyone know?

About the tranny...

> 4 speed to 5 speed when?

The 86, 87 and 88 bikes were 4-speed.  The bike was dropped from the USA line after 88 to reappear again in (I think) 96 with a 5-speed.  Btw, the 80's bikes had a louder pipe, and my 88 'felt' faster than my 96 and S40 (although top speed seems about the same).  The 4-speed was more fun to ride, too, because of the gear spacing and richer jetting--the engine seemed to have more roll-on throttle response (more torque) at low revs.  The 5-speed allowed Suzuki engineers to lower emissions output and keep the EPA happy.  By adding another gear and shortening up the ratios between 1st and 5th, the engine is kept on the boil more which helps keep the revs out of the low RPM polluting zone.  Revs create heat in the top end which improves combustion efficiency.

Kropatchek wrote on 12/31/69 at 16:00:08:


Yep, I still used a small amount of silicone rubber on mine.  You can see it in the photo in the other topic.

Quote:




I think I know which one this is, Susan.  I just did my first oil and filter change on my 98 Savage yesterday and found the drain plug was a 14mm instead of the 17mm that both the owner's manual and the Clymer's claimed it should have been.  I wasn't sure if that was a design change or if the previous owner made a substitution though.

Another difference:
The brake reservoir on the "pulled-back"and "straight" handle bar are different.

The pulled-back handle bar has the connection on the side , while the other one has the connection on the front.

Greetz
kropatchek