Good idea to start a specific topic about this dilemma, that we'll all be in for, sooner or later. As I live in Europe, like some other members, I can give you an opinion that is most common (?) over here.
We don't think it has anything to do with the oil. We seem to have agreed, that synthetic oils are no good for the Savage, since the clutch starts to slip. This does not happen with mineral oil. In my bike I use Quaker State 10 w 40 mineral oil for mc, and I change every 3k kilometer. (Always change the filter when you change the oil, what good is it to have new oil going through a dirty filter?) It seems, from postings I've read during the years, that the old four-gear models did not have this problem. So I think it simply is that Suzuki is buying these parts from another company, and the quality is less good. Pity it seems to be impossible to get in touch with anybody in the company directly !!

From what I recall, the "old" Savages did run well without any camchain rattle to about 50k kilometers. I have a chain in my workshop, that is run 60k kms. It is just slightly longer, you can barely see it is worn a bit, so it sure was not bad quality. The chap who had it changed it at 60k kms when it started to rattle. No problems at all before that.
To cope with this "new" problem, brains are working to develop a modified chaintensioner, that will not "pop out".
There are some good pictures at the German site
http://www.ls-650.de/community/forum/YaBB.pl?num=1168393837 and at
http://www.ls-650.de/Thumperbike/html/body_steuerkettenspanner.htmlhere is a good picture of Norbert's invention :
http://www.ls-650.de/Thumperbike/html/body_steuerkettenspanner_tbks3.htmlSoon we will have reports coming in about how well it works.... 8)