This 40 cubic inch engine with 4 valves and overhead cam with 94mm bore and stroke should be able to be easily modified to deliver 40hp. That's just 1hp per cubic inch. Most automobile engines today do better than this. My Honda gets about 1.78hp/cu-in, peak. The Chevy Corvette gets over 1hp/cu-in with 2-valves per cylinder and pushrod operated valves!
What the heck limits the performance of this 650 engine? We have all modified the exhaust with dramatic improvements. The exhaust has no sharp bends, has plenty of pipe size. We have rejetted to throw more fuel at it. We still can't get better than 35hp out of this thing. We ought to be able to get about 50hp. What's the problem?
Is it possible the valves are to small? Is it possible the stock carburetor isn't very good?
Is there a better carburetor out there? Would fuel injection help?
I suspect the valves are too small and the the flow passages in the cylinder head might have to be modified for better flow. That means a whole
new cylinder head. Well, I don't think a performance cylinder head exists. While we're at it why don't we get rid of those silly forked rocker arms and go with 2 overhead cams? Sounds like a whole new engine project.
Suzuki, I suspect wants to milk the S40 cash cow and spend there development money on the crotch rockets. :'(