For someone thats never been around one what are the common probs this motor have ?

I see one is the cam chain tensioner, when I rebuild the motor I will put in a new chain but what can be done about the tensioner ?

I see the clutch pack is this same as the DR500 or at least the same part number on Denis Kerk...

for the tensioner, do a search for verslavy. it was a mod done to lengthen the tensioner, and extend chain use. the biggest issue is the white spacer, do a search and you will find alot of threads about it. both are in the tech section as well.

The worst thing that can happen to your motor is for the plunger to fall out of the housing allowing the chain to flop about and eventually let your valves go out of time with the piston.

I put a slot in the housing and pin the plunger to it so it can't fall out.

Yeah I just ran across that as I'm reading alot of the back threads, very cool job man !

Whats the best way to bump the comp up on this motor ? Milled head and find a shorter cam chain ?

I like the idea of the stock pistom being completely flat top but I'd realy like to bump up the comp some along with a slightly bigger dia piston.

Yeah I dont want to do much at all to the intake side other than correct lean jetting and a better filter, I will want to smooth out the exhaust ports and raise the compression "to a point" but not so much as to worry about over heating and needing 90+ gas.

I may end up leaving the low comp and just get a bigger piston, it has a 94mm piston now so let me find out what the DR650 has.
I'll put on a diff exhaust but want it a dull thump thump sound but thats after I see what needs to be done to trike it out..

I mainly need to convert it to chain drive and a good rebuild.... IF I can ever get it, it will cost like $300 round trip for my buddy to bring it !

mikestrikes wrote on 09/21/08 at 17:49:46:
The trouble with the Savage is that it was built down to 30hp.

You can get a leeetle bit more power here and there, but to get significant gains you need to change just about everything – or somewhere along the line, something will be restricting the other mods you do.

-  The standard exhaust header has a tiny diameter for a 650 cylinder, so that needs to be changed.

-      Compression is very low.  To raise it a lot you need a custom high-compression domed piston.  More economically and practically, have 1mm/.040” shaved off the top of the barrel.  That, along with the latest spec Suzuki dealer head gasket (a little thinner than original) will take compression from 8.5:1 to about 9.2:1.  That amount of extra slack in the cam chain is manageable.  Better still, re-dowel your cam gear but only if you have the right facilities(I’ve done it, photos are on here somewhere).

-      Porting helps a lot.  The inlet side is pretty good standard, just clean up the edges, while the exhaust port is awful – deliberate restriction designed by Suzuki.  The valve seats are stepped on the underside, so blend those in too.

-      The cam is part of the factory power restriction, but Lancer’s cams are superb and bring loads of midrange.

-      The carb is designed for economy and emissions. A VM carb (again from Lancer) will work wonders.

-      Air filter – original is poor, slot-in K%N doesn’t have much area because of the airbox design.  Get a free flow cone filter (again, Lancer!).

All of the above should give you more like 50hp and a new project – upgrading the clutch!

A guy I talked to here said he has taken it up to a 780cc.