I have owned a Suzuki Savage for about 6 years; total mileage about 16K.  It was my primary  transportation until about three years ago but I switched to a Sportster. The Savage is ridden some by me but mostly by my son. It is maintained religiously. However, it has proven to be costly to keep it dependable. It is now back inthe shop for more engine work. This will be about the third time for engine work, which will reach about $1400 if the current worst case scenario proves true. Why are these bikes so undependable and prone to mechanical problems?  
I would understand if it were run hard but it is ridden at no more than highway speeds. Rarely does it ever venture onto an Interstate Hwy.
I've asked the mechanics to install a modified cam chain adjuster which a friend directed me to from her experience, the link may have even come from this site.

I have highly modified mine.... beefed up the carb, straight pipes, timing, new frame (rigid) and the only problems I have had were oil leaks, which are the common ones and easy to fix.

As already asked, what are the problems? That could better answer your question. These bikes have proven to be highly reliable.

Well then... the Cam and valves can and are contributed to the Cam Chain. There are several, lengthy threads about this. What exactly happened with the piston? Something specific would have to cause an issue with that... unless its related to the valve problems. I valve slapping the piston can sure do some damage.

I would recommend you pick up or download the manual from here. With some simple tools, and a little know how (manual) you can fix just about anything on this bike in your driveway/garage. You can save thousands in repair costs that way. Additionally you get the satisfaction of knowing you fixed the problem. The more intimate you are with your bike, the better she will treat you. It helps to diagnose problems too.

Thanks for the words of hope. I have ridden about 30 years and the Savage is the first cycle that has been such an unpleasant experience; the others were quite dependable and with one exception, were all used. With the exception of the Sportster, I have generally preferred 650s. They always had enough power for me and I am not small. The primary reason for moving to the Sportster was that I use a motorcycle as daily transportation and wanted something dependable. There is an independent Harley mechanic that has a very good reputation -- quality of work and price. Appears I may need to become the mechanic on the Suzuki if I hope to enjoy more carefree riding.

Just a few tid-bits gleaned from a visit to the local Suzuki dealership / service area:
The mechanics' nickname for the Savage is "Salvage."
The service manager was adamant that a top end rebuild is almost essential every 12K or so. Needless to say, the bike is not there any longer.
The 650 Thumpers have no longevity.

I must admit I found all that interesting since I had ridden a 250 single cylinder Yamaha over 16K without any significant issues and it was operated at more demanding levels than the Savage.

Just thought some of you might find the above remarks interesting; I did.

Interesting indeed.

What I also found interesting was 2 yrs ago when I was looking for a used 800cc sportster, I never found even 1 over 5-6 yrs old that did not advertise a "rebuilt" or "new" engine, and as I remember, not 1 of those had over 12,000 miles on the odometer. Interesting indeed.

I am in agreement with the guys responses
here. I would check into getting a manual
as well as listening to the guys advice here.
They can walk you thru whatever you need to
do. You won't find any better advice or help
about this bike than you will here.
Check out the search and make sure you
change the default, it is set for 1 week. You
can change it for up to 1 year..
Good luck and we forgive you for saying
this bike is not as dependable as we know it to be..kim

Top end rebuild at 12 to 15 k? Total nonsense. Whats he think this thing is? A 2 stroke dirt bike?

Barring some mechanical failure, like a valve head falling off & wrecking the piston/head/cylinder, this engine will run to 15 or so thousand miles, then its likely gonna need some cam chain attention, replace it, slap a Verslavy in it,or both,, ,, whatever.

Book says retorque head bolts at 6,000 miles,, mine has 20K on it, never had a head bolt touched, no problems.


Okay,so, could drop a valve, not common, but not unheard of, either.
Then there the cam/paddle that pushes the clutch rod. That blasted thing breaks sometimes. So far, I dont think anyone has suffered catastrophic loss over it. One of my cam chain guides broke when that thing went, but it was the one that can be replaced without pulling the head.

I cant imagine being able to get the work done in a shop that you can do yourself. Those guys dont have time to get really knowledgeable about all the ins & outs on such a low buck machine.

Low Idle RPM= Death.
Slow, but certain. The oil pressure is low. The cam spins in the head, no bearing inserts of any kind, keep that engine spinning at no less than 1,000 rpm.

The $$$ spent on tools will be saved multiple times by not hiring someone else. AND, youll have the tools for the next mechanical hassle you encounter. Your son can learn right along side you. The people here can & will support your efforts. A maintenance manual & some tools,,, heck, youll be on your way.

Well, as Soon as we figure out that intermittent noise & power surging thing,,