I'd do a compression test prior to concluding that a rebuild is in order.

If you just want it running right, once you get the new muffler, spark plug and air filter, spend a half day with a few jets and get the carburetor dialed-in just right. That alone can make the difference between it being a garage queen or a rider.

Since it's a extra/play bike, maybe it's time to make it into something else?

Yeah, if you didn't do Verslagen's cam chain tensionser, I would put that on top of the list.  

Best regards,

The clutch is first on the list...

Justin, this guy is just knee jerk reacting to what he perceives to be the problem.   Someone could simply tell him to go to the Tech section index

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1181745927

and READ the section on clutch

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1270678838/0

but this one has already ordered his gasket kits and Barnett clutch pack so he isn't going to take the time to read anything and realize it is all wasted money and that his issues may very well have other sources.  

The odds of getting him to stop, do a compression test and report what he sees are also nil, so he will never realize his engine isn't worn out either.   I can remember being at that age ....  and I did pretty much the same sort of knee jerk stuff.

However, we do try to guide them to the water and we actually do try to keep them from drinking the sand instead.

Both Gary in NJ and yourself have suggested he do things logically since the odds of his engine being worn out are practically nil and the odds of the pipe and the jetting being his real issues are really very high.

But he isn't really listening, so you did what you could do.


=========================


In reading his last 25 posts I find that he is young, he LIKES to work on his bikes and now that this is his spare bike he's a gonna tear it to pieces anyway because he wants to.

and I love one of his comments from an earlier question series about won't start ......


I dunno man. But how about some help instead?


OK, real help for you where you are right now.

For this one, simply remind him that the biggest reasonable performance boost come from the hot cam mated with the big high compression piston, but when you are all done you will have spent a lot of money to not quite get the performance level that comes stock from a lot of two cylinder bikes of various brand names.   A questionable benefit for a lot of money, in other words.   And your gas mileage will likely suck, BTW ..... bad.   (extra gas makes extra power after all, and those hot cams are not efficient cams)

To go beyond that, go nitrous.  Nitrous is the cheapest way to get a really large performance gain without killing your gas mileage otherwise ---  but it turns the bike into a short lived hand grenade if you get excessive.   Then he really will need the Barnett clutch pack to handle the increase in hp when he hits his button.

Neat thing is the piston/compression ratio he has now is the right one for nitrous work and he can go do nitrous for a bit and impress all his buddies and THEN tear his engine down for a real reason.

And if the clutch springs are stouter, get ready for blowing up the throwout, as it is just sintered metal.. I shimmed my springs, less than 1/8th",and mine broke.  Others have broken, everything stock. If you mess around with the springs, better get a throwout machined from one piece.

You're in the right place for getting THE best advice on how to get the best performance possible for the least money and time invested.The degree to go to HotRodding these things has been explored. If you're just determined to go digging into it, then everyone I know here will be waiting to see how it goes. I'd start with just seeing how good it Will run before you start fixing it.