Sorry if I have posted this before, but I could not find anything suggesting it through a google-search.

Back in February 1991, MOTORRAD magazine printed their 25k miles/40k km long term report. It took them 4 (!) years to reach this milestone after "rider neglect" caused the first Savage (only called LS650 in Europe. Or LS 650, as the Germans would write it) to end up destructed after 75% of the target distance was reached.

So what did they learn?

First, I must inform that this engine had power reduced from 31 to 27 hp in order to enter a more favorable insurance group. This should not affect the results much.

When the bike was dismantled and the engine stripped, it became evident that the engine had suffered somewhat.
- Camshaft lobes showed signs of pitting. Importer's advice to prevent this: Use low rpm when the engine is cold/just started to allow time for oil to fully reach and lubricate the top end, and adjust the valves to the biggest clearance of the permissible range,

- Pitting on the 4th gear pairing. Importer's advice to prevent this: Use third more and avoid big loads in 4th gear. Gears should always be replaced in pairs when pitting is visible.

- Cam chain guide on the tensioner side dry, brittle and split/cracked. Importer's advice to prevent this: None. Must be replaced to prevent engine damage.

- Damaged splines on the output shaft and front pulley. Importer's advice to prevent this: Maintenance failure from the dealer, as all nuts and bolts should be checked at every service. Backed off retaining nut tension likely cause of the wear. Both shaft and pulley must be replaced.

- Ripped final drive belt. Importer's advice to prevent this: Keep the tension correct and the pully retaining nut tight. The peak loads going into the chain due to the loose fit of the front pulley likely primary cause of the final drive belt ripping.

- Worn out shock absorbers. Importer's advice to prevent this: Typical wear for the mileage. Must be replaced for safe handling to be restored.

- Lots of corrosion all over the bike. Importer's advice to prevent this: Better cleaning and waxing, avoid riding on salted roads.

Performance new/end of test:
0-62 mph: 8.6s / 9.1s
SS 1/4mi: 16.5s / 16.8s
Top speed, solo: 80 mph / 78 mph
Top speed, 2-up; 80 mph / 76 mph
Avg fuel consumption: 42.8 mpg
Avg oil consumtion: 0.35 quart per 1000 miles

What happened between 0 and 25k miles:
Serviced every 3700 mi up until 18,500 miles, no record of the expected 22k service
4400 mi.: new front brake pads and new front tire
8000 mi.: new rear tire
8700 mi.: carb cleaned
10600 mi.: new rear tire, new front brake pads
15000 mi.: number plate holder repaired and reinforced
16300 mi.: head gasket replaced, camshaft replaced with good used one
18100 mi.: new front brake pads, new rear tire
19300 mi.: new front tire
21400 mi.: new steering stem bearings
23700 mi.: new steering lock, new exhaust outlet gasket, new front brake pads
24300 mi.: new front tire
25000 mi.: new final drive belt

There were also a couple of clutch and speedo cable replacements, plus two front brake switches.

Needed at the end of the test:
Reworking the valve seats and lapping the valves
Replacing the valve stem seals
Replacing one cam chain guide
Replacing output shaft
Replacing front pulley
Replacing rear wheel rubber dampers
Replacing the rear shocks

Man, that is bleak.  This is the first time I have seen anyone else mention gear pitting.  I suspect these guys were running the guts out of the thing (like me).  I have never seen anyone else complain of gear pitting.  I thought I was the only one.

Unfortunately for me, these guys were testing a de-tuned 4-speed.  I was hoping my 4-speed gear set would be better than the 5-speed in terms of longevity.  So far, the 4-speed gear set with additional spray lubrication is holding up on mine.  I routinely inspect with endoscope and no pits yet.

I'm glad I souped up my oil system.

Comparatively speaking, it's a SAVAGE BEAST of a bike!

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This seems to be pretty average for miles vs. time.
I doubt many Savage 650s average 12k miles annually.

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A yearly avg would have been more telling.
Why? To see if consumption increased? It was fairly constant over the duration. The numbers describe the average for the whole test.


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No rings, no piston? obviously oil consumption wasn't a concern to them.
Piston and rings were OK, no need to replace. Oil consumption is quite normal for an engine living a lot under WOT, I would say. The GPz1100 used more oil per 1000 miles than the RZ350 two-stroke.

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No head plug? and were all of the maintenance items preformed at the recommended times as noted in the owners manual?
Head plug? To seal the end of the camshaft? Dunno. The rest, like oil and filter and spark plugs etc I could not be arsed to mention as they are normal stuff that must/should be replaced as a matter of normal maintenance.

They did the initial performance tests after 200 miles. As to how to break in engines, there are about as many ideas as there are owners. That neither cylinder or piston showed much in the way of wear suggest to me that the engine was not harmed. I reckon high rpm and the resulting higher temperatures that makes the oil thinner has a lot to do with the consumption. It is still only about 20% of what engine makers consider acceptable.

As you mention in the end of your reply, how you typically ride is what matter the most. Load on engine parts increase with rpm squared, so keeping revs below 2/3 of maximum will do a ton of good for longevity.