Demystifying the Tiny Part That Kills Suzuki Savage Engines 

It makes me really happy to hear that you found this video useful! Good luck with your clutch replacement! ✌️

@@HeavyMetalParkingSpot i did same= shook that wheel lolollol.. made sure pin was in / then changed oil/ filter / 5/8 on timeing ajuster.. maybe 1 yr.. i try do mod.. fix dat .! thinks good till 3/4 inch stick out! ?

It was indeed! That's what got me to go back in there and have a look. 🙏 Yeah, that could have ended up really badly, good thing I barely rode the bike before having this and the cam chain checked out.

That's an unwanted find! 😅 Measuring the oil pressure is a great peace of mind!

Wow! Great that you managed to replace the pin before it did any damage and pretty amazing that you managed to find the original one. 😅 Enjoy your Savage, they are really a blast to ride, and thanks for your comment! ✌️

That's true and yet another reason to really make sure the pump is running. Thank you for adding what I failed to mention in the video. ✌️

I agree. It seems like it’s pretty rare to have problems with this pin. But it’s not unheard of, and the information about it is scattered all over and can be somewhat hard to grasp. This is just an attempt to fix that.

The Suzuki Savage/S40 isn't the only bike with a defective cam chain tensioner. The Kawasaki Vulcan 750 has two of them. New ones tend to last around 10,000 miles before they fail. The problem is caused by the tensioner housing being made of soft aluminum, And the threaded plunger being made of hardened steel. In order for the plunger to advance as the chain wears, it must have a loose fit in the tensioner body. When the engine is running, cam chains tend to slap around quite a bit, which causes the threads on the steel plunger to destroy the soft aluminum threads in the tensioned housing, and the tensioner becomes worthless. Fortunately an aftermarket company came up with an all steel manual adjustable tensioner that solved the problem. I used to own a Suzuki Savage many years ago. I actually loved it. It was a small light bike that could still keep up with freeway speeds. It also looks great, at least to me. I do kind of wish they had put the DR650 motor in it, it would have been bulletproof. The reason I got rid of mine was not because of the engine though. I had four flat tires in one year, one of them left me stranded 250 miles from home for three days, and cost me nearly $1000. That was my last bike with tube type tires.

Hell yeah! 🤘

I think it’s hardened. I highly doubt it would snap off. But it would be great if anyone who knew more would chime in.

Realized now that maybe you were asking about the pin I made? It was soft and not something I would actually use, I would be scared of it snapping.

@@HeavyMetalParkingSpot Its just driving the pump, it won't be under much load, even if it was just made of mild steel it would be fine, having said that it will be made of something better, its just the way the Japs do this sort of stuff, Its probably case hardened.

Thanks for the insight! ✌️

Thank you, glad you enjoyed it!

Every now and then you have to get lucky, right? 🍀😀 Nice to hear that you are enjoying your Savage!

So very true! Don’t even bother looking for it, just order a new one. 😂

I don't think anyone should stay away from engines, it's great fun and you learn a lot. But I do agree with the fact that it's important to pay attention. If you pull the clutch basket and manage to missplace the pin, I don't think it’s super obvious where it goes, and that's why I made this video. I hope you didn't feel like I wasted your time just stating the obvious, it makes me glad that you still thought the video was good. Take care! ✌️

I agree! Thanks for watching! ✌️

Haha, please tell me more about that!

Thanks! ✌️

Right?! This little thing is 6x6 millimetres! It could easily be misstaken for an off-cut or something if found on the garage floor. I bet lots of people have found themselves missing important parts like this one when reassembling.

@@HeavyMetalParkingSpot lol it's one of those 10mm socket phenomenon.. you knew it was there but where did it go .. I had a similar issue about a month ago rebuilding a set of carbs on a kwak zzr1100 . 1 moment the float pin was in my hand a slight fumble and into the enth dimension it went ... 2 weeks to wait for new one .. bugger lol

@@garyyorke1080 Haha, exactly like that! That is so frustrating! Isn't that always the case with these small parts? When you need them, nobody has them in stock and you have to wait forever to get them.

@@HeavyMetalParkingSpot just came across the Dan gurney alligator bikes have a Google and a laugh .. a possible project

@@garyyorke1080 Haha, yeah, that bike looks...hm...special! 😂 I will add it, to the bottom, of my possible projects list. 😉

Thank you so much! That sounds like an awesome project! Have you been able to get your hands on a wiring diagram?

@@HeavyMetalParkingSpot yes got book + china no speek english but read his hands lol . wooohoooo it all worked till i found hole in piston and solid locked tranny ! now i bought $1200 .. boulavard s40.. .. its doing weird - while running it only goes down to 2nd/ no first or neutral till shut off and rock it.. ugh.. ! soon i loosen back wheel belt and get to that hidden bolt on the shifter mechanism.... ive nvr done this/ scared i loose a spring lol !!!!

@@chrisstokley7687 When putting the side cover back on it's important to hold the gear lever in the correct position, that might be your issue? I hope you get it sorted!

Thank you my friend! Just trying to help my fellow Savage riders out! ✌️🤘

Unfortunately I have to agree. Can’t believe these bikes have been around for so long and this hasn’t been fixed.

Watching videos of ugly bikes on RU-vid seem like an awful waste of time. There are tons of videos on here of different bikes, I'm sure you will be able to find one featuring a bike you think is beautiful. If you do, make sure to leave a comment letting them know you liked their bike, and make sure to forward the video to me, because I love watching beautiful bikes. Have a nice day! ✌️