Question about 1986 Suzuki LS 650 Savage

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Metal in the engine from a timing chain

Just bought a Savage 650, from my friend who says there's metal in the engine from a timing chain that broke and needs to be fixed. 'm a handy guy (wood worker) but never worked on a motorcycle engine before. Any idea how start down the road to do this? Is there a service manual that i can buy that might help me take it apart clean it out and put it back together step by step?

Any help would be GREATLY appreciated!

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Yes, you will need a manual and they are available; The 2nd of the links below, threads to a free downloadable manual (you just have to register and put up with advert's mailed to you whilst in the free 12 day trial period)
You can order the appropriate Service Manual from a Suzuki dealer at a high cost or seek Clymer or Haynes workshop manuals from bike accessories stores. These generally cover several years and sizes for a specific model and can be very confusing to the novice.
This fixya site has many manual ads.
Alternatively, ebay often has cheap manuals, as do some bike recyclers or wreckers, generally in a big box near sales counter.
For a total strip down you may require "Special Tools" to accomplish this, (at exhorbitant cost from Suzuki) generally a $25 rotor puller and a GOOD toolkit will get you there.
The first site below has exploded views of the motorcycle so you can at least familiarise yourself with the parts of the job ahead. You may also see what type of tools you may require and the gaskets, clips, spacers etc. you will encounter. And the piece of metal you're looking for!
Nearly all work on the motor from barrel, heads and pistons and behind sidecovers of crankcases can be done with motor still in frame.
With a bit of luck, if you drain the engine oil and remove the Right side cover (clutch cover approx 12 bolts) you will see the lower camchain sprocket. The camchain runs OUTSIDE inner crankcase halves and broken piece may lie at bottom of housing. Drain oil over a magnet in a pan.
Goodluck, and Cheers.

Posted on May 13, 2010


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Posted on Jan 02, 2017


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