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General Category >> Rubber Side Down! >> New Savage S40 Problems Need Advice
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Message started by VladzeImpaler on 07/06/25 at 13:30:49

Title: New Savage S40 Problems Need Advice
Post by VladzeImpaler on 07/06/25 at 13:30:49

Newbie on the forum. So I acquired an ’05 S40 Savage 28k bought used from a dealer (dude says he'll never do that again lol). According to him, this thing was reliable up to this year, started stalling, got progressively worse, now won’t stay started if it starts at all. Thus have I rec'd it.

Here is what I have done:

New Raptor petcock
Carb sent in and cleaned rejetted by Carb Shack, rechecked float, jets, etc. Even after, I checked the float etc.
New spark, air filter, oil etc.
New breather hose to airbox
New smaller hoses (fuel, vaccuum, etc.)
Tank - complete cleanout and refill new petrol
New large boots to carb (to engine/airbox)
Recalibrated [valve?’] setting where yo uline up dash to dash on wheel (don’t know what that’s called—crankcase cover area)
Readjusted fuel mixture, idle

Good news: I can take this bike apart and put it back together very fast at this point ;D
Bad news: Still am at the proverbial square one and I'm not sure what I am misssing here. Now, it'll fire when coaxed, but it'll stall eventually and I cannot take it on the street.

I have been advised to check here on this board--any advice?

Title: Re: New Savage S40 Problems Need Advice
Post by VladzeImpaler on 07/06/25 at 15:30:28

UPDATE: I was able to somehow get it idling on its own. Backed it out on the mixture screw about 1 turn more). Let it idle for ~5 mins by itself--no stall! However, when I went to give it some gas and go into 1st, it's got no real power. Dies. Smelled aa bit :P Will attack it again tomorrow.

Buddy of mine says the diaphram may be bad--says it's one of the most common causes of CV carb problems. A lot of people focus on jets and floats but miss a bad diaphragm. Thoughts? (Revzilla asks 152 usd for one of those boys.)

Title: Re: New Savage S40 Problems Need Advice
Post by verslagen1 on 07/06/25 at 16:41:05

’05 S40 Savage 28k
New Raptor petcock
New spark, air filter, oil etc.
New breather hose to airbox
Tank - complete cleanout and refill new petrol
New large boots to carb (to engine/airbox)

People don't have issues with the above [smiley=thumbsup.gif]

There can be issues with the following, I encourage you to recheck with the doc's even if you don't think there could be a problem.
New smaller hoses (fuel, vacuum, etc.) --fuel/we don't recommend filters. vacuum, just cap it. vents are open and routed up.
Carb sent in and cleaned rejetted by Carb Shack, rechecked float, jets, etc. Even after, I checked the float etc. --in the tech section (see link below) there's thread called carb specs. check jet numbers, common issue is swapping the main jet with a jet below the diaphragm.
Readjusted fuel mixture, idle --check the number of turns out by counting the number turns in and turning it back out. be careful not to bottom it out hard or it will get stuck

I don't know what you're talking about here.
Recalibrated [valve?’] setting where you line up dash to dash on wheel (don’t know what that’s called—crankcase cover area)

And your buddy could be right. take out the slide diaphragm and check for cracks and holes. be careful not to bend the needle.

Title: Re: New Savage S40 Problems Need Advice
Post by LANCER on 07/06/25 at 18:10:36

There are some tiny passageways in the carb body, and if any are clogged the carb will not function properly. They must be clear.
Use tiny wire tools, compressed air and aerosol carb cleaner, to insure they are clear.