Suzuki Boulevard S40 Savage LS650 Top Recommendation(s): Replace the OEM Fuel Valve

My next "Top Recommendation" is to replace the overly complicated, vacuum operated, and failure prone Suzuki petcock with a manual petcock, specifically the Yamaha Raptor 660 unit. The Yamaha part is basically bulletproof, is a direct bolt on, and makes removing the fuel tank tons easier.
I also borrow pictures from a detailed forum post which shows the internals of the OEM unit as I've long since recycled mine.
Symptoms of a bad (or failing) petcock include hard starting, excessive fuel consumption, the "Savage Surge," gas in oil, and a no-start condition.
Very simple "upgrade" anyone can do. Remember to refill the tank with pure gasoline (E0).
SuzukiSavage.com thread: suzukisavage.co...
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[@edowen1454]

I bought a 1999 Savage it ran real bad like it was missing etc. I put in the Raptor petcock and she runs perfect I'm amazed that this was the problem.I drained the oil and it was like water there was a lot of gas in the oil . I'm glad I stumbled across this video.

[@someguitarguy.]

That’s awesome. Glad to hear and help. TWD

[@markwhitfield6225]

Great video. I eventually found the same problem after fighting drivabilty, hard starting, and getting stranded twice. The plug would come out super fouled. I rebuilt the carb, even bought another one. When I saw the fuel leaking from the actual petcock I replaced it with the raptor petcock and all these problems went away. It is reliable in starting and riding now over the last 3 years.

[@someguitarguy.]

Glad you figured it out. The forum gurus all swore my carb was dirty. But that didn’t match the symptoms which were basically yours. Blind luck (and being in a rush) solved mine. Ironically, HD used a similar setup on my Sporty BUT they issued a recall. Pisses me off Suzuki never addressed this nor any other issues from their “convenience engineering.” TWD

[@user-ix3qp4hi2i]

Everybody please listen to this Guitar Guy. I'm on my 2nd Savage/S40. My first one was a 2003 with only about 1700 miles that I got in 2007. I remember having what I thought were all sorts of disappointing carburetor problems on a bike with such low miles. I had wide open stalls, bad behavior in the rain, flooding, etc. I tried everything. I even had a guy from the aforementioned forum suggest stiffening the spring on top of the diaphragm (dumb idea). I stumbled on the thread about converting the petcock into a manual one, and I successfully did it. I'm not sure it's the same fix SGG highlights here, but I think it may have been. I'm a stubborn guy, and I resisted the Raptor conversion for some reason. Maybe I wanted to keep everything "stock". The Suzuki petcock was hateful for another reason. The lever was stubby and extremely hard to turn. I remember taking the stock petcock off to do the conversion and finding that the 4 screws on the back weren't even very tight at all. That may have been most of my problem. I think I only kept that bike for 3 years or so, because a beautiful 2003 Sportster caught my eye. All the bugs were worked out when I sold it. Fast forward to 2022: I decided to pick up a 2012 S40 with only ~900 miles on it. It was somewhat of a mess from mostly sitting, and one of the first things I did was swap out the factory petcock for the Raptor one. It was the right decision, because my first oil change included a gushing torrent of gassy thin oil that overflowed the drain pan. This is a symptom of a misbehaving petcock. The bike is now in good working order, and I turn off the petcock every time I stop the engine. *Some* of these bikes are prone to flooding with stock carburetors, especially in hot climates where I live. I think I have a glitchy float valve (over $76, strangely, from OEM suppliers) but a manual petcock eliminates any variables created by a hot pressurized gas tank. I cringe thinking of somebody leaving the bike on PRI all the time, because that wouldn't have worked for me on either bike, I'm afraid. Thanks Some Guitar Guy for the interesting and thorough video. I'm with you on the pure gas too. It's readily available where I live due to the boater culture, but I find myself forgetting to put it in my bikes every time.

[@someguitarguy.]

And thanks for the interesting and parallel story. A Raptor petcock, pure gas, and tuning the idle mix and you’re good to go for a long time. Won’t hurt to check the overly complicated decomp system too. TWD

[@ABCDEFGHIJKELA...]

Just replace it with the Raptor part, like he said. This is the one thing that is an absolute necessity on this bike, you won't regret it!

[@someguitarguy.]

It certain cures a world of woes.

[@HM-gw1pl]

does it matter what year motorcycle is?

[@dmail2614]

Wow, Thank you for responding so quickly to my previous question. Regardong the used 2018 s40 I'm thanking about buying. Is the used 2018 Suzuki s40 a safe choice to buy, or should I avoid it and choose a different make? I've been looking at the Yamaha tw200, Yamaha xt250, and the Honda crf250L, Honda Rebel 300. I just need simple transportation for running errands and an occasional back country stroll with my wife. I trust your insights. Thank you again. And I've subscribed to your channel. Thank you again! and I apologize for all the questions. This is all new to me. I greatly appreciate your time my friend.

[@someguitarguy.]

Thanks for subscribing! Although the S40/Savage enjoys a cult following, it also has its design flaws. All the bikes you mentioned will do the tasks you seek, but it’s basically impossible to go wrong with a Honda. Best wishes on your decision. TWD

[@dmail2614]

Thank you....much appreciated!

[@michaelelse9328]

💥 S 💨 A 💨 V 💨 A 💨 G 💨 E 💥 ✌🏻☮️ Thank you for this video & best wishes from Germany!🤞🏻👌🏻👍🏻☮️

[@someguitarguy.]

Thank you! Cheers!

[@kawasabi1]

Thanks man I had all these problems and just cleaned all the jets in the carb only to find it did nothing to solve the problem. The gas would dump down that vacuum line causing my bike to flood out and when it shut down a massive backfire.. I ordered the petcock from the raptor, only cost me 20 bucks. I hope this does the trick.

[@someguitarguy.]

Glad to help. Did the Raptor petcock fix it?

[@kawasabi1]

@@someguitarguy. You bet, good to go

[@Mr1forthefun]

I have been having the hard starting and not running problem for some time, today the engine would not run unless petcock is on PR1. After seeing your video I have ordered a raptor petcock for Yamaha 660 and I will let you know if it cures my problem, thanks for the video.

[@someguitarguy.]

Glad you found it helpful. Did the Raptor part fix it? A bonus with the Raptor is it makes tank removal much easier.

[@bobcaygeon4533]

Having same problem with mine. Only runs properly on prime. Did you get the petcock in yet? If so, how did it work out. I'm ordering the Raptor petcock today.

[@Mr1forthefun]

Yes indeed getting rid of that vacuum/assist petcock did the trick. Only one small problem the petcock inlet pipe was smaller than the original. Reordered a better one from Amazon fuel valve petcock 8mm compatible with Yamaha raptor 660 660R ------------ 2001,02,03,04,05 5LP 24500 00

[@tgipson20]

Just bought a savage. First bike. Noticed the hard start. Had to choke it and set to prime. I would try and ride with it on the on position and it would putter out after a minute or two. It seems to ride fine in prime position. I also notice a gas smell when it’s been sitting. I got a raptor petcock I have need to put it on already.

[@someguitarguy.]

The Raptor petcock should fix you right up. TWD

[@edowen1454]

Today I'm buying a 1999 Savage it has gas going into the airbox after watching your video I think I should replace the fuel petcock with a Yamaha raptor 660 one do you think the 1999 petcock is the same bolt pattern as your newer bike and the Raptor? Also do I cap my vacuum line?

[@someguitarguy.]

Congrats. I’d change the petcock regardless. If it hasn’t failed it will. But I agree it’s likely the problem. I think all Savages (and Raptors) have the same bolt pattern but ya, I’d order the same year as your bike. That’s what I did. Let us know the results. TWD

[@dmail2614]

Thank you soo much for the excellent video. Very well done. May I ask...? I'm looking to buy a used 2018 Suzuki Boulevard s40 from.a private seller. Do you know, does this video of the petcock issue apply to it, and is there a different model petcock replacement for it than the one recommended since the dates are much different? Thank you in advance for any help you can offer. Much appreciated.

[@someguitarguy.]

Suzuki doggedly used the same vacuum petcock (and other poorly designed assemblies) for the entire production run, all in the name of convenience. I simply bought the Raptor petcock that was the same year as my bike but I’m pretty sure they’re all the same. TWD

[@dmail2614]

Wow, Thank you for responding so quickly! So, should I get a petcock from a 2018 model year of the Raptor, or do you think the design if the petcock on the newer models of the Yamaha may have changed? Would it be a safer choice to go with the older model petcock since that one fit the Suzuki? Also, is the used 2018 Suzuki s40 a safe choice to buy, or should I avoid it and choose a different make? I've been looking at the Yamaha tw200, Yamaha xt250, and the Honda crf250L, Honda Rebel 300. I just need simple transportation for running errands and an occasional back country stroll with my wife. And I've subscribed to your channel. Thank you again! and I apologize for all the questions. This is all new to me. I greatly appreciate your time my friend.

[@robbiew6769]

So I just bought a 2009 s40 and I can only ride with it in the reserve position. Will not work in the on position. I also get backfire. Could this be a system of a bad fuel cock? Should I replace with the raptor? And can you reply with the link for the part that will fit my Suzuki s40? Thanks for any help!

[@someguitarguy.]

Sounds like it’s definitely bad but I’d replace it regardless. I just searched for the same year Raptor part as my bike but I’m sure other years will work fine. As for the backfire (after fire), I’d switch to ethanol-free to see if that helps. If not, tune the idle mixture. Also understand these singles tend to after fire some even under perfect conditions.

[@ColejoeBRO]

Would this explain mine frequent backfire? 2013 s40

[@someguitarguy.]

The fuel leak may not explain the backfiring, nor would a bad petcock. The first thing I’d do is replace the OEM petcock with the Raptor. Then, and forever, ONLY run ethanol free fuel. Backfires are more of a mixture issue. Ethanol free may easily correct your mixture AND it doesn’t turn to goo like ethanol blends.

[@isi3297]

Thank you

[@someguitarguy.]

You're welcome

[@ColejoeBRO]

I recently removed my carb for a cleaning. Unfortunately my fuel outlet (brass tube) came out with the hose due to corrosion. Does that need to be pressed back in? I did my best to tap it in without flaring anything. I’m definitely leaking fuel from it now. Not sure if I just need to get it further in or did I fry the piece completely.

[@someguitarguy.]

The outlet from the petcock? If you replace the petcock with the Raptor that should solve the leak.

[@minisprint46]

There is more vacuum at idle than higher rpms

[@someguitarguy.]

Thanks. Still a poor design that will fail.

[@rhodyriderz]

We’re on the Carburetor do you plug the hose to from the Petcock also what do you do with the vacuum port?

[@someguitarguy.]

Look on the right side of the carb closest to the engine. That’s the vacuum port. If you upgrade the petcock, plug that port with a rubber vacuum line cap.

[@rhodyriderz]

Thank you 🙏

[@BangForYourBuckRc]

My fuel cock for my s40 seems to starve for fuel if the fuel is on and seems to run fine on prime. No leaking yet on either. Is it ok to ride it on “pri”?

[@someguitarguy.]

It’s already failed. PRI mechanically bypasses the shutoff. It’s ok until you can install the replacement.

[@BangForYourBuckRc]

@@someguitarguy. Thanks for your quick reply! I just ordered a raptor 660 fuel per cock. For this. It shouldn’t be long! I appreciate your tutorials, Thanks!👍🏻😎✌🏻

[@someguitarguy.]

Thanks and glad to help. Lemme know if this cures it. TWD

[@kenjensen3728]

Good video sounds like this may be my problem. I don't know if I missed it in the video or what, so what do you do with the vacuum line on the motor

[@someguitarguy.]

Diagnosing this thing can be challenging. I think the surging is the big giveaway. They all fail, btw. Harley tried it with similar results. As for the vacuum port, simply cap it with a rubber cap. It’s on the intake. TWD

[@starzanhorse4758]

runs fine until i off throttle , after fire... ive adjusted the brass engine side to 1.5 wish me luck

[@someguitarguy.]

After fires, to some degree, are common with any single. Suzuki included a Transitional Enrichment Valve (TEV) to reduce this. It's basically a backwards accelerator pump. I don't think upgrading the petcock will have much effect on after fires. Sounds like you're on the right track with adjusting the idle mix. I'd suggest actually tuning the idle mix and don't fixate on 1.5 turns. If you have to go more to get the fastest idle, you're good up to 3 turns. Also, if you're running an ethanol blend, you're probably a bit lean which can make after fires worse. Ethanol blends require a richer mixture than pure gas. I highly recommend pure gas. And good luck! TWD

[@isi3297]

I havea question. What do you do with the vacumm line?

[@someguitarguy.]

If you upgrade to a Raptor petcock, you won't have a vacuum line...BUT...you will need to cap the vacuum port on the intake.

[@gabrielaguilar1489]

Do you have to take the tank off for the install? Or can you just take it off like that

[@someguitarguy.]

No need to remove the tank. Remember to cap the vacuum port on the carb. Let me know how it goes. TWD!

[@gabrielaguilar1489]

@@someguitarguy. I will. I'll try to use most of the gas I have right now and then I'll replace it. Appreciate it man.

[@Ghostsoulless]

@@gabrielaguilar1489 Realize I’m probably late, but you can disconnect the fuel line from the carb with the petcock in the “On” position and move the rubber line out into a fuel can. Then turn it to “Prime” and it’ll drain your tank. To avoid having to run it dry and waste fuel. Just pour it back in when you’re done.