3) chain tensioner has me concerned...if I have it for 10k-15k miles I will address it; at 1250 miles (as of today) the **** thing isn't fully broken in yet
Verslagen (suzukisavage.com moderator, overall S40/Savage/LS650 guru, and creator of the modified tensioner that solves the problem) says:
it's recommended to do something before the [tensioner] piston has extended 18mm, if you let it go until 22mm then it's ready to go any second.
a conservative rule of thumb 1000 miles per mm
so adding 15mm would add 15,ooo to your riding.
Which means that your plan for 10-15K miles before sealing with the tensioner is probably reasonable.
Note, however, that the wear on the cam chain (and thus the tensioner extension) can show some high variability-- there are some that have gone >20K miles without a problem, but there are also those who have had their tensioner let go as early as 3K miles!
Here, again, is Verslagen, answering a question about this low-mile failure scenario:
Q: I heard horror stories about it going between 3k miles and 10k.
Verslagen: If you don't mod the tensioner, then yes, it can go that early but it depends on your riding style... a lot of short trips shorten the chain life vs long rides equals long chain life
So, if you have the time and want to rule out the possibility of having an early failure, you might want to change the tensioner out sooner rather than later.
I have 9.5K miles on mine and have not done this modification yet, mostly due to lack of time. However, it's near the top of my list to get done now that I have retired. So far, I've not had any problems, but I feel like I'm pushing my luck...
header bolts will be an annual check
On my S40, an annual check is not near enough. Even though I have the factory fasteners and carefully torque them to spec, one of them always comes loose fairly quickly. As such, I have to check it every 2-3 rides.
the backfiring occurs for me at engine shutoff during hot idle which seems high...but then it's a single lunger
I don't think the backfire is related to being a single-- several of my bikes are singles, including some big ones (klr650, Blast 500). The S40 is the only one that backfires.
Generally, carbureted bikes have an "air cut valve/coasting enricher/anti-backfire valve" to make the mixture a bit richer on deceleration as it's the leanness when you cut the throttle while coasting that causes the backfire.
S40's simply do not have this system so, combined with the EPA-mandated lean jetting from the factory, this bike is basically designed to be a backfire machine.
Gurus on the forum consider it to be an endearing feature that is part of the charm of the bike. However, I'm not so enamored of it.
As you mention, within about a second of shut-off when hot, my bike will almost always give a noticeable "chuff" or occasionally a loud backfire. When coasting after full warmup, it almost always backfires, and not in a cool way-- it sounds just like a shotgun going off.
Kind of embarrassing when I'm in traffic, and even worse when I'm in a parking garage, so want to get it fixed one way or another.
My understanding is that by eliminating the EPA leanness by changing jetting to a richer mixture will help with reduce backfiring, and that's another mod I intend to do to my S40 in the coming months. We'll see if it works.