Suzuki T250 Hustler / T350 Rebel 1969-1972 OEM Service Manual

Get the exact 32-page factory specifications needed to service, tune, and rebuild the 1969–1972 Suzuki T250 Hustler and T350 Rebel two-stroke engines. Originally published by Suzuki Motor Co. in February 1969, this official reference delivers the raw technical data required for accurate workshop maintenance.

• 21 illustrated special tool references and complete electrical wiring diagrams.
• High-resolution exploded-view engine charts for precise component identification.
• Essential data for Posi-Force lubrication system calibration, ignition timing, and carburetor jetting.

Engine and Transmission Data

Don't guess on critical tolerances. This manual outlines the exact Posi-Force oil pump control cable adjustments and delivery output curves essential for two-stroke longevity. You will find primary engine data covering cylinder head inspections, piston ring installation protocols, and clutch assembly limits, including cork plate thickness standards. Detailed schematics accurately map out the constant-mesh six-speed gear arrangement and neutral brake mechanism.

Technical Specifications & Electrical Tuning

Tuning a vintage two-stroke requires precision. Performance curves document power and torque thresholds across the operational RPM range. The fuel system section lists specific pilot jet and needle settings for both the T250 and T350 carburetors. For accurate top-end rebuilding, the manual provides standard cylinder bore dimensions and cylinder head warp limits.

The electrical section breaks down rotating alternator specifications and ignition timing sequences calibrated at 24° B.T.D.C. Working on vintage motorcycles involves inherent risks, so always cross-reference these factory torque limits, wear tolerances, and safety procedures to ensure reliable operation on the road.