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

This Suzuki factory service manual covers maintenance and repair of the 1969–1972 T250 Hustler and T350 Rebel, with emphasis on the two-stroke engines, drivetrain, carburetors, and electrical equipment. Suzuki Motor Co. published this edition in February 1969.

Text search and wiring detail: PDF text search and embedded bookmarks are not available. Small wire-color codes and ignition-switch terminal labels are readable when enlarged, but require zooming for comfortable reading in the full wiring diagram.

• Engine repair: Cylinder-head inspection, cylinder wear measurement and reboring criteria, oversize-piston data, piston installation, and keystone piston-ring inspection and fitting.

• Posi-Force lubrication: Oil-flow diagrams, separate T250 and T350 pump-performance curves, and oil-pump control-cable adjustment procedures.

• Clutch and transmission: Clutch-housing removal and installation, cork-plate inspection, axial-play checks, gear-position diagrams, and gear-shifting mechanism assembly cautions.

• Carburetor tuning: VM24SH and VM32SH specifications, float-level measurement and adjustment, mixture corrections by throttle opening, and high-altitude jetting guidance.

• Electrical diagnosis: Ignition-timing checks, contact-point specifications, AC generator charging data, silicon rectifier testing, and wiring diagrams.

• Workshop references: The T250/T350 Engine Chart, exploded transmission view, model-specific power and torque curves, and an illustrated list of Suzuki special tools.

Written for mechanics, the manual assumes familiarity with workshop measurements and the use of cylinder gauges, dial indicators, and electrical testers.

Cylinder, Piston and Clutch Repair

The engine section covers cylinder-head mating-surface inspection and resurfacing, with a specific gasket-orientation caution for the T250. Cylinder inspection data distinguish the standard bores and oversize pistons for each model.

Piston-ring end-gap limits and keystone-ring installation markings support top-end repair. The manual warns that installing the offset-pin piston backward can break the rings and seriously damage the engine; it also identifies unfinished port edges after reboring as a cause of rapid ring wear.

Clutch coverage includes cork-plate thickness standards, warp checks, and dial-indicator measurement of clutch-housing axial play. The related spacer-correction procedure addresses housing rattle that plate inspection alone would not explain.

Transmission and Gear-Shifting Mechanisms

Detailed diagrams map out the constant-mesh six-speed gear arrangement, from neutral through top gear. The exploded view identifies shafts, bearings, thrust washers, and retaining hardware.

The positive-shift mechanism, gear shifting cam stopper, and neutral brake each receive an explanation of operation. Assembly cautions identify shifting-shaft indexing and fork orientation errors that can prevent gear selection. The manual does not provide a complete engine-removal or crankcase-overhaul sequence.

Posi-Force Lubrication and Carburetor Tuning

The lubrication section distinguishes pumped oil delivery to the outer crankshaft bearings and cylinders from the center crankshaft bearing's separate gearbox-oil supply. Oil-pump service covers delivery curves and control-cable adjustment; Suzuki specifically warns against pump disassembly because reassembly can change its output.

The fuel system section lists specific pilot jet and needle settings for both the T250 and T350 carburetors. The model-specific needle-jet, jet-needle, and float-level data help prevent applying T250 carburetor settings to a T350 during tuning or repair.

Mixture-adjustment guidance is organized by throttle opening. The opening operating section also covers engine break-in and the separate fuel and lubrication-oil supplies.

Ignition, Charging and Electrical Testing

Ignition checks cover rotor/stator timing marks and verification with a timing gauge and tester, including separate identification of the left and right cylinders. Charging specifications distinguish daytime and nighttime ignition-switch positions.

The AC generator wiring diagram explains the charging and ignition circuits. Silicon rectifier tests distinguish open-circuit and short-circuit faults, while the full T250/T350 wiring diagram adds wire-color codes, an ignition-switch circuit table, and dotted-line wiring for special specifications.

The illustrated list identifies 21 special tools, including clutch sleeve hub holder 09920-51510 and timing gauge 09931-00110. Charging checks involve a running engine; take care around live circuits and rotating components.

PDF Contents and Page Count

Supplied as one printable 32-page PDF: 25 numbered content pages, front and back covers, a foreword, a contents page, a memo page, the Engine Chart, and the Wiring Diagram. All seven unnumbered pages are included in the total.