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

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

PDF Navigation and Page Contents

Text search and wiring detail: Use the printed contents page to find sections. PDF text search and embedded bookmarks are unavailable. Zoom in to read the small wire-color codes and ignition-switch terminal labels on the full wiring diagram.

The download contains one printable, 32-page English PDF. The total includes 25 numbered pages and seven unnumbered pages: the front and back covers, foreword, contents page, memo page, Engine Chart, and Wiring Diagram.

Two-Stroke Engine, Drivetrain, and Electrical Service

These selected workshop topics show the scope of the manual. It also includes engine break-in guidance and exhaust-port decarbonizing.

• Engine repair: Cylinder-head inspection and resurfacing, cylinder wear measurement and reboring criteria, oversize-piston data, and keystone piston-ring inspection and fitting.
• Posi-Force lubrication: Oil-flow diagram, separate T250 and T350 pump delivery curves, and oil-pump control-cable adjustment.
• Clutch and transmission: Clutch-housing removal and installation, cork-plate inspection, axial-play checks, gear-position diagrams, and shift-mechanism assembly cautions.
• Carburetor tuning: Model-specific jet and needle specifications, float-level measurement and adjustment, mixture corrections by throttle opening, and high-altitude jetting guidance.
• Electrical diagnosis: Ignition timing and contact-point checks, AC generator charging specifications, silicon rectifier testing, and wiring diagrams.
• Workshop references: Exploded T250/T350 Engine Chart, illustrated Suzuki special-tool list, and model-specific power and torque curves.

The manual is written for mechanics and assumes familiarity with workshop measurements using cylinder gauges, dial indicators, and electrical testers.

Cylinder, Piston, and Clutch Repair

The engine section gives separate standard cylinder bores and oversize-piston data for each model, along with a T250-specific cylinder-head gasket orientation caution. It explains how the offset piston pin and installation arrow determine piston orientation. A reversed piston can break the rings, and unfinished port edges after reboring can accelerate ring wear.

The clutch section distinguishes plate wear from excessive clutch-housing axial play. It gives cork-plate thickness and warp checks for slippage, plus a dial-indicator check and spacer correction for housing rattle.

Gear Selection and Neutral Brake

The exploded transmission view identifies shafts, bearings, thrust washers, and retaining hardware. Gear-position diagrams trace power flow from neutral through top gear. The manual explains the positive-shift mechanism, cam stopper, and neutral brake, and identifies shifting-shaft indexing and fork orientation errors that can prevent gear selection.

Engine removal and crankcase overhaul fall outside the manual’s step-by-step coverage.

Posi-Force Oil Delivery and Carburetor Settings

The lubrication diagram shows how the pump feeds the cylinders and outer crankshaft bearings, while the center bearing receives oil from the gearbox. The operating section explains the separate gasoline and lubrication-oil supplies. Suzuki cautions that disassembling and reassembling the oil pump can change its output.

The carburetor tables identify pilot jets, needle jets, and jet needles by model. The mixture chart links rich and lean symptoms at different throttle openings to the relevant adjustment, helping mechanics select the correct setting for each carburetor.

Ignition Timing, Charging, and Wiring

Rotor and stator marks identify the timing references for the left and right cylinders. The AC generator wiring diagram shows the charging and ignition circuits, and the charging table gives separate readings for the daytime and nighttime switch positions. The rectifier test distinguishes an open circuit from a short circuit.

The full T250/T350 Wiring Diagram includes wire-color codes, an ignition-switch circuit table, and dotted lines for special wiring configurations. 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.

Selected Piston-Ring and Float Settings

For both models, the piston-ring inspection table gives a standard end gap of 0.15–0.35 mm and a replacement limit of 1.0 mm.

The carburetor float-height specification is 25.7 mm for the T250 and 27.5 mm for the T350. The measurement is taken with the carburetor inverted and the float tang just touching the valve without compressing its spring.