1969-1972 Suzuki T250 Hustler / T350 Rebel Service Manual
Covers T250 Hustler and T350 Rebel with complete engine rebuild, Posi-Force Lubrication system, transmission repair, and electrical troubleshooting procedures. Includes carburetor specs and ignition timing data.
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Models Covered & Key Technical Specifications
Suzuki T250 Hustler, T350 Rebel — 1969–1972 Precision Technical Archive | T250/T350 Series Collection.
- Certified Processing Speed: 32 HP at 8,000 rpm is rated at the maximum engine output Matrix.
- General Mass Specs: For displacement measurement, 247 cc (T250) and 315 cc (T350) establish the piston cylinder volume Standards.
- Design Precision Specs: 3.0 kg-m at 7,000 rpm — supports the peak torque threshold Margin.
- Engineered Locking Torques: The compression system requires 7.5:1 (T250) and 6.94:1 (T350) for standard combustion pressure Protocol.
- Verified Measurement Bounds: Engine oil capacity reaches 1.8 Ltr (1.9/1.6 qt, US/Imp) operational parameters Architecture.
- Factory Cycle Rate: Ignition timing achieves 24° B.T.D.C. (Piston stroke 2.88 mm) combustion sequencing Norms.
Manual Description & Preview
Practical Workshop Manual: 1969-1972 Suzuki T250 Hustler, T350 Rebel Engineering-Archive
Documentation-Type: 1969-1972 Suzuki T250 Hustler and T350 Rebel service procedures // Series-Validation: Transmission and engine system reference documentation // Documentation-Type: Factory specifications and lubrication system technical data.
| Chapter Coverage | System Documentation | Reference Material |
|---|---|---|
| Operating guidance and performance data | Engine specifications and curves | Complete technical specifications |
| Posi-Force lubrication system overview | Transmission configurations and gear ratios | Documented component specifications |
| Engine and electrical system procedures | Carburetor adjustments and fuel system setup | Wiring diagram and electrical component specifications |
The documentation provides guidance on breaking-in procedures for new motorcycles, fuel and lubrication system requirements specific to the Suzuki Posi-Force system, and performance curves for both the T250 and T350 models. These sections cover transmission mechanisms, including the constant-mesh six-speed gearbox, positive shift features, and neutral brake operation. The manual addresses electrical equipment specifications, AC generator charging performance, ignition timing requirements, and silicon rectifier inspection procedures. Suspension, brake, and steering geometry specifications are documented alongside dimensional data and tire pressure recommendations for solo and dual riding configurations.
Maintenance hierarchies are structured into engine overhaul procedures covering cylinder head inspection and gasket installation, cylinder bore measurement and reboring specifications, piston ring end gap limits, and oil pump performance curves. The manual includes the unique Posi-Force lubrication system mechanism, which distributes pressurized oil to the crankshaft, cylinder walls, and connecting rod bearings through a plunger-type pump controlled by throttle opening and engine speed. Transmission service information covers gear shifting operation, the positive stop shifting device, clutch plate wear measurement, and axial play inspection procedures.
Carburetor specifications are documented for both VM24SH and VM32SH models, with float level adjustment measurements, jet sizing data, and throttle-opening adjustment guidance. The manual documents torque specifications for component alignment retention and bolt fastening procedures throughout the engine and transmission systems. Electrical system documentation includes AC generator specifications, contact point gap parameters, condenser capacity ratings, and charging amperage values at various engine speeds for both day and night operation modes. A complete wiring diagram illustrates the ignition system circuit, battery configuration, lighting circuits, and switch operations across both motorcycle models.
Documentation-Type: 1969-1972 Suzuki T250 Hustler and T350 Rebel service manual with complete factory specifications and technical reference data.
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