Description
This Used 1964-1977 Suzuki TC TM TS RL RV 125-400cc Motorcycle Repair Manual is a complete Clymer-style guide designed for riders and mechanics working on 1964-1977 Suzuki single-cylinder motorcycles. Covering popular models such as the TC125, TS185, SP370, and DR400, this manual includes detailed maintenance instructions, step-by-step service procedures, and troubleshooting guidance to keep your vintage Suzuki reliable.
A common repair need for these older Suzuki singles is top-end servicing. Frequent piston wear, ring replacement, and cylinder scoring were well-known on two-stroke models like the TS and TC series. The Suzuki 125-400cc repair manual provides precise measurements, torque specs, and assembly diagrams to guide proper rebuilds. For four-stroke singles such as the SP370 and DR400, valve adjustments and timing chain inspections are thoroughly covered.
Electrical problems are another recurring issue in motorcycles of this era. From faulty magnetos to aging wiring harnesses, the manual offers wiring diagrams, ignition testing, and charging system troubleshooting to help restore spark and lighting functions. Riders will also find carburetor cleaning and tuning sections, essential for keeping two-stroke and four-stroke engines running smoothly.
Routine service instructions such as chain lubrication, clutch adjustment, gear oil changes, and brake maintenance are included, ensuring owners can extend the life of their Suzuki with regular care. For more advanced mechanics, the manual details crankshaft service, gearbox disassembly, and complete engine teardown and rebuild procedures.
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Manual organization, Service hints, Tools, Expendable supplies, Safety first, Motor identification and parts replacement
CHAPTER TWO, TUNE-UP, PERIODIC MAINTENANCE, AND LUBRICATION
Engine tune-up, Transmission oil, Front forks, Clutch adjustment, Electrical equipment, Drive chain, Brakes, Wheels and tires, Steering head bearings, Swinging arm
CHAPTER THREE, TROUBLESHOOTING
Operating requirements, Two-stroke pressure testing, Starting difficulties, Poor idling, Misfiring, Flat spots, Power loss, Overheating, Backfiring, Engine noises, Piston seizure, Excessive vibration, Clutch slip or drag, Poor handling, Brake problems, Lighting problems, Troubleshooting guide
CHAPTER FOUR, ENGINE, TRANSMISSION, AND CLUTCH
Engine principles, Engine lubrication, Preparation for engine disassembly, Engine removal/installation, Cylinder and cylinder head, Piston pin, piston, and piston rings, Clutch, Primary pinion, Kickstarter, Shifter mechanism, Crankcase, Transmission, Crankshaft, Oil seals, Bearings
CHAPTER FIVE, FUEL AND EXHAUST SYSTEMS
Carburetor, Carburetor components, Miscellaneous carburetor problems, Fuel tank
CHAPTER SIX, ELECTRICAL SYSTEM
Flywheel magneto, Magneto troubleshooting and service, PEI ignition system, Rectifier, Battery, Lights, Horn, Fuse, Switches
CHAPTER SEVEN, CHASSIS, SUSPENSION, AND STEERING
Frame, Handlebar, Front fork, Steering stem, Drive chain, Wheels and tires, Brakes, Shock absorbers, Swinging arm
CHAPTER EIGHT, PERFORMANCE IMPROVEMENT
What do you want?, Weight reduction, Tubes and tires, Gearing, Improved braking, improved handling, Drive train, Engine modifications, Oil injection, Carburetion, Air filter, Exhaust system, Ignition, Summary
APPENDIX, SPECIFICATIONS
SUPPLEMENT, 1977 SERVICE INFORMATION
Tune-up, Transmission and front forks, Reed valve assembly
SUPPLEMENT FOR UNITED KINGDOM
INDEX
