Description
This Used 1964-1974 Suzuki T125, S32-2, T200, T10, T20, T250, T305, T350 and T500-2 Motorcycle Repair Manual is a complete Clymer-style guide for riders and mechanics working on 1964-1974 Suzuki twin-cylinder motorcycles. Covering popular models such as the T125, S32-2, T200, T10, T20, T250, T305, T350, and T500-2, the manual delivers step-by-step repair instructions, troubleshooting guidance, and detailed specifications to keep your classic Suzuki reliable.
One of the most common issues with vintage Suzuki twins is top-end wear, especially piston and ring replacement on two-stroke engines. The Suzuki 125-500cc repair manual provides detailed instructions for cylinder inspection, piston servicing, and crankshaft rebuilds—ensuring accurate, lasting repairs. For larger-displacement models like the T500, the manual offers clear guidance on addressing overheating, oil pump adjustments, and vibration-related wear.
Electrical system reliability is another concern for these motorcycles. Aging alternators, rectifiers, and wiring can cause charging and ignition issues. With full wiring diagrams and step-by-step diagnostic methods, this manual helps riders restore consistent spark and dependable lighting performance.
Fuel delivery and carburetor tuning are also highlighted. Many owners experience poor idling, flat spots, or fuel leaks, and the repair manual provides cleaning, jetting, and synchronization instructions to restore smooth operation. Routine service guidance such as brake adjustments, suspension checks, and chain maintenance are also included.
For advanced mechanics, the manual dives into gearbox service, clutch replacement, crankcase splitting, and complete engine rebuilds. Each section is supported with diagrams, torque specs, and proven repair procedures.
Whether you are restoring a T20 “X6 Hustler,” tuning a T500 Titan, or maintaining a smaller T125 commuter twin, this Suzuki 125-500cc repair manual is an essential workshop companion. It ensures accurate service and helps keep these classic two-strokes running strong for years to come.
QUICK REFERENCE DATA
CHAPTER ONE, GENERAL INFORMATION
Service hints, Tools, Expendable supplies
ENGINE, TRANSMISSION, AND CLUTCH
Engine principles, Engine lubrication, Oil pump, Engine removal, Cylinder heads, Cylinders, Piston pins, pistons, and piston rings, Clutch, Primary pinion, Kickstarter, Shifter, Crankcase, Crankshaft, Transmission, Oil seals, Bearings
CHAPTER THREE, ELECTRICAL SYSTEM
Ignition System, Alternator, Rectifier, Solid state regulator, starter/generator, Battery, Lights, Horn, Fuse, Switches
CHAPTER FOUR, FUEL SYSTEMS
Carburetor, Fuel tank, Puel petcock
CHAPTER FIVE, CHASSIS, SUSPENSION, AND STEERING
Frame, Handlebars, Front forks, Steering stem, Drive chain, Wheels and tires, Mechanical brakes, Hydraulic brakes, Shock absorbers, Swinging arm, Exhaust pipes and mufflers
CHAPTER SIX, PERIODIC SERVICE AND MAINTENANCE
CHAPTER SEVEN, TROUBLESHOOTING
Operating requirements, 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 SUMMARY
CHAPTER EIGHT, SPECIFICATIONS
TS125, S32-2, T200, T10, T20, T250, T305, T350 T500-2
INDEX
