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Suzuki Classic Two Stroke Compendium
Technical Bulletins (PDF Format) - thanks to DiamondJ (aka Steve Winters) for most of the scans
Home General Bulletins  
  Index and Bulletins 1 - 9 1. Simple Ignition System Check
2. Ignition Coil Failures
3. Contact breaker Sticking Open
4. Nylon Plug Modules
5. Spark Plugs
6. Battery Maintenance
7. Checking PEI Ignition Timing
8. Adjusting Horns
9. Carburetor Main Jet Types
 
  Bulletins 10 - 18 10. Automatic Petcock Misuse
11. Cleaning Carburetors
12.Oil Pump Lever Sticking
13. Oil Tank Cap Vent
14. Oil tank Breather Obstruction
15. Clutch rattle on Twin Cylinder Models
16. Suzuki Liquid Gasket No.4
17. Wheel Alignment
18. Cold Weather Storage
 
  Bulletins 19 - 30 19. High Speed Steering Oscillation
20. Metric-American Conversions
21. Motorcycle Assembly and Pre-Delivery Reimbursement
22. Oil Tank Breather caps Except GT500
23. Recommended Fuel types
24. Gasket Sets
25. Bolt head Symbols
26. Suzuki CCI Super 2 Recommendations
27. Circlip Installation
28. Front Disk Grease Application
29. ---------------
30. Dealer Obligations for Pre-delivery
 

Bulletins 30 revised - 33
 

 30. Revised - Dealer Obligations for Pre-delivery
31. ----------------
32. New Sealant Suzuki Bond 1201
33. Disk brake Grease Application
 

T

Index and 1 - 5

 

1. T500- Transmission Repair
2. T250/305/350 - Drive shaft/top gear
3. T500 - Increased transmission oil capacity (ie. the infamous gearbox oil issue - long kept under wraps)
4. T500 - Swingarm pivot shaft
5. T/GT500 - Shift cam guide bolt location

GT750

Index and Bulletins 1 - 6

 

  

1. GT750 - Cooling System
2. GT750 - Oil Starvation
3. GT750 - Crankshaft and Gear Replacement
4. GT750 - Starter Clutch Modification
5. GT750 - New Style Cylinder Head Bolt Washer
6. GT750 - Crankshaft Modifications
  Bulletins 7 - 13 7.   GT750 - Increased performance
8.   GT550 - Primary gear noise
9.   GT380 - Kick starter drive gear and oil pump driven gear modification
10. GT380 - Increased transmission oil capacity (oh dear the 380 too!)
11. GT250 - Drive shaft/top gear
12. GT185 - Disk brake manual addendum
13. GT550/750 - Exhaust coupler sealant
 
  Bulletins 14 - 21 14. GT380/550/750 - Battery breather location
15. GT380/550/750 - Air cleaner servicing
16. GT380/550/750 - Optional sprockets and chain
17. GT380/550/750 - Contact breaker cams
18. GT380/550/750 - SRIS oil strainer
19. GT250/380/550/750 - Disk brake modification
20. GT250/380/550 - New style spark plug cap boot
21. GT380/550/750 - Fuel starvation at high rpm
 
  Bulletins 22 - 26 22. GT380/550/750 - Instructions for using carburetor synchronisation tool
23. GT380/550 - Wiring harness temporary colour code changes
24. GT250 - Burned out headlight bulb
25. GT750 - Cylinder puller tool set
26. GT550 - Starter clutch change
 
  Bulletins 27 - 33 27. GT185/250/380/550 - Spark plug caps
28. GT500 - PEI Inspection
29. GT550/750 - 2nd drive and driven gears
30. GT250A - Ignition timing marks
31. All GTs - Constant on headlight
32. GT250 - Changes from 1975 to 1976
33. GT550 - Improved rear brake performance
 
  Bulletins 34 - 39 34. GT500 - Shift cam guide bolt location
35. GT250 - Cylinder head, spark plug and carburetion changes
36. GT75- - Fuel surging
37. GT380/550/750 - Fuel cock seepage
38. GT380/550/750 - Gear shifting switch
39. GT500A & B - Front fender mount
 
RM

Index and Bulletins 1 - 7


 

  

1.  RM125M specifications
2.  RM125 oil recommendations
3.  RM125 Cable guides
4.  RM125 Chain guide roller washers
5.  RM125 Disposing of shock absorbers
6.  RM125 Mis-engagement of 3rd gear
7.  RM250/370 Specifications and general information
 
  Bulletins 8 - 17 8.   RM250/370 Oil recommendation
9.   RM250/370 Setup information
10. RM250/370 Troubleshooting Nippon Denso PEI system
11. RM250/370 Rear fuel tank cushion modification
12. RM100/125 Primary drive gear nut washer
13. RM250/370 Rear brake shoe return spring
14. Rm100/125 Trouble shooting Kokusan PEI system
15. RM100/125 Ignition timing
16. RM250/370 Jetting change
17. RM125 Kick starter drive gear
 
  Bulletins 18 - 26 18. RM250/370 Jetting change
19. RM100 Primary drive/driven gears
20. RM250/370 Engine mount bolts and bushings
21. RM100 Front brake cable routing
22. RM125A Ignition timing specifications
23. RM125A Carburetor needle jet
24. RM125A Trouble shooting PEI system
25. RM125M Kick starter driven gear
26. RM250/370 Bolt and nut inspections
 
  Bulletins 27 - 35 27. RM100/125 Left crankshaft main bearing
28. RM250/370 Modified Air Cleaner Assembly
29. RM370 Second Drive Gear
30. RM250/370 Kick Starter Shaft
31. RM125 Air Front Fork Servicing Procedures
32. RM250 1st and 5th driven gears
33. Troubleshooting the RM B Model PEI systems
34. RM250/370 Piston ring locating pins
35. RM80 Gearshift pawl modification
 
  Bulletins 36 - 50 36. RM80 Transmission gear modification
37. RM model cylinder port chamfer recommendations
38. RM80 second drive gear
39. RM125 and RM80 optional drive chain tensioner
40. RM80 Transmission drain plug
50. RM125X main jet modification

 

 
RE

Index and Bulletins 1 - 5

  

1. Introductory notes
2. Recommended sump and metering pump oil
3. Service manual corrections and additions
4. Throttle cable adjustment procedure
5. Carburetor fuel filter
 
  Bulletins 6 - 9 6. Starter one-way clutch modification
7. Headlight and headlight housing installation procedure
8. Carburetor modification kit
9. Service procedures
 

Bulletins 10 - 16

 

 10. Spark plug installation
11. Additional RE-5 oil recommendation
12. Drive chain
13. Second drive and driven gears
14. Oil cooler
15. Constant on headlight switch
16. Baffle inside diameter change
 
TR500

1970 TR500 Specifications

  
July 1972 TR750 Specifications
 		 Incomplete - page 2 only
  Specifications

Bulletins 1 - 5
 

 
 

1. Piston replacement and piston clearance specifications - all models
2. Piston ring replacement specifications
3. Torque specifications - all models
4. Ignition specifications - all models
5. RM 125 specifications
 
  Bulletins 6 - 9 6. 1971 - 75 Carburetor specifications - all models
7. Crankshaft specifications - all models
8. General updated and 1976 Carburetor specifications - all models
9. PEI troubleshooting - Nippon Denso and Kokusan
 
  Bulletins 10 - 14 10. Oil Pump Discharge Data - all models
11. 1965 - 1970 and General Carburetor Specifications - all models
12. 1977 and General Carburetor specifications updated - all models
13. 1978 DS80/100/185 and General Carburetor specifications
14. RM250C Service specifications
 
  Bulletins 15 - 16V 15.   General Specifications
16D. DS80T Specifications
16K. RM80T Specifications
16O. RM400T Specifications
16T. TS125T Specifications
16N. RM250T Specifications
16S. TS100T Specifications
16U. TS185T Specifications
16V. TS250T Specifications
 
  Bulletins 16Y - 17I 16Y. RS175T specifications
16Z. RS250T specifications
17A. FA50X & FA50MX specifications
17C. FS50X specifications
17D. FZ50X specifications
17E. JR50X specifications
17I. RM125X specifications (I know it is out of sequence)
17G. RM80X specifications (and this one)
17F. RM60X specifications (and this one too!)
17H. RM100X specifications.
  Bulletins 17J - 17S 17J. RM250X specifications
17K. RM465X specifications
17L. PE175X specifications
17M. PE250X specifications
17N. PE400X specifications
17O. RS175X specifications
17P. RS250X specifications
17Q. DS80X specifications
17R. DS100X specifications
17S. DS125X specifications
 
  Bulletins 17T - 8K

 

 17T.   TS100X specifications
17U.   TS125X specifications
17V.   TS185X specifications
17W.  TS250X specifications
8K.    GT550TX specifications
  Tools

Index and Bulletins 1 - 6

 

  

1. SS II Electro tester modification kits
2. 75mm measuring rod
3. New timing tester
4. 160mm connecting rod stopper
5. Engine tachometer instructions
6. Special tool availability
 
 

Bulletins 7 - 10

 

 7.  Pneumatic/coil spring (air) front fork special tools
8.  Front fork damper tool set
9.  Cylinder gauge set 65mm measuring rod
10. SS I, SS II  Electro tester repair
 
  Supplementary Bulletins
from Canada

Service Bulletin 75-1
 

 Supplied by H2Rick - thanks mate


Modified RHS Crank Seal GT750
  Service Bulletin 75-6 GT380M/550M/750M fork modifications - 1975
  Service Bulletin 75-10 Modified Oil Pump Gear - GT185
  Service Bulletin 75-29 Spark Plug Cap GT380/550
  Service Bulletin 117 Modification to SRIS GT750
  Service Bulletin 110 Breakage of exhaust studs - GT380
  Service Bulletin 119 Timing gear modifications - GT380
  Service Bulletin 134 Identification of master cylinders - disk brake models
  Service Bulletin 135 Daytime charging problems - T250/T350 - 1973
  Service Bulletin 137 Battery charging GT389/550/750 - 1973
TR250/X-6/T20

Performance Bulletin No. 3

Performance Bulletin No. 4

Performance Bulletin No. 5

  

X-6 Motocross Kit

T20 Road racing/ Flat track

X6 28mm carb adaptors
  Supplementary Bulletins
from USA

Service Bulletin No.1


Service Bulletin No.2
 

Piston replacement and piston clearance specifications - all models - dated Feb 1973


Piston ring replacement specifications - dated Feb 1973

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