Click the following link to view: Suzuki T500J Owner’s Manual
Category: Technical
Contact Breakers Sticking Open (Points) – Suzuki Service Bulletin -General 3: 1975
SerBulletin General 3
Building a Water Buffalo Rocket
Building a Water Buffalo Rocket Forward These modifications of the Suzuki GT-750 water-cooled two-stroke represent 5 years of research and development, and cover numerous engine and chassis modifications. It must be remembered that in order to acquire speed and handling, all facets must be examined. Some may choose not to completely modify their bike and […]
TWIN LEADING SHOE BRAKES: A step by step guide to a super stopper.
TWIN LEADING SHOE BRAKES A step by step guide to a super stopper. 1. Assemble all new parts likely to be needed before doing anything – usually shoes and cable. 2. Remove wheel and note relationship of cams, levers and springs before stripping back plate completely. If cam ends are not stamped with an alignment […]
T500 2LS brake set-up
It is imperative that the leading edge of each brake shoe comes into contact with the brake drum simultaneously, if maximum braking efficiency is to be achieved. Check by detaching the clevis pin from the eye of one end of the threaded rod, so that the brake operating arms can be applied independently. Operate each […]
How to setup a twin-leading-shoe brake
Borrowed from classicbike.com.uk – Not Suzuki but concept the same. also
TR250-X6-T20 Performance Bulletins
TR250/X-6/T20 Bulletin No. 3Bulletin No. 4 Bulletin No. 5 X-6 Motocross Kit TR250 & T20 Road racing/ Flat track X6 28mm carb adaptors
Suzuki Service Bulletins – Specification & Data – Various Models
Specification & Data 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 – […]
Suzuki RE-5 Technical Bulletins
Bulletin RE Index 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 Bulletin RE 6-9 6. Starter one-way clutch modification 7. Headlight and headlight housing installation procedure 8. Carburetor modification kit 9. Service procedures Bulletin RE 10-16 10. […]
Suzuki GT Technical 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
Suzuki GT Technical 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
Suzuki GT Technical 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
Suzuki GT Technical 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
Suzuki GTTechnical 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 […]
Suzuki GT Technical 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
Suzuki T Model Technical Bulletins
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
Suzuki Technical Bulletins 30 revised – 33
30. Revised – Dealer Obligations for Pre-delivery 31. —————- 32. New Sealant Suzuki Bond 1201 33. Disk brake Grease Application
Suzuki Technical 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
Suzuki Technical 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
Suzuki Technical 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
Ron Grant T500 Hot-up Tips
Hotting up the T500 with Ron Grant Ron Grant shares his tuning secrets Over the past few years a multitude of Suzuki 500s have been sold to a vast cross section of riders, the majority of which were basically interested in primary transportation going to and from work, school or other day to day duties. […]
Service Manual T500 Suzuki incl GT500 Technical Bulletin
Click on link, below, to open: Suzuki T500-II Service Manual_Compress
Oil level for the T500/GT500
An old one but a good one….. All models T500 from 1968 to 1972 (i.e. Cobra to T500J inclusive) carried 1200cc of transmission oil. This amount of oil was inadequate to prevent wear on 4th and 5th gear (the case hardening failed). To overcome this it was necessary to build up the dam wall on […]
Oil Injection or pre-mix
A personal opinion Basically, on the Suzuki oil injection system the outside lines lube the outer mains, the Middle oil lines oil the piston skirt & oil from both of them mixes with the gas. The inner mains are oiled by the transmission oil. To go pre-mix the “Slingers” or as the parts book says […]
Technical tips – Vibration Remedy
Technical tips VIBRATION REMEDY: Remove the engine and counterbore the engine casings to accept the GT750 rubber engine mounts , the mounting lugs on the T500 frame have to be sleeved down with small rings ( knurled and hardened bushes) which are then pressed into frame lugs at the 3 frame mounting points to accept […]
Suzuki T500K Owner’s Manual
Beware the 1200cc transmission oil advice, oil dam needs modification to take 1400cc
