MotoService Log
Suzuki T20 / T200 / T250 / T350 / T500 Titan
Example photo: Thesupermat, CC BY-SA 3.0, Wikimedia Commons
Suzuki · Suzuki two-stroke twin / triple (T20-T500, GT 1965-1977)

T20 / T200 / T250 / T350 / T500 Titan

Library entry covers 1965-1977

1 factory 65 guideline

Published source

Suzuki Service Guide for Motorcycles 1970 (archive.org scan, OCR text)

Factory factory bulletin. Covers 1970 (Suzuki Service Guide, whole two-stroke range).

Open the source

66 items for a 1965 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)
Engine cycle
Two-stroke
Engine lubrication
Two-stroke oil injection (Autolube, Injectolube, Pilgrim pump...)
Oil filtration
None (no filter)
Valve gear
None (two-stroke porting)
Ignition
Battery and coil with contact points
Charging
Alternator / stator with rectifier
Battery
Wet cell (flooded lead-acid, needs topping up)
Fuel system
Two or more carburetors
Cooling
Air / oil cooled
Primary drive
Gear or chain inside engine, shares engine oil
Gearbox oil
Separate gearbox oil
Clutch control
Hand lever, cable
Final drive
Chain
Front suspension
Telescopic fork
Rear suspension
Swingarm, twin shocks
Front brake
Drum (or band / stirrup)
Rear brake
Drum (or band / belt rim)
Wheels
Spoked, tubed
Sidecar
No sidecar
Maintenance schedule

1965 Suzuki T20 / T200 / T250 / T350 / T500 Titan

On the road: every 150 mi

1 item
  • Check two-stroke oil tank / carry premix oil
    Pre-ride / on the road
    Guideline

    Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 300 mi

3 items
  • Check lights, horn, brake light switches
    Pre-ride / on the road
    Guideline
  • Check tire pressures
    Pre-ride / on the road
    Guideline
  • Lubricate drive chain
    Pre-ride / on the road
    Guideline

    Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 500 mi

1 item
  • Walk-around: check nuts and bolts for vibration loosening
    Pre-ride / on the road
    Guideline

    Old machines shake things loose: exhaust nuts, mudguard stays, footrests, tank mounts, battery strap.

On the road: every 600 mi

1 item
  • Check chain slack and rear wheel alignment
    Pre-ride / on the road
    Guideline

On the road: every 1,000 mi

1 item
  • Check road kit: plugs, points file, master link, tube patches, wire, tape
    Pre-ride / on the road
    Guideline

Every 1,000 mi or 1 month

1 item
  • Check battery electrolyte, top up with distilled water
    Ignition and electrics
    Guideline

    Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,000 mi or 6 months

8 items
  • Inspect, clean and gap spark plugs
    Engine
    Guideline
  • Check gearbox oil level
    Primary and gearbox
    Guideline
  • Grease swingarm pivot
    Rear suspension and frame
    Guideline
  • Adjust front drum brake
    Brakes
    Guideline
  • Adjust rear drum brake and rod / cable linkage
    Brakes
    Guideline
  • Check spoke tension and wheel true
    Wheels and tires
    Guideline
  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Guideline
  • Lubricate control cables and lever pivots
    Controls and cables
    Guideline

Every 1,500 mi or 6 months

2 items
  • Clean / inspect air filter
    Fuel and air
    Guideline

    Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.

  • Clean drive chain thoroughly (remove and soak, re-lube)
    Final drive
    Guideline

    Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 1,500 mi or 12 months

1 item
  • Adjust clutch free play, lubricate cable and lever pivot
    Primary and gearbox
    Guideline

Every 2,000 mi or 12 months

1 item
  • Replace spark plugs (two-stroke)
    Engine
    Guideline

Every 2,000 mi

1 item
  • Change gearbox oil
    Primary and gearbox
    Factory

    Manual: Change transmission oil. Factory: Sec. 3-1 table: after first 800 km (500 mi), then every 3,000 km (2,000 mi)

Every 3,000 mi or 12 months

15 items
  • Check engine mounting bolts and plates
    Engine
    Guideline
  • Check throttle cable(s) free play and return
    Fuel and air
    Guideline
  • Clean fuel tap filter / sediment bowl
    Fuel and air
    Guideline
  • Synchronize carburetors
    Fuel and air
    Guideline
  • Check / set ignition timing
    Ignition and electrics
    Guideline
  • Clean and gap contact breaker points, oil cam felt
    Ignition and electrics
    Guideline
  • Adjust clutch pushrod / clutch adjuster
    Primary and gearbox
    Guideline
  • Check chain guard, chain oiler (if fitted), rear chain case
    Final drive
    Guideline
  • Inspect chain and sprockets for wear (measure stretch)
    Final drive
    Guideline
  • Check steering damper (friction or hydraulic)
    Front end
    Guideline
  • Check steering head bearing adjustment
    Front end
    Guideline
  • Inspect fork seals, stanchions and fork boots
    Front end
    Guideline
  • Check footrests, pegs, rear brake and gear lever pivots
    Rear suspension and frame
    Guideline
  • Grease and check center / side stand and springs
    Rear suspension and frame
    Guideline
  • Check wheel bearings for play
    Wheels and tires
    Guideline

Every 3,000 mi or 2 years

1 item
  • Decarbonize exhaust ports, pipes and baffles
    Engine
    Guideline

    Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 4,000 mi or 12 months

3 items
  • Check / bleed / adjust oil injection pump cable
    Engine
    Guideline
  • Replace spark plugs
    Engine
    Guideline
  • Lubricate brake cam spindles, check linings and drums
    Brakes
    Guideline

Every 5,000 mi or 2 years

1 item
  • Check cylinder head bolt torque
    Engine
    Guideline

    Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

5 items
  • Clean carburetor float bowl(s), check float level and jets
    Fuel and air
    Guideline

    Ethanol fuel varnishes old carbs quickly in storage.

  • Check charging voltage and regulator / cut-out
    Ignition and electrics
    Guideline
  • Check swingarm bushes for play
    Rear suspension and frame
    Guideline
  • Inspect rear shocks for leaks and damping
    Rear suspension and frame
    Guideline
  • Lubricate speedometer / tachometer cables, check drive
    Controls and cables
    Guideline

    A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

3 items
  • Lubricate and check automatic advance unit
    Ignition and electrics
    Guideline
  • Change fork oil
    Front end
    Guideline

    Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

  • Repack / replace wheel bearings
    Wheels and tires
    Guideline

    Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 10,000 mi or 2 years

1 item
  • Compression test (or leak-down)
    Engine
    Guideline

Every 10,000 mi or 3 years

1 item
  • Repack / replace steering head bearings
    Front end
    Guideline

    Many old machines use loose balls in cups and cones. Taper roller conversions are common.

Every 10,000 mi

1 item
  • Replace chain and sprockets (wear based)
    Final drive
    Guideline

Every 12,000 mi or 3 years

1 item
  • Replace points and condenser
    Ignition and electrics
    Guideline

Every 15,000 mi or 5 years

1 item
  • Inspect clutch plates and springs
    Primary and gearbox
    Guideline

Every 15,000 mi

1 item
  • Replace brake linings / skim drums (wear based)
    Brakes
    Guideline

Every 25,000 mi or 6 years

1 item
  • Replace swingarm bushes / bearings
    Rear suspension and frame
    Guideline

Every 30,000 mi or 6 years

1 item
  • Rebuild forks: seals, bushes, springs
    Front end
    Guideline

Every 6 months

1 item
  • Clean battery terminals, check charge and strap
    Ignition and electrics
    Guideline

Every 12 months

1 item
  • Check speedometer / odometer against a known distance
    Controls and cables
    Guideline

    Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items
  • Inspect fuel tank for rust, sealer failure, leaks
    Fuel and air
    Guideline
  • Inspect wiring, bullet connectors and ground points
    Ignition and electrics
    Guideline
  • Inspect frame, welds and lugs for cracks
    Rear suspension and frame
    Guideline

Every 4 years

2 items
  • Replace oil injection delivery lines
    Engine
    Guideline
  • Replace fuel lines
    Fuel and air
    Guideline

    Old rubber and modern ethanol fuel do not mix well.

Every 6 years

2 items
  • Replace inner tubes and rim tape with tires
    Wheels and tires
    Guideline
  • Replace tires on age (regardless of tread)
    Wheels and tires
    Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.

Keep up with this schedule on your phone

Add the bike in the app and this chart loads itself, ready to log against and edit.

Coming soon to Google Play

Other 1965 Suzuki models

All 1965 Suzuki
Suzuki Colleda / early two-strokes
1955-1967
Colleda / early two-strokes
Guideline