1957-1966 AJS Matchless Single Service & Repair Manual

SERVICE AND OVERHAUL MANUAL FOR THE AJS & MATCHLESS SINGLE MOTORCYCLES F. NEILL by Covering 1958 to 1964 Lightweight 250 c.c. and 350 c.c. models G2 G2S G2CS G2CSR 14 14S 14CS 14CSR G5 8 and 1957 to 1966 Heavyweight 350 c.c., 500 c.c. and 600 c.c. models G3 G3C G3S G3LS G3LCS G80 G80S G80CS TCS 16 16S 16C 16CS 16MS 16MC 16MCS 18 18S 18CS F. NEILL AJS & MATCHLESS SINGLES 1957-1966 Lodgemark Press Reprinted in Belgium LODGEMARK PRESS LTD BANK HOUSE, SUMMERHILL, CHISLEHURST, KENT BR7 5RD, ENGLAND TWO-STROKE HIGH PERFORMANCE ENGINE DESIGN & TUNING By World famous engine designer Bossaglia who was responsible for most of the Italian rotary valve kart engines including Komets and Parillas from the very first—the V11 to the K89. 227 pages packed with information including : Characteristics and types of two-stroke motors. Multi-cylinder engines, Fuel, Quantity of air necessary for combustion. Determining the power, The Pressure Volume diagram, Performance, The operation of the crank, Balance, The Stroke/bore ratio, Third port induction, Induction through valves, Blade type valves, Cylindrical rotary valves, Rotating disc valves, Transfer and scavenging with transverse flow, tangential flow, uni-directional flow, Counter-flow scavenging, Position of the ports, Bi-metal cylinders, Cylinders with chromed bore, The piston, The gudgeon pin, The piston rings, Constructional ideas for the piston, The head, The crankcase, The crankshaft, Modification of the crank shaft assembly, Modification of cylinder, piston and head, The carburettor, Fuel pumps, Carburation adjustments, Fuel injection, The magneto The sparking plug, Ignition timing, Electronic ignition, Lubrication, Exhaust System, Mufflers, Exhaust system for multi-cylinder engines, Exhaust silencers, Test procedure, Examples of modifications. £4.35 (incl. insurance) Ref 290 TWO STROKES & TUNING TWO-STROKE EXHAUST SYSTEMS Full details on how to calculate design and make competition exhaust systems. 55p Ref 252 Available again March TWO-STROKE PORTS FOR POWER Read how to calculate and design the right port timing for your requirements. 55p Ref 253. TWO-STROKE CARBURATION AND IGNITION Roy Bacon's third book on racing two strokes. Vital information on carburation & ignition. 55p Ref 281 ROTARY VALVE TWO-STROKE KART ENGINES All about 100cc kart engines. Includes Arisco, B.M., Corsair, Famrel, Komet, Parilla, Petry, Saetta, Starr, Basic preparation, using Bleepers, Transistorised Ignition, Tillotson carbs. £1.10 Ref 288 IMPROVING TWO STROKE ENGINE PERFORMANCE Villiers, Maico, Vespa, Marcelle, Zundapp, Itom, DKW, Lambretta. 85p Ref 135 BUILDING KARTS KARTING FOR SCHOOLS & YOUTH GROUPS Organising, driving and building low-cost karts. Forming clubs. 90p Ref 292 JAVELIN SET No. 1 Details and drawings to build a low price kart without a tube bender. Suitable for 2 or 4-stroke engines without gearbox, max 5 hp & 40 lbs for Cadet racing, fun and driver training. Bolted-construction. 50p Ref 270 CADET SET No. 3 Details and drawings to make a fun kart without a tube bender. Suitable for 2 or 4 stroke engines without a gearbox up to 5 hp and weighing up to 40 lbs. New edition provides option of bolted or welded construction. Any parts can be purchased if required. £1.10 Ref 293 ABOUT KART RACING STARTING KARTING How to start the sport explained, details of classes, location of tracks. British clubs and addresses. Where to buy karts, engines fr accessories. 4th Edn. 50p Ref 286 GOING KARTING Covers every aspect of karting, how to buy your kart and engine, racing on motor tracks, etc. 4th Edn. £1.45 Ref 266 R.A.C. KART REGS 1974 All the rules and regulations governing drivers, organisers, tracks, karts and engines. British calendar of events, club addresses and list of tracks. 50p Ref 130 www.ajs-matchless.info

www.ajs-matchless.info

Technical details, together with working instructions given in ensuing chapters are solely confined to the single cylinder A.J.S. and Matchless models, which are similar regarding design, and identified by the petrol tank emblems and colour finish. The engine design of the heavyweight single cylinder models is basically identical since 1948, and in consequence the engine assembly instructions—in the main—apply to all models made from 1948 to 1966. The lightweight models were introduced in 1959 and design changes with minor modifications are described to enable owners to incorporate the later parts into earlier engines, if so desired. As the crankcases for the 350 and 500 heavyweight engines are identical —since 1948—the small capacity engine can be converted to the larger type by substituting parts in the top portion of the engine. The author and the publishers wish to express their thanks to Norton Villiers Ltd. for their co-operation in the preparation of this book and permission to publish the text and illustrations. www.ajs-matchless.info

SERVICE AND OVERHAUL MANUAL FOR THE AJS & MATCHLESS SINGLE MOTORCYCLES by F. NEILL S.B.N. 850770203 © LODGEMARK PRESS LIMITED Bank House, Susan Wood, Chislehurst Kent BR7 5RD, England EDITOR H. A. NIMMO www.ajs-matchless.info

Technical data Engine design changes Lubrication Recommended lubricants Periodical maintenance Engine servicing Engine overhaul Gearbox and Clutch Front forks Rear suspension units Frame Wheel bearings Wheels and Brakes Transmission Carburettor Wipac alternator Wipac electrical service Lucas electrical service Lucas coil ignition Magneto Dynamo Wiring diagrams 5 13 18 20 21 23 35 54 71 84 85 87 90 100 102 104 107 111 112 113 114 120 Contents page … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … www.ajs-matchless.info

Identity Engine Number Frame Number Cylinder Bore Stroke Cubic Capacity Carburettor Type 376/99 Main jet (without air filter) Main jet (with air filter) Choke size Throttle slide Needle position Capacities Petrol tank Oil capacity Gear box Front chain case Compression Ratio General Seat height Wheel base Weight Ground clearance Cylinder bore Nominal size Piston Size Skirt diameter (taken at right angle to gudgeon pin top of the skirt). High limit Low limit On the crankcase near engine plate cowling. On right hand side of frame head lug. 69,85 mm. 64.84 mm. 248.5 c.c. (15.2 cu. ins.) Amal Monobloc (12° inclination) 180 180 1z" 3½ central (.106) pilot 25 3¼ gallons (12.5 litres) 2½ pints (1.4 litres) 3 pints (1.8 litres) 568 c.c. 7.8 to 1 30" (76 cms.) 53" (134.5 cms.) 325 lbs. (148 kilos) 5½" (14 cms.) 2.7500 + .0005" – .0005" 2.7488" 2.7480" 250 c.c. CSR 1962/64 Models Compression Ratio Valve springs (Scrambler Type) Inlet Valve head diameter (New Type) Gear Ratios Top Third Second First 8 to 1 Spring free length 1½" between wire centres. 1S" 6.39 to 1 8.31 to 1 11.82 to 1 18.68 to 1 250 c.c. G2 and G2S Models TECHNICAL DATA 5 www.ajs-matchless.info

Sprocket Sizes Engine Gear box Clutch Rear Wheel Chain Sizes Front Rear Carburettor Main jet Pilot jet Throttle slide Needle jet Needle location Spark Plug 22 teeth 18 teeth 46 teeth 55 teeth Duplex .315 x .638" (72 links) ½" x .305" (124 links) Type 389/82 (18" bore) Size 200 Size 30 3 Size .106" Central notch FE 80 250 c.c. CSR 1965/66 Models Compression Ratio Ignition Timing Valve spring (coil type) Gear Ratios Internal Ratios Top Third Second First Actual Ratios Top Third Second First Spark Plug Piston Rings Compression rings Diameter Width Radial Thickness Scraper ring Diameter Width Radial Thickness Piston Ring Gap Valve Timing Inlet valve opens Exhaust valve closes 9.5 to 1 24 degrees (x") full advance inner free length 1.531" outer free length 1.700" 1 to 1 1.24 to 1 1.75 to 1 2.76 to 1 6.5 to 1 8.05 to 1 11.68 to 1 17.97 to 1 K.L.G. FE 220 2¾" (69.85 mm.) .0625"—.0615" .112"—.106" 2¾" (69.85 mm.) .156"—.155" .112"—.106" .008"—.013" 40° B.T.D.C. with .010" rocker 40° A.T.D.C. clearance. 6 www.ajs-matchless.info

Chain Sizes Front chain Rear chain Gear Ratios Internal Ratios Top Third Second First Actual Ratios Top Third Second First Sprocket Sizes Engine Clutch Final drive Rear wheel a" x .225" (73 links) ½" x .305" (125 links) 1 to 1 1.30 to 1 1.85 to 1 2.92 to 1 6.89 to 1 8.96 to 1 12.75 to 1 20.12 to 1 21 teeth 50 teeth 19 teeth 55 teeth 350 c.c. Lightweight Model identity Engine number Frame number Cylinder bore Stroke Cubic capacity Carburettor Type 389/42 Main jet (without air filter) Main jet (with air filter) Choke size Throttle slide Needle position Capacities Petrol tank Oil capacity Gear box Front chain case Compression Ratio General Seat height Wheelbase Weight Ground clearance Cylinder bore Nominal size On the crankcase near engine plate cowling. On right hand side of frame head lug. 72 mm. 85.5 mm. 347 c.c. (21.17 cu. ins.) Amal Monobloc (12° inclination) 220 220 18" 3½ central (.106) pilot 25 3¼ gallons (12.5 litres) 2½ pints (1.4 litres) 3 pints (1.8 litres) 568 c.c. 6.9 to 1 29.5" (74 cms.) 53" (134.5 cms.) 340 lbs. (154 kilos) 6" (15 cms.) 2.8345 + .0005" – .0005" 7 www.ajs-matchless.info

Piston Size Skirt diameter (taken at right angle to gudgeon pin top of the skirt). High limit Low limit Piston Rings Compression rings Diameter Width Radial Thickness Scraper ring Diameter Width Radial Thickness Piston Ring Gap Ignition Timing Valve Timing Inlet valve opens Exhaust valve closes Spark Plug Chain Sizes Front chain Rear chain Gear Ratios Internal Ratios TOP Third Second First Actual Ratios Top Third Second First Sprocket Sizes Engine Clutch Final drive Rear wheel 2.8286" 2.8276" 72 mm. 3 /64 " .151"—.109" 72 mm. E " .109"—.101" .008"—.013" ¼" B.T.D.C. 40° B.T.D.C. with .010" rocker 40° A.T.D.C. clearance. K.L.G. FE 80 .315" x .628" Duplex (72 links) ½" x .305" (123 links) 1 to 1 1.30 to 1 1.85 to 1 2.92 to 1 6.39 to 1 8.32 to 1 11.82 to 1 18.68 to 1 22 teeth 46 teeth 18 teeth 55 teeth 350 c.c. Heavyweight (Long Stroke) Model Cylinder bore size Compression ratio (1956 onwards) Piston skirt diameter—Top Piston ring gap Gudgeon pin bush size 2.7197—2.7187" 7.4 to 1 2.7180—2.7172" .008"—.0013" d" + .0005" d" – .00025" 8 www.ajs-matchless.info

1957-1966 AJS Matchless Single Service & Repair Manual

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