MAINTENANCE MANUAL ch le ss .in INSTRUCTION BOOK fo AND for 1953 350 c.c. and 500 c.c. A•J•S m at SPRING FRAME AND RIGID SINGLE CILINDER MODELS ww w. aj s- PRICE 2/6 NETT A•J• S MOTOR CYCLES Proprietors: ASSOCIATED MOTOR CYCLE LIMITED PLUMSTEAD • LONDON • S.E.
fo ch le ss .in WHEN CORRESPONDING REGARDING SERVICE OR SPARES ALWAYS QUOTE THE COMPLETE ENGINE NUMBER at (Including Including all letters in it) s- m THIS ENABLES US TO IDENTIFY THE MACHINE EACH SERIAL OF FRAMES IS NUMBERED FROM ZERO THEREFORE aj UPWARDS. THE QUOTATION OF A ww w. FRAME NUMBER ONLY DOES NOT PERMIT A MACHINE TO BE IDENTIFIED.
MAINTENANCE MANUAL AND INSTRUCTION BOOK ch le ss .in A•J•S 1953 fo for at SINGLE CYLINDER MOTOR CYCLES m Compiled and Issued by t he Manufacturers : s- A•J•S MOTOR CYCLES aj (Proprietors : ASSOCIATED MOTOR CYCLES LIMITED) Registered Offices : w. PLUMSTEAD ROAD, PLUMSTEAD LONDON, S.E.18 .. ENGLAND ww Nearest Station: WOOLWICH ARSENAL (Southern Region Railway) Factories: BURRAGE GROVE and MAXEY ROAD PLUMSTEAD, S.E.
2 ww at m s- aj w. ch le ss .
1953 A•J•S MODELS MODEL MODEL MODEL MODEL 16M RIGID FRAME (TOURING) 16MS SPRING FRAME (TOURING) 16MC RIGID FRAME (COMPETITION) 16MCS SPRING FRAME (COMPETITION) 500 500 500 500 MODEL MODEL MODEL MODEL 18 RIGID FRAME (TOURING) 18S SPRING FRAME (TOURING) 18C RIGID FRAME (COMPETITION) 18CS SPRING FRAME (COMPETITION) — Bore 69 m m. — Bore 82·5 mm. ch le ss .in 350 500 fo 350 350 350 350 Stroke 93 mm. Stroke 93 mm. Capacity 347 c.c. Capacity 498 c.c. at INTRODUCTION w.
DATA Identity Engine Number … … Frame Number … … … … … Bore … … … … … … Stamped on left hand side of crankcase Stamped on seat lug of main frame, on right hand side (below the saddle) … … … … … 350 c.c. Models—2·7187 in. (2 F in.) … 500 c.c. Models—3·250 in. (3 ¼ in ) … … … … … Engine capacity, in cubic centimetres … … All Models—93 mm. (approx.) (3·65625 in.
Gear box ratios Model First gear Touring Fourth gear (top) Third gear Second gear … … 2·65 to 1 1·70 to 1 1·308 to 1 1 to 1 Competition (Rigid) … … 3·11 t o 1 2·02 to 1 1·422 to 1 1 to 1 Competition (Spring) … 2·65 to 1 1·70 t o 1 1·308 to 1 1 to 1 … Gear ratios, Touring (Rigid and Spring Frame) and Spring Frame Competition Models First gear Second gear Third gear Fourth gear (top) fo Engine sprocket size 7 to 1 15 teeth … … … 18·55 to 1 11·90 to 1 9·15 to 1 (c) 16 tee
Oversize parts The following are the only " oversize " variations provided for the 350 and 500 c.c. Single Cylinder machines. Big-end rollers : ·001 in. oversize Cylinder re-bore : ·020 in. and ·040 in. oversize Pistons and rings : ·020 in. and ·040 in. oversize Pistons (standard size) Top of skirt diameter Front to rear clearance … … 2·7176 in. ·001 in. 500 … … 3·2490 in. ·001 in. Part number 013504 013505 ch le ss .
CONTROLS Throttle twist grip. On right handlebar. fully closed engine should just idle when hot. Twist inwards to open. When (2) Air lever. Small lever on right handlebar. Pull inwards to increase air supply to carburetter. Once set, when engine has warmed up, requires no alteration for different road speeds. Should be fully closed when starting engine from cold. (3) Ignition lever. Small lever on left handlebar. Advances and retards ignition point. Pull inwards to retard.
ww w. aj s- m at ch le ss .in fo If any adjustment is made to the rear brake pedal make certain the brake does not bind and also see there is not excessive free pedal movement before the brake comes " o n . " Illustration 1 Showing Controls Before using the machine, sit on the saddle and become familiar with the position and operation of the various controls. Pay particular attention to the gear positions.
DRIVING FUEL fo At the time of publishing this Instruction book only one grade of motor fuel (Pool Spirit) Is on sale, but It may be that soon the various grades of pre-war petrol will again be available when the use of best quality fuel is recommended because the small amount of economy that might be considered to accrue by using the cheaper grades is more than offset by the advantages obtained by using only Number One grades. FUEL SUPPLY ch le ss .
Illustration 2 Showing the gear indicator drum which upon assembly is set to record the various gears and neutral position, as the respective figure or letter N registers with index mark on the gearbox shell. ch le ss .in fo Upon re-asembly, after dismantling for any purpose, the index disc should be correctly re-sat for future reference. The first slow and gentle movement is essential to avoid damage to the teeth of the kick-starter quadrant.
STOPPING THE MACHINE To stop the machine, close the throttle, declutch by lifting the large lever on the left handlebar, and gently apply both brakes, increasing the pressure on them as the road speed of the machine decreases. Place the gear change foot pedal In the neutral position and stop the engine. fo Before leaving the machine, turn off the fuel supply. ch le ss .in I M P O R T A N T NOTICE NEVER DRIVE AWAY AT H I G H SPEED WHEN STARTING A RUN WITH A COLD ENGINE.
NOTES ON DRIVING If, at first, the lowest gear will not engage, release the clutch lever and after a second or two, make another attempt. This condition may exist in a new machine, but it tends to disappear after a little use. ch le ss .in fo Always endeavour to make the movements of hand (on the clutch) and foot {on the gear pedal) as simultaneous as possible, and remember, in all gear changes, a steady pressure of the foot is desirable.
CHECKING OIL CIRCULATION Provision is made to observe the oil in circulation and it is advisable to do this before each run. ch le ss .in fo If the filler cap on the oil tank is removed the bent over end of the oil return pipe will be noticed some two inches below the level of the filler cap orifice and the returning oil can be seen running from it. This check should be made immediately after starting the engine from cold.
LUBRICATION LUBRICANTS TO USE Efficient Lubrication is of vital Importance and it is false economy to use cheap oils and greases. FOR ENGINE LUBRICATION SUMMER WINTER Mobiloil D (SAE-50) Castrol "Grand P r i x " (SAE-50) Price's Energol 50 (SAE-50) Essolube 50 (SAE-50) Shell Motor Oil X-100 (SAE-50) (SAE-30) (SAE-30) (SAE-30) (SAE-30) (SAE-40) ch le ss .
ENGINE LUBRICATION SYSTEM fo This is by dry sump system. Oil feeds, by gravity, from the oil tank to the pump in the crankcase. The pump forces oil to various parts, which then drains to the bottom of crankcase sump. The pump then returns oil to the tank. This process is continuous while the engine Is revolving. The pump is so designed that it has a greater capacity on the return side to that on the delivery side to ensure that all oil is extracted from the crankcase.
fo ch le ss .in at m saj w. ww Illustration 4 Engine Oil Circulation THE OIL TANK AND FILTERS The level of oil in the supply tank should never be allowed to fall below the low level mark and, upon replenishment, should not be higher than the top level mark, otherwise, when starting the engine, the bulk of oil in the crankcase sump may be greater than the space available in the tank. The oil filter is made in cylindrical form of thick felt and is supported by a tubular wire cage.
A metal gauze strainer is secured in the tank end of the feed pipe union. After the first 500 miles, again at 1,000 miles, and subsequently at 5,000 mile Intervals. It is recommended that the oil tank is drained, the oil filters cleaned in petrol and the tank replenished with new oil. For access to felt oil filter :—Rigid Frame Models. fo Unscrew the hexagonal headed cap on top of oil tank and withdraw the dished washer and spring.
fo ch le ss .in Illustration 5 The inlet valve guide is shown withdrawn as also is the inlet valve stem s- m at adjusting screw (with lock nut) 8 PLAIN HOLE. FOR OIL FEED TO EXHAUST VALVE. aj 1 PLAIN HOLE. FOR OIL FEED TO INLET VALVE. 2 TAPPED HOLE, TO ACCOMMODATE CARBURETTER RETAINING STUD. w. 9 HOLE. TO ACCOMMODATE DOWEL PIN LOCATING VALVE SPRING SEAT. 3 INLET PORT. ww 10 GUIDE, FOR EXHAUST VALVE. 4 TAPPED HOLE, TO ACCOMMODATE CARBURETTER RETAINING STUD. 11 HEAD. 12 EXHAUST PORT.
GEAR BOX LUBRICATION Use one of the grades of Oil* already specified. be used, In no circumstances must heavy grease Lubricant Is Inserted through the filler cap orifice mounted on top edge of kick-starter case cover. The gear box must not be entirely filled with oil, and, under normal conditions, the addition of two fluid ounces of oil every 1,000 miles will be sufficient. fo Excessive oil will cause leakage. ch le ss .
BRAKE EXPANDER LUBRICATION Grease nipple on each brake expander bush, (One on each brake cover plate.) Use grease sparingly. Excessive grease may impair efficiency of brakes. BRAKE ROD JOINT LUBRICATION A few drops of engine oil on each brake rod yoke end pin and on the threaded portion of brake rod. (One pin on yoke each end of brake rod and on bottom of foot brake cable.) BRAKE PEDAL LUBRICATION fo Grease nipple in heel of foot brake pedal. ch le ss .
ch le ss .in fo LUBRICATION CHART at Illustration 6 m Lubrication Chart Engine Oil Locations Heavy Oil Location MAIN OIL TANK. CONTROL LEVER MOVING PARTS. 8 BRAKE ROD 401NTS. FRONT PROP, AND REAR STAND HINGE PINS. 19 FRONT CHAIN CASE. 12 GEAR BOX. aj s- 1 7 Grease Locations 2 FRONT HUB. w. 3 REAR HUB. Hydraulic Fluid Location FRONT FORKS (Fill at Top). ww 4 5 11 STEERING HEAD BEARINGS. 13 SPEEDOMETER GEAR BOX. 16 FRONT AND REAR BRAKE EXPANDERS. Tallow Location 17 BRAKE PEDAL SPINDLE.
MAINTENANCE PERIODICAL MAINTENANCE fo Regular maintenance, attention to lubrication, and certain adjustments must be made to ensure unfailing reliability and satisfactory service. This necessary attention is detailed below, and owners are strongly recommended to follow carefully these suggestions, and to make a regular practice of doing so from the first. The reference numbers, in brackets, refer to the locations specified on the Lubrication ch le ss .in Chart, illustration 6.
EVERY 1,000 MILES Oil tank Drain at first 1.000 miles and re-fill with new o i l . Rear chain Remove and soak in molten tallow in wet weather. Gear box Add 2 fluid ounces of specified oil. Hubs Inject small amount of grease. (2-3.) Expanders Inject small amount of grease. (16.) Steering head Inject small amount of grease. (11.) (1.) (5.) (12.) Smear all moving parts with engine oil and wipe off surplus. Air Filter (If fitted) clean and re-oil filter element. ch le ss .
FREE SERVICE SCHEME FREE SERVICE SCHEME All owners of N E W MODELS are entitled to one FREE SERVICE A N D INSPECTION at 500 miles, or, at latest, three months after taking delivery. ch le ss .in fo This service Is arranged by the supplying dealer to whom the Free Service Voucher must be handed.
ENGINE SERVICE ACCESS ww w. aj s- m at ch le ss .in fo For almost all service work to the upper parts of the engine, it is necessary, in order to obtain accessibility, first, to remove the petrol tank. The two petrol taps facilitate this operation by removing the need to first drain the tank of petrol. Illustration 7 Showing details and order of assembly, of the fuel tank fixing bolts and components A B ... ... C D E ... ... ... METAL WASHER ... THICK RUBBER PAD . . . T H I N RUBBER PAD . .
TO REMOVE THE PETROL TANK TO REPLACE THE PETROL TANK fo On Spring Frame Models fitted with twin seat remove the three Allen screws securing handlebar half clip and rest the bar on the handlebar lug forward of the head adjusting nut. Close both petrol taps and disconnect the petrol feed pipe from each tap. (Use two spanners, one to hold the tap and the other to unscrew the union nut on the petrol pipe.) Cut the wires Interlacing the four fixing bolts.
DECARBONISATION Instead of the usual stipulated mileage interval between periods of decarbonisation, it is recommended that this is undertaken only when the need for same becomes apparent because of excessive pinking, loss of power or generally reduced performance. When undertaken, unless it is thought necessary to inspect the piston and rings, the cylinder barrel Is best left undisturbed. The various stages in decarbonisation are described below. TO REMOVE THE CYLINDER HEAD fo Remove The petrol tank.
fo ch le ss .in Illustration 8 Showing Application of valve spring compressor 2 COLLAR, FOR VALVE SPRING. 6 OIL PASSAGE FROM ROCKER BOX TO INLET VALVE GUIDE. m 3 COLLAR, FOR VALVE SPRING. at 5 VALVE SPRING COMPRESSOR TOOL 1 COLLET, FOR VALVE. 4 BOLT. THROUGH TOOL AND COILS OF VALVE SPRING s- 7 SCREW WITH LOCK NUT. ADJUSTING OIL FEED TO INLET VALVE. aj NOTE—The special valve spring compressor tool is not part of the standard tool kit but can be obtained from any of our dealers (Part No. 018276.
REMOVING CARBON DEPOSIT ww w. aj s- m at ch le ss .in fo Do not use a sharp implement for removing carbon deposit from the interior of the cylinder head and the piston crown. A blunt piece of soft brass will be found quite suitable and the use of such will obviate the risk of making deep scratches. Care is necessary to avoid damaging the valve seatings and in no circumstances should any abrasive material, such as emery, or emery cloth, be used for cleaning and polishing.
The grinding is accomplished by smearing a thin layer of fine grinding paste (obtainable ready for use at any garage) on the valve face and then, after inserting the valve In the head, partially revolve, forwards and backwards, while applying light finger pressure to the head, raising the valve off its seat and turning to another position after every few movements. (Never revolve the valve continuously in one direction.
Remove One gudgeon pin circlip. It is immaterial which circlip is removed. included in tool kit. Gudgeon pin by pushing it out of piston. Take away piston. Use special pliers fo NOTE—The gudgeon is an easy sliding fit in both piston and connecting rod small-end bush. Rings may be removed from a piston by " peeling off " with a knife, or by introducing behind the rings three pieces of thin steel spaced at 120° from each other and then sliding off the rings. (Do not scratch the piston.
VALVE TIMING Inlet valve timing Inlet valve opens 32° before top dead centre. Inlet valve closes 63° after bottom dead centre. Exhaust valve opens 65° before bottom dead centre. ch le ss .in Exhaust valve closes 30° after top dead centre. fo Exhaust valve timing (See page 89 for particulars of special timing disc graduated in degrees.) aj s- m Camshaft timing marks (Use mark " 2 " ) at Illustration 10 w.
TAPPET ADJUSTMENT The top ends of the two long push rods have screwed extensions. These are locked In position by nuts, thereby providing tappet adjustment. The correct tappet clearances, on all models, with valves closed and engine warm (not hot) is N I L . This means the push rods should be free enough to revolve and, at the same time, there should be no appreciable up and down play. Prepare to adjust tappets by : Set piston to T.D.C. (Both valves closed).
TO RE-TIME THE IGNITION The normal advance is 35½° (v") . Have available a stout screwdriver, or an old type tyre lever with turned up end, also a small rod or stout wheel spoke 5½" long. Before setting the Ignition firing point it is essential the magneto contact breaker points are correctly adjusted. Therefore always check these first. Check contact breaker points by : Set ignition firing point by : Remove :— ch le ss .in Check setting of contact breaker points, and, if necessary, re-set same.
fo ch le ss .in at m saj w. ww Illustration 12 The rotating oil pump plunger is here shown in situ, together with the guide screw which registers in the plunger profiled groove, thereby providing the reciprocating movement 1 DO W E L PEG. LOCATING TIMING GEAR COVER. 2 TIMING SIDE FLYWHEEL A X L E W I T H INTEGRAL GEAR FOR DRIVING OIL PUMP PLUNGER. 3 OIL PUMP PLUNGER 4 SCREW (ONE OF THREE) W I T H FIBRE WASHER. PLUGGING OIL PASSAGES CAST IN CRANKCASE. 5 GUIDE PIN. FOR OIL PUMP PLUNGER.
TO REMOVE A N D REPLACE THE OIL PUMP PLUNGER Remove Lower end of rocker box oil feed pipe by unscrewing union nut. Both oil pump end caps. Oil pump plunger guide screw with pin. (See Illustration 12.) Oil pump plunger, by pushing at front and extracting from rear end of its housing. Replace by : fo Reversing above procedure. ch le ss .
fo ch le ss .in at m saj w. ww Illustration 13 Carburetter details in assembly order.
CARBURETTER SERVICE The information given in this section includes all that will normally be required by the average rider. For further details, particularly those connected with racing and the use of special fuels, we refer the enquirer to the manufacturers of the carburetter, Amal Ltd., Holford Road, W i t t o n , Birmingham, 6. ch le ss .
CARBURETTER ADJUSTMENT To ascertain if the setting is correct, a rough test is to warm up the engine and, with the ignition fully retarded and the air about three-quarters open, gradually open the throttle to full open, during which the engine should respond without a misfire, but, upon a sudden opening of the throttle, it should splutter and stop. (The engine should not be run for more than a few seconds with the ignition fully retarded.) ch le ss .
CARBURETTER T U N I N G INFORMATION fo Poor idling may be due to : Pilot jet not operating correctly. Air leaks. Either at junction of carburetter and inlet port, or by reason of badly worn inlet valve stem or guide. Faulty engine valve seatings. Sparking plug faulty, or its points set too closely. Ignition advanced too much. Contact breaker points dirty, pitted, loose, or set too closely. High-tension wire defective. Rockers adjusted too closely. ch le ss .
TRANSMISSION SERVICE THE GEAR BOX The gear box provides four speeds and has a positive foot change, operated by the right loot and a kick-starter. ch le ss .in fo It is retained to the frame by being clamped between the two engine rear plates by two bolts. The bottom fixing bolt acts as a pivot.
Remove the nut and small spiral spring securing small gear indicator disc from the cam barrel spindle. Next remove the five cheese head screws by which the K.S. case cover is secured to the gear box end plate. Withdraw the cover about ½ inch, holding the K.S. pedal firmly while doing so. Now swing the K.S. crank round until it can be tied to the foot change lever. prevents the K.S. return spring unwinding and facilitates re-assembly.
TO REMOVE FRONT CHAINCASE AND CLUTCH ASSEMBLY To remove outer half of front chaincase Place tray under chaincase to catch oil. Remove left side footrest arm. Remove screw binding chaincase metal band at its rear. Remove metal band, Remove nut and washer, in centre of chaincase front. ch le ss .in Take away outer half of chaincase. fo Remove endless rubber band. To remove front driving chain and clutch assembIy, complete Engage top gear, apply rear brake, and unscrew engine sprocket nut.
TO RE-FIT THE FRONT CHAINCASE A N D CLUTCH Fit back half of front chaincase by : Place on face of crankcase boss and back face of chaincase some liquid Jointing compound, "Wellseal recomended." Ensure the spacer is in position on the centre fixing bolt. the engine plate and the chaincase. (It is 1-13/32" long.) This is located between Place in position rear half of front chaincase. Fit long headed bolt, holding rear chain guard to front chaincase, but do not fully tighten.
Fit the front chain and lock the clutch centre nut by Replace the front driving chain. Ensure the spring connecting link is fitted so that the closed end of the spring clip faces the direction of rotation. Engage top gear, apply the rear brake and then fully tighten the nut that retains the clutch centre to the gear box mainshaft. Turn up the edge of the lock plate so that it tightly abuts against a flat of the nut.
CLUTCH SPRING ADJUSTMENT If clutch slip occurs the most probable cause is either incorrect cable adjustment or absence of free movement of the internal clutch lever. If both are found to be correct the clutch spring adjusting nuts may require adjustment. To obtain access to clutch spring adjusting nuts, remove front half of chaincase as already detailed.
Correct adjustment of the clutch operating mechanism is of the utmost importance and the following instructions must be carefully observed. Clutch cable stretch, which may develop at long intervals, is taken up by means of the adjuster provided at the gear box end of the cable, but when making this adjustment it is important that the normal movement of the internal lever is not encroached upon. The correct procedure is to remove the gear box oil filler plug which exposes the internal lever.
FRONT CHAIN ADJUSTMENT Tighten the front chain by : Slacken : Nut on right-hand side of gear box top fixing bolt. Forward nut on the adjusting eye-bolt. (Two or three turns.) Remove inspection cap from front chaincase. fo Screw up the rear nut on adjusting eye-bolt until, with the finger through the inspection cap orifice, It can be felt that the chain is dead tight.
REAR CHAIN ADJUSTMENT (Rigid Frame Models) To provide rear chain adjustment the rear wheel is bodily moved in the frame fork ends, which are open ended and slotted. Tighten rear chain by : Place machine on rear stand. Slightly slacken nuts on rear wheel solid spindle (left side first). Slacken nut on each chain adjusting bolt, two or three turns. forward end of each frame fork end.
MAGNETO CHAIN ADJUSTMENT The magneto platform hinges on one of its fixing bolts. ment for adjustment to the magneto driving chain. This provides sufficient move- Tighten magneto chain by : Remove magneto chain case cover. Slacken nuts on bolts supporting magneto platform. Insert a screwdriver under that end of the magneto platform which Is slotted and lever upwards until the chain tension is correct. fo The chain whip should be about ¼". Tighten nuts on platform supporting bolts. ch le ss .
FORK & FRAME SERVICE STEERING HEAD ADJUSTMENT The steering head frame -aces are of the floating self-aligning type and have spherical seats. Therefore they do not fit tightly in the head lug. fo Occasionally test the steering head for correct adjustment by exerting pressure upwards from the extreme ends of the handlebars. ch le ss .in It is particularly important that the adjustment is tested after the first one hundred miles because of the initial settling down that always occurs in that period.
fo ch le ss .in at m saj w. illustration 16 ww Introduced in early 1941 for use under strenuous war conditions by all the allied armies, it remains unaltered, except in d e t a i l , to this day, and copied practically universally. T h e hydraulic dampers operate in tubular members located inside the main tubes.
ch le ss .in fo has no other source of escape but past this sleeve and the adjacent small metered bleed h o l e . This intentionally restricted passage causes a considerable damper effect to the recoil action. It w i l l thus be gathered that on the shock movement of t h e fork, slight damper action occurs, w i t h a greatly increased damper action on the reverse movement, both actions automatically increasing in effect the more violent the movement.
Unscrew the hexagon plug on top of each inner tube and slacken the lock nuts securing the damper rods attached. Then, before removing the hexagon plugs, attach a piece of wire about 18 inches long underneath each damper rod lock nut, to enable the damper rods to be raised for reassembly. Remove domed lock nut at top of steering column. Remove lock nut on steering column. To re-fit a complete front fork assembly ch le ss .in Stick, with grease, 28 balls in fork crown ball race.
Illustration 17 55 ww at m s- aj w. ch le ss .
ww w. aj s- m at ch le ss .in fo REF. DESCRIPTION NO. 1. WASHER, LEATHER, FOR FORK SPRING TOP SEATING. 2. BUFFER, RUBBER, FOR FORK INNER TUBE (ONE OF THREE). 3. SPRING, MAIN, FOR FRONT FORK. 4. BUFFER, RUBBER, FOR FORK INNER TUBE (ONE OF THREE). 5. BUFFER, RUBBER, FOR FORK INNER TUBE (ONE OF THREE). 6. WASHER, LEATHER, FOR FORK SPRING BOTTOM SEATING. 7. EXTENSION, FOR FORK SLIDER. 8. OIL SEAL, RUBBER, FOR FORK INNER TUBE (AN ALTERNATIVE OIL SEAL IS MADE OF LEATHER). 9.
REAR SUSPENSION s- m at ch le ss .in fo The rear wheel is mounted in a fork that is hinged just behind the gear box. The hinge has robust plain bearings lubricated from a reservoir of 1½ fluid ounces (42.6 c.c.) of heavy gear oil which is sufficient to last almost indefinitely. Provision is, however, made for replenishment should same be required.
fo ch le ss .in at m saj w.
To check oil content of " TELEDRAULIC " leg and top-up : (DEALERS' SERVICE ONLY) Dealing with one leg at a time, remove top securing bolt, taking care to observe the location of the spacing washers on it. Remove bottom securing bolt and take away the leg. Using a suitable clamp encircling the outer tube adjacent to the bottom pivot lug, grip in a vice and loosen the pivot lug.
TO REMOVE OIL TANK A N D BATTERY CARRIER Two studs on the seat tube, one facing to the front, the other facing to the rear, engage with two right-angle stays on the oil tank and two similar stays on the battery carrier, and two washers and two nuts, fitted to the studs, retain the oil tank and battery carrier in position. fo Remove oil tank and battery carrier by : Drain oil tank. Disconnect wire from the battery where it is attached to the seat lug bolt by a screw.
WHEELS AND BRAKES TO REMOVE FRONT WHEEL fo Place machine on both stands. Remove the split pin, and pin, retaining yoke end of front brake cable to the brake expander lever. Remove bolt retaining brake anchor stay to brake cover plate. Slacken the nut on the left-hand end of front wheel spindle.
TO REMOVE REAR WHEEL (Rigid Frame Models) ch le ss .in fo Place machine on rear stand. Disconnect rear lamp wire at connection near rear wheel spindle. Disconnect speedometer driving cable. (Unscrew gland nut on cable.) Disconnect rear chain connecting link. (Allow chain to hang clear of the rear wheel sprocket without becoming disengaged from the gear box small sprocket.) Slacken the two bolts securing rear portion of rear mudguard to its front portion.
It will be found easier to re-fit the wheel to the fork ends with the brake cover plate hanging free and then, holding the wheel on its left-hand side, as far forward in the fork end as is possible, to swing the right-hand side backwards, lifting up the free cover plate so that the slot in it is positioned to engage with the square headed anchor bolt and then swinging the right-hand end of the axle forwards till engagement has been completed.
fo ch le ss .in Illustration 21 at Showing rear hub, rear chain sprocket, brake and speedometer gear box (Spring Frame Model) s- m (Rigid Frame Models Identical except for items 4-6 and 26) 14 2 GREASE NIPPLE ON SPEEDOMETER GEAR BOX. SPACER, BETWEEN ROLLER BEARINGS. 15 GREASE NIPPLE, IN H U B SHELL. 3 SPEEDOMETER GEAR BOX. 16 OUTER RACE OF RIGHT SIDE TAPER ROLLER BEARING. N U T , L O C K I N G BEARING ADJUSTING RING. aj 1 R I G H T - H A N D SIDE H U B FLANGE. FITS w.
fo ch le ss .in Illustration 22 at Showing exploded view of hub bearing components in the order of assembly. Upper part is that of front bearings. (Rigid and Spring Frame Models). Lower part is that of rear bearings (Spring Frame Model only) m (Rigid Frame Models identical except for items 28 to 32) 19 SPACER, BETWEEN SEARINGS. 1 CIRCLIP. 2 WASHER, METAL, OUTSIDE OIL SEAL. 3 OIL SEAL. s- 20 TAPER BEARING (OUTER CUP. CAGE FOR ROLLERS A N D ROLLERS). THESE ARE N O T SUPPLIED SEPARATELY.
TO DISMANTLE A REAR WHEEL BEARING These instructions need reference to the lower part of Illustration 22. Remove wheel from machine. Remove brake cover plate, with brake shoes, centre solid spindle with cams, spacers, bushes, nut and speedometer gear box. Turn to left-hand side and slacken lock nut (26). Completely unscrew the adjusting ring (25) and take it away with the lock nut (26) still on it. ch le ss .
BRAKE DRUMS The front wheel brake drum is retained to the wheel by ten countersunk screws. The rear wheel brake drum is integral with the rear wheel sprocket and is retained to the wheel hub by five bolts and nuts. Under each nut is a lock washer of the " tab " type and it is essential these are always in position. Harshness in transmission can be caused by the drum retaining bolts and nuts being loose. Rear wheel spokes will break for the same reason.
Centralise brake shoes, Front or Rear, by : Ensure the nut securing the cover plate and also the fulcrum stud nut (front only) are slightly slacked off. Place on the brake expander lever a tubular spanner (to increase the leverage), and, while maintaining pressure on the tubular spanner (to expand fully the brake shoes), fully tighten the spindle nut binding the cover plate to the spindle and also the nut on fulcrum stud. FRONT BRAKE ADJUS T ME N T The adjuster is locked in position by a nut.
Adjust rear b rak e by : Place machine on centre stand if spring frame, otherwise on rear stand. Screw further on the brake rod the knurled adjusting nut t i l l , by rotating the wheel, it can be felt the brake shoes are just touching the brake drum . fo Then unscrew the adjusting nut t w o complete turns.
fo ch le ss .in Illustration 27 Showing brake rod adjustment exhausted, indicating the need for brake thrust pin adjustment at (SPRING FRAME MODELS) TYRES AND SERVICE ww w. aj s- m Obtaining satisfactory life and service from the tyres is largely a matter within the user's control because the first essential is correct inflation. Check tyre pressures with a low pressure gauge at least once a week. Inflate as may be necessary.
Push edge of cover, that is diametrically opposite to the valve, R I G H T I N T O W E L L OF R I M and, using tyre lever OI7O07, pick up edge of cover N E A R V A L V E so that it comes off over the edge of the rim. Work off the remaining edge of the cover t i l l it is clear of the rim. and there is no reason to use force. This is quite easy Push upwards valve stem through its hole in the r i m , and the inner tube is then free to be taken away.
USEFUL INFORMATION In the following five paragraphs are particulars of failures and troubles that can occur, together with the probable reasons. These troubles are arranged in the order of their probability. Engine fails to s t a r t , or is difficult to start, may bo due to : at Oiled up, or fouled, sparking plug. Stuck up engine valve. Weak, or broken, valve spring. Valve not seating properly. Contact points dirty. Incorrect contact point gap. Water on high-tension pick-up. Moisture on sparking plug.
Engine overheats may be due to : Engine stops suddenly may be due to : ch le ss .in No petrol in tank, or choked petrol supply. High-tension wire detached from sparking plug. Choked main jet. Oiled up, or fouled, sparking plug. Water on high-tension pick-up, or sparking plug. Water in float chamber. Vent hole in petrol tank filler cap choked. Stuck up valve. fo Lack of proper lubrication. (Quality or quantity of oil.) Faulty sparking plug. Air control to carburetter out of order.
ABNORMAL TYRE WEAR Abnormal tyre wear may be due to : Incorrect tyre pressure. Wheels not In alignment. Harsh driving methods. (Misuse of acceleration and braking.) fo CLEANING THE MACHINE ch le ss .in Do not attempt to rub, or brush, mud off the enamelled surfaces because this will soon destroy the sheen of the enamel. Mud, and other road dirt, should be soaked off with water.
ELECTRICAL SERVICE ELECTRICAL EQUIPMENT LUCAS electrical equipment Is fitted and this comprises three Independent electrical circuits, as follows : (1) IGNITION—Magneto, High-tension wire and Sparking plug. (2) CHARGING—Dynamo, Automatic Voltage Control Unit and Battery. CIRCUIT ch le ss .in IGNITION fo (3) L I G H T I N G A N D ACCESSORIES—Lamps, Horn, Switches and wiring.
Lubricate contact breaker cam and tappet by : Remove contact breaker as described on page 75. Saturate, with a few drops of thin machine oil, the wick mounted in the core of its carrying screw B, Illustration 28. Push out of the contact breaker body the tappet B, Illustration 29, wipe it with a soft cloth, smear it with thin machine oil and then replace it. ch le ss .
The foregoing instructions do not apply to competition models fitted with Racing Magnetos Type NR1. SPECIAL NOTE—Check the contact breaker point gap after the first one hundred miles and five hundred miles. Owing to the initial settling down, there is a tendency for the gap to alter in the first few hundred miles of use. This may seriously affect the ignition setting. Subsequent adjustment will only be required at long intervals but it is as well to check the gap every two thousand miles.
CHARGING A LUCAS type E3-N dynamo is fitted. It is anti-clockwise in rotation. The cutting in speed is 1 250-1 500 r.p.m. at 7 volts and at 1,850 to 2,200 revolutions per minute it gives an output of 5 amps at 7 volts. The replacement part number is 20028A. The negative brush is insulated and the positive brush is earthed. The two exterior terminals are marked " D " and " F," indicating the respective terminals for the Positive and Field wires that lead to similarly marked terminals on the Regulator Unit.
TO REMOVE THE DYNAMO ww w. aj s- m at ch le ss .in fo Remove the left side foot rest arm. Place a tray under primary chaincase to catch the o i l . Remove chaincase band binding screw and remove metal band and also endless rubber band. Remove nut and washer in centre of chaincase when outer half can be taken away. Remove spring circlip, locking plate and nut securing dynamo sprocket and withdraw sprocket with a suitable tool.
Normally, during day-time running, when the battery is in good condition, the dynamo gives only a trickle charge, so that the ammeter reading will seldom exceed 1 to 2 amperes, i.e. half to one division on scale. The cut-out is an automatic switch which is connected between the dynamo and the battery. When the engine is running fast enough to cause the voltage of the dynamo to exceed that of the battery the cut-out allows the battery to be charged by the dynamo.
If the level of the electrolyte is so low that a hydrometer reading cannot be taken, no attempt should be made to take a reading after adding distilled water until the battery has been on charge for at least 30 minutes. ch le ss .in NEVER transfer the electrolyte from one cell to another. fo The specific gravity of the electrolyte indicates the state of charge of the battery. W i t h a fully charged battery the specific gravity of the electrolyte should be 1·280 to 1·300.
fo ch le ss .in Illustration 34 Showing Unrip panel containing a m m e t e r (at top) switch and cable harness. The ammeter fitted is type CZU-27. (See page 84 for numbered references.) L I G H T I N G A N D ACCESSORIES s- m at Headlamp A LUCAS headlamp is fitted. It has a panel mounted on its top, retained by three screws, in which is the main switch and ammeter and it also supports the cable harness. See Illustration 34. The main bulb has a double filament.
Rear lamp A LUCAS rear lamp is fitted. The body, with bulb holder, is secured to the rear number plate. Details of lamp bulbs are given in " D A T A . " Horn The horn push switch, situated on the right handlebar Fuses There are no detachable fuses in LUCAS motor cycle electrical equipment. ch le ss .in fo Snap w i r e connector The LUCAS snap connector, as shown in Illustration 35, is made up of four components.
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REPAIRS AND SERVICE REPAIRS The instructions regarding repairs should be clear and definite, otherwise the cost may be greater than that expected. We shall be pleased to give estimates for repairs if parts are sent to us for that purpose.
SERVICE The Service and Repair Department is situated in Burrage Grove, Plumstead, London, S.E.18, and is open on Mondays to Fridays from 8.30 a.m. to 12.55 p.m.—2.0 p.m. to 5.30 p.m. It is closed on Saturdays, Sundays and National Holidays. It exists for the purposes of : (a) Giving technical assistance verbally or through the post. (b) Supplying spare parts over the counter or through the post. (c) Repairing and re-conditioning machines, or parts of machines, of our make.
THE MACHINE AND THE LAW Every motorcycle used on the public roads must be registered and carry the registration numbers and licence disc allotted to it. The dealer, from whom the machine is bought, will, generally, attend to all matters legally essential before it is used on the public roads. To register a new machine Send to the Local Registration Authority the following : (a) Form " RF1/2," duly completed.
GUARANTEE fo We give the following guarantee with our motorcycles, motorcycle combinations and sidecars, which is given in place of any implied conditions, warranties or liabilities whatsoever, statutory or otherwise, all such implied conditions, warranties and liabilities being in all cases excluded. Any statement, description, condition or representation contained in any catalogue, advertisement. leaflet or other publication shall not be construed as enlarging, varying or overriding this guarantee.
TOOLS AND SPECIAL EQUIPMENT TOOLS The standard tool kit, issued with each new machine, contains : Tool bag. 017253 1 017251 015023 017257 018055 018153 018657 OPTIONAL Screwdriver. Grease gun. Adjustable wrench. Sparking plug box spanner and tommy bar. Dynamo spanner and clutch spring nut key. Double end spanner, 1·010 in. by 1·200 in. Double end spanner. Small. Double end spanner. Large. Contact point spanner and gauge (Touring), Contact point spanner and gauge. (Competition) Double end spanner.
BADGES ww w. aj s- m at ch le ss .in fo Neat monogram badges are now available at a cost of 1/6, plus 6d. postage. They can be supplied as a tie pin, as a brooch or for fitting in a button hole. When ordering state type required.
INDEX … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … m ww w. aj s- SPARES AND SERVICE DEPARTMENTS HOURS OF BUSINESS FOR CALLERS MONDAYS TUESDAYS WEDNESDAYS THURSDAYS FRIDAYS NOT OPEN ON 8.30 a.m. to 12.55 p.m. 2.0 p.m. to 5.30 p.m.
ILLUSTRATIONS Illustration … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … m … … … … … … … … … … … … at … … … … … … … Page 81 68 69 70 62 67 69 37 46 75 76 8 80 79 31 31 4 9 17 16 14 2 22 21 34 19 6 16 29 55 52 40 10 65 64 82 58 21 3 12 18 13 35 57 … … … … … … … … … …
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