MAINTENANCE MANUAL ch le ss .in INSTRUCTION BOOK fo AND for 1951 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 fo for ch le ss .in A•J•S 1951 m at SINGLE CYLINDER MOTOR CYCLES Compiled and Issued by the 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) A• J • S Factories : BURRAGE GROVE and MAXEY ROAD PLUMSTEAD, S.E.
1951 A•J •S MODELS MODEL MODEL MODEL MODEL 16M RIGID FRAME 16MS SPRING FRAME 16MC COMPETITION RIGID FRAME 16MCS COMPETITION SPRING FRAME 500 500 500 500 MODEL MODEL MODEL MODEL 18 RIGID FRAME 18S SPRING FRAME 18C COMPETITION RIGID FRAME 18CS COMPETITION SPRING FRAME 350 — Bore 69 mm . 500 — Bore 8 2 ·5 mm . ch le ss .in fo 350 350 350 350 Stroke 93 mm . Capacity 34 7 c.c. Stroke 93 mm . Capacity 4 9 8 c.c. at INTRODUCTION w.
ch le ss .in fo 1951 RIGID 16M and 18 m at 1951 SPRING 16MS and 18S ww w.
DATA Identity Make Models … … … … … … … … … … … … … … … … … … … … … … … … 350 c.c. … … … … … Scamped on left hand side of crankcase Stamped on seat lug of main frame, on right hand side (below the saddle) 350 c.c. Models—69 mm. (approx.) (2 Fin.) … … … … … 500 c.c. Models—82·5 mm. (approx.) (34 in.) … … … … … … … … … One Number of Cylinders (all models) … Stroke All Models—93 mm. (approx.) (3·65625 in.
Chains Pitch Location 350 Competition … … 350 Touring … … … … … 500 Competition 500 Touring … … A l l rigid models (Touring) … All spring models … … All competition rigid models All models … … … All models … … … … … … … … … … … … Front driving Front driving Front driving Front driving Rear driving Rear driving Rear driving Dynamo Magneto ½ in. ½ in. ½ in. ½in. s in. s in. s in. a in. a in. Width ·305 in. ·305 in. ·305 in. ·305 in. ·380 in. ·380 in. ·380 in. ·225 in. ·225 in.
Gear ratios (models 16MCS and 18CS) 15 16 17 18 19 20 21 First gear teeth 18·69 to 1 … … … teeth * 17·5 to 1 … … … teeth 16·44 to 1 … … … teeth † 15·57 to 1 … … … teeth … … … 14·6 to 1 teeth 14·01 to 1 … … … teeth … … … 13·35 to 1 * standard Solo sprocket for Model 16MCS. † standard Solo sprocket for Model 18CS.
Spokes (350 and 500 rigid and spring frame models) Location Gauge Type Front, left side Front, right side Rear, left side Rear, right side … … … … … … … … … … … … Butted Butted Butted Butted … … … … Length underhead Quantity 8 x10 9 x 11 7x9 7x9 5 x in. 8 8 in. 011018 011014 011012 011012 20 20 20 20 8 8 in. 8 8 in.
CONTROLS (1) Throttle twist grip. On right handlebar. fully closed engine should just idle when hot. Twist inwards to open. When (2) A i r 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. fo (3) Ignition lever. Small lever on left handlebar. Advances and retards ignition point.
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 " on." 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 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. fo FUEL SUPPLY ch le ss .
STARTING THE ENGINE (a) See that there is sufficient fuel in the petrol tank. (b) See that there is sufficient oil in the oil tank. (c) See that the gear pedal is in the neutral position. (d) Push inward the hexagonal end of off-side petrol tap slide. (e) See that the air control lever is in the fully closed position. (f) Fully advance the ignition and then slack back the control lever two-fifths of its total movement.
STOPPING THE ENGINE To stop the engine, close the throttle, raise the valve lifter lever and keep it raised until the engine has ceased to revolve. ON THE ROAD fo Having started and warmed up the engine, take the machine off the stand, sit astride it, free the clutch by pulling up the large lever on the left bar and engage the lowest gear. Next, slowly release the clutch lever and the machine will commence to move forward.
Special attention must be given, during the running in period, to such details as valve rocker adjustment, chains, brakes, contact breaker points, and steering head bearings, all of which tend to bed down in the first hundred miles or so. Particular note must be made of the adjustment of steering head bearings, which, if run in a slack condition, will be quickly ruined. After this bedding down process has taken place, adjustments to such details will probably only be necessary at lengthy intervals.
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. We recommend the following lubricants to use in machines of our make : SUMMER WINTER (SAE-50) (SAE-60) (SAE-60) (SAE-60) (SAE-50) Mobiloil A Castrol XL Price's Energol 30 Essolube 30 Double Shell (SAE-30) (SAE-30) (SAE-30) (SAE-30) (SAE-30) ch le ss .
FILLING THE GREASE GUN The standard grease gun consists of a barrel having a spring loaded end cap, to which is fixed a central steel piston in the shape of a long rod. This piston fits into a small cylinder made in one with the screwed top cap, on the end of which is the cupped nozzle that fits over the grease nipples. In the barrel of the gun, and sliding on the central piston rod, is a cork piston. The grease must be filled on the TOP of the cork piston.
fo ch le ss .in at m saj Engine Oil Circulation ww w. Illustration 5 THE OIL TANK A N D 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 one inch from the filler cap orifice, 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 (secured to the feed pipe union) stands in the oil tank. 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 oil filter :— Unscrew the hexagonal headed cap on top of oil tank and withdraw the dished washer and spring.
fo ch le ss .in at Illustration 6 s- m The inlet valve guide is shown withdrawn as also is the inlet valve stem adjusting screw (with lock nut) GUIDE, FOR VALVE. 3 4 TAPPED HOLE, TO ACCOMMODATE ROCKER BOX RETAINING BOLT. PLAIN HOLE, TO ACCOMMODATE VALVE GUIDE. 13 PLAIN HOLE, FOR OIL FEED TO INLET VALVE. 6 TAPPED HOLE, TO ACCOMMODATE CARBURETTER RETAINING STUD. 7 14 PLAIN HOLE, TO ACCOMMODATE PUSH ROD COVER TUBE TOP GASKET. INLET PORT. 8 TAPPED HOLE, TO ACCOMMODATE CARBURETTER RETAINING STUD.
GEAR BOX LUBRICATION Use one of the grades of Oils already specified. In no circumstances must heavy grease be used. 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. HUB LUBRICATION ch le ss .
BRAKE EXPANDER LUBRICATION Grease nipple on each brake expander bush. (One on each brake cover plate.) grease sparingly. Excessive grease may impair efficiency of brakes. Use 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.) fo BRAKE PEDAL LUBRICATION ch le ss .in Grease nipple in heel of foot brake pedal.
ch le ss .in fo LUBRICATION CHART at Illustration 7 m Lubrication Chart Tallow Location Engine Oil Locations 5 REAR CHAIN. s- 1 MAIN OIL TANK. 7 CONTROL LEVER MOVING PARTS. Grease Locations aj 8 BRAKE ROD JOINTS. 2 FRONT HUB. 9 FRONT PROP, AND REAR STAND HINGE PINS. 3 REAR HUB. 10 MAGNETO CHAIN CASE. 12 GEAR BOX. 11 STEERING HEAD BEARINGS. ww w. 19 FRONT CHAIN CASE. 13 SPEEDOMETER GEAR BOX. Hydraulic Fluid Location 16 FRONT AND REAR BRAKE EXPANDERS. 17 BRAKE PEDAL SPINDLE.
MAINTENANCE SADDLE ADJUSTMENT fo Saddle adjustment is provided at both front and rear ends. Importance is attached to the desirability of owners selecting the adjustment most to their liking. At the front end, the adjustment consists of three evenly spaced positions for the hinge bolt, accessible only upon removal of the petrol tank. At the rear end, adjustment is obtained by altering the position of the lower spring fixing nuts upon the screwed studs to which the springs are attached. ch le ss .
EVERY 1,000 MILES Oil tank Drain at first 1,000 miles and re-fill with new oil. (1.) Rear chain Remove and soak in molten tallow in bad weather. (5.) Magneto chain Inject small amount of grease through nipple in magneto chain case cover (10.) 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.
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. This voucher, together with the Instruction Manual, are supplied by us upon receipt of the signed application card to be found in the tool box upon taking delivery of a new motor cycle.
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 8 Showing details and order of assembly, of the fuel tank fixing bolts and components Part Number A B C D E … … … … … … 014999 1¼" diameter.
TO REMOVE THE PETROL TANK 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. Unscrew the tank fixing bolts and the tank is then free to be taken away. TO REPLACE THE PETROL TANK fo NOTE—The disposition of the various rubber and metal washers and tubular spacers should be specially observed so that they may be correctly replaced.
Inspect rubber fillet on rocker box side cover and renew if not perfect. Replace the side cover ensuring that a fibre washer is fitted under each of the three retaining nuts. Beware of over tightening these nuts, the joint being made by the rubber fillet excessive pressure is not necessary. Replace the petrol tank. DECARBONISATION ch le ss .
To replace valves :— After cleaning valve guide bores with rag smear each valve stem with clean oil and reverse procedure above. I M P O R T A N T N O T E :— Illustration 9 Showing application of valve spring compressor ch le ss .in fo If for any reason valve springs are removed from their fixing block it is important to see that upon replacement the spring with narrow spaced prongs is entered into the block from the chamfered end. 5 1 INLET VALVE PORT.
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.) When the abrasive ceases to bite, remove the valve and examine its face.
Remove One gudgeon pin circlip. included in tool kit. It is immaterial which circlip is removed. Use special pliers Gudgeon pin by pushing it out of piston. Take away piston. 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 o f f " 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.) ch le ss .
VALVE TIMING Inlet valve timing Inlet valve opens 32° before top dead centre. Inlet valve closes 63° after bottom dead centre. ch le ss .in fo Exhaust valve timing Exhaust valve opens 65° before bottom dead centre. Exhaust valve closes 30° after top dead centre. (See page 92 for particulars of special timing disc graduated in degrees.
TAPPET ADJUSTMENT The top ends of the two long push rods have screwed extensions. position by nuts, thereby providing tappet adjustment. These are locked in The correct tappet clearances, on touring models, with valves closed and engine cold, is N I L (warm engine on competition models). 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. ch le ss .
TO RE-TIME THE IGNITION The maximum advance is ½" (39°). Have available a stout screwdriver, or an old type tyre lever with turned up end, and a piece of stout wire 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 : Remove contact breaker cover. ch le ss .in Check setting of contact breaker points, and, if necessary, re-set same.
fo ch le ss .in Illustration 14 at The rotating oil pump plunger is here shown partially withdrawn, together with the guide screw which registers in the plunger profiled groove, thereby providing the reciprocating movement 1 m (By courtesy of " Motor Cycling ") D O W E L PEG, LOCATING TIMING GEAR COVER. BUSH, FOR INLET CAMSHAFT. 3 PLUNGER, FOR OIL PUMP. 10 s- 2 9 BOLT, FIXING REAR END CAP. BOLT, FIXING REAR END CAP. aj 4 5 TAPPED HOLE, TO ACCOMMODATE CRANKCASE DRAIN PLUG.
NOTE—Remember there is a paper washer under each oil pump end cap and, when fitting a new paper washer to the front cap, ensure the oil passage in the front cap is not obstructed by the paper washer. Make certain that the guide screw pin is correctly located in its groove (cut in the plunger) before tightening down otherwise serious damage will result when the engine is revolved. NOTE :—The guide screw pin is inserted in the screw relieved end first.
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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, Messrs. Amal Ltd., Holford Works, Perry Barr, Birmingham.
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 ch le ss .in fo Poor idling may be due to : Air leaks. Either at junction of carburetter and inlet port, or by reason of badly worn inlet valve stems or guides. 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. Pilot jet not operating correctly. Rockers adjusted too closely.
TRANSMISSION SERVICE THE GEAR BOX The gear box provides four speeds and has a positive foot change, operated by the right foot, 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.
TO REMOVE FRONT CHAINCASE AND CLUTCH ASSEMBLY To remove outer half of front chaincase Place tray under chaincase to catch oil. Remove exhaust pipe and silencer, as one unit. Remove nut on left end of footrest rod, push rod towards the right hand side of machine sufficiently to allow footrest for left foot to be disengaged. Slide footrest arm to one side or completely take away. Remove metal band. Remove rubber band. Take away outer half of chaincase. ch le ss .
TO RE-FIT THE FRONT CHAINCASE AND CLUTCH Fit back half of front chaincase by : Place on face of crankcase boss and back face of chaincase some liquid jointing compound. 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 washer so that it tightly abuts against a flat of the nut. Fit the clutch plates and springs by : at ch le ss .
THE CLUTCH (See Illustration 17) It should be noted that, although the basic design of the clutch fitted to 1951 models is identical to the 1950 and earlier models, most parts have been revised in detail design, and those parts are not interchangeable with those of previous years. Clutch operating lever A is moved in direction of arrow to disengage the clutch.
If, to remedy clutch slip, it is necessary to screw nearly home the five nuts, this is a clear indication that, either the clutch springs have lost their strength, and/or, the fabric inserts in the clutch friction plates have worn so that they are past further useful service. In which case, replace with new. The standard setting of the clutch spring adjusting nuts is obtained by fully tightening all five nuts and then unscrewing each exactly four complete turns.
fo ch le ss .in Illustration 18 Details of clutch operating lever 175-X-4 67-X 330-X 66-X-7 329-X LEVER, OPERATING C L U T C H . BALL (STEEL), FOR OPERATING PLUNGER. OPERATING PLUNGER. PIN, OR AXLE, FOR OPERATING LEVER. FORK, FOR OPERATING LEVER. 331-X 328-X 333-X SLEEVE, OR NUT, FOR OPERATING LEVER FORK. CAP, COVERING SLEEVE (SCREWED TO KICK-STARTER CASE COVER). SCREW, FIXING CAP TO KICKSTARTER CASE COVER.
FRONT CHAIN ADJUSTMENT Tighten the front chain by : Slacken : Nut on right-hand side of gear box top fixing bolt. Nut on right-hand side of gear box bottom fixing bolt. Forward nut on the adjusting eye-bolt. (Two or three turns.) ch le ss .in fo Remove inspection cap from front chaincase. 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. This provides sufficient movement for adjustment to the magneto driving chain. Tighten magneto chain by : Remove magneto chain case cover. Slacken nuts on bolts supporting magneto platform. fo Insert a screwdriver under that end of the magneto platform which is slotted and lever upwards until the chain tension is correct. The chain whip should be about ¼". ch le ss .in Tighten nuts on platform supporting bolts.
FORK & FRAME SERVICE STEERING HEAD ADJUSTMENT The steering head frame races 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.
ww w. aj s- m at ch le ss .in fo Introduced in early 1941, for use under strenuous war conditions by all the allied armies, it remains unaltered, except in detail, to this day, and copied practically universally. The hydraulic dampers operate in t u b u l a r members located inside the main tubes.
ch le ss .in fo has no o t h e r source of escape but past this sleeve and the adjacent small metered bleed hole. This intentionally restricted passage causes a considerable damper effect to the recoil action. It w i l l thus be gathered t h a t on the shock movement of the f o r k , slight damper action occurs, w i t h a greatly increased damper action on the reverse movement, b o t h 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 bail race.
Illustration 20 56 ww at m s- aj w. ch le ss .
fo w. aj 013632 000485 000203 010713 013509 000011 000004 016072 016339 017357 010721 016304 010719 000005 015932 010697 010706 010710 010692 ch le ss .
REAR SUSPENSION (Spring Frame Models) 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 engine oil which is sufficient to last almost indefinitely. Provision is, however, made for replenishment should same ever be required.
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ch le ss .in fo 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.
ch le ss .in fo Remove battery from carrier. Disconnect oil feed pipe from bottom of oil tank. Disconnect oil return pipe from bottom of oil tank. Disconnect vent pipe from back of oil tank. Disconnect voltage control unit from carrier side. Only two bolts to remove. No need to disconnect any of the electric cables. Remove bolt retaining rear stay from oil tank to rear mudguard. Remove screw, in base of carrier, retaining carrier to stay that is supported by the front chaincase.
WHEELS AND BRAKES TO REMOVE FRONT WHEEL Place machine on both stands. Remove the split pin, and pin, retaining yoke end of front brake cable to the brake expander lever. Slacken the nut on the left-hand end of front wheel spindle. fo Remove bolt retaining brake anchor stay to brake cover plate. ch le ss .
Hold left-hand side of wheel tightly forward against the cam stop and pull backwards the right-hand side of the wheel so that the brake cover plate disengages with the square headed anchor bolt. Then, raise the hinged portion of the rear mudguard and pull wheel away from the fork ends. TO REMOVE REAR WHEEL (Rigid Frame Models) Disconnect rear lamp wire at connection near rear wheel spindle. Disconnect speedometer driving cable. (Unscrew gland nut on cable.) fo Place machine on rear stand. ch le ss .
WHEEL BEARINGS AND ADJUSTMENT The wheel bearings are of taper roller type. The inner bearings for the rollers are integral with the wheel spindle in the case of the front wheel, and are separate tracks that are threaded on the centre spindle in the case of the rear wheel, (Reference to Illustration 24 will make that clear.) The outer cups for the rollers are pressed into the hub shell. They have a fixed location one side and an adjustable location on the other.
ch le ss .in fo To re-fit, reverse the above procedure, remembering that, after cup (6), washer (5), spacer (4), oil seal (3) and washer (2) have been inserted in the plain end of the hub, to re-fit the circlip (I) and then carefully to apply steady pressure on the inner edge of the cup (6) to force the above entire assembly tightly back against the circlip (1).
fo ch le ss .in Illustration 24 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) 1 CIRCLIP. 2 WASHER, METAL, OUTSIDE OIL SEAL. 19 SPACER, BETWEEN BEARINGS. 20 TAPER BEARING (OUTER CUP, CAGE FOR ROLLERS A N D ROLLERS). T H E S E A R E N O T SUPPLIED SEPARATELY.
TO DISMANTLE A REAR WHEEL BEARING These instructions need reference to the lower part of Illustration 24. 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). fo 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. fo BRAKE SHOES The two ch le ss .
Centralise brake shoes by : Ensure the nut binding the cover plate to the wheel spindle is slightly slack. 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. FRONT BRAKE ADJUSTMENT Major adjustment of the front brake shoes is made on the brake thrust pins, by fitting packing washers under the pins, as already described.
Adjust rear brake by : Place machine on centre stand if spring frame, otherwise on rear stand. Screw further on the brake rod the knurled adjusting nut till, by rotating the wheel, it can be felt the brake shoes are just touching the brake drum. fo Then unscrew the adjusting nut two complete turns.
fo Illustration 29 ch le ss .in Showing brake rod adjustment exhausted, indicating the need for brake thrust pin adjustment. at (SPRING FRAME MODELS) m TYRES A N D SERVICE s- 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.
TYRE REMOVAL It is not essential to remove a wheel from the machine to repair a puncture but it will usually be found desirable and more convenient to do so. Take off outer cover and remove inner tube by : Remove cap from tyre valve. Remove nut from tyre valve. fo Remove the " inside " from tyre valve. This allows inner tube to deflate. Most valve caps have a reduced and slotted top to engage with the valve " inside " in order to unscrew it. ch le ss .
TYRE PRESSURES The following are correct minimum inflation pressures for specified loads per tyre : Load per tyre, 200 lb. Pressure 16 lb. per square inch do. 240 lb. do. 18 lb. do. do. 20 lb. do. 280 lb. do. 350 lb. do. 24 lb. do. do. 400 lb. do. do. 28 lb. do. 440 lb. do. 32 lb. do. do. ch le ss .in fo The best method of ascertaining the correct pressure is to actually weigh the loads on the front and rear tyres.
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. fo (3) L I G H T I N G A N D ACCESSORIES—Lamps, Horn, Switches and wiring. ch le ss .
Lubricate contact breaker cam and tappet by : Remove contact breaker as described on page 74. Saturate, with a few drops of thin machine oil, the wick mounted in the core of its carrying screw B, Illustration 30. Push out of the contact breaker body the tappet B, Illustration 31, 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 1250-1500 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 positive brush is insulated and the negative 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 DYNAMO (a) Remove Magneto chain cover, (Retained by 6 screws.) (b) Remove nut and its washer fixing each magneto chain sprocket. (c) Using a sprocket withdrawal tool, or wedges behind sprocket, release, in turn, each magneto chain sprocket and take them away, complete with chain. (d) Remove timing gear cover (retained by 5 screws) taking care not to allow the two camshafts to come out of engagement with the small timing pinion. (e) Remove outer portion of front chaincase.
The regulator and cut-out are accurately set during manufacture. If, under normal running-conditions, it is found that the battery is continually in a low state of charge, or is being constantly over-charged, then the regulator setting should be checked by a qualified electrician and, if necessary, re-set. Whenever possible, this should be carried out by a Lucas Service Depot or Agent. The A.V.C. Unit is retained to the battery carrier by two bolts with nuts. The four terminals of the A.V.C.
The specific gravity of the electrolyte indicates the state of charge of the battery. With a fully charged battery the specific gravity of the electrolyte should be 1·280 to 1·300. Check the gravity by means of a hydrometer, and if it is below 1·150 the battery should be charged as soon as possible by the normal running of the motor cycle. If this cannot be arranged, the battery should be charged from an external source.
LIGHTING A N D ACCESSORIES Headlamp fo A LUCAS type SSU-700-P headlamp is fitted. The replacement part number is 50945-A. 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 35. The main bulb has a double filament. One filament provides the main driving beam and the other a dipped beam, brought into operation by the dipping switch on the left handlebar as may be required.
To replace the headlamp rim and light unit Lay the light unit in the rim so that the location block on the unit back engages with the forked bracket on the rim. Replace, by springing in, the spring clips so that they are evenly spaced around the rim. To replace the back shell engage the projections on the inside of the back shell with the slots in the holder, press on and secure by twisting it to the right. NOTE.
Screwed wire connector Illustration 37 Lucas screwed wire connector Part number 571395 Terminals ch le ss .in fo A LUCAS screwed connector of the type shown in Illustration 37 is used in the wire connecting the positive terminal of the battery to the input side of the ammeter (the wire has yellow and black coloured sleeves) in the head lamp. It is made up of four parts.
MAIN BULB PILOT BULB fo AMMETER ch le ss .in LIGHTING SWITCH DIPPER SWITCH SPEEDO ILL. HORN PUSH DYNAMO TO SPARKING PLUG SNAP CONNECTOR MAGNETO at REGULATOR BATTERY CONNECTOR ww w. aj HORN s- m BATTERY (NEGATIVE EARTH) TAIL LAMP Illustration 38 Wiring diagram (See page 96 for key to the cable numbers and colours.
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. TRACING TROUBLES at ch le ss .in Throttle opening too large. Air [evert in open position. Ignition not set just off fully advanced position. . Lack of fuel because of insufficient flooding. Lack of fuel because of pipe, or tap, obstruction. Excessive flooding of carburetter. Pilot jet chocked.
Lack of proper lubrication. (Quality or quantity of oil.) Faulty sparking plug. Air control to carburetter out of order. Punctured carburetter float. Engine carbonised. Weak valve springs. Pitted valve seats. Worn piston rings. Ignition setting incorrect. Choked silencer. ch le ss .in Engine stops suddenly may be due to : fo Engine overheats may be due to : No petrol in tank, or choked petrol supply. High-tension wire detached from sparking plug. Choked main jet. Oiled up, or fouled, sparking plug.
CLEANING THE MACHINE 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. The best method is to use a small hose, taking care not to direct water on to the engine, carburetter, magneto and other such parts. As a poorer substitute, a pail of water and a sponge may be used.
Parts sent to us as patterns, or for repair, should have attached to them a label bearing the sender's full name and address. The instructions regarding such parts should be sent under separate cover. If it is necessary to bring a machine, or parts, to the Works for an urgent repair, IT IS ESSENTIAL you MAKE AN APPOINTMEN T beforehand to A V O I D DISAPPOINTMENT. This can be done by letter or telephone.
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 A N D THE L AW Every motor cycle 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. fo (b) The certificate of insurance.
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 : 017253 Tool bag. 1 017114 Tyre inflator. 2 017007 Tyre levers. 1 017248 Pliers. 1 011188 Gudgeon pin circlip pliers. 1 017256 Screwdriver. 1 017246 Grease gun. 1 017249 Adjustable wrench. 1 017252 Sparking plug box spanner and tommy bar. 1 017254 Dynamo spanner. 1 017255 Triple spanner. 2 017052 Double end spanner. Small. 1 017053 Double end spanner. Large.
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.
ILLUSTRATIONS Illustrations Page Battery … … … Brake adjustment, front … … … … … … … 34 80 … … … … … … 26 69 Brake adjustment, rear (rigid frame) … Brake adjustment, rear (spring frame) Brake shoe adjustment … … … … … … … 28 70 … … … … 29 71 … … … … 25 68 70 … … … … … … … Clutch … … … Clutch lever Contact breaker … Contact breaker details … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 15 38 17 46 18 48 30 74 31 75 … …
INDEX … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … m w. aj s- SPARES AND SERVICE DEPARTMENTS ww 39 8 4 10 74 26 25 52 91 2 15 22 23 89 58 87 89 92 42 85 62 fo … … … … … … … … … … … … … … … … … … … … … ch le ss .
KEY TO THE COLOURED IDENTIFICATION BANDS ON THE NUMBERED CABLES SHOWN IN THE WIRING D I A G R A M ON PAGE 84. 15 BLUE and WHITE 7 RED and BLACK 23 WHITE and PURPLE 8 YELLOW 28 GREEN and BLACK 14 BLUE ch le ss .in 13 YELLOW and BLACK fo 1 RED 31 PURPLE 33 BLACK at GENUINE m A • J • S SPARES s- PURCHASED FROM aj AN AUTHORISED w. FROM ww WITH BY USING "A•J•S" THE FACTORY, THE PARTS DEALER ARE OR IDENTICAL ORIGINALLY BUILT INTO YOUR MOTOR CYCLE.
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