Instruction manual

ManualsBrandsA.J.S. ManualsAutomotive18S

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 :

Slide into position, in the clutch case attached to the clutch sprocket, a steel plain

clutch plate. (On 350 touring models the first plate must be the one extra thick plate,

ensure the recessed part of the steel plate faces to the clutch centre and thereby

overhangs the flange of the clutch centre.)

Slide into place a clutch friction plate (plate with fabric inserts) and follow with a steel

plain plate, then another friction plate and so on, alternatively, till all plates are fitted.

(Five plain plates and four friction plates on 350 c.c. ; six plain, and five friction on

500 c.c. and all competition models.)

Drop into the spring pressure plate the clutch spring cups.

Show up the spring pressure plate and insert over the studs the clutch springs, retaining

each one a few turns, as fitted, with a clutch spring adjusting nut.

Fully tighten the clutch spring adjusting nuts.

Slacken back, four complete turns, each clutch spring adjusting nut. (An old and broad

screwdriver, specially slotted on the engaging edge, is the most suitable tool for clutch

spring adjustment.)

Engage top gear, apply rear brake and then fully tighten the engine shock absorber

retaining nut.

Check front driving chain for adjustment.

Check dynamo driving chain for adjustment.

Fit outer half of front chaincase by :

Ensure faces of both halves of chaincase are clean.

Take off, from the rear brake rod, the adjusting knurled nut.

Ensure the rubber and metal bands are clean and undamaged.

A new type of rubber band is now used and this has a "T" section. It is not symmetrical

and the wider top flange or edge should be outwards.

Apply the rubber band by placing the narrow edge on the rear portion of the chaincase,

arranging it so that the join in the band occurs just to the rear of the battery carrier, and

applying the band first of all to the extreme forward edge of the chaincase.

Fully depress the brake pedal and then place in position the front half of the chaincase,

moving it as may be necessary to ensure its outer edges snap under the exposed part of

the rubber band, and then fit to the centre fixing bolt the plain washer and nut, tightening

the nut fully home.

Fit the metal band, starting at the front end of the chaincase and drawing together the

two free ends of the band with one hand while, with the other hand, replacing its binding

screw.

Fully tighten the metal band binding screw.

Remove the inspection cap from the chaincase and pour in engine oil to the level of the

bottom edge of the inspection cap orifice and then replace the cap.

NOTE—If, after replacing a front chaincase, it is found not to be oil tight, the general

reason is distortion of the two joint faces. These faces must be undamaged and,

on test, should closely fit to a surface plate. They must also be absolutely

clean before replacement and the edges must be in exact register, one with

the other. Any distortion caused by accidental impact must be remedied

before refitting.

If any doubt exists, CHECK for DISTORTION BEFORE ASSEMBLY.