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Matchless 1964 G3 350 Instruction Book

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INSTRUCTION BOOK
MATCHLESS
SINGLE CYLINDER
Model G3
Model G3S
Model G80
TWIN CYLINDER
Model G12
Model G12CSR 650 c.c. O.H.V. Sports
MATCHLESS M O T O R CYCLES L T D
350 c.c. O.H.V.
350 c.c. O.H.V. Sports
500 c.c. O.H.V.
650 c.c. O.H.V.
Issued by:
:
L O N D O N S.E.18

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  • Page 1 350 c.c. O.H.V. Sports Model G80 500 c.c. O.H.V. TWIN CYLINDER Model G12 650 c.c. O.H.V. Model G12CSR 650 c.c. O.H.V. Sports Issued by: MATCHLESS M O T O R CYCLES L T D L O N D O N S.E.18...
  • Page 3 Codes : A.B.C. 5th and 6th Edition; Bentley's; and Private Codes Registered Offices: PLUMSTEAD ROAD, PLUMSTEAD L O N D O N S.E.18 ENGLAND Issued by : MATCHLESS MOT O R CYCLES LTD : L O N D O N S.E.18...

  • Page 4: Table Of Contents

    CONTENTS Page Carburetter … … … … … … … … … … Controls … … … … … … … … … … … Data … … … … … … … … … … … Driving … … …...
  • Page 5 HE MODERN MOTOR CYCLE unquestionably provides one of the most healthy, economical and pleasant means of transport. addition, by reason of its superb braking, high power to weight ratio and ease of control it is, if used with due care, one of the safest vehicles on the road.

  • Page 6: Carburetter

    DATA Identity—Singles Stumped on left-hand side of crankcase Engine Number … … … … … … … Frame Number Stamped on main frame head lug … … … … … … … Identity—Twins Engine Number Stamped on crankcase left in f ro n t of cylinder …...
  • Page 7 Ignition (Magneto)—Twins Make Type Rotation Point gap Anti-clock ·012 in. Lucas … … … … … … … Sparking Plug Reach Point gap Thread Model Hake Type FE80 14 mm. ¾ in. ·020 to ·022 i n . Std. K.L.G. …...
  • Page 8 Camshaft gears Retained by nut, Left hand thread. Gear ratios—Singles 1963 Models fitted with 18" wheels, use a larger engine sprocket, to the extent of one extra tooth to those shown in the tables, given below. Fourth gear Engine sprocket size First gear Second gear Third gear...

  • Page 9: Controls

    CONTROLS Refer to Illustration 1 (1) Throttle twist grip. On right handlebar. Twist inwards to open. When fully closed engine should just idle when hot. (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.
  • Page 10 (21) Trip mileage recorder. The bottom set of figures located in the speedometer dial indicates the number of miles (or kilometres) travelled since the recorder was set to zero. Can be re-set at any time. Used to measure the length of individual trips.

  • Page 11: Driving

    DRIVING FUEL Although various quality fuels are again available owners are advised to use only the best. The small economy that might be considered to accrue by using the cheaper grades is more than offset by the advantages obtained by using only Premium Grades. FUEL SUPPLY A two level petrol tap which gives a reserve supply of fuel is situated at the rear end of the petrol tank on the left side.

  • Page 12: Engine

    Illustration 2 Showing gear pedal indica- t o r which upon assembly is set to record th e various gears also neutral position. U p o n re-assembly after dismantling for any pur- pose th e indicator pointer should be correctly re-set for f u t u r e reference.
  • Page 13 for convenience a limit mark can be used on the twist grip and grip body. The recommendation of limiting the road speed to 30 m.p.h. is most unsuitable for running in, for with this principle the machine could be driven up hill in top gear at 30 m.p.h.
  • Page 14 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. FOR ENGINE LUBRICATION COLD EXTREME COLD above 50° F 32°...
  • Page 15 CHECKING OIL CIRCULATION—ALL MODELS Provision is made to observe the oil in circulation and it is advisable to do this before each run. if the filler cap on the oil tank is removed the end of the oil return pipe will be noticed below the level of the filler cap orifice and the returning oil can be seen running from This check should be made immediately after starting the engine from cold.
  • Page 16 SEE W A R N I N G ON PAGE 15 BEFORE REMOVAL Illustration 4 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 recipro- cating movement.
  • Page 17 ENGINE OIL PUMP (see Illustration 4) The pump has only one moving part. This is the plunger which revolves and reciprocates. Rotation is caused by the worm gear on the timing side flywheel axle. Reciprocation is caused by the guide pin which engages in the profiled groove cut on the plunger. Oil is fed to the pump through the lower of the two oil pipes between tank and crank- case and is returned through the upper pipe.
  • Page 18 Illustration 5 Delivery O i l Pump (on the right) Return Oil Pump (on the left) BALL. FOR NON-RETURN VALVE. FRONT PLATE OF OIL RETURN PUMP. SCREW (1 OF 6) USED TO RETAIN PLATES SPRING, FOR NON-RETURN VALVE. AND BODIES OF OIL PUMPS TO THE PLUG, RETAINING NON-RETURN VALVE CARRYING PLATE.
  • Page 19 The felt filter located in a chamber in the front part of the crankcase and parallel to the exhaust camshaft. The blow off valve is included with the filter (engines after 8089) see illustration 7. The magnetic filter in the crankcase oil sump. NOTE—Filter B is used on twin cylinder models only.
  • Page 20 ADJUSTMENT OF OIL FEED (SINGLES) The internal flow of oil is regulated by fixed restrictions. No adjustment is provided except for the oil feed to the inlet valve stem. This adjustment is made by a needle pointed screw located in the right side of cylinder head. (See illustration 16).
  • Page 21 Illustration 8 Cross section of engine showing oil galleries, oil passages, and release valve...

  • Page 22: Pressure Relief Valve

    TO REMOVE A N D CLEAN CRANKCASE FILTER (TWINS) The crankcase filter, as shown in illustration 7 is made up from a coarse wire frame surrounded by a felt fabric. To remove the filter use a good fitting spanner and unscrew the non-return valve (illustration 9).
  • Page 23 TO DISMANTLE A N D REFIT CRANKCASE RELEASE VALVE IN CRANKSHAFT (see Illustration 8) STANDARD T W I N S Upon removal of the outer portion of front chaincase as described elsewhere, the release valve will be observed on the end of the engine shaft, this valve also retains the engine sprocket.

  • Page 24: Lubrication Chart

    BRAKE DRUM BEARING (CS A N D CSR MODELS) The independent ball bearing upon which the rear brake drum is mounted, is packed with grease upon assembly and requires no further attention for a considerable time. During a general overhaul however it is recommended that the bearing is dismantled and re-packed with fresh hub grease.
  • Page 25 BRAKE ROD J O I N T 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 front brake cable.) BRAKE PEDAL LUBRICATION Grease nipple in heel of foot brake pedal.
  • Page 26 MAINTENANCE PERIODICAL MAINTENANCE 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 carefully follow 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 Chart, illustration 10, page 22.
  • Page 27 EVERY 2,000 to 5,000 MILES (according to road conditions) (If fitted) clean and re-oil filter element. Air Filter EVERY 3,000 MILES Clean crankcase felt filter (twins). Filter In dry weather remove and soak in molten grease. (4) Rear chain Inject small amount of grease. Brake pedal Clean contact breaker points and re-set if necessary.
  • Page 28 ENGINE SERVICE TAPPET ADJUSTMENT—SINGLES 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 .
  • Page 29 TO ADJUST OVERHEAD ROCKERS (Tappet Clearance)—TWINS It is essential to correctly position the engine when making this adjustment. Start by removing the right side rocker cover, use spanner 018055 and take out the sparking plug. Rotate the engine with the kickstarter until the inlet rocker goes down and comes up again.
  • Page 30 For all service work to the upper part of the engine, other than adjustment of the rockers, it is necessary, in order to obtain accessibility, to first remove the petrol tank. TO REMOVE T W I N SEAT Remove both screws at rear of seat, release nuts for front mounting, seat can then be taken away.
  • Page 31 DECARBONISATION Instead of the usual stipulated mileage interval between periods of decarbonisation, ft is recommended that this is undertaken only when the need for same becomes apparent because of loss of power, heavy petrol consumption or generally reduced performance. When undertaken, unless it is thought necessary to inspect the piston and rings, the cylinder barrel/s are best left undisturbed.
  • Page 32 Remove carburetter by: Air filter connection. Unscrew two carburetter retaining nuts. Take away carburetter and lay aside. Remove The four bolts retaining cylinder head to barrel, and head is free to be taken away. While doing this the push rod cover tubes will come away with the head. NOTE—If the sparking plug resists removal, do not use force but brush penetrating oil round the body and leave for a time to soak before making further effort.
  • Page 33 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). It is essential that the collets are correctly located on the valve stems. It will be observed that the collet has two grooves machined in the bore and those two grooves must register with the two rings on the valve stem.
  • Page 34 Illustration 16 The valve guides and the needle adjusting screw are also shown withdrawn. PLAIN HOLE, FOR OIL FEED TO INLET PLAIN HOLE, FOR OIL FEED TO EXHAUST VALVE. VALVE. TAPPED HOLE, ACCOMMODATE HOLE, TO ACCOMMODATE DOWEL PIN CARBURETTER RETAINING STUD. LOCATING VALVE SPRING SEAT.
  • Page 35 Replace the cylinder head by: Carefully clean the top edge of the cylinder barrel and the under face of the cylinder head. Fit the cover tubes, with their rubber gaskets and metal washers, into the cylinder head. Place the cylinder head gasket in position on the top edge of the cylinder barrel. Place a rubber gland round each tappet guide.
  • Page 36 Re-fit piston by: Introduce piston over connecting rod, so that slit in piston faces to the front of the machine. Introduce gudgeon pin in piston and pass it through connecting rod small-end bush and centralise it. Re-fit circlips. (Use special pliers). Use rotary action when bedding circlips in their grooves and make sure each circlip lies snugly in its groove.
  • Page 37 SMALL T I M I N G GEAR PINION—SINGLES This pinion is a taper fit and keyed on to the timing side shaft, the retaining nut has a LEFT HAND THREAD. The timing mark on the pinion is central with the key way. Illustration 17 I G N I T I O N T I M I N G To understand the principle, a study of illustration 17 should be made.
  • Page 38 Remove the bolt securing the automatic timing control to the cam wheel shaft. Fit a 024328 withdrawal bolt in place of the fixing bolt removed which should be lightly tightened. A sharp blow on the end of withdrawal bolt will dislodge the unit from the shaft.
  • Page 39 Illustration 19—Setting the ignition timing Take up the timing rod, check piston position in case the engine has moved. Hold the timing rod as vertically as possible through the sparking plug hole, verify piston is at the top of the stroke. Make a mark on the timing rod flush with the top face of the sparking plug hole, then withdraw the rod.
  • Page 40 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. Important Never attempt to insert the guide screw unless both oil pump end caps are removed, when by moving the pump plunger to and fro with the fingers it can be felt when the pin engages with the groove in the plunger.
  • Page 41 TO REMOVE T H E VALVES First remove rockers from cylinder head (see illustration 12) The importance of correctly locating the valve spring seats is stressed, the wide face of the seat abuts against the cylinder head. Reversal will make the springs coil bound and cause damage to the valve gear.
  • Page 42 REFITTING T H E CYLINDER The cylinder can be fitted more easily and the risk of piston ring breakage can be pre- vented, if a piston ring clamp is used on the piston before refitting the cylinder. W i t h the piston ring clamp encircling the piston, it is only necessary to place the cylinder on to the piston and press down the cylinder until the piston rings have entered the cylinder, when the clamp should be removed.
  • Page 43 TO RE-TIME T H E I G N I T I O N — T W I N S (MAGNETO MODELS) Before proceeding to time the ignition it is advisable first to check the contact breaker point gap, which should be from ·012" to ·015" and correct it if necessary. Having loosened the nut securing the magneto driving pinion, release same from the tapered end of the magneto shaft by means of a special extractor, as described on page 42.
  • Page 44 Thoroughly clean off all traces of jointing compound from ace edges of the timing cover and crankcase and then smear both faces with new jointing compound, which leave till tacky and then re-fit the cover to the crankcase. ("Wellseal" recommended.) The whole operation of timing the ignition will be found quite simple if the foregoing instructions are carefully followed.
  • Page 45 Illustration 21 Valve timing gear See page 96 for particulars of special timing disc graduated in degrees. GEAR WHEEL ON MAGNETO ARMATURE STUD, IN DYNAMO BODY AND PASSING SHAFT. THROUGH CRANKCASE AND TIMING GEAR COVER. MAGNETO. GEAR WHEEL ON INLET CAMSHAFT. CRANKCASE DRAIN PLUG.
  • Page 46 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.
  • Page 47 Illustration 8 Carburetter details in assembly order...

  • Page 48: Air Filter

    TWIST GRIP ADJUSTMENT (Continued) The complete twist grip can be moved on the handlebar by slackening the two screws that clamp together the two halves of the body. The most desirable position is that in which the throttle cable makes the cleanest and most straight path to the under-side of the petrol tank.
  • Page 49 TRANSMISSION SERVICE T H E GEAR B O X The gear box provides four speeds and has a positive foot change, operated by the right foot and a kick-starter. It Is retained to the frame by being clamped between the two engine rear plates by two bolts.
  • Page 50 the gear change pedal, which is also spring loaded by a similar type spring returns the pedal to the central position, after a gear has been selected, upon foot pressure being released. An upward movement of the pedal engages first gear, a downward movement causes engagement of higher gears.
  • Page 51 TO REPLACE GEAR B O X INNE R COVER Ensure gasket is undamaged. Fit inner cover, firmly secure seven fixing nuts. Fit main shaft nut, clutch operating body and steel ball, also clutch actuating arm and roller. NOTE—Before finally tightening lock nut securing operating body, position small dutch operating lever to register with centre of aperture for clutch cable adjuster.
  • Page 52 TO REMOVE CHAINCASE COVER—TWINS Remove left side exhaust pipe with silencer attached. Remove left side footrest. Remove adjusting nut on rear brake rod. Place a tray under chaincase to catch oil. Remove screwed inspection cap (use spanner 018178 in slot). Remove drain plug, allow time to drain (content 8 ozs.).
  • Page 53 TO REPLACE ROTOR A N D ENGINE SPROCKET—SINGLES Re-fit parts in reverse order given for dismantling. When re-fitting chain connecting link ensure spring clip is fitted so that the closed end faces the direction of rotation. Check chain adjustment before re-fitting chaincase cover. TO REMOVE ENGINE SPROCKET—MAGNETO T W I N S Follow dismantling instructions for Single Cylinder Models.
  • Page 54 CLUTCH SPRING ADJUSTMENT In the event of clutch slip and the operating mechanism has been adjusted correctly the clutch spring adjusting nuts and cups may require attention. Remove the chaincase cover to expose clutch assembly. Remove the clutch spring adjusting screws, take out the springs and cups then verify the clutch spring cups are not in contact with the holes machined in the steel plate for the clutch shock absorber assembly (see illustration 27).
  • Page 55 TO REMOVE C L U T C H BEARING The clutch hub is secured to the clutch back plate by the three clutch studs, with lock nuts. The bearing can be removed after separating the clutch hub from the back plate. Apply a little anti-centrifuge grease on bearing before final assembly.
  • Page 56 Fit striker fork spigot into groove in cam plate. Fit layshaft, with small gear, third gear, also second gear with striker fork in second gear. Fit striker fork spigot into groove in cam plate. Fit striker fork spindle, after lining up both forks. NOTE—Moving the cam plate, will assist in lining up striker.
  • Page 57 To adjust the chain place cycle on the stand and slightly slacken the spindle end nut and also slightly slacken the brake drum dummy spindle lock nut the hexagon of which Is adjacent to the spindle end nut on de-luxe models. Then slacken back the adjuster screw lock nut on each side and unscrew each adjuster bolt in turn to exactly the same extent until the correct chain tension is obtained.

  • Page 58: Forks And Frame

    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. Occasionally test the steering head for correct adjustment by exerting pressure upwards from the extreme ends of the handlebars.
  • Page 59 Illustration 29 Exploded view of Teledraulic Forks.
  • Page 60 REF. DESCRIPTION WASHER, LEATHER, FOR FORK SPRING TOP SEATING BUFFER, RUBBER, FOR FORK INNER TUBE. SPRING. MAIN, FOR FRONT FORK. BUFFER, RUBBER, FOR FORK INNER TUBE. BUFFER, RUBBER. FOR FORK INNER TUBE. WASHER, LEATHER, FOR FORK SPRING BOTTOM SEATING. EXTENSION. FOR FORK SLIDER. OIL SEAL.
  • Page 61 Disconnect both damper rods, by releasing the lock nut and unscrewing both bolts. Release both fork crown pinch screws (38). The fork assembly can now be taken away from the machine. If the fork tubes are a tight fit in the fork crown and handlebar lug, use the drawbolt to tap out each tube alternately a small amount, changing the bolt from one tube to the other, until the tubes are clear of the frame.
  • Page 62 Use a soft mallet to tap upward the handlebar lug until it disengages with the fork stem (steering column) and main tubes. The fork assembly can then be withdrawn. (Take care to avoid loss of any of the 56 steering head steel balls.) To refit a complete front fork assembly Secure with grease, 28 balls in fork crown ball race.

  • Page 63: Rear Suspension

    TO REMOVE A FORK INNER TUBE Start by removing the fork slider, release the pinch screw in the fork crown, the tube can then be pulled or driven out from the handlebar and fork crown lug. REAR SUSPENSION 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...

  • Page 64: Centre Stand

    On a new machine, or after replenishment, oil may leak from this bearing. This is of no consequence and the leakage will cease after a few hundred miles have been covered. The rear wheel fork is suspended on springs located in the two suspension units joining the rear fork to the main frame loops.
  • Page 65 WHEELS AND BRAKES TO REMOVE FRONT WHEEL Place machine on centre stand. 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.
  • Page 66 Disconnect the speedometer drive cable from the drive. Release the rear wheel spindle nut several turns, pull the wheel to the right, until the brake plate clears the anchor boss on the frame. Take the chain off its sprocket, the wheel can now be removed. Lean the machine at an angle, take the wheel away under the silencer.
  • Page 67 Illustration 33 Front wheel bearings OIL SEAL CUP. CIRCLIP. ADJUSTING RING. OIL SEAL CUP. ADJUSTING RING L O C K N U T . OIL SEAL. WASHER RETAINING SEAL N U T LOCATING BRAKE COVER PLATE. WHEEL SPINDLE COMPLETE. N U T SECURING BRAKE COVER PLATE. SPINDLE END WASHER.
  • Page 68 Now carefully apply pressure to the threaded end of the wheel spindle which will eject from the opposite end of the hub, the washer (6), oil seal (7) and oil seal cup (8), together with the bearing outer ring (5). The wheel spindle with its two sets of rollers in cages may now be lifted out leaving in situ only the fixed bearing ring together with the oil seal, washer and cup for that side bearing.
  • Page 69 Rear brake and wheel bearings, de-luxe models Illustration 35 W I T H D R A W A B L E WHEEL SPINDLE. SPACER FOR W I T H D R A W A B L E SPINDL SPEEDOMETER GEAR BOX SLEEVE. OUTER SPACER BRAKE...

  • Page 70: Front Brake Adjustment

    When a brake cover plate has been disturbed, it is advisable, upon re-assembly, to centralise the shoes in the brake drum to ensure equal pressure to each. In the case of the front wheel this is best done before refitting the wheel to the machine, but in the case of the rear wheel it is best done after refitting.

  • Page 71: Rear Brake Adjustment

    Illustration 37 Showing front brake cable adjuster thread exhausted, indicating brake shoe thrust pin a d j u s t m e n t necessary. REAR BRAKE ADJUSTMENT Major adjustment of the rear brake shoes is made on the brake thrust pins, by fitting packing washers under the pins, as already described.
  • Page 72 Illustration 38 Showing brake rod adjustment exhausted, indicating the need for brake t h r u s t pin adjustment. BRAKE PEDAL ADJUSTMENT The pedal is located by a spring-loaded sprag which lies between the stop on the pedal and the leg of hair pin spring. To adjust the position of the pedal: slacken the spindle nut on the right hand side of the machine;...
  • Page 73 Brake Anchorage—Illustration 40 1 BRAKE ANCHORAGE BOSS. 3 FIXING BOLT. 2 SPACER. 4 WASHER. THE FRONT WHEEL (excluding Models CS - CSR - Trials) Two journal bearings type RMS 6 are used in the front hub with a pull-out wheel spindle. A super oil seal is fitted against the bearing on the brake drum side to prevent grease entering the brake drum.
  • Page 74 TO ASSEMBLE T H E FRONT H U B Gently heat the right side of the hub, insert the bearing and press it fully home by screwing in the bearing retaining sleeve (LEFTHAND THREAD). Invert the hub and pack some grease against the bearing just fitted. Insert the bearing spacing tube and fill some more grease to the hub.
  • Page 75 Front Wheel Hub Assembly Rear Wheel Hub Assembly TYRES A N D SERVICE Refer to the Booklet "How to keep your motorcycle tyres fit" issued with each new machine.
  • Page 76 ELECTRICAL SERVICE SINGLE CYLINDER A N D ALTERNATOR T W I N S LUCAS A.C. L I G H T I N G - I G N I T I O N U N I T ALTERNATOR MODEL RM19 The alternator consists of a spigot-mounted 6-coil laminated stator bolted to the outer portion of chaincase with a rotor carried on and driven by an extension of the crankshaft.
  • Page 77 EMERGENCY CHARGING Should the battery become discharged a temporary boost charge can be effected during daylight running, by an alteration to the alternator connections. The snap connectors are located behind the frame plate, which is secured by two knurled screws. (1) Disconnect the green and yellow and green and black connectors.
  • Page 78 Smear the surface of the cam very lightly with Mobilgrease No. 2, or, if this is not available, clean (SAE 30-40) engine oil may be used. Squeeze a little grease into the felt wick. Place a spot of clean engine oil on the contact breaker pivot. Remove the central fixing bolt and inject a small amount of clean engine oil into the hole thus exposed.
  • Page 79 Examine the contact breaker. The contacts must be free from grease or oil. If they are burned or blackened, clean with fine carborundum stone or very fine emery cloth, afterwards wiping away any trace of dirt or metal dust with a clean petrol-moistened cloth.
  • Page 80 Contact cleaning is made easier if the contact breaker lever carrying the moving contact is removed. Before re-fitting the contact breaker lever, lightly smear the cam and pivot post with clean engine oil. No grease or oil must be allowed to get on or near the contacts. After cleaning, check the contact breaker setting.
  • Page 81 ELECTRICAL SERVICE MAGNETO MODELS ELECTRICAL E Q U I P M E N T LUCAS electrical equipment is fitted and this comprises three independent electrical circuits, as follows: (1) IGNITION—Magneto, High-tension wires, Sparking plugs and Cut-out switch. (2) CHARGING—Dynamo Compensated Voltage Control Unit and Battery. (3) L I G H T I N G A N D ACCESSORIES—Lamps, Horn, Switches and wiring.
  • Page 82 FIXED CONTACT PLATE SECURING SCREW 0·012"—0·015" SCREW DRIVER IGNITION A LUCAS type K2F magneto is fitted. The replacement part number is 42230-A and the part number of the complete contact breaker is 492854. Lubrication and adjustment is required every 3,000 miles, cleaning is required every 5,000 miles and every 10,000 miles the complete unit should be handed to a Lucas Service Station for dismantling, replacement of worn parts, cleaning and lubrication.
  • Page 83 Remove the high tension pick-ups (held by swinging spring clips), wipe clean and polish with a fine dry cloth. The high tension pick-up brush must move freely in its holder. If it is dirty, clean with a cloth moistened with petrol. If the brush is worn to within 1/8"...
  • Page 84 (c) Connect the negative lead of a moving coil voltmeter (calibrated not less than 0 to 10 volts) to either of the two dynamo terminals and connect the positive lead to a good earth point on the dynamo or engine. (d) Gradually increase the engine speed, when the voltmeter reading should rapidly rise and without fluctuation.
  • Page 85 T O REMOVE C O N T R O L B O X The A.V.C. unit Is held in sponge rubber and housed in a partition at the rear top corner of the tool box. To remove it, open the box lid, grasp the unit between the fingers and thumb of one hand, and gently and firmly pull it out.
  • Page 86 If a battery is found to need an excessive amount of topping-up, steps should be taken to And out the reason. If one cell in particular needs topping-up more than another, it is likely the case or container is cracked, in which event the battery must be replaced and arrangements made to clean up the battery carrier.
  • Page 87 L I G H T I N G A N D ACCESSORIES H E A D L A M P A pre-focus main bulb, also a pilot bulb are mounted in the lamp reflector. The reflector and lamp glass are made up as one assembly and are not sold separately. To remove the head lamp rim, release the screw retaining the lamp rim with one hand and support the Light Unit with the other.
  • Page 88 Illustration 48 Wiring diagram—Singles...
  • Page 89 Illustration 49 Wiring diagram—Alternator Twins...
  • Page 90 Illustration 50 W i r i n g diagram—Magneto Twins...

  • Page 91: Information

    USEFUL INFORMATION In the following 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 Engine fails to start, or is difficult to start, may be due t o : Water on high-tension pick-ups, or distributor.
  • Page 92 Engine overheats may be due to: Lack of proper lubrication. (Quality or quantity of oil Faulty sparking plugs. Air control to carburetter out of order. Punctured carburetter float. Engine carbonised. Weak valve springs. Pitted valve seats. Worn piston rings. Ignition setting incorrect. Automatic timing control faulty.
  • Page 93 CLEANING T H E M A C H I N E 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.
  • Page 94 REPAIRS 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. If the estimate is accepted, no charge is made for the preliminary examination, but, should it be decided not to have the work carried out, it M A Y be necessary to make a charge to cover the cost of whatever dismantling and re-assembly may have been done to prepare the estimate.
  • Page 95 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.
  • Page 96 To register a new machine: Send to the Local Registration Authority the following: (a) Form "RF1/2", duly completed. (b) The certificate of insurance. (c) The invoice you received from your dealer when you purchased the machine. (d) The appropriate registration fee. In due course you will receive: (1) A Registration Book.
  • Page 97 FREE SERVICE SCHEME FREE SERVICE SCHEME All owners of N E W M O D E L S are entitled to one FREE SERVICE A N D I N S P E C T I O N at 500 miles, or, at latest, three months after taking delivery. This service is arranged by the supplying dealer to whom the Free Service Voucher must be handed.

  • Page 98: Spare Parts

    SPARE PARTS ENUINE SPARE PARTS purchased from an Authorised Dealer, or from the Factory, are identical with the parts originally built into your motor cycle. By using them you are assured that they will fit accurately and give satisfactory service. SPARES STOCKISTS For the convenience of owners Spares Stockists are appointed for most districts.

  • Page 99: Tools And Special Equipment

    TOOLS AND SPECIAL EQUIPMENT TOOLS The standard tool kit, issued with each new machine, contains: 017253 Tool bag. 017114 Tyre inflator. Tyre lever. 017007 Pliers. 017248 011188 Gudgeon pin circlip pliers. Screwdriver. 017256 017246 Grease gun. 017249 Adjustable wrench. 017252 Sparking plug box spanner and tommy bar.
  • Page 100 GUARANTEE 1. In this Guarantee the word "machine" refers to the motor cycle, scooter, motor cycle combination or sidecar as the case may be purchased by the Purchaser. 2. In order to obtain the benefit of this Guarantee, the Purchaser must correctly complete the attached registration form and return it to us within fourteen days of the purchase.
  • Page 101 I N D E X Page Page Cylinder barrel, removal 33-39 Air filter … … … … … … Cylinder barrel, replacement 33-40 A.V.C. … … … … … Cylinder head, removal 29-38 Alternator … … … … … … Cylinder head, replacement 32-40 Automatic timing control...
  • Page 102 Page Page Law, the Service … … … … … … … … Lighting Sparking plug … … … … … … … Sparking plug removal Lubricants … … … … … … Speedometer, lubrication Lubrication chart … … … …...

This manual is also suitable for:

1964 g3s 3501964 g12 6501964 g12csr 6501964 g80 500

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