Matchless G3L Maintenance Manual
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Matchless G3L Maintenance Manual

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MAINTENANCE
MANUAL
INSTRUCTION
BOOK
350 c.c. and 500 c.c.
MATCHLESS
SPRING FRAME AND RIGID
SINGLE CYLINDER MODELS
PRICE 2/6 NETT
MATCHLESS
M O T O R
PROPRIETORS : ASSOCIATED MOTOR CYCLES LIMITED
PLUMSTEAD • LONDON • S.E.18
AND
for
1955
C Y C L E S

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  • Page 1 MAINTENANCE MANUAL INSTRUCTION BOOK 1955 350 c.c. and 500 c.c. MATCHLESS SPRING FRAME AND RIGID SINGLE CYLINDER MODELS PRICE 2/6 NETT MATCHLESS M O T O R C Y C L E S PROPRIETORS : ASSOCIATED MOTOR CYCLES LIMITED PLUMSTEAD • LONDON • S.E.18...
  • Page 3 Telegrams and Cables : "MATCHLESS, WOL-LONDON" Telephone : WOOLwich 1 2 2 3 (7 Lines) Codes : A.B.C. 5th and 6th Edition ; Bentley's ; and Private Codes All correspondence to : MATCHLESS MOTOR CYCLES, PLUMSTEAD ROAD, LONDON. S.E.18 Price: TWO SHILLINGS and SIXPENCE A—S...
  • Page 4 1955 MATCHLESS MODELS 350 MODEL G3L RIGID FRAME (TOURING) 350 MODEL G3LS SPRING FRAME (TOURING) 350 MODEL G3LC RIGID FRAME (COMPETITION) 350 MODEL G3LCS SPRING FRAME (COMPETITION) 500 MODEL G80 RIGID FRAME (TOURING) 500 MODEL G80S SPRING FRAME (TOURING) 500 MODEL G80C RIGID FRAME (COMPETITION)
  • Page 5 INTRODUCTION The modern motor cycle unquestionably provides one of the most healthy, economical and pleasant means of transport. In 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. It is our sincere desire that every owner should obtain from his mount the service, comfort and innumerable miles of low cost travel that we have earnestly endeavoured to build into it.
  • Page 6 DATA Engine Number … … … … … … … … Stamped on left hand side of crankcase … … … frame Number Stamped on seat lug of main frame, on right hand side (below the saddle Bore … … …...
  • Page 7 Gear box ratios Model First gear Second gear Third gear Fourth gear (top) 1·308 to 1 Touring … … … 2·65 to 1 1·70 to1 1 to 1 … … 1·575 to 1 Competition (Rigid) 3·199 to 1 2·437 to 1 1 to 1 …...
  • Page 8 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.
  • Page 9 CONTROLS (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 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.
  • Page 11 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 Number One Grades.

  • Page 12: Stopping The Engine

    Illustration 2 Showing the gear indi- cator drum which upon assembly is set to record various gears neutral position, as the respective figure or letter registers with index mark on the gear box shell. Upon re-asembly, after dismantling for any pur- pose, the index disc should correctly re-set...

  • Page 13: Stopping The Machine

    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.
  • Page 14 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. 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.
  • Page 15 CHECKING OIL CIRCULATION 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 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.
  • Page 16 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 WINTER SUMMER Mobiloil D Mobiloil A (SAE-50) (SAE-30)

  • Page 17: Engine Lubrication System

    ENGINE LUBRICATION SYSTEM This is by dry sump system. OH 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.
  • Page 18 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 other- wise, when starting the engine, the bulk of oil in the crankcase sump may be greater than the space available in the tank.
  • Page 19 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.
  • Page 20 Illustration 5 The inlet valve guide is shown withdrawn as also is the inlet valve stem adjusting screw (with lock nut) PLAIN HOLE, FOR OIL FEED TO EXHAUST PLAIN HOLE, FOR OIL FEED TO INLET VALVE. VALVE. TAPPED HOLE, ACCOMMODATE HOLE, TO ACCOMMODATE DOWEL PIN CARBURETTER RETAINING STUD.

  • Page 21: Chain Lubrication

    GEAR BOX LUBRICATION Use one of the grades of Oils 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.
  • Page 22 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 front brake cable.) BRAKE PEDAL LUBRICATION Grease nipple in heel of foot brake pedal.

  • Page 23: Lubrication Chart

    LUBRICATION CHART The figures in diamond frames refer to parts located on the left hand side of the machine and those in circles refer to parts located on the right hand side. Illustration 6 Lubrication Chart Engine Oil Locations Grease Locations 23 FRONT HUB.

  • Page 24: Periodical Maintenance

    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 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 Chart, Illustration 6.
  • Page 25 EVERY 1,000 MILES Oil tank Drain at first 1,000 miles and re-fill with new oil. (16.) In wet weather, remove and soak in molten grease. (See page 14.) (4.) Rear chain Gear box Add 2 fluid ounces of specified oil. (18.) Hubs Inject small amount of grease.
  • Page 26 FREE SERVICE SCHEME FREE SERVICE SCHEME All owners of NEW MODELS are entitled to one FREE SERVICE INSPECTION 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 27: Engine Service

    ENGINE SERVICE ACCESS 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...
  • Page 28 TO REMOVE THE PETROL TANK Close both petrol taps and remove the cap nut securing each petrol pipe banjo con- nector. Use two spanners, one to hold the tap and the other to unscrew the cap nut. Beware losing the fibre washers (4 in all) fitted one each side of each banjo connection. Cut the wires interlacing the four fixing bolts.
  • Page 29 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.
  • Page 30 Illustration 8 Showing application of valve spring compressor VALVE SPRING COMPRESSOR TOOL. COLLET, FOR VALVE. COLLAR, FOR VALVE SPRING. OIL PASSAGE FROM ROCKER BOX TO COLLAR. FOR VALVE SPRING. INLET VALVE GUIDE. SCREW WITH LOCK NUT ADJUSTING BOLT THROUGH TOOL AND! COILS OF VALVE SPRING OIL FEED TO INLET VALVE.
  • Page 31 REMOVING CARBON DEPOSIT 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 wilt 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.
  • Page 32 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.
  • Page 33 Remove One gudgeon pin circlip. It is immaterial which circlip Is removed. Use special pliers included in tool kit. Gudgeon pin by pushing It out of piston. Take away piston. NOTE—The gudgeon pin is an easy sliding fit in both piston and connecting rod small- end bush.
  • Page 34 VALVE TIMING taken with valve ·001" off its seat Inlet valve timing Inlet valve opens 36° before top dead centre—350 c.c. models. Inlet valve opens 18° before top dead centre—500 c.c. models. Inlet valve closes 51° after bottom dead centre—350 c.c. models. Inlet valve closes 69°...
  • Page 35 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 NIL. 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.
  • Page 36 TO RE-TIME THE IGNITION The normal advance is 39° (½"). 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.
  • Page 37 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 recipro- cating movement DOWEL PEG, LOCATING TIMING GEAR SCREWED BODY ACCOMMODATE COVER. THE OIL PUMP PLUNGER GUIDE PIN. TIMING SIDE FLYWHEEL...
  • Page 38 TO REMOVE AND REPLACE THE OIL PUMP PLUNGER IF A N D W H E N NECESSARY ONLY 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.
  • Page 39 Illustration 13 Carburetter details in assembly order.
  • Page 40 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, Witton, Birmingham, 6.

  • Page 41: Air Filter

    CARBURETTER ADJUSTMENT With the taper needle projection, main jet size, and type of throttle slide specified (see page 4) correct carburation except at idling speed is assured. In the event of difficulty being experienced look for cause under heading Useful Inform- ation, pages 72 and 73.
  • Page 42 CARBURETTER TUNING INFORMATION Poor idling may be due to : Pilot jet not operating correctly (partially choked) or incorrect air supply. 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.
  • Page 43 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. It is retained to the frame by being damped between the two engine rear plates by two bolts.
  • Page 44 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.
  • Page 45 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 endless rubber band. Remove nut and washer, in centre of chaincase front.
  • Page 46 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, "Wellseal" recommended. Ensure the spacer is in position on the centre fixing bolt. This Is located between the engine plate and the chaincase.
  • Page 47 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.
  • Page 48 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 the domed clutch cover (secured by eight screws.) With the slotted driver provided on one of the thin spanners In the tool kit, screw each...
  • Page 49 CLUTCH OPERATING MECHANISM ADJUSTMENT Correct adjustment of the clutch operating mechanism is of the utmost importance and the following instructions must be carefully observed. In order to understand the method of clutch withdrawal a study of illustrations 14 and 15 should be made.

  • Page 50: Rear Chain Adjustment

    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. 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.
  • Page 51 NOTES ON REAR CHAIN ADJUSTMENT Before tightening the rear chain always first check front chain adjustment and if attention is necessary adjust the front chain first. This is because adjustment of the front chain disturbs that of the rear chain. Therefore, after making adjustment to the tension of the front chain, always afterwards check that of the rear chain.
  • Page 52 MAGNETO CHAIN ADJUSTMENT The magneto platform hinges on one of its fixing bolts. This provides sufficient move- ment for adjustment to the magneto driving chain. Tighten magneto chain by : Remove magneto chain case cover. Slacken nut on rear bolt supporting magneto platform. Insert a screwdriver under that end of the magneto platform and lever upwards until the chain tension is correct.
  • Page 53 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 54 Illustration 16 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 tubular members located inside the main tubes. As w i l l be seen the aluminium sliding members operate upon steel bushes attached to the b o t t o m ends of the main tubes and also upon bakelite bushes, secured to t h e t o p end of the...
  • Page 55 has no other 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 that 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;...
  • Page 56 Remove the handlebar half clip and lay the handlebars, complete with controls, upon a pad on top of the petrol tank. Detach the front brake cable from the forks. (First remove the slotted yoke end and then completely unscrew the cable adjuster.) Remove the snap on dome caps and unscrew the hexagon plug on top of each inner tube, raise same and slacken the lock nuts securing the damper rods attached.
  • Page 57 Illustration 17...
  • Page 58 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, FOR FORK INNER TUBE.

  • Page 59: Rear Suspension

    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 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.
  • Page 60 Illustration 19 Showing " Ghost " view of " TELEDRAULIC " leg...
  • Page 61 To check oil content of " TELEDRAULIC " leg and top-up : 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.
  • Page 62 TO REMOVE OIL TANK AND BATTERY CARRIER Drain oil tank. Disconnect wires from battery terminals. Remove battery. 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. Remove bolt retaining oil tank stay to frame.
  • Page 63 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. Remove bolt retaining brake anchor stay to brake cover plate. Slacken the nut on the left-hand end of front wheel spindle.
  • Page 64 TO REMOVE REAR WHEEL (Rigid Frame Models) 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 ) Engage a gear to prevent sprocket revolving...
  • Page 65 On rigid frame models 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 engage- ment has been completed.
  • Page 66 Illustration 21 Showing front hub and brake also rear hub Illustration 22 Showing rear wheel bearings and brake drum (Spring Frame Models) WITHDRAWABLE WHEEL SPINDLE SPACER FOR WITHDRAWABLE SPINDLE. SPEEDOMETER GEAR BOX SLEEVE. OUTER SPACER BRAKE COVER RING RETAINING OIL SEAL (Small). PLATE.
  • Page 67 Illustration 23 Showing rear wheel bearings and brake drum (Rigid Frame Models) SPEEDOMETER GEAR BOX COMPLETE. CENTRE SOLID WHEEL SPINDLE. SPEEDOMETER GEAR BOX FIXING N U T . SPEEDOMETER GEAR BOX SLEEVE. RING RETAINING OIL SEAL (Small). SPACER FOR FORK END. OIL SEAL.
  • Page 68 TO DISMANTLE REAR WHEEL BEARINGS With wheel still in situ first of all slacken the nut (16), securing the speedometer drive gear box. Then remove the wheel from cycle when the above nut should be removed and the speedometer gear box withdrawn. (If wheel is of non-detachable type remove the brake cover plate and withdraw the solid centre spindle together with all spacers attached).
  • Page 69 BRAKE DRUMS The front wheel brake drum is a shrunk in fit in the hub shell (assembled under heat) and secured additionally by five screws. The rear wheel brake drum is integral with the rear chain sprocket and on the rigid frame model is secured to the rear hub by five bolts and nuts.

  • Page 70: Front Brake Adjustment

    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.

  • Page 71: Rear Brake Adjustment

    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. Minor adjustment of the rear brake shoes is made by altering the position, on the brake rod, of the knurled adjusting nut.

  • Page 72: Tyre Removal

    Illustration 28 Showing brake rod ad- justment exhausted, dicating need brake thrust pin adjust- ment. TYRES AND SERVICE (SPRING FRAME MODELS) 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.

  • Page 73: Tyre Pressures

    Push edge of cover, that is diametrically opposite to the valve, RIGHT INTO WELL OF RIM and, using tyre lever 017007, pick up edge of cover NEAR VALVE to that It comes off over the edge of the rim. Work off the remaining edge of the cover till it is clear of the rim. This is quite easy and there Is no reason to use force.
  • Page 74 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 Engine fails to start, or is difficult to start, may be due to : Water on high-tension pick-up.
  • Page 75 Engine overheats may be due to : 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.
  • Page 76 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.) 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.
  • Page 77 ELECTRICAL SERVICE IGNITION A Lucas magneto type SR-1 with automatic advance and retard is fitted to all Touring models. A Lucas racing magneto type NR-1 is fitted to all Competition 350 c.c. and 500 c.c. models. On the SR-1 magneto fitted to all Touring models, the contact breaker is exposed by removing the moulded end cover secured with 3 captive screws.
  • Page 78 SPARKING PLUG The K.L.G. Type FE80 " Corundite " Plug is fitted to all models. It has a thread of 14 mm. and the reach is ¾". The point gap is ·020 to ·022". Check the point gaps every time the engine is decarbonised and, if necessary, re-set the points. See that the plug Is fitted with its external seating washer.
  • Page 79 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 negative brush is insulated and the positive brush is earthed.
  • Page 80 TO REMOVE THE DYNAMO Remove the left side foot rest arm. Place a tray under primary chaincase to catch the oil. 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.
  • Page 81 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.
  • Page 82 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.
  • Page 83 LIGHTING AND ACCESSORIES Headlamp A LUCAS headlamp is fitted and snugly mounted on each side is a neat torpedo shaped pilot lamp. These pilot lamps and also the headlamp are secured to the front fork arms by means of tubular bolts through which a wire passes to each pilot lamp. The headlamp bulb has two filaments one of which provides the main driving beam and the other a dipped beam brought into operation as required by the dipping switch on the left handlebar.
  • Page 84 Horn The horn push switch, situated on the right handlebar. Fuses There are no detachable fuses in LUCAS motor cycle electrical equipment. Snap wire connector The LUCAS snap connector, as shown in Illustration 33, is made up of four components. Two are tubular sleeves, having pointed extremities, and which are soldered to the ends of the two wires t6 be connected.

  • Page 85: Wiring Diagram

    SIDELAMP SIDELAMP LIGHTING SWITCH SPEEDOMETER DIPPER SWITCH LIGHT HORN PUSH DYNAMO MAGNETO REGULATOR BATTERY (Positive earth) HORN SNAP CONNECTOR TAIL LAMP W97832 Illustration 34 Wiring diagram...
  • Page 86 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 MAY 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 87 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 88 THE MACHINE AND THE LAW 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 "...
  • Page 89 GUARANTEE 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. 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, In the case of machines (a) which have been used for "...
  • Page 90 TOOLS AND SPECIAL EQUIPMENT TOOLS The standard tool kit, issued with each new machine, contains : 017253 Tool bag. Tyre inflator. 017114 Tyre lever. 017007 017248 Pliers. 011188 Gudgeon pin circlip pliers. Screwdriver. 017256 Grease gun. 017246 017249 Adjustable wrench. Sparking plug box spanner and tommy bar.
  • Page 91 BADGES 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. Tool Kit Illustration 35...
  • Page 92 INDEX … … … … … … Carburetter Service … … … … … … … … Controls … … … … … … … Data … 4 to 6 Driving … … … … … … … … Electrical Service …...
  • Page 93 ILLUSTRATIONS Illustrations Page … … … … … … … Battery … … … … … Brake adjustment, front … … … Brake adjustment, rear (rigid frame) … … … Brake adjustment, rear (spring frame) … … … … … Brake anchorage, rear Brake shoe adjustment …...

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