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Related Manuals for A.J.S. 16
Summary of Contents for A.J.S. 16
- Page 1 INSTRUCTION BOOK • • • SINGLE CYLINDER 350 c.c. 500 c.c. MODEL Model 16 Model 18 SPINGTWINS Standard 20 and 20 De-Luxe (500 c.c.) Standard 31 and 31 De-Luxe (650 c.c.) CS and CSR Models (650 c.c) Issued by: A.J.S. MOTOR...
- Page 3 INSTRUCTION BOOK A•J•S 350 c.c. SINGLE CYLINDER MODELS 500 c.c. 500 c.c. T W I N CYLINDER MODELS 650 c.c. Factories: BURRAGE GROVE and MAXEY ROAD PLUMSTEAD, S.E.18 Telephone: WOOIwich 1223 (7 lines) Telegrams: "ICANHOPIT, WOL-LONDON" Cables: "ICANHOPIT, LONDON" TELEX 22617 Codes: A.B.C.
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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.
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Page 6: Data
DATA Identity—Singles … … … … … … … Engine Number Stamped on left-hand side of crankcase … … … … … … … Frame Number Stamped on main frame head lug Identity—Twins … … … … … … Engine Number Stamped on crankcase left in front of cylinder …... - Page 7 Part number 2 Q in. 2 33/64 in. 018348 018347 Renew valve springs when 3/16 to 1/4 in. less than normal free length. Valve timing All timing gears are marked for ease of setting. See page 34 and 42. Oversize parts—Singles The following are the only "oversize"...
- Page 8 … 16 teeth 17·63 to 1 11·7 t o 1 8·41 to 1 6·89 to 1 … … 16·6 to 1 11·05 to 1 7·91 to 1 6·48 to 1 17 teeth … … 10·39 to 1 7·46 to 1 6·12 t o 1...
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Page 9: Controls
"safety" device to prevent loss that might be occasioned by unauthorised meddling. Oil tank filler cap. Located on top edge of oil tank. To remove, unscrew. (16) Dipping switch. Trigger switch on left handlebar. Used to select normal or (17) "dipped"... - Page 10 Trip mileage recorder. The bottom set of figures located in the speedometer (21) 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.
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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 Two fuel feed taps are situated underneath the rear end of the petrol tank. - Page 12 Illustration 2 Showing gear pedal Indica- t o r which upon assembly is set to record the various gears also neutral position. U p o n re-assembly after dismantling for any pur- pose t h e indicator pointer should be correctly re-set for future 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.
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Page 14: Lubrication
LUBRICATION LUBRICANTS TO USE Efficient lubrication is of vital importance and it is false economy to use cheap oils and greases. The use of multigrade oils is not recommended. We recommend the following lubricants to use in machines of our make. FOR ENGINE LUBRICATION EXTREME COLD COLD... - 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 it.
- Page 16 SEE WARNING 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. DO W E L PEG, LOCATING TIMING GEAR SCREWED BODY ACCOMMODATE...
- 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, If, for any reason, the crankcase is dismantled the oil pump plunger must be removed...
- Page 18 Illustration 5 Delivery Oil 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. A N D BODIES OF OIL PUMPS TO THE PLUG, RETAINING NON-RETURN VALVE CARRYING PLATE.
- Page 19 The metal filter located in a chamber in the front part of the crankcase and parallel to the exhaust camshaft. The crankcase metal filter is made integral with the non-return valve, which|i$ a sealed unit (see illustration 7). If the valve is difficult to unscrew, do this after a run or when the crankcase is hot.
- Page 20 This adjustment is made by a needle pointed screw located in the right side of cylinder head. (See illustration 16). It is locked in position by a nut. The approximate correct setting is one-sixth of a complete turn from the fully closed position.
- Page 21 Illustration 8 Cross section of engine showing oil galleries, oil passages, and release valve.
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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 fine mesh metal gauze. 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) DE-LUXE MODELS 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. On the De-Luxe Models this valve also retains the engine sprocket.
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Page 24: Lubrication Chart
BRAKE DRUM BEARING (DE-LUXE 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.
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Page 26: Maintenance
The reference numbers, in brackets, refer to the locations specified on the Lubrication Chart, illustration 10, page 22. DAILY Oil tank Inspect oil level (16) and top-up to top line level if necessary. Check oil circulation. Petrol tank Check level and re-fill if necessary. - Page 27 Rockers Check O.H.V. rocker adjustment and correct if necessary. EVERY 5,000 MILES Oil tank Drain and re-fill with new oil. (16). If machine is only used for short runs renew oil every three months instead of mileage interval. Filters Clean metal mesh filter in oil tank (illustration 3), and metal filter in crankcase on twins.
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Page 28: Engine
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 The tappet rods are made of Light Alloy, and in manufacture, the sleeve marked 5 in illustration 11 is fitted to the bare rod and then the push sleeve and the rod are threaded to take the adjusting screw marked 3. It will consequently be seen that, contrary to the practice when steel rods are used, it is not possible to supply and fit sleeve 5 to an existing light alloy rod.
- 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. The two petrol taps facilitate this operation by removing the need to drain the tank of petrol.
- Page 31 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 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 D O W E L PIN CARBURETTER RETAINING STUD.
- 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 THE VALVES 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. Proceed by removing the rockers (see illustration 12 for assembly sequence).
- Page 42 Oversize or undersize parts The following are the only "oversize" variations provided for the Vertical Twin machines. Big-end and crankshaft centre main bearings: below normal (jounals to be re-ground to suit). Undersize ·010 … … … ·020 ” ” ” ”...
- 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 ·010" to ·012" 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 face 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 D Y N A M O BODY A N D PASSING SHAFT. T HRO UG H CRANKCASE A N D TIMING...
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Page 46: Carburetter
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 22 Carburetter details in assembly order...
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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
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 INNER 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 clutch 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 CLUTCH 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. TO DISMANTLE GEAR B O X Dismantle outer and inner covers as described.
- 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.
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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, M A I N , FOR FRONT FORK. BUFFER, RUBBER, FOR FORK INNER TUBE. BUFFER, RUBBER, FOR FORK INNER TUBE. WASHER, LEATHER, FOR FORK SPRING BOTTOM SEATING. EXTENSION.
- 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.
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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
WHEELS AND BRAKES T O 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 CIRCLIP. OIL SEAL CUP. ADJUSTING RING. OIL SEAL CUP. ADJUSTING RING L O C K N U T . OIL SEAL. WASHER RETAINING SEAL. N U T LOCATING BRAKE COVERPLATE. WHEEL SPINDLE COMPLETE. N U T SECURING BRAKE COVER PLATE. SPINDLE END WASHER.
- Page 68 TO DISMANTLE REAR WHEEL BEARINGS Refer to Illustration 35. 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.
- Page 69 Rear brake and wheel bearings, de-luxe models Illustration 35 W I T HDRA W A B L E WHEEL SPINDLE. SPACER FOR W I T H D R A W A B L E SPINDLE. SPEEDOMETER GEAR BOX SLEEVE. OUTER SPACER BRAKE COVER...
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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 thrust 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 75 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 RM15 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 76 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 77 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 78 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 doth.
- Page 79 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 80 ELECTRICAL SERVICE MAGNETO MODELS ELECTRICAL EQUIPMENT 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. Illustration 44 Contact Breaker IGNITION...
- Page 81 (b) The contact breaker lever also requires lubrication and the complete contact breaker must be removed for this purpose. Take out the hexagon-headed screw from the centre of the contact breaker and pull the contact breaker off the tapered shaft on which it fits. Then push aside the lever retaining spring, prise the lever off its bearing and lightly smear the bearing with clean engine oil.
- Page 82 Inspect commutator and brush gear every 5,000 to 6,000 miles (Maker's Recommendation.) Remove the cover band to inspect commutator and brush gear. The brushes are held in contact with the commutator by means of springs. Move each brush, see they are free to slide in their holders, if dirty, or if sticking, remove and clean with a cloth moistened with petrol.
- Page 83 Illustration 45 Control box connections 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 of scale. If, under normal running conditions, it is found that the battery is continually in a low state of charge, or is being constantly overcharged, then the regulator setting should be checked by a qualified electrician and, if necessary, re-set.
- Page 84 FITTING THE BATTERY The battery must be inserted with the negative terminal on the right side of the battery compart- ment. 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 1·270 to 1·290.
- Page 85 SPARKING PLUG—ALL MODELS (Single or three-point type) The K.L.G. Type FE80 "Corundite" Plug is fitted to all models except CSR. 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 necesasry, reset the points.
- Page 86 Main bulb 30/24-watt prefocus (left-hand Home Models Lucas No. 373 6-volt … dip). 30/24-watt prefocus (vertical General Export Models Lucas No. 312 6-volt dip). 35/35-watt prefocus duplo Continental Models Lucas No. 403 6-volt … (vertical dip). 36/36-watt 3-pin duplo (verti- French Export Models Lucas No.
- Page 87 Illustration 48 Wiring diagram—Singles...
- Page 88 Illustration 49 W i r i n g diagram—Magneto Twins...
- Page 89 Illustration 50 Wiring diagram—Alternator Twins...
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Page 90: 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 91 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 92 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 93 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 94 SERVICE The Service and Repair Department is situated in Burrage Grove, Plumstead, London, S.E.I8, 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 95 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.
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Page 96: Free Service
FREE SERVICE SCHEME FREE SERVICE SCHEME All owners of N E W MODELS 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 97: 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 98: 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. 017007 Tyre lever. 017248 Pliers. 011188 Gudgeon pin circlip pliers. 017256 Screwdriver. 017246 Grease gun. 017249 Adjustable wrench. Sparking plug box spanner and tommy bar. 017252 018178 Spanner 1·010"... -
Page 99: Tool Kit
TOOL KIT Illustration 52... -
Page 100: Guarantee
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: Index
… … Brake, pedal Engine lubrication … … 13-15 … … … Brake, rear Engine oil pumps … … 14-16 … … … Brake shoes … … Brake shoe adjustment … … … Forks, front Forks, rear lubrication … …... - Page 102 Page Page Law, the … … … … … … … … Service Lighting … … … … … … … Sparking plug … … … Sparking plug removal … … Lubricants … … … … Speedometer, lubrication Lubrication chart Starting …...