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Matchless G11 Workshop Manual

1957 500 c.c 600 c.c. twin cylinder models ajs model 20 ajs model 30

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Table Of Contents

Table of Contents

Workshop Manual
Data
Controls
Driving
Fuel Supply
Starting the Engine from Cold
Stopping the Engine
On the Road
Stopping the Machine
Running in
Notes on Driving
Lubrication
Lubricants to Use
Engine Lubrication System
Engine Oil Pumps
Checking Oil Circulation
Engine Oil Circulation
The Oil Tank
The Oil Filters
Cleaning Oil Filters
To Remove and Clean the Felt Crankcase Filter
To Remove the Magnetic Filter Located in the Crankcase
Location of Oil Non-Return Valve
Gear Box Lubrication
Chain Lubrication
Hub Lubrication
Brake Drum Bearing
Lubrication Chart
Steering Head Bearing Lubrication
Control Cable Lubrication
Rear Fork Hinge
Maintenance
Engine Service
To Adjust Overhead Rockers - Tappet Clearance
Access to the Engine
To Remove the Petrol Tank
To Replace the Petrol Tank
Decarbonisation
To Remove Cylinder Heads for Decarbonisation
To Remove the Valves
To Remove Valve Guides
Removing Carbon Deposit
Valve Grinding
Removing Cylinder Barrels and Pistons
Fitting Pistons and Cylinder Barrels
Cross Section of Engine
To Re-Fit the Cylinder Heads
Valve Timing Gear
Valve Timing
Removal of Gears
To Re-Time the Ignition
To Dismantle and Refit Crankcase Release Valve in Crankshaft
Carburetter Service
Removing Sparking Plug
Carburetter Function
Twist Grip Adjustment
Air Filter
To Remove the Air Filter Element
Carburetter Tuning Information
Carburetter Details View in Assembly Order
Transmission Service
The Gear Box
Foot Change Operation
To Remove Gear Box Outer Cover
To Replace Gear Box Outer Cover
To Remove Gear Box Inner Cover/To Replace Gear Box Inner Cover
To Remove Front Chaincase and Clutch Assembly
To Remove Clutch and Front Chain
Clutch Spring Adjustment
Clutch Operating Mechanism Adjustment
To Remove Back Half of Chaincase
To Re-Fit the Front Chaincase and Clutch
To Dismantle Clutch Shock Absorber
To Remove Clutch Bearing
To Dismantle Gear Box
Removal of Cam Plate
Refitting Cam Plate
Fitting Gears into Gear Box
Dismantling Kick Starter Assembly
To Replace Kick Starter Assembly
Front Chain Adjustment
Rear Chain Adjustment
Fork and Frame Service
Removing and Refitting Rear Chain
Steering Head Adjustment
Front Forks - Teledraulic
Front Fork "Topping Up"
To Remove the Complete Front Fork Assembly
Exploded View of Teledraulic Forks
To Remove a Fork Slider
To Remove a Fork Inner Tube Assembly
Rear Suspension
The Cam Ring Adjuster
Prop Stand
Centre Stand
To Remove Oil Tank
Wheels and Brakes
To Remove the Rear Chain Guard
To Remove Front Wheel/To Re-Fit Front Wheel
To Remove Quickly Detachable Rear Wheel
Wheel Bearings and Adjustment
To Dismantle Front Wheel Bearings
To Dismantle Rear Wheel Bearings
Front Brake Cover Plate
Brake Drums
Brake Shoes
Brake Shoe Adjustment
Front Brake Adjustment
Rear Brake Adjustment
Brake Pedal Adjustment
Tyres and Service
Tyre Removal
Tyre Fitting
Tyre Pressures
Electrical Service
Electrical Equipment
Ignition
Sparking Plug
Magneto Removal and Fitting
Dynamo
AVC Unit
To Remove and Re-Fit Dynamo
Battery
Battery Unit
To Remove AVC Unit
Lighting and Accessories
Headlamp
Rear Lamp
Horn
Fuses
Snap Wire Connector
Wiring Diagram
Cleaning the Machine
Chromium Plating
Terminals
Tools and Special Equipment
Tool Kit
Troubleshooting

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Workshop Manual

for

1957

MATCHLESS

G11

500 c.c

TWIN CYLINDER MODELS

600 c.c.

AJS Model 20

AJS Model 30

Also suits

AJS

Issued by:

MATCHLESS MOTOR CYCLES

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