Matchless G9 British Motorcycle Manuals

Manuals and User Guides for Matchless G9 British Motorcycle. We have 1 Matchless G9 British Motorcycle manual available for free PDF download: Workshop Manual

Matchless G9 Workshop Manual (71 pages)

1957 500 c.c 600 c.c. TWIN CYLINDER MODELS AJS Model 20 AJS Model 30

Brand: Matchless | Category: Motorcycle | Size: 2 MB

Workshop Manual
1
Data
3
Controls
5
Driving
7
Fuel Supply
7
Starting the Engine from Cold
7
Stopping the Engine
8
On the Road
8
Stopping the Machine
9
Running in
9
Notes on Driving
9
Lubrication
10
Lubricants to Use
10
Engine Lubrication System
11
Engine Oil Pumps
12
Checking Oil Circulation
12
Engine Oil Circulation
13
The Oil Tank
13
The Oil Filters
13
Cleaning Oil Filters
13
To Remove and Clean the Felt Crankcase Filter
14
To Remove the Magnetic Filter Located in the Crankcase
14
Location of Oil Non-Return Valve
14
Gear Box Lubrication
15
Chain Lubrication
15
Hub Lubrication
15
Brake Drum Bearing
15
Lubrication Chart
16
Steering Head Bearing Lubrication
16
Control Cable Lubrication
16
Rear Fork Hinge
16
Maintenance
17
Engine Service
18
To Adjust Overhead Rockers - Tappet Clearance
18
Access to the Engine
19
To Remove the Petrol Tank
19
To Replace the Petrol Tank
20
Decarbonisation
20
To Remove Cylinder Heads for Decarbonisation
20
To Remove the Valves
21
To Remove Valve Guides
21
Removing Carbon Deposit
21
Valve Grinding
21
Removing Cylinder Barrels and Pistons
22
Fitting Pistons and Cylinder Barrels
22
Cross Section of Engine
23
To Re-Fit the Cylinder Heads
24
Valve Timing Gear
24
Valve Timing
25
Removal of Gears
25
To Re-Time the Ignition
26
To Dismantle and Refit Crankcase Release Valve in Crankshaft
26
Carburetter Service
27
Removing Sparking Plug
27
Carburetter Function
27
Twist Grip Adjustment
28
Air Filter
28
To Remove the Air Filter Element
28
Carburetter Tuning Information
28
Carburetter Details View in Assembly Order
29
Transmission Service
30
The Gear Box
30
Foot Change Operation
30
To Remove Gear Box Outer Cover
31
To Replace Gear Box Outer Cover
31
To Remove Gear Box Inner Cover/To Replace Gear Box Inner Cover
31
To Remove Front Chaincase and Clutch Assembly
31
To Remove Clutch and Front Chain
32
Clutch Spring Adjustment
32
Clutch Operating Mechanism Adjustment
32
To Remove Back Half of Chaincase
33
To Re-Fit the Front Chaincase and Clutch
33
To Dismantle Clutch Shock Absorber
34
To Remove Clutch Bearing
34
To Dismantle Gear Box
34
Removal of Cam Plate
35
Refitting Cam Plate
35
Fitting Gears into Gear Box
35
Dismantling Kick Starter Assembly
35
To Replace Kick Starter Assembly
36
Front Chain Adjustment
36
Rear Chain Adjustment
36
Fork and Frame Service
37
Removing and Refitting Rear Chain
37
Steering Head Adjustment
37
Front Forks - Teledraulic
38
Front Fork "Topping Up"
38
To Remove the Complete Front Fork Assembly
39
Exploded View of Teledraulic Forks
41
To Remove a Fork Slider
42
To Remove a Fork Inner Tube Assembly
42
Rear Suspension
43
The Cam Ring Adjuster
43
Prop Stand
44
Centre Stand
44
To Remove Oil Tank
44
Wheels and Brakes
45
To Remove the Rear Chain Guard
45
To Remove Front Wheel/To Re-Fit Front Wheel
45
To Remove Quickly Detachable Rear Wheel
45
Wheel Bearings and Adjustment
46
To Dismantle Front Wheel Bearings
46
To Dismantle Rear Wheel Bearings
47
Front Brake Cover Plate
48
Brake Drums
49
Brake Shoes
49
Brake Shoe Adjustment
49
Front Brake Adjustment
50
Rear Brake Adjustment
50
Brake Pedal Adjustment
51
Tyres and Service
52
Tyre Removal
52
Tyre Fitting
53
Tyre Pressures
53
Electrical Service
54
Electrical Equipment
54
Ignition
54
Sparking Plug
56
Magneto Removal and Fitting
56
Dynamo
57
AVC Unit
58
To Remove and Re-Fit Dynamo
58
Battery
59
Battery Unit
59
To Remove AVC Unit
59
Lighting and Accessories
60
Headlamp
60
Rear Lamp
61
Horn
61
Fuses
61
Snap Wire Connector
61
Wiring Diagram
62
Cleaning the Machine
63
Chromium Plating
63
Terminals
63
Tools and Special Equipment
64
Tool Kit
65
Troubleshooting
66

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