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G3L G3LS G3LC G3LCS (G80 G80S G80C G80CS)

1. 12 HORN SWITCH 2 AiR CONTROL 8 GEAR CHANGE LEVER 25 GEAR INDICATOR DISC RIDER S FOOTREST I4 14 RIDER S FOOTREST GEAR BOX FILLER CAP 9 KICK STARTER LEVER 16 TANK FILLER CAP TANDEM SEAT PILLION FOOTREST 24 24 PILLION FOOTRES Illustration 1 Showing Controls Before using the machine sit on the saddle and become familiar with the position and operation of the various controls Pay particular attention to the gear positions DRIVING Now that pre war 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 is more than offset by the advantages obtained by using only Number One rades FUEL SUPPLY Two fuel feed taps are situated underneath the rear end of the petrol tank One each side Both must be shut off when the machine is left standing for more than a few minutes The tap plungers work horizontally To open the hexagon knob marked push on Is pushed towards the body of the tap To close press the round milled knob marked push off Normally only use the tap on the right hand side of the machine and then the other side will act as a reserve supply Always re fuel as soon as possible after being forced to call upon the reserve approx 2gallon and then at once close the reserve tap It will be noted that by fitting two petrol feed
2. 36 SPRING CLIP LOCKING FIXING TOP FOR MIXING BODY ee CONTROL CABLE GUIDE FOR AIR VALVE SPRING SPRING FOR AIR VALVE M SPRING FOR AIR VALVE is THROTTLE VALVE FOR TAPER THROTTLE VALVE gt 7 NEEDLE SPLIT PIN TAPER NEEDLE MIXING BODY THROTTLE VALVE STOP SCREW AND LOCK NUT FLANGE SCREW AND LOCK NUT FOR yc PILOT JET AIR AIR INTAKE LOCK SCREW r CHAMBER ee ADJUSTMENT TICKLER FLOAT NEEDLE CHOKE OR JET BARREL FIBRE WASHER FLOAT NEEDLE JET FLOAT CHAMBER UNION NUT MAIN JET NEEDLE SEAT AND UNION FOR FUEL PIPE BANJO NUT FIXING BANJO A BOLT HOLDING FLOATS CHAMBER TO MIXING BODY A 5 FIBRE WASHER PLUG SCREW FIBRE WASHER Illustration 13 Carburetter details in assembly order 37 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 Our Spare Parts Department does not stock every part of the carburetter but confines its stock to those parts tha
3. ISTHE ADJUSTING BOLT LOCK NUT ISTHE REAR BRAKE ROD Illustration 25 Showing the rear brake pedal with its adjusting bolt and lock nut To permanently raise the toe end of the pedal slacken lock nut B and unscrew the adjusting bolt A Check back brake adjust ment after BRAKE PEDAL ADJUSTMENT The position of the rear brake pedal can be adjusted within narrow limits This is done by means of a bolt screwed into the heel of the pedal The adjusting bolt is locked by a nut The best position for normal use is to position the pedal so that when the brake is off it is just clear of the under side of the footrest arm After altering the adjustment of the brake pedal rear brake adjustment should be checked Illustration 26 Showing brake rod adjust ment exhausted indicat ing brake shoe thrust pin adjustment is essential RIGID FRAME MODELS RIMS AND SPOKES The front and rear rims are each drilled for forty spokes and are now interchangeable 69 NN Illustration 27 Showing brake justment exhausted dicating the need for brake thrust pin adjust ment SPRING FRAME MODELS TYRES AND SERVICE 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 Inflate as may be necessary Avoid unn
4. 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 Moisture on sparking plug Oiled up or fouled sparking plug Throttle opening too large Pilot jet choked Air lever in open position or bad air leak at carburetter flange Lack of fuel because of insufficient flooding cold only Lack of fuel because of pipe or tap obstruction Excessive flooding of carburetter with hot engine only Stuck up engine valve Weak or broken valve spring Valve not seating properly Contact points dirty Incorrect contact point gap Engine misses fire may be due to Defective or oiled sparking plug Incorrect contact point gap Contact breaker points loose Rocker adjustment incorrect Oil on contact breaker points Defective sparking plug wire Partially obstructed petrol supply Loss of power may be due to Faulty sparking plug Lack of oil in tank Weak or broken valve spring Sticky valve stem Valve not seating properly Brakes adjusted too closely Badly fitting or broken piston rings Punctured carburetter float Engine carbonised Choked silencer 72 Engine overheats may due to Lack of proper lubrication Quality or
5. 2 7 D Utm S Y N 22 3 A 100 Illustration 12 The rotating oil pump plunger is here shown situ together with the guide screw which registers in the plunger profiled groove thereby providing the recipro cating movement 1 DOWEL PEG LOCATING TIMING GEAR COVER 2 TIMING SIDE FLYWHEEL AXLE WITH INTEGRAL GEAR FOR DRIVING OIL PUMP PLUNGER 3 OIL PUMP PLUNGER 4 SCREW ONE OF THREE WITH FIBRE WASHER PLUGGING OIL PASSAGES CAST IN CRANKCASE 5 GUIDE PIN FOR OIL PUMP PLUNGER 35 6 SCREWED BODY TO ACCOMMODATE THE OIL PUMP PLUNGER GUIDE PIN 7 BODY WITH GUIDE PIN IN POSITION ENGAGED IN PROFILED CAM GROOVE OF OIL PUMP PLUNGER TAPPED HOLE FOR PIPE FEEDING OIL TO OIL PUMP TAPPED HOLE FOR PIPE RETURNING OIL TO OIL TANK REMOVE AND REPLACE THE OIL PUMP PLUNGER 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 Replace by Reversing above procedure 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 Make certain that the guide screw pin is correctly located in
6. 8 6 RIGHT HAND SIDE CAM RING FOR ADJUSTING BEARING 9 ROLLER PART OF LEFT SIDE TAPER 7 NUT LOCKING SPEEDOMETER GEAR ROLLER BEARING BOX POSITION 20 BOLT SECURING BRAKE DRUM AND 8 SPACER BETWEEN SPEEDOMETER GEAR SPROCKET TO HUB BOX AND RIGHT HAND SIDE TAPER ROLLER BEARING 21 REAR BRAKE COVER PLATE 9 OIL SEAL 22 BRAKE LINING 10 COLLAR ENCIRCLING RIGHT HAND OIL 23 BRAKE SHOE SEAL 24 SPIGOT BUSH FITS IN LEFT HAND FORK 11 CIRCLIP LOCATING RIGHT HAND SIDE END TAPER ROLLER BEARING 25 NUT ON CENTRE SOLID SPINDLE 12 WASHER RETAINING OIL SEAL ONE 26 LEFT HAND SIDE CAM EACH SIDE OF SEAL 27 s 13 SPACER BETWEEN SEAL INNER SPRING BRAKE SHOE WASHER AND TAPER BEARING 28 BRAKE DRUM AND SPROCKET 64 N Illustration 22 Showing exploded view of hub bearing components in the order of assembly Upper part is that of front bearings Frame Models Rigid and Spring Lower part is that of rear bearings Spring Frame Model only Rigid Frame Models identical except for items 28 to 32 CIRCLIP WASHER METAL OUTSIDE OIL SEAL OIL SEAL SPACING COLLAR ENCIRCLING OIL SEAL WASHER METAL BETWEEN OIL SEAL AND TAPER BEARING OUTER RACES 2 OFF CENTRE SPINDLE ROLLERS IN CAGES 2 SETS THESE ARE NOT SUPPLIED SEPARATELY ALSO ROLLERS ARE NOT SUPPLIED SEPARATELY WASHER METAL BET
7. The pedal must be moved to the full extent of its travel when selecting a gear either up or down It must not be stamped down or jabbed but firmly and decisively moved till it stops A half hearted movement may not give full engagement Keep the foot off the pedal when driving and between each gear change because unless the lever can freely return to its normal central position the next gear cannot be engaged Finally fully advance the ignition 350 c c models and leave it in that position unless it is necessary to retard in order to ease the engine and so prevent pinking when pulling hard on a gradient 10 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 Before leaving the machine turn off the fuel supply IMPORTANT NOTICE NEVER DRIVE AWAY AT HIGH SPEED WHEN STARTING A RUN WITH A COLD ENGINE GIVE THE OIL A CHANCE TO WARM UP AND THIN OUT PARTICULARLY WHEN THE MACHINE IS COLD UNTIL THE OIL REACHES ITS NORMAL RUNNING TEMPERATURE THE CIRCULATION IS RESTRICTED SEIZURES CAN BE AVOIDED BY TAKING THIS SIMPLE ESSENTIAL PRECAUTION RUNNING IN Although it is customary to quote permitted maximum speeds on the various gears during the period of running in these are really no
8. 7700 SUPPORTING m TUBE AND SPRIN 016075 LOWER BUSH oo CIRCLIP RETAINING BUSH 016407 OUTER TUBE O10 710 016349 DAMPER TUBE 22 i 22 BOTTOM PIVOT 016060 EN DA 016324 SEALING WASHERS AS if 010262 RUBBER BUSH 016206 SPACER Illustration 19 Showing Ghost view of TELEDRAULIC leg 58 To check oil content of TELEDRAULIC leg and top up DEALERS SERVICE ONLY 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 Using a suitable clamp encircling the outer tube adjacent to the bottom pivot lug grip in a vice and loosen the pivot lug Then holding leg vertically bottom end uppermost carefully remove the loosened pivot lug and gripping the exposed end of the damper tube with the fingers raise and lower several times pumping action after which pour the oil contents into a graduated measure It may be necessary to repeat the pumping action to eject oil from underneath the damper valve and finally the open end of tube should be supported above the measure and left to drain for several minutes If the leg contained the correct amount of oil 75 c c 2 ozs should have been drained out into the graduated measure leaving 10 c c 02 which cannot be withdrawn All that now remains is to pour carefully back into the leg exactly 75 c c 2 ozs of oil after which
9. Battery Inspect each cell for level of electrolyte and top up with distilled water if necessary See pages 80 and 81 Level of electrolyte should just be over top of plates 22 EVERY 1 000 MILES Oil tank Drain at first 1 000 miles and re fill with new oil 16 Rear chain In wet weather remove and soak in molten tallow for preference 4 Gear box Add 2 fluid ounces of specified oil 18 Hubs Inject small amount of grease 14 amp 23 Expanders Inject small amount of grease 3 amp 10 Steering head Inject small amount of grease 9 amp 21 Small parts Smear all moving parts with engine oil and wipe off surplus Air Filter If fitted clean and re oil filter element EVERY 3 000 MILES Rear chain In dry weather remove and soak in molten tallow for preference 4 Brake pedal Inject small amount of grease 5 Speedometer Inject small amount of grease into speedometer gear box 15 Magneto Clean contact breaker points and re set if necessary Plug Clean sparking plug and re set points as necessary Steering head Test steering head for up and down movement and adjust if necessary Bolts and nuts Check all nuts and bolts for tightness and tighten If necessary but beware of over tightening 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 in
10. plus 6d postage 74 ELECTRICAL SERVICE IGNITION A Lucas magneto type N1 4 with manual advance and retard is fitted to 350 c c Touring models A Lucas magneto type SR 1 with automatic advance and retard is fitted to 500 Touring models A Lucas racing magneto type NR 1 is fitted to all Competition 350 c c and 500 c c models The only service attention required by the N1 4 magneto is the occasional lubrication of the contact breaker cam and tappet and infrequent adjustment of the contact breaker points To lubricate the contact breaker cam and tappet it is necessary to remove the complete contact breaker LOCK 6 e i CONTACT BREAKER SECURING SCREW m N SPRING j SCREW CARRYING N LUBRICATION WICK BACKING SCREW SECURING SPRING CONTACT BREAKER Illustration 28 Showing Contact Breaker To remove contact breaker Magneto type N1 4 Swing away the flat blade retaining contact breaker cover and remove same Remove the screw E Illustration 28 retaining the spring arm A to the contact breaker body and take away the backing spring F Illustration 29 and also the spring arm E Note there is a spring washer under the screw Unscrew screw B Illustration 28 carrying the lubrication wick and take away the fibre insulating bush encircling the screw Straighten the tab on the lock washer D Illustration 29 under the central screw retaining the contact breaker body A to the armatur
11. 21 teeth it aad ee 5 55 to 1 10 09 to 1 7 41 to 1 5 0 to 1 a Standard for 350 c c Models b Standard for 500 c c Models Ignition magneto Ignition point before top dead centre with control Model Make Type Rotation Point gap in fully advanced position Touring 350 c c Lucas N1 4 Anti clock 012 Normal 37 7 16 Max t2 Touring 500 c c Lucas SR 1 Anti clock 012 in Normal 37 7 16 v All Competition Lucas NR 1 Anti clock 012 in Normal 37 7 16 Max 2 Lighting bulbs Part Location Type Voltage Wattage number Head lamp Pre focus Double filament 6 30x24 312 Pilot lamps jk aaa Single contact 6 3 988 Rear lamp n ni Double filament 6 18 amp 3 352 Speedometer A Single contact 6 18 53205 Oversize parts The following are the only oversize Big end rollers 001 in oversize Cylinder re bore 020 in and 040 in oversize Pistons and rings 020 in and 040 in oversize Pistons standard size Model Top of skirt diameter Front to rear clearance Part number 350 m 2 7176 001 in 013504 500 m se 3 2490 in 001 in 013505 All above measurements are subject to a toleration limit of or 0005 in Piston rings Piston ring gap Normal 006 in Permissible maximum ess T 030 in Piston ring clearance in groove sie 002 Sparking Plug Model Make Type Thread Reach Point gap All m FE80 14 mm 34 in 015 to 018 in Valve timing with 014 inch r
12. A plain steel washer is fitted under the HEAD of each of the two bolts that retain the rear stand to the fork ends The washers should NOT be fitted UNDER the nuts of those bolts 59 TO REMOVE OIL TANK AND BATTERY CARRIER Two studs on the seat tube one facing to the front the other facing to the rear engage with two right angle stays on the oil tank and two similar stays on the battery carrier and two washers and two nuts fitted to the studs retain the oil tank and battery carrier in position Remove oil tank and battery carrier by Drain oil tank Disconnect wire from the battery where it is attached to the seat lug bolt by a Screw Disconnect wire from the battery at the point close to the battery where there is a double screwed connector Pull back the rubber sleeve to reveal the two main components of the connector Hold one component in a wrench or pliers while the second component is unscrewed from it Remove battery from carrier 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 rear stay from oil tank to rear mudguard Remove screw in base of carrier retaining carrier to stay that is supported by the front chaincase Remove the two nuts and washers retaining the oil tank and battery carrier to the two studs Oil tank and battery carrier are now free to be taken away and when doing so it
13. Allows insertion of lubricant and access to clutch inner wire and internal clutch operating lever 14 Footrest for rider 15 Petrol tank filler cap Located in top offuel tank To release slightly depress turn fully to the left and then lift away There are two locking positions The middle position between the fully tightened down and lift away positions is in the nature of a safety device to prevent loss that might be occasioned by unauthorised meddling 16 Oil tank filler cap Located on top edge of oil tank The construction and operation is exactly as the petrol tank filler cap 17 Dipping switch Trigger switch on left handlebar Used to select normal or dipped beam of head lamp when main lighting switch lever is in the position The main head lamp bulb has two filaments 7 C M S 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 TOTAL MILEAGE 2C MILES PER HOUR 19 _ 5 AMMETER LIGHTING SWITCH TRIP MILEAGE 2I REMOVE TO ADD REMOVE TO ADD GN A HYDRAULIC FLUID 22 KNOB RESET TRIP s RECORDER HYDRAULIC m e CLUTCH LEVER S 9 M A EN IGNITION CONTROL ae Lb 20 VALVE LIFTER LEVER 4 3 ee DUMMY 18 DIPPING SWITCH REAR BRAKE LEVER T 6 FRONT BRAKE LEVER PETROL TANK THROTTLE TWIST FILLER
14. Corundite Plug is fitted to all models has a thread of 14 mm and the reach is 34 The point gap is 015 Check the point gaps every time the engine is decarbonised and if necessary re set the points See the plug is fitted with its external seating washer Coat the thread with Oil Dag or Graphite paste See page 36 Firmly tighten the plug by using the standard box spanner and tommy bar Part No 017252 All that is required is a GAS TIGHT joint Therefore do not over tighten which will not make a gas tight joint more gas tight but can and possibly will distort and damage the body of the plug Set the gaps to 015 inch Never try to move the central electrode To widen or narrow the gap between the electrodes only move the earth side electrodes Check the gaps first with gap gauge If they are too wide tap the earth side electrodes towards the central electrode using preferably a small copper drift and light hammer Check the gaps between each tap and stop when the gauge is a nice sliding fit between the central electrode and the three earth side electrodes If the gaps are too small to start with gently lever the earth electrodes away from the centre electrode using a small screw driver and then tap them back as described above Avoid damaging the centre electrode and do not attempt to move the electrodes apart by forcing anything between them For maximum efficiency plugs should be cleaned at every 3 000
15. Locations Heavy Gear Oil Location al FRONT TELEDRAULIC FORKS 17 REAR FORK HINGE Heavy Engine Oil Location Tallow Location 18 GEAR BOX 4 REAR CHAIN When buying oils and greases it is advisable to specify the Brand as well as the grade and as an additional precaution to buy only in sealed containers or from branded cabinets 21 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 DAILY Oil tank Inspect oil level 16 and top up if necessary Check oil circulation Petrol tank Check level and re fill if necessary WEEKLY Oil tank Check level 16 and re fill if necessary Tyres Check pressures and inflate if necessary EVERY 500 MILES Oil tank Drain at first 500 miles and re fill with new oil and clean felt filter 16 Gear box Drain at first 500 miles and re fill 18 1 pint Chaincase Check level of oil when machine is standing vertically on level ground when level of oil should not be less than 36 below bottom edge of Inspection orifice 7 Rear chain If dry apply engine oil with a brush 4
16. a V hydrometer and if it is below 1 150 the battery MN should be charged as soon as possible by the normal running of the motor cycle If this cannot be arranged the battery should be charged from an external source If the level of the electrolyte is so low that a hydrometer reading cannot be taken no attempt should be made to take a reading after adding distilled water until the battery has been on charge for at least 30 minutes NEVER transfer the electrolyte from one cell to another Illustration 33 NEVER leave a battery in a discharged condition Lucas PU7E 9 It must be put on charge as soon as possible Battery Check If the electrolyte in each cell is level with the top of the separators Top up if necessary with distilled water Do not allow the distilled water to come Into contact with metals always only use a glass or earthenware container and funnel See filling instructions on underside of battery lid If a battery is found to need an excessive amount of topping up steps should be taken to find out the reason For example the battery may be receiving an excessive charge in which case the regulator setting may need adjustment 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 Metal parts should be well cleaned and if possible washed with a solution of a
17. against its stop The kick starter mechanism must be allowed to engage properly before putting heavy pressure on the kick starter crank pedal pin That means there are two definite and separate movements when operating the mechanism by depressing the crank The first is a slow and gentle movement which ends when it is felt the quadrant has engaged with the teeth on the ratchet pinion 9 Illustration 2 UPWARDS TO ENGAGE Showing the gear indi cator drum which upon assembly is set to record the various gears and neutral position as the respective figure or letter registers with index mark on the gearbox shell Upon re asembly after dismantling for any pur pose the index disc should DOWNWARDS be correctly re set for TO ENGAGE future reference HIGHER NEUTRAL POSITION GEAR The first slow and gentle movement is essential to avoid damage to the teeth of the kick starter quadrant After the engine has started slowly open the air lever until it runs evenly Then set the throttle so that the engine is running at a moderate speed neither racing nor ticking over and allow to warm up While doing this check the oil circulation as detailed in page 13 The machine can then be taken on the road NOTE Do not race up the engine from cold and do not flood the carburetter to such an extent that petrol is dripping because then in the event of a backfire there is a danger of such loose petrol igniting This cannot possibly
18. cams spacers bushes nut and speedometer gear box Turn to left hand side and slacken lock nut 26 Completely unscrew the adjusting ring 25 and take it away with the lock nut 26 still on it Turn to the right hand end of the hub and carefully apply steady pressure on the visible steel washer avoiding fouling the circlip that can be seen in the hub end so that in turn the cup housing 24 for the oil seal the oil seal 23 the metal washer 22 that is behind the oil seal the spacing ring 21 that is between the metal washer and the taper bearing and outer cup 20 are ejected These may be lifted away as they emerge The rollers in cage 20 the centre spacer 19 and the rollers in cage 18 may now be lifted out of the hub Turn to the right hand end of the hub carefully apply steady pressure to the visible washer avoiding fouling the circlip that can be seen in the hub end so that the complete right hand assembly of oil seal and outer cup is pushed a trifle further into the hub shell This will take off pressure on the circlip thereby making its extraction an easy matter Extract circlip 12 Through the open end of the hub carefully apply steady pressure to the inner edge of the outer cup 18 so that it is forced out of the hub As it emerges it will push in front of it the oil seal plain washer 13 the oil seal 14 with its encircling spacer collar 15 the oil seal internal plain washer 16 and the
19. circlip thereby making its extraction an easy matter Extract circlip 1 and then reversing the hub apply pressure on the inside edge of the outer cup 6 so that it is forced out ofthe hub As It emerges it will push in front of it the oil seal external plain washer 2 the oil seal 3 with its encircling spacer collar 4 and the oil seal inner plain washer 5 all of which can be lifted away as they appear to be finally followed by the cup 6 The dismantling is then completed To re fit reverse the above procedure remembering that after cup 6 washer 5 Spacer 4 oil seal 3 and washer 2 have been inserted in the plain end of the hub to re fit the circlip 1 and then carefully to apply steady pressure on the inner edge of the cup 6 to force the above entire assembly tightly back against the circlip 1 Position disc to permit access to grease nipple 63 QOO 5 M OOOO Illustration 21 Showing rear hub rear chain sprocket brake and speedometer gear box Spring Frame Model Rigid Frame Models Identical except for items 4 6 and 26 1 RIGHT HAND SIDE HUB FLANGE 4 SPACER BETWEEN THE TWO TAPER 2 GREASE NIPPLE ON SPEEDOMETER GEAR BEARINGS BOX 5 GREASE NIPPLE IN HUB SHELL 3 SPEEDOMETER GEAR BOX 6 OUTER RACE OF RIGHT SIDE TAPER 4 SPIGOT BUSH FITS RIGHT HAND ROLLERS BEARING FORK END 7 NUT LOCKING BEARING ADJUSTING RING 5 NUT ON CENTRE SOLID SPINDLE
20. circumstances should any abrasive material such as emery or emery cloth be used for cleaning and polishing di 2n y ifs Illustration 9 Showing flywheel in exploded form VALVE GRINDING Before commencing valve grinding carefully examine the face of each valve and if found to be deeply pitted have them refaced Most garages have suitable equipment for that purpose Any attempt to remove deep pit marks by grinding will inevitably cause undue and undesirable widening of the seats As a rule inlet valves require very little attention and one light application of fine grinding paste should be sufficient to restore an even matt finish to both valve face and seat The exhaust valves may require two or even three applications but as already mentioned excessive grinding is both unnecessary and harmful 29 The grinding is accomplished by smearing 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 Never revolve the valve continuously in one direction When the abrasive ceases to bite remove the valve and examine its face The grinding may be considered to be satisfactorily completed when a co
21. damper action occurs with a greatly increased damper action on the reverse movement both actions automatically increasing in effect the more violent the movement Before concluding this description it should be mentioned that upon a very violent impact as a result of which the main springs are almost fully compressed the damping of the upward movement of the sliders is intentionally increased by the automatically greatly restricted passage for the displaced oil brought about by the lower ends ofthe main tubes encircling the tapered enlarged ends of the damper tubes as the sliders near the limit of their up ward movement Thus bottoming is prevented no matter how violent the impact For ordinary purposes the recommended oil content is 61 ozs 184 6 c c each leg of one of the S A E 20 oils specified To deal with heavier loads than normal the oil content may be increased to a permissible maximum of 10 fluid ozs 284 c c per leg To increase damping oil of heavier grade may be used It will be found however that for normal purposes the recommended grade and quantity of oil will give the most comfortable ride FRONT FORK TOPPING UP No part of the TELEDRAULIC Front Fork requires individual lubrication but lt is advisable to check the oil content once every five thousand miles The normal content as already stated is 6 fluid ounces 184 6 c c each side Support motor cycle vertically with weight on both wheels steady under each
22. do not undertake to replace or refix or bear the cost of replacing or refixing such new part in the motorcycle motorcycle combination or sidecar We undertake subject to the conditions mentioned below to make good at any time within six months any defects in these respects As motorcycles motorcycle combinations and sidecars are easily liable to derangement by neglect or misuse this guarantee does not apply to defects caused by wear and tear misuse or neglect The term misuse shall include amongst others the following acts 1 The attaching of a sidecar to a motorcycle in such a manner as to cause damage or calculated to render the latter unsafe when ridden 2 The use of a motorcycle or of a motorcycle and sidecar combined when carrying more persons or a greater weight than that for which the machine was designed by the manufacturers 3 The attaching of a sidecar to a motorcycle by any form of attachment not provided supplied or approved by us or to a motorcycle which is not designed for such use Any motorcycle motorcycle combination or sidecar sent to us to be plated enamelled or repaired will be repaired upon the following conditions i e we guarantee that all precautions which are usual and reasonable have been taken by us to secure excellence of materials and Workmanship such guarantee to extend and be in force for three months only from the time such work shall have been executed or until the expiration of the six m
23. foot rest is the best method Unscrew the hexagonal plugs at top of fork inner tubes These are on level with handle bars and attached to them are the damper rods Have a graduated measure of not less than 10 fluid ozs capacity available in which to catch and measure the oil Remove the drain plug from the bottom ofa slider and catch the oil which drains out Then reinsert drain plug and work the top plugs to which damper rods are attached up and down pumping action making upward strokes as violent as possible but using only fingers to do so This pumping action is to eject any oil trapped in the damper tubes above the damper disc valve Wait two minutes and again remove drain plug Repeat the action until no further oil can be drained off when if the fork had the correct oil content about 6 fluid ozs 170 4 c c will have been drained off If less add to make this quantity or reduce if an excess quantity has been drained off Next refit drain plug and carefully pour into the top of the tube being checked exactly 6 fluid ozs 170 4 c c after which the top plug may be replaced NOTE Although the normal oil content of each side is specified as 62 fluid ozs it is not possible to drain all the oil via the drain plug This explains the lesser quantity of 6 fluid ozs 170 4 c c referred to above However ifthe fork is at any time completely dismantled and then reassembled in a dry state it should be noted that in that event the correc
24. guide to overdriving the only essential thing to avoid being the use of large throttle opening If the precaution is taken of limiting the use of the throttle to about one third of Its opening during the first 1 000 miles irrespective of the road speed and whether on the level or climbing the necessary conditions for running in will have been observed Special attention must be given during the running in period to such details as valve rocker adjustment chains brakes contact breaker points and steering head bearings all of which tend to bed down in the first hundred miles or so Particular note must be made of the adjustment of steering head bearings which if run in a slack condition wilt be quickly ruined After this bedding down process has taken place adjustments to such details will only be necessary at lengthy intervals After about 1 000 miles have been covered larger throttle openings may be gradually Indulged in for short bursts only Until at least 2 000 miles have been covered the owner of a new machine is strongly advised to curb his natural desire to learn the mount s maximum capabilities Restraint In this direction will be amply repaid later 11 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
25. happen if the starting instructions are carefully followed but in the event ofa fire there is no cause for panic Merely turn off the petrol tap to isolate the main supply open wide the throttle and turn over the engine by operating the kick starter pedal when suction will extinguish the fire STOPPING THE ENGINE To stop the engine close the throttle raise the valve lifter lever and keep it raised until the engine has ceased to revolve ON THE ROAD Having started and warmed up the engine take the machine off the stand sit astride It free the clutch by pulling up the large lever on the left bar and engage the lowest gear Next slowly release the clutch lever and the machine will commence to move forward As it does this the engine speed will tend to drop as it picks up the load so It will be necessary to increase the throttle opening gradually to keep the engine speed gently rising When well under way disengage the clutch slightly close the throttle engage second gear and release the clutch lever then open up the throttle to increase the speed of the machine Repeat these operations in order to engage third and top gears To engage a higher gear the pedal is pressed downward with the toe and a lower gear is obtained by raising the pedal with the instep To engage first gear from the neutral position the pedal is therefore raised After each pedal movement internal springs return the pedal to its normal horizontal position
26. is controlled by a bolt that has an eye encircling the gear box top fixing bolt and which passes through an eye block secured to the right hand side engine rear plate Two nuts threaded on the eye bolt one on each side of the eye block provide means of accurately tensioning the front chain and after that adjustment locking the eye bolt in Its required position Illustration 14 clearly shows the general internal gearbox layout the simple gear selection and kickstarter mechanism t will be seen that movement of the foot change lever causes movement of the cam barrel through the medium of an ingenious trip fork to which the lever is attached This cam movement actuates the sliding gear striker forks causing movement of the sliding gears which engage the stationary gears by dogs As each gear is selected it is held in engagement by means of a spring loaded conical ended plunger operating in depressions on the end of the cam barrel The trip mechanism referred to allows the foot change lever to return to its normal position upon foot pressure being released in readiness for the next change of gear Downward direction of movement causes engagement of higher gears and upward movement with the toes causes a lower gear to become engaged As mentioned elsewhere an external marked disc shows at a glance which gear or neutral is engaged The unusual method of clutch operation should be noted the necessary thrust rod movement to free being obtain
27. is sinch Check the adjustment in more than one position and adjust as above at tightest place It is important that these instructions to over tighten and then slack back are carefully followed Tighten nut on gear box top fixing bolt Replace chaincase inspection cap REAR CHAIN ADJUSTMENT Spring Frame Models To provide rear chain adjustment the rear wheel is bodily moved in the rear frame fork ends which are open ended and slotted The rear wheel centre spindle has two cams attached to it These cams abut against projections in each of the rear fork two slotted ends The projection on the right hand fork end is adjusted at the Factory and its position is locked by a nut That adjustment is provided to ensure the rear wheel is positioned in line with the front wheel and once it has been determined during assembly there should be no necessity ever to alter It again The chainside cam has a hexagonal body to accommodate a spanner and is turned for wards or backwards to position the rear wheel so that the rear driving chain is correctly tensioned Both cams turn together The correct chain tension is such that when the machine is on the centre stand finger pressure applied to the chain midway between gear box sprocket and rear wheel sprocket in an upward and downward direction allows a total movement up and down of 1 The rear wheel should be rotated to several positions and tests made at each because chains never wear
28. 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 Choked silencer Engine stops suddenly may be due to No petrol in tank or choked petrol supply High tension wire detached from sparking plug Choked main Jet Oiled up or fouled sparking plug Water on high tension pick up or sparking plug Water in float chamber Vent hole in petrol tank filler cap choked Stuck up valve EXCESSIVE OIL CONSUMPTION Excessive oil consumption may be due to Clogged or partly clogged oil filter Stoppage or partial stoppage in the pipe returning oil from the engine to the oil tank Badly worn or stuck up piston rings Causing high pressure in the crankcase Air leak in dry sump oiling system Worn inlet valve stem or guide Improper non return valve action EXCESSIVE PETROL CONSUMPTION Excessive petrol consumption may be due to Leaks in the petrol feed system Damaged fibre washers loose union nuts on piping defective float needle action Incorrect ignition setting Ignition not advanced sufficiently Defective engine valve action Incorrect use of air control lever Moving parts of carburetter badly worn Only possible after very considerable mileage Bad air leak at carburetter junction STEERING UNSATISFACTORY Incorrect steering h
29. spacing ring 17 between the metal washer and the taper bearing to be finally followed by the cup 18 The dismantling is then completed To re fit reverse the above procedure remembering that after cup 18 spacer 17 washer 16 oil seal 14 spacer 15 and washer 13 have been inserted in the plain end of the hub to re fit the circlip 12 and then carefully to apply steady pressure on the inner edge of the cup 18 to force the above entire assembly tightly back against the circlip 12 FRONT BRAKE COVER PLATE It Is most important the front brake cover plate is correctly positioned It is retained to the front wheel spindle by an inside nut part number 017003 and an outside nut part number 018071 Between the inside nut and the brake cover plate is a locating washer part number 017222 The inside nut must be positioned so that when the locating washer is placed next to it and the cover plate applied the outer face of the latter lies flush with the hub shell edge The outside nut is fitted so that its hexagonal side is against the brake cover plate 66 BRAKE DRUMS The front wheel brake drum is 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 wheel sprocket and is retained to the wheel hub by five bolts and nuts Under each nut is a lock washer of the tab type and it is essential these are always in posi
30. taps it is possible to remove the petrol tank from the machine without the necessity of first draining it of fuel STARTING THE ENGINE a See that there is sufficient fuel in the petrol tank b See that there is sufficient oil in the oil tank c See that the gear pedal is in the neutral position d Push inward the hexagonal end of off side petrol tap slide e See that the air control lever is in the fully closed position f On models with manual control fully advance the ignition and then pull back the control lever two fifths of its total movement g Open the throttle not more than one sixth of the total movement of the twist grip h Depress the plunger on the top of the carburetter float chamber until it can be felt the chamber is full of petrol i Raise the valve lifter lever and while keeping it raised turn over the engine several times by depressing the kick starter pedal three times the object being to free the engine This only applies if the engine is cold j Depress the kick starter until compression is felt then raise the valve lifter lever and ease the engine just over compression Then after allowing the kick starter pedal to return nearly to its normal position give it a long swinging kick with the valve closed Flywheel momentum will carry over compression and the engine should fire immediately If it fails to do so repeat exactly the same process Do not allow kick starter to return violently
31. the top compression ring is chromium plated These chrome plated rings have a slightly tapered exterior and when new are clearly marked with the word TOP on one side to indicate assembly position After use this word tends to become indiscernable but over a large mileage the assembly position can be determined by brightness of the edge contacting cylinder wall This bright edge is the lower one When as the result of wear contact with the cylinder wall appears rr re over the whole width of the ring it is then immaterial which way round it is re fitted Smear gudgeon pin with engine oil Refit 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 This is essential otherwise considerable damage will result Re fit cylinder barrel by Take new cylinder base washer Coat one side with liquid jointing compound and apply it to cylinder base Ensure jointing does not choke any of the cylinder base oil holes Smear cylinder bore and piston with clean engine oil Space piston rings so that the gaps are evenly spaced at 120 to each other Gently fit barrel over piston and carefully compress each ring in turn with the fingers as it ente
32. 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 Smooth throttle operation is assured by the provision of a cable oil nipple Atthe first signs of jerky action a little engine oil should be injected applying the gun as near vertical as possible nozzle downward AIR FILTER In locations such as the United Kingdom where the roads and atmosphere are particularly free from dust it is not considered necessary to have an air filter fitted to the carburetter but in countries where the atmosphere contains a very heavy dust content an air filter is essential in order to prevent abrasive wear The filter available optional extra for the conditions mentioned above is of the Oil Wetted type and this requires periodical servicing When servicing the air filter withdraw the filter element Thoroughly wash this in petrol paraffin or other suitable solvent and allow to dry Then re oil using one ofthe light oils SAE 20 enumerated in the final table on page 14 and allow to drain before replacing in the filter case Clean regularly at intervals of 1 000 miles and renew the element every 10 000 miles 39 G M S CARBURETTER TUNING INFORMATION Poor idling may be due to Pilot jet not operating correctly Air leaks Either at junction of carburetter and inlet port by reason of badly worn inlet valve stem or guide Fau
33. the machine but those of the front wheel can be dealt with in situ A service method of ensuring correct adjustment is Slacken the lock nut Tighten the adjusting ring until all slackness has been taken up Slacken back the adjusting ring exactly one half turn Tighten the lock nut making sure that when doing so the adjusting ring does not creep round TO DISMANTLE A FRONT WHEEL BEARING These instructions need reference to the upper part of Illustration 22 Remove wheel from machine Remove nuts and brake cover plate with shoes etc from left hand side of wheel Turn to right hand side and slacken lock nut 11 Completely unscrew the adjusting ring 10 and take it away with the lock nut 11 still on it together with cover disc Carefully apply steady pressure on the threaded end of the wheel spindle which will in turn eject from the opposite end of the hub the cup housing for the oil seal 9 the oil seal 8 the metal washer 7 that is behind the oil seal and the outer cup 6 These may be lifted away as they emerge The front wheel spindle 6 with its two sets of rollers in cages may now be lifted out of the hub Turn to the left hand end of the hub carefully apply steady pressure on the visible washer avoiding fouling the circlip that can be seen in the hub end so that the complete left hand assembly of oil seal and outer cup is pushed a trifle further into the hub shell This will take off pressure on the
34. the mainshaft end nut and draw off the KS ratchet driver pinion spring and bush upon which the pinion is mounted Remove the three cheese head screws by which the end plate is secured to the gear box shell and the end plate is then free to be withdrawn leaving the gears and gear striker shafts in situ Take care to avoid losing the steel ball fitted in the end of the mainshaft and interposed between the clutch actuating lever and the clutch thrust rod To Re assemble If gears have been disturbed insert them in their proper order with slider shafts In correct location and apply end plate with paper joint gasket in position Re fit the three cheese head screws and firmly tighten down with a stout screwdriver Then insert conical ended plunger and spring and apply the gear selection cam barrel with any one ofthe depressions on its underside engaging with the conical end ofthe spring loaded plunger Next insert the selector shaft pins and secure each in position with its split pin Complete the assembly in reverse order of dismantling ascertaining before applying the K S case cover that the ball is inserted in the end of the mainshaft Fill to correct level with one of the recommended oils and lastly re fit the gear indicator disc and adjust its position to give correct indication of gears 42 TO REMOVE FRONT CHAINCASE AND CLUTCH ASSEMBLY To remove outer half of front chaincase Place tray under chaincase to catch oil Remove l
35. the pivot lug may again be screwed on and securely tightened down to prevent oil leakage when the leg is re fitted after which the other leg may be dealt with in a similar manner NOTE Shortage of oil is evidenced by very lively action PROP STAND The prop stand hinges on a bolt which passes through a lug brazed to the frame and screws into the jaw ofthe stand leg Itis then locked by a nut and split pin Care in tightening this bolt is necessary to avoid pinching and it is essential to observe after securely tightening the lock nut that the stand is perfectly free Smear the hinge bolt with engine oil before replacing it CENTRE STAND Spring Frame Models The centre stand is mounted on a bolt set across the bottom rear of the main frame and is removed by taking off a nut of the centre bolt and pushing bolt through the frame During removal and replacement the stand should be in a horizontal position in order to take off as much of the tension off the return spring as is possible FRONT STAND The front stand is intended to operate only as a support and care is necessary when using to avoid passing the vertical position stops are provided and dragging the machine backward with the stands down is likely to fracture the lugs on the aluminium sliders of the forks to which the stand is attached Do not attempt to use the FRONT STAND unless the machine is already supported by the main stand REAR STAND Rigid Frame Models
36. to the body of the dynamo Therefore by partially revolving the dynamo in its housing the distance between the two dynamo driving sprockets can be varied thereby allowing latitude for chain adjustment Tighten dynamo chain by Remove inspection cap from front chaincase Slacken dynamo clamping strap bolt With the fingers turn dynamo bodily in an anti clockwise direction till by passing a finger through the inspection cap opening it can be felt the chain tension is correct The chain whip should be about 1 4 Ensure when feeling tension the front driving chain is not confused with the dynamo chain which lies behind the front driving chain Tighten dynamo clamping strap bolt Re check chain tension Replace chaincase inspection cap 49 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 The chain whip should be about J Tighten nut on platform supporting bolt Re check chain tension Place supply of grease on magneto driving chain Replace magneto chain cover ENGINE SHOCK ABSORBER The engine shock absorber is a spring device for smoothing out the engine impulses The engine spro
37. which registers with a hole drilled on the valve guide boss to ensure accurate positioning To remove a valve guide thoroughly clean protruding end of guide to be removed Apply gentle heat and press guide downwards Re heat when replacing and see that correct projection is obtained viz V7 Also see that oil hole in guide is in correct alignment TO REPLACE A VALVE After cleaning valve guide bores smear each valve stem with clean oil insert and apply top collar and split collet Then apply the valve springs which although possible to fit by hand are more easily manipulated with a special compressor tool Part No 018276 illustration 8 To operate this tool apply the top end of the valve spring to its groove in the top cap then insert a short rod one of the rocker box fixing bolts suits admirably through the holes in this tool and the valve spring coils and pull outward and upward until the ends of the prong of the spring can be rested on the seat then press down with the fingers Withdraw the bolt or rod when the compressor lies against the cylinder head retaining pressure with the fingers until the bolt has been withdrawn and the tool removed when the spring can be readily pushed down to its proper location with the prongs laying flat upon the seat 27 Illustration 8 Showing application of valve spring compressor 1 COLLET FOR VALVE 5 VALVE SPRING COMPRESSOR TOOL 2 COLLAR FOR VALVE SPRING 6 OIL PASSAGE FROM ROCKER BO
38. 14 inch so that the tappets may be well clear of the quietening curves of the camshafts The timing gears are marked to facilitate their replacement To re set the valve timing by using the marks on the gears proceed as follows Turn over the engine till the mark on the small timing pinion is in line with the centre of the Inlet rear camshaft bush Insert the inlet camshaft so that the No 2 or No 3 mark on it is in mesh with the mark on the small timing pinion according to model Rotate the engine in a forward direction till the mark on the small timing pinion is in line with the centre of the exhaust front camshaft bush Insert the exhaust camshaft so that the No 2 mark on it is in mesh with the mark on the small timing pinion 32 ADJUSTMENT top ends of the two long push rods have screwed extensions These are locked 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 Prepare to adjust tappets by Set piston to T D C Both valves closed Remove the three nuts and fibre washers under them retaining tappet cover to rocker box Take away cover Adjust tappets on all 350 and 500 models by With spanners hold the sleeve 5 either valve Illustration 11 and sl
39. Air Filter Messrs Vokes Ltd Henley Park Nr Guildford Surrey All the above manufacturers except S Smith amp Sons M A Ltd issue instructive literature regarding their products which is obtainable by writing to them 85 SERVICE The Service and Repair Department is situated in Burrage Grove Plumstead London 5 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 Giving technical assistance verbally or through the post b Supplying spare parts over the counter or through the post c Repairing and re conditioning machines or parts of machines of our make Burrage Grove is the first turning on the left from Burrage Road when entering Burrage Road from the Plumstead Road See final paragraph below The nearest Railway Station is WOOLWICH ARSENAL SOUTHERN REGION RAILWAY This Station is five minutes walk from our Service Depot in Burrage Grove There is an excellent service of electric trains from Charing Cross Waterloo Cannon Street and London Bridge Stations Southern Region Railway Bus routes 53 54 99 122 and 122 Trolleybus routes 696 and 698 pass the end of Burrage Road one minute from the Service Depot Bus routes 21a 75 and 161 serve Beresford Square which is three minutes walk from the Service and Repair Department Visitors from the North can pass into Woolwich via
40. ER OUTER SLEEVE Illustration 35 Lucas snap connector Part number 900269 CONNECTING SLEEVE SOLDERED CABLE NIPPLES One snap connector is used in the rear lamp wire and another is used in the wire con necting the regulator unit to the output side of the ammeter in the head lamp Two more are used in the headlamp interior pilot lamp wires Screwed wire connector A LUCAS screwed connector of the type shown in Illustration 36 is used in the wire connecting the terminal of the battery to the input side of the ammeter in the head lamp It is made up of four parts One part a metal sleeve is threaded internally and accommodates a collet which is placed on the end of one of the wires to be con nected in such a manner that the wire ends protrude through the centre of the collet The third metal part screws into the first and has passing through it the second of the wires to be connected The wire ends are splayed out and the act of screwing the two threaded parts together binds the ends of the two wires thereby making a good electrical contact that can be immediately broken as and when it is wished to remove the battery from the machine A rubber sleeve encircles the whole assembly serving the dual purpose of insulation and prevention of loss through vibration Illustration 36 Lucas screwed wire connector RUBBER Part number 571395 SLEEVE BRASS CONNECTORS Terminals All models have the POSITIVE battery terminal connect
41. G 500 MODEL 6805 SPRING FRAME TOURING 500 MODEL G80C RIGID FRAME COMPETITION 500 MODEL G80CS SPRING FRAME COMPETITION 350 Bore 69 mm Stroke 93 mm Capacity 347 c c 500 Bore 82 5 mm Stroke 93 mm Capacity 498 c c INTRODUCTION Motorcycling is one of the most economical and pleasurable modes of transport It is our sincere wish that every MATCHLESS 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 However it must be remembered that although a motor cycle is of simple design and construction it is nevertheless a highly specialised piece of engineering In consequence it must be intelligently and efficiently maintained in order to provide unfailing reliability In this book are non technical instructions for carrying out all the mainten ance operations likely to be called for in strenuous service and illustrations are provided to assist Neglect to make essential adjustments only casual attention to lubrication and the lack of periodical maintenance attention will soon neutralise the best efforts of the designers and may bring needless trouble to the owner We are always pleased to give MATCHLESS owners the full benefit of our wide experience in matters relating to motor cycles of our manu facture and elsewhere will be found details of the particulars that should be given us when making such an enquiry MA
42. INING 016339 OIL SEAL 010718 TOP BUSH PLASTIC FOR INNER TUBE 015286 ROD FOR FORK DAMPER 017357 FORK INNER TUBE 016322 BUFFER SPRING O10360 FORK SLIDER VALVE FOR FORK DAMPER O16304 STOP PIN FOR VALVE 0721 SEAT FOR DAMPER VALVE 010719 NUT LOCK FOR VALVE SEAT 5 BOTTOM BUSH FOR INNER TUBE 010692 CIRCLIP RETAINING BOTTOM BUSH O10710 FORK DAMPER TUBE 015932 WASHER FOR TUBE BOLT 010706 BOLT FIXING DAMPER TUBE 010697 STUD SECURING SLIDER 010713 THREADED HOLE TO ACCOMMODATE MUDGUARD STAY BOLT BLEED HOLE IN DAMPER TUBE 13932 HOLES B IN 016322 INNER TUBE HOLES A IN 015932 DAMPER TUBE CONED END 015932 DAMPER TUBE WHICH CAUSES A RESTRICTED PASSAGE WHEN INNER TUBE 016322 NEARS THE EXTREMITY OF ITS MOVEMENT TAPPED HOLE TO ACCOMMODATE 000485 DRAIN PLUG WASHER FOR SLIDER STUD OOOO0 l NUT FOR SLIDER CAP STUD 000004 FORK SLIDER CAP 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 will be seen the aluminium sliding members operate upon steel bushes attached to the bottom ends of the main tubes and also upon bakelite bushes secured to the top end
43. MAINTENANCE MANUAL AND INSTRUCTION BOOK for 1954 350 and 500 MATCHLESS SPRING FRAME AND RIGID SINGLE CYLINDER MODELS PRICE 2 6 NETT tS MATCHLESS MOTOR CYCLES WHEN CORRESPONDING REGARDING SERVICE OR SPARES ALWAYS QUOTE THE COMPLETE ENGINE NUMBER Including all letters it THIS ENABLES US TO IDENTIFY THE MACHINE EACH SERIAL OF FRAMES IS NUMBERED FROM ZERO UPWARDS THEREFORE THE QUOTATION OF A FRAME NUMBER ONLY DOES NOT PERMIT A MACHINE TO BE IDENTIFIED MAINTENANCE MANUAL AND INSTRUCTION BOOK for MATEHLESS 1954 SINGLE CYLINDER MOTOR CYCLES Compiled and Issued by the Manufacturers MATCHLESS MOTOR CYCLES Proprietors ASSOCIATED MOTOR CYCLES LIMITED Registered Offices PLUMSTEAD ROAD PLUMSTEAD LONDON S E18 ENGLAND Nearest Station Factories WOOLWICH ARSENAL BURRAGE GROVE and MAXEY ROAD Southern Region Railway PLUMSTEAD S E 18 Telegrams and Cables MATCHLESS WOL LONDON Telephone WOOlwich 1 223 5 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 EDITION CM 26 A M S 1954 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 TOURIN
44. N ON NATIONAL HOLIDAYS 91 ILLUSTRATIONS Battery Brake adjustment front Brake adjustment rear rigid frame Brake adjustment rear spring frame Brake anchorage rear Brake shoe adjustment Brake pedal adjustment Carburetter Clutch Contact breaker Contact breaker details Controls Cut out unit Dynamo Removal Engine lubrication Flywheels Fork component details Fork damper details Gear box Gear lever positions Hub bearing details Hub rear Lamp panel Leg teledraulic rear Lubrication chart Oil tank Oil pump Rear spring frame Sparking plug Tank fixing details Tappet adjustment Timing valve inlet only Tools Valve lubrication Valve spring compressor Wire connector snap type Wire connector srewed type Wiring diagram 92 Illustration 33 24 26 27 20 23 25 13 15 28 29 1 32 31 4 9 17 16 14 2 22 21 34 19 6 3 12 18 30 7 11 10 38 5 35 36 37 81 68 69 70 62 67 69 37 46 75 76 8 80 79 16 29 55 52 40 10 65 64 82 58 21 13 35 57 77 25 33 32 90 18 28 83 83 84
45. ORK TOP COVER TUBE BOTTOM LOCATION FORK CROWN TUBE FORK COVER BOTTOM EXTENSION FOR FORK SLIDER SLIDER FOR FORK WITH CAP STUDS AND NUTS SCREW PLUG WITH FIBRE WASHER FOR FORK SLIDER OIL DRAIN HOLE 56 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 15 fluid ounces 42 6 of heavy gear oil which is sufficient to last almost indefinitely Provision is however made for replenishment should same be required A small screw will be observed in the right hand end cap of the hinge bearing upon removal of this screw oil can be injected into the reservoir the screw orifice operating as a level control MAIN FRAME LEFT LOOP MAIN_ FRAME RIGHT LOOP SUPPORT BOLT TOP PIVOT BODY TOP COVER TUBE BOTTOM COVER UBE NUT SUPPORTING COVER TUBE AND SPRING BOTTOM PIVOT BOLT NUT FORK END PROJECTION FOR CAM LOCK NUT BOTTOM PIVOT BODY FORK HINGE FORK END BEARINGS PIVOT BOLT Illustration 18 Showing rear sprung frame and TELEDRAULIC legs The rear wheel fork is suspended on springs located in the two TELEDRAULIC legs joining the rear of the fork to the main frame rear loops and the spring action is damped by hydraulic dampers identical in design to those used in the TELEDRAULIC Front Fork Assembly The hydraulic fluid used is o
46. P LUG WASHER RUBBER FOR TOP COVER TUBE BOTTOM CAP CAP FOR FORK TOP COVER TUBE BOTTOM LOCATION TUBE FORK INNER TUBE FORK COVER BOTTOM SLIDER FOR FORK WITH STUDS BUSH BOTTOM STEEL FOR FORK INNER TUBE CIRCLIP LOCATING FORK INNER TUBE BOTTOM BUSH BOLT FIXING DAMPER TUBE TO SLIDER WASHER PLAIN FOR FORK SLIDER CAP SECURING STUD BOLT TOP FOR FORK INNER TUBE NUT LOCK FOR TOP END OF DAMPER ROD ROD FOR FORK DAMPER SLEEVE PLUNGER ON FORK DAMPER ROD PIN STOP FOR FORK DAMPER VALVE NUT LOCK FOR DAMPER VALVE SEAT STUD SECURING CAP TO FORK SLIDER WASHER FIBRE FOR DAMPER TUBE BOLT CAP FOR FORK SLIDER NUT FOR FORK SLIDER CAP SECURING STUD RING RUBBER SEALING FOR INNER TUBE TOP BOLT WASHER PLAIN FOR INNER TUBE TOP BOLT NUT ADJUSTING FOR FORK STEM CAP FOR FORK TOP COVER TUBE TOP LOCATION LUG FOR HANDLEBAR AND STEERING HEAD STEM FOR FORK CROWN NOT SOLD SEPARATELY FORK CROWN SOLD ONLY AS AN ASSEMBLY OF CROWN STEM AND STEM CIRCLIP SCREW PINCH FOR FORK CROWN CLIP RETAINING DAMPER ROD SLEEVE VALVE FOR FORK DAMPER SEAT FOR FORK DAMPER VALVE 1 N C UBE FOR FORK DAMPER UT LOCK DOMED FOR FORK STEM LIP HALF ONLY FOR HANDLEBAR LUG SCREW PINCH FOR HANDLEBAR LUG CLIP BOLT TOP FOR FORK INNER TUBE WASHER PLAIN FOR INNER TUBE TOP BOLT CAP FOR FORK TOP COVER TUBE TOP LOCATION TUBE FORK COVER TOP LEFT WITH LAMP LUG CAP FOR F
47. TANK On Spring Frame Models remove the twin seat Close both petrol taps and disconnect the petrol feed pipe from each tap Use two spanners one to hold the tap and the other to unscrew the union nut on the petrol pipe Cut the wires interlacing the four fixing bolts Unscrew the tank fixing bolts and the tank is then free to be taken away NOTE The disposition of the various rubber and metal washers and tubular spacers should be specially observed so that they may be correctly replaced TO REPLACE THE PETROL TANK Proceed in reverse order to removal Screw firmly home the four fixing bolts and interlace them in pairs with 22 gauge copper wire TO REMOVE THE ROCKER BOX Remove the petrol tank Remove the three nuts and fibre washers retaining the rocker box side cover and take away the cover Disconnect the oil pipe feeding oil to the rocker box Turn over engine until both valves are completely closed Remove engine steady bracket by removing bolt from frame clip and nuts and washers from the rocker box bolt extensions Remove the nine bolts retaining rocker box to cylinder head Disconnect valve lifter cable Tilt upward the right hand side of rocker box and extract the two long pushrods Lay these aside so they may be identified and replaced in their original position The rocker box may then be lifted off TO REPLACE THE ROCKER BOX Carefully clean the top of cylinder head and lower face of rocker box Revolve e
48. TCHLESS MOTOR CYCLES B M S Identity Engine Number Stamped on left hand side of crankcase Frame Number m Stamped on seat lug of main frame on right hand side below the saddle Bore 350 c c Models 2 7187 in 2 352 in Stroke Engine capacity in cubic centimetres 500 c c Models 3 250 3 Ain Models 93 mm approx 3 65625 in 350 Models 54 G3L 54 G3LS 54 G3LC and 54 G3LCS 347 500 Models 54 G80 54 G80S 54 G80C and 54 G80CS 498 Capacities Location British Metric Engine 350 c c 21 170 cub in 347 Engine 500 c c 30 380 cub in 498 Gear box 1 pint 568 2 c c Front fork each side 6 fl ozs 1846 c c Rear leg each leg 3 fl ozs 85 Rear wheel fork hinge bearing 1 fl ozs 42 6 Fuel tank Rigid and Spring frame 350 3 gallons 13 638 litres Fuel tank Rigid and Spring frame 500 c c 3 gallons 17 04 litres Fuel tank Competition 2 gallons 10 2285 litres Oil tank to top level mark 4 pints 2 557 litres On Spring Frame Models only Carburetter 350 500 Type 76AV IED 89N IED Main jet size no air filter fitted 150 180 Main jet size air filter fitted 130 160 Throttle valve size 6 4 29 4 Jet taper needle position 3rd notch 2nd notch Jet taper needle position air filter fitted 2nd noh from top from top Compression ratios Normal High Model ratio ratio 350 6 53 to 1 According to piston 500 6 26 to 1 S
49. WEEN OIL SEAL AND TAPER BEARING OIL SEAL CUP HOUSING FOR OIL SEAL ADJUSTING RING LOCK NUT FOR ADJUSTING RING CIRCLIP WASHER METAL OUTSIDE OIL SEAL OIL SEAL SPACING COLLAR ENCIRCLING OIL SEAL WASHER METAL BETWEEN OIL SEAL AND SPACER SPACER BETWEEN OIL SEAL WASHER AND TAPER BEARING TAPER BEARING OUTER CUP CAGE FOR ROLLERS AND ROLLERS THESE NOT SUPPLIED SEPARATELY ALSO ROLLERS ARE NOT SUPPLIED SEPARATELY 65 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 SPACER BETWEEN BEARINGS TAPER BEARING OUTER CUP CAGE FOR ROLLERS AND ROLLERS THESE ARE NOT SUPPLIED SEPARATELY ALSO ROLLERS ARE NOT SUPPLIED SEPARATELY SPACER BETWEEN SEAL WASHER AND TAPER BEARING WASHER METAL BETWEEN OIL SEAL AND SPACER OIL SEAL CUP HOUSING FOR OIL SEAL ADJUSTING RING LOCK NUT FOR ADJUSTING RING NUT EXTERNAL FOR REAR WHEEL SPINDLE BUSH FOR REAR WHEEL SPINDLE FITS IN FORK END KEYWAY ACCOMMODATE KEY LOCKING CAM TO REAR WHEEL SPINDLE REAR WHEEL SOLID CENTRE SPINDLE KEYWAY TO ACCOMMODATE KEY LOCKING CAM TO REAR WHEEL SPINDLE BUSH FOR REAR WHEEL SPINDLE FITS IN FORK END NUT EXTERNAL SPINDLE FOR REAR WHEEL DISMANTLE A REAR WHEEL BEARING These instructions need reference to the lower part of Illustration 22 Remove wheel from machine Remove brake cover plate with brake shoes centre solid spindle with
50. X TO 3 COLLAR FOR VALVE SPRING INLET VALVE GUIDE 4 BOLT THROUGH TOOL AND COILS OF 7 SCREW WITH LOCK NUT ADJUSTING VALVE SPRING OIL FEED TO INLET VALVE 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 Iffitted so that only gne of the grooves engages the ringed valve stem damage will almost certainly result On 350 c c the inlet valve head is larger in diameter than the exhaust Therefore unintended interchange is not possible On 500 c c both valve heads are identical in dimensions but are made of different materials Therefore upon removal valves should be laid aside so that they may be identified for re fitting In case of doubt see marking In or Ex on stem adjacent to collet grooves SPARES LIST EDITION CL 29 PRICE 2 6 IS THE APPROPRIATE LIST FOR THIS SERVICE MANUAL 28 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 will obviate the risk of making deep scratches Care is necessary to avoid damaging the valve seatings and in no
51. ace machine on both stands Slacken lock nut on cable adjuster Unscrew the cable adjuster till by rotating the front wheel it can be felt the brake shoes are just touching the brake drum Then screw back the adjuster two complete turns and tighten the lock nut Illustration 23 Showing front brake cable adjuster thread exhausted indicating brake shoe thrust pin adjustment is necessary 4 UL 0 2 2 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 Screw the nut further on the rod to take the rear brake 68 Adjust rear brake by Place machine on centre stand if spring frame otherwise on rear stand Screw further on the brake rod the knurled adjusting nut till by rotating the wheel it can be felt the brake shoes are just touching the brake drum Then unscrew the adjusting nut two complete turns The adjusting nut is automatically locked in position in virtue of the two projecting noses on it engaging in accommodating slots cut in the clip which connects the brake rod and brake expander lever and being retained in that position by the spring which encircles the rear end of the brake rod IS THE PEDAL ADJUSTING BOLT 2
52. acken lock nut 2 Then screw in or out the head 3 until the clearance is nil Tighten lock nut 2 and re check the clearance Treat other valve in like manner Illustration 11 Tappet adjustment Finally Check adjustments so that with no up and down movement the long push rods are free to revolve when the valves are closed 1 INLET ROCKER ARM TAPPET END 4 CUPPED ADJUSTING SCREW AND LOCK 2 NUT LOCKING ADJUSTING CUPPED NUT SCREW 5 SLEEVE TO ACCOMMODATE ADJUSTING SCREW ON TOP END OF PUSH ROD 3 CUPPED ADJUSTING SCREW 6 EXHAUST ROCKER ARM TAPPET END Complete adjustment by Replace rocker tappet cover taking care to replace the fibre washer that is under each retaining nut As mentioned elsewhere do not over tighten the nuts because the joint is made with a rubber fillet and undue pressure is not necessary NOTE In normal conditions tappet adjustment should not be necessary more frequently than about every five thousand miles or after decarbonising and grinding valves If adjustment is found necessary more frequently the cause should be investigated at once 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 ex
53. after which the hexagonal plug may be removed and a piece of wire passed down through the inner tube Loop the bottom end of this wire underneath the damper rod lock nut The slider is then carefully pushed upward while at the same time pulling on the wire until the top end of the damper rod projects sufficiently to permit the screwed plug to be attached and secured with the lock nut after which the wire may be removed It may be found necessary to apply a little heat to enable the oil seal to be pressed home with the fingers before screwing on the tubular extension 54 Illustration 17 D A a pro hp ananaanakR RRR RRA 9 9 9 DUDE t 50 0 LE OL ROI 750 X0 DESCRIPTION WASHER LEATHER FOR FORK SPRING TOP SEATING BUFFER RUBBER FOR FORK INNER TUBE ONE OF THREE SPRING MAIN FOR FRONT FORK BUFFER RUBBER FOR FORK INNER TUBE ONE OF THREE BUFFER RUBBER FOR FORK INNER TUBE ONE OF THREE WASHER LEATHER FOR FORK SPRING BOTTOM SEATING EXTENSION FOR FORK SLIDER OIL SEAL RUBBER FOR FORK INNER TUBE AN ALTERNATIVE OIL SEAL IS MADE OF LEATHER WASHER PAPER FOR USE ONLY WITH LEATHER OIL SEAL BUSH TOP PLASTIC FOR FORK INNER TUBE SPRING BUFFER FOR FRONT FORK TUBE FORK COVER TOP RIGHT WITH LAM
54. amo sprocket and holding same unscrew the nut retaining the dynamo sprocket Holding sprocket thus relieves the dynamo shaft of bending strain Release dynamo sprocket with suitable extractor Take away one assembly the dynamo sprocket dynamo chain and engine shock absorber assembly The dynamo chain is endless Straighten tabs on lock washers under the three bolts retaining the back half of chaincase to the boss on the crankcase and remove the three bolts Remove the long headed bolt under battery carrier fixing rear chain guard to front chaincase Remove wide nut and washer on centre fixing bolt when back half of chaincase can be taken away 43 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 recomended Ensure the spacer is in position on the centre fixing bolt This is located between the engine plate and the chaincase It is 1 13 32 long Place in position rear half of front chaincase Fit long headed bolt holding rear chain guard to front chaincase but do not fully tighten Fit to crankcase boss the three lock washers and bolts retaining case to boss Fully tighten the three bolts and turn up the tabs of the three lock washers Fit spacer nut inside chaincase 7 long and washer to the centre fixing bolt and fully tighten Fully tighten long headed bolt holding r
55. amo sprocket and withdraw sprocket with a suitable tool Use spanner 017254 to hold sprocket while nut is being slackened this relieves the dynamo shaft of all bending strain Detach dynamo cables and loosen dynamo clamping bolt to fullest extent Twist dynamo by hand until the locating strip on its body is in line with the keyway cutaway in the rear engine plate housing the dynamo in which position same can be withdrawn tilting upwards to clear gear box while doing so see illustration 31 To re fit the dynamo reverse the foregoing taking care to accurately locate the dynamo sprocket key when applying the sprocket See separate instructions for correct dynamo chain adjustment and re fitting outer half of chaincase Ensure that dynamo sprocket securing nut is well tightened before refitting locking plate and retaining circlip V Al Illustration 31 1 STRAP metal CLAMPING DYNAMO IN 3 BOLT FOR TIGHTENING DYNAMO POSITION CLAMPING STRAP fo EE WHOL TIGUT ENS EYNAMO 4 HINGE PIN FOR ANCHORING LOWER CLAMPINGSTRAE END OF DYNAMO CLAMPING STRAP The cut out and regulator unit A V C is type MCR 2 and the replacement part number is 37144 A Although the voltage regulator and the cut out are combined structurally they are electrically separate The regulator is set to maintain a pre determined generator voltage at all speeds and regulates the output of the dynamo to the battery according to the state of ch
56. arge of the battery The charge rate is at its maximum when the battery is discharged automatically tapering off to a minimum as the battery becomes charged and its voltage rises 79 Normally during day time running when the battery is in good condition the dynamo gives only atrickle 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 When the engine is running fast enough to cause the voltage of the dynamo to exceed that of the battery the cut out allows the battery to be charged by the dynamo the other hand when the engine speed is low the engine is stationary the cut out disconnects the battery from the dynamo thereby preventing current flowing back from the battery to the dynamo a proceeding that would soon cause the battery to become completely discharged The regulator and cut out are accurately set during manufacture under normal running conditions it is found that the battery is continually in a low state of charge or is being constantly over charged then the regulator setting should be checked by a qualified electrician and if necessary re set Whenever possible this should be carried out by a Lucas Service Depot or Agent The A V C Unit is retained by two bolts with self locking nuts The self locking nature of the nuts prevents subsequent slacking off The four ter
57. bre washer located under the head A sharp jerk downward should now enable the slider to be withdrawn but should difficulty be experienced apply a little heat to the enlarged top end ofthe slider This will cause sufficient expansion to release the oil seal which is normally a snug push in fit in the top of the slider The re assembly is carried out in exactly the reverse order again if necessary applying a little heat to enable the oil seal to be pushed down into the slider top before screwing in the slider extension After completion the oil which has escaped MUST be returned viathe top See Front Fork Topping up TO REMOVE A FORK INNER TUBE ASSEMBLY either side Dealers service only First unscrew the hexagonal plug at the top of the inner tube it is intended to remove and after slackening the lock nut by which the damper rod is secured to this plug unscrew the plug allowing the rod to fall Next proceed to remove the slider as already detailed except do not disturb the bolt securing the damper tube This damper tube and pro truding rod can be removed intact with the slider Now loosen the fork crown clamping screw when it should be possible to draw the entire inner tube assembly down through the crown lug Upon re assembly the inner tube is first pushed home as far as possible by hand and then pulled right home by screwing down the top hexagonal plug With this plug tightened down then proceed to tighten the crown clamping screw
58. cessive 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 The various stages in decarbonisation are described below TO REMOVE THE CYLINDER HEAD Remove The petrol tank The sparking plug The rocker box Remove the exhaust system by Remove nut and washers retaining exhaust pipe to its stay Remove nut and washers retaining silencer to its stay Remove complete exhaust system by pulling away from stays and then downwards from the exhaust port in cylinder head Remove carburetter by Unscrew two carburetter retaining nuts Take away carburetter and rest on saddle 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 If the sparking plug resists removal do not use force but brush paraffin round the body and leave for a time to soak before making further effort TO REMOVE AND REPLACE THE VALVES Remove the cylinder head Remove the valve springs by inserting a finger in the spring coil and sharply pull upward The top spring collar and split collet can then be removed leaving the valve free to be withdrawn A sharp light tap on the valve collar may be necessary to free the taper split collet It will be observed that the valve spring seat has a raised impression on its under side
59. cket is a free fit on the driving side flywheel axle It has integral with it a face cam that engages with a similar face cam shock absorber cam which Is keyed to the driving side flywheel axle by splines A spring keeps the shock absorber cam in close engagement with the cam on the sprocket and the shock absorber cam being driven by the engine over rides the sprocket cam under the influence of the engine Impulses The shock absorber spring is compressed by the over riding of the cams thereby absorbing the shocks It is essential the faces of the cams are adequately lubricated otherwise the shock absorbing action will be nullified and this is automatically taken care of providing the level of the oil in the front chaincase is maintained according to the instructions given in the Lubrication Section The shock absorber spring is retained by a cap washer and a retaining bolt which must be fully tightened The dynamo sprocket is integral with the engine sprocket Behind the engine sprocket between the sprocket and the crankshaft ball bearing Is a spacing collar which is a sliding fit on the driving side flywheel axle and in no circum stances must this be omitted NOTE At the first sign of transmission harshness examine front chaincase for correct oil level and dismantle and lubricate the shock absorber parts if the harshness continues For access to the shock absorber parts it is necessary to remove the outer half of the front c
60. d jet taper needle With the standard setting it is possible to use nearly full air in all conditions except perhaps when the engine is pulling hard up hill or is on full throttle when some benefit may be obtained by slightly closing the air control Weak mixture is always indicated by popping or spitting at the air intake A rich mixture usually causes bumpy or jerky running and in cases of extreme richness is accompanied by the emission of black smoke from the exhaust 38 CARBURETTER ADJUSTMENT To ascertain if the setting is correct 350 c c models only a rough test Is to warm up the engine and with the ignition fully retarded and the air about three quarters open gradually open the throttle to full open during which the engine should respond without a misfire but upon a sudden opening ofthe throttle it should splutter and stop engine should not be run for more than a few seconds with the ignition fully retarded NOTE On 500 c c models the ignition is automatically retarded at low engine revs To check the setting of the pilot jet and its air control warm up the engine then with the ignition about one third retarded and the air about three quarters open the engine should idle positively and evenly when the throttle is almost closed If it fails to do so adjust the pilot Jet air screw inwards or outwards until even firing is obtained The pilot jet air screw is at the base of the mixing chamber and its
61. e cover plate Slacken the nut on the left hand end of front wheel spindle Remove the four nuts retaining the caps to the fork sliders which will permit the removal of the two caps and putting pressure on the front wheel in order to decrease the effective height of the wheel spindle the wheel can be withdrawn towards the front NOTE The two caps MUST be re fitted in same order and position as originally Therefore lay them aside so that the order and position of assembly will be correctly made Do not attempt to use the FRONT STAND unless the machine is Supported by the centre stand on SPRING FRAME MODELS or by the REAR AND on RIGID FRAME MODELS TO RE FIT FRONT WHEEL Holding the left side cap on the wheel spindle offer wheel up so as to engage the cap with its securing studs Then apply fixing nuts and washers but only loosely tighten NOTE To pass the wheel spindle into position it may be necessary to apply pressure to flatten the tyre so as to enable the spindle to pass the forward fixing studs Next fit the right side cap and again only loosely tighten the securing nuts Now attach the brake anchor arm and refit the yoke end pin Next fully tighten the nuts securing the left side cap taking care to keep the gap fore and aft approximately equal Then tighten the left side spindle nut and lastly the nuts securing the right side cap Should any fork stiffness be apparent after re fixing the front wheel loosen the nuts secur
62. e internal lever at the end where the cable is attached must be carefully checked This is best done by applying light backward pressure to the lever end as already described at the same time operating the handlebar lever The correct free movement is 710 sinch It should be explained that the free movement is readily felt on the handlebar lever by reason of the greatly increased effort required as the clutch commences to disengage As the result of wear of the clutch plate fabric inserts the plates tend to close up towards each other This closing up has the effect of reducing the free movement referred to Clutch slip resulting from lack of free movement will rapidly ruin the inserts and may generate sufficient heat to soften the clutch springs Therefore should clutch slip occur immediately examine for free movement of the internal operating lever To adjust this free movement it is necessary to remove the domed clutch cover secured by eight screws when the screwed adjusting plug fitted to the centre of the clutch presssure plate will be exposed The lock nut securing this screwed adjusting plug is of sparking plug size and can therefore be loosened for adjustment and subsequently securely tightened by means of the sparking plug box key provided in the tool kit Then to check the free movement of the internal lever apply backward pressure as described and observe the movement at the extreme end of the lever before resistance is felt The co
63. e shaft and with spanner 017251 remove the central screw Finally lever off the contact breaker To lubricate contact breaker cam and tappet Magneto type NI 4 remove the contact breaker as described Saturate with a few drops of thin machine oil the wick mounted in the core of its carrying screw B Illustration 28 Push out of the contact breaker body the tappet B Illustration 29 wipe it with a soft cloth smear it with thin machine oil clean and replace NOTE When replacing the contact breaker parts ensure the backing spring F Illustration 29 is fitted so that its bent over end faces outwards 75 CONTACT BREAKER BODY i BACKING SPRING Q CONTACT BREAKER CONTACT ARM 5 SECURING SCREW LOCKING PLATE Illustration 29 Showing component details of Contact Breaker To clean check and adjust contact breaker points Magneto type N1 4 If dirty oily or burnt contact points must be cleaned with a fine carborundum stone or very fine emery cloth and afterwards wiped with a cloth moistened with petrol Cleaning is made easier if the spring arm A Illustration 28 is removed To adjust turn over engine until the points are fully open Insert the gauge Part of spanner 017251 which should be a sliding fit If there is appreciable variation from the gauge Slaken the lock nut G Illustration 28 with spanner 017251 then with the same spanner turn the screw inward to increase the gap or out
64. ead adjustment too tight or excessively slack Pitted steering head ball races resulting from loose adjustment Wheels out of alignment Front and or rear tyre tread not correctly manipulated to run true with wheel causes handlebar oscillation at low road speed Damaged front fork main tubes resulting from impact 73 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 Mud and other road dirt should be soaked off with water The best method is to use a small hose taking care not to direct water on to the engine carburetter magneto and other such parts As a poorer substitute a pail of water and sponge be used After washing down with water the surplus moisture should be removed with a chamois leather and when the enamelled surfaces are thoroughly dry they may be polished with a good wax polish and soft dusters Such parts as the engine crankcase and the gear box can be cleaned by applying paraffin with a stiff brush and with a final application of petrol will come up like new CHROMIUM PLATING Under some climatic conditions a rusty looking deposit may be observed on ferrous parts that are chromium plated This is not ordinary rust ferric oxide bu
65. ear chain guard to front chaincase Fit dynamo sprocket and chain and engine shock absorber by Ensure dynamo sprocket key is in position in dynamo armature shaft Ensure the spacing collar which fits between crankcase ball bearing and the back of the engine sprocket is in position on the driving side flywheel axle Take dynamo driving chain and place it round the small sprocket of the engine sprocket assembly and the sprocket that fits on the dynamo shaft and fit these three parts in one movement to the driving side flywheel axle and the dynamo shaft Fit the dynamo shaft plain washer and sprocket retaining nut screwing nut with fingers only Hold the dynamo sprocket by applying spanner 017254 to the flats on the back of the sprocket and fully tighten the sprocket retaining nut This holding relieves the dynamo shaft of all bending and twisting strains while the sprocket retaining nut is being securely lightened Fit the dynamo sprocket retaining nut lock washer and lock ring Ensure the lock ring lies snugly in the groove cut in the nut Fit engine shock absorber cam spring cap washer and retaining nut but do not fully tighten nut Fit the clutch centre and sprocket by Place on the gear box main shaft splined sleeve the thicker of the two clutch sprocket roller bearing retaining washers Place on the gear box main shaft splined sleeve the clutch sprocket roller bearing ring With grease stick In place on the beari
66. ecessary or stunt acceleration and fierce braking which wear out tyres by causing wheel spin and skid Do not drive in tram lines It is dangerous especially when wet and the uprising edges of worn rails will damage the tyres Remove flints etc that become embedded in the tread and if any oil gets on the tyre or spokes clean it off with petrol Make sure the front and rear wheels are in track When the wheel alignment is correct a piece of thin string stretched taut across both wheels about four inches from and parallel to the ground should just touch each tyre at both sides of the wheel centres Alternatively a straight wooden batten about five feet long is handy to use for checking wheel alignment This should be applied as in the case of string parallel to and about four inches from the ground Always check the rear chain adjustment and the rear brake adjustment after making an alteration to the rear wheel position TYRE REMOVAL It is not essential to remove a wheel from the machine to repair a puncture but it will usually be found desirable and more convenient to do so Take off outer cover and remove inner tube by Remove cap from tyre valve Remove nut from tyre valve Remove the inside from tyre valve This allows inner tube to deflate Most valve caps have a reduced and slotted top to engage with the valve inside In order to unscrew it 70 Push edge of cover that is diametrically opposite to t
67. ed through the medium of three balls operating on inclined planes see illustration 15 Operation of the clutch handlebar lever moves clutch operating lever B causing inward movement of the thrust rod by reason of the three balls mounting the inclined planes in which they are located The resulting inward movement of the clutch thrust rod forces out the pressure plate normally maintained in contact with the friction plates by the springs E thereby allowing the engine to drive the clutch sprocket D without imparting drive to the mainshaft C Consequently no power is transmitted to the rear wheel the clutch is said to be or free Upon releasing the clutch handlebar lever the clutch operating lever returns to its normal position by the pressure of the spring forcing the balls down these inclined planes thereby allowing the spring pressure through the medium of the pressure plate to be transferred to the friction plates which causes the gear box mainshaft to revolve and impart driving power to the rear wheel TO REMOVE KICKS TARTER CASE COVER FOR EXPOSURE OF KS GEAR CHANGE AND INTERNAL CLUTCH ACTUATING MECHANISM Remove oil drain plug and drain off oil contents of the gear box Remove the large oil filler plug and slack off the clutch cable adjuster sufficiently to permit the cable end to be detached from the slotted end of the internal clutch operating lever which is exposed by the removal of filler cap Unscrew the clutch cable adju
68. ed to EARTH The earth wires two one from regulator the other from terminal of battery and the high tension wire on sparking plug end of wire from magneto to sparking plug have terminals of the solid sleeve type having an eye at the extreme end To make such a connection it is necessary to bare the end of the wire for 38 pass the terminal over the wire so that the bared end fully enters the reduced core of the terminal and then flatten that part by either pinching in a vice or by hammering The two earth wires mentioned above are connected to the earth by securing them to the left side of the seat lug bolt which is situated just under the saddle by means of a washer and a screw It is essential that the connections are kept clean and the screw must be kept fully tight 83 SIDELAMP SIDELAMP SPEEDOMETER LIGHT DIPPER SWITCH HORN PUSH DYNAMO MAGNETO REGULATOR Go BATTERY POSITIVE EARTH ceo HON SNAP CONNECTOR TAIL LAMP W97832 te G RET LE WITH cede Sit Bre Hed ES PER dene eo d PI ors WITH 41 RED Bi H E PUARE Illustration 37 Wiring diagram 84 REPAIRS ano SERVICE REPAIRS The instructions regarding repairs should be clear and definite otherwise the cost may be greater than that expected We shal
69. ee Spares List for ratios available 4 Gear box ratios Model First gear Second gear Third gear Fourth gear top Touring E xe 2 65 to 1 1 70 to 1 1 308 to 1 1to1 Competition Rigid e 3 1101 2 02 to 1 1 422 to 1 1to1 Competition Spring 2 65 to 1 1 70 to 1 1 308 to 1 1to1 Gear ratios Touring Rigid and Spring Frame and Spring Frame Competition Models Fourth gear Engine sprocket size First gear Second gear Third gear top 15 teeth 18 55 to 1 11 90 to 1 9 15 1 7101 c 16 teeth 17 32 to 1 11 15 to 1 8 58 to 1 6 56 to 1 17 teeth 16 32 to 1 10 47 10 1 8 05 to 1 6 16 to 1 a 18 teeth 1544 to 1 9 90 to 1 7 63 to 1 5 83 to 1 19 teeth 14 55 to 1 9 33 to 1 7 18 to 1 5 49 to 1 20 teeth 13 91 to 1 8 91 to 1 6 86 to 1 5 25 to 1 b 21 teeth m NS 13 25 to 1 8 50 to 1 6 54 to 1 5 0 to 1 a Standard for 350 c c Touring Models and 500 c c Spring Frame Competition Models b Standard for 500 c c Touring Models c Standard for 350 c c Spring Frame Competition Models Gear ratios Competition Rigid Frame Models Fourth gear Engine sprocket size First gear Second gear Third gear top 15 teeth 21 77 to 1 14414 to 1 10 37 to 1 710 1 a 16 teeth 20 40 to 1 13 25 to 1 9 72 to 1 6 56 to 1 17 teeth 9 56 to 1 1244 to 1 9 13 to 1 6 16 to 1 b 18 teeth 8 13 to 1 11 78 to 1 8 64 to 1 5 83 to 1 19 teeth 7 07 to 1 11 09 to 1 8 14 to 1 5 49 to 1 20 teeth 6 33 to 1 10 60 to 1 7 78 to 1 5 25 to 1
70. eft 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 Take away outer half of chaincase To remove front driving chain and clutch assembly complete Engage top gear apply rear brake and unscrew engine sprocket nut Unscrew the nuts retaining the clutch springs using end of spanner Part No 017254 Take away the clutch spring pressure plate with the clutch springs and clutch spring cups and flatten the turned up part of the lock plate that is under the large central nut Remove front chain connecting link and take away chain Engage top gear apply rear brake and unscrew nut retaining the clutch centre to the gear box mainshaft sleeve Remove the lockplate and plain washer from gear box mainshaft Remove complete clutch assembly by pulling it away as one unit from gear box mainshaft Take care not to lose any of the twenty four clutch sprocket bearing rollers which may be displaced when the clutch centre and sprocket assembly is withdrawn from the main shaft The clutch centre is a sliding fit on the mainshaft sleeve and an extractor should not be required To remove dynamo chain and back half of chaincase Remove the spring lock ring on dynamo sprocket retaining nut Take away lock washer surrounding dynamo sprocket nut Apply spanner 017254 included in tool kit to the two flats on the back of the dyn
71. etal filter may come away with the rubber sleeve in which case there is no need to disturb it the other hand it may remain in the oil tank bottom pipe in which case it may be withdrawn by grasping the ringed open end and pulling away After removal the filter should be cleaned in petrol and allowed to dry before re fitting Reverse the above procedure to re fit the filter and pipes ADJUSTMENT OF OIL FEED The internal flow of oil is regulated by fixed restrictions 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 5 It is locked in position by a nut The approximate correct setting is one sixth of a complete turn from the fully closed position Once set it requires little or no adjustment Inlet valve squeak indicates the oil feed adjustment is not open enough Excessive oil consumption a smoky exhaust or an oiled sparking plug generally indicates the oil feed adjustment is open too much EXHAUST VALVE STEM LUBRICATION The exhaust valve stem is lubricated by oil flowing through a passage drilled in the cylinder head No adjustment is provided LUBRICATION POINTS TO REMEMBER A dirty or choked felt oil filter causes heavy oil consumption This is because the return flow of oil to the oil tank is reduced thereby allowing an excess of oil to build up in the crankcase sump much of which
72. evenly and there is usually one position where the chain It tighter than in any other The adjustment of 1 total whip should be set for the tightest position found When off the stand and with the rider on the saddle this measurement is reduced to about total whip which is the correct adjustment when on the road To adjust the rear chain Place the machine on the centre stand Slacken nut to right of speedometer gear box Slacken exterior nut on left hand end of rear wheel spindle Push forward the wheel so that both cams are in contact with the projections on the rear fork ends Apply adjustable wrench 017249 to hexagonal body of chainside cam and while maintaining a forward pressure on the wheel to ensure contact of the two cams turn with the wrench until the chain whip of 1 detailed above is obtained Then holding the wheel in that position fully re tighten the spindle exterior nut Finally fully tighten the nut to the right of the speedometer gear box after being satisfied that the gear box is in such a position that no strain is being placed on the driving cable 48 REAR CHAIN ADJUSTMENT Rigid Frame Models To provide rear chain adjustment the rear wheel is bodily moved in the frame fork ends which are open ended and slotted Tighten rear chain by Place machine on rear stand Slightly slacken nuts on rear wheel solid spindle left side first Slacken nut on each chain adjusting bolt two or three turn
73. g the rear wheel check the rear chain adjustment and if necessary re set it Then check the rear brake adjustment and if necessary re set it Also check that brake cover plate anchorage is correct see illustration 20 WHEEL BEARINGS AND ADJUSTMENT The wheel bearings are of taper roller type The inner bearings for the rollers are integral with the wheel spindle in the case of the front wheel and are separate tracks that are a push fit on the centre spindle in the case of the rear wheel Reference to Illustration 21 will make that clear The outer cups for the rollers are pressed into the hub shell They have a fixed location one side and an adjustable location on the other The fixed location is provided by a circlip in a groove cut in one end of the hub shell while the adjustable location is regulated by a screwed ring that is threaded into the opposite end of the hub and the position of which can be locked by an encircling nut On the rear wheel the adjusting ring is located on the left hand side of the hub while on the front wheel the adjustment is on the right hand side is rarely necessary to make adjustment to wheel bearings It is most important they are not adjusted too tightly as this would quickly ruin them There must always be a slight amount of end play This should be about 002 which represents a just perceptible rim rock Not more than 1 4 rock To adjust the rear wheel bearings the wheel must first be removed from
74. gainst the cam stop and pull backwards the right hand side of the wheel so that the brake cover plate disengages with the square headed anchor bolt Then pull wheel away from the fork ends 61 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 Slacken the two bolts securing rear portion of rear mudguard to its front portion Loosen nut and washer from bolt securing mudguard side bridge and tool box stay to tubular stay Remove adjusting nut from rear brake rod Slacken the two nuts unscrew about four turns retaining the rear mudguard side stays to their studs Slacken the two nuts on the rear wheel spindle the rear portion of the rear mudguard with its stays leaving tool box and stay position Remove the rear wheel from the fork ends by twisting it sideways to release and clear the rear brake cover plate anchor bolt and then withdrawing it to the rear Re fit In the reverse order but before finally tightening the rear wheel spindle nuts ensure the speedometer gear box is so positioned that the speedometer driving cable can be correctly replaced When the whee
75. gine is stationary oil from all parts of the interior of the engine drains back into the crankcase sump so that until this surplus Is cleared the return flow is very positive and continuous Therefore if the oil circula tion is deranged the fact is apparent at once by the lack of a steady return flow VENT PIPE PREVENTING AIR LOCKS REMOVE CAP SPRING AND DISHED SEAT FOR SPRING TO OBTAIN ACCESS TO FELT FILTER FOR ITS 4 WITHDRAWAL p F WITH REMOVED THE 7 T OIL FLOW IS VISIBLE TOP LEVEL MARK TUBE FORMING CHAMBER FOR OIL FILTER THEREBY ISOLATING IT FROM THE OIL TANK DRAIN PLUG OIL RETURN PIPE FROM ENGINE RETURN PUMP METAL GAUZE FILTER PULL OFF OIL FEED PIPE WITH ITS CONNECTING RUBBER TUBE AND FILTER CAN THEN BE WITHDRAWN DOWNWARDS GRAVITY PIPE TO ENGINE OIL FEED PUMP Showing the oil tank with the felt filter in its cylindrical housing and the metal strainer mounted on the entry end of the feed pipe union Also shows the direction of flow of oil from tank to engine and return flow from engine to tank via the small spout located so that it can be inspected by removing the tank filler cap An air vent pipe is provided to ensure free dom from air locks 13 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 ma
76. gnated with oil In the two former instances renewals are necessary but if oil is the cause of slip this may be rectified by soaking the plates in petrol and allowing to dry off If inserts are glazed roughen with sand paper a T W ZW SN A Js z 9 VU A N zm it SSS EROS MN em p e XQ AL Illustration 15 FIXED CLUTCH INTERNAL ACTUATING E CLUTCH SPRING PLATE B CLUTCH INTERNAL OPERATING LEVER Ce GEAR BOX MAINSHAFT G THRUST CUP in dutch pressure plate FOR D CLUTCH SPROCKET CLUTCH ROD Showing clutch gear box main shaft and clutch operating mechanism 46 Correct adjustment of the clutch operating mechanism is of the utmost importance and the following instructions must be carefully observed Clutch cable stretch which may develop at long intervals is taken up by means of the adjuster provided at the gear box end of the cable but when making this adjustment it is important that the normal movement of the internal lever is not encroached upon The correct procedure is to remove the gear box oil filler plug which exposes the internal lever The end ofthis lever to which the cable is attached must then be pressed backward with the finger or end of a screw driver and while thus held all slack in the cable should be taken up by means of the adjuster Having done this the amount of free movement of th
77. h areas No such Dealer is authorised to transact any business give any warranty make any representation or incur any liability on our behalf 88 TOOLS AND SPECIAL EQUIPMENT TOOLS The standard tool kit issued with each new machine contains 1 017253 Tool bag 1 017114 Tyre inflator 2 017007 Tyre lever 1 017248 Pliers 1 011188 Gudgeon pin circlip pliers 1 017256 Screwdriver 1 017246 Grease gun 1 017249 Adjustable wrench 1 017252 Sparking plug box spanner and tommy bar 1 017254 Dynamo spanner and clutch spring nut key 1 018178 Double end spanner 1 010 in by 1 200 2 017052 Double end spanner Small 1 017053 Double end spanner Large 1 017251 Contact point spanner and gauge Touring 1 015023 Contact point spanner and gauge Competition 1 017257 Double end spanner 1 018055 Handlebar clip screw key 1 018153 Single spanner for petrol tap 1 018657 Key for fork crown clamp screw not illustrated OPTIONAL EQUIPMENT The following items of optional equipment are available They are described and priced in the Spares List Stop rear light Air cleaner Mudguard type pillion seat Rigid Frame Models Pillion footrests bolted on to fold up when not in use and specially designed for these machines Not on competition Detachable luggage carrier Not on competition Timing disc 015955 circular timing disc graduated in degrees and made of ivorine A very useful device Valve holder for valve g
78. haincase The order of assembly of the engine shock absorber is The spacing collar between the crankshaft bearing and the engine sprocket The engine sprocket The shock absorber cam The shock absorber spring The cap washer The retaining nut 50 FORK amp 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 It is particularly important that the adjustment is tested after the first one hundred miles because of the initial settling down that always occurs in that period Should any shake be apparent adjust the steering head bearings Adjust steering head bearings by Jack up the front of the machine so that all weight is taken off the front wheel A box under each footrest serves that purpose Slacken the two fork crown pinch screws Slacken the domed nut at top of the steering column Screw down the nut underneath the domed nut a little at a time using spanner 018178 and while doing so test the head assembly for slackness by placing the fingers over the gap between handlebar lug and frame top lug at the same time exerting upward pressure by lifting from the front edge of the front mudguard Tested in this manner the slightes
79. 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 This pressure should be maintained until the clutch is fully released It is not sufficient just to jab the foot pedal and then release the clutch lever When actually in motion it will be found sufficient to merely free the clutch a trifle to ease the drive when changing gear and with reasonable care changes of gear then can be made without a sound Do not unnecessarily race the engine or let in the clutch sufficiently suddenly to cause the rear wheel to spin Take a pride in making a smooth silent get away When changing up to a higher gear as the clutch is freed the throttle should be slightly closed so that the engine speed is reduced to keep in step with the higher gear ratio Conversely when changing down to a lower gear the throttle should be regulated so that the engine speed is increased to keep in step with the lower gear ratio Do not slip the clutch to control the road speed The clutch is intended to be used only when starting from a standstill and when changing gear It must NOT be operated to ease the engine instead of changing gear or be held out in order to free wheel The exhaust valve lifter is NOT used in normal driving on main and secondary roads When travelling slowly such as may occur in traffic or on a hill and the engine commences to labour it is
80. he 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 Any 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 hiring out purposes b any motorcycle and or sidecar used for any dirt track cinder track or grass track racing or competitions or any competition of any kind within an enclosure for which a charge is made for admission to take part in or view the competition or c machines from which the trade mark name or manufacturing number has been removed no guarantee condition or warranty of any kind is given or is to be implied We guarantee subject to the conditions mentioned below that all precautions which are usual and reasonable have been taken by us to secure excellence of materials and workmanship but this guarantee is to extend and be in force for six months only from date of purchase and damages for which we make ourselves responsible under this guarantee are limited to the free supply of a new part in exchange for the part of the motorcycle motorcycle combination or sidecar which may have proved defective We
81. he valve RIGHT INTO WELL OF RIM and using tyre lever 017007 pick up edge of cover NEAR VALVE so 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 Push upwards valve stem through its hole in the rim and the inner tube is then free to be taken away Remove cover from rim by pushing it right into well of rim and diametrically opposite picking it up with the tyre lever and then working it off all the way round TYRE FITTING Re fit inner tube and outer cover by Place one edge of cover right into well of rim with the three white dots on the cover side adjacent to the valve hole and commencing diametrically opposite and using the hands only work the cover over the edge of the rim Replace the valve inside and slightly inflate the innertube Do not distend the tube Fit the valve into its hole in the rim and replace its nut only screwing It on the valve stem about half an inch Tuck in the inner tube so that it lies snugly in the cover Ensure it is not twisted Smear some soapy water round the free edge of the cover This is a great help in fitting and in ensuring the cover centralises itself on the rim and should always be employed if at all possible Introduce the free edge of the cover into the rim at the spot diametrically opposite to the valve Get this edge right into the well of the rim and then by wo
82. head 4 Clutch 9 Alignment of wheels 5 Chains 10 Tyre pressures b Tighten all external nuts and bolts including cylinder bolts and fork crown pinch screws battery and check all lighting equipment d Clean out carburetter and check for correct idling e Adjust and lubricate all cables f Grease all nipples 9 Drain oil system Clean filter and replenish h Check oil level in front chaincase i Top up gear box j Test machine on the road NOTE Oils greases and materials used are chargeable to the customer FOR THE CONVENIENCE OF OWNERS SPARES STOCKISTS ARE APPOINTED FOR MOST DISTRICTS TO SAVE DELAY AND THE DELIVERY SURCHARGE CUSTOMERS ARE RECOMMENDED TO ALWAYS APPLY TO THEIR NEAREST SPARES STOCKIST 24 ENGINE SERVICE 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 Part Number A METAL WASHER L0 se e 014999 114 diameter B THICK RUBBER PAD a 014995 5 high THIN RUBBER PAD 01496 e high D TANK FIXING BOLT 0s 014997 14 x Se x 26 E SLEEVE FOR FIXING BOLT ae wee 014998 946 long 25 TO REMOVE THE PETROL
83. hould be allowed to soak for several hours to ensure penetration to all joints Lubricate rear chain every three thousand miles in Summer and every thousand miles in Winter Magneto chain runs in case packed with grease BRAKE EXPANDER LUBRICATION Grease nipple on each brake expander bush One on each brake cover plate Use grease sparingly Excessive grease may impair efficiency of brakes 19 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 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 SPEEDOMETER LUBRICATION One grease nipple on top of speedometer gear box attached to right side of rear wheel spindle other part of the speedometer requires lubrication STAND FIXING BOLT LUBRICATION Several of the parts of a motor cycle that have a very small amount of movement such as the hinge bolts of the stands should be lubricated STEERING HEAD BEARING LUBRICATION pne grease nipple on Front Frame Head Lug and another on right hand side of Handlebar ug CONTROL CABLE LUBRICATION To ensure free smooth action the clutch and throttle cables are fitted with a conveniently situated grease nipple Use engine oil and hold the grease gun as near verticle as possible spout downward to obtain efficient ejection of oil the gun being primarily inte
84. ing a front chaincase it is found not to be oil tight the general reason is distortion of the two joint faces or incorrect position of rubber band These faces must be undamaged and on test should closely fit to a surface plate They must also be absolutely clean before replacement and the edges must be in exact register one with the other Any distortion caused by accidental impact must remedied before refitting If any doubt exists CHECK for DISTORTION BEFORE ASSEMBLY 45 CLUTCH SPRING ADJUSTMENT clutch slip occurs the most probable cause is either incorrect cable adjustment 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 nut in turn fully home then unscrew exactly four complete turns Before replacing the domed clutch cover test for slip by starting up the engine engaging top gear and applying the rear brake when it should be possible to pull up the engine on full throttle without slip occurring If to cure slip it is found neccessary to further tighten the adjusting nuts this is a clear Indication that either the clutch springs have lost their tension the inserts are so worn that they require renewal or that they have become impre
85. ing the right side cap and after working the fork up and down violently re tighten This action will ensure that the wheel clamp occupies its natural position on the spindle end on which it is intentionally not positioned TO REMOVE REAR WHEEL Spring Frame Models Place the machine on the centre stand Loosen the bolt in rearmost position on each tubular member to which the detachable rear portion of the mudguard is fixed Also slacken the two bolts securing the two portions of mudguard together The rear portion can then be removed Disconnect the snap connector in the wire of the rear lamp Remove adjusting nut from rear brake rod Revolve rear wheel till the chain connecting link is in its most possible rear most position Remove connecting link and allow chain to come right away from the rear wheel sprocket but ensure it hangs so it cannot come away from the gear box sprocket Engage a gear to prevent sprocket revolving Disconnect speedometer cable from speedometer gear box by unscrewing the cable gland nut Slacken the nut on the rear wheel spindle that positions the speedometer gear box Slacken both exterior nuts on the rear wheel spindle three complete turns Using adjustable wrench 017249 apply it to the hexagonal body of the adjusting cam on the left hand end of the wheel axle and turn the cam till by pushing the wheel forwards the wheel is in its most forward possible position Hold left hand side of wheel tightly forward a
86. is necessary to give each a slight rotary movement in order to disengage from the frame studs NOTE The frame studs are fixed to the frame To re fit Locate tank and battery carrier on their two fixing studs and before doing anything else fit both oil pipes engine end first if pipes have been removed Then reverse the instructions given above TO REMOVE THE REAR CHAIN GUARD Spring Frame Models Remove the rear wheel See Wheel Section Remove the bolt retaining the front end of the chain guard to the rear fork Remove the bolt retaining the rear end of the chain guard to the rear fork There are two spacers on this bolt one is between the two sides of the guard and the other is between the head of the fixing bolt and the guard TO REMOVE THE REAR CHAIN GUARD Rigid Frame Models Remove The rear portion of rear mudguard The bolt retaining the front top end of the chain guard to the front chaincase The bolt retaining the front bottom end of the chain guard to the rear frame The bolt retaining the rear top end of the chain guard to the rear frame The chain guard is then free to be taken away BY USING GENUINE SPARES YOU ARE ASSURED THEY WILL FIT ACCURATELY AND GIVE SATISFACTORY SERVICE 60 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 brak
87. isting Light Alloy rod Consequently the Push Rod bare will only be supplied for spares purposes complete with sleeve 5 already fitted and threaded 33 RE TIME THE IGNITION The normal advance is 37 7e max permissible 39 72 Have available a stout screwdriver or an old type tyre lever with turned up end also a small rod or stout wheel spoke 5 long Before setting the ignition firing point it is essential the magneto contact breaker points are correctly adjusted Therefore always check these first Check contact breaker points by Remove contact breaker cover Check setting of contact breaker points and if necessary re set same Set ignition firing point by Remove The sparking plug high tension cable from plug The sparking plug The magneto chain case cover The rocker box side cover Unscrew several turns nut retaining magneto sprocket to camshaft need to remove nut Lever off sprocket until it is loose on the taper of the shaft Use stout screw driver or old type tyre lever Turn over engine till both valves are closed Insert rod through sparking plug hole feel piston by rocking engine forwards or backwards till it is felt the piston is at the top of its stroke with both valves closed Mark rod flush with top face of sparking plug hole Remove rod and measure v above the flush mark and record position on rod On 350 c c models place the handlebar ignition control
88. its groove cut in the plunger before tightening down NOTE The guide screw pin is in serted in the screw relieved end first Do not revolve the engine until quite certain that the guide screw pin is properly located otherwise damage is inevitable OVERSIZE PARTS AND RE BORING CYLINDER BARREL Pistons and rings 020 and 040 larger than standard are available These degrees of oversize make it essential for the cylinder barrel to be re bored to accommodate them We can provide that service at prices quoted in the Spares List On the 350 c c the cylinder standard bore is 2 7187 0005 500 c c cylinder standard bore is 3 250 0005 When the wear at the top of the barrel reaches 008 the barrel should be bored out 020 oversize and a new oversize piston and rings fitted Crankpin rollers 001 larger than standard can be supplied We recommend only skilled mechanics should fit these because it is almost general that the big end journals and sleeves require lapping to ensure a correct fit REMOVING SPARKING PLUG Always exercise the greatest care to avoid thread seizure when removing a sparking plug If any resistance is felt apply paraffin Before replacing plug it is desirable to coat the thread with Oil Dag or Graphite paste This will guard against seizure upon subsequent removal WHEN IN DOUBT REGARDING THE NAMES AND PART NUMBERS OF THE PARTS YOU REQUIRE PLEASE SEND THE OLD PARTS TO SERVE AS PATTERNS
89. k engages with the forked bracket on the rim Replace by springing in the spring clips so that they are evenly spaced around the rim To replace the back cap engage the projections on the inside of the back cap with the slots in the holder press on and secure by twisting it to the right Engage bottom tag on lamp rim with the small slit in the shell and gently force the top of the rim back into the shell after which re tighten the locking screw on the top of the lamp body Access to the pilot lamps interior for bulb removal is obtained by removing the screw at the rear end and gently pulling forward on the glass rim 82 Rear lamp A LUCAS rear lamp is fitted The body with bulb holder is secured to the rear number plate Details of lamp bulbs are given in DATA 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 35 is made up of four components Two are tubular sleeves having pointed extremities and which are soldered to the ends of the two wires to be connected The third part is the centre split ferrule into which the two sleeves snap and the fourth component is a rubber sleeve which covers the whole connector That rubber sleeve serves the dual purpose of insulating the various metal parts and also preventing same from separation as the result of vibration RUBB
90. ke FOR ENGINE LUBRICATION SUMMER WINTER Mobiloil D SAE 50 Mobiloil A SAE 30 Castrol Grand Prix SAE 50 Castrol XL SAE 30 Energol 50 SAE 50 Energol 30 SAE 30 Essolube 50 SAE 50 Essolube 30 SAE 30 Shell Motor Oil X 100 SAE 50 Shell Motor Oil X 100 SAE 40 FOR GEAR BOX LUBRICATION Mobiloil D SAE 50 Castrol Grand Prix SAE 50 Energol 50 SAE 50 Essolube 50 SAE 50 Shell Motor Oil X 100 SAE 50 FOR HUB LUBRICATION AND ALL FRAME PARTS USING GREASE Mobilgrease No 4 Castrolease Heavy Energrease C 3 Esso Pressure Gun Grease Shell Retinax Grease CD or A FOR TELEDRAULIC FRONT FORKS AND TELEDRAULIC REAR LEGS Mobiloil Arctic SAE 20 Castrolite SAE 20 Energol 20 SAE 20 Essolube 20 SAE 20 Shell Motor Oil X 100 SAE 20 FOR REAR CHAINS Tallow When buying oils and greases it is advisable to specify the Brand as well as the grade and as an additional precaution to buy only in sealed containers or from branded cabinets 14 ENGINE LUBRICATION SYSTEM This is by dry sump system Oil 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 The pump is so designed that it has a greater capacity on the return side to that on the delivery side to ensure that ail oil is extracted from the cra
91. l low down at rear facilitates gear box flushing and change of lubricant An oil level plug adjacent to K S spindle indicates maximum permissible oil level content 1 pint HUB LUBRICATION Keep hubs packed with grease This prevents entry of water and dirt Grease nipples in centre of rear hub and side of front hub Inject small quantity of grease Excessive grease may impair efficiency of brakes CHAIN LUBRICATION Front driving chain and dynamo chain run in oil bath Front chaincase Use engine oil Maintain level to height of the inspection cap opening Oil in front chaincase also lubricates the engine shock absorber Transmission harshness generally indicates level of oil in chaincase is too low Remove chaincase inspection cap each week inspect level of oil top up as necessary To remove inspection cap Unscrew knurled screw about four turns Slide cap sideways till the back plate can be slipped through the opening and take away the complete cap assembly When replacing inspection cap centralise cork washer and then fully tighten knurled screw Essential this is kept tight otherwise cap assembly will be lost Rear driving chain should be removed for lubrication Clean chain in paraffin drain and wipe Immerse in bath of molten tallow for preference leave for several minutes remove and allow excess lubricant to drain off and then replace on machine Engine oil is a poor substitute for tallow and if used chain s
92. l alignment is correct a piece of thin string stretched taut across both wheels about four inches from and parallel to the ground should just touch each tyre at both sides of the wheel centres Alternatively a straight wooden batten about five feet long is handy to use for checking wheel alignment This should be applied as in the case of string parallel to and about four inches from the ground NOTE Always check the rear chain tension and the rear brake adjustment after making an alteration to the rear wheel position TO RE FIT REAR WHEEL Spring Frame Model Reverse the removal procedure see that the speedometer drive dogs are engaged but leave the tightening of the nut that locates the speedometer gear box for the final operation i e after the speedometer cable has been re connected and the exterior axle nuts have been tightened This also applies to Rigid Frame Models Illustration 20 REAR BRAKE COVER 1 PLATE 2 BOLT ANCHORING COVER PLATE TO REAR FRAME 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 engagement has been completed After re fittin
93. l 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 Customers desiring that old parts which are replaced with new during the course of overhaul or repair be retained must make the fact known prior to the work being put in hand because normally such parts having no further useful life are scrapped upon removal Parts sent to us as patterns or for repair should have attached to them a label bearing the sender s full name and address The instructions regarding such parts should be sent under separate cover If it is necessary to bring a machine or parts to the Works for an urgent repair IT IS ESSENTIAL you MAKE AN APPOINTMENT beforehand to AVOID DISAPPOINT MENT This can be done by letter or telephone CORRESPONDENCE AND ORDERS Our routine is organised into different departments therefore delay cannot be avoided If matters relating to more than one department are contained in one letter Consequently it is desirable when communicating with more than one department to do so on SEPARATE SHEETS each of which should bear your name and address When writing on a technical matter or when ordering spares it is essential to quote
94. lates red and white and you must not take a PILLION PASSENGER unless that passenger is the holder of a current UNRESTRICTED driving licence As soon as you receive your driving licence sign it in the appropriate place and do so each time it is renewed It is an offence not to Make sure you are well acquainted with the recommendations set down in the Highway Code a copy of which can be obtained from any main Post Office 86 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 RF1 2 duly completed b The certificate of insurance The invoice you received from your dealer when you purchased the machine c d The appropriate registration fee In due course you will receive 1 A Registration Book Commonly called the log book 2 A Licence Disc 3 Your Insurance Certificate 4 Your Invoice The Registration Book and the Licence Disc will bear the registration numbers that have been allotted to your machine and will also show the date the Road Licence expires Your number plates must then be painted in white upon a black background with the registration number
95. lever in the fully advanced position On 500 c c models turn the front plate of the automatic unit with the fingers and thumb to its limit of movement and insert a wood wedge to hold the control in the fully advanced position Replace rod in sparking plug hole Slightly rotate engine BACKWARDS until upper mark on rod is flush with top face of sparking plug hole To rotate engine engage top gear and turn back wheel by hand Rotate sprocket on magneto armature shaft in anti clockwise direction as seen from sprocket end of magneto till the contact breaker points are just about to separate To find the exact moment for the commencement of the point separation place a piece of tissue paper between the points and turn the armature shaft by the sprocket on it until the paper is just released and no more upon a gentle pull Tighten nut on camshaft and ensure engine and or magneto shaft does not move in doing so Re check the setting which must be before top dead centre With the ignition fully advanced Do not omit to remove the wood wedge securing the automatic unit on 500 c c models in the fully advanced position before refitting the chain cover See page 89 for particulars of special timing disc graduated in degrees Replace Rocker box side cover Contact breaker cover Magneto chain case cover Sparking plug see note on page 36 re graphite on sparking plug thread and Sparking plug wire 34 lt
96. lty engine valve seatings Sparking plug faulty or its points set too closely Ignition advanced too much Contact breaker points dirty pitted loose or set too closely High tension wire defective Rockers adjusted too closely Heavy petrol consumption may be due to Late ignition setting Bad air leaks Probably at carburetter joint Weakened valve springs Leaky float Causing flooding Taper needle extension insufficient Poor compression due to worn piston rings or defective valve seatings compression with throttle wide open s ie lt NS m C A Js Illustration 14 A LOW GEAR ON MAINSHAFT LOW GEAR LAYSHAFT F THIRD GEAR ON LAYSHAFT G SECOND GEAR ON LAYSHAFT Oe SE COND GEAR ONS MAINSHART H SMALL PINION ON LAYSHAFT B THIRD GEAR ON MAINSHAFT D MAIN DRIVING GEAR OIL LEVEL PLUG Test Section through gearbox showing gears and clutch with actuating mechanism 40 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 clamped between the two engine rear plates by two bolts The bottom fixing bolt acts as a pivot The top fixing bolt passes through the gear box top lug and the rear plates which are slotted thereby allowing a swinging fore and aft movement of the gear box to enable the front driving chain to be adjusted That movement
97. lutch lever Lifts exhaust valve from seat releasing compression in combustion chamber enabling engine to be easily rotated for starting Also used for stopping engine if throttle stop is set as advised above 5 Clutch lever Large lever on left handlebar Grip to release clutch so that drive to rear wheel is disconnected 6 Front brake lever Large lever on right handlebar Grip to operate front wheel brake and for normal braking use in conjunction with rear brake application 7 Rear brake lever Pedal close to left side foot rest Depress with left foot to apply rear brake Apply gently and use increasing pressure as the road speed decreases 8 Gear change lever Pedal in horizontal position close to right foot rest Con trols selection of the four speeds or ratios between engine and rear wheel revolutions with a free or neutral position See illustration 2 9 Kick starter lever Vertical pedal on right hand side of gear box 10 Lighting switch In top of head lamp Controls lamps by a rotating lever which has three positions 1 OFF Lamps not on 2 L Pilot lamps rear lamp and speedometer lamp on 3 H Main head lamp rear lamp and speedometer lamp on 11 Ammeter In top of head lamp Indicates flow of electric current in or out of battery Charge or Discharge 12 Horn switch Press switch on right handlebar 13 Gear box filler cap Located on top edge of kick starter case cover
98. miles To take the plug to pieces for cleaning unscrew the gland nut by holding the smaller hexagon on the gland nut upside down in a vice and then using the box spanner to unscrew the larger hexagon the body Then lift away the central electrode assembly which should be washed in petrol or paraffin Then using fairly coarse glass paper remove the carbon deposit and wash again The central firing point should be cleaned with fine emery cloth The inside of the body should be scraped clean with a knife and finally rinsed in petrol Illustration 30 There is an internal washer between the insulator and its seat ing in the body On re assembly lightly smear this with thin oil and then screw up the gland nut sufficiently tight to give a gas tight joint Finally adjust the gap to 015 018 77 CHARGING A LUCAS type 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 The two exterior terminals are marked D and F indicating the respective terminals for the Positive and Field wires that lead to similarly marked terminals on the Regulator Unit Inspect commutator and brush gear every 5 000 to 6 000 miles Maker s Recommendation Remove the cover band to inspect commutato
99. minals of the A V C Unit are plainly marked by the letters F A D E Wires from F and D go to similarly marked terminals on the dynamo The A terminal is connected to one of the ammeter terminals and the E terminal is earthed We specially warn against unskilled meddling with the settings of the regulator and the cut out contacts TO EARTH TO TERMINAL D ON DYNAMO TO TERMINAL 3 TERMINAL SWITCH F ON DYNAMO Illustration 32 Showing connections to regulator and cut out unit Type MCR 2 Later machines may be fitted with a new A V C Unit type RB 107 but the foregoing notes will still apply with the exception of terminal grouping which will be F A E D Battery The battery fitted is LUCAS type PU7E 9 This is a lead acid battery in which the electrolyte is in free liquid form The voltage is 6 and the capacity is 12 ampere hours Maintenance once every 14 days Remove battery cover brush dirt from top of battery and remove vent plugs There are three vent plugs NOTE NEVER bring a naked light near a battery when the vent plugs have been removed or when the battery is being charged as the gas given off by the electrolyte is highly explosive 80 The specific gravity of the electrolyte indicates the m CORRECT ACID LEVEL state of charge ofthe battery With afully charged PEE battery the specific gravity of the electrolyte should AT 55 1 280 to 1 300 Check the gravity by means of
100. mmonia or bicarbonate of soda in water Vent plugs should be kept clean and air passages in them kept free Re fix vent plugs tightly Keep the battery and surrounding parts particularly the tops of the cells clean and dry Brush away any sand dust or road slush Battery electrolyte which contains sulphuric acid in a diluted form is destructive to practically everything except rubber lead glass or earthenware Therefore rags used to clean battery tops etc should be thrown away afterwards If put back in the tool box they will cause the tools to rust Assuming the temperature of the electrolyte is about 60 F a test with a hydrometer quickly shows the state of charge as under Reading 1 280 to 1 300 indicates fully charged Reading about 1 210 indicates half discharged Reading below 1 150 indicates fully discharged If the electrolyte exeeds this 002 must be added to the hydrometer reading for each 5 F rise to give the specific gravity at 60 F Similarly 002 must be subtracted from the hydrometer reading for every 5 F below 60 F 81 LIGHTING SWITCH 47 y VERD who ON Illustration 34 Showing lamp panel containing ammeter at top switch and cable harness The ammeter fitted is type CZU 27 See page 84 for numbered references LIGHTING AND ACCESSORIES Headlamp A LUCAS headlamp is fitted and snugly mounted on each side is a neat torpedo shaped pilot lamp These pilot lam
101. n the clutch spring adjusting nuts using end of spanner Part No 017254 Slacken back four complete turns each clutch spring adjusting nut Engage top gear apply rear brake and then fully tighten the engine shock absorber retaining nut Check front driving chain for adjustment Check dynamo driving chain for adjustment Check clutch operarating lever for correct free movement as detailed elsewhere Fit outer half of front chaincase by Ensure faces of both halves of chaincase are clean Ensure the rubber and metal bands are clean and undamaged After carefully positioning the outer half so that Its exterior edge exactly coincides with that of the inner half apply the endless rubber band Fit the metal band starting at the front end of the chaincase and drawing together the two free ends with the fingers of one hand while with he other hand insert the binding screw Whilst slowly tightening this binding screw apply at the same time light taps all round the band exterior using a small rubber mallet These light taps will cause the metal band to creep on the rubber to ensure an even all round pressure and make an astounding difference in the extent to which the binding screw can be tightened down Replace footrest arm and exhaust pipe with silencer Remove the inspection cap from the chaincase and pour in engine oil to the level of the bottom edge of the inspection cap orifice and then replace the cap after replac
102. nded for grease Lubricate at first sign of stiff or jerky action CONTROL LEVER LUBRICATION Occasionally a drop of engine oil on all moving parts of the handlebar control levers If twist grip is too stiff remove two screws binding the two halves of the clip This releases the grip which may be pulled off the handlebar Smear handlebar the drum on which the inner wire is wound and the friction spring on the half clip with grease and replace REAR FORK HINGE spring frame models Heavy Gear Oil see page 57 WHEN ORDERING SPARES ALWAYS QUOTE THE COMPLETE ENGINE NUMBER Including all the Letters in it THIS ENABLES THE MACHINE TO BE IDENTIFIED EACH SERES OF FRAMES IS NUMBERED FROM ZERO UPWARDS THEREFORE THE QUOTATION OF A FRAME NUMBER ONLY DOES NOT FACILITATE IDENTIFICATION 20 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 9 90 O 1D OY 9 OO 9 99 OG Illustration 6 Lubrication Chart Engine Oil Locations Grease Locations 16 MAIN OIL TANK 23 FRONT HUB 7 FRONT CHAINCASE 14 REAR HUB 8 CONTROL LEVER MOVING PARTS 21 STEERING HEAD TOP BEARING 201 9 STEERING HEAD BOTTOM BEARING 2 BRAKE ROD JOINTS 15 SPEEDOMETER GEAR BOX 6 FRONT CENTRE AND PROP STAND 10 FRONT BRAKE EXPANDER 1 3 REAR BRAKE EXPANDER 19 HINGE PINS 5 BRAKE PEDAL SPINDLE Hydraulic Fluid
103. ne of the grades of oil specified in the Lubrication Section for use in the TELEDRAULIC Front Forks The recommended quantity for each leg is 85 c c or a trifle under 3 fluid ozs of S A E 20 grade of one of the brands specified abnormal loads the next heavier S A E grade may be used but unlike the front fork recoil damping as well as maximum load capacity is increased by this alteration of grade alone and under no circumstances should the oil content of each leg exceed 90 c c or roughly 3 fluid ozs Unless serious doubt exists as to the correct functioning of the rear legs owners are advised to leave well alone Should the need arise however the oil content of each leg should be separately checked as follows 57 010262 RUBBER BUSH TOP PIVOT O16059 016206 SPACER COLLAR 016343 A LOCK NUT 000074 BUFFER 016251 V p ed 16291 SEALING RING CA 016082 LEATHER WASHER fa LR NC a e oF y 016342 DAMPER ROD MAIN SPRING 519594 0 016406 INNER TUBE H 016410 SZ TOP COVER TUBE 016408 2 7 Y 2 4 AN 016072 PLUNGER SLEEVE CLIP LOCATING SLEEVE 016078 COLLAR 3 016339 010718 OIL SEAL 4 A M 016409 sorrow covere 1 UPPER BUSH 016077 STOR PIN 010721 01126 BUFFER SPRING L2 11 1 EN Wa DAMPER VALVE 016304 IN j O10719 VALVE SEAT P Va LOCK NUT O00005 016082 LEATHER WASHER NE 2 I IU
104. ng ring the twenty four clutch sprocket bearing rollers Introduce clutch sprocket over the rollers Place on the gear box main shaft splined sleeve the thin clutch bearing retaining washer Push on the splined sleeve the clutch centre hub Fit the plain washer lock plate and nut that retains the clutch centre but do not fully tighten the nut 44 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 Turn up the edge of the lock plate so that it tightly abuts against a flat of the nut Fit the clutch plates and springs by Slide into position in the clutch case attached to the clutch sprocket a steel plain clutch plate Slide into place a clutch friction plate plate with fabric inserts and follow with a steel plain plate then another friction plate and so on alternatively till all plates are fitted Five plain plates and four friction plates on 350 c c six plain and five friction on 500 c c and all competition models Drop into the spring pressure plate the clutch spring cups Show up the spring pressure plate and insert over the studs the clutch springs retaining each one a few turns as fitted with a clutch spring adjusting nut Fully tighte
105. ngine until both tappets are down the top dead centre of firing stroke Lay the composition jointing washer on cylinder head This must be faultless f necessary renew Lay the rocker box in position then slightly raise the right hand side to allow the long push rods to be inserted into their original respective positions Insert all nine rocker box fixing bolts and note that the bolt with short head is in the centre right hand position and the bolts with threaded extensions are fitted one each Side of the central short head bolt Tighten each bolt in turn bit by bit until all are fully home Replace the engine steady stay Turn engine over several times to ensure parts have bedded home Re fix valve lifter cable Re fix rocker box oil pipe union nut using two spanners to ensure that the union screwed into rocker box does not turn while the nut is being tightened Check tappet clearances and re set if necessary Inspect rubber fillet on rocker box side cover and renew if not perfect Replace the side cover ensuring that a fibre washer is fitted under each of the three retaining nuts Beware of over tightening these nuts the joint being made by the rubber fillet excessive pressure is not necessary Replace the petrol tank 26 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 ex
106. nkcase A felt cartridge filter in the oil tank removes foreign matter collected by the oil in its passage through the engine A metal gauze strainer is fitted to the oil feed pipe in the oil tank to prevent pieces of fluff etc which may find their way into the tank when replenishing from entering the oil pump See Illustration 3 Felt filter and metal strainer should be cleaned in petrol each time the oil tank is drained ENGINE OIL PUMP 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 from its housing before attempting to separate the crankcase halves It is not necessary to remove the small timing pinion which will pass through in situ ENGINE OIL CIRCULATION The oil pump forces oil through a A passage cut through the timing side flywheel axle timing side flywheel and crank pin to lubricate the big end bearing The splash passes to interior of cylinder to lubricate the cylinder and piston and then falls into the crankcase sump b A passage in crankcase controlled by ball valve direct to the cylinder t
107. ntinuous matt ring is observed on both valve face and seat After grinding all traces of abrasive must be carefully washed off with petrol and a piece of rag moistened in petrol should be pulled through the bore of each valve guide to remove any abrasive that may have entered A holder for the valve when grinding in the valve can be supplied The part number is 017482 TO REPLACE THE CYLINDER HEAD A gasket is fitted between cylinder head and barrel Touring models only The top ends of the push rod cover tubes have rubber gaskets between tubes and head they are a push fit and metal washers are located between the top edges of the gaskets and the cylinder head recesses If the cover tubes are pulled away from the head the gaskets will probably remain in position in the head A rubber gland is fitted at the bottom of each cover tube 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 Place the cylinder head in position Ensure each cylinder head securing bolt has a plain steel washer on it and then replace the bolts and engage each a few turns Finally screw down the cylinder head securing bolts In turn bit by bit until all are fully h
108. o assist in cylinder and piston lubrication and then falls into the crankcase sump c A passage in timing gear case where it builds up to a predetermined level to lubricate the timing gears and then overflows into the crankcase sump d Through a pipe from the front of oil pump housing to the rocker box by which all rocker gear and valve stems are lubricated and then falls through the push rod cover tubes and tappet guides to the timing gear case and from there drains into the crankcase sump as detailed in Para c The oil pump extracts oil in the crankcase sump and returns it to oil tank On its way it passes through the felt cartridge filter located in the oil tank 15 D M S TAKEN 1 ALS OVER ROCKERS t t TIMING GEAR f CHANNEL iN CYLINDER BASE WILL NE FEEDS HOLES IN f CYLINDER WALL gt 1 FROM PUMP TO ROCKER BOX Seva lt a VAS SURPLUS FROM Wie TIMING GEAR DROPSM Mw SUMP lt IN TO OIL IS DELIVERED UNDER PRESSURE TO BIG END BEARING TANK N TANK SURPLUS u DRAWN UP FROM SUMP RETURNS TO TANK 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 sum
109. ocker clearance Standard cams INLET VALVE EXHAUST VALVE Opens before T D C 350 36 500 18 Opens before B D C 350 50 500 50 Closes after B D C 350 51 500 69 Closes after T D C 350 30 500 30 Taken with valve 001 off its seat Valve Guide Projection Top of Inlet v2 Exhaust 2 Valve timing pinion Retained by nut threaded Weight Weight of machine with empty tanks standard Model Rigid frame 350 344 Ibs 500 m e 353 Ibs Wheels bearing end play Bearing end play in by 26 threads in variations provided for the 350 and 500 c c Single Cylinder machines Guide to Boss Left hand thread Part number 000221 Competition Spring frame Rigid frame 375 Ibs 300 Ibs 386 Ibs 303 Ibs 002 in just a perceptible rim rock 6 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 Should be fully closed when starting engine from cold 3 Ignition lever When fitted Small lever on left_ handlebar Advances and retards ignition point Pull inwards to retard Retard two fifths of total movement for starting 4 Valve lifter lever Small lever close to c
110. of the sliders themselves Above these bushes an oil seal is fitted the object of which is to prevent leakage of oil from below into the main spring chamber The normal level of oil is well above the bottom extremity of the main inner tubes and bearing this in mind it is at once clear that upward movement of the sliders resulting from impact with road bumps in addition to meeting resistance from the main springs also causes oil to be ejected by the close fitting steel bushes This oil is forced upward through the open ends ofthe main inner tubes and also through the holes A Illustration 16 in the bottom of the damper tubes then past the damper disc valve which the passing oil raises off its seat As the oil level rises inside the main inner tubes air trapped is compressed thereby forming an air buffer acting as auxiliary to the main springs This displacement of oil upon impact imposes a certain amount of damper effect the extent of which increases with the violence of the shock or in other words the bigger the bump the greater the damping effect Upon the recoil movement the damper disc valve returns to its seat and the oil trapped between this valve and the plunger sleeve above 52 has 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 will thus be gathered that on the shock movement of the fork slight
111. ome Replace The sparking plug but before doing so it is desirable to coat thread with Oil Dag or graphite paste to prevent seizure upon next removal The rocker box carburetter exhaust system and the petrol tank NOTE lf old gaskets are re fitted they must be in an undamaged state otherwise new must be used Whether new or re used the gasket should be annealed just prior to fitting This is done by heating to blood red heat and plunging into clean cold water TO REMOVE THE CYLINDER BARREL AND PISTON Remove The cylinder head The four nuts retaining cylinder barrel to crankcase Take away Cylinder barrel Ensure piston is not damaged in doing this Steady piston with hand as barrel is withdrawn Fill throat of crankcase with clean rag to prevent entry of foreign matter 30 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 is an easy sliding fit in both piston and connecting rod small end bush Rings may be removed from a piston by peeling off with a knife or by Introducing behind the rings three pieces of thin steel spaced at 120 from each other and then sliding off the rings Do not scratch the piston TO REPLACE THE PISTON AND CYLINDER BARREL All parts must be clean Place rings on piston scraper first then the two compression rings On all models
112. onnect the two terminals with a short length of wire b Start the engine and set to run at normal idling speed 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 Do not allow the voltmeter reading to rise above 10 volts Do not race the engine in an attempt to increase the voltage is sufficient to run up the engine to a speed of 1 000 r p m If the above reading is obtained the dynamo is in order If there is no reading check the brush gear If there is a low reading of approximately 15 volt the field winding may be at fault If there is a low reading of approximately 120 2 volts the armature winding may be at fault If the tests mentioned above clearly indicate the dynamo is not charging it is then desirable to remove the dynamo from the machine in order to make further tests and repairs or replacements 78 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 dyn
113. onths above referred to and this guarantee is in lieu and in exclusion of any common law or statute warranty or condition and the damages recoverable are limited to the cost of any further work which may be necessary to amend and make good the work found to be defective CONDITIONS OF GUARANTEE If a defective part should be found in our motorcycles motorcycle combinations or sidecars or in any part supplied by way of exchange before referred to it must be sent to us CARRIAGE PAID and accompanied by an intimation from the owner that he desires to have it repaired or exchanged free of charge under our guarantee and he must also furnish us at the same time with the number of the machine the date of the purchase or the date when the alleged defective part was exchanged as the case may be Failing compliance with the above such articles will lie here AT THE RISK OF THE OWNER and this guarantee and any implied guarantee warranty or condition shall not be enforceable We do not guarantee specialities such as tyres saddles chains electrical equipment lamps etc or any component parts supplied to the order of the Purchaser differing from standard specifications supplied with our motorcycles motorcycle combinations sidecars or otherwise NOTICE We do not appoint agents for the sale on our behalf of our motor cycles or other goods but we assign to motor cycle dealers areas in which we supply to such dealers exclusively for re sale in suc
114. p may be greater than the space available in the tank The oil filter is made in cylindrical form of thick felt and is supported by a tubular wire cage The felt is not detachable from the cage 16 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 TO REMOVE THE FELT OIL FILTER Unscrew the hexagonal headed cap on the top of oil tank and withdraw the dished washer and spring Then insert a finger in the exposed open end of the felt filter and gently raise As the filter emerges from the tank gently strain inward and backward on rigid frame model to clear the saddle frame or outward and forward on spring frame model to clear the twin seat Care in this operation is necessary to avoid kinking the filter To re fit filter Reverse above instructions after the filter has been removed from the tank it is damaged so that the felt is perforated or the ends distorted it is essential to discard it and to fit new filter Be careful to avoid damaging the filter or the cork washer under the hexagonal cap To remove and clean the feed pipe metal filter Release the oil feed pipe from the rubber connecting sleeve on the metal feed pipe protruding from the bottom of the oil tank The m
115. passes to the piston A clogged metal strainer in the gravity feed pipe will also cause improper or no oil circulation This can only occur as the result of adding dirty oil when replenishing the tank Both end caps on pump plunger housing must be air tight Check oil circulation before starting each run 17 Illustration 5 The inlet valve guide is shown withdrawn as also is the inlet valve stem adjusting screw with lock nut 1 PLAIN HOLE FOR OIL FEED TO INLET 8 PLAIN HOLE FOR OIL FEED TO EXHAUST VALVE VALVE 2 TAPPED HOLE TO ACCOMMODATE 9 HOLE TO ACCOMMODATE DOWEL PIN CARBURETTER RETAINING STUD LOCATING VALVE SPRING SEAT 3 INLET PORT 10 GUIDE FOR EXHAUST VALVE 4 TAPPED HOLE TO ACCOMMODATE 11 HEAD CARBURETTER RETAINING STUD 12 EXHAUST PORT 5 HOLE TO ACCOMMODATE DOWEL LOCATING VALVE SPRING SEAT 13 NEEDLE SCREW ADJUSTING OIL FEED TO INLET VALVE 6 GUIDE FOR INLET VALVE 14 LOCK NUT FOR NEEDLE ADJUSTING 7 TAPPED HOLE FOR SPARKING PLUG SCREW 18 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 Excessive oil will cause leakage A screwed drain plug in gear box shel
116. position is locked by a nut This adjustment is not unduly sensitive and it should be possible to obtain the correct adjustment in a few seconds In the event of the adjustment of the air screw failing to provide the required result it is possible the pilot jet is obstructed with dirt The pilot jet is actually a passage drilled in the sprayer base or choke and is very small so there is always latent danger of this becoming choked Upon removing the float chamber and the large nut at the bottom of the mixing chamber the sprayer base can be pushed out of the mixing chamber and the jet can be cleared by using a strand of fine wire Before concluding that incorrect carburation is responsible for heavy petrol consumption and before carrying out any of the tests and adjustments described above it is most Important to make sure the ignition is set correctly Late ignition usually causes a great increase in petrol consumption TWIST GRIP ADJUSTMENT A screw is provided in one of the halves of the twist grip body to regulate the spring tension on the grip rotating sleeve This screw which is locked by a nut must be screwed Into the body to increase the tension The most desirable state of adjustment is that when the grip is quite free and easy to operate but at the same time will stay in the position in which it is placed The complete twist grip can be moved on the handlebar by slackening the two screws that clamp together the two halves of
117. ps 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 head lamp has a panel mounted on its top retained by three screws see Illustration 34 This panel carries the main switch and ammeter 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 The headlamp reflector and glass are made up as one assembly and are in consequence not sold separately as spares The main bulb is ofthe pre focus type and the design of its holder is such that the bulb is correctly positioned in the reflector No focussing is therefore necessary when a replacement bulb is fitted See Controls page 7 for switch functions To remove headlamp rim and light unit Slacken the screw on the top of the lamp body at the front pull the rim outward from the top and as the front comes away lower slightly to disengage the bottom tag from the lamp shell Twistthe back cap in an anti clockwise direction and pull it off the bulb can then be removed The light unit is secured to the rim by means of spring clips These can be disengaged from the turned up inner edge of the rim by pressing with a screwdriver blade and at the same time working away from the edge To replace the headlamp rim and light unit Lay the light unit in the rim so that the location block on the unit bac
118. r 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 Take care to replace brushes in their original positions otherwise they will not bed properly on the commutator If after long service the brushes have become worn to such an extent that the brush flexible wire is exposed on the running face or if the brushes do not make good contact with the commutator they must be replaced by genuine LUCAS brushes The commutator must be free from any trace of oil or dirt and should have a highly polished appearance Clean a dirty or blackened commutator by pressing a fine dry cloth against it while the engine is slowly turned over by means of the kick starter It is an advantage to remove the sparking plug before doing this If the commutator is very dirty moisten the cloth with petrol At every 10 000 miles the complete dynamo should be handed to a Lucas Service Station for dismantling replacement of worn parts cleaning and lubrication Electrical breakdown of the dynamo is most unusual and therefore before assuming this unit is defective it should be tested as follows Check that the dynamo regulator and battery are correctly connected To remove the dynamo see page 79 Test Dynamo in position by a Remove the two wires from the dynamo terminals and c
119. r plate has been disturbed it is advisable upon re assembly to centralise the shoes in the brake drum to ensure equal pressure to each the case of the front wheel this is best done before re fitting the wheel to the machine but in the case of the rear wheel it is best done after re fitting If brake shoes tend to squeak when the brake is applied it is generally an indication the brake shoes are not centralised in the drum 1 Brake shoe thrust pin Illustration 23 2 Thrust pin packing washer 3 Brake shoe 4 Rivet securing brake shoe lining 5 Brake shoe lining 67 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 FRONT BRAKE ADJUSTMENT Major adjustment of the front brake shoes is made on the brake thrust pins by fitting packing washers under the pins as already described Minor adjustment of the front brake shoes is made by altering the position of the brake cable adjuster on the fork assembly Unscrew the adjuster to take up the front brake The adjuster is locked in position by a nut Adjust front brake by Pl
120. rinding Part number 017482 Valve spring compressor Part number 018276 See page 28 Pannier frames and bags for spring frame and rigid models SPARES LIST An illustrated and priced spares list is available at a cost of 2 6 postfree See page 28 GASKET SETS For convenience in ordering standard sets of engine washers and gaskets as well as the washers used in the petrol and oil feed systems are stocked Full details of contents and prices are included in the Spares List 89 Neat monogram badges are now available at 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 017254 017007 017256 01 7251 amp 015023 018055 018153 a m i Ou 017249 017114 Illustration 38 90 INDEX Carburetter Service Controls Data Driving Electrical Engine Service Free Service Fork and Frame Introduction Lubrication Lubrication Chart Maintenance Service LR Rear teledraulic legs Repairs and Service The Law Tools and Special Equipment Transmission Service Useful Information Wheel Brake and Tyre Service BE SPARES ano SERVICE DEPARTMENTS HOURS OF BUSINESS FOR CALLERS MONDAYS 8 30 to 12 55 p m 2 0 p m to 5 30 p m TUESDAYS Ditto WEDNESDAYS Ditto THURSDAYS Ditto FRIDAYS Ditto NOT OPE
121. rking round the cover equally on either side of the valve position the cover will slip into place without excessive exertion fitting the part nearest to the valve last of all Slightly inflate the inner tube and inspect for the inner tube being trapped between the outside edge of the cover and the rim at the spots where the valve is located Half inflate tyre spin wheel and test for trueness because it is essential the pattern of the tread runs evenly and the cover must be manipulated till that occurs This centralisa tion of the cover is most important Inflate to required pressure Screw fully home the nut on the valve Replace the valve cap TYRE PRESSURES The following are correct minimum inflation pressures for specified loads per tyre Load per tyre 200 Ib Pressure 16 16 per square inch do 240 1 do 181 do do 280 Ib do 20 lb do do 350 Ib do 24 do do 400 Ib do 2816 do do 440 Ib do 32lb do The best method of ascertaining the correct pressure is to actually weigh the loads on the front and rear tyres This should be done on a weighbridge and is a service that can usually be provided by British Railways at a Goods Depot or by a Corporation at its Depot When the weights are known the table above can then be used As a rough guide it may be stated that with a rider of average weight and with normal equipment solo the pressure should be 18 Ib for the front tyre and 22 Ib for the rear 71
122. rrect amount of movement as stated is to 6inch measured at the end of the operating lever A careful study of Illustrations 14 and 15 will help considerably in making the foregoing instructions readily understandable To remove a clutch control cable Remove the oil filler cap from the kick starter case cover Screw right home the clutch cable adjuster that is located in the top of the kick starter case cover Disengage from the operating lever the clutch cable inner wire by operating through the oil filler cap opening Completely unscrew the clutch cable adjuster Disengage from the handlebar operating control lever the clutch inner wire Pull cable by its lower end till removed from the machine easing it through the frame cable clips while doing so To replace a clutch control cable Reverse the above instructions and finally adjust as detailed earlier 47 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 Then slack off the rear nut and carefully tighten the forward nut until the correct chain tension is obtained after which securely tighten the rear nut to lock the assembly correct chain whip
123. rs the chamfered mouth of the barrel Remove rag from crankcase throat Replace cylinder barrel holding down nuts screwing each down in turn bit by bit till all are fully home CAM CONTOUR On the flanks of the cams are quietening curves which are very slight inclines from the base circles to the feet of the humps Therefore It is necessary to ensure the tappet ends are on the base circles when checking valve clearances and valve timing Itis for this reason valve clearances must be checked when the piston is at the top of its compression stroke at which position both tappets are well clear of the quietening curves 31 F M S 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 after bottom dead centre 500 c c models Exhaust valve timing Exhaust valve opens 50 before bottom dead centre All models Exhaust valve closes 30 after top dead centre All models See page 89 for particulars of special timing disc graduated in degrees Illustration 10 Camshaft timing marks Use mark 2 for exhaust cam all models mark 2 for inlet cam 500 c c and mark 3 for inlet cam on 350 c c models only When checking the valve timing the tappet clearances must be set to 0
124. s These bolts screw into forward end of each frame fork end Screw in turn each chain adjusting bolt further into the fork ends until the chain tension is correct Each bolt must be turned the same amount The chain whip should be 3 to v2 Check adjustment in more than one position by partly revolving the rear wheel Tighten wheel spindle nuts Re check chain tension Tighten nuts on chain adjusting bolts NOTES ON REAR CHAIN ADJUSTMENT Before tightening the rear chain check the front chain adjustment and if attention is necessary adjust the front chain first Altering the adjustment of the front chain upsets the adjustment of the rear chain Therefore after making a front chain adjustment always check the rear chain adjustment and re set if necessary Altering the adjustment of the rear chain may upset the adjustment of the rear brake Therefore after making a rear chain adjustment always check the brake adjustment and re set if necessary The whip of chains should always be tested mid way between the two sprockets and the sprockets should be turned and tests made in several positions This is because chains never wear evenly and there is usually one position where the chain Is tighter than in any other The adjustment should be set for the tightest position found Always re check the chain tension after making it and tightening all bolts and nuts DYNAMO CHAIN ADJUSTMENT The dynamo armature shaft is eccentric
125. s in characters of even thickness as follows The numbers on the front plate must be 134 high 114 wide and 9 thick with spaces of Ye between each two characters The numbers on the rear plate must be 2 high 134 wide and 3 thick with spaces 7 between each two characters The Licence Disc must be enclosed in a water tight container having a transparent front and this must be fixed to the machine in a conspicuous position near the front and on the left hand side It is not legally necessary to carry your Driving Licence Insurance Certificate and Registration Book while driving your machine Ignition Suppressors As required by law all 1954 Home models are issued with an approved type of radio interference suppressor already installed Speedometer A speedometer MUST be fitted and it MUST BE so ILLUMINATED that it is possible to read the dial after lighting up time Lamps During the official LIGHTING UP hours the machine must exhibit a white light facing forwards and a red light facing rearwards The rear number plate must be adequately illuminated by a white light Each front electric light bulb MUST be marked with its Wattage Beware of cheap imported bulbs that do not have this marking All motor cycles made by us have electric equipment that complies with the law regarding position size of bulbs marking on bulbs and the correct illumination of the rear number plate 87 GUARANTEE We give t
126. ster until it is free from the K S case cover and withdraw the cable nipple through the adjuster hole 41 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 12 holding the K S pedal firmly while doing so Now swing the K S crank round until it can be tied to the foot change lever This prevents the K S return spring unwinding and facilitates re assembly The entire cover can now be removed Re assemble in exactly reverse order taking care to avoid damage to the paper joint gasket NOTE The position of the various cheese head screws securing the K S case cover are as follows In the top position screw measuring 3 inches under head In the bottom position screw measuring 2 under head In the rear position screw measuring inch under head In the front position top screw measuring 1 inches under head In the front position bottom screw measuring 138 inches under head TO REMOVE GEAR BOX END PLATE FOR EXAMINATION OF GEARS Remove K S case cover as already described Remove split pin securing both gear striker shaft pins and withdraw the pins and also the cam barrel in which they operate together with the spring loaded conical ended plunger which engages depressions on the underside of the cam barrel Remove
127. t from time to time may need replacement as the result of wear Those parts include floats and float needles jet taperneedles needle jets and washers CARBURETTER FUNCTION The petrol level is maintained by a float and needle valve and in no circumstances should any alteration be made to this In the event of a leaky float or a worn needle valve the part should be replaced with new Do not attempt to grind a needle to its seat The petrol supply to the engine is controlled firstly by the main jet and secondly by means of a taper needle see Illustration 13 which is attached to the throttle valve and operates in a tubular extension of the main jet The main jet controls the mixture from three quarters to full throttle the adjustable taper needle from three quarters down to one quarter throttle the cut away portion of the Intake side of the throttle valve from one quarter down to about one eighth throttle and a pilot jet having an independently adjusted air supply takes care ofthe idling from one eighth throttle down to the almost closed position These various stages of control must be kept in mind when any adjustment is contemplated See Illustra tion 13 for location of the pilot jet air adjustment screw The pilot jet consists of a small hole drilled In the choke or jet block The size of the main jet should not be altered save for some very good reason See DATA for details of standard sizes of jet throttle valve an
128. t is a salt deposit that in most cases and in its early stages can be quickly and easily removed with a damp chamois leather In stubborn cases it may be necessary to use a special chromium cleaning compound Lack of attention will lead to more serious damage The safest precaution during Winter is to wipe over all chromium plated parts with a soft rag soaked TEKALL which is a lanoline base rust preventative marketed small tins and available at most garages This material so applied leaves an almost invisible film that is impervious to moisture and its use cannot be too highly recommended to owners who value the appearance of their mounts In Summer when those conditions do not prevail chromium parts should be frequently cleaned with a damp chamois leather and afterwards polished with a soft duster or better still with a polishing cloth of the Selvyt type If a polish is used it must be one of the special compounds for chromium plating only Ordinary metal polishing liquids in particular must not on any account be used because these almost without exception contain acids which attack chromium NOTE Tekall is a product of 20th Century Finishes Ltd 175 177 Kirkgate Wakefield and is retailed in 2 pint and 1 pint tins It can be obtained from our Spare Parts Department as follows Ve pint tin Tekall Part number 011957 price 2 plus 6d postage 1 pint tin Tekall Part number 011958 price 3
129. t quantity of oil to add to each leg is 6 ozs 184 6 c c TO REMOVE THE COMPLETE FRONT FORK ASSEMBLY Support the machine with the front wheel clear of the ground A box of suitable height under each footrest is the best method Remove the front wheel as described in Wheel Section Remove the front stand and front mudguard Slaken the screw on headlamp top gently prise out the rim and reflector assembly detach with a slight rotary and lifting movement the cap to which headlamp wires are attached and take away rim and reflector assembly Gently ease back the rubber sleeves covering the pilot lamp wire snap connectors and pull latter apart Remove the three screws securing switch panel and lift same off with all wires attached Remove the nuts on the tubular bolts through which the pilot lamp wires pass which enables the pilot lamps and headlamp shell to be taken away Disconnect the driving cable from the speedometer head and detach the speedometer lamp bulb with its holder Remove the two bolts securing speedometer head and take same away 53 Remove the handlebar half clip and Jay the handlebars complete with controls upon 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 Unscrew the hexagon plug on top of each inner tube and slacken the lock nuts securing the damper rods attached Then before remo
130. t slackness is discernible Continue to tighten the lower adjusting nut until no perceptible movement can be felt and yet the steering head is perfectly free to turn then tighten down the domed nut in order to lock the adjustment Securely tighten the two fork crown pinch screws This is very important Remove packing from under footrest FRONT FORKS TELEDRAULIC Owing to the unusual construction of the TELEDRAULIC fork it is desirable to understand what happens in use and in order to follow clearly the descriptions and subsequent assembly and adjustment instructions reference to Illustrations 16 and 17 will be necessary As will be seen from the general arrangement drawing Illustration 17 the main members of the forks are two long tubes These are of heavy gauge and are externally ground to very fine limits These fork main inner tubes are firmly fixed to the handlebar clip lug by the top bolts 016718 and are clamped to the fork crown by the clamping screws Upon the external of these tubes are mounted the springs and sliding members to which latter the front wheel mudguards and front stand are fixed The telescopic action of the sliders combined with the hydraulic dampers described later explain the word Teledraulic coined for the description of the fork 51 PORTION OF SLIDER EXTENSION 14341 FORK MAIN SPRING O16526 LEATHER WASHER 010698 PLUNGER SLEEVE 016072 n SLEEVE RETA
131. terval Filters Clean metal mesh filter in oil tank Illustration 3 Clean felt fabric filter in oil tank Dynamo Clean as detailed in Electrical section Front fork Check each side of front fork for hydraulic fluid content and if necessary top up 12 amp 24 Insufficient oil content is indicated by abnormally lively action Rear legs If fitted Check each leg for hydraulic fluid content and if necessary top up Insufficient oil content is indicated by abnormally lively action Dealers Service only Carburetter Remove carburetter float chamber and clean its interior EVERY 10 000 MILES Magneto and Get a Lucas Service Station to dismantle clean lubricate and Dynamo generally service Air Filter If fitted renew filter element 23 E M S FREE SERVICE SCHEME FREE SERVICE SCHEME All owners of NEW MODELS are entitled to one FREE SERVICE AND 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 This voucher together with the Instruction Manual are supplied by us upon receipt of the signed application card to be found in the tool box upon taking delivery of a new motor cycle The INSPECTION AND SERVICE consists of a Check and if necessary adjust 1 Rocker clearances 6 Wheel bearings 2 Contact breaker points 7 Brakes 3 Sparking plug 8 Forks legs and steering
132. the COMPLETE ENGINE NUMBER Some numbers have one or more letters incorporated in them and these letters MUST BE QUOTED otherwise model identifi cation is not possible Orders should always be sent in list form and not as part of a letter Owners are strongly advised to purchase a Spare Parts List so that correct part numbers can be quoted Most parts are clearly illustrated in this list which makes it very easy to recognize the part or parts required PROPRIETARY FITTINGS No expense is spared to secure and fit the most suitable and highest quality instruments and accessories for the standard equipment of our machines Nevertheless our Guarantee does not cover such parts and in the event of trouble being experienced the parts in question should be returned to and claims made direct on the actual manufacturers who will deal with them on the terms of their respective guarantees Those manufacturers are Carburetters Messrs Amalgamated Carburetters Ltd Holford Road Witton Birmingham 6 Chains The Renold and Coventry Chain Co Ltd Didsbury Manchester Electrical Equipment Messrs Joseph Lucas Ltd Great King Street Birmingham 19 Gear Boxes Messrs Burman amp Sons Ltd Wychall Lane King s Norton Birmingham 30 Sparking Plugs K L G Sparking Plugs Ltd Putney Vale London S W 15 Speedometers Messrs S Smith amp Sons M A Ltd Cricklewood London Tyres Messrs Dunlop Rubber Co Ltd Fort Dunlop Birmingham
133. the Free Ferry between North Woolwich and Woolwich North Woolwich is a British Railways terminus and is also served by Bus and Trolleybus routes 101 569 669 and 685 There is also a tunnel under the River Thames at this point for foot passengers The Free Ferry accom modates all types of motor vehicles and there is a very frequent service The Southern landing stage is less than a mile from the Service Depot Visitors arriving by road if they are strangers to the locality should enquire for Beresford Square Woolwich Upon arrival there the road skirting the Royal Arsenal should be followed in an Easterly direction for about four hundred yards and Burrage Road is the second turning on the right after leaving the Square Burrage Grove is then the first turning on the left THE DRIVER AND THE LAW The driver of a motor cycle MUST be INSURED against Third Party Claims and MUST be able to produce an INSURANCE CERTIFICATE showing that such an insurance is in force If your Insurance Certificate specifies you can only drive one particular machine you MUST NOT DRIVE any other machine unless its owner has a current Certificate covering ANY DRIVER and it is advisable to remember that in the absence of Such a provision the penalties for doing so are very heavy The driver of a motor cycle MUST hold a current DRIVING LICENCE If you area learner and hold a Provisional Driving Licence your machine must show front and back the standard L p
134. then necessary to change to a lower gear Engine knocking or pinking and a harshness in the transmission are symptoms of such labour A good driver is able to sense such conditions and will make the change before the engine has reached the stage of distress The gear box is provided to be used and consequently full use should be made of the intermediate gears to obtain effortless running and smooth hill climbing Keep the feet clear of the brake and gear pedals when not actually using them and keep the hand off the clutch lever when not in use Drive as much as possible on the throttle making the minimum use of the brakes When using the machine on wet or greasy roads It is generally better to apply BOTH brakes together because sudden or harsh application of either brake only under such conditions may result in a skid In all conditions It is advisable to make a habit of always using both brakes together rather than habitually using the rear brake and reserving the front brake for emergency 12 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 This check should be made Immediately after starting the engine from cold This is because while the en
135. tion Harshness in transmission can be caused by the drum retaining bolts and nuts being loose Rear wheel spokes will break for the same reason BRAKE SHOES The front and rear brake shoes springs and expanders are interchangeable The two shoes in each brake are NOT identical they are handed One end of each shoe bears on a fulcrum fixed in the brake cover plate The other end accommodates a detachable thrust pin By inserting washers under a thrust pin its effective height can be increased thereby compensating for wear on the brake linings BRAKE SHOE ADJUSTMENT Brake adjustment to compensate for lining wear is normally made by means of a finger adjuster on the rear brake rod and a cable adjuster for the front brake cable After a very considerable mileage this continual adjustment causes the brake cam to occupy a position whereby the available leverage is considerably reduced and as a result the brake loses efficiency To overcome this a hardened headed thrust pin is fitted to each shoe to enable a packing washer to be fitted under the head as and when required Eight of these washers 000174 are provided in the tool kit When wear of the brake linings is taken up in this manner it is then necessary to unscrew considerably the adjusting nut on the rear brake rod or screw in the cable adjuster of the front brake cable and afterwards adjust the brake as described afterwards Sj When a brake cove
136. ving the hexagon plugs attach a piece of wire about 18 inches long underneath each damper rod lock nut to enable the damper rods to be raised for reassembly Remove domed lock nut at top of steering column Remove lock nut on steering column Use a soft mallet to tap upward the handlebar lug until it disengages with the fork stem steering column and the fork assembly can then be withdrawn Take care to avoid loss of any of the 56 steering head steel balls To re fit a complete front fork assembly Secure with grease 28 balls in fork crown ball race Secure with grease 28 balls in main frame top ball race Proceed to fit fork assembly by reversing the instructions given above to dismantle carefully retightening the damper rod locknuts before inserting the hexagonal headed plugs to which they are attached TO REMOVE A FORK SLIDER either side Dealers service only Support the motor cycle with the front wheel clear of the ground and unscrew the tubular slider extension from the slider which it is intended to remove Special articulated clamp tool required Available in workshop tools Next remove the front wheel front stand and mudguard as detailed above Then witha thin tubular box key remove the bolt securing the damper tube The hexagonal head of the bolt is sunk in the upper half of the wheel spindle clamp Place a receptacle under neath to catch the oil which will drain out upon removing the bolt and take care of the fi
137. ward to decrease it Finally tighten the lock nut and re check the setting On the SR 1 magneto fitted to 500 c c models the contact breaker is exposed by re moving the moulded end cover secured with 3 captive screws To remove the contact breaker lever slacken the nut securing the end of the contact breaker spring which is slotted to permit easy withdrawal of the moving contact lever Adjustment of contact breaker Magneto type SR 1 If and when adjustment is necessary slacken the two screws securing the fixed contact plate and adjust the position of the plate until the gap when the contacts are fully opened is set to the thickness of the gauge The correct gap should be 010 to 012 Special Notes all models Check the contact breaker gap after the first 500 miles Owing to the initial settling down there is a tendency for the gap to alter in the first few hundred miles of use Subsequent adjustment will only be required at long intervals but it is nevertheless advisable to check every two thousand miles Lubrication magnetos are provided with ball bearings on the driving shaft These bearings are packed with grease upon assembly and require no attention for a considerable time About every two years or when the engine is undergoing a general overhaul the magneto should be dismantled at a Lucas Service Depot and the bearings re packed with high melting point grease 76 SPARKING PLUG The K L G

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