The National Motorcycle Museum houses the largest collection of British motorcycle’s in the world with over 1000 machines from 170 different manufacterers spanning no less than three centuries! Of the 1000 plus machines in the collection there are around 850 on display at any one time throughout the museum’s five huge display halls. With our earliest pioneer machine dating from 1898 through to the latest British superbikes of this century the museum collection highlights both the development of the motorcycle as well as showcasing the UKs proud motorcycle manufacturing heritage.
On the collection page you will find a taster of just how amazing the National Motorcycle Museum really is with an alphabetical list of each of the 170 marques that make up our unique inventory. Our main display halls page gives you an overview of the Museum collection with an east to follow list & images which give a glimpse of what to expect when you visit the world’s greatest British motorcycle museum. With 170 marques and over 850 British motorcycle’s on display at any one time we certainly can’t show you everything that our five huge display halls contain! However our (mainly alphabetical listings) are designed to whet your appetite as regards just how special a place The National Motorcycle Museum really is. It’s not just the bikes at The National Motorcycle Museum that make us so special!
Our friendly and knowledgeable staff are here to make your visit informative as well as enjoyable. With decades of combined experience our team are able to help with many of the queries that you might have about the British Motorcycles that make up the Museum collection. You can discover more about everyone on the main Meet the Team page and find out more about their roles within the greatest motorcycle museum in the world. The National Motorcycle Museum The National Motorcycle Museum is recognised as the finest and largest British motorcycle museum in the world and originally opened its doors in October 1984 with a collection of 350 motorcycles on display.
The Museum collection now boasts some 1000 plus machines, fully restored to the manufacturers original specifications with over 850 on display at any one time. The National Conference Centre The National Conference Centre situated on the same site as the National Motorcycle Museum is also one of the UKs largest conferencing and events facilities. The award winning conference centre has 13 purpose built suites available, including the Wardroom, seating small parties of up to 20 guests, and the Imperial Suite which can host 1000. Close. 2014 saw the launch of “Friends of The National Motorcycle Museum” which is the most exciting and innovative Membership scheme ever undertaken by a Museum or similar organisation. Museum Director James Hewing stated “we have tremendous plans over the next few years to make The National Motorcycle Museum a truly dynamic resource for everyone who love’s old motorcycles. Building on Museum founder Roy Richards incredible legacy we want to give enthusiasts the chance not only to be part of, but more importantly, to take part in some unique activities that just wouldn’t be possible otherwise.
The unique content of our Museum Friends Scheme will allow people to learn about, ride & enjoy old bikes whilst benefiting financially from the huge savings that can be made by insuring their machines via ”. More details can be found by clicking on the various pages opposite which also contain some exciting video footage showing what you can expect when you become a Friend of the Museum!. Close. Bruce Main-Smith & Company Ltd is a specialist supplier of motorcycle books & technical literature which has formed part of the National Motorcycle Museum’s portfolio since 2013. We are pleased to be able to continue to supply all the photocopy sets, workshop manuals, parts books, sale’s catalogues & instruction books that have always formed such a valuable resource to both restorers & enthusiasts over the past years. On the Bruce Main Smith page you will find full details of all our specialist technical literature which is all available to purchase on-line.
The National Motorcycle Museum is proud to be able to supply Castrol classic lubricants, associated products and Castrol heritage memorabilia in both the museum shop and online. Established in 1899, originally as C.C.Wakefield, Castrol launched their first lubricant for motorcycles in 1906 and has been at the leading edge of motor technology ever since. On the main Castrol page you will find more details of the products we stock as well as how to receive them directly to your front door by mail-order. Whilst The National Motorcycle Museum might hold the biggest and best collection of British motorcycles in the world we are about so much more than just our bikes!
It is our stated aim to provide a wealth of specialist services and unique activities (via our ) which allow people to make the very most of owning classic British motorcycles. More information can be found within the Specialist Services section or on the pages listed on the menu to the left.
Don’t forget that our archive of photocopy technical literature is an invaluable service to all restorers and owners of classic bikes. Close.
Product Description AJS 1949 Maintenance Manual. Models 49/16M and 49/18. Almost a Workshop Manual. VOLVO/1800 This AJS Maintenance Manual and Instruction Manual/ AJS almost Workshop Manual covers models: – AJS 1949 model 16M 347cc – AJS 49/16M – AJS 1949 model 18 498cc – AJS 49/18 In this book are non-technical instructions for carrying out all the maintenance operations likely to be called for in strenuous service and illustrations are provided to assist.
Wiring Diagrams: Pages 79 and 89 Pages: 92 Please Note: Black & White photocopy set. “Some originals available on request”.
We have made it easy for you to find a PDF Ebooks without any digging. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with. To get started, you are right to find our website which has a comprehensive collection of manuals listed. Our library is the biggest of these that have literally hundreds of thousands of different products represented. easily to access, read and get to your devices.
This ebooks document is best solution for you. A copy of the instructions for digital format from original resources. Using these online resources, you will be able to find just about any form of manual, for almost any product. Additionally, they are entirely free to find, so there is totally free (read cloudamericainc-library.com: privacy policy). File Name Size Status.pdf 56543 KB AVAILABLE Click the button or link below to register a free account.
. MAINTENANCE MANUAL INSTRUCTION BOOK 1951 350 c.c. A.J.S SPRING FRAME AND RIGID SINGLE CILINDER MODELS PRICE 2/6 NETT A J. S. M O T O R C Y C L E S Proprietors: ASSOCIATED MOTOR CYCLE LIMITED PLUMSTEAD.
WHEN CORRESPONDING REGARDING SERVICE OR SPARES ALWAYS QUOTE THE COMPLETE ENGINE NUMBER (Including all letters in it) Including Including all letters in it) all letters in it) THIS ENABLES US TO IDENTIFY THE MACHINE EACH SERIAL OF FRAMES IS NUMBERED FROM ZERO UPWARDS. MAINTENANCE MANUAL AND INSTRUCTION BOOK A. J. S 1 9 5 1 SINGLE CYLINDER MOTOR CYCLES Compiled and Issued by the Manufacturers: MOTOR CYCLES.
(Proprietors: ASSOCIATED MOTOR CYCLES LIMITED) Registered Offices: PLUMSTEAD ROAD, PLUMSTEAD LONDON, S.E.18 ENGLAND Nearest Station. 1951 A.J.S MODELS 350 MODEL 16M RIGID FRAME 350 MODEL 16MS SPRING FRAME 350 MODEL 16MC COMPETITION RIGID FRAME 350 MODEL 16MCS COMPETITION SPRING FRAME 500 MODEL 18 RIGID FRAME 500 MODEL 18S SPRING FRAME 500 MODEL 18C COMPETITION RIGID FRAME.
1951 RIGID 16M and 18 1951 SPRING 16MS and 18S 1951 RIGID C O M P E T I T I O N 16MC and 18C 1951 SPRING C O M P E T I T I O N 16MCS and 18CS. All Models—93 mm. (approx.) (365625 in.) Engine capacity, in cubic centimetres 350 Models—51/16M, 51/16MS, 51/16MC and 51/16MCS—347 Models—51/18, 51/18S, 51/18C 51/18CS—498 Brake Liners Length W i d t h Thickness Radius Quantity off. 64 to 1 50 to 1 1335 to 1.Standard Solo sprocket for Models 16M and 16MS. †Standard Solo sprocket for Models 18 and 18S. Gear ratios (models 16MC-18C) Part Fourth gear First gear Second gear (top). Solo sprocket for Model 18CS.
Ignition (magneto) Ignition point before top dead centre (with control Model Make Type Point gap in fully advanced position) Rotation 16M-16MS-18 Lucas N1-4 Anti-clock 012 in. (39°) 16MC-18C 012 in. Lucas Anti-clock ½ in. (39°). Spokes (350 and 500 rigid and spring frame models) Length Part Location Type Gauge Quantity number underhead 5 x in. Front, left side Butted 011018 (37-X-H51) 8 x 1 0 8 8 in.
Front, right side Butted 011014 (12399). CONTROLS Throttle twist grip. On right handlebar. Twist inwards to open.
When fully closed engine should just idle when hot. 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. If any adjustment is made to the rear brake pedal make certain the brake does not bind and also see there is not excessive free pedal movement before the brake comes ' on.' Illustration 1 Showing Controls Before using the machine, sit on the saddle and become familiar with the position and operation of the various controls.
DRIVING FUEL At the time of publishing this instruction book only one grade of motor fuel (Pool Spirit) is on sale, but it may be that soon the various grades of pre-war petrol will again be avail- able when the use of best quality fuel is recommended because the small amount of economy that might be considered to accrue by using the cheaper grades is more than offset by the advantages obtained by using only Number One grades. 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. 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.
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, will be quickly ruined. 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. LUBRICATION LUBRICANTS TO USE Efficient lubrication is of vital importance and it is false economy to use cheap oils and greases. We recommend the following lubricants to use in machines of our make: FOR ENGINE LUBRICATION SUMMER WINTER Mobiloil D (SAE-30) (SAE-50) Mobiloil A. FILLING THE GREASE GUN The standard grease gun consists of a barrel having a spring loaded end cap, to which is fixed a central steel piston in the shape of a long rod.
This piston fits into a small cylinder made in one with the screwed top cap, on the end of which is the cupped nozzle that fits over the grease nipples. Illustration 5 Engine Oil Circulation THE OIL TANK A N D 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 one inch from the filler cap orifice, otherwise, when starting the engine, the bulk of oil in the crankcase sump may be greater than the space available in the tank. A metal gauze strainer (secured to the feed pipe union) stands in the oil tank. 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. Illustration 6 The inlet valve guide is shown withdrawn as also is the inlet valve stem adjusting screw (with lock nut) PLAIN HOLE, TO ACCOMMODATE CYLIN- TAPPED HOLE, ACCOMMODATE DER HEAD RETAINING BOLT. NEEDLE SCREW.
GUIDE, FOR VALVE. NEEDLE SCREW, ADJUSTING OIL FEED TO INLET VALVE. GEAR BOX LUBRICATION Use one of the grades of Oils already 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. BRAKE EXPANDER LUBRICATION Grease nipple on each brake expander bush. (One on each brake cover plate.) grease sparingly. Excessive grease may impair efficiency of brakes.
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. LUBRICATION CHART Illustration 7 Lubrication Chart Tallow Location Engine Oil Locations MAIN OIL TANK. CONTROL LEVER MOVING PARTS. Grease Locations BRAKE ROD JOINTS. FRONT PROP, AND REAR STAND HINGE PINS.
FRONT CHAIN CASE. MAGNETO CHAIN CASE. MAINTENANCE SADDLE ADJUSTMENT Saddle adjustment is provided at both front and rear ends. Importance is attached to the desirability of owners selecting the adjustment most to their liking. At the front end, the adjustment consists of three evenly spaced positions for the hinge bolt, accessible only upon removal of the petrol tank. EVERY 1,000 MILES Drain at first 1,000 miles and re-fill with new oil. (1.) Oil tank Rear chain Remove and soak in molten tallow in bad weather.
(5.) Magneto chain Inject small amount of grease through nipple in magneto chain case cover (10.) Gear box Add 2 fluid ounces of specified oil. FREE SERVICE SCHEME FREE SERVICE SCHEME All owners of N E W MODELS are entitled to one FREE SERVICE A N D 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. ENGINE SERVICE ACCESS For almost all service work to the upper parts of the engine, it is necessary, in order to obtain accessibility, first, to remove the petrol tank. The two petrol taps facilitate this operation by removing the need to first drain the tank of petrol.
Illustration 8 Showing details and order of assembly, of the fuel tank fixing bolts and components. TO REMOVE THE PETROL TANK 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. 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. To replace valves:— After cleaning valve guide bores with rag smear each valve stem with clean oil and reverse procedure above.
I M P O R T A N T N O T E:— If for any reason valve springs are re- moved from their fixing block it is important to see that upon replace- ment the spring with narrow spaced. 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 circumstances should any abrasive material, such as emery, or emery cloth, be used for cleaning and polishing. The grinding is accomplished by smearing a thin layer of fine grinding paste (obtainable ready for use at any garage) on the valve face and then, after inserting the valve in the head, partially revolve, forwards and backwards, while applying light finger pressure to the head, raising the valve off its seat and turning to another position after every few movements. 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. VALVE TIMING Inlet valve timing Inlet valve opens 32° before top dead centre.
Inlet valve closes 63° after bottom dead centre. Exhaust valve timing Exhaust valve opens 65° before bottom dead centre. Exhaust valve closes 30° after top dead centre. Craftsman 917 lawn mower. (See page 92 for particulars of special timing disc graduated in degrees.) Illustration 11 Inlet Camshaft timing marks.
TAPPET ADJUSTMENT The top ends of the two long push rods have screwed extensions. These are locked in position by nuts, thereby providing tappet adjustment. The correct tappet clearances, on touring models, with valves closed and engine cold, is N I L (warm engine on competition models).
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. TO RE-TIME THE IGNITION The maximum advance is ½' (39°).
Have available a stout screwdriver, or an old type tyre lever with turned up end, and a piece of stout wire 5½' long. Before setting the ignition firing point it is essential the magneto contact breaker points are correctly adjusted. Illustration 14 The rotating oil pump plunger is here shown partially with- drawn, together with the guide screw which registers in the plunger profiled groove, thereby providing the recipro- cating movement (By courtesy of ' Motor Cycling ') D O W E L PEG, LOCATING TIMING GEAR TAPPED HOLE, ACCOMMODATE. 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. Make certain that the guide screw pin is correctly located in its groove (cut in the plunger) before tightening down otherwise serious damage will result when the engine is revolved. Illustration 15 Showing the mixing chamber with details of the pilot jet with its air adjusting screw and the throttle stop screw. 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, Messrs. Amal Ltd., Holford Works, Perry Barr, Birmingham. CARBURETTER ADJUSTMENT To ascertain if the setting is correct, 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 of the throttle, it should splutter and stop. CARBURETTER T U N I N G INFORMATION Poor idling may be due to: Air leaks.
Either at junction of carburetter and inlet port, or by reason of badly worn inlet valve stems or guides. Faulty engine valve seatings. Sparking plug faulty, or its points set too closely. 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.
TO REMOVE FRONT CHAINCASE AND CLUTCH ASSEMBLY To remove outer half of front chaincase Place tray under chaincase to catch oil. Remove exhaust pipe and silencer, as one unit. Remove nut on left end of footrest rod, push rod towards the right hand side of machine sufficiently to allow footrest for left foot to be disengaged.
TO RE-FIT THE FRONT CHAINCASE AND CLUTCH Fit back half of front chaincase by: Place on face of crankcase boss and back face of chaincase some liquid jointing compound. Ensure the spacer is in position on the centre fixing bolt.
This is located between the engine plate and the chaincase. 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.
THE CLUTCH (See Illustration 17) It should be noted that, although the basic design of the clutch fitted to 1951 models is identical to the 1950 and earlier models, most parts have been revised in detail design, and those parts are not interchangeable with those of previous years. Clutch operating lever A is moved in direction of arrow to disengage the clutch. If, to remedy clutch slip, it is necessary to screw nearly home the five nuts, this is a clear indication that, either the clutch springs have lost their strength, and/or, the fabric inserts in the clutch friction plates have worn so that they are past further useful service.
In which case, replace with new. Illustration 18 Details of clutch operating lever LEVER, OPERATING C L U T C H. 175-X-4 331-X SLEEVE, OR NUT, FOR OPERATING LEVER FORK. BALL (STEEL), OPERATING 67-X PLUNGER. 328-X CAP, COVERING SLEEVE (SCREWED TO KICK-STARTER CASE COVER).
OPERATING PLUNGER. 330-X 333-X SCREW. FRONT CHAIN ADJUSTMENT Tighten the front chain by: Slacken: Nut on right-hand side of gear box top fixing bolt. Nut on right-hand side of gear box bottom fixing bolt. Forward nut on the adjusting eye-bolt. (Two or three turns.) Remove inspection cap from front chaincase.
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 turns. 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 nuts on bolts supporting magneto platform.
Insert a screwdriver under that end of the magneto platform which is slotted and lever upwards until the chain tension is correct. FORK & FRAME SERVICE STEERING HEAD ADJUSTMENT The steering head frame races are of the floating self-aligning type and have spherical seats. Therefore they do not fit tightly in the head lug. Occasionally test the steering head for correct adjustment by exerting pressure upwards from the extreme ends of the handlebars. 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 t u b u l a r members located inside the main tubes. As w i l l be seen the aluminium sliding members operate upon steel bushes attached to the b o t t o m ends of the main tubes and also upon bakelite bushes, secured to the t o p end of t h e.
has no o t h e r source of escape but past this sleeve and the adjacent small metered bleed hole. This intentionally restricted passage causes a considerable damper effect to the recoil action.
It w i l l thus be gathered t h a t on the shock movement of the f o r k, slight damper action occurs, w i t h a greatly increased damper action on the reverse movement, b o t h actions automatically increasing in effect the more violent the movement. Unscrew the hexagon plug on top of each inner tube and slacken the lock nuts securing the damper rods attached.
Then, before removing 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. Illustration 20. NUMBER DESCRIPTION 013631 LUG, FOR HANDLEBAR A N D STEERING HEAD.
016718 BOLT, TOP, FOR FORK INNER TUBE. 010709 WASHER, PLAIN, FOR FORK INNER TUBE TOP BOLT.
010703 CAP, FOR FORK TOP COVER TUBE, TOP L O C A T I O N. 013694 TUBE, FORK COVER, TOP, RIGHT W I T H LAMP LUG. REAR SUSPENSION (Spring Frame Models) The rear wheel is mounted in a fork that is hinged just behind the gear box. The hinge has robust plain bearings lubricated from a reservoir of 1½ fluid ounces (42.6 c.c.) of engine oil which is sufficient to last almost indefinitely. Provision is, however, made for replenishment should same ever be required. Illustration 22 Showing ' Ghost ' view of ' TELEDRAULIC ' leg. 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. 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. Disconnect voltage control unit from carrier side. Only two bolts to remove.
Need to disconnect any of the electric cables. WHEELS AND BRAKES TO REMOVE FRONT WHEEL Place machine on both stands. Remove the split pin, and pin, retaining yoke end of front brake cable to the brake expander lever. Remove bolt retaining brake anchor stay to brake cover plate.
Slacken the nut on the left-hand end of front wheel spindle. Hold left-hand side of wheel tightly forward against 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, raise the hinged portion of the rear mudguard and pull wheel away from the fork ends. 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 threaded on the centre spindle in the case of the rear wheel, (Reference to Illustration 24 will make that clear.) The outer cups for the rollers are pressed into the. 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 (I) 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).
Illustration 24 Showing exploded view of hub bearing components in the order of assembly. Upper part is that of front bearings (Rigid and Spring Frame Models). Lower part is that of rear bearings (Spring Frame Model only) (Rigid Frame Models Identical except for items 28 to 32) CIRCLIP. TO DISMANTLE A REAR WHEEL BEARING These instructions need reference to the lower part of Illustration 24. Remove wheel from machine. Remove brake cover plate, with brake shoes, centre solid spindle with cams, spacers, bushes, nut and speedometer gear box. Turn to left-hand side and slacken lock nut (26).
BRAKE DRUMS The front wheel brake drum is retained to the wheel by ten countersunk 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 '. Centralise brake shoes by: Ensure the nut binding the cover plate to the wheel spindle is slightly slack. 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.
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.
Illustration 29 Showing brake rod ad- justment exhausted, in- dicating need brake thrust pin adjust- ment. (SPRING FRAME MODELS) TYRES A N D 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. 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. TYRE PRESSURES The following are correct minimum inflation pressures for specified loads per tyre: Load per tyre, 200 lb. Pressure 16 lb. Per square inch 240 lb.
ELECTRICAL SERVICE ELECTRICAL EQUIPMENT LUCAS electrical equipment is fitted and this comprises three independent electrical circuits, as follows: (1) IGNITION—Magneto, High-tension wire and Sparking plug. (2) CHARGING—Dynamo, Automatic Voltage Control Unit and Battery. (3) L I G H T I N G A N D ACCESSORIES—Lamps, Horn, Switches and wiring. IGNITION CIRCUIT A LUCAS type N1-4 magneto is fitted (Type NR1 to competition models) and the only service attention this requires is occasional lubrication of the contact breaker cam. Lubricate contact breaker cam and tappet by: Remove contact breaker as described on page 74.
Saturate, with a few drops of thin machine oil, the wick mounted in the core of its carry- ing screw B, Illustration 30. Push out of the contact breaker body the tappet B, Illustration 31, wipe it with a soft cloth, smear it with thin machine oil and then replace it. The foregoing instructions do not apply to competition models fitted with Racing Magnetos Type NR1. SPECIAL NOTE—Check the contact breaker point gap after the first one hundred miles and five hundred miles. Owing to the initial settling down, there is a tendency for the gap to alter in the first few hundred miles of use.
CHARGING A LUCAS type E3-N dynamo is fitted. It is anti-clockwise in rotation. 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 positive brush is insulated and the negative brush is earthed. TO REMOVE DYNAMO Remove Magneto chain cover, (Retained by 6 screws.) Remove nut and its washer fixing each magneto chain sprocket. Using a sprocket withdrawal tool, or wedges behind sprocket, release, in turn, each magneto chain sprocket and take them away, complete with chain. Remove timing gear cover (retained by 5 screws) taking care not to allow the two camshafts to come out of engagement with the small timing pinion. The regulator and cut-out are accurately set during manufacture. If, 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.
The specific gravity of the electrolyte indicates the state of charge of the battery. With a fully charged battery the specific gravity of the electrolyte should be 1280 to 1300. Check the gravity by means of a hydrometer, and if it is below 1150 the battery should be charged as soon as possible by the normal running of the motor cycle. LIGHTING A N D ACCESSORIES Headlamp A LUCAS type SSU-700-P headlamp is fitted. The replacement part number is 50945-A. It has a panel mounted on its top, retained by three screws, in which is the main switch and ammeter and it also supports the cable harness.
See Illustration 35. To replace the headlamp rim and light unit Lay the light unit in the rim so that the location block on the unit back 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 shell engage the projections on the inside of the back shell with the slots in the holder, press on and secure by twisting it to the right. Screwed wire connector A LUCAS screwed connector of the type shown in Illustration 37 is used in the wire connecting the positive terminal of the battery to the input side of the ammeter (the wire has yellow and black coloured sleeves) in the head lamp.
It is made up of four parts. MAIN BULB PILOT BULB AMMETER LIGHTING SWITCH DIPPER SWITCH SPEEDO ILL. HORN PUSH DYNAMO TO SPARKING PLUG SNAP MAGNETO CONNECTOR REGULATOR BATTERY BATTERY CONNECTOR (NEGATIVE EARTH) HORN TAIL LAMP Illustration 38 Wiring diagram (See page 96 for key to the cable numbers and colours.). 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: Throttle opening too large. Engine overheats may be due to: Lack of proper lubrication.
(Quality or quantity of oil.) Faulty sparking plug. Air control to carburetter out of order. Punctured carburetter float. Engine carbonised. Weak valve springs. Pitted valve seats. Worn piston rings.
Ignition setting incorrect. 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.
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 APPOINTMEN T beforehand to A V O I D DISAPPOINT- MENT. SERVICE The Service and Repair Department is situated in Burrage Grove, Plumstead, London, S.E.18. And is open on Mondays to Fridays from 8.30 a.m. To 12.55 p.m.—2.0 p.m.
It is closed on Saturdays, Sundays and National Holidays. It exists for the purposes of: (a) Giving technical assistance verbally or through the post. THE MACHINE A N D THE L AW 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 '. GUARANTEE We give the following guarantee with our motorcycles, motorcycle combinations and sidecars, which is given in place of any implied conditions, warranties or liabilities whatsoever, statutory or otherwise, all such implied conditions, warranties and liabilities being in all cases excluded.
Statement, description, condition or representation contained in any catalogue, advertisement, leaflet or other publication shall not be construed as enlarging, varying or overriding this guarantee. TOOLS AND SPECIAL EQUIPMENT TOOLS The standard tool kit, issued with each new machine, contains: 017253 Tool bag. 017114 Tyre inflator.
017007 Tyre levers. 017248 Pliers. 011188 Gudgeon pin circlip pliers. 017256 Screwdriver. 017246 Grease gun. 017249 Adjustable wrench.
017252 Sparking plug box spanner and tommy bar. BADGES Neat monogram badges are now available at a cost of 1/6, plus 6d. They can be supplied as a tie pin, as a brooch or for fitting in a button hole.
When ordering state type required. Illustration 39. ILLUSTRATIONS Illustrations Page Battery Brake adjustment, front Brake adjustment, rear (rigid frame) Brake adjustment, rear (spring frame) Brake shoe adjustment. INDEX Carburetter Service Controls Data Driving.
COLOURED IDENTIFICATION BANDS ON NUMBERED CABLES SHOWN IN THE WIRING D I A G R A M ON PAGE 84. BLUE and WHITE RED and BLACK WHITE and PURPLE YELLOW GREEN and BLACK YELLOW and BLACK PURPLE BLACK BLUE GENUINE A.
AJS DD125E-8 (2003 - 2015) Written from hands-on experience gained from the complete strip-down and rebuild of a AJS DD125E-8, Haynes can help you understand, care for and repair your AJS DD125E-8. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your AJS DD125E-8 can help maintain its resale value, save you money, and make it safer to ride. Step-by-step maintenance and repairs guides for your vehicle in two formats.
. INSTRUCTION BOOK. 1956 SINGLE CYLINDER 350 c.c. MODELS 16MS Issued by: A.J.S. MOTOR CYCLES. LONDON S.E.18 Proprietors: ASSOCIATED MOTOR CYCLES LTD. INSTRUCTION BOOK A.
J. S SINGLE CYLINDER MODELS 350 c.c. 1956 Price TWO SHILLINGS and SIXPENCE Factories: BURRAGE GROVE and MAXEY ROAD PLUMSTEAD, S.E.18 Telephone: WOOlwich Telegrams: 'ICANHOPIT, WOL-LONDON' Cables: 'ICANHOPIT, LONDON' Codes: A.B.C. 5th and 6th Edition; Bentley's; and Private Codes Registered Offices: PLUMSTEAD ROAD, PLUMSTEAD.
CONTENTS Page Carburetter Controls Data. ILLUSTRATIONS Illustrations Page A.V.C. Unit Battery Brake adjustment, front Brake adjustment, rear Brake anchorage, rear. SINGLE CYLINDER MODELS 350 c.c. Model 16MS 500 c.c.
HE MODERN MOTOR CYCLE unquestionably provides one of the most healthy, economical and pleasant means of transport. Addition by reason of its superb braking, high power to weight ratio and ease of control it is, if used with due care, one of the safest vehicles on the road.
DATA Engine Number Stamped on left hand side of crankcase Frame Number Stamped on seat lug of main frame, on right hand side (below the saddle) Bore. Gear ratios, Touring Models Fourth gear Engine sprocket size First gear Second gear Third gear (top) 15 teeth 7 t o 1 1855 to 1 1190 to 1 915 to 1 16 teeth 1732 to 1 858 to 1 656 to 1 1115 to 1.
Weight w i t h empty tanks Model Standard Trials 375 Ibs. Wheels (bearing end play) 002 in. (just a perceptible rim rock). Liugong forklift engine workshop manual. THROTTLE TWIST GRIP AIR CO NT RO L EXHAUST VALVE LIFTER. CONTROLS Refer to Illustration 1 page 8. (1) Throttle twist grip.
On right handlebar. Twist inwards to open.
When fully closed engine should Just idle when hot. Small lever on right handlebar. Pull inwards to increase air supply to carburetter. DRIVING FUEL Although various quality fuels are again available owners are advised to use only the best.
The small economy that might be considered to accrue by using the cheaper grades is more than offset by the advantages obtained by using only Number One Grades. Illustration 2 Showing the gear indi- cator drum which upon assembly is set to record various gears neutral position, as the respective figure or letter registers with index mark on the gear box shell.
Upon re-asembly, after dismantling for any pur- pose, the index disc should be correctly re-set for. 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. NOTES ON DRIVING If, at first, the lowest gear will not engage, release the clutch lever and after a second or two, make another attempt. This condition may exist in a new machine, but it tends to disappear after a little use. Always endeavour to make the movements of hand (on the clutch) and foot (on the gear pedal) as simultaneous as possible, and remember, in all gear changes, a steady pressure of the foot is desirable. LUBRICATION LUBRICANTS TO USE Efficient lubrication is of vital importance and it is false economy to use cheap oils and greases.
We recommend the following lubricants to use in machines of our make. FOR ENGINE LUBRICATION COLD EXTREME COLD above 50° F 32°.
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. Illustration 3 Engine Oil Circulation THE OIL TANK A N D FILTER The level of oil in the supply tank should never be allowed to fall below the low level mark and, upon replenishment, should not be higher than the top level mark other- wise, when starting the engine, the bulk of oil in the crankcase sump may be greater than the space available in the tank. 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 end of the oil return pipe will be noticed below the level of the filler cap orifice and the returning oil can be seen running from it. TO REMOVE T H E MAGNETIC FILTER (located in the crankcase) Incorporated with the crankcase drain plug is a powerful magnetic filter.
To remove the filter merely unscrew the plug. As the metal particles will adhere very strongly to the magnet they must be forcibly removed by wiping the magnet with a greased rag. 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. BRAKE ROD JOINT LUBRICATION A few drops of engine oil on each brake rod yoke end pin and on the threaded portion of brake rod. (One pin on yoke each end of brake rod and on bottom of front brake cable.) BRAKE PEDAL LUBRICATION Grease nipple in heel of foot brake pedal. LUBRICATION CHART The figures in diamond frames refer to parts located on the left hand side of the machine and those in circles refer to parts located on the right hand side.
Illustration 6 Lubrication Chart Engine O i l Locations Grease Locations MA I N OIL T A N K. 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. 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 grease.
Gear box Add 2 fluid ounces of specified oil. (18.) Hubs Inject small amount of grease. ENGINE SERVICE ACCESS For almost all service work to the upper parts of the engine, it is necessary, in order to obtain accessibility, first, to remove the petrol tank.
The two petrol taps facilitate this operation by removing the need to first drain the tank of petrol. Illustration 7 Details and order of assembly of the fuel tank fixing bolts and components Part Number. TO REMOVE THE PETROL TANK Close both petrol taps and remove the cap nut securing each petrol pipe banjo con- nector. Use two spanners, one to hold the tap and the other to unscrew the cap nut. Beware losing the fibre washers (4 in ail) fitted one each side of each banjo connection. Cut the wires interlacing the four fixing bolts.
DECARBONISATION Instead of the usual stipulated mileage interval between periods of decarbonisation, it is recommended that this is undertaken only when the need for same becomes apparent because of excessive pinking, loss of power or generally reduced performance. When undertaken, unless it is thought necessary to inspect the piston and rings, the cylinder barrel is best left undisturbed. Illustration 8 Application of valve spring compressor VALVE SPRING COMPRESSOR TOOL. COLLET, FOR VALVE. COLLAR, FOR VALVE SPRING. OIL PASSAGE FROM ROCKER BOX TO INLET VALVE GUIDE.
COLLAR, FOR VALVE SPRING. BOLT THROUGH TOOLS AND COILS OF SCREW WITH LOCK NUT ADJUSTING VALVE SPRING. 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 circumstances should any abrasive material, such as emery, or emery cloth, be used for cleaning and polishing. The grinding is accomplished by smearing a thin layer of fine grinding paste (obtainable ready for use at any garage) on the valve face and then, after inserting the valve in the head, partially revolve, forwards and backwards, while applying light finger pressure to the head, raising the valve off its seat and turning to another position after every few movements. Remove One gudgeon pin circlip. It is immaterial which circlip is removed.
Use special pliers included in tool kit. Gudgeon pin by pushing, it out of piston.
Take away piston. NOTE—The gudgeon pin is an easy sliding fit in both piston and connecting rod small- end bush.
VALVE T I M I N G, Standard models t aken w i t h valve 0 0 1 ' off its seat Inlet valve timing Inlet valve opens 36° before top dead centre—350 c.c. Inlet valve opens 18° before top dead centre—500 c.c. Inlet valve closes 51°. TAPPET ADJUSTMENT The top ends of the two long push rods have screwed extensions. These are locked in position by nuts, thereby providing tappet adjustment. The correct tappet clearances, on all models, with valves closed and engine warm (not hot) is NIL.
This means the push rods should be free enough to revolve and, at the same time, there should be no appreciable up and down play. TO RE-TIME T H E I G N I T I O N The normal advance is 39° (½'). Have available a stout screwdriver, or an old type tyre lever with turned up end, also a small rod or stout wheel spoke 5½' long.
Before setting the ignition firing point it is essential the magneto contact breaker points are correctly adjusted. TO REMOVE A N D REPLACE THE OIL PUMP PLUNGER IF A N D W H E N NECESSARY O N L Y 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. Illustration 12 The rotating oil pump plunger is here shown in situ, together with the guide screw which registers in the plunger profiled groove, thereby providing the recipro- cating movement DOWEL PEG, LOCATING TIMING GEAR SCREWED BODY ACCOMMODAT E COVER. THE OIL PUMP PLUNGER GUIDE PIN. CARBURETTER SERVICE The information given in this section includes all that will normally be required by the average rider.
For further details, particularly those connected with racing and the use of special fuels, we refer the enquirer to the manufacturers of the carburetter, Amal Ltd., Holford Road, W i t t o n, Birmingham, 6. Illustration 13 Carburetter details in assembly order. T W I S T 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. 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 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. 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 anyone of the depressions on its underside engaging with the conical end of the spring loaded plunger.
TO RE-FIT THE FRONT CHAINCASE AND CLUTCH Fit back half of front chaincase by: Place on face of crankcase boss and back face of chaincase some liquid jointing compound, ' Wellseal ' recommended. Ensure the spacer Is in position on the centre fixing bolt. This is located between the engine plate and the chaincase. 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. CLUTCH SPRING ADJUSTMENT If clutch slip occurs the most probable cause is either incorrect cable adjustment or absence of free movement of the internal clutch lever.
If both are found to be correct the clutch spring adjusting nuts may require adjustment. To obtain access to clutch spring adjusting nuts, remove the domed clutch cover (secured by eight screws.) W it h the slotted driver provided on one of the thin spanners in the tool kit, screw each. C L U T C H OPERATING MECHANISM ADJUSTMENT Correct adjustment of the clutch operating mechanism is of the utmost importance and the following instructions must be carefully observed. In order to understand the method of clutch withdrawal a study of illustrations 14 and 15 should be made. FRONT C H A I N ADJUSTMENT Refer to Illustration 16 Remove engine plate cover.
Slacken the nut of bolt (5). Slacken the nut (3). Screw bolt (1) in to the crosshead (2) to take up slack in the chain. Pull on the rear chain to move the gearbox, and tighten the front chain. NOTES ON REAR CHAIN ADJUSTMENT Before tightening the rear chain always first check front chain adjustment and if attention is necessary adjust the front chain first. This is because adjustment of the front chain disturbs that of the rear chain.
Therefore, after making adjustment to the tension of the front chain, always afterwards check that of the rear chain. 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.
FORK & FRAME SERVICE STEERING HEAD ADJUSTMENT The steering head frame races are of the floating self-aligning type and have spherical seats. Therefore they do not fit tightly in the head lug. Occasionally test the steering head for correct adjustment by exerting pressure upwards from the extreme ends of the handlebars. Illustration 17 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 of the. Study guide template.
has no other source of escape but past this sleeve and the adjacent small metered bleed hole. This intentionally restricted passage causes a considerable damper effect to the recoil action.
It will thus be gathered that on the shock movement of the fork, slight damper action occurs, with a greatly increased damper action on the reverse movement, both actions automatically increasing in effect the more violent the movement. Illustration 18 Exploded view of Teledraulic Forks. WASHER, LEATHER, FOR FORK SPRING TOP SEATING.
BUFFER, RUBBER, FOR FORK INNER TUBE SPRING, M A I N, FOR FRONT FORK. BUFFER, RUBBER, FOR FORK INNER TUBE. BUFFER, RUBBER, FOR FORK INNER TUBE. WASHER, LEATHER, FOR FORK SPRING BOTTOM SEATING. EXTENSION, FOR FORK SLIDER. Remove the handlebar half clip and lay the handlebars, complete with controls, upon a pad on top of the petrol tank.
Detach the front brake cable from the forks. (First remove the slotted yoke end and then completely unscrew the cable adjuster.) Remove the rubber grommetts and top bolts at the top of each inner tube, raise same and slacken the lock nuts securing the damper rods attached.
REAR SUSPENSION The rear wheel is mounted in a fork that is hinged just behind the gear box. The hinge has robust plain bearings lubricated from a reservoir of 1½ fluid ounces (42.6 c.c.) of heavy gear oil which is sufficient to last almost indefinitely. Provision is, however, made for replenishment should same be required. Illustration 20 ' G h o s t ' view of ' T E L E D R A U L I C ' leg. To check oil content of ' TELEDRAULIC ' leg and top-up: Dealing with one leg at a time, remove top securing bolt, taking care to observe the location of the spacing washers on it. Remove bottom securing bolt and take away the leg. TO REMOVE THE OIL TANK Remove the Twinseat Remove the frame shield.
It is held in position by two large knurled and slotted screws. Remove the oil tank drain plug and empty the tank. Disconnect the oil feed and return pipes from the bottom of the tank by sliding the rubber connectors down the pipes. WHEELS AND BRAKES TO REMOVE FRONT WHEEL Place machine on centre stand. Remove the split pin, and pin, retaining yoke end of front brake cable to the brake expander lever. Remove bolt retaining brake anchor stay to brake cover plate. Slacken the nut on the left-hand end of front wheel spindle.
REAR WHEEL REMOVAL, Trials model Place machine on the centre stand. Disconnect: speedometer drive; chain; rear brake rod. Remove wheel spindle nut (21), washer (20), and distance piece (19). Gently tap out the spindle. Distance piece (18) will fall as spindle is withdrawn. Remove the wheel from the fork ends by twisting it sideways to release the brake anchorage plate, and then pull out of the fork ends. Illustration 22 R e a r W h e e l B r a k e A n c h o r a g e 1 BRAKE ANCHORAGE BOSS.
3 FIXING BOLT. WHEEL BEARINGS A N D ADJUSTMENT The wheel bearings are of taper roller type.
TO DISMANTLE FRONT WHEEL BEARINGS Remove wheel from machine. Remove nut securing brake cover plate, withdraw cover plate with brake shoes, etc. Then remove brake cover positioning nut and washer.
Then turn to the right-hand side of wheel, remove adjusting ring lock nut and lift off cover disc. TO DISMANTLE REAR WHEEL BEARINGS With wheel still in situ first of all slacken the nut (16), securing the speedometer drive gear box. Then remove the wheel from cycle when the above nut should be removed and the speedometer gear box withdrawn. (If wheel is of non-detachable type remove the brake cover plate and withdraw the solid centre spindle together with all spacers attached).
Reassembly is carried out in exactly reverse order, care being necessary after pressing in the brake side bearing ring sufficiently far to permit fitting the circlip, to then force the ring back until seal cup (5) is tightly in contact with the retaining circlip before proceeding with further assembly. 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. BRAKE SHOES The front and rear brake shoes, springs and expanders are interchangeable. The two shoes in each brake are N O T 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. When a brake cover plate has been disturbed, it is advisable, upon re-assembly, to centralise the shoes in the brake drum to ensure equal pressure to each.
In the case of the front wheel this is best done before re-fitting the wheel to the machine, but in the case of the rear wheel it is best done after re-fitting. 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. ELECTRICAL SERVICE IGNITION A Lucas magneto type SR-1 with automatic advance and retard is fitted to all Touring models. A Lucas racing magneto is fitted to all Competition models. On the SR-1 magneto fitted to all Touring models, the contact breaker is exposed by removing the moulded end cover secured with 3 captive screws.
SPARKING PLUG The K.L.G. Type FE80 ' Corundite ' Plug is fitted to all models. It has a thread of 14 mm.
And the reach is ¾'. The point gap is 020 to 022'. Check the point gaps every time the engine is decarbonised and, if necessary, re-set the points.
See that the plug is fitted with its external seating washer. DYNAMO A LUCAS type E3-N dynamo is fitted. It is anti-clockwise in rotation. 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.
TO REMOVE THE DYNAMO Remove the left side foot rest arm. Place a tray under primary chaincase to catch the oil. Remove chaincase band binding screw and remove metal band and also endless rubber band.
Remove nut and washer in centre of chaincase when outer half can be taken away. Remove spring circlip, locking plate and nut securing dynamo sprocket and withdraw sprocket with a suitable tool.
Normally, during day-time running, when the battery is in good condition, the dynamo gives only a trickle charge, so that the ammeter reading will seldom exceed 1 to 2 amperes, i.e. Half to one division on scale. The cut-out is an automatic switch which is connected between the dynamo and the battery. The specific gravity of the electrolyte indicates the state of charge of the battery. Wit h a fully charged battery the specific gravity of the electrolyte should be 1280 to 1300. Check the gravity by means of a hydrometer, and if it is below 1150 the battery should be charged as soon as possible by the normal running of the motor cycle.
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. 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 ' D A T A.
' Horn The horn push switch, situated on the left handlebar. Fuses There are no detachable fuses in LUCAS motor cycle electrical equipment. Illustration 35 Wiring diagram. 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.
Engine overheats may be due to: Lack of proper lubrication. (Quality or quantity of oil.) Faulty sparking plug. Air control to carburetter out of order. Punctured carburetter float. Engine carbonised. Weak valve springs.
Pitted valve seats. Worn piston rings.
Ignition setting incorrect. 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. SERVICE REPAIRS REPAIRS The instructions regarding repairs should be clear and definite, otherwise the cost may be greater than that expected. We shall be pleased to give estimates for repairs if parts are sent to us for that purpose.
Engine Manual For A Cat C13
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. SERVICE The Service and Repair Department is situated in Burrage Grove, Plumstead, London, S.E.18, and is open on Mondays to Fridays from 8.30 a.m. To 12.55 p.m—2.0 p.m. It is closed on Saturdays, Sundays and National Holidays. It exists for the purposes of: (a) Giving technical assistance verbally or through the post. THE MACHINE A N D THE L AW 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 '. FREE SERVICE SCHEME FREE SERVICE SCHEME All owners of N E W MODELS are entitled to one FREE SERVICE A N D 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.
SPARE PARTS ENUINE SPARE PARTS purchased from an Authorised Dealer, or from the Factory, are identical with the parts originally built into your motorcycle. By using them you are assured that they will fit accurately and give satisfactory service. SPARES STOCKISTS For the convenience of owners Spares Stockists are appointed for most districts. TOOLS AND SPECIAL EQUIPMENT TOOLS The standard tool kit, issued with each new machine, contains: 017253 Tool bag. 017114 Tyre inflator. 017007 Tyre lever.
017248 Pliers. 011188 Gudgeon pin circlip pliers. 017256 Screwdriver. 017246 Grease gun. 017249 Adjustable wrench.
017252 Sparking plug box spanner and tommy bar. TOOL KIT Illustration 37. GUARANTEE We give the following guarantee with our motorcycles, motorcycle combinations and sidecars, which is given in place of any implied conditions, warranties or liabilities whatsoever, statutory or otherwise, all such implied conditions, warranties and liabilities being in all cases excluded. 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 '.
Engine Manual For A Ajs Stormer
INDEX Page Page Data Air filter Decarbonisation 72,73 A.V.C. Driving notes 41,47 Dynamo chain Badge. Page Page Law, the 82,83 Service Lighting Sparking plug Lubricants Sparking plug removal Lubrication chart Speedometer, lubrication.
Comments are closed.
|
AuthorWrite something about yourself. No need to be fancy, just an overview. ArchivesCategories |