Model:
Lightweight 350 cc
Production Years Covered:
1958, 1959, 1960, 1961, 1962, 1963, 1964
Engine Code Designation:
Model 18CS / Model 18S (depending on specific variant, 350cc OHV single)
Target Audience:
Mechanics and DIY enthusiasts undertaking maintenance, repairs, and restoration of 1958-1964 AJS Lightweight 350 cc motorcycles.
Manual Value Proposition:
Provides essential, detailed technical information for servicing and repairing a classic motorcycle, enabling owners and technicians to maintain the vehicle effectively and preserve its operational integrity and value.
Illustration Quality:
Features detailed illustrations, exploded diagrams, drawings, and photos to guide users through service procedures.
Clarity Of Instruction:
Explanations are simplified for ease of understanding, allowing even less experienced personnel to perform satisfactory after-services.
Completeness:
Stated as 100% complete and intact, with no missing or corrupt pages/sections.
Coverage Description:
Comprehensive repair and service for the AJS Lightweight 350 cc motorcycle covering the specified years. Includes maintenance, adjustments, troubleshooting, removal, installation, disassembly, and assembly of all major components and systems.
Manual Type:
Workshop Service Repair Manual
Engine System:
Detailed coverage of the 350 cc OHV single-cylinder engine, including top-end (cylinder head, valves, camshaft), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling (air-cooled), ignition system (magneto/coil), and fuel system (carburetor).
Transmission System:
Comprehensive instructions for the gearbox (likely a 4-speed), including clutch operation, gear shifting mechanisms, lubrication, and potential repairs.
Suspension System:
Information on front fork (telescopic) and rear suspension (swingarm with shock absorbers), including maintenance, adjustments, and potential rebuild procedures.
Braking System:
Details on front and rear brake systems (likely drum brakes), including adjustment, lining replacement, and servicing.
Electrical System:
Guidance on the lighting system, ignition wiring, battery maintenance (if applicable), and potential troubleshooting of electrical faults.
Chassis And Bodywork:
Procedures for frame inspection, wheel maintenance, seat and tank removal/installation, and general body component servicing.
Maintenance:
Periodic maintenance schedules, lubrication points, chain adjustment, brake adjustments, tire pressure checks, and general cleaning procedures.
Troubleshooting:
Systematic troubleshooting guides for common engine performance issues, starting problems, electrical faults, and operational anomalies.
Repair And Rebuild:
Step-by-step instructions for engine disassembly, component inspection, wear limit specifications, and reassembly for major engine and transmission components.
Removal And Installation:
Detailed procedures for removing and installing various parts and assemblies, such as the engine, gearbox, forks, wheels, and body panels.
Technical Depth:
Comprehensive, covering basic maintenance to in-depth engine and transmission rebuilds. Includes detailed diagnostic information, service data, special tool requirements, and factory specifications.
Engine Type:
4-stroke, OHV (Overhead Valve) Single Cylinder
Displacement:
350 cc (approx. 21.3 cubic inches)
Bore X Stroke:
Exact figures would be detailed within the manual, but typical for a 350cc OHV single of this era.
Cooling System:
Air-cooled
Horsepower Output:
Specific figures would be in the manual, generally in the range of 18-22 bhp depending on tune.
Torque Output:
Specific figures would be in the manual, crucial for understanding engine responsiveness.
Carburetor Type:
Typically Amal concentric carburetors (e.g., 376/375 series) or similar British carburetion of the era. Specific model would be detailed.
Fuel Type:
Petrol (Gasoline), likely requiring leaded fuel or appropriate additives for modern use if the engine is not modified.
Oil Type:
Specific viscosity grade (e.g., SAE 20W50 or similar) and type (e.g., classic motorcycle oil withZDDP) would be detailed. Likely a wet sump system.
Ignition Type:
Typically Lucas magneto ignition or a coil ignition system with battery and dynamo/alternator for charging. Specific setup would be detailed.
Transmission Type:
Constant mesh, 4-speed manual gearbox
Gear Ratios:
Specific ratios for each gear would be provided in the manual, crucial for performance tuning and diagnosis.
Clutch Type:
Wet multi-plate clutch, operated by cable.
Transmission Lubrication:
Gearbox oil specification and capacity would be detailed. Often shared oil with the engine in vintage British motorcycles.
Wheelbase:
Typical for a 350cc roadster of the era, exact specification within manual.
Dry Weight:
Generally in the region of 300-350 lbs (136-159 kg), specific figure would be in the manual.
Kerb Weight:
With all fluids and ready to ride, would be slightly higher than dry weight.
Safety Certification:
Not applicable in the modern sense for vintage motorcycles, but the manual covers safe operating procedures.
Braking System Type:
Drum brakes front and rear, likely with rod or cable actuation. Adjustment and maintenance covered.
Frame Construction:
Typically a steel duplex cradle frame, providing structural integrity. Frame inspection and repair covered.
Lighting System:
Headlight, taillight, brake light, and potentially turn signals. Electrical system coverage includes this.
Oil Change Interval:
Detailed in the manual, typically every few thousand miles or annually for vintage bikes.
Valve Adjustment Interval:
Crucial for OHV engines. Intervals would be specified, often requiring periodic checks and adjustments.
Spark Plug Replacement:
Recommended interval for optimal ignition performance.
Engine Oil Viscosity:
Typically SAE 20W50 or similar viscosity for air-cooled engines of this era. ZDDP content is important.
Gearbox Oil Type:
If separate from engine oil, a specific gear oil would be recommended. Often shared.
Brake Fluid Type:
Likely DOT 3 or DOT 4 for drum brake systems (if hydraulic), or mineral oil if it's a cable/rod actuated system without hydraulic assistance. Manual would specify.
Typical Wear Items:
Cam followers, valve guides, piston rings, clutch plates, and gearbox components are common wear items on vintage motorcycles.
Electrical Reliability:
Lucas electrical components of this era, while iconic, could be prone to wear and require careful maintenance. Wiring insulation degradation over time is also common.
Carburetor Tuning:
Amal carburetors require precise tuning for optimal performance and can be sensitive to air leaks or wear.
Gasket Seals:
Aging rubber and cork gaskets can lead to oil leaks, requiring replacement during servicing.
Manufacturer Heritage:
AJS (Associated Motor Cycles) was a prominent British motorcycle manufacturer with a long history dating back to the early 20th century, known for its sporting and road-going motorcycles.
Model Lineage:
The 'Lightweight' designation implies a specific chassis or engine configuration within the AJS 350cc range, likely emphasizing manageability and versatility. The 350cc OHV single was a staple engine size for many British manufacturers during this period.
Manufacturing Era:
Produced during the transition period of British motorcycle manufacturing, leading up to significant industry changes.
Brand Awards:
AJS motorcycles were historically competitive in racing and achieved many accolades for their performance and reliability in their time.
Owner Satisfaction:
High owner satisfaction for enthusiasts of classic British motorcycles, valuing their character and mechanical simplicity.
Manual Quality Certification:
Described as '100 percents COMPLETE and INTACT'.
