Model:
Lightweight & Heavyweight Motorcycles
Years Covered By Manual:
1957-1966
Lightweight Models:
G2, G2S, G2CS, G2CSR, 14, 14S, 14CS, 14CSR, G5, 8
Heavyweight Models:
G3, G3C, G3S, G3LS, G3LCS, G80, G80S, G80CS, TCS, 16, 16S, 16C, 16CS, 16MS, 16MC, 16MCS, 18, 18S, 18CS
Target Audience:
DIY enthusiasts and professional mechanics working on AJS & Matchless motorcycles
Advantage:
Comprehensive coverage, digital convenience, cost-effectiveness compared to older paper manuals
Features:
Hundreds of pages, detailed illustrations and photos, step-by-step instructions, all styles covered
Benefit:
Save money on repairs, empower owners to perform maintenance and repairs, increase vehicle knowledge
Primary Coverage:
Service, Repair, Maintenance, Overhaul
Estimated Page Count:
Hundreds (as stated, specific number not provided)
Type:
Factory Service Repair Manual
Completeness:
Complete official full factory service repair manual.
Engine:
Engine design changes, servicing, overhaul, lubrication, recommended lubricants
Transmission Clutch:
Gearbox and Clutch operations
Suspension:
Front forks, Rear suspension units
Frame Wheels Brakes:
Frame, Wheel bearings, Wheels and Brakes
Electrical:
Wipac alternator, Wipac electrical service, Lucas electrical service, Lucas coil ignition, Magneto, Dynamo, Wiring Diagrams
Fuel System:
Carburettor (servicing and tuning implied)
Transmission Drivetrain:
Transmission (specific details likely covered within gearbox section)
Maintenance:
Periodical maintenance, routine servicing
Repair Overhaul:
Step-by-step instructions based on complete disassembly, engine overhaul, gearbox and clutch repair, suspension component replacement, brake servicing
Diagnostics Troubleshooting:
Implied through detailed service procedures and electrical system coverage
Wiring Diagrams:
Detailed wiring diagrams for various electrical configurations are included.
Technical Data:
Includes essential technical data for all covered models.
Carburetor Service:
Detailed procedures for servicing and tuning of carburetors.
Frame And Suspension Repair:
Instructions for frame maintenance, wheel bearing replacement, and suspension unit servicing.
Electrical Troubleshooting:
Guidance for troubleshooting issues with Wipac and Lucas electrical components, ignition, and charging systems.
Depth:
Comprehensive, covering all aspects from basic maintenance to complete rebuilds, suitable for both DIY and experienced mechanics
Engine Types:
2-stroke and 4-stroke single-cylinder engines
Displacement Lightweight:
250 c.c. and 350 c.c.
Displacement Heavyweight:
350 c.c., 500 c.c., 600 c.c.
Carburetion:
Models typically utilized Amal or similar British motorcycle carburetors (details in manual)
Valvetrain:
Overhead Valve (OHV) for most 4-strokes, piston port for 2-strokes (details in manual)
Lubrication System:
Total Loss or Combined Lubrication systems depending on model and year (details in manual)
Crash Test Data:
N/A (Motorcycle era predates standardized crash testing)
Braking System:
Drum brakes (front and rear) across most models
Lighting:
Headlight, taillight, brake light, indicators (where fitted)
Routine Maintenance:
Spark plug checks, chain lubrication, general lubrication, brake adjustments (specific intervals in manual)
Engine Oil:
Specific grades and types for engine lubrication (e.g., SAE 20W/50, or specialized motorcycle oils – refer to manual)
Gearbox Oil:
Specific gear oil recommendations (likely SAE 90 or similar, refer to manual)
Fork Oil:
Specific viscosity and type for front fork damping (refer to manual)
Common Wear Items:
Gaskets, seals, clutch plates, primary drive chain, wheel bearings, electrical contacts, carburetor jets
Typical Failures:
Oil leaks (especially from engine cases and gearbox), electrical contact issues, ignition timing problems, carburetor tuning sensitivity
