Target Audience:
Owners, mechanics, and DIY enthusiasts of AJS Heavyweight 500 cc motorcycles from 1957-1966.
Documentation Style:
Step-by-step explanations with pictorial diagrams, drawings, and photos.
User Friendliness:
Prepared with simple explanations to assist even novice mechanics.
Safety Emphasis:
Includes DANGER, CAUTION, and NOTE remarks for safe operation and to prevent damage.
Resource Type:
Indispensable resource for maintaining and restoring AJS Heavyweight 500 cc motorcycles.
Download Benefit:
Instant download delivery provides immediate access to vital repair information.
Market Segment:
Classic British motorcycle market, appealing to enthusiasts of mid-century British engineering.
Engine Overhaul:
Complete disassembly, assembly, and adjustment procedures for the 500cc engine.
Transmission Service:
Detailed instructions for gearbox removal, repair, and maintenance.
Electrical System:
Wiring diagrams, troubleshooting, and repair for ignition, lighting, and charging systems.
Chassis And Suspension:
Information on forks, rear suspension, frame, and wheel assembly.
Braking System:
Repair and adjustment procedures for drum brakes.
Fuel System:
Carburetor tuning, fuel tank, and fuel line maintenance.
Troubleshooting:
Systematic approach to diagnosing common problems.
Maintenance:
Regular servicing, lubrication, and adjustments.
Repair:
Step-by-step instructions for component repair and replacement.
Disassembly Assembly:
Detailed guidance for taking apart and reassembling various vehicle components.
Technical Specifications:
Torque values, clearances, and wear limits.
Depth Of Coverage:
Comprehensive, from routine maintenance to complete engine rebuilds, with detailed illustrations.
Completeness Statement:
100% complete and intact, no missing or corrupt pages/sections.
Detailed Illustrations:
Includes detailed illustrations, exploded diagrams, drawings, and photos for all procedures.
Pictorial Diagrams:
Extensive use of pictorial diagrams to simplify complex procedures.
Technical Notes:
Contains special notes, important points, service data, and precautions.
Factory Specifications:
Provides factory specifications and allowable limits for adjustments and measurements.
Wear Limits:
Specific wear limits for components are provided to guide repair decisions.
Tightening Torques:
Comprehensive torque charts for all threaded connections and fasteners.
Construction Function Info:
Includes information on the construction and function of systems before detailing repair procedures.
Diagnostic Information:
Diagnostic information is included where necessary for troubleshooting.
Engine Type:
Air-cooled, single-cylinder, four-stroke (typical for AJS 500cc models of the era).
Displacement:
Approximately 500 cc (exact specifications to be found within the manual).
Horsepower:
Not specified in product information, but typically in the 25-35 HP range for this era and displacement.
Torque:
Not specified in product information, but focus on low-end grunt for classic British singles.
Carburetor Type:
Likely Amal or similar concentric/monobloc carburetor (details in manual).
Fuel Type:
Leaded gasoline (typical for the era, specific octane may be detailed).
Oil Change Interval:
Typically every 1000-1500 miles, detailed in manual.
Valve Adjustment Interval:
Often at oil change intervals or every 2000-3000 miles, specific to manual.
Engine Oil Type:
Viscosity grade like SAE 20W/50 or similar, specific oil type (e.g., mineral, semi-synthetic) and capacity in manual.
Gearbox Oil:
Specific lubricant type and quantity for the gearbox, detailed in manual.
Fork Oil:
Specific viscosity and quantity for front forks, detailed in manual.
Brake Fluid:
Not applicable as typically drum brakes using mechanical actuation (details on cable lubrication may be present).
Common Wear Points:
Valve guides, piston rings, gearbox components, and electrical connections are common wear points on vintage bikes.
Carburetor Tuning:
Carburetors require regular tuning for optimal performance and fuel economy.
Electrical Reliability:
Ageing wiring looms and components can lead to intermittent electrical issues.
Frame Integrity:
Regular inspection of frame and welds for stress cracks is recommended.
Lighting System:
Lucas electrical components can be prone to issues with age; manual provides troubleshooting.
Periodic Maintenance Chart:
Included for systematic servicing at specific mileage or time intervals.
Special Service Tools:
References specific AJS service tool numbers for specialized repair operations.
Manufacturer Origin:
Associated Motorcycles (AMC) group, UK.
Model Significance:
AJS Heavyweights were known for their robust construction and reliable performance in the post-war era.
Production Period Details:
Covers a significant decade in British motorcycle development, incorporating evolving designs and technologies.
