AJS MATCHLESS Single 1957-1966 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 135016

Tags: 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 AJS Matchless MATCHLESS Single Motorcycle Motorcycles

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Description

This manual covers the AJS Matchless Single motorcycle models produced between 1957 and 1966. These British-manufactured single-cylinder machines were renowned for their robust engineering, reliability, and straightforward design, making them popular choices for riders seeking dependable transportation and a rewarding mechanical experience. The AJS Matchless Single represents a significant chapter in motorcycle history, offering a blend of classic styling and functional performance characteristic of its era. This comprehensive Service and Repair Manual in English provides detailed guidance for the maintenance and repair of your AJS Matchless Single. It encompasses essential areas such as engine overhaul, lubrication, carburettor servicing, gearbox and clutch maintenance, chassis components including forks, suspension, wheels, and brakes, as well as the electrical systems managed by components. With step-by-step procedures, technical specifications, and troubleshooting advice, this manual is an invaluable resource for owners and technicians aiming to preserve the performance and longevity of these classic motorcycles.

🏷️ Basic Information

Identification

Make:

Model:

Matchless Single

Generation

Production Years:

1957-1966

👋 Introduction

Market Position

Target Audience:

Owners of AJS Matchless single-cylinder motorcycles from 1957-1966 seeking to perform maintenance and repairs themselves or understand workshop procedures.

Competitive Analysis

Manual Value Proposition:

Offers significant cost savings for owners by enabling DIY repairs, leveraging the same information used by professional garages.

Key Features

Content Highlight:

Includes detailed illustrations, diagrams, technical specifications, and step-by-step explanations, making complex procedures accessible with basic mechanical knowledge.

📋 Manual Details

Coverage Areas

Primary Focus:

Service and Repair

Page Count

Estimated Count:

Detailed sections suggest a comprehensive manual, likely exceeding 300 pages when compiled and formatted for print.

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Printable (Individual Files)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, lubrication, recommended lubricants, engine design changes, carburettor servicing.

Transmission Systems:

Gearbox and Clutch overhaul and servicing, Transmission systems.

Chassis Systems:

Front forks, Rear suspension units, Frame inspection and repair, Wheel bearings, Wheels and Brakes.

Electrical Systems:

Wipac alternator, Wipac electrical service, Lucas electrical service, Lucas coil ignition, Magneto operation and service, Dynamo maintenance, Wiring diagrams.

Procedures Included

Maintenance Procedures:

Periodical maintenance, lubrication, fluid checks, brake adjustments, chain adjustment, ignition timing checks.

Repair Procedures:

Complete engine overhaul, gearbox rebuild, clutch replacement, suspension overhaul, brake system repairs, electrical component troubleshooting and replacement, carburettor tuning.

Diagnostic Procedures:

Troubleshooting common issues related to engine performance, electrical faults, braking, and suspension using provided diagrams and technical data.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from routine maintenance to complete engine and component overhauls, suitable for both amateur and professional mechanics.

📊 Manual Specifications

File Format

Digital Format:

Likely PDF or similar digital format, with individual files allowing for selective printing.

Print Quality

Print Recommendation:

High-quality printing recommended for clarity of diagrams and illustrations, especially for technical data and wiring schematics.

Binding Type

Binding Suggestion:

Spiral binding or three-ring binder recommended for ease of use and page laying flat during work.

Paper Type

Paper Recommendation:

Durable paper stock advised to withstand workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke (typical for AJS Matchless singles of the era, specific displacement varies by model).

Performance

Typical Power Output:

Varies by displacement, but typically in the range of 15-30 bhp for common single-cylinder models of the period (e.g., 250cc, 350cc, 500cc).

Fuel System

Carburetor Types:

Likely utilizes common British motorcycle carburetors of the era, such as Amal concentric or Monobloc, with specific tuning and maintenance procedures detailed.

🔧 Transmission

Standard

Transmission Type:

Likely a pre-unit construction, four or five-speed gearbox, integrated with the engine or as a separate unit bolted to the crankcase.

Optional

Clutch Type:

Wet multi-plate clutch is a common configuration for motorcycles of this era.

Features

Gear Shifting Mechanism:

Right-hand side, foot-operated gear shift lever with a heel-and-toe mechanism or a single lever.

📐 Dimensions

Exterior

Wheelbase:

Varies by specific model but typically in the range of 53-57 inches (1346-1448 mm).

Weights

Dry Weight:

Typically ranges from 300-400 lbs (136-181 kg) depending on the specific model and engine size.

🛡️ Safety Features

Ratings

Safety Features Era:

Reflects the safety standards of the late 1950s to mid-1960s. Focus on mechanical integrity and basic braking systems.

Active Features

Braking System:

Drum brakes (front and rear) are standard. Maintenance and adjustment procedures for optimal performance will be covered.

Passive Features

Frame Construction:

Robust steel frame designed for durability and rider stability.

💡 Technology Features

Infotainment

Entertainment Systems:

N/A (focus is on mechanical and electrical systems, no electronic infotainment).

Driver Assistance

Assistance Features:

N/A (focus is on mechanical and electrical systems, no electronic driver assistance).

Connectivity

Connectivity Features:

N/A (focus is on mechanical and electrical systems, no electronic connectivity).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 1,000-2,000 miles (1,600-3,200 km), depending on operating conditions and specific engine lubrication system.

Fluid Specifications

Engine Oil Type:

The manual will specify appropriate mineral-based motorcycle oils, likely SAE 20W/50 or 30, potentially with a focus on specific additives suitable for older engines.

Gearbox Oil Type:

Specific gearbox oil grades (e.g., SAE 80 or 90 gear oil) will be detailed, separate from engine oil if applicable.

Known Issues

Common Wear Points:

Valve seat wear, cam chain tensioner issues (if applicable), oil seal leaks, gearbox bearing wear, and Amal carburetor jetting or float bowl issues.

Periodic Maintenance

Typical Tasks:

Spark plug inspection/replacement, ignition timing adjustment, valve clearance checks, chain lubrication and adjustment, brake shoe wear checks, and general fastener tightening.

📚 Vehicle History

Brand Heritage

Manufacturer:

Associated Motorcycles (AMC), which also produced the Norton brand. AJS and Matchless were distinct brands under AMC.

Model Evolution

Product Line Context:

The 'Single' designation covers a range of AJS and Matchless models powered by single-cylinder engines, popular for their simplicity, reliability, and affordability.

Production

Manufacturing Origin:

United Kingdom

🏆 Awards & Recognition

Recognitions

Historical Awards:

While specific awards for individual models from this era are not readily documented, AJS and Matchless were respected brands in their time, known for competitive success in various motorsport events.