Model:
Heavyweight 500 cc
Production Years Covered:
1957, 1958, 1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966
Engine Type:
500 cc OHV Vertical Twin (likely G50/RGS/G11/G12 variants)
Target Audience:
Mechanics and DIY enthusiasts for Matchless Heavyweight 500cc motorcycles.
Manual Value Proposition:
Provides comprehensive, step-by-step procedures and technical data to ensure accurate and efficient repair and maintenance.
Ease Of Use:
Simple explanations, easy-to-read reference, suitable for personnel with varying experience levels.
Instant Access:
Immediate download upon purchase, facilitating prompt repair work.
Technical Accuracy:
Based on latest product information available at the time of publication approval, ensuring accuracy of specifications and procedures.
Engine Systems:
Engine overhaul, top-end components (cylinder head, valves, piston), bottom-end components (crankshaft, connecting rods, gearbox integration), lubrication system, cooling system (air-cooled), ignition system, fuel system (carburetor and fuel delivery).
Transmission Systems:
Gearbox disassembly, assembly, maintenance, lubrication, and troubleshooting.
Chassis Systems:
Frame, front forks (suspension, damping), rear suspension (shock absorbers, swingarm), wheel bearings, steering head bearings, braking systems (drum brakes), controls (throttle, clutch, brake levers).
Electrical Systems:
Wiring diagrams, lighting, charging system (generator/alternator), ignition coil, battery, horn.
Bodywork And Fittings:
Fuel tank removal/installation, seat, fenders, instrument cluster, levers, cables.
Maintenance Procedures:
Regular servicing, lubrication points and schedules, basic adjustments, cleaning procedures.
Repair Procedures:
Engine rebuilds, transmission repairs, suspension overhauls, brake servicing, electrical component replacement.
Troubleshooting:
Diagnosis of common problems, fault finding for engine, transmission, and electrical issues.
Disassembly And Assembly:
Detailed step-by-step instructions for component removal and reinstallation.
Adjustments:
Valve clearance, ignition timing, carburetor tuning, clutch and brake lever adjustments.
Diagnostic Capability:
Advanced diagnostics for mechanical and electrical faults.
Rebuild Procedures:
Comprehensive rebuild procedures for major mechanical components.
Pictorial Guidance:
Detailed illustrations, exploded diagrams, and photos for service procedures.
Special Tool References:
Identification and usage of required special service tools.
Engine Configuration:
500 cc OHV Vertical Twin
Engine Bore Stroke:
Specifications would vary by specific model variant (e.g., G50, G11, G12), detailed within the manual.
Horsepower:
Typically in the range of 26-36 bhp depending on model and tune, as detailed in the manual.
Torque:
Specific torque figures and power delivery curves are typically found within the manual.
Carburetor Type:
Likely a single or twin Amal carburetor, specific model and jetting detailed in manual.
Fuel Type:
Lead-free gasoline (historical context suggests leaded gasoline may have been specified originally), with specific octane recommendations in manual.
Oil System:
Wet sump or optional pre-mix/oil injection depending on specific model variant, manual will specify.
Ignition System:
Magneto ignition or coil ignition system, timing specifications provided in manual.
Crash Test Ratings:
Not applicable for this era of motorcycle; safety is addressed through proper maintenance and operation.
Braking System:
Front and rear drum brakes, manual details adjustment and maintenance.
Lighting:
Headlight, taillight, brake light, turn signals (may be optional or market-dependent), manual covers electrical system for these.
Frame Integrity:
Robust steel frame construction, manual provides guidance on frame inspection and repair.
Oil Change Interval:
Typically every 2,000-3,000 miles or annually, specific recommendation in manual.
Valve Clearance Check:
Usually every 3,000-5,000 miles, detailed procedure in manual.
Engine Oil Type:
Viscosity typically SAE 20W-50 or 20W-40 for this era; specific grades and types (mineral oil recommended) detailed in manual.
Gearbox Oil Type:
Specific gearbox oil grade (e.g., SAE 90 or similar) and capacity will be listed in the manual.
Brake Fluid Type:
Drum brakes typically use DOT 3 or DOT 4 fluid, but older recommendations might differ; check manual for specifics.
Common Wear Points:
Valve guides, piston rings, clutch plates, primary chain wear, gearbox selector mechanism wear. Manual provides guidance on inspection and repair.
Electrical Reliability:
Older wiring can degrade, generators may require maintenance, manual assists in diagnosis and repair.
Carburetor Tuning:
Amal carburetors can require periodic adjustment for optimal performance and starting, manual details this process.
Suspension Wear:
Fork seals and bushings, rear shock absorber seals can wear over time, manual covers overhaul procedures.
Manufacturer:
Associated Motorcycles (AMC) Group, owners of Matchless and AJS brands.
Model Lineage:
The Heavyweight 500cc series represented a core offering for Matchless, evolving from earlier models with continuous improvements in engine performance and chassis design.
Manufacturing Location:
United Kingdom
Era Significance:
This period was a significant time for British motorcycle manufacturing, with the 500cc models being popular for commuting, touring, and sports riding.
