Category:
Classic British Motorcycle Service Manual
Value Proposition:
Provides essential, detailed technical information for owners and mechanics of the Matchless Lightweight 250 cc, enabling accurate maintenance and repair to preserve the longevity and performance of these vintage machines.
Manual Highlights:
Step-by-step procedures, pictorial diagrams, exploded views, torque specifications, special tool references, troubleshooting guides, and detailed service data.
Engine Systems:
Engine disassembly, assembly, inspection, adjustment, troubleshooting, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system.
Transmission Systems:
Gearbox disassembly, assembly, inspection, adjustment, lubrication, troubleshooting.
Chassis Systems:
Frame, front suspension (forks), rear suspension (shock absorbers/springs), wheels, tires, spokes, bearings, steering system, brakes (front and rear drum), clutch operation and adjustment.
Electrical Systems:
Wiring diagrams, lighting system, battery, ignition coil, dynamo/alternator, rectifier, regulator, horn, switches, cables.
Bodywork And Fittings:
Fuel tank, seat, handlebars, fenders, chain guard, levers, footrests, control cables, basic cosmetic repair guidance.
Maintenance Procedures:
Periodic maintenance, lubrication schedules, cleaning procedures, chain adjustment, brake adjustment, carburetor adjustment, ignition timing adjustment.
Repair Procedures:
Engine rebuild, gearbox repair, suspension overhaul, brake relining, electrical component testing and replacement, cable replacement, minor frame straightening.
Troubleshooting:
Step-by-step diagnosis for common running issues, electrical faults, braking problems, and starting difficulties.
Installation And Removal:
Detailed instructions for removing and installing all major components and sub-assemblies.
Special Tools:
References to specific Matchless or general BSA Group special service tools for certain adjustments and disassembly tasks.
Depth:
Comprehensive, covering routine maintenance to full engine and gearbox overhauls, with detailed explanations and diagrams. Suitable for both experienced mechanics and DIY enthusiasts.
Diagrams And Illustrations:
Features detailed diagrams, exploded views, and photographs to guide users through complex procedures.
Accessibility:
Instant download available, allowing immediate access after purchase.
Printability:
Yes, all pages are printable.
Binding:
Not Applicable (Digital Download)
Paper Quality:
Not Applicable (Digital Download)
Reader Software:
Adobe Reader required.
Operating Systems:
Compatible with Windows, Mac, and Linux OS.
Engine Type:
Four-stroke, parallel-twin (common configuration for this era and displacement, though specific variants may exist).
Bore X Stroke:
Typically around 54mm x 54mm, resulting in approximately 249cc displacement.
Compression Ratio:
Likely in the range of 6.5:1 to 7.5:1 for standard models of the era.
Horsepower:
Estimated 15-18 bhp at around 6000-6500 RPM.
Torque:
Estimated 14-16 lb-ft at around 4000-4500 RPM.
Carburetor Type:
Typically a single Amal concentric or Monobloc carburetor, likely 24mm or 26mm bore.
Fuel Type:
Regular leaded gasoline (e.g., 90-94 octane). The manual will specify if unleaded conversion is addressed or recommended.
Ignition Type:
Battery and coil, with contact breaker points and distributor (or magneto ignition in some cases).
Transmission Type:
Constant mesh, foot-operated, sequential gearbox.
Number Of Gears:
Typically 4-speed or 5-speed.
Optional Gearbox:
Not typically applicable for this model year range; variations were usually engine-based.
Clutch Type:
Multi-plate, wet clutch, operated by cable.
Primary Drive:
Chain drive from engine to gearbox.
Final Drive:
Chain drive from gearbox to rear wheel.
Crash Test Ratings:
N/A for this era of motorcycle.
Braking System:
Drum brakes front and rear. The manual will detail adjustment procedures and lining replacement.
Lighting:
Headlight, taillight, brake light, turn signals (may be optional or added later).
Frame Construction:
Steel frame, typically duplex cradle design for rigidity.
Suspension:
Telescopic front forks, often with hydraulic damping. Rear swingarm with twin shock absorbers.
Oil Change Interval:
Typically every 2,000-3,000 miles or annually. Manual will provide precise intervals and oil type.
Spark Plug Maintenance:
Checking and cleaning/replacement every 3,000-5,000 miles, depending on usage and plug type.
Valve Clearance Adjustment:
Recommended at intervals such as 3,000-5,000 miles or annually. Manual specifies exact figures and procedure.
Engine Oil Type:
Typically SAE 20W/50 or SAE 30 motorcycle-specific oil. Manual will list exact specifications (e.g., Castrol GTX or similar). Note: Mineral oil is standard.
Gearbox Oil Type:
Often shares engine oil, or a specific gear oil might be recommended. Manual will specify.
Fork Oil Type:
Specific grade of suspension oil (e.g., SAE 10W or 20W). Manual will provide type and quantity.
Common Wear Points:
Valve guides, piston rings, clutch plates, gearbox dogs, swinging arm bushes, fork seals, and electrical components (particularly wiring and stator).
Carburetor Tuning:
Can be sensitive to adjustment; the manual provides detailed carburetor tuning and synchronization steps.
Ignition Timing:
Contact breaker points require regular cleaning and adjustment; manual details timing procedures.
Oil Leaks:
Common in vintage motorcycles; manual addresses seals and gasket replacement procedures.
Manufacturer Origin:
United Kingdom
Brand Reputation:
Matchless was a well-respected British motorcycle manufacturer known for robust and reliable machines, particularly in the post-war era.
Lightweight 250Cc Development:
The Lightweight 250 cc was designed to offer a balance of performance and economy, fitting into the popular middleweight class for everyday riding and touring.
Manufacturing Period:
1958-1964, covering significant design updates and variations within this range.
