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AJS & MATCHLESS 1957-1966 Factory Service Repair Manual
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Basic Information Identification Make: AJS & Matchless Model: Lightweight (G2, G2S, G2CS, G2CSR, 14, 14S, 14CS, 14CSR, G5, 8) & Heavyweight (G3, G3C, G3S, G3LS, G3LCS, G80, G80S, G80CS, TCS,...
Typ: Motorcycles
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Art.-Nr: 103006
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| Basic Information | |
| Identification | |
| Make: | AJS & Matchless |
| Model: | Lightweight (G2, G2S, G2CS, G2CSR, 14, 14S, 14CS, 14CSR, G5, 8) & Heavyweight (G3, G3C, G3S, G3LS, G3LCS, G80, G80S, G80CS, TCS, 16, 16S, 16C, 16CS, 16MS, 16MC, 16MCS, 18, 18S, 18CS) |
| Generation | |
| Production Years: | 1957-1966 |
| Codes | |
| Chassis Codes: | G2 series, 14 series, G5, 8, G3 series, G80 series, 16 series, 18 series |
| Introduction | |
| Market Position | |
| Target Audience: | Owners, mechanics, and restorers of AJS and Matchless motorcycles from 1957-1966 seeking authentic factory repair information. |
| Value Proposition: | An indispensable resource for any serious owner or restorer of AJS and Matchless motorcycles. |
| Competitive Analysis | |
| Manual Authenticity: | Genuine factory service manuals, not third-party reproductions, offering superior accuracy and completeness. |
| Key Features | |
| User Benefits: | Enables DIY maintenance and repair, saving significant labor costs ($50-$60 per hour). Empowers owners to understand their machines and communicate effectively with mechanics. |
| Cost Savings: | Significant savings on labor costs by enabling owners to perform their own servicing and repairs. |
| Search And Print: | Facilitates easy navigation via search function, allowing users to print only the necessary pages for specific tasks. |
| User Benefits | |
| Empowerment Through Knowledge: | Enables owners to make informed decisions about maintenance and repairs, acting as their own expert mechanic. |
| Manual Details | |
| Coverage Areas | |
| Manual Scope: | Comprehensive factory service and repair for AJS & Matchless motorcycles from 1957 to 1966, covering both lightweight and heavyweight models. |
| Page Count | |
| Estimated Page Count: | Hundreds of pages (specific count not provided, but described as extensive). |
| Content Volume: | The manual is described as having 'hundreds of pages', indicating a substantial amount of detailed information. |
| Manual Type | |
| Type: | Factory Service Repair Manual |
| Information Source: | Directly reflects the information used by factory-trained technicians. |
| Language | |
| Language: | English |
| Content Language: | Written entirely in English, ensuring broad accessibility for users. |
| Format | |
| Format: | PDF Download |
| Digital Delivery Method: | Download link provided immediately after payment confirmation. |
| Manual Coverage | |
| Systems Covered | |
| Engine And Powertrain: | Engine design, engine servicing, engine overhaul, lubrication, recommended lubricants, gearbox, clutch, transmission, carburettor. |
| Chassis And Suspension: | Front forks, rear suspension units, frame, wheel bearings, wheels, brakes. |
| Electrical System: | Wipac alternator, Wipac electrical service, Lucas electrical service, Lucas coil ignition, magneto, dynamo, wiring diagrams. |
| Electrical Components: | Detailed service information for Wipac alternators and electrical systems, and Lucas electrical components, coils, and magnetos. |
| Suspension Details: | Comprehensive coverage of front forks and rear suspension units, including servicing and repair. |
| Wheel And Brake Systems: | In-depth coverage of wheels, wheel bearings, and the braking systems for both front and rear. |
| Procedures Included | |
| Maintenance And Tuning: | Periodical maintenance, engine servicing, engine overhaul, tuning procedures, common fixes. |
| Diagnostics And Troubleshooting: | Diagnosing engine fault symptoms, researching and evaluating repair approaches, testing suspected parts, advanced troubleshooting guide, diagnosing and repairing electrical system problems. |
| Diagnostics Methodology: | Provides methods for diagnosing fault symptoms, evaluating repair approaches, and testing suspected parts using 'secret techniques'. |
| Repair Procedure Guidance: | Step-by-step instructions, with detailed substeps, notes, cautions, and warnings, ensure accurate repair execution. |
| Mechanic Interaction: | Empowers owners to understand repairs and communicate effectively with mechanics, ensuring quality work and fair pricing. |
| Technical Depth | |
| Depth Of Information: | Complete factory-level technical details, step-by-step repair procedures, detailed illustrations, diagrams, photos, and specifications. Covers fundamentals to advanced rebuilds. |
| Illustrations And Diagrams: | Contains all necessary illustrations, drawings, and photos to guide users through every repair procedure. |
| Diagnostic Tools Usage: | Instructions on how to test suspected parts using techniques favored by top mechanics. |
| Manual Specifications | |
| File Format | |
| Digital Format: | PDF (Adobe Acrobat Reader required) |
| Operating System Compatibility: | Compatible with all PC-based Windows operating systems and Mac. |
| High Resolution Quality: | Described as a 'high resolution downloadable manual,' ensuring clarity of text and diagrams. |
| Print Quality | |
| Printability: | Fully printable, including individual pages, chapters, or the entire manual without restriction. |
| Printing Flexibility: | Users can print entire sections or specific pages as needed, avoiding wear and tear on a single physical copy. |
| Binding Type | |
| Digital Delivery: | Downloadable link provided after purchase. |
| Paper Type | |
| Digital Storage: | Can be saved to hard drive or burned to CD-ROM. |
| Engine Specifications | |
| Primary Engine | |
| Engine Displacement Lightweight: | 250 c.c. and 350 c.c. |
| Engine Displacement Heavyweight: | 350 c.c., 500 c.c., and 600 c.c. |
| Engine Types Covered: | Covers both single-cylinder and parallel-twin engine configurations common in the AJS and Matchless lineups of the period. |
| Performance | |
| Engine Characteristics: | Details on engine design changes across the model years are provided, allowing for understanding of evolution and specific model variations. |
| Engine Overhaul Details: | In-depth procedures for engine overhaul are provided, covering complete rebuilds. |
| Fuel System | |
| Carburettor Information: | Comprehensive coverage of carburettor systems, including servicing and tuning, is a key feature of the manual. |
| Carburetor Servicing: | Covers servicing and maintenance of the carburettor systems for optimal fuel delivery. |
| Transmission | |
| Standard | |
| Gearbox Coverage: | Detailed information on gearbox and clutch systems, including repair and maintenance procedures. |
| Optional | |
| Transmission Types: | While specific transmission types (e.g., number of gears) aren't detailed here, the manual covers the 'Transmission' system comprehensively. |
| Features | |
| Clutch Servicing: | Procedures for clutch maintenance and repair are included, essential for driveline longevity. |
| Dimensions | |
| Exterior | |
| Frame And Chassis: | The manual details the frame, forks, and suspension, which are integral to the motorcycle's dimensions and handling characteristics. |
| Interior | |
| Bodywork Repair: | While not directly dimensions, the manual covers bodywork aspects as part of the overall repair scope. |
| Weights | |
| Wheel And Tire Specifications: | Information on wheels, wheel bearings, and brakes is provided, which relates to the motorcycle's overall weight distribution and handling. |
| Safety Features | |
| Ratings | |
| Brake System Servicing: | Detailed procedures for servicing wheels and brakes ensure optimal stopping power and rider safety. |
| Active Features | |
| Electrical System Diagnostics: | Comprehensive coverage of electrical systems, including ignition (Lucas coil ignition, magneto) and lighting, is crucial for safe operation. |
| Passive Features | |
| Suspension And Handling: | Coverage of front forks and rear suspension units ensures proper handling and stability, contributing to rider safety. |
| Technology Features | |
| Infotainment | |
| Vintage Technology Overview: | The manual covers the electrical systems of the era, including Wipac and Lucas components, which were state-of-the-art for their time. |
| Electrical System Components: | Focuses on the electrical systems of the era, including generators (Wipac, dynamo) and ignition (magneto, Lucas coil). |
| Driver Assistance | |
| Ignition Systems: | Detailed information on magneto and Lucas coil ignition systems, essential for engine performance and reliability. |
| Engine Management: | Guidance on understanding and analyzing engine management systems relevant to the era. |
| Connectivity | |
| Wiring Diagrams: | Extensive wiring diagrams are included, crucial for understanding and troubleshooting the electrical system. |
| Maintenance | |
| Service Intervals | |
| Periodical Maintenance: | The manual outlines recommended periodical maintenance schedules to ensure the longevity and optimal performance of the motorcycles. |
| Periodic Checks: | Details recommended checks and services at regular intervals for optimal motorcycle health. |
| Fluid Specifications | |
| Lubrication And Fluids: | Covers lubrication procedures and specifies recommended lubricants for various components. |
| Engine Oil Recommendations: | Specific recommendations for lubricants are detailed within the manual. |
| Known Issues | |
| Troubleshooting Guide: | Includes an advanced troubleshooting guide to help diagnose and correct common and uncommon problems experienced by owners. |
| Preventative Tips: | Offers tips to prevent common problems from escalating. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer History: | AJS and Matchless are iconic British motorcycle manufacturers with a rich history in motorcycle sport and production. |
| Model Evolution | |
| Year Specific Updates: | The manual covers a decade of production (1957-1966), detailing engine design changes and model variations within this period. |
| Lightweight Vs Heavyweight: | Distinguishes and provides specific coverage for both the lightweight (250/350cc) and heavyweight (350/500/600cc) models. |
| Production | |
| Production Era: | Focuses on the post-war era of these classic British motorcycles. |
| Awards & Recognition | |
| Recognitions | |
| Manual Authenticity Recognition: | Distinguished as 'Actual Genuine Repair Service Factory Manuals,' signifying its authoritative and official status. |