🏷️ Basic Information Identification Make: AJS Model: 16/18/20/31/31CS/31CSR Year: 1962 Codes Model Codes: 16, 18, 20, 31, 31CS, 31CSR 👋 Introduction Market Position Target Audience: AJS motorcycle owners, restorers, and classic motorcycle mechanics Competitive Analysis Era Competitors: Norton Commando, Triumph Bonneville, BSA Gold Star Key Features Manual Value Proposition: Essential resource for maintaining and restoring classic AJS models, providing factory-level technical guidance. 📋 Manual Details Coverage Areas Covered Models: AJS 16, 18, 20, 31, 31CS, 31CSR Covered Years: 1962 Page Count Estimated Pages: Approx. 150-200 (typical for this era's service manuals) Manual Type Type: Service/Repair Manual Language Language: English Format Format: Printed (likely facsimile or original) 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly Fuel System: Carburetor tuning and overhaul (e.g., Amal Monobloc), fuel tank, fuel lines Ignition System: Magneto ignition, timing, spark plug specifications Transmission: Gearbox maintenance, lubrication, and repair; clutch operation Suspension: Front fork (Girling or similar) servicing, rear shock absorber maintenance Brakes: Drum brake adjustment and maintenance, brake shoe replacement Electrical System: Lighting circuits, wiring diagrams, battery maintenance Chassis And Frame: Frame inspection, headstock bearings, wheel bearing maintenance Controls: Handlebar controls, throttle and clutch cable adjustment Bodywork: Fender, tank, seat mounting and basic repair guidance Procedures Included Preventative Maintenance: Lubrication charts, routine checks, adjustment procedures Troubleshooting: Common problems and diagnostic steps for engine, ignition, and fuel issues Repair Procedures: Step-by-step instructions for major component overhauls and replacements Tune Up Procedures: Carburetor synchronization, ignition timing adjustments Specifications And Tolerances: Detailed technical data, measurements, and wear limits for critical components Technical Depth Depth: Comprehensive: Covers full rebuilds and in-depth diagnostics, suitable for skilled mechanics Diagnostic Tools: Basic mechanical tools, feeler gauges, torque wrench, timing light (optional for magneto). 📊 Manual Specifications File Format Digital Format: PDF (assumed for modern sales) Print Quality Scan Resolution: High-resolution scans ensuring clarity of text and diagrams (if digital) Binding Type Binding: Stapled or perfect bound (if printed facsimile) Paper Type Paper Quality: Durable, high-quality paper suitable for workshop use (if printed facsimile) Completeness Content Scope: Comprehensive service and repair information, often including electrical diagrams and torque specifications. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, parallel twin (most models), single cylinder (some 16/18 variants) Displacement: Approx. 350cc (16/31 models), 500cc (18/20 models), 600cc (31CSR variants) Performance Horsepower Range: 20-35 hp (estimated, depending on model and state of tune) Fuel System Carburetor Type: Amal Monobloc (common), possibly concentric carburetors on later models Fuel Type: Leaded gasoline (typical for the era), octane rating 90-95 RON recommended for modern use with additives Lubrication Oil System: Wet sump (most models), integrated oil tank (some models) Cooling Cooling Method: Air-cooled Ignition System Ignition Timing: Typically 5/16" or 3/8" before TDC (Top Dead Center) BTDC, specific to model and timing setting. 🔧 Transmission Standard Gearbox Type: 4-speed constant mesh (pre-unit construction) Features Clutch Type: Multi-plate, wet clutch Primary Drive: Chain driven (engine to gearbox) Final Drive: Chain driven (gearbox to rear wheel) 📐 Dimensions Exterior Wheelbase: Approximately 54-56 inches (varies by model) Weights Dry Weight: Approximately 350-450 lbs (varies by model) 🛡️ Safety Features Ratings Safety Features Era: Basic; focus on mechanical reliability. No electronic safety systems. Active Features Braking System: Single leading shoe (front), possibly dual leading shoe (rear on some models), drum brakes Passive Features Lighting: Headlight, taillight, brake light (as standard for the era) 💡 Technology Features Infotainment Infotainment System: None; purely mechanical operation. Driver Assistance Assistance Systems: None. Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change: Every 1,000-1,500 miles (or 3-4 months) Valve Clearance Check: Every 2,000-3,000 miles Ignition Timing Check: As needed, or every major service Fluid Specifications Engine Oil: SAE 20W-50 or 50 (for older engines), API SF or SG rated; consult manual for specific recommendations. Capacity: Approx. 3-4 pints. Gearbox Oil: EP 90 gear oil or equivalent (e.g., Castrol EPX 90) Fork Oil: SAE 10W or 20W fork oil (consult manual for exact type and quantity) Brake Fluid: Not applicable (mechanical cable actuation). Known Issues Prevalent Problems: Oil leaks (gaskets, seals), worn valve guides, clutch slip, carburetor float issues, weak headlight output. Ignition Problems: Magneto wear, condenser failure, sparking at commutator. Recommended Parts Spark Plugs: Champion L7Y or equivalent (verify with manual) Air Filter: Oil-wetted foam or wire mesh element (clean and re-oil regularly) 📚 Vehicle History Brand Heritage Manufacturer: Associated Motor Cycles (AMC), parent company of AJS and Matchless Historical Significance: AJS was a renowned British motorcycle manufacturer with a strong racing heritage, particularly in the pre- and post-war eras. Model Evolution 1962 Context: These models represent the later stages of AMC's twin-cylinder motorcycle development before the decline of British motorcycle manufacturing dominance. Production Production Period: The AJS 16, 18, and 20 models had long production runs, evolving through the 1950s and into the early 1960s. The 31 series was a more modern...