This manual covers the AJS & Matchless Lightweight and Heavyweight Motorcycles produced between 1957 and 1966. These British-manufactured motorcycles, known for their robust engineering and racing heritage, include a wide range of models such as the G2, G2S, G80, and 18S series. They are characterized by their single-cylinder engines, ranging from 250 c.c. to 600 c.c., utilizing both 2-stroke and 4-stroke designs with Overhead Valve configurations for many 4-strokes. The motorcycles feature telescopic front forks, swingarm rear suspension with twin shock absorbers, and drum brakes. This manual provides comprehensive information for maintaining and repairing these classic machines, empowering owners and mechanics alike. This factory service repair manual is designed to assist DIY enthusiasts and professional mechanics with the service, repair, maintenance, and overhaul of AJS & Matchless motorcycles from 1957-1966. It offers detailed step-by-step instructions for a vast array of procedures, including engine design changes, lubrication, gearbox and clutch operations, suspension component servicing, brake adjustments, and electrical system troubleshooting for both Wipac and Lucas components. The manual also includes detailed wiring diagrams, technical data, and carburetor servicing and tuning procedures, covering common wear items and typical failures to ensure the longevity and optimal performance of these vintage motorcycles. 🏷️ Basic Information Identification Make: AJS & Matchless Model: Lightweight & Heavyweight Motorcycles Years Covered By Manual: 1957-1966 Codes Lightweight Models: G2, G2S, G2CS, G2CSR, 14, 14S, 14CS, 14CSR, G5, 8 Heavyweight Models: G3, G3C, G3S, G3LS, G3LCS, G80, G80S, G80CS, TCS, 16, 16S, 16C, 16CS, 16MS, 16MC, 16MCS, 18, 18S, 18CS 👋 Introduction Market Position Target Audience: DIY enthusiasts and professional mechanics working on AJS & Matchless motorcycles Competitive Analysis Advantage: Comprehensive coverage, digital convenience, cost-effectiveness compared to older paper manuals Key Features Features: Hundreds of pages, detailed illustrations and photos, step-by-step instructions, all styles covered Value Proposition Benefit: Save money on repairs, empower owners to perform maintenance and repairs, increase vehicle knowledge 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Overhaul Page Count Estimated Page Count: Hundreds (as stated, specific number not provided) Manual Type Type: Factory Service Repair Manual Completeness: Complete official full factory service repair manual. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine design changes, servicing, overhaul, lubrication, recommended lubricants Transmission Clutch: Gearbox and Clutch operations Suspension: Front forks, Rear suspension units Frame Wheels Brakes: Frame, Wheel bearings, Wheels and Brakes Electrical: Wipac alternator, Wipac electrical service, Lucas electrical service, Lucas coil ignition, Magneto, Dynamo, Wiring Diagrams Fuel System: Carburettor (servicing and tuning implied) Transmission Drivetrain: Transmission (specific details likely covered within gearbox section) Procedures Included Maintenance: Periodical maintenance, routine servicing Repair Overhaul: Step-by-step instructions based on complete disassembly, engine overhaul, gearbox and clutch repair, suspension component replacement, brake servicing Diagnostics Troubleshooting: Implied through detailed service procedures and electrical system coverage Wiring Diagrams: Detailed wiring diagrams for various electrical configurations are included. Technical Data: Includes essential technical data for all covered models. Carburetor Service: Detailed procedures for servicing and tuning of carburetors. Frame And Suspension Repair: Instructions for frame maintenance, wheel bearing replacement, and suspension unit servicing. Electrical Troubleshooting: Guidance for troubleshooting issues with Wipac and Lucas electrical components, ignition, and charging systems. Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to complete rebuilds, suitable for both DIY and experienced mechanics 📊 Manual Specifications File Format File Type: PDF Software Requirements: Adobe PDF Reader Print Quality Printability: Printable (entire manual or specific pages) Digital Accessibility: Accessible on Windows, Mac, smartphones, tablets, and via web browser Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Types: 2-stroke and 4-stroke single-cylinder engines Performance Displacement Lightweight: 250 c.c. and 350 c.c. Displacement Heavyweight: 350 c.c., 500 c.c., 600 c.c. Fuel System Carburetion: Models typically utilized Amal or similar British motorcycle carburetors (details in manual) Engine Design Valvetrain: Overhead Valve (OHV) for most 4-strokes, piston port for 2-strokes (details in manual) Lubrication Lubrication System: Total Loss or Combined Lubrication systems depending on model and year (details in manual) 🔧 Transmission Standard Gearbox Type: Constant Mesh, Foot-shiftable gearboxes (4 or 5-speed common) Optional Clutch Type: Wet multi-plate clutch Features Drive Type: Chain drive to rear wheel 📐 Dimensions Exterior Chassis Type: Telescopic front forks, swingarm rear suspension with twin shock absorbers Weights Dry Weight: Varies significantly by model, typically ranging from 300-450 lbs (check manual for specific models) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle era predates standardized crash testing) Active Features Braking System: Drum brakes (front and rear) across most models Passive Features Lighting: Headlight, taillight, brake light, indicators (where fitted) 💡 Technology Features Infotainment Infotainment Systems: N/A (Pre-digital era) Driver Assistance Rider Aids: N/A (Relied on rider skill) Connectivity Connectivity Features: N/A Electrical Systems Ignition Systems: Magneto ignition, Coil and battery ignition systems Charging Systems: Dynamo (often Lucas) and...