This comprehensive workshop service repair manual provides in-depth instructions and guidance for maintaining and repairing your AJS Heavyweight 500 cc motorcycle, covering models from 1957 to 1966. It's packed with detailed step-by-step procedures, numerous illustrations, exploded diagrams, and clear photographs, ensuring you have all the information you need to tackle any repair task, from minor adjustments to major overhauls.

The manual includes special notes, important points, service data, precautions, and more, offering expert insights into the intricacies of your AJS Heavyweight 500 cc. You'll find everything from component removal and installation guides to comprehensive explanations of troubleshooting, servicing specifications, tightening torques, checking and adjusting procedures, and disassembly and assembly steps. This manual is designed to be a valuable resource for both professional mechanics and knowledgeable DIY enthusiasts, making the maintenance and repair process easier and more efficient.

You'll find detailed information on all aspects of your AJS Heavyweight 500 cc, including:

* **General Information:** An overview of the motorcycle's design and function.
* **Diagnosis & Testing:** Strategies for identifying and resolving mechanical issues.
* **Adjustments:** Precise instructions for adjusting various components.
* **Removal & Installation:** Step-by-step procedures for removing and reinstalling components.
* **Disassembly & Assembly:** Detailed guides for dismantling and reassembling parts.
* **Servicing:** Comprehensive maintenance procedures for keeping your motorcycle in optimal condition.

This manual is structured to provide a clear and concise understanding of your AJS Heavyweight 500 cc. It is an essential tool for ensuring your motorcycle operates safely and reliably. The manual encourages users to follow its instructions diligently for optimal results.

The AJS Heavyweight 500 cc, produced from 1957 to 1966, was a robust and iconic motorcycle that cemented AJS's reputation for quality engineering and performance. This model marked a significant shift for the brand, moving away from the smaller capacity machines for which it was previously known. The Heavyweight 500 cc was designed to be a true touring motorcycle, capable of covering vast distances with comfort and reliability. Its air-cooled, four-stroke, single-cylinder engine, displacing 498 cc, was a powerhouse for its time, offering ample torque and smooth power delivery, making it ideal for tackling challenging road conditions and hauling a passenger or luggage. The engine was mated to a four-speed gearbox, providing a range of gears for all situations.

The AJS Heavyweight 500 cc embodied the classic British motorcycle aesthetic, with its chrome-plated components, timeless lines, and robust construction. The telescopic front fork and swingarm rear suspension provided a comfortable ride, while the drum brakes offered reliable stopping power. The machine's thoughtful design included features like a large fuel tank and a comfortable saddle, ensuring a pleasant and practical experience for both rider and passenger. While production of the AJS Heavyweight 500 cc ceased in 1966, these motorcycles have maintained a devoted following over the decades. Their timeless design, impressive performance, and rugged build make them highly sought after by collectors and enthusiasts alike. The AJS Heavyweight 500 cc stands as a testament to a bygone era of motorcycle engineering and continues to hold a special place in the hearts of those who appreciate the enduring legacy of classic British motorcycles.