A.J.S. 350 1950 User manual
MAINTBNANCD
MANUAL
INSTNUCTION
BOOII
tq
1950
350 c.. and, 5n .,a
A.J.S
APnING FAIAITD /IND IIGID IIODEI,g
PfiCE 2/6 Nf,TI
-,{lt'
A.J.S
lIOTOn OvOLBS
PIUNSTEAD. LONOON . S.E.IE
IIAINTENANCD l}IANUAL
ANII TNSTRUOTION BOOIT
.tb,
A.J .S
SINGLE t950
CYLINDER MOTOR CYCLES
comlll.d hd li!!!d bv tI.Iro,!llorur.B '
A.J.S DIOTOB CYCLDS
(Prcori.!8 ' AssocLrTED MOToR cYCLI:s LIMnED)
Rclist€lc.l Ofiic€3:
PLUMSTEAD I{OAD. PI-UMSTEAD
LONDON. S.E.I8 .. ENGLAND
woolwlcE -{RstrNAr,
souLlcrn R.{ionRail*")
codq | ^.3.c 5'hrd6'h tdroi
A,J.S MO',r'OR CtCr F:S, PL0MSITAD ROrlD. LONDON. s.Il.r||
BIJRRAGtr GROV!] .Nd TTA)iDY IIOAD
rl-fiMs'rl:AD. s,E,la
Price: TWO SHILLINGS and SIXPE)iCll
EDIIION CM-I3
r95O A.J.S. MODELS
350 MODEL I6M RIGID FRAN,IE
350 NIODEI. I6YS SPRING FRAIIL
350 IIODEL 16}TC CO}TPETITION
5OO MODEL 18 RIGID FRAI,IE
5OO NTODEI- 18S SPRING FRAN{F],
500 lloDEL l8c cotrPETt lIoN
350 -
soo -
NTRODACTION
t'lotorcyclihS le on€ of rhe mosr econdmical and plersu.abl€ mod6 ol
..ansport. k i! our since.e wirh rhat cvert ., A.l.s " owncr
rhould obt.in, from h 5 mounr, th. r.rvice, comtoft lnd lnnumerable miles
or low-con travel rhrt we havc carne$ly endervoured to bulld lnlo it,
fiowev€f, i! 6ust b€ remembefed thaq ihhoush . motor.y.le k oisinPle
d6ign and conrfucion. it is, .everthelB, r highly 3pecialiscd paec6 ot
engineering. In consequence, i. must be inrellig.ntl/ and eficic.tly
maintained ln ordef ro provide unfrlling .eliabiity
1n thk book aro nonrechn cal in*ructioos for cany n8 out all the maint.n-
.nce opfalio.! llkeLy to b€ call.d ior in srrenuous ,ervice and illu$ratlo.s
.re prcvided to.sti3t. Neglec. @ nake €srential .dirrmen6, onlt calual
attention to lubrication and th. ltk ol p€riodical maint€nance att.nllon
willsoon neurBllse the be$ effoft3 orthe desl8ne8 and oa/ brinE n..dle$
We are alwa/3 pl.aed b giv. 1'A.J.s" owners the iull b.ncnt
or our wide .xperience i. datleB rela.irg to motor .ycl€s or our nanu-
lrct!re and ekcwhdc will be found detaik of thc Panlcuhrs ihat should
beg vcn us whci hakins such an.nquiry. A.,I. S MOTOR CYCLES
l6MS and ISS SPRING FRAME
l6M and l8 RIGID FRAME
I3C COMPETITION
3
DATA .. . i;-,
5m... so/i3
(bdow d. $dd!e)
Gr rodes) .. ^ P ". '-:., '
r "Fo o., (, ,,,
50r'6H50/l6M5itrd50ll6Mc_3]7
sorras eJ 50/r3crr3
NDCATEO BY (ts) ANO *E LOW BY (L)
aerrinsi (ball dnd rolled
crDkoh rcr4 be'id3, (rore arn
r, 21 L ii.
r* h.
- 1ln 1!.
4
non 6a Gnh rie)
Rei eg GEh er!
r!o rnir (R rn a.r sp,hg rame)
tu! Err (.qi,( rot
'oi spr is han! Modc 5 ony (50/ 6 rs lnd 50/rst.
. 76AL/ AK T6AE| AK 39M/IAK 3'8,/IAK
. 6/4 611 tt/4 1el+
ti 305i.
+h.
ih.
; i .30i,
*h.
;i 3dlh
th
i ii.
Chain whip (all modek)
I h. :toi h.}
hh lfie oi sPrhs turmc Moddr is tt ii
35o % n.
@frFre$o|Plac
5
Gear ratios (models lbl'1 l6s l8 l85)
r a4ii
Tn{diid soosprark*br fodc' 3 &d r6s.
G€ar ratios (modals l6C-l8C)
G.Pl
rB @{r t
lsiitiob Gparkins plug)
A[ reve,e*!ren.i6 a! abic!
a!!frry
2tj " 0625 h. (Hl 0o h (ts)
0615 D. (L) oe2ii. (r)
2r h. r23 ;. (ts) 0o h (H)
. 21 f. (L) 0e2 h. (L)
3: h 0625 i lts) 116 i. (H)
'c6r5 io. (L) r03 h tL)
3+ h r25 h lts) .16 n. (H)
. 24 D (L) r03i'. t)
rjgid and spring rfame nodek)
3rr0 5ri i
3i h.
3,t i
500 Competition modek)
,1i'
ii 305ii
:f r05i 0102
sprockets (a I nodols)
,'40,]i
.. 6 iil
42 :n
:j
l
j
l
l:
1
I
J
.i
e
i
z
,
E
F
Valve tihing (wlth 016 inch rocker
t 00225 r. (Lt 1735 D. (H)
r tr 00175 tr rHl rrd i (L)
Valve tining pinion
Rqlho! b} im sre?ded *
3
(2)
(r)
CONTROLS
14l
Throttle twilt grip.. On risht handleba'. Twist inward, ro open. When
lully ccscd edtlne sho!ld iusr idlc wIcn hot_
A'r lever. Salrl leve- on r,gs hiqd cbl pult 'nwJ,d5 ro ,1c,ea" ,,r luDDry
b orb r-he-. o e . , a-^r .-g ne nl rr-ieo .p. eqj -c ro r reai oil
'o- nir" , n road 3Dr.d<. Sto, o oe,r . oFo$hc.ir',"tc)gi.efrom.otd,
lgnition l€ver. Snall lev.r on le{r h!ndteb:., Advan..s and reerds ap.ition
poi\.. Purlinwrrd: ro dd,ri.e on ro!ri' g mod.k r..tird o".oqpdii,on m;d.tt).
movemenr for stJrt ns
Valve lif.er lever. smrlevercoseroctutch ever. Liit, cxhrus. vatve trom
'e!t. .clc'.'r8 coaprebion in ,oFbu*ion ,nrmDcr, enaot,n! en? np ro bc crrv
'orlcd ror *rnns Alro 6:d ro' *oppin3 eng'ne 'r (h;okt; sbD 6 5et ;
(s) Clutch leve.. . Large l€ver on tei. hand ebaf, crtp to re case cturch so that
dfive b rear whee s disconnertcd. Uscd when m;vins rwa/ from a srandsritl
and when chuSing gcar-
16l Front br.k€ l.ver. a-8e h o" -s'r t-aldtebr,. c.ip ro ope,ai. Lonr
&Fe€l b'd." d-d.ro'o rrl b.r. rs, Fe n o' rL ct:o. ^'. rei-bra.a "pp icaron,
O) R.ar brrke lever. Peor .lo\e ro lelt iide ioo! r.tr. Deprers {,rh tplr IooL (o
appry rcrr bhle. Appl/ Scntl/ rnd ute int'6in8 prcsurc a! rhe rord speed
(8) Ge.r.hanse lorer. Pedal n horizonral posilion ctose to fiphttoot resi, Con-
trok se e.tion ot the lou. speeds, or ratios, beiweed en:inc and rear wh€el
rtvolutions, {i.h a 'free,'o. neurrlt, posirion. See i usthlion l.
(9) KickBtarter l€v€r. vertcrr pedat on rshr hand side of €enr box, Op.r.ted
{lOt Lightingswitch. llropolneadtimp. conr.o,r,!mD\b)!rota,,ngteverwh(h
hs rhrce Doitions :
(l) " OFF ' Lamp: not on.
(2) "1" Plorbulbtnh€ad ampan!feaf tampandspeedom€rort.npon,
(3) H " Haad and rcar tanp lnd rpeelome.er ramp on,
(l l) Amm.t€r. ln_rop oi head trhp. Indicatg ltow of etedri. (ur
ol batter/. ( Chrrge or " Discharse )
(12) Horn switch. Pre$ switch on righ! handlebar, DeDre$ butlon to so!nd horn.
(ll) G.T 60r fill€f ap. I o.rred on Lop edae oa trk+rarter cdc cover. Artos
.$ to.tdtcr Jnrc, wirc.
(14) Footrest for ride.. Odc tocated each nd€ ot machtne,
(15) Pettol trnk nlt.r crp. Lc.ted in rop ot tuet ran(. To retese.,l,ehrtv dcD.6s-
rurn lulrr ro the leit. and then hrr away. rhc,c:rc $o to(t,in! D;ni;tu, Th;
ar.de po.i'ion. ber/"er !f€ r'tl ltftened oo,- ra trt! i;dy podt.1,,
Ernr-enrtureora sa,e!/ de!,cetoorere1. o$r-d n 8-t b- orftr ored by
unauthorised meddl'np.
(15) oil ta.k lirlcr ep. tocat€d on rop cdge ofo tank. The onstructton dd
op.ra(ion is ern(tly rs rhe D*roltrnk nlt.r dD
(17, Dipplns rwit.h, TrisSerssrhol efr l"ndeoa-. U.ec to set^-r norha or
'dipped beaft or hef,d trmp wnen main,,gnrin! swir.h l.v.r k in rhe .,H
polron. (rhe h.id tamp butb h6 rwo fitrmenB.)
All the con$ok afe adjustabi€ tor posjtion, tfany adidnment k mad€ !o rh€ rear brake
pedalmake certain.he brake ioes nor bind and aso see there is not exce$iv€ lr€e Dedal
movement betd.e rhe braLe con€s ion.'.
RI\1OVF TO
AI]D HYDRA].]LIC FLU D
L 6itltNc
SW]TCH
?
IGN T]ON A I Ca tR.lt
AMI'1ITi-R
FRONi ERAXI
LTVFR
IFVIP
THROTit I
]I!IST CA P
iF- -
ii-l
; CIAR C,lr\f,CF
PIDqt
OOTRiST
GEAR BOX
F ]ttFR CAP
I
KICK6TARI.!R
fllAl
the sadd e and become lamiliar with the posirion
Pay particu ar attcniion to rhe g€ar posirions,
CLUTCH
LTVER
CONTROI
\ALVI LIFTTR
I.FVIR
RFAR BMKE PtD1.L
@
FOOTRE5T
Befof€ using the machine, sit on
opedioi oI the various controh.
DRIVING
FUEL
Ar trre timc of publ'35ing ' hA 'n{ ru(uon b@l onl/ ore Erade of moror fucl (Poor Sp,rit)
k on \rle. bLt ( Ta' be rhrr <6 rh",:"oL5g.ider6i p c wJ pcr oldtlrg, n bert: I
able whc^ ihe use of best qu!it/ fue s rccommended because rha smal amounr of
e oroT/ thlt n8tr be co1.'d -d o :((-Le by rif8 l " lheaper Erades 3 rorc r\rr
ol r' b/ rLle rdrar.r8p, obtdi.ed b/ , ! 19 o-ly \rrb.r O " s "o".,
FUEL SUPPLY
Two ruel leed lrps ar€ siturted underneath th. .ear end ol the p€.rolrank. (One .ad
side.) Soth mu* be shut ofi when the toichinc ir lert standins tor more rh.n a l€w
Thekp plungers work horizontally. Toopen, ihc hexaaon knob (markcd.. push o.,,)
is pushed towards.he body ol.he tap- Toclose, press the.ound nilled knob (nark€d
Nofmr ly, oily ule the tap on the rish! hlnd sidc 6r the machine and rhen rhe other
id.s I a.! as r -erche s rpD /. A^:ysre-r-e r,<oo1apo. D e rf(.' bel-g,o -d
ro .r rpon tt€ -e!e\ei "d-f.-,d.o.ce.closclfe
lr *i o. -orco t.a(, b/ lLri g ' 'o oe(-ol fc.d rap5. r n po-. te ro enole lhe pet-ol
tank lrom th. mach ho wirhour the nc.e$ i, ol n|n drdininS ir ol lu€I.
lllu3ration 2
Ki.k-.t.ra.r
qradrant and ratch€r Pinion
]l
IS THE
(IC('STARTER
THAT MUSIST
D rsrHE xrcK-
STARTING THE ENGINE
(d) See that th€re is suff.len!lucl in lhc peiio rank.
(b) S€e thar lhere is sufficicnt oll in lhe o | !ank.
(.) see that the gedr peda! is r the neutral posirion,
(d) P6h inwrd the herlgona end of off{lde pero tap sl de,
G) S€e thar rh€ air cbdfollever lr In lhe full/ coted position.
(f) Full/ advrnce the isnition and then da.k ba.k the .ontrol lever iwo-Rfth! of 16
(g) Open the firotde noi no.c than onetixth ol the total movement otthe twGt 8.ip.
(h) Dep|B th€ plunser on rhe top oI (he .arburctrer ndi chamber until it can bc
felt the chamber is rullor petrol.
(,) Raise th€ valye l"ter leverand, whilc k.€pine i. rris€d, turn over rhc englne scvcr.l
rines b/ d,p'!y 18 rle l,lc(irr.er pedrl, t1'cc r,Te.,!e ob.ect bcnt !o iee
tl-e e18i e. (-l n on r ippl es f lfc c18i1. r co d )
(l) Ocpres the klccnrrer und compre$lon is rek, then rahe the valv€ lftef lev.r
and ease the ensine iu$ ovef compfessio^. Then, after allowing tho k ck+trter
pedrLto returd deir / to ls norfia pdirion, give it a lon8 swinginS kic< wih rhe
vnlve closed and the en8 ie should immediatcly firc.
The (k\dr" a-\r'^Tr-srbcrlo$cd!oengigeprope ) Dcrore pr!!19 Fca\y
p.c$rre on rte ,cl{rrae'(r_k pedal o,n lldr n.:n lhere lre two denlte
and teparate movemens when operatinS thc machanism by depre$ing thc fiank.
Th. fi6t is a slow and gentle movemen! whrch ends when k k felt thc quadrlnt hD
.nsased with the reerh on (he ratchet pinion. (scc illunration 2.)
G!AR
Thc fiEt slow and Eende noveFcnt k esenrial to avoid damase to tn€ heth ol rhe
A,t€. the ensine ha strrted, llowly open rhe air levcr untir it ruN evenly. Then e.r
lhe rhro$lesothatth..nsin. i! ruininE n!i noderrtespeed (neiiher r.ci.l norricking
-D, wlie!o.r(hr.(jc, r ol. cu rrior rs delr leo n
Prrr 12. The ma.h'nc crn rhen b. !in.n;n the rord.
NOIE-Do no! E.e up rhe .i8in. trom .old nnd do not flood thc .arbur.ltcr to such
1n cxtenrthai peto s dripp rg, becau:eth€n, in thccvent olabac<Rfe, rh.re
h d dMger ol5uch loos€ p€tfol l8n tln!. Thk cannot po$ibly happen t the
startinB instruct ons arc carciu ly fol owed, but, in !he event oJ a nrc, th$. s
no cause lor pan c. Merely turn ofi rhe petfol tap ro ko ate rhe main supplyl
open wide lhe ihrolt e and iurn over the engine by opeffirS thc kick+tafter
peda whed suction wll exriigu rh lhe ffe,
l2
STOPPING THE ENGINE
lo nop rhe engine, .lose ihe thrott e, raisc th€ vave ii!.r l.v€r and keeP ii mised
untllrh. cngine has cea3ed to revolve,
ON THE ROAD
Bavins naded and warm.d up the en! nc, take .h€ mach nc off the stand, !ii asrrine i!,
lree thc . ut.h by pulLina up lhe lary€ Lev€r on rhe l€fr bar lnd engag€ rhe lowesr 8ear.
Nexr, slowly relcasc the clutch levcrand rhe hrchinc *ill commenc. rc nove lo'wrd-
As ir does this, the e.Ainc apeed will tend to drop s it picki up the lo so it will be
nece$ary ro in.rerse s iShrly ihc throtrle oP.Ain3, bit by bit, to keep rhc enSine speed
Whcn we under way, dkcnSue the clutch, i lEhdy close !hc throlt e, €ngige secood
3eaf and r.l.i!€ thc .lut.h lever, then opei (p th. throlt e ro inficac the 5peed of
rhc mrhine. Repeariherc op€ratjons in order ro engrgc third and 6p 8ciE.
To cngage a hi8her gerrthc p€dll is p.escd downw.rd with rh€ toe and a lower gerr h
ob'. io ot r:'J"g l-" pedrL $ 'r '5p i *.p. To p B'ge li's g"" l'or rhe.er"r
po ' o . rte ped Iii t\erc'o'e .i:.d. ^te- e-(l p.drl no\ere r,.nrc-r 'p"'3:
retufn !he p.ddlto its nofmi horzontal posnion.
Thc pedr mlst be moved io the iull €xtcnt of its ifavel when sdle.rinA a g.ar, .ither
up or down. l. nust not be iamped down ' or iabbed, but firml/ and decisivcl/
Tov"d r'll ( rops. A hrlf.herdcd movefren' mrt not Bivc rull en8rgehcnr Ke€p
''1" loo o{ !f e pedI d5en d v 1B : d ber$ee. .r.h sca" cFrns- be.aure, u.l.r( r' e
evef c.n lrccly retufn ro ir! iormal .enth Poririon, the noxt Serr crnnot be eisased.
Fidr l/, ful y Bdvance the i8n r on and lcave lt n that posltlon unles it is nece$art to
relafd n ordcr to ease the en8ine and so Pr.ven! " pinking when purring hifd on a
STOPPING THE MACHINE
To stop the machlne, clos. the throtrlc, !eclut.h b/ lrrin! rh. llfse lever o. the lett
hand ebar, lnd g.ntly appl/ both bra(€s, in..€asin8 rhe presuf€ on thcm a th€ road
sp€ed ol rhe mrhihe dc(reaes. Pla.e the get.h2ngetoot p.dal in lhe neutral pGitjon
aerore leavlng rhe ma.hine, turn oirthe iuelsupply,
IMPORTANT NOTICE
NEVER DRIVE AWAY AT HIGH SPEED WHEN 5TARTING A RUN WITH A
COLD ENGINE, GIVE THE OII A CHANCE TO WARI'4 UP AND IHIN OIJr,
PARTICULARLY WHEN THE MACHINE S COLD. IJNTIL THE OIL REACHES
ITS NORMAL RUNNING TEMPERATURE THE CIRCULATION IS
RESTRICTED. SEIZUR€S CAN BE AVOIDED gY TAKING TTIS 5II'1PLE
ESSENTIAI. PRECAUTION.
RUNNING IN
Athough it !.usionafy to quote permirte! mrximun speeds on rhe various g€:6
dur ngrhe perlod oi runnin8 in, thesc are rea ly io Suide.o orerdrivinA,the only e$em r
'hinA b r,o'd b€ing rha ure ol lrrae th.o'(le op€n'n!.
lf the prccau.ion k hken oi linirins rh. use of the throlrle !o abour one{hird ol its
6penins dur n8 th€ nBr 1,000 miles, irrespactive ol thc road speed, and whether on .he
evc or climblnS, the necc$rfy conditions for runn ns in w ll have been observed.
t3
Spe.ial a(eniion musr be siven, durinS lhe runn ns tn p.riod, to such detaik $ vaLv.
tode' rdjr{h.nt. chiinr, b'dre!, <ontact bredker po'nB, rnd !.c"n! h€rd bcar'nls,
arrolwhi(h knd ro bcd down in the fiar hundred m'tes or so. Pad'.uE' noi. mu{;.
hade ol the rdruimenr ol {eerinS hcrd ber' 'nA\. whnh, il run ,n i 5tr.t cond'non, w'tl
be quickly ruin.d Aak hA beddinS down pro.c$ hs (arcn pt&e. adiu3then6 @
such deo'k wll probrbtt on y be.ece$ar) I te4srhy 'nte'vrtr.
A'p .boJt.,000ric\ ,a,. oce. co?ered L'EerLr-o!tcooe.i.g rdy ba grldLa /
Indr ged In ror siori burns on r.
u-' l r! c$r 2.000 (o/e.^d le o,ner o, a -e4 r. ,c 6 5lronrty
rd? ec (o (u-b r:3 nlrL rl de!.re ro tor.n rnc hounr t mrx,m!m .aDaDi'irie5. Re*rr;hi
an this di.e.don will be amplt repald ldrcr,
NOTES ON DRIVING
lf, at firer, the low.si seaf wi I not engig., rclease rhe cturch evc. dnd after a s.cond or
txo. r. ernothe"rlrerb'. T.ir co-d t ol -'. -, .( i- r -el -.- e bLr !!ela! ro
Alwrt\ enderyour b nike rhe mov.henrs ol h,nd {on thc c'utchr and toot (on lhe rc.r
p€dar) a nmuh.ncous s poss'ble. rnd rchcmb.r, '; all gelr (fanse!, r steady pr.;ure
or.rhe f@t is deslrablc. This p.csure shoutd be maintained !n;it rhc ctui.ti i! tu y
releacd. k 6 not sufii.ien' tu{ rc tab tfie root pedrt .nd tfcn re erje rhe cturch teve;,
wher acrurll/ li Foror,rt wil beroJnd.u't!ier rc tre-.b Lp- e.Llchat-ifle.
roed,etledJve*-en.ld.Bi88.a-a-o.q'r',.C^ o,g.!rtne.
Do not unn.c.lsrri y rre the €n3inc or ler in tho . ui.h sufcien! y suddenly ro clusc
the re whee to sp n. Tdke a prld. in rakins a smoorh senawry.
When .hrn8'nE up to a highp' ssr, ai the.lukh is lrued, rh. rhro' rle >hould be 3tiShrlt
d6ed so Lhn the ent'nespeed mrt b. r.dured to keep in lrep w'rh rhc h'3her8.rr ntio.
convcBelyi wh€n chrnaina down to r lower gc,r. rhe throrle should be r€8u[e<l $
thrt rhe en8'n. rpced is in.'eaed to kccp in srcp $irh the lowcr g u' 'I'o,
Do not s ip lhe c utch to conrrol the road spean,
The'u.,1 tr-tr ol y be ..ea wlon sErli-s I or d {andi Irnd r1e. -lr-lilp !.ar
h r .s NOT be ooer:r' d'o ea!. rFc c-8 ne, i aea..f .-rlg 1g s, " o be-ld-a-oJt
The exhrun v.lve nr), be lift€d, when lhe na.hine is bainS slowly riddcn, rlrl fiBi
aer' enSaged. down erceptionrlly steep, or difil.ulr, gdd'cnB 'o prevent th. rcrr
wheel lekinr on ! l6e surface.
Il-e e,l ).*-rrre li'rer k NOT -sea lr -or rr . rngor Fai- J rd :econdary .oads.
w'"n',vel ng r o^ v. .' (' L I a/ occr- r r-rff co-o a -i . 1-0,""' c 1e.o;F€nce,
'olbo-'. ! !rhe. " d, (oc\artc.oa odcr gea'.. E-gr. Inockt.E o-
'' p',.s rnd a r!ah e.( "he!-ar5r *lon r'd yrpror! ols_c\ rbou-rno.l!\oLr!
-el- ('1 !o..t Fc! be ornd b/ rctr.o ng rre,gn r o-, '! 3 Bc-. "1, rr(r bcre- io
chrngc down, A t@d driver is .bl. ro 3cnse su.h .onditions ind will make rh..haqe
hefore th€ €ntino hd r@hed the st.ge of disircss- Th. Scar box ir providcd ro 6c
used and .ontequenil/ full ure should bc nde of tho inGrmediate gcaE io obtain
efiortles running lnd smooth hill climbing.
<c.p r5e reet Cea or'(e bnlc and ge.- pcdr s $l e I not adli rv -r ns r' er a-o k.cp
Drive as much N Po$ible on rhc thfottle, Frkins the miiimum ure of the bru<or,
wLrer usi18 t5€ Fa.Lr're on $e( o.greaiy roid!. ir h gereri,l/ b^r'i ' ro rpp r BOTH
brakes toaeth.r, be.ause srdden or haBh appliGtion of etrher brakc only, under 3u(h
@nditi6n!, mat r6!li in a skid.
In all rcnditions. n is advArble to mlle i ha6'r ol alw.r utn! borh bBtc\ to.cther
6'ha'(hrnhib(ualrtusiisrh"reirb.ak€lndresen,nriFefro;tbrurefo.emeiency.
CHECKING OIL CIRCULATION
Prov riotr s made !o obscfve the o I in circu rrion ?nd k s advtab e to do rhis b.fore
rr thc fl ef crp on the oi tank h rcmoved thc ben! ovcf end ot thc oil fetrrn p pc w tl
be noiiccd some two in.hes below thc leve olihcfler.ap oficeand the reiur. n8
orr cin bc seen funning from it, Thh cho.k shoutd be made immediarety after n!tr .!
th. cngine r.oh coltl, Th s is bec.ure whi c the engin. is *rt onary, oi trom a prrB
orihc interiorofih. engine drrins brck (rorh.crai{.aicsump,sothat,un(trhij:u.pus
k ( ea.cd, rhe feturn low tr very posittvo and .onrinuous. Theretore, irrhe oit<irruta.
.ion k deran86d, rhe la.i is rpprcnr.t ohcc by the )ack ota sieady relurn flow.
lllu*ration 4
Showins the oir tank with the felt
lilt€r in its.ylindri<al houring and
the metal srrainer mounted on the
entrt end of the le€d pipe qnlon.
Also shows the direction ol no{ of
oil trom tank to ensine and retlrn
nowfrom €nsinetotankviathermall
rpolt, locat€d so that ir .an b.
intpe.ted by removing the trnk
For the convenience of Owners, SPARES
STOCKISTS are appointed for most districts.
To save delay, and the del very surcharge,
customers are recommended to always first
apply to rheir nearest Agent or spares stockist.
t5
LUBRICATION
LUBRICANTS TO USE
Eficient lubric.!on h ol vital impoftance and it k lahe economy to use cherp olh dnd
We rc.omhenn the loilowing lubricants io use id machines orouf makc :
FOR ENGINE LUBR]CATION
SUMMER
Caslro ..Grand Prix"
W NTER
Mobilo A (SAE-30)
Double shc I (SAE 30)
E$o ubc 30 (SAE-10)
Pricet En€rgol lO (SAE-30)
Cx*ro XL 1SAE-1o)
(sAE-60)
(sAE-50)
(sAE-60)
(sAE-60)
(sAE,60)
FOR GEAR BOX LUBRICATLON
MobiolD (SAE-60)
Triple shell (SAE-501
E*o ube s0 (SAE-50)
Pricet Energol 60 (sAE 60)
Cxs.rol Grand Prix (sAE 60)
FOR HUB LUBRICATION AND ALL FRAME PARTS USING GREASE
Mobilsrease No.2
Sh€ll Retinax Gr€ase C,D.
Esso cfease
FOR TELEDRAULIC FRONT FORKS AND TELEDRAULIC REAR LEGS
(sAE.20)
' 6AE-20)
(sAE-2C)
(sAE-20)
6AE-20)
When bu/ing olk and sfeases it s advkable !o specify th€ Brand a well as the sfane
md,asanadnitionaofecrution,tobryonyiiscilcd.ontaineEdrlrombrandcd.abncts.
FILLING THE GREASE GUN
Thc stailrrd Er€nse gun cons sts ol a brtre havin8 a spfins oaded end .ap, to whlch
trrredr(e1. rl re"l o o"' 'r"5fapcofalo-sr.d. T1(psor4R nloa!m.ll
cyl lder Fade'n onc $i \ r a (ir ^cn roP c.p. o_ lhe e d or$h - . tie lupped nozz o
!r1!'soie thegrere Dple. 1 !te ba"-c' oi lfc g ' . 'd.ld.'Bo-r1.ce-r..|
Dkton rod- is a cork Dnton.
Thc greree must be n lcd od the ToP ol ih..ork p*on, The sun may b€ fi led by
ins.ftint the 8rede ln the barr€l ol the Eun by means oia lath or similar " spoon."
Howcvcr, it k bcttcr.o obtain the grese Flcked in the specirl contrir€rs.ha! ar.
ovcr rhc hor€ or 'he . cnr',1 noJr'nB plarc rnd pre$ing downqrdi rhe Eun u '.i.ndt
(ha.ged wirh Brede. T$i.rin8'he GUn, a.d, rt rhc $mc r'm., rrk'ng'rrwrt lrcm the
floldn8 plrte, leaves ihc top orthc gun barrcltl6h wirh sr€se. and then lll rhat redain3
!o be don. k.o replrethe screwed 6p cap.
ENGINE LUSRICATION SYSTEM
Th r k by nrl slmp sy$en. oilrccd!, by sraviry, from the oiltankro th€ pump in th€
.rankcde, Th€ Dumo lorces oi to various oaft!, whi.h then drains to the b.tt6m 6l
cmn<aosump- Tho pump thcn re(ufnr oll !orh€tnnk. Thk proce$ h contlnuou!
whlle lhe engine is revovlng. The pump 5 lesigned to reiurn more oil to ihc lan(
than tcrnfof.eintotheengine. Therclorcthccrln(c6csump k kept. earofexce$ol,
A feir crrftidSe n rcf, id rhe o I tank, femov.! loreisn malrer co lecrej by rhe oll ln its
pdsage lhrou8h rhe ensine. A nelaigauze lirqiner i5 ntted !o the oilleed pipc ln th.
o ta-k to p'er"1r p" " o ll'{, rr., sfic\ -a/ n1d r 'r'. rr/ ' 'ro 'l.e dnt wl.en
reple.hfint. i.om erkri,g tne oi, pLmp. (5ee llnr'rL o1 4,)
Fcltfiltcr&d mctal shaide. rh6uld bcclcancd in pctolcich tiherh€ diltank irdrain.d.
ENGINE OIL PUl.IP
Th€ pump haonlyonc mov'nB p2'r thuuihcplun8crwhi.hr.volveirndre<lpr4.t.s,
Rotrtior s .rused bv rhe worm Seir on r\e dnhg !ide tlvwheel a,le. Reciprocarlon
k .llied bv t\e BLi!e pi wL (l- e,gages 1 !fe p-o'leo B oorc (L' on rLc plLn3.r.
Oll k'cd to t5c pL np'5 ou8h rr^ o4cr of rh. rco o pipes betleen hrk a1! c.arl-
.a!e dnd l5 retufned throush rhe uppef plpe,
lf, fo- anv relo-, '1" r "" !, e l-c res a-€ ,epr-a!eo. (he oit pump ptuna.r hu3!
b€ remov.d trom its housing befor. aR.mpting to separar. (he .r.nkcar.
ENGINE OIL CIRCULATION
The oil pump forces oilthrough :
{d) A ps:r8e cur rhtuuBh 'he uming rde n,/wheetrxte, r'mins side flrwhc.r rnd crank
pin to lubridre $e bi8 cnd beannS. The spllsh pa.esro'n'p"o' olctlind.., to
lubrica(b rhe ctlinder a4d pkron, rnd thcn fJlk Inro the cnnl rise sump,
rb) A p:s$Be In (rank(ase,.orr'ollcd b/ brttvr'vc. dir.cr ro rhc.tt'ndcr, to ssist :n
c/l nder ald D.vo' lLb ar'o and t\en ral!'rr. (-e \'an .!e imp,
(c) A,PNlge in iimins seaf cse where i bui ds up i to . predetermined teve !o
ubrlcale ihe riming gears a^d then tr k into !he ciankc6e sump,
(dl -LrorSn r pipe r'oi ' - orLofotD-rDlo,,nErcrterocte-bo.bvwht.h
al -o(.er s"rr ar o va ?. . n, ,.e Lo-klied rnd rnen J. t rourh lhe DUsh roo
.o..rLb* 1-o pDerB'iae.roihctri-88ci' Irr"'d,I'on h"'".ddn,i-to
rne crnnk.rse sumD, r dcbied in Prd. a.t.
Tte ol pLmp e,rncr. oi '1 Ll-e (.r r'.care srnD rnd retu-
it pr$e. rhrouSl rne iel! crri'dRe fi 'ter'oca!ed rn rne o,t un, .
t7
En8in. Oil Circul.tion
'
I
I
THE OIL TANK AND FILTERS
Tha level ol oil in the 3upplr tank should nev.r be allowed to lall below the low level
mark and, upon replenthnent. should not b€ higher (han one inch rrom lhe liller cap
orifr.e, otherwise, when rtrnins rhe.i6ine, the bulk oto!l in the crankcile sump may be
sreat$ than the space aviihble in th. iank.
The oi lilter is made n .ylndrica lofm 6lthick te t.nd k suppotred by a tuburaf wife
ese. The felt is not dcdchable lrcm the ege.
ta
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1
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