Matchless 1949 CLUBMAN G3L User manual

MATCHLESS
MOTOR CYCLES
PROPRIETORS : ASSOCIATED MOTOR CYCLES LIMITED
PLUMSTEAD · LONDON · S.E.18
MAINTENANCE
MANUAL
AND
INSTRUCTION
BOOK
for
1 9 4 9
350 c
.
c. and 500 c.c.
CLUBMAN MODELS
O
.
H.V., MA TCHLESS
EDITION CM-7

Supplied free, upon application, with each new motor cycle. Replacement Copies, 2/6 each
EDITION CM-7
A — M
Matchless Motor Cycles
MAINTENANCE MANUAL
AND INSTRUCTION BOOK
for 1949
Models 49/G3L and 49/G80L
Compiled and Issued by the Manufacturers :
MATCHLESS MOTOR CYCLES
(Proprietors: ASSOCIATED MOTOR CYCLES LIMITED)
Registered Offices:
PLUMSTEAD ROAD, PLUMSTEAD
LONDON, S.E.18 .. ENGLAND
Nearest Station :
WOOLWICH ARSENAL
(Southern Railway)
Factories :
BURRAGE GROVE and MAXEY ROAD
PLUMSTEAD, S.E.18
Telegrams and Cables: "MATCHLESS, WOL-LONDON"
Telephone : WOOIwich 1 22 3 (5 Lines)
Codes : A.B.C. 5th and 6th Edition ; Bentley's ; and Private Codes
All correspondence to :—
MATCHLESS MOTOR CYCLES, PLUMSTEAD ROAD, LONDON, S.E.18

1949 MATCHLESS "Clubman" MODELS
350 "CLUBMAN" Model G3L 500 "CLUBMAN" Model G80L
49/G3L — Bore 69 mm. Stroke 93 mm. Capacity 347 c.c.
49/G80L — Bore 82·5 mm. Stroke 93 mm. Capacity 498 c.c.
Motorcycling is one of the most economical and pleasurable
modes of transport. It is our sincere wish that every
" MATCHLESS" owner should obtain, from his mount, the
service, comfort and innumerable miles of low-cost travel
that we have earnestly endeavoured to build into it.
However, it must be remembered that although a motor cycle
is of simple design and construction, it is, nevertheless, a
highly specialised piece of engineering. In consequence, it
must be intelligently and efficiently maintained in order to
provide unfailing reliability.
In this book are non-technical instructions for carrying out
all the maintenance operations likely to be called for in
strenuous service and illustrations are provided to assist.
Neglect to make essential adjustments, only casual attention
to lubrication and the lack of periodical maintenance attention
will soon neutralise the best efforts of the designers and may
bring needless trouble to the owner.
We are always pleased to give " MATCHLESS " owners the
full benefit of our wide experience in matters relating to
motor cycles of our manufacture and in paragraph 113 will
be found details of the particulars that should be given us
when making such an enquiry.
MATCHLESS MOTOR CYCLES
INTRODUCTION
2

DATA
1 DATA
(a) Description.
Models
Engine number
Frame number
Cubic Capacity (Actual)
Cylinder bore
Stroke
Compression Ratio
Standard
"350"
"500"
350 & 500
350 & 500
350
500
350
500
350 & 500
350
500
500
Stamped on left-hand side of crankcase.
Stamped on right-hand side of seat lug.
(Below saddle).
347 Cubic Centimetres.
498 Cubic Centimetres.
69 Millimetres.
82.5 Millimetres.
93 Millimetres.
6.4 to 1.
6.2 to 1. (With plate fitted).
7.47 to 1. (No plate fitted).
(b) Capacities.
Front fork
Gear box
Oil tank
Petrol tank
10 fluid ounces, 284 c.c.
20 fluid ozs. (1 pint), 568 c.c.
4 pints.
3 gallons.
(c) Carburetter.
Main Jet size
Throttle size
Choke size
Taper needle
350
500
350
500
350
500
350
500
150.
180.
6/4.
29/4.
1 inch diameter.
1-3/32 inches diameter.
T-6-Std.
T-29-Std.
(d) Chains.
Front chain
Rear chain
Dynamo chain
Magneto chain
350
500
350 & 500
350 & 500
350 & 500
½"pitch,
½"pitch,
s"pitch,
a" pitch,
a" pitch,
.305 wide, 66 links.
.305 wide, 67 links.
.380 wide, 94 links.
.225 wide, 49 links.
.225 wide, 58 links.
B—M
Taper needle located in 3rd notch from top, 350, and 2nd from top, 500.
(Dynamo and Magneto chains are " endless.")
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3

(e) Gear ratios (Touring).
Top
Third
Second
First
350 Solo.
Engine Sprocket,
18teeth
5.83 to
1
7.5 to 1
10.2 to 1
15.5 to 1
500 Solo.
Engine Sprocket,
21 teeth
5.0 to
1
6.4 to 1
8.8 to 1
13.4 to 1
500 Sidecar.
Engine Sprocket,
19teeth
5.4 to 1
7.0 to
1
9.6 to 1
14.6 to 1
(f) Gear Ratios (Competition).
Top
Third
Second
First
350 Solo.
Engine Sprocket,
6 teeth 17 teeth
6.56 6.13
8.38 7.93
14.42 12.91
20.94 19.58
500 Solo.
Engine Sprocket,
18 teeth 19 teeth
5.83
7.46
12.84
18.50
5.49
7.1
11.55
17.52
(g) Ignition setting.
The ignition setting, with the ignition control in the fully advanced position, is
½"before top dead centre.
(h) Sparking plug.
Type
Thread
Reach
Point gap
LODGE H-14,
14Millimetres.
½".
.020" to .025".
(i) Piston dimensions.
Top land
Second land
Third land
Top of skirt
Bottom of skirt
350
2.6877"
2.6962"
2.6962"
2.7172"
2.7177"
500
3.2145"
3.2260"
3.2190"
3.2485"
3.2490"
(j) Piston rings
All above measurements are subject to a toleration limit of + or — .0005".
Model
350
500
Diameter
2-23/32"
3¼"
Width of
Com-
pression
ring
z"
z"
Width of
Scraper
ring
8"
8"
Ring
gap
(Normal)
.006" to
.008"
.006" to
.008"
Maximum
permiss-
ible wear
.030"
.030"
Clearance
in
groove
.003"
.003"
Two compression and one scraper ring are fitted to each piston.
All piston rings supplied by us are "gapped " before despatch and therefore
are ready for immediate fitting and use.
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4

(k) Spokes. (300 and 500).
(I) Valve timing. (350 and 500).
(m) Valves.
(n) Gear box ratios.
(o) Wheel sizes. (350 and 500).
(p) Weight Unladen.
Front, left side. 5 x"by 8g. by 10g. Butted.
Front, right side. 8 8" by 9g. by 11g. Butted.
Rear, both sides. 8 8" by 6g. by 9g. Butted.
Spoke lengths are measured under the head. (Not overall length).
Inlet valve opens 32° before top dead centre.
Inlet valve closes 63° after bottom dead centre.
Exhaust valve opens 65° before bottom dead centre.
Exhaust valve closes 30° after top dead centre.
(For checking, see Para. 49.)
Model
350
500
Clearance
(with cold
engine).
Nil.
Nil.
Inlet head
diameter
1-19/32"
1.687"
Exhaust
head
diameter
1½"
1.687"
Stem
diameter
a"
a"
Seat
angle
45°
45°
Valve head measurements are subject to a toleration limit of + or — 0005".
Valve stem actual measurement is minus .0035" to minus .0045" exhaust and .002"
to .003 ' inlet.
Standard Models
Top 1 to 1
3rd 1 to 1.28
2nd 1 to 1.76
1st 1 to 2.67
Competition Models
Top 1 to 1
3rd 1 to 1.28
2nd 1 to 2.09
1st 1 to 3.16
Touring Models:
Tyres. 26" by 3.25". (Front and back), 350 c.c. model.
26" by 3.25" Front, 26" by 3.50" Rear, 500 c.c. model.
Rims. 19" by 2½". (Front and back).
Front and rear rims are not interchangeable because the spoke nipple
diameters differ. Those used in the front are .225" in diameter and those
used in the rear are .250" in diameter.
Competition Models:
Tyres. 27" by 3.00" Front, 27" by 4.00" Rear.
Rims. 21" by 2¼" Front, 19" by 3" Rear.
Wheel bearing end play is .002".
350 c.c. Model — 340 lbs.
500 c.c. Model — 350 lbs.
5

CONTROLS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Throttletwistgrip.Twistinwardstoopen.Whenfullyclosedengineshould
justidlewhenhot.
Aircontrollever.Pullinwardstoincreaseairsupply.Onceset,whenengine
haswarmedup,requiresnoalterationfordifferentroadspeeds.Shouldbefully
closedtostartenginefromcold.
Ignitioncontrol.Advancesandretardsignitionpoint.Pullinwardstoadvance.
Retardtwo-fifthsoftotalmovementforstarting.
Valvelifterlever.Smallleverclosetoclutchlever.Liftsexhaustvalvefrom
seat,releasingcompressionincombustionchamber,enablingenginetobeeasily
rotatedforstarting.Alsousedforstoppingengineifthrottlestopisset
asadvisedinPara.(1)above.AlsoseePara.6.
Clutchlever.Largeleverinfrontoflefthand.Griptoreleaseclutchsothat
drivetorearwheelisdisconnected.Usedwhenmovingawayfromstandstill
andwhenchanginggear.
Frontbrakelever.Largeleverinfrontofrighthand.Griptooperatefront
wheelbrakeand,fornormalbraking,useinconjunctionwithrearbrakeappli-
cation.SeePara.9.
Rearbrakepedal.Depresswithleftfoottoapplyrearbrake.Applygently
anduseincreasingpressureasroadspeeddecreases.
Gearchangepedal.Controlsselectionofthefourspeeds,orratios,between
engineandrearwheelrevolutions,witha " free,"orneutral,position.See
Para.7 andIllustration3.
Kick-starterpedal.Thealmostverticalpedalonrighthandsideofgearbox.
FordetailsofuseseePara.5 andIllustration2.
Lightingswitch.Intopofheadlamp.Controlslampsbyrotatingleverwhich
hasthreepositions:—
(1)" OFF."Lampsnoton.
(2)" L."Pilotbulbinheadlampandrearlampon.
(3)" H."Headandrearlampson.Headlamphasa doublefilament.See
Item(17)below.
Ammeter.Intopofheadlamp.Indicatesflowofelectriccurrentin,orout,
ofbattery.("Charge" or" Discharge.")
Hornpushswitch.Depressbuttontosoundhorn.
Gearboxfillercap.SeeParas.23and66.
Footrest.Forrider.
Petroltankfillercap.Torelease,slightlydepress,turn,andthenliftaway.
Oiltankfillercap.OperatedasPetroltankfillercap(15).
Dippingswitch.Triggerswitchonlefthandlebar.Usedtoselectnormalor
"dipped" beamofheadlampwhenmainlightingswitchleverisinthe" H "
position.
2CONTROLS
6

Before using the machine, sit on the saddle and become familiar with the position and
operation of the various controls. Pay particular attention to the gear positions See
Para. 7 and Illustration 3.
Although all the controls are adjustable for position, the only ones that may require
alteration to suit the individual taste of the rider are the foot brake pedal (see Para. 89),
and the gear change foot pedal (see Para. 7). If any adjustment is made to the rear
brake pedal make certain the brake does not bind and also see there is not excessive
free pedal movement before the brake comes ',' on." (See Para. 90).
Illustration1
Showing Controls.
C—M
7

DRIVING
3FUEL
AtthetimeofpublishingthisInstructionBookonlyonegradeofmotorfuelison
sale,butitmaybethatsoonthevariousgradesofpre-warpetrolwillagainbe
available.
Werecommendtheuseonlyofbestqualityfuelbecausethesmallamountofeconomy
thatmightbeconsideredtoaccruebyusingthecheaperfuelsismorethanoffsetby
theadvantagesobtainedbyusingonlyNumberOnegrades.
Whenusinganti-pinkingfuels,ifbyreasonoftravellingslowlyintopgear(suchas
mayoccurunderheavytrafficconditionsorwhenascendinga steephill),theengine
commencestolabour,itisnecessarytochangedowntoa lowergearinorderto
lessonthestrainontheengineandtransmission.A gooddriverisabletosense such
conditionsandwillmakethechangebeforetheenginehasreachedthestageofdistress.
Rememberthegearboxisprovidedtobeusedandfulluseshouldbemadeofthe
lowergearsinordertoobtaineffortlessrunningandhillclimbing.
4FUELSUPPLY
Twopetroltapsaresituatedunderneaththerearendofthepetroltank.(Oneeach
side).Bothmustbeshutoffwhenthemachineisleftstandingformorethana few
minutes.
Thetapplungersworkhorizontally.Toopen,thehexagonknob(marked" Push-On")
ispushedtowardsthebodyofthetap.Toclose,presstheroundmilledknob(marked
"Push-Off").
Normally,onlyusethetapontherighthandsideofthemachineandtheothersidewill
thenactasa reservesupply.Alwaysre-fuelassoonaspossibleafterbeingforcedto
calluponthereserve,andthenatonceclosethe" reserve " tap.
Itwillbenotedthat,byfittingtwopetroltaps,itispossibletoremovethepetroltank
fromthemachinewithoutthenecessityoffirstdrainingitoffuel.
Illustration 2
Kick-starterquadrant
andratchetpinion.
8