Matchless 46/G3L 1946 User manual

MATCHLESS
MOTOR CYCLES
PROPRIETORS : ASSOCIATED MOTOR CYCLES LIMITED
PLUMSTEAD · LONDON · S.E.18
MAINTENANCE
MANUAL
AND
INSTRUCTION
BOOK
for
1 9 4 6
350 c
.
c. and 500 c.c.
CLUBMAN MODELS
O.H.V., MA TCHLESS
EDITION CM-1
(Revised)

Supplied free, upon application, with each new motor cycle. Replacement Copies, 1/6 each
EDITION CM-1 (Revised)
A — M
Matchless Motor Cycles
MAINTENANCE MANUAL
AND INSTRUCTION BOOK
for 1946
Models 46/G3L and 46/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

1946 MATCHLESS "Clubman" MODELS
350 "CLUBMAN" Model G3L 500 "CLUBMAN" Model G80L
46/G3L — Bore 69 mm. Stroke 93 mm. Capacity 347 c.c.
46/G80L — Bore 82·5 m.m. Stroke 93 mm. Capacity 498 c.c.
Motorcycling is one of the most economical and pleasurable
modes of transport. It is our slncere wish that every
"MA T C H L E S S " 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 "MATC HL ESS " 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

(a) Description.
Models
Engine number
Frame number
Cubic Capacity (Actual)
Cylinder bore
Stroke
Compression Ratio
"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.
6.3 to 1.
5.97 to 1. (With plate fitted).
7.24 to 1. (No plate fitted).
(b) Capacities.
Front fork
Gear box
Oil tank
Petrol tank
.
6½ fluid ounces.
1 lb. 14 ozs.
3 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.
Taper needle located in 3rd notch from top, 350, and 2nd from top, 500.
(d) Chains.
Front chain
Rear chain
Dynamo chain
Magnetochain
350
500
350 & 500
350 & 500
350 & 500
½" pitch,
½" pitch,
s"pitch,
a" pitch,
a" pitch,
.305 wide, 67 links.
.380wide,91 links.
.225 wide, 47 links.
.225 wide, 58 links.
(Dynamo and Magneto chains are "endless.")
DATA
1 DATA
.305 wide, 65 links.
…
…
…
…
…
…
…
…
…
…
…
…
3

(e) Gear ratios (Touring).
Top
Third
Second
First
350 Solo.
Engine Sprocket,
18 teeth
5.8 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,
19 teeth
5.5 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,
17 teeth
6.13
7.93
12.91
19.58
500 Solo.
Engine Sprocket,
19 teeth
5.49
7.1
11.55
17.52
(g) Ignition letting.
The ignition setting, with the ignition control in the fully advanced position, is
v" before top dead centre.
(h) Sparking plug.
Type
Thread
Reach
Point gap
CHAMPION L-10 on 350 c.c. LODGE H-145 on 500 c.c.
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-
2.7132"
2.7143"
500
3.2145"
3.2260"
3.2190"
3.2435"
3.2446"
All above measurements are subject to a toleration limit of + or — .0005".
(j) Piston rings
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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……………
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… … … … … … …
…
… … … … … … …
… … … … … … …
… … … … … …
… … … … … …
4

(k) Spokes. (300 and 500).
Front, left side, 5 m" by 8g. by 10g. Butted.
Front, right side, 8 x" by 9g. by 11g. Butted.
Rear, both sides, 8 x" by 6g. by 9g. Butted.
Spoke lengths are measured under the head. (Not overall length).
(I) Valve timing. (350 and 500).
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.)
(m) Valves.
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".
(n) Valve springs. (350 and 500).
2.gnirpsevlavretuOfohtgneleerF z".
Free length of Inner valve spring. 1 m".
Renew valve springs when free length is more than xevobaehtwoleb"¼ot"
measurements.
(o) Wheel sizes. (350 and 500).
Tyres. 26" by 3.25" (Front and back).
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.
Wheel bearing end play is .002".
B—M
5

CONTROLS
2 CONTROLS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Throttle twist grip. Twist inwards to open. When fully closed engine should
just idle when hot.
Air control lever. Pull inwards to increase air supply. Once set, when engine
has warmed up, requires no alteration for different road speeds. Should be fully
closed to start engine from cold.
Ignition control. Advances and retards ignition point. Pull inwards to advance.
Retard two-fifths of total movement for starting.
Valve lifter lever. Small lever close to clutch lever. Lifts exhaust valve from
seat, releasing compression in combustion chamber, enabling engine to be easily
rotated for starting. Also used for stopping engine if throttle stop is set
as advised in Para. (1) above. Also see Para. 6.
Clutch lever. Large lever in front of left hand. Grip to release clutch so that
drive to rear wheel is disconnected. Used when moving away from standstill
and when changing gear.
Front brake lever. Large lever in front of right hand. Grip to operate front
wheel brake and. for normal braking, use in conjunction with rear brake appli-
cation. See Para. 9.
Rear brake pedal. Depress with left foot to apply rear brake. Apply gently
and use increasing pressure as road speed decreases.
Gear change pedal. Controls selection of the four speeds, or ratios, between
engine and rear wheel revolutions. with a " free," or neutral, position. See
Para. 7 and Illustration 3.
Kick-starter pedal. The almost vertical pedal on right hand side of gear box.
For details of use see Para. 5 and Illustration 2.
Lighting switch. In top of head lamp. Controls lamps by rotating lever which
has three positions :—
(1) "OFF." Lamps not on.
(2) " L." Pilot bulb in head lamp and rear lamp on.
(3) " H." Head and rear lamps on. Head lamp has a double filament. See
Item (17) below.
Ammeter. In top of head lamp. Indicates flow of electric current in, or out,
of battery. (" Charge " or " Discharge.")
Horn push switch. Depress button to sound horn.
Gear box filler cap. See Paras. 23 and 66.
Footrest. For rider.
Petrol tank filler cap. To release, slightly unscrew and then lift away.
Oil tank filler cap. Operated as Petrol tank filler cap (15),
Dipping switch. (Not Illustrated). Trigger switch on left handlebar. Used to
select normal or " dipped " beam of head lamp when main lighting switch lever
is in the " H " position.
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 ofthe 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).
Illustration 1
Showing controls. The dip switch (reference 17) it not shown but Is
situated close to the ignition control.
7

DRIVING
At the time of writing this instruction book only one grade of motor fuel is on sale
but it is certain that, very soon, the various grades of pre-war petrol will again be
available.
We recommend the use only of best quality fuel because the small amount of economy
that might be considered to accrue by using the cheaper fuels is more than offset by
the various advances obtained by only using Number One grades.
Fuel to which " Lead " has been added will materially prevent " pinking " but it is a
very debatable point whether the use of such a fuel, which discourages the use of the
gear box, is not generally detrimental. It must be remembered that the gear box
is there to used and therefore we suggest the use of " straight '' petrol plus the
free use of the gear box to prevent the engine labouring under heavy stresses at low
engine speeds.
Two petrol taps are situated underneath the rear end of the petrol tank. (One each
side). Both must be shut off when the machine is left standing for more than a few
minutes.
The tap plungers work horizontally. To open, the hexagon knob (marked " Push-On ")
is pushed towards the body of the tap. To close, press the round milled knob (marked
" Push-Off " ).
Normally, only use the tap on the left hand side of the machine and the other side will
then act as a reserve supply. Always re-fuel as soon as possible after being forced to
call upon the reserve, and then at once close the " reserve " tap.
It will be noted that, by fitting two petrol taps, it is possible to remove the petrol tank
from the machine without the necessity of first draining it of fuel.
Illustration 2
Kick-starter quadrant
and ratchet pinion.
3 FUEL
4 FUEL SUPPLY
8