Matchless G2CS User manual

INSTRUCTION BOOK
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Issued by:
MATCHLESS MOTOR CYCLES : LONDON S.E.18
Proprietors: ASSOCIATED MOTOR CYCLES LTD.
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INSTRUCTION BOOK
MATCHLESS
MODEL G2 250 c.c. O.H.V.
MODEL G2S 250 c.c. O.H.V. SPORTS
MODEL G2CS 250 c.c. O.H.V. SCRAMBLER
MODEL G5 350 c.c. O.H.V.
Factories:
BURRAGE GROVE and MAXEY ROAD
PLUMSTEAD, S.E.18
Telephone: WOOIwich 1223 (7 lines)
Telegrams: "MATCHLESS, WOL-LONDON"
Cables: "MATCHLESS WOL-LONDON" TELEX 22617
Codes: A.B.C. 5th and 6th Edition; Bentley's; and Private Codes
Registered Offices:
PLUMSTEAD ROAD, PLUMSTEAD
LONDON, S.E.18 ENGLAND
MATCHLESS MOTOR CYCLES : L ONDON S.E.18
Proprietors: ASSOCIATED MOTOR CYCLES LTD.
Issued by
::
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Carburetter
Controls
Data
Driving
Electrical Equipment
Engine
Forks and Frame
Free Service
Guarantee
Information
Lubrication
Maintenance
Repairs and Service
Spare Parts
Tools and Special Equipment
Transmission
Wheels and Brakes
22
7
4
8
40
15
30
52
55
47
10
14
49
53
54
25
37
CONTENTS
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HE MODERN MOTOR CYCLE unquestionably provides one of the
most healthy, economical and pleasant means of transport. In
addition, by reason of its superb braking, high power to weight ratio and
ease of control it is, if used with due care, one of the safest vehicles on
the road.
It is our sincere desire that every 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.
It must be borne in mind, however, that although of simple design and
construction, it is nevertheless a highly specialised piece of engineering
and must in consequence be intelligently and efficiently maintained in
order to provide unfailing reliability.
In this book we provide non-technical instructions for carrying out all the
maintenance operations likely to be called for in normal service, together
with assisting illustrations.
To owners of long experience we tender apologies for the elementary
nature of some of the contents of this handbook, but owners, whether
novice or expert, are advised to read the contents from beginning to end.
We are at all times pleased to give owners the full benefit of our wide
experience in matters relating to motor cycles of our manufacture and
elsewhere will be found details of the particulars required when making
enquiries of our Service Department.
Safety on the Road
N the interest of Safety on the Road, a few words of warning will not
be out of place.
The outstanding manoeuvrability of a motor cycle over most other
vehicles on the road makes it necessary to exercise caution at all times.
There are, unfortunately, a few motor-cyclists whose reckless driving
constitutes a menace not only to themselves but also to other road users
resulting in the totally false impression in some quarters that motor-
cycling is a dangerous pastime.
REMEMBER IT IS NOT THE MOTOR CYCLE THAT CAUSES
ACCIDENTS, IT IS THE MAN WHO IS RIDING IT.
Take a pride in your riding technique and never rely upon the other
fellow doing the right thing,
Your example of careful and courteous riding will materially contribute
to road safety and to the reputation of a fine sporting pastime.
NO ACCIDENTS PLEASE
Your motor cycle, as issued from the factory, is fitted with an efficient
silencing system, and with careful and unobtrusive driving, particularly
in built-up areas, will not cause annoyance to the general public-
Owners who interfere with the silencing system by removing the baffles
are purely exhibitionists and such conduct can only bring motor-cyclists
in general into disrepute.
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Data 350 c.c. Model G5
Identity
Engine Number On the crankcase near engine plate cowling
Frame number On right side of frame head lug
Cylinder bore 72 rnm.
Stroke 85·5 mm.
Cubic capacity 347 cc. (21·17 cu. ins.)
Carburetter
Type 389/42 Amal Monobloc (12° inclination)
Main jet (without air filter) 220
Main jet (with air filter) 220
Choke Size 18"
Throttle slide 3½
Needle position central (·106) pilot 29
Capacities
Petrol tank 3¼ nollag s (12·5 litres)
Oil capacity 2½ tnip s (1·4 litres)
Gear box 3tnip s (1·8 litres)
Front chain case 568 c.c.
Compression ratio
6·9 to 1
General
Seat height
Wheelbase
Weight
Ground clearance
29·5" (74 cms.)
53" (134·5 cms.)
340 Ibs. (154 kilos)
6" (15 cms.)
Cylinder bore
Nominal size
2·8345 + ·0005"
— ·0005 "
Piston size
Skirt diameter (taken at right angle to gudgeon pin top of the skirt)
High limit
Low limit 2·8286"
2·8276"
Piston rings
Compression rings diameter 72 mm.
Compression rings 3/64" width
Compression rings radial thickness ·151" — ·109
Scraper ring diameter 72 mm.
Scraper ring width E"
Scraper ring radial thickness ·109 — ·101"
Piston ring gap 800· "— ·013"
Ignition timing
¼" B.T.D.C.
Valve timing
Inlet valve opens
Exhaust valve closes 40° B.T.D.C. Xwith ·01 rocker clearance
40° A.T.D.C. X
Sparking plug
Chain sizes
Front (72 links) ·315" x ·628" Duplex
Rear (123 links) ½" x ·305
Gear ratio
Internal ratios 1·30 to 1, 1·85 to 1, 2·92 to 1
Actual ratios—Top 6·39 to 1
Third 8·32 to 1
Second 8·11 2 to 1
First 18·68 to 1
Engine
Clutch
Final drive
Rear wheel
22 teeth
46 teeth
18 teeth
55 teeth
Sprockets
K.L.G. FE. 80
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Data 250 c.c. Models G2 and G2S
Identity
Engine Number On the crankcase near engine plate cowling
Frame Number On right side of frame head lug
Cylinder bore 69·85 mm.
Stroke 64·84 mm.
Cubic capacity 248·5 c.c. (15·2 cu. ins.)
Carburetter
Type 376/99 Amal Monobloc (12° inclination)
Main jet (without air filter) 180
Main jet (with air filter) 180
Choke size 1z"
Throttle slide 3½
Needle position central (·106) pilot 25
Capacities
Petrol tank 3¼ nollag s (12·5 litres)
Oil capacity 2½ tnip s (1·4 litres)
Gear box 3 pints (1·8 litres)
Front chain case 568 c.c .
Compression ratio
7·8 to 1
General
Seat height 30" 7( 6 cms.)
Wheelbase 53" (134·5 cms.)
Weight 325 lbs. (148 kilos)
Ground clearance 5½" 1( 4 cms.)
Cylinder bore
Nominal size 2·7500 + ·0005"
— ·0005"
Piston size
Skirt diameter (taken at right angle to gudgeon pin top of the skirt)
High limit
Low limit 2·7488"
2·7480"
Piston rings
Compression rings diameter 2¾" (69·85 mm.)
Compression rings width ·0625"—·0615"
Compression rings radial senkciht s ·112—·106"
Scraper ring diameter 2¾" (69·85 mm.)
Scraper ring width ·156"—·155"
Scraper ring radial senkciht s ·112—·106"
Piston ring gap 310·—"800· "
Ignition timing
¼" B.T.D.C.
Valve timing
Inlet valve opens
Exhaust valve closes 40° B.T.D.C.
40° A.T.D.C. with ·01" rocker clearance
Sparking plug
K.L.G. FE. 80
Chain sizes
Front (73 links)
Rear (125 links) ax ·225 ½ x ·305
Gear ratios
Internal ratios 1·30 to 1, 1·85 to 1, 2·92 to 1
Actual ratios—Top 6·89 to 1
Third 8·96 to 1
Second 12·75 to 1
First 20·12 to 1
Sprockets
Engine
Clutch
Final drive
Rear wheel
21 teeth
50 teeth
19 teeth
55 teeth
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250 SCRAMBLES MODEL. Model G2CS
TECHNICAL DATA.
Engine capacity
Bore and stroke
Compression ratio
Carburetter AMAL Monobloc
Choke Diameter
Main Jet No.
Pilot Jet No.
Slide No.
Needle Position
Needle Jet
Petrol Tank Capacity
Oil Tank Capacity
Brakes
Rear Chain
Primary Chain
Sparking Plug (for running-in)
Sparking Plug (for racing)
Front Fork capacity
Ignition Timing
Engine Sprocket
Rear Wheel Sprocket
Clutch Sprocket
Gear Box Sprocket
248 c.c.
70 x 65 mm.
10·6 : 1
376/276
1z"
200
25
3
Four
·107
2·75 gallons
2·5 pints
6" dia.
131 links ½" x ·305"
55 links ½" x ·205"
FE. 80
FE. 220
6·5 ozs. S.A.E. 20
32° B.T.D.C.
17 teeth
70 „
37 „
17 „
GEAR RATIOS. 250 c.c. SCRAMBLES MODELS.
Internal Ratios.
First Gear
2·42 to 1
SecondGear
1·85 to
1Third Gear 1·30 to 1
Gear Ratios with 17 teeth Engine Sprocket.
First Gear
21·62 to 1
SecondGear
16·55 to 1 Third Gear 11·63 to 1Top Gear
8·95 to 1
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Controls
Throttletwistgrip.Onrighthandlebar.Twistinwardstoopen.Whenfullyclosed
engineshouldjustidlewhenhot,
ValveLifter.Smallleveronleftsidehandlebar,
Airlever.Smallleveronrighthandlebar.Pullinwardstoincreaseairsupplyto
carburetter.Onceset,whenenginehaswarmed up,requiresnoalterationfordifferent
roadspeeds.Shouldbefullyclosedwhenstartingenginefromcold.
Clutchlever.Largeleveronlefthandlebar.Griptoreleaseclutchsothatdriveto
rearwheelisdisconnected.
Frontbrakelever.Largeleveronrighthandlebar.Griptooperatefrontwheel
brakeand,fornormalbraking,useinconjunctionwithrearbrakeapplication,
Rearbrakelever.Pedalclosetoleftsidefootrest.Depresswithleftfoottoapply
rearbrake.Applygentlyanduseincreasingpressureastheroadspeeddecreases.
Gearchangelever.Pedalinhorizontalpositionclosetorightfootrest.Controls
selectionofthefourspeeds,orratios,betweenengineandrearwheelrevolutions,with
a''free"orneutral,position.
Kick-starterlever.Verticalpedalonrighthandsideofgearbox.
Gearindicator.Movesunderthecontrolofthegearchangeleverandthenumber
registeringwitha lineongearboxindicatesgearinengagement(orneutral).
Gearboxfillercap.Locatedonsideofgearcasecover.Allowsinsertionoflubricant
andaccesstoclutchinnerwireandinternalclutchoperatinglevel,
Petroltankfillercap.Locatedintopoffueltank.Torelease,slightlydepress,turn
fullytotheleft,andthenliftaway.Therearetwolockingpositions.Themiddleposi-
tion,betweenthefullytighteneddownand"liftaway"positions,isinthenatureofa
"safety"devicetopreventlossthatmightbeoccasionedbyunauthorisedmeddling.
Oilreservoirfillercap.Locatedonrightsidecrankcase.Toremove,unscrew.
Lightingswitch.Lefthandoneontopofheadlamp,withthreepositions:
OFF...Off.
L....Pilot,rearandspeedometerON.
H....Main,rearandspeedometerON.
Ignitionswitch.Righthandoneonheadlamp.Threepositions—EMG.,OFF.,IGN.
Turnclockwiseforignition.
Ammeter.Intopofheadlamp.Indicateschargeordischarge.
Dippingswitch.Onlefthandlebar.Operateswhenlampswitchisat"H".
Hornswitch.Onlefthandlebar,incorporatedwithDipSwitch.
Speedometer.Intopofheadlamp.
Beforeusingthemachine,sitonthesaddleandbecomefamiliarwiththepositionand
operationofthevariouscontrols.Payparticularattentiontothegearpositions,
Ifanyadjustmentismadetotherearbrakepedalmakecertainthebrakedoesnotbind
andalsoseethereisnotexcessivefreepedalmovementbeforethebrakecomes"on".
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FUEL
Althoughvariousqualityfuelsareagainavailableownersareadvisedtouseonlythebest.
Thesmalleconomythatmightbeconsideredtoaccruebyusingthecheapergradesis
morethanoffsetbytheadvantagesobtainedbyusingonlyPremiumGrades.
FUELSUPPLY
Twofuelfeedtapsaresituatedunderneaththerearendofthepetroltank.(Oneeach
side).Bothmustbeshutoffwhenthemachineisleftstandingformorethana few
minutes.
Normally,onlyusethetapontherighthandsideofthemachineandthentheotherside
willactasa reservesupply.Always re-fuel assoon aspossible after being forced COcalf
upon the reserve andthen, atonce, dose the "reserve"tap.
STARTINGTHEENGINEFROMCOLD
SPECIALNOTE
ItisNOTnecessarytofloodthecarburetter,bydepressingtheplungeranthe
floatchamber,beforeattemptingtostarttheengine.Floodingthecarburetter
unnecessarilywillresultindifficultstarting.
Checkthatthereissufficientfuelinthepetroltank.
Checkthatthereissufficientoilintheoilreservoir.
Checkthatthegearpedalisintheneutralposition.
Turndownleverofoff-sidepetroltap.
Checkthattheaircontrolleverisinthefullyclosedposition.
Depressthekickstartertwoorthreetimestorotateandfreetheengine.
Openthethrottletotheslightestamountpossible.
TurntheignitionswitchtoIGN.Raisevalveliftertoreleasecompression.
Givethekickstartera long,deliberateswingingkickwhentheengineshouldcommence
running.
Donotallowthekickstartertoreturnviolentlyagainstitsstop.
Thekickstartermechanismmustbeallowedtoengageproperlybeforeputtingheavy
pressureonthekickstartercrankpedalpin.Thatmeanstherearetwodefiniteand
separatemovementswhenoperatingthemechanismbydepressingthecrank.
Thefirstisa slowandgentlemovementwhichendswhenitisfeltthepawlhasengaged
withtheteethontheratchetpinion.
Aftertheenginehasstarted,slowlyopentheairlever.Thensetthethrottlesothatthe
engineisrunningata moderatespeed(neitherracingnortickingover)andallowto
warmup.Whiledoingthis,checktheoilcirculationasdetailedinpage11.Themachine
canthenbetakenontheroad.
STOPPINGTHEENGINE
Tostoptheengine,closethethrottle,TURNOFFIGNITION.Beforeleavingthe
machine,turnoffthefuelsupply.
ONTHEROAD
Havingstartedandwarmeduptheengine,takethemachineoffthestand,sitastrideit,
freetheclutchbypullingupthelargeleverontheleftbarandengagethelowestgear.
Next,slowlyreleasetheclutchleverandthemachinewillcommencetomoveforward.
Asitdoesthis,theenginespeedwilltendtodropasitpicksuptheloadsoitwillbe
necessarytoincreasethethrottleopening,gradually,tokeeptheenginespeedgently
rising.
Whenwellunderway,disengagetheclutch,slightlyclosethethrottle,engagesecond
gearandreleasetheclutchlever,thenopenupthethrottletoincreasethespeedof
themachine.Repeattheseoperationsinordertoengagethirdandtopgears.
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Driving
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Toengagea highergearthepedalispresseddownwardwiththetoeanda lowergearis
obtainedbyraisingthepedalwiththeinstep.Toengagefirstgearfromtheneutral
position,thepedalisthereforeraised.Aftereachpedalmovement,internalsprings
returnthepedaltoitsnormalhorizontalposition.
Thepedalmustbemovedtothefullextentofitstravelwhenselectinga gear,either
upordown.Itmustnotbe"stampeddown"orjabbed,butfirmlyanddecisively
movedtillitstops.A half-heartedmovementmaynotgivefullengagement.Keep
thefootoffthepedalwhendrivingandbetweeneachgearchangebecause,unlessthe
levercanfreelyreturntoitsnormalcentralposition,thenextgearcannotbeengaged-
RUNNINGINTHEENGINE
Itisa naturaldesiretolearnthecapabilitiesofone'smachine,similarlyitcanbeirritating
tobeovertakenbya riderofa machinefittedwitha smallercapacityengine.Never-
theless,theownerofa newmachinemust,inhisowninterest,strictlyadheretothe
principlesofrunningin,whichwillresultina quieterengine,witha betterperformance
thana simitarmachineownedbya riderwhoisunwillingtodrivewithrestraintduring
theinitialstageofrunningin.
Theloadimposedontheengineisgovernedbytheamountofthrottlethatisused,and
themakersofyourmachine,knowfromexperience,thatifthethrottleortwistgripis
notopenedinexcessofone-third ofits total movement forthefirst1,000milesindependent
ofroadspeed,theenginecannotbeoverloaded.
Afterthisdistancetheamountofthrottlecanbeprogressivelyincreased.
Specialattentionmustbegiven,duringtherunninginperiod,tosuchdetailsasvalve
rockeradjustment,chains,brakes,contactbreakerpoints,andsteeringheadbearings,
allofwhichtendtobeddowninthefirsthundredmilesorso.Particularnotemustbe
madeoftheadjustmentofsteeringheadbearings,which,ifrunina slackcondition,will
bequicklyruined.Afterthisbeddingdownprocesshastakenplace,adjustmentsto
suchdetailswillonlybenecessaryatlengthyintervals,
Donotoverlookinstructionsforchangingoil(seepage14).
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LUBRICANTSTOUSE
Efficientlubricationisofvitalimportanceanditisfalseeconomytousecheapoilsand
greases.Theuseofmultigradeoilsisnotrecommended.
Werecommendthefallowinglubricantstouseinmachinesofourmake.
FORENGINELUBRICATION
HOT
aboveSO0F
SAE50
MobiloilD
CastrolGrandPrix
EnergolSAE50
Essolube50
ShellX-100MotorOil50
COLD
32°F to 50° F
SAE30
MobiloilA
CastrolXL
EnergolSAE30
Essolube30
ShellX-100MotorOil30
EXTREMECOLD
belowfreezingpoint(32°F)
SAE20
MobiloilArctic
Castrolite
EnergolSAE20
Essolube20
ShellX-100MotorOil
20/20W
NOTE—FortheBritishIslesandmuchofEuropetheColdandHotrecommenda-
tionsapproximatetoWinterandSummerconditionsrespectively.
TheExtremeColdrecommendationsrefertowintryconditionsinparts
ofNorthernEurope,Canada,theBalticandScandinaviancountries,and
highmountainousdistrictswhereextremecoldistheaveragecondition.
FORGEARBOXLUBRICATION
HOT
above50°F
SAE50
MobiloilD
CastrolGrandPrix
EnergolSAE50
Essolube50
ShellX-100MotorOil50
COLD
32° F to50°F
SAE50
MobiloilD
CastrolGrandPrix
EnergolSAE50
Essolube50
ShellX-100MotorOil50
EXTREMECOLD
belowfreezingpoint(32°F)
SAE30
MobiloilA
CastrolXL
EnergolSAE30
Essolube30
ShellX-100MotorOil30
NOTE—FortheBritishislesandmuchofEuropetheColdandHotrecommenda-
tionsapproximatetoWinterandSummerconditionsrespectively.
TheExtremeColdrecommendationsrefertowintryconditionsinparts
ofNorthernEurope,Canada,theBalticandScandinaviancountries,and
highmountainousdistrictswhereextremecoldistheaveragecondition.
FORHUBLUBRICATIONANDALLFRAMEPARTSUSINGGREASE
MobilgreaseNo.4 CastroleaseHeavyEnergreaseC3
EssoPressureGunGrease.ShellRetinaxA.orCD.
250c.c.TELEDRAULICFRONTFORKS
MobiloilA (SAE-30)CastrolXL(SAE-30)Energol(SAE-30)
Essolube30(SAE30)ShellX-100MotorOil30(SAE-30)
350c.c.TELEDRAULICFRONTFORKS
MobiloilArctic(SAE-20)Castrolite(SAE-20)Energol(SAE-20)
Essolube20(SAE-20)ShellX-100MotorOil20(SAE-20)
FORREARCHAINS
MobilgreaseNo.2 EssoFluidGreaseEnergreaseA.O.
CastroleaseGreaseGraphited
HeatedUntilJustFluid.
WhenbuyingoilsandgreasesitisadvisabletospecifytheBrandaswellasthegrade
and,asanadditionalprecaution,tobuyonlyinsealedcontainersorfrombrandedcabinets.
10
Lubrication
10
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CHECKINGOILCIRCULATION
Provisionismadetoobservetheoilcirculating,whichisvisibleafterremovingtheoil
fillercapontherightsideofthecrankcase.
Illustration1
Cut-awaysectionofengine
ENGINELUBRICATIONSYSTEM
Thisisbytruedrysumpsystem.Theoiltank,orreservoir,isintegralwiththecrankcase.
Theoilpumphasonlyonemovingpart,i.e., theoilpumpplunger,whichrotatesand
reciprocates.Rotationiscreatedbythewormgearonthetimingsideflywheelaxle.
Reciprocationiscausedbyengagementoftheoilpumpguidepinwiththeprofitedgroove
intheoilpumpplunger.Theoilpumpisdesignedsothatthesumpscavengingcapacity
isgreaterthanthedelivery,thuskeepingthecrankcasesumpfreeofoilduringnormal
runningconditions
Whilsttheoilreservoirisintegralwiththecrankcase,oilisfedtothepumpbygravity,
onthesameprincipleasa machinefittedwitha separateoiltank,butwithouttheuseof
externaloilpipes.
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ENGINEOILPUMP(seelllstration1)
If,foranyreason,thecrankcaseisdismantledthe oil pump plunger must beremoved from
its housingbefore attempting toseparate the crankcase halves.Itisalsonecessarytoremove
thesmalltimingpinion.
IMPORTANT
Under no circumstances must either the pump plunger or guide screw be disturbed
in ordinary routine maintenance.
ENGINEOILCIRCULATION
Theoilpumpforcesoilthrough:—
(a)Passagesdrilledthroughthetimingsideflywheelaxle,timingsideflywheelandcrank
pintolubricatethetimingsidebearingandthebig-endbearing.Thesplashpasses
tointeriorofcylinder,tolubricatethecylinderandpiston,andthenfallsintothe
crankcasesump.
(b)Fromthefrontoilpumphousingtotherockerboxviapassagesinthecylinder
barrel,lubricatingtherockergearandvalvestems.Oilfromtherockergeardrains
bygravityviathepushrodtunnelstothetiminggearcaseata pre-determinedlevel.
Theover-spilldrainsintothecrankcasesump.
(c)Theoilpumpextractsoilfromthecrankcasesump,metalimpuritiesarecollected
bya magneticfilterincorporatedinthesumpdrainplug.Theoilisagainfilteredby
afeltfilterlocatedinthecrankcase(seeillustration1),beforereturningtothe
oiltankreservoir.
Forvalveguidelubricationseeparagraph"Adjustmentofoilfeed".
THEOILRESERVOIR
Thenormaloillevelis1 inchbelowthefillercaporifice,theoilcontentis2½pints.
Runtheenginefora shortperiodtoscavengethesump,before"toppingup".
Afterthefirst500miles(800kilometres)againat1,000miles(1,600kilometres)and
subsequentlyat3,000mileintervals(4,800kilometres)theoilreservoirshouldbedrained,
theoilfiltercleanedinpetrolandthereservoirreplenishedwithnewoil.Itispreferable
todraintheoilaftera runandwhentheoiliswarm.A drainplugisfittedtoboththe
crankcasesumpalsotheoilreservoir.Thedrainplugforthereservoirisclosetothe
bottomfrontcrankcasebolt.
THECRANKCASEFILTER
Thefilteriscylindricalinshapemadefroma close-grainedfelt,supportedbya wirecage.
Thefilterishousedinthedrive-sidecrankcase.(Seeillustration1).
TOREMOVETHEFILTER
UseAllenKey018667tounscrewthedomednutandtakeoutthespring.Removethe
capwasher,withdrawthefilterwithcaretoavoiddamage.Thoroughlycleanfilterin
petrolandreplacewhendry.
TOREMOVEMAGNETICFILTER
Incorporatedwiththecrankcasesumpplugisa powerfulmagnet,whichdoesnotrequire
frequentattention.Forcleaningplacea trayunderthecrankcase,unscrewthesump
plug,withtheuseofa goodfittingringspanner.
Metalparticlesadheringtothemagnetcanberemovedbywipingwitha greasecoated
rag,thegreasewillcollectmetalparticlesontherag.Keepthemagnetawayfrom
targepiecesofsteeloriron,ascontactcanimpairtheefficiencyofthemagnet.
ADJUSTMENTOFOILFEED
Theinternalflowofoiliscontrolledbyfixedrestrictions,withtheexceptionoftheoil
feedtotheinletvalveguide,whichisregulatedbya needlepointedscrewlocatedinthe
cylinderhead(seeillustration3)andsecuredbya locknut.
Toadjusttheoilfeedloosenthelocknutandscrewhomelightlytheregulatingscrew,
thenunscrewitthesmallestamountpossibleandretightenthelocknut.
Anexcessofoiltotheinletvalveguidewillcausea smokyexhaustandheavyoilcon-
sumption.
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EXHAUSTVALVESTEMLUBRICATION
Froma drillingintheexhaustrockeraxlebossintherockerbox,oilisfedtoa cavityin
thecylinderhead.A furtherdrillingfromthiscavity,throughthecylinderheadtoan
oilholeinthevalveguide,providespositivelubricationforthispartoftheengineand
needsnoadjustment.
CRANKCASERELEASEVALVE
Crankcasepressureisreleasedintotheatmospherethrougha timedandportedrelease
valve.Theportedportionforthisvalveissituatedbetweenthetwodrivingsidebearings,
thevalveoutletisadjacenttothegearboxhousing.Thevalvecannotbecomederanged
andneedsnoattention.
GEARBOXLUBRICATION
Totopuporreplenishoilforthegearboxremovetheinspectionplatesecuredbytwo
screwsonthegearboxendcover.
Useoneofthegradesofoilspecified,onnoaccountmustgreasebeused.
Thenormaloilcontentis3 pints(1·8litres),thegearboxmustnotbecompletelyfilled
withoil.Afterdrainingandreplenishingtheoilatthefirst500miles(800kilometres)
topupeverysubsequent1,000miles(1,600kilometres)toa leveljustbelowthebottom
oftheorificefortheinspectionplate.
FRONTCHAINLUBRICATION
Thefrontchainislubricatedwithengineoilfilledtothefrontchaincase,whichforms
anoilbath.Ifthelowerofthetwoslattedscrewedcapsonthechaincaseisremoved,
theoillevelcanbeobserved.Thecorrectoillevelisjustabovethebottomrunofthe
primarychain.Totopup,removebothslottedscrewedcapsandfillOilthroughthe
uppermostaperture,checkingthelevelthroughthelower.A drainplugissituated
immediatelybelowtheclutchassembly.Ifthechaincaseisdrained,refillwith1 pint
(·6litres)ofengineoil.
REARCHAINLUBRICATION
Whena totallyenclosedrearchaincaseis fitted,thechainis lubricatedby oilmist
dischargedfromthecrankcasereleasevalvetubeontothechain.Additionallubrication
shouldnotbenecessary.Wheretherearchainisexposeditshouldbelubricated
periodicallyparticularlyduringwintryorprolongedinclementweather.Foreffective
lubricationthechainshouldberemoved,cleanedinparaffin(kerosene)andimmersedin
greasethatisheateduntilitbecomesfluid.Removesurplusgreasebeforerefitting.
CAUTION:Whenrefittingthechainconnectinglink,theclosedendofthespring
clipmustfacethewaythechaintravels.
WHEELHUBLUBRICATION
Bothhubsarepre-packedwithgreaseduringassembly,whichpreventstheentryof
wateraswellaslubricatingthebearings.Afterthefirst5,000miles(8,000kilometres)
:andbefore10,000miles(16,000kilometres)dismantleandcleanthehubbearingsand
repackwithfreshgrease.
SPEEDOMETERLUBRICATION
Manuallubricationisnotnecessary,ifa greasenippleisnotfittedtothespeedo-
metergearbox.
REARFORKHINGE(SWINGINGARM)
Applygreasegunonnipplemountedontherightsideoftheforkhinge,duringroutine
maintenance(useS.A.E.140oil).
REARBRAKEPEDAL
Agreasenippleisfittedunderneaththepivotpartofthepedal*
GENERAL
Occasionallyapplya littleengineoiltopartssuchascontrollevers,andcables,brakerods,
stands,etc.Usea littlegreasetolubricatethetwistgriprotor.
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Maintenance
PERIODICAL MAINTENANCE
Regular maintenance attention to lubrication and certain adjustments must be made to
ensure unfailing reliability and satisfactory service. This necessary attention is detailed
below and owners are strongly recommended to carefully follow these suggestions and
to make a regular practice of doing so from the first.
14
DAILY
Oil Reservoir
Petrol tank
WEEKLY
Oil reservoir
Tyres
Inspect oil level and top-up if necessary. Check oil circulation.
Check level and refill if necessary.
Check level and top-up if necessary.
Check pressures and inflate if necessary. Inflator under twin seat.
EVERY 500 MILES (800 KILOMETRES)
Oil reservoir
Ignition
Gear box
Chaincase
Battery
Drain at first 500 miles and re-fill with new oil, and clean filters,
Check contact breaker points. Regrease felt pad.
Drain at first 500 miles and re-fill 1 pints (1·8 litres).
Check level of oil when machine is standing vertically on level ground.
(See chain lubrication).
Inspect each cell for level of electrolyte and top up with distilled water
if necessary. Level of electrolyte should just be over top of plates.
Beware of overfilling.
EVERY 1,000 MILES (1,600 KILOMETRES)
Oil reservoir
Rear chain
Gear box
Small parts
Chaincase
Drain at first 1,000 miles and re-fill with new oil.
In wet weather remove and soak in molten grease. See page 13.
Check oil level.
Smear all moving parts with engine oil and wipe off surplus.
Drain, and re-fill, or monthly.
EVERY 2,000 to 5,000 MILES (3,200 to 8,000 KILOMETRES)
(according to road conditions)
Air filter (If fitted) clean and re-oil filter element.
EVERY 3,000 MILES (4,800 KILOMETRES)
Oil reservoir
Filter
Rear chain
Brake pedal
Speedometer.
Ignition
Plug
Steering head
Drain and re-fill with new oil. If machine is only used for short runs
renew oil every three months instead of mileage interval.
Clean fitter in crankcase.
In dry weather remove and soak in molten grease.
Inject small amount of grease.
Inject grease into gear box if nipple is fitted.
Clean contact breaker points and re-set if necessary. Regrease felt pad.
Clean sparking plug and re-set points as necessary.
Test steering head for up and down movement and adjust if necessary.
Bolts and Nuts. Check all nuts and bolts for tightness and tighten if necessary but
Rockers beware of over-tightening. Check O.H.V. rocker adjustment and correct If necessary.
EVERY 5,000 MILES (8,000 KILOMETRES)
Ignition
Front fork
Carburetter
Clean and adjust contact points. Check gap.
Drain and re-fill with fresh oil.
Insufficient oil content is indicated by abnormally lively action.
Remove carburetter float chamber side cover and clean interior.
Also detach petrol pipe banjo and clean gauze strainer.
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EngineService
TAPPETADJUSTMENT
Thetopendsofthetwolongpushrodshavescrewedextensions.Thesearelockedin
positionbynuts,therebyprovidingtappetadjustment,
Thecorrecttappetclearances,withvalvesclosedandenginewarm(nothot)isNIL.
Thismeansthepushrodsshouldbefreeenoughtorevolveand,atthesametime,there
shouldbenoappreciableupanddownplay.
Preparetoadjusttappetsby:
SetpistontoT.D.C.(bothvalvesclosed).
Removethethreenuts,andfibrewashersunderthem,retainingtappetcovertorocker
box.
Takeawaycover.
Adjusttappetsby:
Withspanners,holdthesleeve5.eithervalve(illustration21andslackenlocknut2,
Thenscrew,inorout,thehead3 untiltheclearanceisnil.
Tightenlocknut2 andre-checktheclearance.
Finally
Checkadjustmentssothat,withnoupanddownmovement,thelongpushrodsarefree
torevolvewhenthevalvesareclosed.
Illustration2
Tappetadjustment
Completeadjustmentby:
Replacerockertappetcovertakingcaretoreplacethefibrewasherthatisundereach
retainingnut.
Asmentionedelsewheredonotover-tightenthenutsbecausethejointismadewitha
rubberfilletandunduepressureisnotnecessary.
NOTE—lnnormalconditionstappetadjustmentshouldnotbenecessarymorefrequently
thanabouteveryfivethousandmilesorafterdecarbonisingandgrindingvalves,
Ifadjustmentisfoundnecessarymorefrequentlythecauseshouldbeinvestigated
atonce.
Forserviceworkontheupperpartoftheengine,with
theexceptionoftappetadjustment,thetwinseatand
petroltankshouldberemovedforaccessibility.
15
1
2
3
4
INLETROCKERARM(TAPPETEND).
NUT,LOCKINGADJUSTINGCUPPED
SCREW.
CUPPEDADJUSTINGSCREW,
CUPPEDADJUSTINGSCREWANDLOCK
NUT.
5
6
7
SLEEVE.TOACCOMMODATEADJUSTING
SCREW,ONTOPENDOFPUSHROD.
EXHAUSTROCKERARM(TAPPETEND).
ROCKERBOXBOLT.
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TOREMOVETWINSEAT
Removetwoboltsundertherearendoftheseat,releasethenutssecuringthefront
portionoftheseat,whichnowcanbeliftedoff.
TOREMOVETHEPETROLTANK
Closebothpetroltaps,unscrewthetwocapnutssecuringthepetrolpipe(watchfor4
fibrewasherseachsideofthebanjounions).Takeouttwoboltssecuringthefrorntof
thepetroltankanda furtherboltsecuringtherear,notingthelocationofthetankbolt
rubbersandspacers,thefrontonesarethickthereararethin,thesteelwashersare
alsodissimilar.
TOREMOVETHEROCKERBOX
Removethethreenutsandfibrewasherssecuringtherockerboxcover,alsothesparking
plug.
Turntheengineuntilbothvalvesareclosed,i.e.,aftertheinletvalvehasopenedandjust
closed.
Removetworutsandtheboltsecuringtheenginesteadybrackettotherockerboxand
frame.Disconnectvalveliftercable.
Takeoutthenineboltssecuringtherockerboxtothecylinderhead(oneofthesebolts
isinsidetherockerbox(seeillustration2), thelocationoftheseboltsmustbenoted
astheyaredissimilar.
Tiltupwardstherightsideoftherockerbox,extractbothpushrodsandidentifytheir
locationforreplacementintheiroriginalpositions,removetherockerboxfromthe
cylinderhead.
TOREMOVETHECYLINDERHEAD
Removetheexhaustpipeandsilencerasoneunit,thentheaccessorycompartmentcover
andairfiltertubeiffitted.Donotrocktheexhaustpipesidewaysundulytoextractit
fromtheexhaustportwhichcancausetheendofthepipetocloseinandresultingas
leakage,alsomovementbetweenthepipeandtheportwhentheengineishot.Instead
squirta littleparaffinorpetrolintotheportandtryagain.
Unscrewthecaponthecarburettermixingchamber,cakeoutbothslides,wrapthem
ina pieceofragandattachittotheframe,outofharm'sway.
Unscrewthepetrolpipeunionandtakeawaythepetrolpipe.Foursleevenutsandone
boltretainsthecylinderheadtothebarrel,withtheseremoved,thecylinderheadwith
carburetterattachedtoitcanbeseparatedfromthecylinder.
DECARBONISATION
Insteadoftheusualstipulatedmileageintervalbetweenperiodsofdecarbonisation,itis
recommendedthatthisisundertakenonlywhentheneedbecomesapparentbecauseof
lossinpower,heavypetrolconsumptionorgenerallyreducedperformance.
Whenundertaken,unlessitisthoughtnecessarytoinspectthepistonandrings,the
cylinderbarrelisbestleftundisturbed.
Beforestartingthisworkhaveavailablea gasketset,andifthemachinehascovered
considerablemileage,a newsetofpistonringsalso,
Carbonformedonthepistoncrownandinthesphereofthecylinderhead,canbe
scrapedoffwitha cheapsteelrule,withthesharpcornersremoved,orsimilartool.
Dealwiththecylinderheadbeforeremovingthevalves,anddonotuseemeryclothor
otherabrasivesforthiswork,
TOREMOVEANDREPLACETHEVALVESANDGUIDES
Thevalvespringsareremovedbyinsertingtheindexfingerthroughthecoilofthe
springandpullingupwardssharply.
Alighttaponthevalvespringcollarwillexposethevalvesplitcollets(whichshouldbe
putina placeofsafety),thentakeoutthevalve.
Bothvalveguidesarelocatedbyanexternalcirclip,thecylinderheadmustbegentlyand
uniformlyheatedbeforeattemptingtoremoveorreplacetheguides.
Withtheheadpre-heatedtaptheguideupwardsoutoftheportsufficientlytoenablethe
circliptobeprisedoutofitsgroove.Reheattheheadanddriveouttheguidesthrough
thecylinderhead.Whenrefittingtheguides,pre-heattheheadandverifythattheoil
holesareinalignmentwithholesinthecylinderhead.
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Illustration3
Thevalveguidesandtheneedleadjustingscrewarealsoshownwithdrawn
VALVEGRINDING
Thegrindingisaccomplishedbysmearinga thinlayeroffinegrindingpaste(obtainable
readyforuseatanygarage)onthevalvefaceandthen,afterinsertingthevalve\nthe
head,partiallyrevolve,forwardsandbackwards,whileapplyinglightfingerpressureto
thehead,raisingthevalveoffitsseatandturningtoanotherpositionafterevery few
movements.(Neverrevolvethevalvecontinuouslyinonedirection,)
Whentheabrasiveceasestobite,removethevalveandexamineitsface.
Thegrindingmaybeconsideredtobesatisfactorilycompletedwhena continuousmat
ringisobservedonbothvalvefaceandseat.
Aftergrinding,alltracesofabrasivemustbecarefullywashedoffwithpetrolanda piece
ofrag,moistenedinpetrol,shouldbepulledthroughtheboreofeachvalveguideto
removeanyabrasivethatmayhaveentered.
Aholderforthevalve,whengrindinginthevalve,canbesupplied.Thepartnumber
is017482.
REPLACINGTHEVALVES
Avalvespringcompressorisrequiredtocompressthesprings,a specialtoolwhichis
inexpensive,canbeobtainedfromdealers,orfromourSparePartsDepartment.The
applicationofthistoolisshowninillustration4.Beforefittingthevalvesprings,
positioncorrectlythevalvespringseat—theraisedportionontheundersideislocated
withthedepression(5)incylinderhead.(Seeillustration3).
Theinletvalveisthelargerofthetwovalvesanditisvitallyimportanttolocatecorrectly
thetwosplitcolletsintothegroovesoneachvalvestem.
Cleanthevalveguideboreswitha pieceofcleanrag,applya littleoilonthevalvestems
andalsoinsideeachguidebeforeassembly.
17
1
1
3
4
5
6
7
PLAINHOLE,FOROILFEEDTOINLET
VALVE.
TAPPEDHOLE,TOACCOMMODATE
CARBURETTERRETAININGSTUD.
INLETPORT.
TAPPEDHOLE,TOACCOMMODATE
CARBURETTERRETAININGSTUD.
HOLE.TOACCOMMODATEDOWEL
LOCATINGVALVESPRINGSEAT.
GUIDE,FORINLETVALVE,
TAPPEDHOLE.FORSPARKINGPLUG.
8
9
10
II
12
13
14
PLAINHOLE.FOROILFEEDTOEXHAUST
VALVE.
HOLE,TOACCOMMODATEDOWELPIN
LOCATINGVALVESPRINGSEAT.
GUIDE,FOREXHAUSTVALVE.
CIRCLIP(BOTHGUIDES).
EXHAUSTPORT.
NEEDLESCREW,ADXUSTIMGOILFEED
TOINLETVALVE.
LOCKNUT.FORNEEDLEADJUSTING
SCREW.
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REMOVINGTHECYLINDERANDPISTON
Withthecylinderheadremoved,thebarrelcanberaisedverticallytocleartheholding
downstuds.Beforedoingso,positiontheenginewiththepistononthetopofitsstroke,
haveavailablea pieceofcleanrag.Raisethecylindersufficientlytoenabletheragtobe
putintothethroatofthecrankcase(underthepiston)asa precautionagainsta broken
ringfallingintothecrankcase,thenliftthecylinderclearofthefourstudspassing
throughit.Makea markinsidethepistontoindicatefront,
Thegudgeonpinisa slidingfitinboththepistonandconnectingrod.Useroundnose
plierstocompressandextractthecirclip(Itisimmaterialwhichoneisremoved)then
pushoutthegudgeonpinandliftthepistonofftheconnectingrod.
Donotdisturbthepistonringsunlessabsolutelynecessary.
IfnewpistonringsarefittedandiftheyareobtainedfromourSparePartsDepartment
theyarereadyforfitting,astheringgapisallowedforduringmanufacture.
Thetopcompressionringischromiumplatedandhasa slightlytaperedextension.
Whennew,thewordTOPisetchedontheringfacetoindicatewhichwayitshouldbe
fitted.Fitfirstthescraperoroilcontrolring,thenthetwocompressionrings,toavoid
breakagedonotexpandtheseringsunnecessarily.
REFITTINGTHEPISTON
Beforerefittingthepistonapplya littleoiltothegudgeonpin,alsotothebossesforthe
gudgeonpininthepiston.Placethepistonovertheconnectingrodinthesameway
asitwasremoved,orinaccordancewiththemarkingmade,andthenintroducethe
gudgeonpinthroughthepiston,connectingrodandpistonbosses.
Itisvitallyimportanttocorrectlylocatethegudgeonpincirclip,anda littleextracare
andtimeshouldbedevotedtothismostsimpleandimportantoperation.Useround-
nosedplierstointroducethecirclipintoitsgroove,usinga rotarymotionthenverify
thatthecirclipIscorrectlylocated.
Illustration4
Applicationof
valvespringcompressor
18
1
2
3
4
COLLET,FORVALVE.
COLLAR,FORVALVESPRING.
COLLAR,FORVALVESPRING.
BOLTTHROUGHTOOLSANDCOILSOF
VALVESPRING.
5
6
7
VALVESPRINGCOMPRESSORTOOL.
OILPASSAGEFROMROCKERBOXTO
INLETVALVEGUIDE.
SCREWWITHLOCKNUTADJUSTING
OILFEEDTOINLETVALVE.
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