A.J.S. 16 Instruction Book Download Page 4

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Carburetter

Controls

Data

Driving

Electrical Equipment

Engine

Forks and Frame

Free Service

Guarantee

Index

Information

Lubrication

Maintenance

Repairs and Service

Spare Parts

Tools and Special Equipment

Transmission

Wheels and Brakes

CONTENTS

PAGE

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Summary of Contents for 16

Page 1: ...del 16 500 c c Model 18 SINGLE CYLINDER MODEL SPINGTWINS Standard 20 and 20 De Luxe 500 c c Standard 31 and 31 De Luxe 650 c c CS and CSR Models 650 c c Issued by A J S MOTOR CYCLES LONDON S E 18 Prop...

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Page 3: ...ON Cables ICANHOPIT 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 Issued by A J S MOTOR CYCLES LONDON...

Page 4: ...ment Engine Forks and Frame Free Service Guarantee Index Information Lubrication Maintenance Repairs and Service Spare Parts Tools and Special Equipment Transmission Wheels and Brakes 44 7 4 9 73 26 5...

Page 5: ...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 N the interest of Safety on the R...

Page 6: ...n Central notch 376 072 size 1065 500 c c 376 100 size 260 250 376 076 size 30 389 060 size 3 1 E in Central notch 376 072 size 1065 Carburetter Standard De Luxe and Sports Twins Main jet Main jet air...

Page 7: ...key for the rotor must line up with this marking for correct location Valve guide projection top of guide to boss Singles Inlet in Exhause in Valve timing pinion Singles Retained by nut threaded v in...

Page 8: ...ring Models c S C Engine Sprocket Gear ratios Twins Engine sprocket size c 19 teeth 20 teeth a 21 teeth 22 teeth b 23 teeth First gear 14 85 14 11 13 42 12 81 12 23 Second gear 9 86 9 37 8 93 8 52 8 1...

Page 9: ...l pedal on right hand side of gear box Lighting switch In top of head lamp Controls lamps by a rotating lever which has three positions 1 OFF Lamps not on 2 L Pilot lamps rear lamp and speedometer lam...

Page 10: ...ition switch See page 73 Valve lifter Small lever on left handlebar 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 THROTTLE TWIST GRIP AIR CONTROL IGNITION CONTROL MAGNETO CUT...

Page 11: ...s the object being to free the engine This only applies if the engine is cold Depress the kick starter until compression is felt then raise the valve lifter lever and ease the engine just over compres...

Page 12: ...s therefore raised After each pedal movement internal springs return the pedal to its normal horizontal position The pedal must be moved to the full extent of its travel when selecting a gear either u...

Page 13: ...or let in the clutch sufficiently suddenly to cause the rear wheel to spin Take a pride in making a smooth silent get away When changing up to a higher gear as the clutch Is freed the throttle should...

Page 14: ...astrol Grand Prix Energol SAE 50 Essolube 50 Shell X 100 Motor Oil 50 COLD 32 F to 50 F SAE 50 Mobiloil D Castrol Grand Prix Energol SAE 50 Essolube 50 Shell X 100 Motor Oil 50 EXTREME COLD below free...

Page 15: ...rainer mounted on the entry end of the feed pipe union the return flow pipe from the engine to tank via the small spout located so that it can be inspected by removing the tank filler cap and air vent...

Page 16: ...SIDE FLYWHEEL AXLE WITH INTEGRAL GEAR FOR DRIVING OILPUMP PLUNGER OIL PUMP PLUNGER SCREW ONE OF THREE WITH FIBRE WASHER PLUGGING OIL PASSAGES CAST IN CRANKCASE GUIDE PIN FOR OIL PUMP PLUNGER INSERTED...

Page 17: ...ravity to the delivery pump by which it is forced under pressure to various parts of the engine from whence it drains back to the crankcase sump to be collected by the return pump and returned to the...

Page 18: ...feed pipe Return Oil Pump on the left 1 2 3 4 5 6 7 8 9 10 11 12 BALL FOR NON RETURN VALVE SPRING FOR NON RETURN VALVE PLUG RETAINING NON RETURN VALVE SPRING AND BALL BLEED HOLE PLATE CARRYING OIL FEE...

Page 19: ...e metal filter is made integral with the non return valve which i a sealed unit see illustration 7 If the valve is difficult to unscrew do this after a run or when the crankcase is hot C The magnetic...

Page 20: ...pen enough Excessive oil consumption a smoky exhaust or an oiled sparking plug generally indicates the oil feed adjustment is open too much The exhaust valve stem is lubricated by oil flowing through...

Page 21: ...Illustration 8 Cross section of engine showing oil galleries oil passages and release valve 19...

Page 22: ...to dry before re fitting PRESSURE RELIEF VALVE This valve not shown in illustration 21 is located in the timing half crankcase below dyno stud No 9 This valve must NOT be interfered with during normal...

Page 23: ...S spindle indicates maximum permissible oil level content 1 pint CHAIN LUBRICATION The front driving chain runs in oil bath Front chaincase Use engine oil to lubricate and maintain level to just belo...

Page 24: ...ROL LEVER MOVING PARTS BRAKE ROD JOINTS CENTRE A N D PROP STAND HINGE PINS Hydraulic Fluid Locations FRONT TELEDRAULIC FORKS Heavy Engine Oil Location GEAR BOX 23 14 21 9 15 10 3 5 17 4 Grease Locatio...

Page 25: ...ot necessary STEERING HEAD BEARING LUBRICATION One grease nipple on front frame head lug and another on right hand side of handlebar lug CONTROL LEVER LUBRICATION Occasionally a drop of engine oil on...

Page 26: ...miles and re fill to top line level with new oil and clean filter 16 Ignition Check contact breaker points Gear Box Drain at first 500 miles and re fill 18 1 pint Chaincase Check level of oil when mac...

Page 27: ...ery three months instead of mileage interval Filters Clean metal mesh filter in oil tank illustration 3 and metal filter in crankcase on twins Ignition Clean and adjust as detailed in Electrical secti...

Page 28: ...il Tighten lock nut 2 and re check the clearance Finally Check adjustments so that with no up and down movement the long push rods are free to revolve when the valves are closed Illustration 11 Tappet...

Page 29: ...for both inlet and exhaust It is best to ensure that each piston in turn is at the top of its firing stroke when adjusting rocker clearances The method of obtaining that position is explained in the p...

Page 30: ...seat release nuts for front mounting seat can then be taken away Illustration 13 TO REMOVE PETROL TANK Disconnect the petrol pipes release seat front fixing bolts and raise the seat slightly On Twin...

Page 31: ...ring stroke Lay the composition jointing washer on cylinder head This must be faultless If necessary renew Lay the rocker box in position then slightly raise the right hand side to allow the long push...

Page 32: ...aper split collet It will be observed that the valve spring seat has a raised impression on its under side which registers with a hole drilled on the valve guide boss to ensure accurate positioning To...

Page 33: ...r each valve stem with clean oil insert and apply top collar and split collet Then apply the valve springs which although possible to fit by hand are more easily manipulated with a special compressor...

Page 34: ...e forwards and backwards while applying light finger pressure to the head raising the valve off its seat and turning to another position after every few movements Never revolve the valve continuously...

Page 35: ...away Cylinder barrel Ensure piston is not damaged in doing this Steady piston with hand as barrel is withdrawn Fill throat of crankcase with clean rag to prevent entry of foreign matter Remove One gu...

Page 36: ...the quietening curves VALVE TIMING Taken with valve 001 off its seat Inlet valve timing Inlet valve opens 36 before top dead centre 350 c c models Inlet valve opens 18 before top dead centre 500 c c m...

Page 37: ...achable the position of the cam should be noted before it is removed Before setting the ignition timing it is essential to check the contact breaker gap CHECK CONTACT BREAKER GAP See also Electrical S...

Page 38: ...ove H T cable and sparking plug Automatic timing control as already described The rocker box side cover Turn engine so that both valves are closed inlet valve opens then closes then engage top gear In...

Page 39: ...o clock lightly tighten the fixing screws The exact position of contact point separation is best determined by inserting a strip of cigarette paper between the contact points and moving the plate in a...

Page 40: ...and sleeves require lapping to ensure a correct fit REMOVING SPARKING PLUG ALL MODELS Always exercise the greatest care to avoid thread seizure when removing a sparking plug If any resistance is felt...

Page 41: ...iece of rubber tube with a bore diameter of part number 011381 can be used for manipulating the valves for grinding All traces of abrasive must be removed after grinding particularly from the valve gu...

Page 42: ...ng each piston ring with the fingers as it enters the barrel Press the cylinder barrel right down into the throat of the crankcase Fit the second piston gudgeon pin rings and barrel in a like manner R...

Page 43: ...s with the plug boss This applies also to the standard twins Place the ignition control lever in the fully advanced position Next taking care not to disturb the piston position turn the magneto in a c...

Page 44: ...Exhaust valve closes 43 after top dead centre Check valve timing with 012 rocker clearance Upon removing the timing gear cover secured by 10 screws and 1 nut and the pump plate assembly it will be ob...

Page 45: ...d the subsequent removal of the gear from the dynamo shaft is a simple workshop operation ALTERNATOR TWINS To remove distributor pinion spring outwards the circlip take out the parallel pin passing th...

Page 46: ...See DATA for details of standard sizes of jet throttle valve and jet taper needle With the standard setting it is possible to use nearly full air in all conditions except perhaps when the engine is p...

Page 47: ...Illustration 22 Carburetter details in assembly order 45...

Page 48: ...the final table on page 12 and allow to drain before replacing in the filter case Clean at intervals of 2 500 to 5 000 miles according to road conditions and renew the element every 10 000 miles TO RE...

Page 49: ...ble the front driving chain to be adjusted That movement is controlled by an adjusting bolt marked 1 in illustration 28 secured in an eye bolt marked 2 in illustration 28 and locked in the required po...

Page 50: ...cable Remove kick starter crank by releasing pinch bolt Remove foot change indicator plate by unscrewing bolt in foot change ratchet plate spindle leave the foot change pedal in position Remove five...

Page 51: ...ses through the rear portion of the chain case Therefore take away the outer cover with extreme care to avoid a strain on the cable See illustration 25 Illustration 25 TO REMOVE OUTER CHAINCASE COVER...

Page 52: ...into position and gently take up the cable slack by pulling lightly the cable from the rear of the chaincase if fitted Locate the cover with the central fixing nut and lightly tighten Fit the fixing s...

Page 53: ...in tool kit loosen lock nut B Then with a screw driver gently screw in the thrust cup C until contact with the thrust rod can be felt after which unscrew exactly one half turn and then securely re tig...

Page 54: ...gear box main shaft and clutch operating mechanism TO DISMANTLE CLUTCH SHOCK ABSORBER The six rubber blocks used in the shock absorber can be replaced by Removing front chaincase Removing clutch sprin...

Page 55: ...e used seal can be prised out then gently press replacement into position If this part of dismantling is to be carried out with gear box in frame remove the chain sprocket nut before removing outer ge...

Page 56: ...spring pull the spring sufficiently to enable the turned in end to enter hole drilled in the cover Replace inner and outer cover as detailed previously To replace a clutch control cable Reverse the ab...

Page 57: ...adjusting the rear chain will disturb rear brake adjustment which should therefore always be checked subsequently REMOVING AND REFITTING REAR CHAIN To protect the rear chain from mud and water it is...

Page 58: ...se and in order to clearly follow the descriptions and subsequent assembly and adjustment instructions reference to illustration 29 will be necessary As will be seen from the general arrangement drawi...

Page 59: ...Exploded view of Teledraulic Forks Illustration 29 57...

Page 60: ...UBE BOLT TOP FOR FORK INNER TUBE ADAPTOR NUT LOCK FOR TOP END OF DAMPER ROD ROD FOR FORK DAMPER SLEEVE PLUNGER ON FORK DAMPER ROD PIN STOP FOR FORK DAMPER VALVE NUT LOCK FOR DAMPER VALVE SEAT STUD SEC...

Page 61: ...less add to make this quantity or reduce if an excess quantity has been drained off Next refit drain plug and carefully pour into the top of the tube being checked exactly 6 fluid ozs 170 4 c c after...

Page 62: ...FORK SLIDER Raise the front wheel clear of the ground Unscrew the top fork tube bolt and disconnect the damper rod Unscrew the screwed slider extension 54 Next remove the front wheel mudguard and sta...

Page 63: ...ox The hinge has robust plain bearings lubricated from a reservoir of 1 fluid ounces 42 6 c c of heavy gear oil which is sufficient to last almost indefinitely Provision is however made for replenishm...

Page 64: ...aw of the stand leg It is then locked by a nut and split pin Care in tightening this bolt is necessary to avoid pinching and it is essential to observe after securely tightening the lock nut that the...

Page 65: ...hat the wheel clamp occupies its natural position on the spindle end on which it is intentionally not positioned REAR WHEEL REMOVAL ALL MODELS All I960 Models are fitted with a deep section one piece...

Page 66: ...of the hub shell while the adjustable location is regulated by a screwed ring that is threaded into the opposite end of the hub and the position of which can be locked by an encircling nut On each wh...

Page 67: ...AKE WITH LININGS LININGS FOR BRAKE SHOES SPRING FOR BRAKE SHOES PIN THRUST ADJUSTING BRAKE SHOES EXPANDER FOR BRAKE SHOES SPACER FOR COVER PLATE INNER BOLT RETAINING SPROCKET TO HUB SHELL SPROCKET A N...

Page 68: ...re to the end of the projecting sleeve which pressure will force out wheel bearing ring 7 together with the two taper roller bearings 7 and the spacing sleeve 8 leaving in situ only the bearing ring o...

Page 69: ...angeable The two shoes in each brake are N O T identical they are handed One end of each shoe bears on a fulcrum fixed in the brake cover plate The other end accommodates a detachable thrust pin By in...

Page 70: ...expand fully the brake shoes fully tighten the spindle nut binding the cover plate to the spindle and also the nut on fulcrum stud 1 2 3 4 5 Brake shoe thrust pin Thrust pin packing washer Brake shoe...

Page 71: ...further on the rod to take up the rear brake Adjust rear brake by Place machine on centre stand Screw further on the brake rod the knurled adjusting nut till by rotating the wheel it can be felt the...

Page 72: ...t least once a week Inflate as may be necessary Avoid unnecessary or stunt acceleration and fierce braking which wear out tyres by causing wheel spin and skid Remove flints etc that become embedded in...

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Page 74: ...72...

Page 75: ...purpose to remove the rotor there is no necessity to fit keepers to the rotor poles When the rotor is removed wipe off any metal swarf which may have collected on the pole tips Place the rotor in a cl...

Page 76: ...hat the connections are clean and tight The nut clamping the rectifier plates together must not under any circumstances be slackened as it has been carefully set during manufacture to give correct rec...

Page 77: ...l free before use To adjust the gap keep the engine in the position giving maximum contact opening and slacken the screws securing the fixed contact plate Adjust the position of the plate until the ga...

Page 78: ...ust be free from grease or oil If they are burned or blackened clean with fine carborundum stone or very fine emery cloth afterwards wiping away any trace of dirt or metal dust with a clean petrol moi...

Page 79: ...acken slightly the screw securing the fixed contact plate Insert the screwdriver between the two projections on the base plate and the notch in the fixed contact plate and adjust to obtain the correct...

Page 80: ...nd adjustment is required every 3 000 miles cleaning is required every 5 000 miles and every 10 000 miles the complete unit should be handed to a Lucas Service Station for dismantling replacement of w...

Page 81: ...moistened cloth After replacing the contact breaker check the point gap and if necessary re set it Remove the high tension pick ups held by swinging spring clips wipe clean and polish with a fine dry...

Page 82: ...lead to a good earth point on the dynamo or engine d Gradually increase the engine speed when the voltmeter reading should rapidly rise and without fluctuation Do not allow the voltmeter reading to ri...

Page 83: ...outwards The four terminals of the control box are plainly marked by the letters D E A F Wires from F and D go to similarly marked terminals on the dynamo The A terminal is connected to one of the am...

Page 84: ...rometer reading for every 5 F below 60 F TOPPING UP THE BATTERY Fortnightly or more often in warm climates check if the electrolyte in each cell is level with the top of the separators Top up if neces...

Page 85: ...them For maximum efficiency plugs should be cleaned at every 3 000 miles To take the plug to pieces for cleaning unscrew the gland nut by holding the smaller hexagon on the gland nut upside down in a...

Page 86: ...y LUCAS STOP TAIL LAMP MODEL 564 The correct size of bulb to be used in rear lamps is based on the cubic capacity of the engine The replacement bulb for this lamp is Lucas No 384 6 volt 6 18 watt Smal...

Page 87: ...Illustration 48 Wiring diagram Singles SINGLE CYLINDER MODELS 85...

Page 88: ...Illustration 49 Wiring diagram Magneto Twins TWIN CYLINDER MODELS 86...

Page 89: ...Illustration 50 Wiring diagram Alternator Twins 87...

Page 90: ...p engine valve Weak or broken valve spring Valve not seating properly Contact points dirty Incorrect contact point gap Ignition not switched on Discharged battery Engine misses fire may be due to Defe...

Page 91: ...g system Worn inlet valve stems Improper crankcase release valve action EXCESSIVE PETROL CONSUMPTION Excessive petrol consumption may be due to Leaks in the petrol feed system Damaged fibre washers lo...

Page 92: ...in most cases and in its early stages can be quickly and easily removed with a damp chamois leather In stubborn cases it may be necessary to use a special chromium cleaning compound The safest precaut...

Page 93: ...bear your name and address When writing on a technical matter or when ordering spares it is essential to quote the COMPLETE ENGINE NUMBER Some numbers have one or more letters incorporated in them and...

Page 94: ...he Service Depot Visitors arriving by road if they are strangers to the locality should enquire for Beresford Square Woolwich Upon arrival there the road skirting the Royal Arsenal should be followed...

Page 95: ...are issued with an approved type of radio interference suppressor already installed Speedometer A speedometer MUST be fitted and it MUST BE so ILLUMINATED that it is possible to read the dial after l...

Page 96: ...Contact breaker points 7 Brakes 3 Sparking plugs 8 Forks and steering head 4 Clutch 9 Alignment of wheels 5 Chains 10 Tyre pressures b Tighten all external nuts and bolts including cylinder head nuts...

Page 97: ...fore the quotation of a frame number only does not facilitate identification SPARES LIST An illustrated spares list covering the models described in this Instruction Book is available on application P...

Page 98: ...details of contents and prices are included in the Spares List BADGES Neat monogram badges are now available at a cost of 1 6 plus 6d postage They can be supplied as a brooch or for fitting in a butto...

Page 99: ...Illustration 52 TOOL KIT 97...

Page 100: ...nes whose trade mark name or manufacturing number has been altered or removed or in which has been used any part not supplied or approved by us or to tyres saddles chains speedometers revolution count...

Page 101: ...68 70 69 67 67 32 44 44 46 62 54 21 54 49 62 90 90 50 51 52 7 74 95 21 Cylinder barrel removal Cylinder barrel replacement Cylinder head removal Cylinder head replacement Data Decarbonisation Driving...

Page 102: ...4 89 28 33 39 54 62 91 84 61 74 91 73 10 Service Sparking plug Sparking plug removal Speedometer lubrication Starting Steering causes of unsatisfactory Steering head adjustment Steering head lubricati...

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