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AJS 350 1954, Maintenance Manual And Instruction Book, Page: 1 / 96

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MAINTENANCE

MANUAL

INSTRUCTION

BOOK

AND

for

1954

350

c.c.

and

500

c.c.

A

•

J

SPRING FRAME AND RIGID 

SINGLE CILINDER MODELS 

PRICE 2/6 NETT

A J

•

S

M O T O R

C Y C L E S

Proprietors: ASSOCIATED MOTOR CYCLE LIMITED

PLUMSTEAD • L O NDO N • S.E.18

EDITION CM-27

•

•

S

Summary of Contents for 350 1954

Page 1: ...TRUCTION BOOK AND for 1954 350 c c and 500 c c A J SPRING FRAME AND RIGID SINGLE CILINDER MODELS PRICE 2 6 NETT A J S M O T O R C Y C L E S Proprietors ASSOCIATED MOTOR CYCLE LIMITED PLUMSTEAD LONDON...

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Page 5: ...mbered 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...

Page 6: ...nk Rigid and Spring frame 500 c c Fuel tank Competition Oil tank to top level mark British 21 170 cub in 30 380 cub in 1 pint 6 fl ozs 3 fl ozs 1 fl oat 3 gallons 3 gallons 2 gallons 4 pints Metric 34...

Page 7: ...ame Competition Models Gear ratios Competition Rigid Frame Models Engine sprocket size 15 teeth a 16 teeth 17 teeth b 18 teeth 19 teeth 20 teeth 21 teeth First gear 21 77 to 1 20 40 to 1 19 56 to 1 18...

Page 8: ...g Plug Model All Make K L G Type FE80 Thread 14 mm Reach in Point gap 015 to 018 in Valve timing with 014 inch rocker clearance Standard cams INLET VALVE EXHAUST VALVE Opens before T D C Closes after...

Page 9: ...orizontal position close to right foot rest Con trols selection of the four speeds or ratios between engine and rear wheel revolutions with a free or neutral position See Illustration 2 Kick starter l...

Page 10: ...ustration 1 Showing Controls TOTAL MILEAGE MILES PER HOUR TRIP MILEAGE REMOVE TO ADD HYDRAULlC FLUID CLUTCH LEVER IGNITION CONTROL VALVE LIFTER LEVER DUMMY GRIP DIPPING SWITCH REAR BRAKE LEVER RlDER S...

Page 11: ...side petrol tap slide See that the air control lever is in the fully closed position On models with manual control fully advance the ignition and then pull back the control lever two fifths of its tot...

Page 12: ...THE ROAD Having started and warmed up the engine take the machine off the stand sit astride it free the clutch by pulling up the large lever on the left bar and engage the lowest gear Next slowly rel...

Page 13: ...hrottle opening If the precaution is taken of limiting the use of the throttle to about one third of Its opening during the first 1 000 miles irrespective of the road speed and whether on the level or...

Page 14: ...peed The clutch must only be used when starting from a standstill and when changing gear It must NOT be operated to ease the engine instead of changing gear or be held out in order to free wheel The e...

Page 15: ...f a steady return flow Showing the oil tank with the felt filter in its cylindrical housing and the metal strainer mounted on the entry end of the feed pipe union Also shows the direction of flow of o...

Page 16: ...GEAR BOX LUBRICATION Mobiloil D Castrol Grand Prix Energol 50 Essolube 50 Shell Motor Oil X 100 SAE 50 SAE 50 SAE 50 SAE 50 SAE 50 FOR HUB LUBRICATION AND ALL FRAME PARTS USING GREASE Mobilgrease No 4...

Page 17: ...lower of the two oil pipes between tank and crank case and is returned through the upper pipe if for any reason the crankcase is dismantled the oil pump plunger mutt be removed from its housing before...

Page 18: ...level mark and upon replenishment should not be higher than the top level mark other wise when starting the engine the bulk of oil in the crankcase sump may be greater than the space available in the...

Page 19: ...which case it may be withdrawn by grasping the ringed open end and pulling away After removal the filter should be cleaned in petrol and allowed to dry before re fitting Reverse the above procedure t...

Page 20: ...STUD INLET POUT TAPPED HOLE TO ACCOMMODATE CARBURETTER RETAINING STUD HOLE TO ACCOMMODATE DOWEL LOCATING VALVE SPRING SEAT GUIDE FOR INLET VALVE TAPPED HOLE FOR SPARKING PLUG 8 9 10 11 12 13 14 PLAIN...

Page 21: ...es the engine shock absorber Transmission harshness generally Indicates level of oil in chaincase is too low Remove chaincase inspection cap each week Inspect level of oil top up as necessary To remov...

Page 22: ...and throttle cables are fitted with a conveniently situated grease nipple Use engine oil and hold the grease gun as near verticle as possible spout downward to obtain efficient ejection of oil the gun...

Page 23: ...GEAR BOX FRONT BRAKE EXPANDER REAR BRAKE EXPANDER BRAKE PEDAL SPINDLE 16 7 8 20 2 11 19 22 MAIN OIL TANK FRONT CHAINCASE CONTROL LEVER MOVING PARTS BRAKE ROD JOINTS FRONT CENTRE AND PROP STAND HINGE...

Page 24: ...ary Check oil circulation Check level and re fill if necessary DAILY WEEKLY Oil tank Tyres Check level 16 and re fill if necessary Check pressures and inflate if necessary EVERY 500 MILES Oil tank Gea...

Page 25: ...own movement and adjust If necessary Check all nuts and bolts for tightness and tighten If necessary but beware of over tightening Check O H V rocker adjustment and correct if necessary EVERY 5 000 MI...

Page 26: ...nts Sparking plug Clutch Chains 6 7 8 9 10 Wheel bearings Brakes Forks legs and steering head Alignment of wheels Tyre pressures b c d e f g h i j Tighten all external nuts and bolts including cylinde...

Page 27: ...rol taps facilitate this operation by removing the need to first drain the tank of petrol Illustration 7 Showing details and order of assembly of the fuel tank fixing bolts and components A B C D META...

Page 28: ...may be Identified and replaced In their original position The rocker box may then be lifted off TO REPLACE THE ROCKER BOX Carefully clean the top of cylinder head and lower face of rocker box Revolve...

Page 29: ...ward The top spring collar and split collet can then be removed leaving the valve free to be withdrawn A sharp light tap on the valve collar may be necessary to free the taper split collet It will be...

Page 30: ...ms It will be observed that the collet has two grooves machined in the bore and those two grooves must register with the two rings on the valve stem If fitted so that only one of the grooves engages t...

Page 31: ...flywheel in exploded form VALVE GRINDING Before commencing valve grinding carefully examine the face of each valve and if found to be deeply pitted have them refaced Most garages have suitable equipm...

Page 32: ...the gaskets wilI probably remain in position In the head A rubber gland is fitted at the bottom of each cover tube Replace the cylinder head by Carefully clean the top edge of the cylinder barrel and...

Page 33: ...ston over connecting rod so that slit in piston faces to the front of the machine introduce gudgeon pin in piston and pass it through connecting rod small end bush and centralise it Re fit circlips Us...

Page 34: ...inlet cam on 350 c c models only When checking the valve timing the tappet clearances must be set to 014 inch so that the tappets may be well clear of the quietening curves of the camshafts The timin...

Page 35: ...END NUT LOCKING ADJUSTING CUPPED SCREW CUPPED ADJUSTING SCREW 4 5 6 CUPPED ADJUSTING SCREW AND LOCK NUT SLEEVE TO ACCOMMODATE ADJUSTING SCREW ON TOP END OF PUSH ROD EXHAUST ROCKER ARM TAPPET END Compl...

Page 36: ...tion control lever in the fully advanced position On 500 c c models turn the front plate of the automatic unit with the fingers and thumb to its limit of movement and insert a wood wedge to hold the c...

Page 37: ...ING SIDE FLYWHEEL AXLE WITH INTEGRAL GEAR FOR DRIVING OIL PUMP PLUNGER OIL PUMP PLUNGER SCREW ONE OF THREE WITH FIBRE WASHER PLUGGING OIL PASSAGES CAST IN CRANKCASE GUIDE PIN FOR OIL PUMP PLUNGER 6 7...

Page 38: ...hese degrees of oversize make it essential for the cylinder barrel to be re bored to accommodate them We can provide that service at prices quoted in the Spares List On the 350 c c the cylinder standa...

Page 39: ...Illustration 13 Carburetter details in assembly order 37...

Page 40: ...e main jet The main jet controls the mixture from three quarters to full throttle the adjustable taper needle from three quarters down to one quarter throttle the cut away portion of the intake side o...

Page 41: ...the tests and adjustments described above it is most Important to make sure the ignition is set correctly Late ignition usually causes a great increase in petrol consumption TWIST GRIP ADJUSTMENT A s...

Page 42: ...closely Heavy petrol consumption may be due to Late ignition setting Bad air leaks Probably at carburetter joint Weakened valve springs Leaky float Causing flooding Taper needle extension insufficient...

Page 43: ...of higher gears and upward movement with the toes causes a lower gear to become engaged As mentioned elsewhere an external marked disc shows at a glance which gear or neutral is engaged The unusual m...

Page 44: ...loaded conical ended plunger which engages depressions on the underside of the cam barrel Remove the mainshaft end nut and draw off the K S ratchet driver pinion spring and bush upon which the pinion...

Page 45: ...e unit from gear box mainshaft Take care not to lose any of the twenty four clutch sprocket bearing rollers which may be displaced when the clutch centre and sprocket assembly is withdrawn from the ma...

Page 46: ...d the sprocket that fits on the dynamo shaft and fit these three parts in one movement to the driving side flywheel axle and the dynamo shaft Fit the dynamo shaft plain washer and sprocket retaining n...

Page 47: ...tment Check clutch operating lever for correct free movement as detailed elsewhere Fit outer half of front chaincase by Ensure faces of both halves of chaincase are clean Ensure the rubber and metal b...

Page 48: ...uld be possible to pull up the engine on full throttle without slip occurring If to cure slip it is found neccessary to further tighten the adjusting nuts this is a clear indication that either the cl...

Page 49: ...nserts and may generate sufficient heat to soften the clutch springs Therefore should clutch slip occur immediately examine for free movement of the internal operating lever To adjust this free moveme...

Page 50: ...side cam has a hexagonal body to accommodate a spanner and Is turned for wards or backwards to position the rear wheel so that the rear driving chain is correctly tensioned Both cams turn together The...

Page 51: ...adjustment of the rear brake Therefore after making a rear chain adjustment always check the brake adjustment and re set if necessary The whip of chains should always be tested mid way between the two...

Page 52: ...lses The shock absorber spring is compressed by the over riding of the cams thereby absorbing the shocks It is essential the faces of the cams are adequately lubricated otherwise the shock absorbing a...

Page 53: ...d Tested in this manner the slightest slackness is discernible Continue to tighten the lower adjusting nut until no perceptible movement can be felt and yet the steering head is perfectly free to turn...

Page 54: ...d movement of the sliders resulting from impact with road bumps in addition to meeting resistance from the main springs also causes oil to be ejected by the close fitting steel bushes This oil is forc...

Page 55: ...lug from the bottom of a slider and catch the oil which drains out Then reinsert drain plug and work the top plugs to which damper rods are attached up and down pumping action making upward strokes as...

Page 56: ...located under the head A sharp jerk downward should now enable the slider to be withdrawn but should difficulty be experienced apply a little heat to the enlarged top end of the slider This will cause...

Page 57: ...Illustration 17 55...

Page 58: ...LT TOP FOR FORK INNER TUBE 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 SECURING CAP TO F...

Page 59: ...rame rear loops and the spring action is damped by hydraulic dampers identical in design to those used in the TELEDRAULIC Front Fork Assembly The hydraulic fluid used is one of the grades of oil speci...

Page 60: ...Illustration 19 Showing Ghost view of TELEDRAULIC leg 58...

Page 61: ...a similar manner NOTE Shortage of oil is evidenced by very lively action PROP STAND The prop stand hinges on a bolt which passes through a lug brazed to the frame and screws into the jaw of the stand...

Page 62: ...tank and battery carrier to the two studs Oil tank and battery carrier are now free to be taken away and when doing so it is necessary to give each a slight rotary movement in order to disengage from...

Page 63: ...he right side cap Should any fork stiffness be apparent after re fixing the front wheel loosen the nuts securing the right side cap and after working the fork up and down violently re tighten This act...

Page 64: ...rawing it to the rear Re fit in the reverse order but before finally tightening the rear wheel spindle nuts ensure the speedometer gear box is so positioned that the speedometer driving cable can be c...

Page 65: ...ethod of ensuring correct adjustment is Slacken the lock nut Tighten the adjusting ring until all slackness has been taken up Slacken back the adjusting ring exactly one half turn Tighten the lock nut...

Page 66: ...COLLAR ENCIRCLING RIGHT HAND OIL SEAL CIRCLIP LOCATING RIGHT HAND SIDE TAPER ROLLER BEARING WASHER RETAINING OIL SEAL ONE EACH SIDE OF SEAL SPACER BETWEEN OIL SEAL INNER WASHER AND TAPER BEARING 14 1...

Page 67: ...IL SEAL SPACING COLLAR ENCIRCLING OIL SEAL WASHER METAL BETWEEN OIL SEAL AND SPACER SPACER BETWEEN OIL SEAL WASHER AND TAPER BEARING TAPER BEARING OUTER CUP CAGE FOR ROLLERS AND ROLLERS THESE ARE NOT...

Page 68: ...thereby making its extraction an easy matter Extract circlip 12 Through the open end of the hub carefully apply steady pressure to the inner edge of the outer cup 18 so that it is forced out of the h...

Page 69: ...ront brake cable After a very considerable mileage this continual adjustment causes the brake cam to occupy a position whereby the available leverage is considerably reduced and as a result the brake...

Page 70: ...r on the fork assembly Unscrew the adjuster to take up the front brake The adjuster is locked in position by a nut Adjust front brake by Place machine on both stands Slacken lock nut on cable adjuster...

Page 71: ...ts adjusting bolt and lock nut To permanently raise the toe end of the pedal slacken lock nut B and unscrew the adjusting bolt A Check back brake adjust ment after BRAKE PEDAL ADJUSTMENT The position...

Page 72: ...eels are in track When the wheel alignment is correct a piece of thin string stretched taut across both wheels about four inches from and parallel to the ground should just touch each tyre at both sid...

Page 73: ...edge of the cover into the rim at the spot diametrically opposite to the valve Get this edge right into the well of the rim and then by working round the cover equally on either side of the valve posi...

Page 74: ...pipe or tap obstruction Excessive flooding of carburetter with hot engine only Stuck up engine valve Weak or broken valve spring Valve not seating properly Contact points dirty Incorrect contact poin...

Page 75: ...oil tank Badly worn or stuck up piston rings Causing high pressure in the crankcase Air leak in dry sump oiling system Worn inlet valve stem or guide Improper non return valve action EXCESSIVE PETROL...

Page 76: ...an be quickly and easily removed with a damp chamois leather In stubborn cases it may be necessary to use a special chromium cleaning compound Lack of attention will lead to more serious damage The sa...

Page 77: ...e is a spring washer under the screw Unscrew screw B Illustration 28 carrying the lubrication wick and take away the fibre insulating bush encircling the screw Straighten the tab on the lock washer D...

Page 78: ...ker spring which is slotted to permit easy withdrawal of the moving contact lever Adjustment of contact breaker Magneto type SR 1 If and when adjustment is necessary slacken the two screws securing th...

Page 79: ...ing fit between the central electrode and the three earth side electrodes If the gaps are too small to start with gently lever the earth electrodes away from the centre electrode using a small screw d...

Page 80: ...ge to remove the sparking plug before doing this If the commutator is very dirty moisten the cloth with petrol At every 10 000 miles the complete dynamo should be handed to a Lucas Service Station for...

Page 81: ...are to accurately locate the dynamo sprocket key when applying the sprocket See separate instructions for correct dynamo chain adjustment and re fitting outer half of chaincase Ensure that dynamo spro...

Page 82: ...pot or Agent The A V C Unit is retained by two bolts with self locking nuts The self locking nature of the nuts prevents subsequent slacking off The four terminals of the A V C Unit are plainly marked...

Page 83: ...e charge In which case the regulator setting may need adjustment If one cell in particular needs topping up more than another it is likely the case or container is cracked in which event the battery m...

Page 84: ...tted See Controls page 7 for switch functions To remove headlamp rim and light unit Slacken the screw on the top of the tamp body at the front pull the rim outward from the top and as the front comes...

Page 85: ...is threaded internally and accommodates a collet which is placed on the end of one of the wires to be con nected in such a manner that the wire ends protrude through the centre of the collet The thir...

Page 86: ...Illustration 37 Wiring diagram 84...

Page 87: ...nd 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 these letters M...

Page 88: ...s The Free Ferry accom modates all types of motor vehicles and there is a very frequent service The Southern landing stage is less than a mile from the Service Depot Visitors arriving by road If they...

Page 89: ...ick with spaces of between each two characters The numbers on the rear plate must be 2 high 1 wide and a thick with spaces between each two characters The Licence Disc must be enclosed in a water tigh...

Page 90: ...rcycle or of a motorcycle and sidecar combined when carrying more persons or a greater weight than that for which the machine was designed by the manufacturers 3 The attaching of a sidecar to a motorc...

Page 91: ...NAL EQUIPMENT The following Items of optional equipment are available They are described and priced in the Spares List Stop rear light Air cleaner Mudguard type pillion seat Rigid Frame Models Pillion...

Page 92: ...S Neat monogram badges are now available at a cast of 1 6 plus 6d postage They can be supplied as a tie pin as a brooch or for fitting in a button hole When ordering state type required Illustration 3...

Page 93: ...lic legs Repairs and Service The Law Tools and Special Equipment Transmission Service Useful Information Wheel Brake and Tyre Service 38 7 4 9 75 25 24 51 88 3 14 21 22 86 57 85 87 89 41 72 61 SPARES...

Page 94: ...k r o F Gear box Gear lever positions Hub bearing details Hub rear Lamp panel Leg teledraulic rear Lubrication chart Oil tank Oil pump Rear spring frame Sparking plug Tank fixing details Tappet adjus...

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