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TO REMOVE CHAINCASE OUTER COVER

Use a tray under chain case to catch oil.

Remove drain plug,

Remove near side footrest.

Remove engine plate cowling (two screws).

Remove three snap connectors on wire in BLACK sheath, push the sheath towards the

chain case a small amount.

Remove six cover screws and inspection cap.

Carefully pull off the cover, without strain on the alternator cables.

If the cover is completely removed, turn back one of the snap connectors, to permit the

black sheath to pass through the metal duct on the chain case rear portion.

When refitting the case, the gasket must be undamaged, ensure the cable colours match

with those in the connector block.

Replace parts in reverse order, gently take up the cable slack by pulling the sheath at the

rear of the case.

Screw locations length (under head)

Top right and bottom left 1

Top left 2¼".

Top centre

Bottom centre 1

Bottom right 1

TO REMOVE ALTERNATOR ROTOR

A N D ENGINE SPROCKET

Remove the chain case outer cover as

described previously.

Release and remove the engine shaft

Illustration 8

nut (nut measures 1" across flats).

Take off the shaft washer, rotor, shaft

Rotor

key and finally the engine sprocket.

(See front chain removal, 350 Model.)

Illustration 9

Exploded view of Clutch Mechanism

TO REMOVE CLUTCH CONTROL CABLE

Remove the oil filler cap from the kick-starter case cover.

Screw right home the clutch cable adjuster (adjacent to the handlebar lever).

Disengage, from the operating lever, the clutch cable inner wire by operating through

the oil filler cap opening.

Disengage, from the handlebar operating control lever, the clutch inner wire.

Pull cable, by its lower end, till removed from the machine, easing it through the frame

cable clips while doing so.

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Содержание 8, 14

Страница 1: ...INSTRUCTION BOOK MODEL 14 250 c c O H V 350 c c O H V MODEL 8 Issued by A J S MOTOR CYCLES LONDON S E 18 Proprietors ASSOCIATED MOTOR CYCLES LTD w w w a j s m a t c h l e s s i n f o ...

Страница 2: ...w w w a j s m a t c h l e s s i n f o ...

Страница 3: ...h 1223 7 lines Telegrams ICANHOPIT WOL LONDON Cables ICANHOPIT 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 INSTRUCTION BOOK A J S A J S MOTOR CYCLES LONDON S E 18 Proprietors ASSOCIATED MOTOR CYCLES LTD Issued by w w w a j s m a t c h l e s s i n f o ...

Страница 4: ...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 Page 2 w w w a j s m a t c h l e s s i n f o ...

Страница 5: ...ng to motor cycles of our manufacture and elsewhere will be found details of the particulars required when making enquiries of our Service Department T 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 ...

Страница 6: ... gudgeon pin top of the skirt High limit Low limit 2 8286 2 8276 Compression rings diameter 72 mm Compression rings h widt 4 6 3 s ring n o i s s e r p m o C radial thickness 115 109 Scraper ring diameter 72 mm Scraper ring width E Scraper ring radial thickness 109 101 Piston ring gap 3 1 0 0 08 Inlet valve opens 40 B T D C Exhaust valve closes 40 A T D C with 01 rocker clearance Front 72 links Re...

Страница 7: ...r bore Nominal size 2 7500 0005 0005 Piston size Skirt diameter taken at right angle to gudgeon pin top of the skirt High limit 2 7488 2 7480 Piston rings Compression rings diameter 2 69 85 mm Compression rings width 0625 0615 Compression rings radial thickness 112 106 Scraper ring diameter 2 69 85 mm Scraper ring width 156 155 Scraper ring radial thickness 112 106 Piston ring gap 0 008 013 Igniti...

Страница 8: ...ne Sprocket Rear Wheel Sprocket Clutch Sprocket Gear Box Sprocket 248 c c 70 x 65 mm 11 5 1 376 250 1z 180 25 3 Four 107 2 75 gallons 2 5 pints 6 dia 131 links x 305 55 links 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 Gear Ratios with 17 teeth Engine Sprocket First Gear Second Gear Third Gear Top Gear 21 62 to 1 16 55 to 1 11 63 to 1 8 95 ...

Страница 9: ...n engagement or neutral Gear box filler cap Located on side of gear case cover Allows insertion of lubricant and access to clutch inner wire and internal clutch operating level Petrol tank filler cap Located in top of fuel tank To release slightly depress turn fully to the left and then lift away There are two locking positions The middle posi tion between the fully tightened down and lift away po...

Страница 10: ...berate swinging kick when the engine should commence running Do not allow the kickstarter to return violently against its stop The kickstarter mechanism must be allowed to engage properly before putting heavy pressure on the kickstarter crank pedal pin That means there are two definite and separate movements when operating the mechanism by depressing the crank The first is a slow and gentle moveme...

Страница 11: ...ly adhere to the principles of running in which will result in a quieter engine with a better performance than a similar machine owned by a rider who is unwilling to drive with restraint during the initial stage of running in The load imposed on the engine is governed by the amount of throttle that is used and the makers of your machine know from experience that if the throttle or twist grip is no...

Страница 12: ...iloil D Castrol Grand Prix Energol SAE 50 Essolube 50 Shell X 100 Motor Oil 50 EXTREME COLD below freezing point 32 F SAE 30 Mobiloil A Castrol XL Energol SAE 30 Essolube 30 Shell X 100 Motor Oil 30 NOTE For the British Isles and much of Europe the Cold and Hot recommenda tions approximate to Winter and Summer conditions respectively The Extreme Cold recommendations refer to wintry conditions in p...

Страница 13: ...ciprocates Rotation is created by the worm gear on the timing side flywheel axle Reciprocation is caused by engagement of the oil pump guide pin with the profiled groove in the oil pump plunger The oil pump is designed so that the sump scavenging capacity is greater than the delivery thus keeping the crankcase sump free of oil during normal running conditions Whilst the oil reservoir is integral w...

Страница 14: ...ile intervals 8 000 kilometres the oil reservoir should be drained the oil filter cleaned in petrol and the reservoir replenished with new oil It is preferable to drain the oil after a run and when the oil is warm A drain plug is fitted to both the crankcase sump also the oil reservoir The drain plug for the reservoir is close to the bottom front crankcase bolt THE CRANKCASE FILTER The filter is c...

Страница 15: ...ough the uppermost aperture checking the level through the lower A drain plug is situated immediately below the clutch assembly If the chaincase is drained refill with 1 pint 6 litres of engine oil REAR CHAIN LUBRICATION When a totally enclosed rear chaincase is fitted the chain is lubricated by oil mist discharged from the crankcase release valve tube on to the chain Additional lubrication should...

Страница 16: ...er remove and soak in molten grease See page 13 Gear box Check oil level Small parts Smear all moving parts with engine oil and wipe off surplus Chaincase 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 Rear chain In dry weather remove and soak in m...

Страница 17: ...ds are free to revolve when the valves are closed Illustration 2 Tappet adjustment Complete adjustment by Replace rocker tappet cover taking care to replace the fibre washer that is under each retaining nut As mentioned elsewhere do not over tighten the nuts because the joint is made with a rubber fillet and undue pressure is not necessary NOTE In normal conditions tappet adjustment should not be ...

Страница 18: ...r take out both slides wrap them in a piece of rag and attach it to the frame out of harm s way Unscrew the petrol pipe union and take away the petrol pipe Four sleeve nuts and one bolt retains the cylinder head to the barrel with these removed the cylinder head with carburetter attached to it can be separated from the cylinder DECARBONISATION Instead of the usual stipulated mileage interval betwe...

Страница 19: ...ve spring compressor is required to compress the springs a special tool which is inexpensive can be obtained from dealers or from our Spare Parts Department The application of this tool is shown in illustration 4 Before fitting the valve springs position correctly the valve spring seat the raised portion on the underside is located with the depression 5 in cylinder head See illustration 3 The inle...

Страница 20: ...d has a slightly tapered extension When new the word TOP is etched on the ring face to indicate which way it should be fitted Fit first the scraper or oil control ring then the two compression rings to avoid breakage do not expand these rings unnecessarily REFITTING THE PISTON Before refitting the piston apply a little oil to the gudgeon pin also to the bosses for the gudgeon pin in the piston Pla...

Страница 21: ...g bolt until all are firmly tightened If a torque spanner is available it should be set to 35 foot Ibs for the four sleeve nuts only REFITTING THE ROCKER BOX Before attempting to refit make sure the piston is on T D C of the firing stroke with both cam followers down Use a new rocker box gasket for this assembly In the centre portion of this gasket is a projection with a small hole in it There is ...

Страница 22: ...top mark on the wire registers with the seating for the sparking plug the piston is now before top dead centre A s hole is drilled in the contact breaker base plate to enable a small screwdriver to be inserted and engaged between the two bob weights for the automatic ignition control See illustration 5 Turning the screwdriver clockwise will separate the bob weights to the fully advanced position I...

Страница 23: ... cam wheel raise both cam followers then introduce the cam into the crankcase with the mark on the tooth gap to register with the mark on the small pinion These markings have been selected to give the most effective valve timing and best engine performance To check the valve timing as a single piece camshaft is used it is only necessary to record the inlet valve opening also the exhaust valve clos...

Страница 24: ...es of jet throttle valve and jet taper needle Weak mixture is always indicated by popping or spitting at the air intake A rich mixture usually causes bumpy or jerky running and in cases of extreme richness is accompanied by the emission of black smoke from the exhaust CARBURETTER ADJUSTMENT With the taper needle projection main jet size and type of throttle slide specified correct carburation exce...

Страница 25: ...Illustration 6 Carburetter details in assembly order 23 w w w a j s m a t c h l e s s i n f o ...

Страница 26: ... Remove the accessory compartment cover by unscrewing the top central screw then take out the bolts under the cover Slide the rubber connection along the carburetter intake remove the nut for the filter clamp take out the filter To dismantle the filter remove the central bolt CARBURETTER T U N I N G INFORMATION Poor idling may be due to Air leaks At function of carburetter and cylinder head or by ...

Страница 27: ...ve four screws securing timing cover The cover can now be removed Illustration 7 Gearbox with end cover removed TO REMOVE GEAR BOX END COVER Remove the outer cover as described Use a tray under gear box to catch oil and remove drain plug Remove six screws securing end cover Temporarily refit footchange pedal to pull off the cover NOTE If the gasket is renewed the cut away for clutch cable entry is...

Страница 28: ...on of the primary drive cover after removing the six fixing screws The nut securing the sleeve gear sprocket is firmly tightened and has a LEFT HAND thread A well fitting ring spanner is required to release it after turning back the tab washer Engaging top gear and pressing the rear brake pedal will prevent the gear sprocket turning whilst the nut is unscrewed Disconnect the rear chain the sprocke...

Страница 29: ... locations length under head Top right and bottom left 1d Top left 2 Top centre Bottom centre 1c Bottom right 1z TO REMOVE ALTERNATOR ROTOR AND ENGINE SPROCKET Remove the chain case outer cover as described previously Release and remove the engine shaft Illustration 8 nut nut measures 1 across flats Take off the shaft washer rotor shaft Rotor key and finally the engine sprocket See front chain rem...

Страница 30: ...CH NOTE Nuts and screws in the clutch and gear box assembly have a right hand thread with the exception of the nut retaining the gear box rear chain sprocket which has a LEFT HAND THREAD Commence by removing the primary drive cover Unscrew in turn the three clutch spring adjusting screws take away the clutch spring pressure plate complete with the spring cups and springs leaving the steel and fric...

Страница 31: ...n adjustment is obtained taking care to move both adjusters exactly the same amount to maintain wheel alignment While on the stand the chain whip should be to ensure whip when rider is seated Check the adjustment in several positions and adjust at tightest part of chain Remove the rubber cap on the totally enclosed chain guard to check chain tension Retighten wheel spindle nuts and adjuster lock n...

Страница 32: ... forks are self lubricating and normally require no attention beyond changing the oil every 5 000 miles The oil should be drained by removing plugs 7 After the fork legs have drained the drain plugs and washers should be replaced With the machine on the stand remove the filler Plugs 2 and refill each leg with 70 ccs of SAE 30 oil Since 30 ccs of oil will remain trapped in the damper plugs after dr...

Страница 33: ...ER SHAKEPROOF TOP COVER TUBE SCREW NUT TOP COVER TUBE SCREW SEAL OIL FORK TUBES SLEEVE END TOP COVER TUBE EXTENSION SLIDER TUBE DAMPER SCREW RETAINING DAMPER TUBE WASHER FIBRE DAMPER TUBE RETAINING SCREW WASHER FIBRE DRAIN PLUG CLIP MUDGUARD ATTACHMENT LEFT CLIP MUDGUARD ATTACHMENT RIGHT BOLT MUDGUARD ATTACHMENT CLIP WASHER MUDGUARD ATTACHMENT CLIP BOLT NUT MUDGUARD ATTACHMENT CLIP BOLT NUT DOMED ...

Страница 34: ...uld be poured down the fork inner tube through the aperture exposed by the removal of the hexagonal bolt The reason why 6 ozs is refilled is due to the fact that there must be a little oil left in the fork tube that cannot be extracted by draining If however the forks are com pletely dismantled then the contents should be 6 fluid ozs as previously stated Six and a half fluid ozs represents 184 6 c...

Страница 35: ...Illustration 12 350 c c Front Forks For description see page 34 33 w w w a j s m a t c h l e s s i n f o ...

Страница 36: ... 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 FORK SLIDER WASHER FIBRE FOR DAMPER TUBE BOLT CAP FOR FORK SLIDER NUT FOR FORK SLIDER CAP SECURING STUD RING RUBBER SEALING FOR INNER TUBE TOP BOLT WASHER PLAIN FOR INNER TUBE TOP BOLT NUT ADJUSTING FOR ...

Страница 37: ...ase nipple situated above the pivot on the right hand side Movement of the fork is con trolled by Girling suspension units These units are of the sealed unit type and topping up is not necessary The springs are lubricated before assembly and the fluid in the damper unit is the exact quantity and sufficient for life of the unit The unit is shown in illustration 13 Illustration 13 Ghost view of Rear...

Страница 38: ... operating rod the centre stand can be removed TO REMOVE THE REAR CHAIN GUARD Fully Enclosed Type Remove bottom fixing nut on left hand rear suspension unit and slide the lower end of the unit off the stud slacken the left hand wheel spindle nut Remove the two chain case securing bolts The large spindle washer is used outside the guard The top and bottom halves of the chain case can then be remove...

Страница 39: ... brakes are correctly adjusted and oil is not used to lubricate the bearings the brakes will not require attention for many thousands of miles Petrol or paraffin should not be used to wash brake shoes these liquids have an adverse effect on the linings and braking efficiency will be lost Front brake adjustment is effected by a cable adjuster on the left hand fork slider Rear brake adjustment is ef...

Страница 40: ...OE EXPANDER LEVER 5 SPACER HEXAGON FRONT COVER PLATE 6 COVER FRONT BRAKE PLATE 7 BRAKE SHOES PAIR 8 ENCLOSURE CUP OIL SEAL 9 SEAL FELT FOR BEARING 10 WASHER BEARING FELT SEAL 11 BEARING FOR HUB 12 SPACING TUBE BEARING 13 PRESSING SPACING TUBE 14 SEAL RUBBER FOR BEARING 15 ENCLOSURE CAP 16 SPACER FRONT SPINDLE 17 NUT FRONT SPINDLE 18 38 w w w a j s m a t c h l e s s i n f o ...

Страница 41: ...Illustration 15 Rear Hub Assembly 39 w w w a j s m a t c h l e s s i n f o ...

Страница 42: ...n a resistance unit we can obtain the following changes in the circuits to provide varying outputs from the alternator The resistance unit is wound in the main loom of wires and is not visible as a separate unit Its location can be seen in the wiring diagram The switch positions are OFF IGN Normal charge rate LOW IGN Normal charge rate HIGH IGN Normal charge rate OFF EMG Boost charge rate LOW EMG ...

Страница 43: ...oating deposited in high vacuum and gives a much greater light reflection than the older plated types As this high efficiency coating is extremely thin the reflecting surface should never be touched This also means that reflec tors cannot be supplied as spares with out the glass front which acts as protection during transit and stocking HEADLAMP BULB 30 x 24 Watts The bulb is a double filament pre...

Страница 44: ...o unscrew the larger hexagon on the body Then lift away the central electrode assembly which should be washed in petrol or paraffin Then using fairly coarse glass paper remove the carbon deposit and wash again The central firing point should be cleaned with fine emery cloth The inside of the body should be scraped clean with a knife and finally rinsed in petrol There is an internal washer between ...

Страница 45: ...d water Never bring a naked light near a battery with vent plugs removed or when the battery is being charged the gas given off by the electrolyte is dangerously explosive Battery acid is highly corrosive therefore throw away any cleaning rags used to clean the battery lest their use on other parts of the machine causes rust Never let a battery completely run down if this does occur get it charged...

Страница 46: ...Illustration 20 Wiring Diagram 250 c c Scrambler 44 w w w a j s m a t c h l e s s i n f o ...

Страница 47: ...Illustration 21 Wiring diagram 250 c c Scrambler with lights removed 45 w w w a j s m a t c h l e s s i n f o ...

Страница 48: ...Illustration 22 Wiring diagram Model 8 and 14 46 w w w a j s m a t c h l e s s i n f o ...

Страница 49: ...y Loss of power may be due to Faulty sparking plug Lack of oil in tank No rocker clearance or too much clearance Weak or broken valve spring Sticky valve stem Valve not seating properly Brake adjusted too closely Badly fitting or broken piston rings Punctured carburetter float Engine carbonised Choked silencer Bad air leak between carburetter and head Engine overheats may be due to Lack of proper ...

Страница 50: ...a chamois leather and when the enamelled surfaces are thoroughly dry they may be polished with a good wax polish and soft dusters Such parts as the engine crankcase and the gear box can be cleaned by applying paraffin with a stiff brush and with a final application of petrol will come up like new CHROMIUM PLATING Under some climatic conditions a rusty looking deposit may be observed on ferrous par...

Страница 51: ...n them and these letters MUST BE Q U O T E D otherwise model identification is not possible Orders should always be sent in list form and not as part of a letter Owners are strongly advised to purchase a Spare Parts List so that correct part numbers can be quoted Most parts are clearly illustrated in this list which makes it very easy to recognise the part or parts required PROPRIETARY FITTINGS No...

Страница 52: ...s situated in Burrage Grove Plumstead London S E 18 and is open on Mondays to Fridays from 8 30 a m to 12 55 p m 2 0 p m to 5 30 p m It is closed on Saturdays Sundays and National Holidays It exists for the purposes of a Giving technical assistance verbally or through the post b Supplying spare parts over the counter or through the post c Repairing and re conditioning machines or parts of machines...

Страница 53: ...ld a Provisional Driving Licence your machine must show front and back the standard L plates in red and white and you must not take a PILLION PASSENGER unless that passenger is the holder of a current UNRESTRICTED driving licence As soon as you receive your driving licence sign it in the appropriate place and do so each time it is renewed It is an offence not to Make sure you are well acquainted w...

Страница 54: ...plug Clutch Chains 6 7 8 9 10 Wheel bearings Brakes Forks and steering head Alignment of wheels Tyre pressures b c d e f g h i j Tighten all external nuts and bolts including cylinder head nuts and fork crown pinch screws Top up battery and check all lighting equipment Clean out carburetter and check for correct idling Adjust all cables Grease all nipples Drain oil system Clean filter and replenis...

Страница 55: ... 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 Price 3s 6d each PART NUMBERS If there is any doubt about the names of parts required or their part numbers please send the old parts as patterns REMINDER Do not forget to include your name and full postal address We do...

Страница 56: ...r for valve grinding Valve spring compressor Tools and Special Equipment TOOLS The standard tool kit issued with each new machine contains SPECIAL TOOLS Not supplied in tool kit OPTIONAL EQUIPMENT The following items of optional equipment are available They are described and priced in the Spares List Prop Stand Assembly Part Number 043389 Air Cleaner GASKET SETS For convenience in ordering standar...

Страница 57: ...rk 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 counters and electrical equipment or to parts supplied to the order of the Purchaser and different from our standard specification 6 Our liability and that of our dealer who sells the machine shall be limited to that set ou...

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