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INSTRUCTION BOOK

MATCHLESS

SINGLE CYLINDER

Model G3

350 c.c. O.H.V.

Model G3S

350 c.c. O.H.V. Sports

Model G80

500 c.c. O.H.V.

TWIN CYLINDER

Model G12

650 c.c. O.H.V.

Model G12CSR 650 c.c. O.H.V. Sports

Issued by:

MATCHLESS M O T O R CYCLES L T D

L O N D O N S.E.18

Содержание 1964 G12 650

Страница 1: ...SS SINGLE CYLINDER Model G3 350 c c O H V Model G3S 350 c c O H V Sports Model G80 500 c c O H V TWIN CYLINDER Model G12 650 c c O H V Model G12CSR 650 c c O H V Sports Issued by MATCHLESS MOTOR CYCLE...

Страница 2: ......

Страница 3: ...s 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 L O ND O N S E 18 ENGLA...

Страница 4: ...ical 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 44 7 4...

Страница 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 Safety on the Road N the interes...

Страница 6: ...00 300 376 076 size 25 389 060 size 3 1 5 32 in Central notch 376 072 size 106 Carburetter Standard De Luxe and Sports Twins Main Jet Main jet air filter Pilot jet Throttle valve Needle position Needl...

Страница 7: ...In the form of a d o t The key for the rotor must line up with this marking for correct location Valve guide projection top of guide to boss Singles Inlet in Exhaust in Valve timing pinion Singles Ret...

Страница 8: ...01 4 79 a S C Engine Sprocket 650 c c b Standard 650 c c Engine Sprocket Gear ratios Models CS CSR 11 51 1 7 45 1 5 49 1 4 5 1 Sprockets Location Clutch Gear box Rear wheel Number of teeth 42 16 or 1...

Страница 9: ...pedal on right hand side of gear box 10 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 la...

Страница 10: ...ver on left handlebar Two separate switches are now used in the head lamp the right switch is for ignition 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 A...

Страница 11: ...edal three times 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 ju...

Страница 12: ...refore 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 up or...

Страница 13: ...r 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 b...

Страница 14: ...ell X 100 Motor Oil 50 Regent Advanced Havo line 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 Reg Advanced Havo line 50 EXTREME COLD be...

Страница 15: ...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 pipe provided to ensure freedom from air locks After removing oil pipe...

Страница 16: ...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 RELIEVED TIP...

Страница 17: ...urning oil to the tank Oil feeds by gravity 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...

Страница 18: ...NED DURING ASSEMBLY DRIVING GEAR FOR OIL FEED PUMP BODY OF OIL FEED PUMP BACK PLATE OF OIL FEED PUMP PAPER WASHER FOR OIL FEED PUMP BLEED HOLE Return Oil Pump on the left Pressure relief valve not ill...

Страница 19: ...case and parallel to the exhaust camshaft The blow off valve is included with the filter engines after 8089 see illustration 7 C The magnetic filter in the crankcase oil sump NOTE Filter B is used on...

Страница 20: ...ST VALVE STEM LUBRICATION SINGLES The exhaust valve stem is lubricated by oil flowing through a passage drilled in the cylinder head No adjustment is provided CLEANING OIL FILTERS ALL MODELS To remove...

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

Страница 22: ...F VALVE This valve previously fitted in the base of the filter compartment is now incorporated in the pump plate on engines after 8912 The plunger is retained by a split pin which should not be distur...

Страница 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 so that botto...

Страница 24: ...TROL LEVER MOVING PARTS BRAKE ROD JOINTS CENTRE AND PROP STAND HINGE PINS Hydraulic Fluid Locations FRONT TELEDRAULIC FORKS Heavy Engine Oil Location GEAR BOX When buying oils and greases it is advisa...

Страница 25: ...ws binding the two halves of the clip This releases the grip which may be pulled off the handlebar Smear handlebar the drum on which the inner wire is wound and the friction spring on the half clip wi...

Страница 26: ...st 500 miles and re fill to top line level with new oil and clean filter 16 Check contact breaker points Drain at first 500 miles and re fill 18 1 pint Check level of oil when machine is standing vert...

Страница 27: ...ry three months instead of mileage interval Clean metal mesh filter in oil tank illustration 3 Clean and adjust as detailed in Electrical section Clean as detailed in Electrical section Check each sid...

Страница 28: ...l 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...

Страница 29: ...ut the feeler Deal with the other valve in a similar manner then turn to the lefthand cylinder NOTE Do not over tighten the clamp nut Engines made before 1960 use 006 rocker clearance Engines with spe...

Страница 30: ...on 13 TO REMOVE THE PETROL TANK The petrol tank is retained by two fixing nuts at the front end also by a rubber ring encircling the frame tube A rubber block is used between the bottom of the tank an...

Страница 31: ...ing 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...

Страница 32: ...e taper 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...

Страница 33: ...ply 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 tool Part No 018276 illustration 14 To operate...

Страница 34: ...evolve 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 continuo...

Страница 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...

Страница 36: ...e 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 mod...

Страница 37: ...on 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 Service Remove two...

Страница 38: ...rocker box side cover Turn engine so that both valves are closed inlet valve opens then closes then engage top gear Insert timing rod through sparking plug hole feel piston by rocking engine forwards...

Страница 39: ...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 clockw...

Страница 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...

Страница 41: ...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 guides App...

Страница 42: ...the lower one When as the result of wear contact with the cylinder wall appears uniform over the whole width of the ring it is immaterial which way round it is refitted Space the piston rings so that...

Страница 43: ...ns Place the ignition control lever in the fully advanced position Next taking care not to disturb the piston position turn the magneto in a clockwise direction looking at the contact breaker end of t...

Страница 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 obs...

Страница 45: ...nuts having left hand threads have to be mechanically withdrawn and each has two holes drilled and threaded to accommodate the two bolts of a bridge type extractor part number 015374 which has a centr...

Страница 46: ...ee 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 pul...

Страница 47: ...Illustration 8 Carburetter details in assembly order 45 45...

Страница 48: ...ble 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 REMOVE THE AIR...

Страница 49: ...e 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 posi...

Страница 50: ...able 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 ch...

Страница 51: ...s 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 Re...

Страница 52: ...to 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 scr...

Страница 53: ...n tool kit loosen lock nut B Then with a screwdriver 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 tight...

Страница 54: ...ar 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 spring...

Страница 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...

Страница 56: ...ring 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 abov...

Страница 57: ...ed subsequently The correct chain adjustment must be maintained when a complete chaincase is fitted otherwise the chain will make contact with the case Remove rubber grummet in the case to check chain...

Страница 58: ...e 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 drawin...

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

Страница 60: ...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 BOLT FIXING D...

Страница 61: ...ess 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 w...

Страница 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 stay...

Страница 63: ...x 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 replenishme...

Страница 64: ...stand is perfectly free Smear the hinge bolt with engine oil before replacing it CENTRE STAND The centre stand is mounted on a bolt set across the bottom rear of the main frame and is removed by taki...

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

Страница 66: ...of the hub shell white 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 whe...

Страница 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 AND...

Страница 68: ...e 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 on the brake side to...

Страница 69: ...ed to permit the rear wheel to be taken out of the frame BRAKE SHOES The front and rear brake shoes and springs are interchangeable The two shoes in each brake are N O T identical they are handed One...

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

Страница 71: ...t Screw the nut 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 c...

Страница 72: ...lacken the spindle nut on the right hand side of the machine move the pedal to the desired position hold the pedal in this position and tighten the spindle nut The most suitable position for normal us...

Страница 73: ...Both wheel bearings are a press fit into the hub To avoid scruffing the bearing housings in the hub during the process of removing and refitting the bearings the hub must be gently heated to cause th...

Страница 74: ...wheel spindle when the speedometer drive will come away from the hub with the drive cable attached Slide out and towards the rear the spindle distance piece 029243 the wheel will now come away from th...

Страница 75: ...TYRES AND SERVICE Refer to the Booklet How to keep your motorcycle tyres fit issued with each new machine 73 Rear Wheel Hub Assembly Front Wheel Hub Assembly 73...

Страница 76: ...re 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 clean place NORMAL R U N N I N G...

Страница 77: ...at 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 rect...

Страница 78: ...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 gap...

Страница 79: ...t 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 moist...

Страница 80: ...cken 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...

Страница 81: ...this comprises three independent electrical circuits as follows 1 IGNITION Magneto High tension wires Sparking plugs and Cut out switch 2 CHARGING Dynamo Compensated Voltage Control Unit and Battery 3...

Страница 82: ...ng ensure the projecting key on the assembly engages with the keyway cut in the armature shaft Incorrect assembly will affect ignition timing Adjustment every 3 000 miles Remove the contact breaker co...

Страница 83: ...ior terminals are marked D and F indicating the respective terminals for the output and field wires that lead to similarly marked terminals on the Regular Unit Inspect commutator and brush gear every...

Страница 84: ...heel on the exhaust cam shaft Upon merely slackening the clamping strap and removing the sleeve nut on the outside of timing cover the dynamo complete with its driving gear can be withdrawn from the c...

Страница 85: ...the negative terminal on the right side of the battery compart ment The specific gravity of the electrolyte indicates the state of charge of the battery With a fully charged battery the specific grav...

Страница 86: ...Therefore do not over tighten which will not make a gas tight joint more gas tight but can and possibly will distort and damage the body of the plug Set the gaps to 020 to 022 Never try to move the c...

Страница 87: ...ing its normal load the driving beam is projected straight ahead and is parallel with the road surface Dipper switch Every 5 000 miles the moving parts of the dipper switch should be lubricated with t...

Страница 88: ...Illustration 48 Wiring diagram Singles 86 86...

Страница 89: ...Illustration 49 Wiring diagram Alternator Twins 87 87...

Страница 90: ...Illustration 50 Wiring diagram Magneto Twins 88 88...

Страница 91: ...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 Defect...

Страница 92: ...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 loos...

Страница 93: ...alt deposit that 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 T...

Страница 94: ...of which should 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 incorpo...

Страница 95: ...rvice 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 in an...

Страница 96: ...s The Licence Disc must be enclosed in a water tight container having a transparent front and this must be fixed to the machine in a conspicuous positron near the front and on the left hand side It is...

Страница 97: ...Contact breaker points 7 Brakes 3 Sparking plugs 8 Forks and steering head 4 Clutch 9 Alignment of wheels 5 Chains 0 1 Tyre pressures b Tighten all external nuts and boltss including cylinder head nut...

Страница 98: ...tation 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 4s 6d e...

Страница 99: ...priced In the Spares List An inexpensive thief proof locking bar 018691 Illustration 51 Air Cleaner Gear extractor 015274 A bridge type extractor consisting of bridge central screw and two side bolts...

Страница 100: ...ines 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 coun...

Страница 101: ...ankcase release valve 46 83 73 35 97 83 23 66 66 68 70 69 67 67 32 44 44 46 62 54 21 54 49 62 91 91 50 51 52 7 75 96 21 Cylinder barrel removal Cylinder barrel replacement Cylinder head removal Cylind...

Страница 102: ...85 12 22 80 80 81 90 17 16 18 20 16 62 97 26 27 24 90 28 33 39 54 62 92 85 61 75 92 74 10 Service Sparking plug Sparking plug removal Speedometer lubrication Starting Steering causes of unsatisfactory...

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