INSTRUCTION BOOK A J S • • o f 1956 n i . s s e l h c t a m - s j a . 350 c.wc. SINGLE CYLINDER 500c.c. 16wMS MODELS 18S w Issued by: A.J.S. MOTOR CYCLES • LONDON S.E.18 Proprietors : ASSOCIATED MOTOR CYCLES LTD. o f n i . s s e l h c t a m - s j a . w w w INSTRUCTION BOOK A• J• S o 350 c.c. SINGLE CYLINDER MODELS 500 c.c. f n 1956 i . s s e Price l TWO SHILLINGS and hSIXPENCE c t a mFactories: BURRAGE GROVE and MAXEY ROAD PLUMSTEAD, S.E.18 - s Telephone: WOOlwich 1223 (7 lines) Teljegrams: "ICANHOPIT, WOL-LONDON" a Cables: "ICANHOPIT, LONDON" Code.s: A.B.C.5th and6th Edition;Bentley's; andPrivateCodes w w Registered Offices: w PLUMSTEAD ROAD, PLUMSTEAD LONDON, S.E.18 .. ENGLAND Issued by: A.J.S. MOTOR CYCLES • LONDON S.E.18 Proprietors: ASSOCIATED MOTOR CYCLES LTD. CONTENTS o fPage n Carburetter … … … … … … … … … … 36 i Controls … … … … … … … … ….… 9 s Data … … … … … … … … … … … 6 s Driving … … … … … … … …e… … … 10 Electrical Equipment … … … … l… … … … 69 h Engine … … … … … … … … … … … 24 c Forks and Frame … … … t… … … … … … 49 a Free Service … … … … … … … … … … 84 m Guarantee … … … … … … … … … … 88 Index … … … -… … … … … … … … 89 s Information … j… … … … … … … … … 78 a Lubrication … … … … … … … … … … 14 . Maintenanwce … … … … … … … … … … 22 Repwairs and Service … … … … … … … … … 81 wSpare Parts … … … … … … … … … … 85 Tools and Special Equipment … … … … … … … 86 Transmission … … … … … … … … … … 39 Wheels and Brakes … … … … … … … … … 59 2 ILLUSTRATIONS Illustrations Page A.V.C. unit … … … … … … 32 73 Battery … … … … … … … 33 74 Brake adjustment, front … … … … … 26 64 Brake adjustment, rear … … … … … 27 65 Brake anchorage, rear … … … … … 22 61 o Brake pedal adjustment … … … … … 28 66 f Brake shoe adjustment … … … … … 29 n67 Carburetter … … … … … … 13 37 i Clutch … … … … … … … .15 44 Controls … … … … … … … s 1 8 Dynamo Removal … … … … … s… 31 72 Engine lubrication … … … … e… 3 16 Flywheels … … … … … … 9 28 l Fork exploded view … … … h… … 18 52 Fork damper details … … … … … 17 50 c Front chain adjustment … … … … … 16 46 t Gearbox … … … … … … 14 39 a Gear lever positions … … … … … 2 11 m Headlamp … … … … … … 34 75 Hub bearing details, front … … … … … 23 62 - Hub bearing details, rear (Standard) … … … … 25 63 s Hub bearing details, rear (Trials) … … … … 21 60 j Hub, rear and fronat … … … … … 24 62 Lubrication chart … … … … … … 6 21 . Oil tank w … … … … … … 4 17 Oil pump … … … … … … 12 35 w Sparking plug … … … … … … 30 70 Spring frame … … … … … … 19 55 w Spring frame, Teledraulic leg … … … … 20 56 Tank fixing details… … … … … … 7 24 Tappet adjustment … … … … … 11 32 Tools … … … … … … … 37 87 Valve lubrication … … … … … … 5 19 Valve spring compressor … … … … … 8 27 Valve timing … … … … … … 10 31 Wire connector, snap type … … … … … 35 76 Wiring diagram … … … … … … 36 77 3 o SINGLE CYLINDER MODELS f n i . s s e l h c t a m 350 c.c. Model 16MS - s j a . w w w 500 c.c. Model 18S 4 THE 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 o earnestly endeavoured to build into it. f It must be borne in mind however, that although of simple design and n construction, it is nevertheless a highly specialised piece of engineering and must in consequence be intelligently and efficiently maiintained in order to provide unfailing reliability. . s In this book we provide non-technical instructions for carrying out all the s maintenance operations likely to be called for in normal service, together with assisting illustrations. e l To owners of long experience we tender apologies for the elementary h nature of some of the contents of this handbook, but owners whether novice or expert are advised to read thec contents from beginning to end. We are at all times pleased to givet owners the full benefit of our wide a experience in matters relating to motor cycles of our manufacture and elsewhere will be found detaimls of the particulars required when making enquiries of our Service Department. - s j Safety on athe Road . IN the winterest of Safety on the Road a few words of warning will not be out of place. w The outstanding manoeuverability of a motor cycle over all other vehicles on the road makes it necessary to exercise caution at all times. w 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 motorcycling is a dangerous pastime. Take a pride in your riding technique and never rely upon the other fellow doing the right thing. Your example of careful, courteous and unobtrusive riding will materially contribute to road safety and to the reputation of a fine sporting pastime. 5 DATA Engine Number … … … … … … … … Stamped on left hand side of crankcase Frame Number … … … Stamped on seat lug of main frame, on right hand side (below the saddle) Bore… … … … … … … … … … 350 c.c. Models—2·7187 in. ( 2F in.) 500 c.c. Model—3·250 in. (3¼ in.) Stroke … … … … … … … … … All Models—93 mm. (3·65625 in.) Engine capacity, in cubic centimetres… … … … … 350 Models—347 500 Model—498 o f Capacities n Location British Metric i Engine … … … … … 350c.c. 21·170 cub. in. 347 c.c. Engine'… … … … … 500c.c. 30·380 cub. in. 498 c.c . Gear box … … … … … … 1 pint 568·2 c.c. s Front fork (each side) … … … … 6½ fl. ozs. 184·6 c.c. Rear leg (each leg) … … … … 3 fl. ozs. 85 cs.c. Rear wheel fork hinge bearing … … … 1½ fl. ozs. 426 c.c. Fuel Tank (all except Competition) … … 3¾ gallons 17·04e litres Fuel tank (Competition) … … … … 2 gallons 9 litres Oil tank (to top level mark) … … … 5 pints l2·8 litres h Carburetter, Touring and Trials Models c t 350 c.c. 500 c.c. Type … … … … … … a… … Monobloc 376/5 Monobloc 389/1 Main jet … … … … … … … 376/100 size 210 376/100 size 260 Pilot jet … … … … m… … … 376/076 size 30 376/076 size 30 Throttle valve … … … … … … … 376/060 size 3 389/060 size 3 Choke size … … … … … … … 1·z" 1·E" Needle position … …-… … … … Central notch Central notch Needle jet … … …s… … … … 376/072 size ·1065 376/072 size ·1065 j Compression raatios Normal Low Model . ratio ratio w 350 7·5 to 1 According to piston. 500 7·3 to 1 See Spares List for w ratios available. w Ignition (magneto) Ignition point before top dead centre (with control Model Make Type Rotation Point gap in fully advanced position) Touring 350 c.c. Lucas SR-1 Anti-clock ·012 in. Normal 39°—½" Touring 500 c.c. Lucas SR-1 Anti-clock ·012 in. Normal 39°—½" Trials Lucas Racing Anti-clock ·012 in. Normal 39°—½" Gear box ratios Model First gear Second gear Third gear Fourth gear (top) Touring … … … 2·65 to 1 1·70 to 1 1·308 to 1 1 to 1 Trials … … … … 3·199 to 1 2·437 to 1 1·575 to 1 1 to 1 6 Gear ratios, Touring Models Fourth gear Engine sprocket size First gear Second gear Third gear (top) 15 teeth … … … 18·55 to 1 11·90 to 1 9·15 to 1 7 to 1 16 teeth … … … 17·32 to 1 11·15 to 1 8·58 to 1 6·56 to 1 17 teeth … … … 16·32 to 1 10·47 to 1 8·05 to 1 6·16 to 1 (a) 18 teeth … … … 15·44 to 1 9·90 to 1 7·63 to 1 5·83 to 1 19 teeth … … … 14·55 to 1 9·33 to 1 7·18 to 1 5·49 to 1 20 teeth … … … 13·91 to 1 8·91 to 1 6·86 to 1 5·25 to 1 (b) 21 teeth … … … 13·25 to 1 8·50 to 1 6·54 to 1 5·0 to 1 (a) Standard for 350 c.c Touring Models (b) Standard for 500 c.c. Touring Models. o Gear ratios, Trials Model f Fnourth gear Engine sprocket size First gear Second gear Third gear (top) 15 teeth … … … 22·4 to 1 17·25 to 1 11·03 to 1 i 7 to 1 16 teeth Standard … … 21·0 to 1 15·98 to 1 10·33 to 1. 6·56 to 1 17 teeth … … … 19·7 to 1 15·0 to 1 9·7 tso 1 6·16 to 1 18 teeth … … … 18·68 to 1 14·2 to 1 9·2 to 1 5·83 to 1 19 teeth … … … 17·57 to 1 13·38 to 1 s8·65 to 1 5·49 to 1 20 teeth … … … 16·8 to 1 12·8 to 1 8·37 to 1 5·25 to 1 21 teeth … … … 16·0 to 1 12·18 to 1 e7·81 to 1 5·0 to 1 Lighting (bulbs) l h Part Location Type Voltage Wattage number c Head lamp (Pre-focus) … Double filament … … … 6 30X24 312 Pilot lamps … … Single contact …t… … 6 3 988 Rear lamp… … … Double filament a… … … 6 18 & 3 352 Speedometer … … Single contact … … … 6 1·8 53205 m Oversize parts The following are the only " oversize " variations provided for the 350 and 500 c.c. Single Cylinder machines Big-end rollers : Cylin-der re-bore : Pistons and rings : ·001 in. oversize s ·020 in. and ·040 in. oversize · 020 in. and ·040 in. oversize j Pistons (standard Size) All measurements are subject to a toleration limit of + or — ·0005 in. a Model Top of skirt diameter Front to rear clearance Part number 350 … … 2·7176 in. ·001 in. 013504 500 … .… 3·2490 in. ·001 in. 013505 w Piston ring gap Normwal … … … … … … … … … … … … … ·006 in. Permissible maximum… … … … … … … … … … … ·030 in. Piston ring clearance in groove … … … … … … … … … ·002 in. w Sparking Plug Model Make Type Thread Reach Point gap All … … K.L.G. FE80 14 mm. ¾ in. ·020 to ·022 in. Valve timing (See Illustration 10) All timing gears are marked for ease of setting. With Marks coinciding correct timing is assured. Valve Guide Projection (Top of Guide to Boss) inlet—½" Exhaust—½" Valve timing pinion Retained by nut, threaded v in. by 26 threads per in. Left hand thread. Part number 000221. 7 C—S Weight with empty tanks Model Standard Trials 350 … … … … … … 375 Ibs. 320 Ibs. 500 … … … … … … 386 Ibs. — Wheels (bearing end play) 002 in. (just a perceptible rim rock). o f n i . s s e 1 THROTTLE TWIST GRIP 2 AIR CONTROL l 4 EXHAUST VALVE LIFTER h LEVER 5 CLUTCH LEVER c 6 FRONT BRAKE LEVER 7 REAR BRAKE PEDAL t 8 GEAR CHANGE LEVER 9 KICK-STARTER PEDAL a 10 LAMP CONTROL SWITCH 11 AMMETER m 12 HORN BUTTON 13 GEAR BOX FILLER CAP 14 RIDER'S FOOTREST - 15 PETROL TANK FILLER CAP s 16 OIL TANK FILLER CAP 17 HEADLAMP DIP SWITCH j 18 DUMMY GRIP 19 SPEEDOMETER, MILES PER a HOUR DIAL 20 SPEEDOMETER, TOTAL . MILEAGE w 21 SPEEDOMETER, TRIP MILEAGE 22 SPEEDOMETER, TRIP RECORDER RESET KNOB w 23 GEAR POSITION INDICATOR 24 PILLION FOOTRESTS; w 25 FORK TOP BOLT (Remove to add oil) Illustration 1 Controls 8