Table Of ContentF
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TWO-STROKE HIGH TWO STROKES & TUNING
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PERFORMANCE ENGINE E
DESIGN & TUNING TWO-STROKE EXHAUST I
By World famous engine designer SYSTEMS L
Bossaglia who was responsible for Full details on how to calculate design L f
most of the Italian rotary valve kart and make competition exhaust systems. n
engines including Komets and Parillas 55p Ref 252 Available again March
from the very first—the V11 to the K89. TWO-STROKE PORTS FOR
227 pages packed with information POWER
including : Characteristics and types of Read how to calculate and design the i
two-stroke motors. Multi-cylinder right port timing for your requirements. A .
engines, Fuel, Quantity of air necessary 55p Ref 253.
for combustion. Determining the power, TWO-STROKE CARBURATION J s
The Pressure Volume diagram, AND IGNITION S
Performance, The operation of the Roy Bacon's third book on racing two
crank, Balance, The Stroke/bore ratio, strokes. Vital information on carburation & s
Third port induction, Induction through & ignition.
valves, Blade type valves, Cylindrical 55p Ref 281
M SeERVICE AND OVERHAUL MANUAL
rotary valves, Rotating disc valves, ROTARY VALVE TWO-STROKE
Transfer and scavenging with transverse KART ENGINES A
flow, tangential flow, uni-directional All about 100cc kart engines. Includes l FOR THE
flow, Counter-flow scavenging, Arisco, B.M., Corsair, Famrel, Komet, T
Position of the ports, Parilla, Petry, Saetta, Starr, Basic C h
Bi-metal cylinders, Cylinders with preparation, using Bleepers,
chromed bore, The piston, The gudgeon Transistorised Ignition, Tillotson carbs. H AJS & MATCHLESS
pin, The piston rings, Constructional £1.10 Ref 288 L c
ideas for the piston, The head, The IMPROVING TWO STROKE E
crankcase, The crankshaft, Modification ENGINE PERFORMANCE
of the crank shaft assembly, Modification Villiers, Maico, Vespa, Marcelle, S t SINGLE MOTORCYCLES
of cylinder, piston and head, The Zundapp, Itom, DKW, Lambretta. S
carburettor, Fuel pumps, Carburation 85p Ref 135 a
adjustments, Fuel injection, The magneto S
The sparking plug, Ignition timing,
Electronic ignition, Lubrication, m IN by
Exhaust System, Mufflers, Exhaust
system for multi-cylinder engines, BUILDING KARTS G
F. NEILL
Exhaust silencers, Test procedure, KARTING FOR SCHOOLS & L
Examples of modifications.
£4.35 (incl. insurance) Ref 290 YOUTH GROUPS - E
Organising, driving and building s S Covering 1958 to 1964 Lightweight 250 c.c. and 350 c.c.
ABOUT KART RACING low-cost karts. Forming clubs.
90p Ref 292 models G2 G2S G2CS G2CSR 14 14S 14CS 14CSR
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SHToAw RtoT sINtaGrt thKe AspRoTrtI NexGplained, details JDAeVtaEilsL IaNn d SdEraTw inNgos. to1 build aj low 9 G5 8 and 1957 to 1966 Heavyweight 350 c.c., 500 c.c.
of classes, location of tracks. British price kart without a tube beander. 5 and 600 c.c. models G3 G3C G3S G3LS G3LCS G80
clubs and addresses. Where to buy Suitable for 2 or 4-stroke engines 7
karts, engines fr accessories. 4th Edn. without gearbox, max 5 hp & 40 lbs for - G80S G80CS TCS 16 16S 16C 16CS 16MS 16MC
50p Ref 286 Cadet racing, fun an.d driver training. 1 16MCS 18 18S 18CS
GOING KARTING Bolted-construction. 9
Covers every aspect of karting, how to 50p Ref 270 w 6
buy your kart and engine, racing on CADET SET No. 3 6
motor tracks, etc. 4th Edn. Details and drawings to make a fun kart
£1.45 Ref 266 withoutw a tube bender. Suitable for 2 or
R.A.C. KART REGS 1974 4 stroke engines without a gearbox up to
All the rules and regulations governing 5 hp and weighing up to 40 lbs. New
drivers, organisers, tracks, karts and edition provides option of bolted or
engines. British calendar of events, wwelded construction.
club addresses and list of tracks. Any parts can be purchased if required.
50p Ref 130 £1.10 Ref 293
LODGEMARK PRESS LTD L
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BANK HOUSE, SUMMERHILL, CHISLEHURST, g
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KENT BR7 5RD, ENGLAND m
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Technical details, together with working instrucetions given in ensuing
chapters are solely confined to the single cylinder A.J.S. and Matchless
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models, which are similar regarding design, and identified by the petrol
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tank emblems and colour finish. The engine design of the heavyweight
single cylinder models is basically identicacl since 1948, and in consequence
the engine assembly instructions—in the main—apply to all models made
from 1948 to 1966. The lightweight mtodels were introduced in 1959 and
design changes with minor modificaations are described to enable owners
to incorporate the later parts into earlier engines, if so desired.
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As the crankcases for the 350 and 500 heavyweight engines are identical
—since 1948—the small capacity engine can be converted to the larger
type by substituting parts- in the top portion of the engine.
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The author and the publishers wish to express their thanks to Norton
Villiers Ltd. for their co-operation in the preparation of this book and
permission to publish the text and illustrations.
SERVICE AND OVERHAUL MANUAL
FOR THE
AJS & MATCHLESS
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SINGLE MOTORCYCLES
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F. NEILL
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S.B.mN. 850770203
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EDITOR H. A. NIMMO
© LODGEMARK PRESS LIMITED
Bank House, Susan Wood, Chislehurst
Kent BR7 5RD, England
Contents
page
Technical data … … … … 5
Engine design changes … … … 13 o
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Lubrication … … … … … 18
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Recommended lubricants … … … 20
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Periodical maintenance … … s… 21
Engine servicing … … …s … 23
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Engine overhaul … … … … 35
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Gearbox and Clutch … … … 54
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Front forks … … … … … 71
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Rear suspension uanits … … … 84
Frame …m … … … … 85
Wheel bea-rings … … … … 87
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Wheels and Brakes … … … 90
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Transmission … … … … … 100
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wCarburettor … … … … … 102
w Wipac alternator … … … … 104
w Wipac electrical service … … … 107
Lucas electrical service … … … 111
Lucas coil ignition … … … … 112
Magneto … … … … … 113
Dynamo … … … … … 114
Wiring diagrams … … … … 120
TECHNICAL DATA
250 c.c. G2 and G2S Models
Identity
Engine Number On the crankcase near engine
plate cowling.
Frame Number On right hand side of frame head
lug.
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Cylinder Bore 69,85 mm.
Stroke 64.84 mm.
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Cubic Capacity 248.5 c.c. (15.2 cu. ins.)
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Carburettor
Type 376/99 Amal Monobloc (12i° inclination)
Main jet (without air filter) 180 .
Main jet (with air filter) 180 s
Choke size 1z"
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Throttle slide 3½
Needle position central (.1e06) pilot 25
Capacities
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Petrol tank 3¼ gallons (12.5 litres)
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Oil capacity 2½ pints (1.4 litres)
Gear box c3 pints (1.8 litres)
Front chain case 568 c.c.
Compression Ratio t7.8 to 1
General a
Seat height 30" (76 cms.)
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Wheel base 53" (134.5 cms.)
Weight 325 lbs. (148 kilos)
Ground clearance - 5½" (14 cms.)
Cylinder bore s
Nominal size 2.7500 + .0005"
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a – .0005"
Piston Size
Skirt diamete.r (taken at right angle
to gudgewon pin top of the skirt).
High limit 2.7488"
Low liwmit 2.7480"
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250 c.c. CSR 1962/64 Models
Compression Ratio 8 to 1
Valve springs (Scrambler Type) Spring free length 1½" between
wire centres.
Inlet Valve head diameter (New Type) 1S"
Gear Ratios
Top 6.39 to 1
Third 8.31 to 1
Second 11.82 to 1
First 18.68 to 1
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Sprocket Sizes
Engine 22 teeth
Gear box 18 teeth
Clutch 46 teeth
Rear Wheel 55 teeth
Chain Sizes
Front Duplex .315 x .638" (72 links)
Rear ½" x .305" (124 links)
Carburettor Type 389/82 (18" bore) o
Main jet Size 200
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Pilot jet Size 30
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Throttle slide 3
Needle jet Size .106" i
Needle location Central notch .
Spark Plug FE 80 s
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250 c.c. CSR 1965/66 Models
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Compression Ratio 9.5 to 1
Ignition Timing 2c4 degrees (x") full advance
Valve spring (coil type) inner free length 1.531"
touter free length 1.700"
Gear Ratios a
Internal Ratios
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Top 1 to 1
Third 1.24 to 1
Second - 1.75 to 1
First s 2.76 to 1
Actual Ratios
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Top a 6.5 to 1
Third 8.05 to 1
Second . 11.68 to 1
First w 17.97 to 1
Spark Plug K.L.G. FE 220
PistonwRings
Compression rings
Dwiameter 2¾" (69.85 mm.)
Width .0625"—.0615"
Radial Thickness .112"—.106"
Scraper ring
Diameter 2¾" (69.85 mm.)
Width .156"—.155"
Radial Thickness .112"—.106"
Piston Ring Gap .008"—.013"
Valve Timing
Inlet valve opens 40° B.T.D.C. with .010" rocker
Exhaust valve closes 40° A.T.D.C. clearance.
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Chain Sizes
Front chain a" x .225" (73 links)
Rear chain ½" x .305" (125 links)
Gear Ratios
Internal Ratios
Top 1 to 1
Third 1.30 to 1
Second 1.85 to 1
First 2.92 to 1 o
Actual Ratios
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Top 6.89 to 1
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Third 8.96 to 1
Second 12.75 to 1
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First 20.12 to 1 .
Sprocket Sizes s
Engine 21 teeth
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Clutch 50 teeth
Final drive 19 teeth e
Rear wheel 55 teeth
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350 c.c. Lightweight Model
identity c
Engine number On the crankcase near engine
tplate cowling.
Frame number a On right hand side of frame head
lug.
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Cylinder bore 72 mm.
Stroke 85.5 mm.
Cubic capacity - 347 c.c. (21.17 cu. ins.)
Carburettor s
Type 389/42 Amal Monobloc (12° inclination)
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Main jet (withouat air filter) 220
Main jet (with air filter) 220
Choke size . 18"
Throttle slwide 3½
Needle position central (.106) pilot 25
Capacwities
Petrol tank 3¼ gallons (12.5 litres)
Owil capacity 2½ pints (1.4 litres)
Gear box 3 pints (1.8 litres)
Front chain case 568 c.c.
Compression Ratio 6.9 to 1
General
Seat height 29.5" (74 cms.)
Wheelbase 53" (134.5 cms.)
Weight 340 lbs. (154 kilos)
Ground clearance 6" (15 cms.)
Cylinder bore
Nominal size 2.8345 + .0005" – .0005"
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Piston Size
Skirt diameter (taken at right angle
to gudgeon pin top of the skirt).
High limit 2.8286"
Low limit 2.8276"
Piston Rings
Compression rings
Diameter 72 mm.
Width 3/64" o
Radial Thickness .151"—.109"
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Scraper ring
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Diameter 72 mm.
Width E" i
Radial Thickness .109"—.101" .
Piston Ring Gap .008"—.013" s
Ignition Timing ¼" B.T.D.C.
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Valve Timing
Inlet valve opens 40° B.T.De.C. with .010" rocker
Exhaust valve closes 40° A.T.D.C. clearance.
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Spark Plug K.L.G. FE 80
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Chain Sizes
Front chain c.315" x .628" Duplex (72 links)
Rear chain ½" x .305" (123 links)
Gear Ratios t
Internal Ratios a
TOP 1 to 1
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Third 1.30 to 1
Second 1.85 to 1
First - 2.92 to 1
Actual Ratios s
Top 6.39 to 1
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Third a 8.32 to 1
Second 11.82 to 1
First . 18.68 to 1
Sprocket Swizes
Engine 22 teeth
Clutchw 46 teeth
Final drive 18 teeth
Rwear wheel 55 teeth
350 c.c. Heavyweight (Long Stroke) Model
Cylinder bore size 2.7197—2.7187"
Compression ratio (1956 onwards) 7.4 to 1
Piston skirt diameter—Top 2.7180—2.7172"
Piston ring gap .008"—.0013"
Gudgeon pin bush size d" + .0005"
d" – .00025"
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Description:Technical details, together with working instructions given in ensuing chapters are solely confined to the single cylinder A.J.S. and Matchless
