A.J.S. 16MS, Instruction Book

Page 1: ...INSTRUCTION BOOK A J S 1956 SINGLE CYLINDER MODELS 500 c c 18S 350 c c 16MS 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...

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

Page 3: ...egrams ICANHOPIT WOL LONDON Cables ICANHOPIT LONDON Codes A B C 5th and 6th Edition Bentley s and Private Codes Registered Offices PLUMSTEAD ROAD PLUMSTEAD LONDON S E 18 ENGLAND Issued by A J S MOTOR...

Page 4: ...d Frame Free Service Guarantee Index Information Lubrication Maintenance Repairs and Service Spare Parts Tools and Special Equipment Transmission Wheels and Brakes 36 9 6 10 69 24 49 84 88 89 78 14 22...

Page 5: ...b bearing details rear Trials Hub rear and front Lubrication chart Oil tank Oil pump Sparking plug Spring frame Spring frame Teledraulic leg Tank fixing details Tappet adjustment Tools Valve lubricati...

Page 6: ...SINGLE CYLINDER MODELS 350 c c Model 16MS 500 c c Model 18S 4 w w w a j s m a t c h l e s s i n f o...

Page 7: ...ure of some of the contents of this handbook but owners whether novice or expert are advised to read the contents from beginning to end We are at all times pleased to give owners the full benefit of o...

Page 8: ...tter Touring and Trials Models Type Main jet Pilot jet Throttle valve Choke size Needle position Needle jet 350 c c Monobloc 376 5 376 100 size 210 376 076 size 30 376 060 size 3 1 z Central notch 376...

Page 9: ...ad lamp Pre focus Pilot lamps Rear lamp Speedometer Type Double filament Single contact Double filament Single contact Voltage 6 6 6 6 Wattage 30X24 3 18 3 1 8 Part number 312 988 352 53205 Oversize p...

Page 10: ...OL SWITCH AMMETER HORN BUTTON GEAR BOX FILLER CAP RIDER S FOOTREST PETROL TANK FILLER CAP OIL TANK FILLER CAP HEADLAMP DIP SWITCH DUMMY GRIP SPEEDOMETER MILES PER HOUR DIAL SPEEDOMETER TOTAL MILEAGE S...

Page 11: ...ght foot rest Controls selection of the four speeds or ratios between engine and rear wheel revolutions with a free or neutral position See illustration 2 9 Kick starter Vertical pedal on right hand s...

Page 12: ...ngine is cold i Depress the kick starter until compression is felt then raise the valve lifter lever and ease the engine just over compression Then after allowing the kick starter pedal to return near...

Page 13: ...valve lifter lever and keep ft raised until the engine has ceased to revolve ON THE ROAD Having started and warmed up the engine take the machine off the stand sit astride it free the clutch by pullin...

Page 14: ...e 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 climbing the necessa...

Page 15: ...trol the road speed The clutch is intended to be used only when starting from a standstill and when changing gear It must N O T be operated to ease the engine instead of changing gear or be held out i...

Page 16: ...SAE 50 Mobiloil 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 Mot...

Page 17: ...tween tank and crank case and Is returned through the upper pipe If for any reason the crankcase is dismantled the oil pump plunger must be removed from Its housing before attempting to separate the c...

Page 18: ...when starting the engine the bulk of oil in the crankcase sump may be greater than the space available in the tank A metal gauze strainer is secured in the tank end of the feed pipe union After the fi...

Page 19: ...crankcase sump so that until this surplus is cleared the return flow is very positive and continuous Therefore if the oil circulation is deranged the fact is apparent at once by the lack of a steady r...

Page 20: ...or no adjustment Inlet valve squeak indicates the oil feed adjustment is not open enough Excessive oil consumption a smoky exhaust or an oiled sparking plug generally indicates the oil feed adjustment...

Page 21: ...ing grease fluidity Then hang to drain off surplus and replace Engine oil is a poor substitute for one of the recommended greases and if used the chain should be allowed to soak for several hours to e...

Page 22: ...nsure free smooth action the clutch 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 obta...

Page 23: ...Engine Oi l Location GEAR BOX 23 14 21 9 15 10 3 5 17 4 Grease Locations FRONT HUB REAR HUB STEERING HEAD TOP BEARING STEERING HEAD BOTTOM BEARING SPEEDOMETER GEAR BOX FRONT BRAKE EXPANDER REAR BRAKE...

Page 24: ...rculation Petrol tank Check level and re fill If necessary WEEKLY Oil tank Check level 16 and re fill if necessary Tyres Check pressures and Inflate if necessary EVERY 500 MILES Oil tank Drain at firs...

Page 25: ...lts for tightness and tighten if necessary but beware of over tightening Rockers Check O H V rocker adjustment and correct If necessary EVERY 5 000 MILES Oil tank Drain and re fill with new oil 16 If...

Page 26: ...tate this operation by removing the need to first drain the tank of petrol Details and order of assembly of the fuel tank fixing bolts and components Illustration 7 A B C D E Part Number METAL WASHER...

Page 27: ...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 28: ...A sharp light tap on the valve collar may be necessary to free the taper split collet It will be observed that the valve spring seat has a raised impression on Its under side which registers with a ho...

Page 29: ...cated on the valve stems 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...

Page 30: ...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 equipment for that purpose Any at...

Page 31: ...obably 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 the under face of t...

Page 32: ...ton by Introduce piston over connecting rod so that slit in piston faces to the front of the machine Introduce gudgeon pin in piston and pass ft through connecting rod small end bush and centralise it...

Page 33: ...be well clear of the quietening curves of the camshafts The timing gears are marked to facilitate their replacement To re set the valve timing by using the marks on the gears proceed as follows Turn...

Page 34: ...W CUPPED ADJUSTING SCREW 4 5 6 CUPPED ADJUSTING SCREW A N D LOCK NUT SLEEVE TO ACCOMMODATE ADJUSTING SCREW ON TOP END OF PUSH ROD EXHAUST ROCKER ARM TAPPET END Complete adjustment by Replace rocker ta...

Page 35: ...d record position on rod 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 control in the fully advanced position Repla...

Page 36: ...rew to prevent any possibility of it unscrewing in use Under no circumstances must either the pump plunger or guide screw be disturbed in ordinary routine maintenance OVERSIZE PARTS AND RE BORING CYLI...

Page 37: ...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 INSERTED RELIEVED TIP D O W N W A R D AS SHOWN...

Page 38: ...air adjustment screw The pilot jet unlike on earlier models is now detachable for cleaning purposes The size of the main jet should not be altered save for some very good reason See DATA for details...

Page 39: ...Illustration 13 Carburetter details in assembly order 37 w w w a j s m a t c h l e s s i n f o...

Page 40: ...lvent and allow to dry Then re oil using one of the light oils SAE 20 enumerated in the final table on page 14 and allow to drain before replacing in the filter case Clean regularly at intervals of 1...

Page 41: ...arly shows the general internal gearbox layout the simple gear selection and kickstarter mechanism It will be seen that movement of the foot change lever causes movement of the cam barrel through the...

Page 42: ...from the slotted end of the internal clutch operating lever which is exposed by the removal of filler cap Unscrew the clutch cable adjuster until it is free from the K S case cover and withdraw the ca...

Page 43: ...spring cups and flatten the turned up part of the lock plate that is under the large central nut Remove front chain connecting link and take away chain Engage top gear apply rear brake and unscrew nut...

Page 44: ...de flywheel axle and the dynamo shaft Fit the dynamo shaft plain washer and sprocket retaining nut screwing nut with fingers only Hold the dynamo sprocket by applying spanner 017254 to the flats on th...

Page 45: ...in for adjustment Check dynamo driving chain for adjustment Check clutch operarating lever for correct free movement as detailed elsewhere Fit outer half of front chaincase by Ensure faces of both hal...

Page 46: ...e 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 clutch springs h...

Page 47: ...e the clutch cover and then make the final adjustment by unscrewing the cable adjuster until the recommended free movement of the casing is obtained after which retighten the cable adjuster lock nut A...

Page 48: ...th lock nuts are provided at each slotted end To adjust the chain place cycle on stand and slightly slacken wheel spindle end nut also slightly slacken the brake drum dummy spindle locknut the hexagon...

Page 49: ...rand each side of the sprocket teeth When the chain is well clear cut the string one side only at a point about one foot from where it is looped through the chain link Leave the string then in situ aw...

Page 50: ...he engine over rides the sprocket cam under the influence of the engine impulses The shock absorber spring is compressed by the over riding of the cams thereby absorbing the shocks it is essential the...

Page 51: ...n 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 then tigh...

Page 52: ...ovement 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 forced...

Page 53: ...measure the oil Remove the drain plug 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 pumpi...

Page 54: ...Illustration 18 Exploded view of Teledraulic Forks 52 w w w a j s m a t c h l e s s i n f o...

Page 55: ...D 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 B...

Page 56: ...le 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 sufficient expansion to release the oil sea which is normal...

Page 57: ...RK END BOTTOM PIVOT BOLT CHAIN ADJUSTER FORK HINGE BEARING The rear wheel fork is suspended on springs located in the two TELEDRAULIC legs joining the rear of the fork to the main frame rear loops and...

Page 58: ...Illustration 20 Ghost view of TELEDRAULIC leg 56 w w w a j s m a t c h l e s s i n f o...

Page 59: ...may again be screwed on and securely tightened down to prevent oil leakage when the leg is re fitted after which the other leg may be dealt with in a similar manner NOTE Shortage of oil is evidenced...

Page 60: ...pipes from the bottom of the tank by sliding the rubber connectors down the pipes The tank is held in position by four brackets and nuts and bolts two at the top one at the front and one at the back R...

Page 61: ...at the wheel clamp occupies its natural position on the spindle end on which it is intentionally not positioned TO REMOVE QUICKLY DETACHABLE REAR WHEEL Place the machine on the centre stand Loosen the...

Page 62: ...t Illustration 21 Rear wheel bearings Competition models 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WHEEL SPINDLE SPEEDOMETER GEAR BOX SLEEVE RING RETAINING OIL SEAL Small OIL SEAL CUP FOR OIL SEAL OIL SEAL DIS...

Page 63: ...circling nut On all wheels the adjusting ring is located on the right hand side It is rarely necessary to make adjustment to wheel bearings It is most important they are not adjusted too tightly as th...

Page 64: ...andrel or a piece of tubing of external diameter a trifle smaller than the hub bore apply pressure to the inner edge of the fixed bearing ring so that it is forced out of the hub end As it emerges it...

Page 65: ...r the circlip until it is possible to extract the circlip The outer seal cup 5 the oil seal 4 and the retaining washer 10 are then free to be withdrawn The bearing ring may then be forced out of the e...

Page 66: ...or that purpose FRONT BRAKE ADJUSTMENT Major adjustment of the frontbrake shoes is made on the brake thrust pins by fitting packingwashers under the pins as already described Minor adjustment of the f...

Page 67: ...position in virtue of the two projecting noses on it engaging in accommodating slots cut in the clip which connects the brake rod and brake pedal lever and being retained in that position by the spri...

Page 68: ...and nuts Under each nut is a lock washer of the tab type and it is essential these are always in position Harshness in transmission can be caused by the drum retaining bolts and nuts being loose On qu...

Page 69: ...with a low pressure gauge at least once a week Inflate as may be necessary Avoid unnecessary or stunt acceleration and fierce braking which wear out tyres by causing wheel spin and skid Do not drive...

Page 70: ...water round the free edge of the cover This is a great help in fitting and in ensuring the cover centralises itself on the rim and should always be employed If at all possible Introduce the free edge...

Page 71: ...ken the two screws securing the fixed contact plate and adjust the position of the plate until the gap when the contacts are fully opened is set to the thickness of the gauge The correct gap should be...

Page 72: ...en 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 driver and the...

Page 73: ...arking 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 dismantling replac...

Page 74: ...he foregoing taking care 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 En...

Page 75: ...e ammeter terminals and the E terminal is earthed We specially warn against unskilled meddling with the settings of the regulator and the cut out contacts Illustration 32 1 To Earth 2 To Terminal D on...

Page 76: ...monia or bicarbonate of soda In water Vent plugs should be kept clean and air passages in them kept free Re fix vent plugs tightly Keep the battery and surrounding parts particularly the tops of the c...

Page 77: ...s on the inside of the back cap with the slots in the holder press on and secure by twisting it to the right Engage bottom tag on lamp rim with the small slit in the shell and gently force the top of...

Page 78: ...ctor is used in the rear lamp wire and another Is used in the wire con necting the regulator unit to the output side of the ammeter in the head lamp Two more are used in the headlamp interior pilot la...

Page 79: ...Illustration 35 Wiring diagram 77 w w w a j s m a t c h l e s s i n f o...

Page 80: ...ding of carburetter with hot engine only Stuck up engine valve Weak or broken valve spring Valve not seating properly Contact points dirty Incorrect contact point gap Engine misses fire may be due to...

Page 81: ...n 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 CONSUMPTION Excessive petrol consumpt...

Page 82: ...ges 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 Lack of attention will lead to more serious damage T...

Page 83: ...atter 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 MUST BE QUOTED otherwise model identifi c...

Page 84: ...com 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 are strangers to th...

Page 85: ...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 tight container having...

Page 86: ...r box j Test machine on the road NOTE Oils greases and materials used are chargeable to the customer FREE SERVICE SCHEME All owners of N E W MODELS are entitled to one FREE SERVICE AND INSPECTION at 5...

Page 87: ...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 receive orders without this very necessary information PAYMENT 1...

Page 88: ...ear light Air cleaner Pillion footrests bolted on to fold up when not in use and specially designed for these machines Not on competition Detachable luggage carrier Not on competition Timing disc 0220...

Page 89: ...TOOL KIT Illustration 37 87 w w w a j s m a t c h l e s s i n f o...

Page 90: ...orcycle 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 motorcycle by any form o...

Page 91: ...l replacement Cylinder head removal Cylinder head replacement 38 72 73 86 73 19 20 65 66 64 66 65 66 66 28 36 36 38 57 46 19 47 41 57 80 80 44 45 44 8 9 81 29 30 26 29 Data Decarbonisation Driving not...

Page 92: ...57 81 76 55 57 81 Rocker box removal and replacement 25 Running in 12 Service Sparking plug Sparking plug removal Speedometer lubrication Starting Steering causes of unsatisfactory Steering head adjus...

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