1957-1966 Ajs Matchless Service Repair Workshop Manual

This is the COMPLETE Service and Repair Manual for the 1957-1966 Ajs Matchless Service Repair Workshop Manual. It covers every single detail.

1957-1966 AJS Matchless Service Repair Workshop Manual PDF VEHICLE/EQUIPMENT INTRODUCTION: The AJS and Matchless brands were produced by Associated Motor Cycles (AMC) at the Woolwich factory in London, and by the late 1950s and early 1960s the two marques shared nearly identical engineering with only branding and cosmetic differences distinguishing them. The 1957 to 1966 period saw the production of both lightweight and heavyweight models ranging from 250cc to 600cc. The lightweight range included the G2, G2S, G2CS, G2CSR, Model 14, G5 and Model 8 series. The heavyweight range covered the G3, G3C, G3S, G3LS, G3LCS, G80, G80S, G80CS, TCS, Model 16 and Model 18 series. These classic British motorcycles were built with the traditional overhead valve single-cylinder and twin-cylinder engines with rigid or plunger-suspension frames depending on model and year. They feature Wipac or Lucas electrical systems, Amal carburetors, and girder-style or telescopic front forks. The AMC twins in particular represent the pinnacle of British motorcycle engineering before financial difficulties ended production, and remain highly sought after by collectors and vintage racing competitors. SERVICE & REPAIR SCOPE: - Engine bottom-end rebuild with crankshaft and connecting rod bearing replacement - Cylinder head valve grinding and seat cutting - Camshaft and timing chain inspection - Piston ring replacement and cylinder bore honing - Amal carburetor cleaning, jetting and float adjustment - Wipac alternator output testing and coil replacement - Lucas coil ignition timing and distributor service - Lucas electrical system wiring fault diagnosis - Magneto strip-down, point setting and advance mechanism overhaul - Dynamo output testing and brush replacement - Clutch plate replacement and spring adjustment - Gearbox layshaft and mainshaft bearing service - Kick-starter repair quadrant replacement - Telescopic fork oil seal and oil change - Girder fork spring adjustment - Rear suspension plunger unit overhaul - Rear frame unit mounting inspection - Drum brake shoe fitting and cam lubrication - Fuel tap and sediment bowl service - Exhaust system repair and re-chroming guidance - Full engine and transmission specification tables - Wiring diagrams for Wipac and Lucas systems TECHNICAL SPECIFICATIONS: - Manufacturer: Associated Motor Cycles (AMC) / AJS / Matchless - Lightweight range: 250cc and 350cc single-cylinder and twin models - Heavyweight range: 350cc, 500cc and 600cc single-cylinder models - Models: G2, G2S, G2CS, G2CSR, Model 14, 14S, 14CS, 14CSR, G5, Model 8 - Models: G3, G3C, G3S, G3LS, G3LCS, G80, G80S, G80CS, TCS, Model 16, 16S, 16C, 16CS, 16MS, 16MC, 16MCS, Model 18, 18S, 18CS - Engine type: OHV single and parallel twin - Carburetion: Amal - Ignition: Wipac alternator, Lucas coil, or magneto depending on model - Electrical: Wipac or Lucas systems - Transmission: 4-speed manual - Frame: Rigid or plunger rear suspension - Brakes: 7-inch or 8-inch drum DIAGNOSTIC INFOR

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