A.J.S. 16 - Page 104

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Table of Contents4
Safety on the Road5
Technical Data6
Carburetter6
Controls9
Driving11
Fuel11
Starting the Engine from Cold11
Stopping the Engine12
On the Road12
Running the Engine12
Notes on Driving13
Lubrication14
Checking Oil Circulation15
Engine Lubrication System15
Engine Oil Pump17
The Oil Tank18
Engine Oil Circulation Diagram19
Adjustment of Oil Feed20
Cleaning Oil Filters20
Cross Section of Engine - Oil Galleries, Oil Passages, Release Valve21
To Remove and Clean Crankcase Filter22
Pressure Relief Valve22
To Remove Magnetic Filter22
To Dismantle and Refit Crankcase Release Valve in Crankshaft23
Gearbox Lubrication23
Chain Lubrication23
Hub Lubrication23
Brake Drum Bearing24
Brake Expander Lubrication24
Lubrication Chart24
Brake Rod Joint Lubrication25
Brake Pedal Lubrication25
Steering Head Bearing Lubrication25
Control Lever Lubrication25
Periodical Maintenance26
Engine Service28
Tappet Adjustment28
To Adjust Overhead Rockers (Tappet Clearance)29
To Remove Twin Seat30
To Remove Petrol Tank30
Decarbonisation31
To Remove the Rocker Box31
To Replace the Rocker Box31
To Remove the Cylinder Head31
To Remove and Replace the Valves and Guides32
To Replace a Valve33
Removing Carbon Deposit34
Valve Grinding34
To Replace the Cylinder Head - Singles34
To Remove the Cylinder Barrel and Piston35
To Replace the Pistion and Cylinder Barrel35
Cam Contour36
Valve Timing36
Small Timing Gear Pinion - Singles37
Ignition Timing37
Check Contact Breaker Gap37
Removing the Automatic Timing Control37
Setting the Ignition Timing38
To Remove and Replace the Oil Pump Plunger if and When Necessary39
Oversize Parts and Reboring Cylinder Barrel40
Removing Sparking Plug40
Decarbonisation - Twins40
Removing Cylinder Barrels and Pistons41
Fitting Pistons and Cylinder Barrels42
To Refit the Cylinder Heads42
To Re-Time the Ignition - Twins (Magneto Models)43
To Re-Time the Ignition (Alternator Twins)44
Valve Timing44
Removal of Gears44
Carburetter Service46
Carburetter Adjustment46
Twist Grip Adjustment46
Carburetter Details in Assembly Order47
Air Filter48
To Remove the Air Filter Element48
Carburetter Tuning Information48
Transmission Service49
The Gearbox49
Foot Change Operation49
To Remove Gear Box Outer Cover50
To Replace Gear Box Outer Cover50
To Remove Gear Box Inner Cover50
To Replace Gear Box Inner Cover51
Front Chaincase Cover51
To Remove Outer Chaincase Cover51
To Remove Clutch and Front Chain52
To Replace Front Chaincase Cover52
To Remove AC Rotor and Engine Sprocket52
To Replace Fotor and Engine Sprocket53
To Remove Engine Sprocket53
Clutch Operating Mechanism Adjustment53
Clutch Spring Adjustment54
To Dismantle Clutch Shock Absorber54
To Remove Clutch Bearing55
To Dismantle Gear Box55
Removal/Refitting of Cam Plate55
Fitting Gears into Gear Box55
Dismantling Kick Starter Assembly56
To Replace Kick Starter Assembly56
Front Chain Adjustment56
Rear Chain Adjustment56
Notes on Rear Chain Adjustment57
Removing and Refitting Rear Chain57
Fork and Frame Service58
Steering Head Adjustment58
Front Forks (Teledraulic)58
To Expose the Fork Springs58
Exploded View of Teledraulic Forks59
To Refit the Forks as a Unit61
Front Fork "Topping Up"61
To Remove the Complete Front Fork Assembly61
To Remove a Fork Slider62
To Remove a Fork Inner Tube63
Rear Suspension63
A Cam Ring Adjuster64
Prop Stand/Centre Stand64
To Remove Oil Tank64
To Remove the Rear Chain Guard64
Wheels and Brakes65
To Remove Front Wheel65
To Re-Fit Front Wheel65
Rear Wheel Removal65
To Refit Rear Wheel66
Wheel Bearings and Adjustment66
To Dismantle Front Wheel Bearings66
Non-Quick-Detachable Wheel Assembly67
To Dismantle Rear Wheel Bearings68
Front Brake Cover Plate68
Brake Drums68
Brake Shoe Adjustment69
Front Brake Adjustment70
Rear Brake Adjustment71
Brake Pedal Adjustment72
Tyres and Service72
Electrical Service75
Alternator Model RM1575
Emergency Starting75
Emergency Charging76
Rectifier76
Lucas Coil Ignition76
Contact Breaker Setting77
Distributor Diagram78
Ignition Coil79
Capacitor79
Electrical Service - Magneto Models80
Ignition80
Contact Breaker Diagram80
Magneto Removal and Fitting81
Dynamo81
Control Box82
Dynamo Testing82
To Remove and Re-Fit Dynamo82
To Remove Control Box83
Battery83
Battery Unit83
Fitting the Battery84
Topping up the Battery84
Sparking Plug85
Lighting and Accessories85
Headlamp85
Lucas Stop Tail Lamp86
Lucas Horn86
Terminals86
Wiring Diagrams87
Troubleshooting90
Cleaning the Machine92
Chromium Plating92
Free Service96
Guarantee97
Spare Parts97
Tools and Special Equipment98
Tool Kit99
Index101

A.J.S. 16 - Page 104

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