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AJS 500 1954 - User Manual

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MAINTENANCE
MANUAL
INSTRUCTION
BOOK
AND
for
1954
350 c.c.
and 500 c.c.
AJ
SPRING FRAME AND RIGID
SINGLE CILINDER MODELS
PRICE 2/6 NETT
A JS
M O T O R C Y C L E S
Proprietors: ASSOCIATED MOTOR CYCLE LIMITED
PLUMSTEAD LONDON S.E.18
EDITION CM-27
S

Table of Contents

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Summary

Data

Identity

Details about engine and frame identification numbers.

Capacities

Specifications for fluid capacities like engine, gearbox, and forks.

Gear box ratios

Ratios for different gears in touring and competition models.

Valve timing (with 014 inch rocker clearance) Standard cams

Valve timing specifications for inlet and exhaust valves.

Controls

Driving

FUEL SUPPLY

Details on fuel tap operation and reserve supply.

STARTING THE ENGINE

Step-by-step instructions for starting the engine.

STOPPING THE ENGINE

Procedure for stopping the engine safely.

ON THE ROAD

Guidance on riding the machine, gear changes, and throttle control.

RUNNING IN

Recommendations for the initial running-in period of a new machine.

NOTES ON DRIVING

Advice on smooth gear changes, clutch usage, and braking.

Lubrication

LUBRICANTS TO USE

Recommended oils and greases for various machine parts.

ENGINE LUBRICATION SYSTEM

Explanation of the dry sump lubrication system.

ENGINE OIL PUMP

Description of the oil pump's function and parts.

ENGINE OIL CIRCULATION

Details on how oil circulates through the engine.

THE OIL TANK AND FILTERS

Information on the oil tank, its level marks, and filters.

GEAR BOX LUBRICATION

Lubrication requirements for the gear box.

Maintenance

PERIODICAL MAINTENANCE

Schedule for regular maintenance tasks.

DAILY

Daily checks and top-ups for oil and fuel.

EVERY 500 MILES

Maintenance tasks required every 500 miles.

EVERY 1,000 MILES

Maintenance tasks required every 1,000 miles.

EVERY 3,000 MILES

Maintenance tasks required every 3,000 miles.

EVERY 5,000 MILES

Maintenance tasks required every 5,000 miles.

EVERY 10,000 MILES

Maintenance tasks required every 10,000 miles.

Engine Service

TO REMOVE THE PETROL TANK

Instructions for removing the petrol tank.

TO REMOVE THE ROCKER BOX

Steps to remove the rocker box assembly.

Decarbonisation

TO REMOVE THE CYLINDER HEAD

Instructions for removing the cylinder head.

TO REMOVE AND REPLACE THE VALVES

Procedure for removing and replacing engine valves.

TO REMOVE THE CYLINDER BARREL AND PISTON

Steps to remove the cylinder barrel and piston.

TO REPLACE THE PISTON AND CYLINDER BARREL

Procedure for refitting the piston and cylinder barrel.

VALVE TIMING taken with valve 001 off its seat

Detailed valve timing specifications and procedures.

Tappet Adjustment

To Re-time The Ignition

Set ignition firing point by:

Steps for setting the ignition firing point.

Carburetter Service

CARBURETTER TUNING INFORMATION

Information for tuning the carburetter for optimal performance.

CARBURETTER ADJUSTMENT

Steps for adjusting the carburetter settings.

Transmission Service

THE GEAR BOX

Overview of the gear box operation and components.

To Remove Front Chaincase and Clutch Assembly

To remove front driving chain and clutch assembly complete

Procedure to remove the front chain and clutch.

To Re-fit The Front Chaincase and Clutch

Clutch Spring Adjustment

Fork & Frame Service

STEERING HEAD ADJUSTMENT

How to adjust the steering head bearings for proper steering.

FRONT FORKS (TELEDRAULIC)

Details on the front fork system and its maintenance.

Rear Suspension

Wheels and Brakes

Wheel Bearings and Adjustment

Brake Drums

BRAKE SHOE ADJUSTMENT

Method for adjusting brake shoes to compensate for wear.

FRONT BRAKE ADJUSTMENT

Procedure for adjusting the front brake.

REAR BRAKE ADJUSTMENT

Procedure for adjusting the rear brake.

Tyres and Service

Useful Information

Engine fails to start, or is difficult to start

Common reasons for engine starting difficulties.

Engine misses fire

Potential causes for engine misfiring.

Loss of power

Factors that can lead to reduced engine power.

Engine overheats

Reasons for the engine overheating.

Engine stops suddenly

Causes for the engine stopping unexpectedly.

EXCESSIVE OIL CONSUMPTION

Causes and remedies for high oil consumption.

EXCESSIVE PETROL CONSUMPTION

Causes and remedies for high petrol consumption.

STEERING UNSATISFACTORY

Troubleshooting for steering issues.

Electrical Service

IGNITION

Information on the ignition system components and maintenance.

Sparking Plug

Charging

Lighting and Accessories

Tools and Special Equipment

TOOLS

List of standard tools included in the kit.

AJS 500 1954 Specifications

General IconGeneral
BrandAJS
Model500 1954
CategoryMotorcycle
LanguageEnglish

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