AJS G2 User Manual

SERVICE AND OVERHAUL MANUAL
FOR THE
AJS & MATCHLESS
SINGLE MOTORCYCLES
F. NEILL
by
Covering 1958 to 1964 Lightweight 250 c.c. and 350 c.c.
models G2 G2S G2CS G2CSR 14 14S 14CS 14CSR
G5 8 and 1957 to 1966 Heavyweight 350 c.c., 500 c.c.
and 600 c.c. models G3 G3C G3S G3LS G3LCS G80
G80S G80CS TCS 16 16S 16C 16CS 16MS 16MC
16MCS 18 18S 18CS
F.
NEILL
AJS &
MATCHLESS SINGLES 1957-1966 Lodgemark Press
Reprinted in Belgium
LODGEMARK PRESS LTD
BANK HOUSE, SUMMERHILL, CHISLEHURST,
KENT BR7 5RD, ENGLAND
TWO- ST RO KE HIGH
PE RFORMANCE ENGINE
DESIGN & TU NING
By World famous engine designer
Bossaglia who was responsible for
most of the Italian rotary valve kart
engines including Komets and Parillas
from the very first—the V11 to the K89.
227 pages packed with information
including : Characteristics and types of
two-stroke motors. Multi-cylinder
engines, Fuel, Quantity of air necessary
for combustion. Determining the power,
The Pressure Volume diagram,
Performance, The operation of the
crank, Balance, The Stroke/bore ratio,
Third port induction, Induction through
valves, Blade type valves, Cylindrical
rotary valves, Rotating disc valves,
Transfer and scavenging with transverse
flow, tangential flow, uni-directional
flow, Counter-flow scavenging,
Position of the ports,
Bi-metal cylinders, Cylinders with
chromed bore, The piston, The gudgeon
pin, The piston rings, Constructional
ideas for the piston, The head, The
crankcase, The crankshaft, Modification
of the crank shaft assembly, Modification
of cylinder, piston and head, The
carburettor, Fuel pumps, Carburation
adjustments, Fuel injection, The magneto
The sparking plug, Ignition timing,
Electronic ignition, Lubrication,
Exhaust System, Mufflers, Exhaust
system for multi-cylinder engines,
Exhaust silencers, Test procedure,
Examples of modifications.
£4.35 (incl. insurance) Ref 290
TWO STROKES & TUNING
TWO-STROKE EXHAUST
SYSTEMS
Full details on how to calculate design
and make competition exhaust systems.
55p Ref 252 Available again March
TWO-STROKE PORTS FOR
POWER
Read how to calculate and design the
right port timing for your requirements.
55p Ref 253.
TWO-STROKE CARBURATION
AND IGNITION
Roy Bacon's third book on racing two
strokes. Vital information on carburation
& ignition.
55p Ref 281
ROTARY VALVE TWO-STROKE
KART ENGINES
All about 100cc kart engines. Includes
Arisco, B.M., Corsair, Famrel, Komet,
Parilla, Petry, Saetta, Starr, Basic
preparation, using Bleepers,
Transistorised Ignition, Tillotson carbs.
£1.10 Ref 288
IMPROVING TWO STROKE
ENGINE PERFORMANCE
Villiers, Maico, Vespa, Marcelle,
Zundapp, Itom, DKW, Lambretta.
85p Ref 135
BUILDING KARTS
KARTING FOR SCHOOLS &
YOUTH GROUPS
Organising, driving and building
low-cost karts. Forming clubs.
90p Ref 292
JAVELIN SET No. 1
Details and drawings to build a low
price kart without a tube bender.
Suitable for 2 or 4-stroke engines
without gearbox, max 5 hp & 40 lbs for
Cadet racing, fun and driver training.
Bolted-construction.
50p Ref 270
CADET SET No. 3
Details and drawings to make a fun kart
without a tube bender. Suitable for 2 or
4 stroke engines without a gearbox up to
5 hp and weighing up to 40 lbs. New
edition provides option of bolted or
welded construction.
Any parts can be purchased if required.
£1.10 Ref 293
ABOUT KART RACING
STARTING KARTING
How to start the sport explained, details
of classes, location of tracks. British
clubs and addresses. Where to buy
karts, engines fr accessories. 4th Edn.
50p Ref 286
GOING KARTING
Covers every aspect of karting, how to
buy your kart and engine, racing on
motor tracks, etc. 4th Edn.
£1.45 Ref 266
R.A.C. KART REGS 1974
All the rules and regulations governing
drivers, organisers, tracks, karts and
engines. British calendar of events,
club addresses and list of tracks.
50p Ref 130
www.ajs-matchless.info

AJS G2 Specifications

General

Transmission	5-speed
Front Brake	Disc
Rear Brake	Drum
Tires (Front)	90/90-18
Power	11.5 hp @ 8, 500 rpm
Torque	9.5 Nm @ 7500 rpm
Fuel Capacity	12 litres
Frame	Tubular Steel
Front Suspension	Telescopic Forks
Engine Type	Air-cooled, 4-stroke, single cylinder
Rear Suspension	Dual shock absorbers

Summary

Technical Data

250 c.c. Models

Technical specifications for 250cc AJS and Matchless single cylinder models.

350 c.c. Models

Technical specifications for 350cc AJS and Matchless single cylinder models.

500 c.c. Models

Technical specifications for 500cc AJS and Matchless single cylinder models.

1964-1966 Model Data

Specific technical data and changes for 1964-1966 models.

Engine Design Changes

250 c.c. Model

Engine design modifications for the 250 c.c. model, starting from 1962.

Lubrication

Lightweight Models

Lubrication system and procedures specific to Lightweight models.

Recommended Lubricants

Recommended grades and brands of lubricants for various components.

Periodical Maintenance

Maintenance Schedules

Schedules for routine maintenance tasks for all models.

Engine Servicing

All Models

General engine servicing procedures, including tappets and decarbonisation.

Removing Cylinder and Piston

Steps for removing the cylinder and piston assembly from the engine.

Engine Overhaul

Lightweight Models

Procedures for overhauling 250cc and 350cc Lightweight engines.

Heavyweight Models

Procedures for overhauling 350cc and 500cc Heavyweight engines.

Scrambler Engine

Engine overhaul procedures specific to Scrambler models.

Gearbox and Clutch

The Gear Box

Gearbox details, faults, and procedures for lightweight and heavyweight models.

Clutch

Clutch assembly, adjustment, and faults for lightweight and heavyweight models.

Front Forks

Multi-Model Procedures

Front fork maintenance and troubleshooting for multiple models.

250 c.c. Model

Dismantling and assembly of front forks for 250cc models.

Rear Suspension Units

Table of Rear Suspension Springs

Specifications for rear suspension springs across different models.

The Frame

Lightweight Models

Frame maintenance for lightweight models.

Frame Strip Down (Heavyweight Model)

Procedure for dismantling the frame on heavyweight models.

Wheel Bearings

Heavyweight Models

Front and rear wheel bearing maintenance for heavyweight models.

Lightweight Models

Front and rear wheel bearing maintenance for lightweight models.

250 c.c. CSR Model

Wheel bearing details for the 250cc CSR model.

Wheels and Brakes

Lightweight Models

Brake adjustment and wheel hub details for lightweight models.

Heavyweight Models

Brake adjustment and wheel hub details for heavyweight models.

1964-1966 Models

Brake and wheel procedures for 1964-1966 models.

Transmission

Heavyweight Models

Front and rear chain adjustment for heavyweight models.

Lightweight Models

Front and rear chain adjustment for lightweight models.

Carburettor

Carburettor Tuning Information

Information on tuning carburetors and common idling issues.

Notes on Carburation

Advice and tips on adjusting carburetor settings.

WIPAC ALTERNATOR

Alternator Function

Functionality of the Wipac alternator, including starting and charging.

Charge Rate Test

Procedure for testing the alternator's charge rate.

WIPAC ELECTRICAL SERVICE

Lamp Bulb Blowing

Troubleshooting premature bulb failure in DC battery systems.

Ignition System

Checks and maintenance for the ignition system, including contact breakers.

LUCAS COIL IGNITION

Contact Breaker Setting

Procedure for checking and adjusting the contact breaker gap.

MAGNETO MODELS Electrical Equipment

To Remove Contact Breaker

Steps to remove the contact breaker assembly from the magneto.

Adjustment & Cleaning

Routine adjustment and cleaning of contact breaker points.

DYNAMO

Test Dynamo in Position

Procedures for testing the dynamo's function and output.

A.V.C. UNIT

Regulator Function

Explanation of the voltage regulator and cut-out function.

Wiring Diagrams

250 c.c. Scrambler

Wiring diagram for the 250cc Scrambler model.

250 c.c. Scrambler (with lights removed)

Wiring diagram for 250cc Scrambler without lights.

250 c.c. and 350 c.c.

Wiring diagram for 250cc and 350cc models.

1957 model

Wiring diagram specific to the 1957 model.

1958-1959 model

Wiring diagram specific to 1958-1959 models.

1960-66 models

Wiring diagram for 1960-1966 models.