Matchless G11 Repair Manual

70 pages

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Workshop Manual

for

1957

MATCHLESS

G11

500 c.c TWIN CYLINDER MODELS 600 c.c.

AJS Model 20

AJS Model 30

Also suits

AJS

Issued by:

MATCHLESS MOTOR CYCLES

Workshop Manual1
Data3
Controls5
Driving7
Fuel Supply7
Starting the Engine from Cold7
Stopping the Engine8
On the Road8
Stopping the Machine9
Running in9
Notes on Driving9
Lubrication10
Lubricants to Use10
Engine Lubrication System11
Engine Oil Pumps12
Checking Oil Circulation12
Engine Oil Circulation13
The Oil Tank13
The Oil Filters13
Cleaning Oil Filters13
To Remove and Clean the Felt Crankcase Filter14
To Remove the Magnetic Filter Located in the Crankcase14
Location of Oil Non-Return Valve14
Gear Box Lubrication15
Chain Lubrication15
Hub Lubrication15
Brake Drum Bearing15
Lubrication Chart16
Steering Head Bearing Lubrication16
Control Cable Lubrication16
Rear Fork Hinge16
Maintenance17
Engine Service18
To Adjust Overhead Rockers - Tappet Clearance18
Access to the Engine19
To Remove the Petrol Tank19
To Replace the Petrol Tank20
Decarbonisation20
To Remove Cylinder Heads for Decarbonisation20
To Remove the Valves21
To Remove Valve Guides21
Removing Carbon Deposit21
Valve Grinding21
Removing Cylinder Barrels and Pistons22
Fitting Pistons and Cylinder Barrels22
Cross Section of Engine23
To Re-Fit the Cylinder Heads24
Valve Timing Gear24
Valve Timing25
Removal of Gears25
To Re-Time the Ignition26
To Dismantle and Refit Crankcase Release Valve in Crankshaft26
Carburetter Service27
Removing Sparking Plug27
Carburetter Function27
Twist Grip Adjustment28
Air Filter28
To Remove the Air Filter Element28
Carburetter Tuning Information28
Carburetter Details View in Assembly Order29
Transmission Service30
The Gear Box30
Foot Change Operation30
To Remove Gear Box Outer Cover31
To Replace Gear Box Outer Cover31
To Remove Gear Box Inner Cover/To Replace Gear Box Inner Cover31
To Remove Front Chaincase and Clutch Assembly31
To Remove Clutch and Front Chain32
Clutch Spring Adjustment32
Clutch Operating Mechanism Adjustment32
To Remove Back Half of Chaincase33
To Re-Fit the Front Chaincase and Clutch33
To Dismantle Clutch Shock Absorber34
To Remove Clutch Bearing34
To Dismantle Gear Box34
Removal of Cam Plate35
Refitting Cam Plate35
Fitting Gears into Gear Box35
Dismantling Kick Starter Assembly35
To Replace Kick Starter Assembly36
Front Chain Adjustment36
Rear Chain Adjustment36
Fork and Frame Service37
Removing and Refitting Rear Chain37
Steering Head Adjustment37
Front Forks - Teledraulic38
Front Fork "Topping Up"38
To Remove the Complete Front Fork Assembly39
Exploded View of Teledraulic Forks41
To Remove a Fork Slider42
To Remove a Fork Inner Tube Assembly42
Rear Suspension43
The Cam Ring Adjuster43
Prop Stand44
Centre Stand44
To Remove Oil Tank44
Wheels and Brakes45
To Remove the Rear Chain Guard45
To Remove Front Wheel/To Re-Fit Front Wheel45
To Remove Quickly Detachable Rear Wheel45
Wheel Bearings and Adjustment46
To Dismantle Front Wheel Bearings46
To Dismantle Rear Wheel Bearings47
Front Brake Cover Plate48
Brake Drums49
Brake Shoes49
Brake Shoe Adjustment49
Front Brake Adjustment50
Rear Brake Adjustment50
Brake Pedal Adjustment51
Tyres and Service52
Tyre Removal52
Tyre Fitting53
Tyre Pressures53
Electrical Service54
Electrical Equipment54
Ignition54
Sparking Plug56
Magneto Removal and Fitting56
Dynamo57
AVC Unit58
To Remove and Re-Fit Dynamo58
Battery59
Battery Unit59
To Remove AVC Unit59
Lighting and Accessories60
Headlamp60
Rear Lamp61
Horn61
Fuses61
Snap Wire Connector61
Wiring Diagram62
Cleaning the Machine63
Chromium Plating63
Terminals63
Tools and Special Equipment64
Tool Kit65
Troubleshooting66

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Matchless G11 Specifications

General

Suspension (Front)	Telescopic forks
Suspension (Rear)	Swingarm with twin shock absorbers
Brakes (Front)	Drum
Brakes (Rear)	Drum
Transmission	4-speed

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