1941 MATCHLESS Motor Cycles 41-G3L MAINTENANCE & INSTRUCTION MANUAL - PDF DOWNLOAD

1941 MATCHLESS Motor Cycles 41-G3L MAINTENANCE & INSTRUCTION MANUAL - PDF DOWNLOAD

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1941 MATCHLESS Motor Cycles 41-G3L MAINTENANCE & INSTRUCTION MANUAL - PDF DOWNLOAD

Language :English
Pages :100
Downloadable : Yes
File Type : PDF

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1941 MATCHLESS Motor Cycles 41-G3L MAINTENANCE MANUAL - PDF DOWNLOAD

Introduction

• THE MATCHLESS Model G 3 L Motor Cycle, dealt with in this Manual, although of simple design and construction, is, nevertheless, a highly to some special tools and extractors and alt of them can be made by a good mechanic from the illustrations of same. (Blue prints are available.)
• must be intelligently and efficiently maintained to provide unfailing reliability in service. In the following pages are non-technical instructions for carrying out most of the maintenance operations likely to be called for under strenuous service and, where necessary assembly illustrations are provided as a guide. In the instructions references are made that every faul t has a definite cause and the methodical repairer will locate the cause before attempting the cure.
• By this means repetition is avoided and knowledge Is acquired which cannot possibly be imparted efficiently by a manual of this description. Such knowledge grades the repairer and, for this reason, every single maintenance job should be given individual thought and attention.

TABLE OF CONTENTS:

1941 MATCHLESS Motor Cycles 41-G3L MAINTENANCE MANUAL - PDF DOWNLOAD

GENERAL ILLUSTRATIONS.
Controls
Clutch.
Crankcase.
Cylinder
Engine
Flywheels.
Fork
Gear box.
Hub
DETAIL ILLUSTRATIONS.
Battery
Brake thrust collar
Camshaft (Gear box) Carburetter mixing chamber Clutch adjustment
Contact breaker
Cylinder head
Dynamo commutator and brushes
Fork components
Fork damper
Magneto
Oil pump. Tappet adjustment.
TOOLS AND JIGS.
Armature bearing tool..
Armature bearing extractor
Ball bearing drift (Flywheel axle)
Big-end liner lap
Big-end liner tool.
Cam bush reamer.
Chain grip Extractor (Claw type). Flywheel separating tool Gudgeon pin bush tool. Tappet removing tool.
WW
Timing side flywheel axle jig. Tools (In Machine tool kit).. Valve guide drift.
DIAGRAMS.
Oil circulation (Engine)
Timing (Inlet).
Timing (Exhaust).
Wiring (Lucas)
Wiring (Miller),
CARBURETTER SERVICE INFORMATION.
Carburetter adjustment Carburetter function
Carburetter tuning useful information Carburetter, type....
Control levers and cables Twist grip adjustment
CONTROLS.
Controls..
DATA.
Data
ELECTRICAL SERVICE INFORMATION.
Ammeter
Battery
Battery charging
Cut-out
test and repair
Dynamo Armature
Dynamo Assembly, Lucas
Dynamo Assembly, Miller
Dynamo Brushes
Dynamo Commutator cleaning.
Dynamo Commutator repair
Dynamo Dismantling. Lucas
Dynamo Dismantling. Miller
Dynamo Field coil repair Dynamo Lubrication, Lucas Dynamo Lubrication, Miller Dynamo Removal
Dynamo Removal note Dynamo Replacement Dynamo Test and repair Dynamo type
Earth connection
Fuses
High-Tension wire
Horn
Ignition timing
Immobilizer
Lamp, Head, Lucas
Lamp, Head, Miller
Lamp notes
Lamp, Rear, Lucas
Lamp, Rear, Miller
Magneto assembly
Magneto chain drive
Magneto contact breaker cleaning
Magneto contact breaker Lubrication
Magneto contact breaker point adjustment
Magneto contact breaker special note
Magneto dismantling
Magneto high-tension pick-up
Magneto test and repair
Magneto type
Make of electrical equipment Regulator
Sparking plug Suppressor Switch, Lucas Switch, Miller Terminals, Lucas Terminals, Miller Wire loom
ENGINE SERVICE INFORMATION.
Big-end liner removal and fitting Camshafts
Camshaft bushes Cam contour
Cylinder barrel, removal.. Cylinder barrel, replacement. Cylinder head removal Cylinder head replacement Decarbonisation
Engine dismantling Engine removal Flywheel assembly
Flywheel axle ball bearings Flywheel axle bush
Flywheel axle roller bearing. Flywheel axle timing side Flywheel dismantling
Gudgeon pin bush
Ignition timing
Overhead valve rockers.
Oversize parts
Petrol tank removal
Petrol tank replacement
Piston removal
Piston replacement
Power unit removal (Engine and Gear box)
Rocker box removal
Rocker box replacement
Tappets
Tappet adjustment
Tappet guides
Tappet quide removal
Valve grinding
Valve guide fitting
Valve guide removal
Valve removal
Valve replacement
Valve timing.
FRAME AND FORK SERVICE INFORMATION.
Battery carrier removal
Front Forks
Front fork assembly
Front fork final assembly
Nuts, bolts, etc.
Oil tank removal Stand, Front
Stand, Prop
Stand, Rear
Steering head adjustment
LUBRICATION.
Brake cam lubrication Brake pedal
lubrication Brake rod joint
lubrication Chain lubrication........
Control lever lubrication Dynamo lubrication.. Engine lubrication
Engine oil circulation
Engine oil pump Front fork lubrication
Gear box lubrication Hub lubrication
Lubrication points to remember Magneto
lubrication. Oil circulation check
Oil feed adjustment Oil filter.
Oil tank
Speedometer lubrication
Stand bolt lubrication-
Steering head bearing lubrication
Valve stem lubrication
TRANSMISSION SERVICE INFORMATION.
Camshaft
Chain adjustment. Dynamo chain
Chain adjustment.
Magneto chain
Rear chain
Chain adjustment. Front chain
Chain adjustment.
Chaincase refitting
Clutch
Clutch adjustment Clutch cable access Clutch cable adjustment
Clutch plate access Clutch refitting Clutch removal Clutch spring
Clutch spring adjustment
Forks (Camshaft) Gear box
Gear box assembly Gear box dismantling
Gear box removal
Kick-starter
Layshaft bush refitting
Shock absorber (Engine)
Sprocket nut removal
Transmission of power through the gears
USEFUL INFORMATION.
Mechanical troubles
Tools
Tracing troubles
WHEEL, BRAKE AND TYRE SERVICE INFORMATION
Brake drums
Brake pedal adjustment
Brake shoes......
Brake shoe adjustment
Front brake adjustment
Front brake cover plate
Front wheel removal Rear
brake adjustment Rear
wheel removal Rims
Security bolts
Spokes
Tyres
Tyre fitting
Tyre removal
Wheel alignment Wheel bearings...
Wheel bearing adjustment- Wheel
bearing assembly. Wheel
bearing dismantling

S.M 22/3/2025