Ajs Heavyweight 500 Cc 1957-1966 Workshop Service Manual (MT009524)

Ajs Heavyweight 500 Cc 1957-1966 Workshop Service Manual (MT009524)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Workshop Service Manual for Repair.

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  This AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 service manual provides data, characteristics, instructions and methodology to perform repair interventions on the vehicle and its components.

  This manual includes special notes, important points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of vehicle components for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  The most detailed, comprehensive step by step procedures, explanations, and pictorial diagrams from bumper to bumper you will ever see for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.

  AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service Repair Manual meets all your information needs to repair or make some adjustments to your AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service Repair Manual. This manual is intended as a handy, easy to read reference book for the mechanics and DIY persons. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

  Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service Repair Manual.

  Adjustment and repair operations include reference to Service tool numbers and the associated illustration depicts the tool for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966. Where usage is not obvious the tool is shown in use.

  This AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 service manual can be viewed on any computer, as well as zoomed and printed.
  
  This service manual has been specially prepared so that the explanation is very simple. It has been prepared so that if this manual is thoroughly read, even comparatively new personel can give satisfactory after services to the customers as well as disassemble and maintain the vehicle.

  All service and repair instructions included for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation.
  
  Where accurate measurements are required, they can only be made using calibrated, precision instruments.
  
  Providing that the service schedules are respected, the customers can be sure of obtaining the maximum satisfaction and best result from his car. This manual provides general descriptions for accomplishing service and repair work with tested, efective tehniques. Following them will help assure reliability.
  
  Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling and servicing which cover procedures, precautions, factory specifications and allowable limits.
  
  Information in this manual for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. Appropiate service methods and correct repair procedures are esential for the safe, reliabe operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

  The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions. They may not show exactly the AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 in your possession.

  Adjustment and repair operations also include reference to wear limits for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966. Relevant data, useful assembly details all in this SERVICE MANUAL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.
  
  All work should be performed with great care and in a clean working area with adequate lighting.

  Please peruse and utilize this manual for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 fully to ensurea complete repair work for satisfying you or your customers by keeping their vehicle in optimum condition.
  
  All information, illustration and specifications contained in this manual are based on the latest product information avaiable at the time of publication approval. The specification, maintenance and other information for the components are included, and diagnostic information has also been added where necessary. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed.
  
  This AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 book outlines procedures for servicing and repairing vehicles using safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed along with standard safety procedures to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

  To maximise the life of your AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966:
  
  Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual.
  
  Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966. Rectify all problems as soon as possible (immediately if safety related).
  
  Use only genuine AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 parts as listed in the parts catalogue.
  
  Follow the procedures in this manual carefully and completely. Do not take short cuts.
  
  Keep complete records of all maintenance and repairs with dates and any new parts installed.
  
  Use only approved lubricants, as specified, in the manual of the AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.

  This manual for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 has been issued to provide you with technical information regarding the design, function, disassembly, adjusting work and troubleshooting on the components and model of the AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  The descriptions are brief but precise and are supported by photographs, notes, drawings and schematics, as well as exploded and sectional drawings. All this information is intended to simplify any necessary repair work which can be performed on AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  This manual also contains information about adjusting work and valuable reference data for such adjustment values.
  
  For all maintenance and repair work on AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966, all accident prevention guidelines must be strictly observed. To perform all repairs listed in this manual, a complete set of standard tools, as well as the special tools and fixtures shown and listed are necessary.
  
  No special emphasis is put on replacing sealing components as we assume that these items are replaced during any repair. Unless specific values are given, all threaded connections should be tightened according to the required tightening torques listed on torque charts.
  
  When describing work, which can be dangerous, we have described the required safety measures in this manual and indicated them by special remarks DANGER, CAUTION or NOTE.

  This AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service Service Repair Manual QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out!

  This AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service manual is known in many names:
  
  AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service service manual.
  
  AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service repair manual.
  
  AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service workshop manual.
  
  AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service shop manual.

  This manual for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job.
  
  A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work, satisfactorily.

  GENERAL TAGS FOR MOTORCYCLES:

  SPECIFICATIONS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  VEHICLE IDENTIFICATION NUMBER (V.I.N.) for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  WHEELS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FRONT WHEEL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  REAR WHEEL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  TIRES for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FRONT BRAKE MASTER CYLINDER AND HAND LEVER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FRONT BRAKE LINE for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FRONT BRAKE CALIPER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  BRAKE PEDAL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  REAR BRAKE MASTER CYLINDER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  REAR BRAKE LINE for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  REAR BRAKE CALIPER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FENDERS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FRONT FORK for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FORK CLAMPS: UPPER AND LOWER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  STEERING HEAD BEARINGS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  SWINGARM AND BRACE for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FRAME for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  REAR SHOCK ABSORBER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  THROTTLE CONTROL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  CLUTCH CONTROL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  HEADLAMP ASSEMBLY AND SUPPORT BRACKET for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FOOTPEG, HEEL GUARD AND MOUNT for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  SPROCKET COVER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  BELT GUARDS. for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  INTAKE COVER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  SIDESTAND for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  SEAT LOCKS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  ENGINE for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  ENGINE REMOVAL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  ENGINE INSTALLATION for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  CYLINDER HEAD for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  CYLINDER AND PISTON for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  LUBRICATION SYSTEM for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  OIL RESERVOIR AND OIL HOSE ROUTING for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  OIL COOLER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  OIL PRESSURE INDICATOR SWITCH for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  CRANKCASE BREATHING SYSTEM for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  OILING SYSTEM for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  OIL PUMP for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  HYDRAULIC LIFTERS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  GEARCASE AND CAM GEARS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  CRANKCASE for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  AIR CLEANER ASSEMBLY for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  ELECTRONIC CONTROL MODULE (ECM) for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  THROTTLE POSITION SENSOR (TPS) for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  IGNITION COIL for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FUEL TANK for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  FUEL PUMP for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  THROTTLE BODY for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  EXHAUST SYSTEM for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  STARTER for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  IGNITION SYSTEM for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  IGNITION/HEADLAMP KEY SWITCH for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  SPARK PLUG CABLES for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  CHARGING SYSTEM for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  BATTERY CABLES for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  VOLTAGE REGULATOR for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  ALTERNATOR for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  TURN SIGNAL FLASHER, FRONT TURN SIGNALS, REAR TURN SIGNALS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  HEADLIGHT, TAIL LAMP for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  MAIN FUSE AND FUSES for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
  
  WIRING DIAGRAMS for AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.

  AND MORE…

  AJS Heavyweight 500 cc 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Workshop Service Manual for Repair.

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