Zenoah EXtremeTM EXZ2500S Manuel d'instructions

MAINTENANCEMANUALANDINSTRUCTIONBOOK1955350 c.c. and 500 c.c. forMATCHLESSSPRING FRAME AND RIGIDSINGLE CYLINDER MODELSPRICE 2/6 NETT MATCHLESSM O T O

If any adjustment is made to the rear brake pedal make certain the brake does not bindand also see there is not excessive free pedal movem

DRIVING FUEL Although various quality fuels are again available owners are advised to use only the best. The small economy that might be considered to

Illustration 2 Showing the gear indi-cator drum which upon assembly is set to record the various gears and neutral position, as the respective figure

STOPPING THE MACHINE To stop the machine, close the throttle, declutch by lifting the large lever on the left handlebar, and gently apply both brakes,

NOTES ON DRIVING If, at first, the lowest gear will not engage, release the clutch lever and after a second or two, make another attempt. This conditi

REMOVE CAP SPRING ANDDISHED SEAT FOR SPRING,TO OBTAIN ACCESS TOFELT FILTER FOR I T SWITHDRAWAL.VENT PIPE PR E V E N T I N GAIR L OC KS

LUBRICANTS TO USE Efficient lubrication is of vital importance and it is false economy to use cheap oils and greases. We recommend the following lubri

ENGINE LUBRICATION SYSTEMThis is by dry sump system. OH feeds, by gravity, from the oil tank to the pump In thecrankcase. The pump forces oil t

Illustration 4 Engine Oil Circulation THE OIL TANK AND FILTERS The level of oil in the supply tank should never be allowed to fall below the low level

A metal gauze strainer is secured in the tank end of the feed pipe union. After the first 500 miles, again at 1,000 miles, and subsequently at 5,000 m

The inlet valve guide is shown withdrawn as also is the inlet valve stem adjusting screw (with lock nut) 1 2 3 4 5 6 7 PLAIN HOLE, FOR OIL FEED TO INL

GEAR BOX LUBRICATION Use one of the grades of Oils specified. In no circumstances must heavy grease be used. Lubricant is inserted through the filler

WHEN ORDERING SPARESALWAYS QUOTE THE COMPLETE ENGINE NUMBER (Including all the Letters in it). THIS ENABLES THE MACHINE TO BE IDENTIF

LUBRICATION CHART The figures in diamond frames refer to parts located on the left hand side of the machine and those in circles refer to parts locate

MAINTENANCEPERIODICAL MAINTENANCERegular maintenance, attention to lubrication, and certain adjustments must be made toensure unfailing reliabilit

EVERY 1,000 MILES Oil tank Rear chain Gear box Hubs Expanders Steering head Small parts Air Filter Drain at first 1,000 miles and re-fill with new oil

FOR THE CONVENIENCE OF OWNERS,SPARES STOCKISTSARE APPOINTED FOR MOST DISTRICTS. TOSAVE DELAY, AND THE DELIVERY SURCHARGE,CUSTOMERS ARE

ENGINE SERVICEACCESSFor almost all service work to the upper parts of the engine, it is necessary, in order toobtain accessibility, first,

TO REMOVE THE PETROL TANK Close both petrol taps and remove the cap nut securing each petrol pipe banjo con-nector. Use two spanners, one to hold the

DECARBONISATION Instead of the usual stipulated mileage interval between periods of decarbonisation, it is recommended that this Is undertaken only wh

for1955SINGL E CYLINDER M OTOR CYCLESCompiled and Issued by the Manufacturers :MATCHLESS MOTOR CYCLES(Proprietors : ASSOCIATED MOTOR CYCLES LIMITED)Re

AN ILLUSTRATED SPARES LIST COVERING ALL MODELSDESCRIBED IN THIS MANUAL IS AVAILABLE UPONAPPLICATION PRICE: 2s. 6 d .Illustration 8 Show

REMOVING CARBON DEPOSIT Do not use a sharp implement for removing carbon deposit from the interior of the cylinder head and the piston crown. A blunt

The grinding is accomplished by smearing a thin layer of fine grinding paste (obtainable ready for use at any garage) on the valve face and then, afte

RemoveOne gudgeon pin circlip. It is immaterial which circlip Is removed. Use special pliersincluded in tool kit.Gudgeon pin by pushing It

VALVE TIMING taken with valve ·001" off its seat Inlet valve timing Inlet valve opens 36° before top dead centre—350 c.c. models. Inlet valve ope

TAPPET ADJUSTMENT The top ends of the two long push rods have screwed extensions. These are locked in position by nuts, thereby providing tappet adjus

TO RE-TIME THE IGNITION The normal advance is 39° (½"). Have available a stout screwdriver, or an old type tyre lever with turned up end, also a

Illustration 12 The rotating oil pump plunger is here shown in situ, together with the guide screw which registers in the plunger profiled groove, the

WHEN IN DOUBT REGARDING THE NAMES AND PARTNUMBERS OF THE PARTS YOU REQUIRE, PLEASE SENDTHE OLD PARTS TO SERVE AS PATTERNS.TO REMOV

Illustration 13 Carburetter details in assembly order. 37

1955 MATCHLESS MODELS 350 MODEL G3L RIGID FRAME (TOURING) 350 MODEL G3LS SPRING FRAME (TOURING) 350 MODEL G3LC RIGID FRAME (COMPETITION) 350 MODEL G3L

CARBURETTER SERVICE The Information given in this section includes all that will normally be required by the average rider. For further details, parti

CARBURETTER ADJUSTMENT With the taper needle projection, main jet size, and type of throttle slide specified (see page 4) correct carburation except a

CARBURETTER TUNING INFORMATION Poor idling may be due to : Pilot jet not operating correctly (partially choked) or incorrect air supply. Air leaks. Ei

TRANSMISSION SERVICE THE GEAR BOX The gear box provides four speeds and has a positive foot change, operated by the right foot and a kick-starter. It

Remove the nut and small spiral spring securing small gear Indicator disc from the cambarrel spindle.Next remove the five cheese head screws

TO REMOVE FRONT CHAINCASE AND CLUTCH ASSEMBLY To remove outer half of front chaincase Place tray under chaincase to catch oil. Remove left side footre

TO RE-FIT THE FRONT CHAINCASE AND CLUTCHFit back half of front chaincase by : Place on face of crankcase boss and back face of chaincase so

Fit the front chain and lock the clutch centre nut byReplace the front driving chain. Ensure the spring connecting link is fitted so th

CLUTCH SPRING ADJUSTMENT If clutch slip occurs the most probable cause is either incorrect cable adjustment or absence of free movement of the interna

CLUTCH OPERATING MECHANISM ADJUSTMENT Correct adjustment of the clutch operating mechanism is of the utmost importance and the following instructions

INTRODUCTION The modern motor cycle unquestionably provides one of the most healthy, economical and pleasant means of transport. In addition by reason

FRONT CHAIN ADJUSTMENTTighten the front chain by : Slacken : Nut on right-hand side of gear box top fixing bolt.Forward nut on the adju

NOTES ON REAR CHAIN ADJUSTMENT Before tightening the rear chain always first check front chain adjustment and if attention is necessary adjust the fro

MAGNETO CHAIN ADJUSTMENT The magneto platform hinges on one of its fixing bolts. This provides sufficient move-ment for adjustment to the magneto driv

FORK & FRAME SERVICE STEERING HEAD ADJUSTMENT The steering head frame races are of the floating self-aligning type and have spherical seats. There

Illustration 16Introduced in early 1941 for use under strenuous war conditions by all the allied armies,It remains unaltered, except in d

has no other source of escape but past this sleeve and the adjacent small metered bleed hole. This intentionally restricted passage causes a considera

Remove the handlebar half clip and lay the handlebars, complete with controls, upon a pad on top of the petrol tank.Detach the fron

Illustration 17 55

REF.NO.DESCRIPTION1.2.3.4.5.6.7.8.9.10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28.29.30.31.32.33.34.35.36.37.38.39.40.41.42.43.44.45.46.47.

REAR SUSPENSION The rear wheel is mounted in a fork that is hinged just behind the gear box. The hinge has robust plain bearings lubricated from a res

DATAEngine Number Stamped on left hand side of crankcaseframe NumberStamped on seat lug of main frame, on right hand side (below the

Illustration 19 Showing " Ghost " view of " TELEDRAULIC " leg 58

To check oil content of " TELEDRAULIC " leg and top-up : Dealing with one leg at a time, remove top securing bolt, taki

BY USING GENUINE SPARES YOU ARE ASSURED THEY WILL FIT ACCURATELY AND GIVE SATISFACTORY SERVICE TO REMOVE OIL TANK AND BATTERY CARRIER Dra

WHEELS AND BRAKES TO REMOVE FRONT WHEEL Place machine on both stands. Remove the split pin, and pin, retaining yoke end of front brake cable to the br

TO REMOVE REAR WHEEL (Rigid Frame Models) Place machine on rear stand Disconnect rear lamp wire at connection near rear wheel spindle Disconnect speed

On rigid frame models it will be found easier to re-fit the wheel to the fork ends with the brake cover plate hanging free and then, holding the wheel

Illustration 21 Showing front hub and brake also rear hub Illustration 22 Showing rear wheel bearings and brake drum (Spring Frame Models) 1 2 3 4 5 6

Illustration 23 Showing rear wheel bearings and brake drum (Rigid Frame Models) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CENTRE SOLID WHEEL SPINDLE. SPEEDOMET

TO DISMANTLE REAR WHEEL BEARINGSWith wheel still in situ first of all slacken the nut (16), securing the speedometer drivegear box. T

BRAKE DRUMS The front wheel brake drum is a shrunk in fit in the hub shell (assembled under heat) and secured additionally by five screws. The rear wh

ModelTouringCompetition (Rigid)Competition (Spring)First gear2·65 to 1 3·199 to 1 2·65 to 1 Second gear1·70 to1 2·437 to 1 1·70 to 1 Third

Centralise brake shoes, Front or Rear, by : Ensure the nut securing the cover plate and also the fulcrum stud nut (front only) are slightly slacked of

REAR BRAKE ADJUSTMENT Major adjustment of the rear brake shoes is made on the brake thrust pins, by fitting packing washers under the pins, as already

Illustration 28Showing brake rod ad-justment exhausted, in-dicating the need forbrake thrust pin adjust-ment.TYRES AND SERVICE (SPRING

Push edge of cover, that is diametrically opposite to the valve, RIGHT INTO WELLOF RIM and, using tyre lever 017007, pick up edg

USEFUL INFORMATION TRACING TROUBLES Engine fails to start, or is difficult to start, may be due to : Water on high-tension pick-up. Moisture on sparki

Engine overheats may be due to : Lack of proper lubrication. (Quality or quantity of oil.) Faulty sparking plug. Air control to carburetter out of ord

ABNORMAL TYRE WEAR Abnormal tyre wear may be due to : Incorrect tyre pressure. Wheels not in alignment. Harsh driving methods. (Misuse of acceleration

ELECTRICAL SERVICE IGNITION A Lucas magneto type SR-1 with automatic advance and retard is fitted to all Touring models. A Lucas racing magneto type N

SPARKING PLUG The K.L.G. Type FE80 " Corundite " Plug is fitted to all models. It has a thread of 14 mm. and the reach is ¾". The point

CHARGING A LUCAS type E3-N dynamo is fitted. It is anti-clockwise in rotation. The cutting in speed is 1250-1500 r.p.m. at 7 volts and at 1,850 to 2,2

Oversize partsThe following are the only " oversize " variations provided for the 350 and 500 c.c. Single Cylinder machines.Big-en

TO REMOVE THE DYNAMO Remove the left side foot rest arm. Place a tray under primary chaincase to catch the oil. Remove chaincase band binding screw an

Normally, during day-time running, when the battery is in good condition, the dynamo gives only a trickle charge, so that the ammeter reading will sel

The specific gravity of the electrolyte indicates the state of charge of the battery. With a fully charged battery the specific gravity of the electro

LIGHTING AND ACCESSORIES Headlamp A LUCAS headlamp is fitted and snugly mounted on each side is a neat torpedo shaped pilot lamp. These pilot lamps an

HornThe horn push switch, situated on the right handlebar.FusesThere are no detachable fuses in LUCAS motor cycle electrical equipment.Snap wire

83Illustration 34 Wiring diagram W97832 SIDELAMP SIDELAMP LIGHTING SWITCH DIPPER SWITCH SPEEDOMETER LIGHT HORN PUSH DYNAMO MAGNETO REGULATOR BATTERY (

REPAIRSThe instructions regarding repairs should be clear and definite, otherwise the cost maybe greater than that expected. We shall be

SERVICE The Service and Repair Department is situated in Burrage Grove, Plumstead, London, S.E.18, and is open on Mondays to Fridays from 8.30 a.m. to

THE MACHINE AND THE LAWEvery motor cycle used on the public roads must be registered and carry the registrationnumbers and licence disc allotted

GUARANTEEWe give the following guarantee with our motorcycles, motorcycle combinations and sidecars,which is given in place of any i

CONTROLS(1) Throttle twist grip. On right handlebar. Twist inwards to open. Whenfully closed engine should just Idle when hot.(2) Air l

TOOLS AND SPECIAL EQUIPMENT OPTIONAL EQUIPMENT The following items of optional equipment are available. They are described and priced in the Spares Li

BADGES Neat monogram badges are now available at a cost of 1/6, plus 6d. postage. They can be supplied as a tie pin, as a brooch or for fitting in a b

Carburetter ServiceControlsDataDrivingElectrical ServiceEngine ServiceFree ServiceFork and Frame ServiceGuaranteeIntroductionLubricationLubrication Ch

ILLUSTRATIONSBatteryBrake adjustment, frontBrake adjustment, rear (rigid frame)Brake adjustment, rear (spring frame)Brake anchorage, rearBrake shoe ad