SERVICE Velocettte 350 & 500

discs (93) should not show evidence of
overheating and should be perfectly
flat. When assembling, use soap to as-
sist installation of rubber cushions
(90).
GEAR BOX. The transmission
gears and shafts can be disassembled
after the engine is removed and the
generator assembly, primary drive
gear and clutch assembly are removed.
The intermediate (gear) cover, shift
cam, input shaft, countershaft and as-
sociated parts can then be withdrawn
from crankcase (Fig. TM3-31).
Late transmissions use different
parts (66, 67, 73 & 79—Fig. TM3-30),
Later parts can be installed in early
models, but only if all of these parts are
the late type. The early shift cam (66)
can be identified by "T** stamped on
cam. The late cam is marked "69"
stamped as shown in Fig. TM3-32. The
late shift fork (67—Fig. TM3-30) has
7/16-inch diameter boss. The late
second gear (73) and third gear (79) are
stamped "57". Jumping out of gear can
be caused by weak spring (110).

YELOCETfE
350 AND 500CC MODELS
350 500
350 Clubman & 500 500 Clubman & 500
MODEL Viper Scrambler MSS Venom Scrambler Thruxtron
Displacement—cc 349 349 499 499 499 499
Bore—mm 72 72 86 86 86 86
Stroke—mm 86 86 86 86 86 86
Number of cylinders 1 1 1 1 1 1
Plug gap—inch 0.018-0.023 0.018-0.023 0.018-0.023 0.018-0.023 0.018-0.023 0.018-0.023
Point gap—inch 0.012-0.015 0.012-0.015 0.012-0.015 0.012-0,015 0.012-0.015 0.012-0.015
Ignition timing
Degrees BTDC—Full advance 38 38 36 38 38 38
Valve Clearance—cold
Inlet—inch 0.005 0.006 0.005 0.005 0.006 0.006
Exhaust—inch 0.006 0.008 0.005 0.005 0.008 0.008
Electrical System Voltage 6 6 6 6 6 6
Battery terminal grounded Positive Positive Positive Positive Positive Positive
Tire size—front 3.25 x 19 3.00x21 3.25x19 3.25x19 3.00x21 3.00x19
Rear 3.25x19 4.00x21 3.25x19 3.25x19 4.00x21 3.50x19
Tire pressure—front 16 16 16 22-24
Rear 18 18 18 24-29
Rear chain free play—inch See Text See Text See Text See Text See Text See Text
Number of speeds 4 4 4 4 4 4
Weight^lbs. (Approx.) 380 385 385 404 385 365

MAINTENANCE Clip (4) in third groove from top of

SPARK PLUG. Spark plug elec- needle (5).
trode gap should be 0.018-0.023 inch.
The following plugs are recommended. Venom
KLG type FE80 or FEIOO, Lodge HLN Refer to Fig. VLl-1
or 3HLN, Champion N3 or N4. Carburetor model 389/14
Main jet (13) 260
CARBURETOR. Amal carburetors Needlejet(ll) 106
are used on all models. The main jet Pilotjet{6) 30
size listed in the following specifica- Clip (4) in second groove from top of
tions is considered minimum and needle (5).
should be one or two sizes larger for
prolonged full throttle operation. Venom
Refer to Fig. VLl-1
Viper Carburetor model 389/15
Refer to Fig. VLl-1 Main jet (13) 330
Carburetor model 376/56 Needlejet(ll) 106
Mainjet(13) 230 Pilotjet(6) 30
Needlejet(ll) 106 Clip (4) in fourth |p"oove from top of
Pilotjet(6) 25 needle (5).
Clip (4) in second groove from top of
needle (5). MSS
Fig. VL1-1-Expioded view of Amai Monobioc
Refer to Fig. VLl-1
carburetor typicai of that used on some modeis. Viper Carburetor model 376/49
1. Pilot air screw 10. Jet holder
Refer to Fig. VLl-1 Mainjet(13) 240
2. Jet block screw 11. Needle jet Carburetor model 376/61 Needle jet (11) 105
3. Throttle slide 13. Main jet
4. Clip 15. Jetblock Mainjet(13) 270 Pilotjet (6) 25
5. Valve needle 16. Float Needlejet(ll) 106 Clip (4) in third groove from top of
6. Pilotjet 17. Inlet valve
7. Idle stop screw 19. Primer Pilotjet(6) 30 needle (5).
129
Velocette 350 & 500 MOTORCYCLE
Thruxton
Refer to Fig. VLl-3
Carburetor model 5GP2
Mainjet (13) 280
Needlejet(ll) 109
Throttle slide (3) No. 4
Pilot jet (6) 25
Starting jet (8) 125
Clip (4) should be in fourth groove from
top of needle (5).
Idle mixture is adjusted by turning
pilot air adjusting screw (1—Fig. VLl-
1, VLl-2 or VLl-3), idle speed is ad-
justed at stop screw (7).
On models with GP carburetors (Fig.
VLl-3), the fuel level should be at
mark (line—Fig. VLl-4) on side of float
bowl 0.640 inch below gasket surface of
float bowl. When mounting the float
17 chamber, turn the mounting sjtud nuts
(N) until the line on float chamber (fuel
level) is exactly in line with bottom of
Fig. VL1-2-Exptoded view of Amal carburetor of circle on the air jet plug as shown in Fig. VL1-4-The fuel level line marked on float
type used on Clubman and Scrambler models. chamber should be exactly in line with bottom of
Refer to Fig. VL1-1 for legend. Fig. VLl-4.
IGNITION AND ELECTRICAL, circle on the air jet plug as shown. Adjustment Is
accomplished at nuts (N). If float chamber Is too
Clubman (500cc) Ignition point gap should be 0.012- high or too low, the fuel-air ratio will be affected.
Refer to Fig. VLl-2 0.015 inch. Full advanced ignition
Carburetor model 10TT9 timing should occur 38 degrees BTDC
Choke bore 1 3/16 inch
Mainjet (13) 370
Needle jet (11) 109
Throttle slide (3) No.4
Clip (4) should be in third groove from
top of needle (5).
Pilot adjusting screw (1) initial
setting lV^ turns open
Scrambler (500cc)
Refer to Fig. VLl-2
Carburetor model 10TT9
Choke bore 13/16 inch
Mainjet(13) 390
Needlejet(ll) 109
Throttle slide (3) No. 7
Clip (4) should be in third groove from
top of needle (5).
Pilot adjusting screw (1) initial
setting lV^ turns open
Clubman (350cc)
Refer to Fig. VLl-2
Carburetor model TT9
Choke bore 11/16 inch
Mainjet (13) 360
Needlejet(ll) 109
Throttle slide (3) No. 7
Cl^p (4) should be in fourth groove from
top of needle (5).
Pilot adjusting screw (1) initial
setting lVfe turns open
Scrambler (350cc)
Refer to Fig. VLl-2 -24
Carburetor model TT9
Choke bore 11/16
Mainjet (13) 340
Needle jet (11) 109
Fig. VL1-3-Explod0d view of Amal QP carburetor and float boiW usBd on Thruxton models.
Throttle slide (3) No. 4
Clip (4) in third groove from top of N. Nuts 8. Startine air valve 15. Jet block
1. Pilot air screw 10. Jet holder 16. Float 21. Float pivot
needle (5). 3. Throttle slide 11. Needle jet 17. Inlet valve 22. Flexible mount
4. Clip 12. Airjet 19. Primer 23. Mounting stud
Pilot adjusting screw (1) initial 5. Valve needle 13. Mainjet 20. Float bowl gasket 24. Fuel inlet baiuo bolt
setting i ^ turns open 6. Pilotjet 14. Airjet plug surface 25. Washer

130
SERVICE
on compression stroke for all models
except MSS. On MSS models, the igni-
tion breaker points should just open
then the crankshaft is 36 degrees
BTDC on compression stroke. Make
certain that ignition timing is checked
at full advanced position. On models
with automatic (centrifugal) advance,
weights can be wedged out when
checking timing. Ignition timing can
be checked after removing the timing
gear cover. A degree wheel can be at-
tached to the crankshaft. To change the
timing, turn the crankshaft to correct
timing position and loosen the re-
taining nut in the middle of the igni-
tion drive gear. NOTE: Loosening the
nut will pull gear from the tapered end
of magneto shaft. Turn the ignition
breaker points assembly until the
points just open, then retighten gear
retaining nut and recheck timing.
VALVE SYSTEM. Inlet and ex-
haust valves are actuated by a cam-
shaft located on the right side of the
crankcase, via rocker type cam follers,
push rods and rocker arms. Valve
clearance should he adjusted with en-
gine cold. To check valve clearance,
remove the cover from right side of
rocker box. Turn the crankshaft until
the inlet push rod (IN—Fig. VLl-6)
moves up then back down. When the
inlet valve just closes, the exhaust
valve clearance can be checked as
shown. To check inlet valve clearance,
turn the crankshaft 240 degrees until
the exhaust valve just begins to open
(push rod EX—Fig. VL1-6* starts to
move up) then measure clearance be-
tween top end and push rod. Valve
clearance should be 0.005 inch for hoth
valves on Viper, Venom and MSS
models. Clearance for Clubman,
Scrambler and Thruxton should be
0.006 inch for inlet, 0.008 inch for ex-
haust.
LUBRICATION. The engine is lu-
bricated hy approximately 2 quarts of
SAE 40 oil above 60°F. or SAE 30 oil
below 60°F. Engine oil should he
changed at least every 2000 miles.
When the oil is drained from the reser-
voir, the suction filter at bottom (right
crankcase half) of engine should he
removed and cleaned. Oil should be
Fig. VL1-6-Refer to text
when adjusting vaive dear-
ance (C) between end (4)
and push rod (S). Inlet push
rod (IN) Is toward cyiinder
and exhaust (EX) is toward
outside.
1. A4ju8ting screw
2.
3.
Locknut
Rocker arm
4. End
5. Push rod
6. Cam follower
7. Camshaft
Velocette 350 & 500
5 4 2 1
Fig. VL1-9-The transmission ott shoutd be main-
tained at ievei of piug (L). Refer~to text for ad-
justing the primary chain.
D. Drain plug F. Filler plug L. Level plug
oil. If the oil tube (6) is allowed to
drain, make certain that tube is filled
before starting engine. The primary
chain case and gear box are lubricated
hy SAE 40 engine oil. Capacity of the
Fig. VL1-8-Expioded view of the oil tank and res- chain case is approximately Vs pint.
ervoir assembly. Make certain that oil suction Capacity of the gear box is 1.2 pints
tube (6) is full of olt before starting engine after and oil should be maintained at level of
servicing.
plug (L—Fig. VLl-9). Oil is filled
1. Drain p
plug
g 8. Stud
nd check
2. Screen and c 9. Center tube through hole for plug (F).
valve seat
3. Check valve ball
10. Lower plate
11. Lower gasket
CLUTCH CONTROLS. The clutch
4. Check valve spring 12. Oil tank is provided with two adjustment points.
5. Adaptor 13. Filter
6. Suction tube 14. Top gasket The clutch cahle should have 1/8-3/16
7. Return tube 15. Top plate inch free play and can be adjusted at
the cable adjuster (1—Fig. VLl-11) in
maintained at iy2 inches from the top the middle of the cable. If the clutch
of the oil tank filler neck. The oil tank slips or does not disengage, proceed as
filter (13—Fig. VLl-8) should be re- follows: Turn the clutch cable adjuster
newed every 10,000 miles. If oil drains (1) all the way in and disconnect cable
from the reservoir (tank) into the from the hand levijr. Open the throttle
crankcase, the check valve (3) is and starting air ccmtrols completely,
leaking and should be reseated or re- shift transmission to neutral and press
newed. kick starter pedal against engine com-
Oil circulation can be checked after pression.
removing the oil tank filler cap. If oil is If the clutch slips, remove the front
not circulating back to the tank, make section of the rear chain guard. Insert
certain that suction tube (6) is full of special tool (part number KA62/2)
through one of the holes in the output
2 13 sprocket and into a notch in clutch
spring holder (C—Fig. VLl-11). Turn
the rear wheel in normal (forward)
direction which will move the sprocket
and clutch spring holder in direction
(T—Fig. VLl-12) until all slippage is
removed. Connect the clutch cable and
turn adjuster (1—Fig. VLl-11) until
cable has V8-3/16 inch free play.
If the clutch will not disengage, in-
sert special tool as shown in Fig. VLl-
12 and turn rear wheel, sprocket and
clutch spring holder in direction (L).
DRIVE CHAINS. The primary
chain should have l^ inch free play at
inspection hole in primary chain cover
at the tightest point. To adjust loosen
131
Velocette 350 & 500
C. Clutch spring holder
1. Cable a((juster
2. Cam lever
3. Rod
4. Thrust cup
5. Thrust bearing and
races
6. Thrust pins
7. Back plate
8. Front plate
8
Fig. VL1-11 "Drawing of the dutch operating linkage. Refer to text for adjustment
mounting screws (1 & 2—Fig. VLl-9)
and the third screw under the trans-
mission. Turn the adjusting nuts (4 &
5) to move the transmission as required
to set the correct chain free play, then
tighten the three mounting screws. If
the primary chain tension is adjusted,
the rear chain should also be adjusted.
The rear chain free play should be ^
inch when the rear shock absorbers are
compressed until the mounting screws
are IVA inches between centers. The
rear chain free play can be adjusted
with the rear wheel off of the ground.
With motorcycle on the center stand
and rear wheel free, rear chain should
have lVi inch free play.
SUSPENSION. Each front suspen-
sion unit on Viper, Venom and MSS
models should contain 7Ice of SAE 20
engine oil. On Scrambler, Clubman
and Thruxton models, each front sus-
pension unit should contain 120cc of
SAE 20 oil. The front suspension
should be drained at plug (1—Fig.
yLl-14) and filled at plug (2) with new
oil every 10,000 miles.
The rear suspension units are adjust-
able for varying load and riding condi-
tion. With top mount in the forward
Fig. VL1-12-Clutch adjustment Is accomplished
using special tool as shown. Sprocket is shown
partially cut away. The clutch spring holder is
shown at (C).
132
MOTORCYCLE
1. Drain plug
2. Filler plug
3. Oil seal
4. Bushing
5. Snap ring
6. Damper bushing
7. Bushing
8. Snap ring
9. Damper valve
10. Damper piston
11. Washer
12. Lockwasher
13. Nut
14. Damper retaining
screw
position (S—Fig. VLl-15), suspension
is soft. The top mount can be located at
any position in the slot and the rear
most position (F) is firm. NOTE: Make
certain that both suspension units are
in exactly the same position.
REPAIRS
CYLINDER HEAD AND VALVES.
Remove the carburetor, fuel tank,
spark plug, rocker arm oil tube and
cover from right side of rocker box.
Turn the crankshaft with kick starter
until the inlet push rod (IN—Fig. VLl-
6) opens (moves up), then closes (moves
down). Remove the rocker box re-
taining screws and stud nuts. Lift the
rocker box slightly and turn around the
push rods until it can be lifted straight
off of push rods. NOTE: The rocker box
may be warped if all retaining screws
and stud nuts are not loosened evenly.
Remove the exhaust pipe. Remove the Fig. VL1-14-When assembling the front suspen-
rocker drain tube from the cylinder sion unit the chamfered side of bushing (6)
head and push rod tube, then slide the should be toward top.
top of push rod tube down into lower
part. Lift the push rods out and remove
the cylinder head retaining stud nuts.
The cylinder head studs are slotted on
the end and studs should be removed.
The cylinder can now be removed.
Face and seat angle for both valves is
45 degrees. Clearance between inlet
valve stem and guide should be
0.00125-0.0025 inch. Clearance be-
tween exhaust valve stem and guide
should be 0.00225-0,0035 inch. If
guides are renewed, the cylinder head
should be heated in water to 212°F.
(100°C) before pressing old guides out
or new guides in. New guides should be
pressed in from top until valve guide
protrudes 11/32 inch above the ma-
chined surface as shown at (A—Fig.
VLl-16).
Fig. VL1-15-Rear suspension Is adjustable. At
When assembling, the valve springs front of slot (S) suspension Is soft and at rear (F)
(32 & 33—Fig. VLl-17) overlap. Is firm.
SERVICE Velocette 350 & 500
VL1-17-Exploded view of the
crankshaft, camshaft and
27 associated parts. Beiieviite
washer (W) Is Instatted be-
tween crankcase and cam
fottowers.
1. Spring collar
2. Washer
3. Generator pulley
t. Shock absorber spring
3. Shock absorber cfrive clutch
i3. Primary drive sprocket
7. Shims
3. Roller bearing
9. Roller bearing
10. Shims
11. Crankshaft timing gear
12. Idler gear
13. Bushing
U. Idler shaft
VL1-16~Vatve guides shoutd protrude 11132 Inch 15. Camshaft spindle
16. Camshaft
above machined surface as shown at (A). 17. Bushing
13. Magneto drive gear and
advance assembly
Tighten screws and stud nuts retaining 19. Oil pump worm gear
20. Oil pump drive gear
the cylinder head and rocker box 21. Oil pump pressure gears
22. Oil pump return geare
evenly to prevent distortion. Make cer- 23. Cam followers
tain that push rods are correctly posi- 24. Push rods
25. End caps
tioned as shown in Fig. VLl-6. Refer to 26. Exhaust rocker arm
27. Inlet rocker arm
VALVE SYSTEM paragraphs in the 28. Valve guide
Maintenance section for adjusting 29. Keepers
30. Cap
valve clearance. 31. Retainer
32. Valve spring (large loop)
PISTON, RINGS AND CYL- 33. Valve spring (small loop)
INDER. The cylinder can be removed 3 2 34. Spring lower adaptor
without removing engine after re-
moving the cylinder head and posi-
tioning piston at bottom of stroke. Ring
clearance in groove should be 0.001-
0.003 inch for compression rings;
0.0027-0.0047 inch for the oil control
ring. Refer to the following specifica-
tions:
Ring end gap— four screws. It is necessary to remove
Compression rings— the oil pump assembly and worm gear
350cc 0.010 inch (19—Fig. VLl-17) before removing the
Oil control—350cc 0.012 inch crankshaft timing gear (11). The nut
Venom—all rings 0.010 inch retaining the oil pump worm gear and
MSS—all rings 0.015 inch timing gear to the crankshaft is left
All other 500cc models . . . 0.020 inch hand thread.
Standard cylinder bore diameter— Camshaft bushing (17) should have
350cc models 2.8347 inches 0.001 inch clearance on spindle (15).
500cc models 3.385 inches
Cylinder bore taper or out of
round limit 0.008 inch
Pistons and rings are available in
standard size and oversizes of 0.020
and 0.040 inch. The piston pin should
have 0.0007-0,0016 inch clearance in
the rod bushing. The oil hole in the top
of piston pin bushing should be aligned
with hole in top of connecting rod. If
bushing is worn or loose in connecting
Fig. VL1-18-Expioded view of
rod, renew bushing. Connecting rod the crankcase, cyttnder
alignment must be checked after in- head and rocker box. Refer
stalling the bushing. atso to Ftg. VLl-17.
When assembling, the split in piston 1. Timing cover oil jet
skirt must be toward front. Compres- 3.2. Rocker
Timing cover
arm pressure line
sion ratio is changed by installing 4. Rocker box drain tube
5. Suction oil filter
compression plates (11—Fig. VLl-18) 6. Timing plate
of different thicknesses. 7. Camshaft oil jet
8. Push rod tube (lower)
CAMSHAFTS AND TIMING 9. Push rod tube (upper)
10. Push rod guide plate
GEARS. The timing cover (2—Fig. 11. Cylinder spacer
VLl-18) is attached to the right side of 12. Decompression lever
13. Rocker box
engine with 10 screws. When remov-
ing, be careful not to warp or burr the
cover or sealing surfaces. The timing
gear steady plate (6) is attached with 1 2
133
Velocette 350 & 500
Fig. VL1-19-ViBW of the camshaft timing gears
with marks (A & B) aligned.
MOTORCYCLE SERVICE
Idler gear bushing (13) should have Remove the air cleaner, oil tank,
0.0015 inch clearance on spindle (14). generator and front section of the rear
End play of idler gear (12) and cam- chain guard. Disconnect clutch and
shaft (16) should not exceed 0.0015 decompression control cables. Remove
inch. the cylinder head steady strap, car-
When assembling, align timing buretor and exhaust pipe. Remove the
marks as shown at (A & B—Fig. VLl- final drive sprocket from the transmis-
19). Backlash of timing gears can be sion output shaft, support the engine
adjusted by loosening the three screws and remove bolts from the engine front
attaching spindle (14—Fig. VLl-17) to and rear mounting plates. Tilt the en-
the crankcase, then moving spindle gine and gear box forward and lift out
and idler gear (12) toward rear. Refer of frame. Remove the clutch assembly,
to preceding paragraphs in Mainte- primary drive shock absorber and the
primary drive chain. The gear box can
nance section for adjusting the ignition
timing. When installing cover (2—Fig. now be unbolted from the rear of crank-
VLl-18, leave oil tube (3) loose until case. Remove the engine oil pump,
engine is started. Tighten the connec- timing gears, cylinder head, cylinder
tion to cover after oil begins flowing and piston.
from the loose connection. The connecting rod and crankpin are
removed by pressing the crankshaft
CONNECTING ROD AND apart. When assembling, crankshaft
CRANKSHAFT. To remove the con- eccentricity must not exceed 0.001 inch
necting rod and crankshaft, the engine when measured at main bearing sur-
and gear box must be removed from the faces with crankshaft between lathe
frame and crankcase halves must be centers. Connecting rod side play
separated. should be 0.008 inch.

Fig. VL1-20-Exploded view of the clutch and gear box. Most service can be accompiished without removing the engine and gear box from the fram:

134