**The Matchless G80: A British Icon of Motorcycling**

## Introduction

The Matchless G80 is a legendary British motorcycle that gained immense popularity from its introduction in 1957 to its discontinuation in 1966. With its distinctive styling, exceptional performance, and reliable engine, the G80 cemented its place as one of the most iconic motorcycles of its era.

## Design and Aesthetics

The G80 exudes a timeless charm that has captivated enthusiasts for generations. Its classic lines and understated elegance embody the essence of British motorcycle design.

- **Distinctive Headlight:** The iconic nacelle-style headlight is a defining feature of the G80, providing ample illumination while adding a touch of retro flair.
- **Reshaped Fuel Tank:** The 1959 models introduced a reshaped fuel tank that offered increased capacity and a more streamlined appearance.
- **Comfortable Seat:** The dual seat provides ample space and support, ensuring a comfortable ride for both rider and passenger.

## Mechanical Innovations

Beneath its stylish exterior, the G80 boasts a robust and innovative mechanical package that delivers exceptional performance.

- **Side Valve Engine:** The air-cooled, side-valve engine is known for its durability and reliability, making it an ideal choice for long-distance touring.
- **Bore and Stroke:** The engine features a bore of 79mm and a stroke of 93mm, resulting in a displacement of 498cc.
- **Overhead Camshaft:** The incorporation of an overhead camshaft allows for improved breathing and power output, contributing to the G80's impressive performance.
- **Amal Monobloc Carburetor:** The Amal monobloc carburetor provides precise fuel metering, ensuring optimum air-fuel mixture for smooth and efficient operation.
- **Girling Rear Shocks:** The Girling rear shock absorbers offer adjustable damping, allowing riders to customize suspension settings to suit their preferred riding style.

## Model Variants

Over its production lifespan, the Matchless G80 was offered in several variants to cater to diverse rider needs.

- **G80:** The base model G80 featured a rigid frame and was primarily intended for solo riding or touring.
- **G80S:** The G80S incorporated a swinging arm rear suspension, providing enhanced comfort and handling.
- **G80CS:** The G80CS introduced a larger 646cc engine, offering increased power for spirited riding.
- **TCS:** The TCS model was a specialized off-road variant with modified suspension, high-level exhaust, and knobby tires for navigating challenging terrain.

## Legacy and Impact

The Matchless G80 left an indelible mark on the motorcycling world, becoming a symbol of British engineering excellence and enduring appeal.

- **Cult Following:** Enthusiasts around the globe continue to cherish and restore G80s, forming vibrant owner clubs and participating in classic motorcycle rallies.
- **Racing Success:** The G80 was a formidable competitor in racing events, achieving notable victories in trials and endurance competitions.
- **Historical Significance:** The G80 played a pivotal role in the development of British motorcycles, influencing subsequent models and inspiring future generations of engineers.

In conclusion, the Matchless G80 is an automotive masterpiece that captivates with its timeless styling, robust engineering, and enduring legacy.

Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Workshop Service Manual for Repair.

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This Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.

Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966. Where usage is not obvious the tool is shown in use.

This Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 in your possession.

Adjustment and repair operations also include reference to wear limits for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966. Relevant data, useful assembly details all in this SERVICE MANUAL for Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966. Rectify all problems as soon as possible (immediately if safety related).
Use only genuine Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.

This manual for Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service manual is known in many names:
Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service service manual.
Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service repair manual.
Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service workshop manual.
Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Service shop manual.

This manual for Matchless G80 G80S G80CS TCS 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 Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
VEHICLE IDENTIFICATION NUMBER (V.I.N.) for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
WHEELS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FRONT WHEEL for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
REAR WHEEL for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
TIRES for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FRONT BRAKE MASTER CYLINDER AND HAND LEVER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FRONT BRAKE LINE for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FRONT BRAKE CALIPER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
BRAKE PEDAL for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
REAR BRAKE MASTER CYLINDER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
REAR BRAKE LINE for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
REAR BRAKE CALIPER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FENDERS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FRONT FORK for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FORK CLAMPS: UPPER AND LOWER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
STEERING HEAD BEARINGS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
SWINGARM AND BRACE for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FRAME for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
REAR SHOCK ABSORBER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
THROTTLE CONTROL for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
CLUTCH CONTROL for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
HEADLAMP ASSEMBLY AND SUPPORT BRACKET for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FOOTPEG, HEEL GUARD AND MOUNT for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
SPROCKET COVER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
BELT GUARDS. for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
INTAKE COVER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
SIDESTAND for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
SEAT LOCKS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
ENGINE for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
ENGINE REMOVAL for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
ENGINE INSTALLATION for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
CYLINDER HEAD for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
CYLINDER AND PISTON for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
LUBRICATION SYSTEM for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
OIL RESERVOIR AND OIL HOSE ROUTING for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
OIL COOLER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
OIL PRESSURE INDICATOR SWITCH for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
CRANKCASE BREATHING SYSTEM for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
OILING SYSTEM for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
OIL PUMP for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
HYDRAULIC LIFTERS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
GEARCASE AND CAM GEARS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
CRANKCASE for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
AIR CLEANER ASSEMBLY for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
ELECTRONIC CONTROL MODULE (ECM) for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
THROTTLE POSITION SENSOR (TPS) for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
IGNITION COIL for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FUEL TANK for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
FUEL PUMP for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
THROTTLE BODY for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
EXHAUST SYSTEM for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
STARTER for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
IGNITION SYSTEM for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
IGNITION/HEADLAMP KEY SWITCH for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
SPARK PLUG CABLES for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
CHARGING SYSTEM for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
BATTERY CABLES for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
VOLTAGE REGULATOR for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
ALTERNATOR for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
TURN SIGNAL FLASHER, FRONT TURN SIGNALS, REAR TURN SIGNALS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
HEADLIGHT, TAIL LAMP for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
MAIN FUSE AND FUSES for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.
WIRING DIAGRAMS for Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966.

AND MORE...

Matchless G80 G80S G80CS TCS 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 Workshop Service Manual for Repair.