Download NORTON Commando 961 - Service Manual PDF

TitleNORTON Commando 961 - Service Manual
File Size10.3 MB
Total Pages348
Document Text Contents
Page 1

Norton Motorcycles Service Manual
Commando 961 – All variants

Page 2

2


Quick Reference Guide



1 General Information .................................................................................................................................................. 8

2 Fuel System ............................................................................................................................................................. 28

3 Cooling System ........................................................................................................................................................ 43

4 Engine Top End ........................................................................................................................................................ 55

5 Clutch...................................................................................................................................................................... 96

6 Engine Lubrication System .................................................................................................................................... 117

7 Engine Removal / Installation ............................................................................................................................... 137

8 Crankshaft / Transmission ..................................................................................................................................... 143

9 Wheels / Tyres ....................................................................................................................................................... 170

10 Final Drive .............................................................................................................................................................. 187

11 Brakes .................................................................................................................................................................... 196

12 Suspension ............................................................................................................................................................ 219

13 Steering ................................................................................................................................................................. 256

14 Frame .................................................................................................................................................................... 271

15 Electrical System ................................................................................................................................................... 284

16 Appendix ............................................................................................................................................................... 322

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174



Ball and Needle Bearing Replacement
Caution: Do not remove the ball or needle bearings unless it is necessary. Removal may damage them.

 Using a press or puller, remove the ball and/or needle bearings.


Note: In the absence of the above mentioned tools, satisfactory results may be obtained by heating the
case to approximately 75˚C max, and tapping the bearing in or out.

Caution: Do not heat the case with a torch. This will warp the case.

 Using a press and a bearing drive, install the new bearing until it stops at the bottom of its housing.


Ball and Needle Bearing Wear
Caution: Do not remove the bearings for inspection. Removal may damage them.

 Check the ball bearings.

 Since the ball bearings are made to extremely close tolerances, the wear must be judged by feel

rather than measurement. Clean each bearing in a high-flash point solvent, dry it (do not spin the

bearing while it is dry), and oil it with engine oil.

 Spin the bearing by hand to check its condition.

 If the bearing is noisy, does not spin smoothly, or has any rough sports, replace it.

 Check the needle bearings.

 The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of

measuring, inspect the bearing for abrasion, colour change, or other damage.

 If there is any doubt as to the condition of a needle bearing, replace it.



Oil Seal Inspection

 Inspect the oil seals.

 Replace it if the lips are misshapen, discoloured (indicating that the rubber has deteriorated),

hardened or otherwise damaged.

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175


Wheels/Tyres

Exploded View ................................................................................................................................................ 171

Specification ................................................................................................................................................... 178

Wheels ........................................................................................................................................................... 179

Front Wheel Removal ...................................................................................................................... 179

Front wheel Installation ................................................................................................................... 179

Rear Wheel Removal ....................................................................................................................... 180

Rear wheel Installation .................................................................................................................... 180

Front wheel Disassembly ................................................................................................................. 180

Front wheel Assembly ..................................................................................................................... 181

Rear wheel Disassembly .................................................................................................................. 181

Rear wheel Assembly ....................................................................................................................... 182

Wheel Inspection ............................................................................................................................. 182

Spoke Inspection .............................................................................................................................. 182

Rim Inspection ................................................................................................................................. 182

Axle Inspection ................................................................................................................................. 183

Wheel Balance ............................................................................................................................................... 183

Wheel Balance Inspection ............................................................................................................... 183

Wheel Balance Adjustment ............................................................................................................. 183

Tyres ............................................................................................................................................................... 184

Air Pressure Inspection / Adjustment .............................................................................................. 184

Tyre Inspection ................................................................................................................................ 184

Tyre Removal ................................................................................................................................... 185

Tyre Installation ............................................................................................................................... 185

Hub Bearings (wheel Bearings ....................................................................................................................... 186

Bearing Removal .............................................................................................................................. 186

Bearing Installation .......................................................................................................................... 186

Bearing Inspection ........................................................................................................................... 186

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347


L x 2.113 = pint (US)
L x 1.816 = pint (imp)

mL x 0.03381 = oz (US)
mL x 0.02816 = oz (imp)

mL x 0.06102 = cu in



Units of Force

N x 0.102 = kg
N x 0.2248 = lb
kg x 9.807 = N

kg x 2.205 = lb







Units of Temperature:



 
F

C o
o




 40
5

409


 
C

F o
o




 40
9

405


Units of Length

km x 0.6214 = mile
m x 3.281 = ft

mm x 0.02937 = in











Units of Torque

Nm x 0.102 = kgm
Nm x 0.7376 = ftlb
Nm x 8.851 = inlb
kgm x 9.807 = Nm
kgm x 7.233 = ftlb

kgm x 86.8 = inlb



Units of pressure

kPa x 0.0102 = kg/cm²
kPa x 0.145 = psi

kPa x 0.7501 = cm Hg
kg/cm² x 98.07 = kPa
kg/cm² x 14.22 = psi

cm Hg x 1.333 = kPa



Units of Speed

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348


km/h x 0.6214 = mph



Units of Power

kW x 1.36 = PS
kW x 1.341 = HP
PS x 0.7355 = kW

PS x 0.9863 = HP

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