Table Of Contents - Norton Commando Workshop Manual

Table of Contents

Index3
Technical Data6
Recommended Lubricants7
Lubrication System8
Oil Pressure Relief Valve8
Crankcase Release Valve8
The Oil Pump8
Dismantling the Oil Pump9
The Oil Pump Seal9
Timing Cover Oil Seal9
Checking Oil Pressure9
Engine Exploded View10
Engine Parts List11
Decarbonising the Engine12
Removing the Cylinder Head12
Valve Check12
Removing the Valves12
Valve Guides13
Refitting the Valves13
Removing the Cylinder Barrel13
Removing the Tappets and Rockers13
Removing the Rocker Ball End14
Refitting the Rockers14
Removing the Pistons14
Refitting the Cylinder14
Refitting the Cylinder Head15
Rocker Adjustment15
Order of Tightening down Cylinder Head Nuts and Bolts16
Engine Overhaul17
Removing Engine18
Clutch Tool in Use - Illustration18
Clutch Diaphragm Removed View19
Removing Engine Sprocket19
Dismantling the Engine20
Separating the Crankcase20
Removing the Roller Bearing21
Removing the Roller Bearing Sleeve21
Removing the Ball Bearing21
Retaining Valve Timing View22
The Crankshavt View22
The Crankshaft23
Dismantling the Crankshaft23
Checking Oil Pump Seal23
Fitting the Intermideate Pinion Shaft23
Re-Grinding Dimensions Commando Crankshaft24
The Driving Side Crankcase Oil Seal25
Fitting the Driving Side Bearings25
Fitting the Timing Side Bearing25
Assembling the Crankcase25
Camshaft Chain Assembled View26
Cut-Away Timing Cover View26
Refitting Engine27
Primary Chain Alignment27
Setting Ignition Timing27
Contact Breaker Location View27
The Contact Breaker Type 6CA28
Adjusting the Contact Breaker Gap28
To Reset Ignition Timing28
To Adjust Ignition Timing28
The Gearbox29
Dismantling the Gearbox29
Removing the Outer and Inner Cover29
Removing the Sleeve Gear29
The Gearbox Exploded View30
Removing the Bushes31
Assembling the Gearbox31
Replacing the Kickstarter Spring31
The Clutch31
Clutch Bearing Dismantled View32
To Remove the Clutch Bearing32
Refitting the Clutch Bearing32
Clutch Cable Adjustment32
Chain Adjustment33
To Adjust Primary Chain33
Rear Chain Adjustment33
Workshop Clutch Diaphragm Tool Diagram33
Front Forks34
Steering Head Adjustment34
To Drain the Front Forks34
Rear Chain Lubrication34
Dismantling the Front Forks35
Front Fork Assembly35
To Remove One Fork Leg36
Dismantling Fork Inner Tube36
Assembling the Fork Tube36
Removing Forks as a Unit36
The Frame (Registered Design)37
Removing the Oil Tank37
Removing the Air Filter37
To Remove the Battery Carrier37
Removing the Side and Central Stand39
Checking Front Engine Mounting Side Play39
Checking Rear Engine Mounting Side Play39
Fitting New Shims for Rear Engine Mounting39
Removing Rear Engine Mounting40
Removing the Engine Mounting Bush40
The Swinging Arm40
Wheels and Brakes41
Front Wheel Removal and Refitting41
Removing Rear Wheel41
Removing the Rear Brake Drum41
Dismantling Rear Wheel Hub42
Assembling the Rear Wheel Hub42
Dismantling Front Wheel Hub42
Front Hub and Rear Hub Exploded Views42
Assembling Front Hub43
Wheel Balancing43
Front Brake Adjustment43
To Reset the Link Rod43
Centralising the Brake Shoes44
Front Brake Air Scoops44
Rear Brake Adjustment44
Removing the Brake Shoes44
Amal Concentric Carburetor Exploded View45
Carburetors46
Electrical Equipment46
The Capacitor46
Running with the Battery Removed46
Motorcycle Alternator Model RM 21 (Positive Earth)47
Testing the Alternator Charging System in Situ47
Cecking the Alternator Voltage (A/C) Output47
Stator-Winding Assembly47
Zener Diode Charge Control49
The Contact Breaker 6CA49
Part Exploded View of Model 6CA Contact Breaker49
Contact Breaker Dismantling50
Automatic Advance Unit50
The Rear Lamp50
The Headlamp50
The Battery51
Lucas Lead-Acid Batteries Model PUZ5A (12 Volt)51
Figure 5352
Models after Engine No. 13125753
Engine Camshaft Chain53
Contact Breaker Oil Seal53
Removing and Fitting the Oil Seal53