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Manuals
Brands
Norton Manuals
Motorcycle
Commando 850
Workshop manual
Norton Commando 850 Workshop Manual
Norton commando 850
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Table Of Contents
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Contents
Table of Contents
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Table of Contents
Contents
Technical Data
Technical Data: Frame, Engine Mountings and Rear Suspension Units
Technical Data: Speedometer Gearing
Technical Data: Wheels and Brakes
Technical Data: Electrical
Technical Data: Engine
Technical Data: Torque Settings
Technical Data: Gearbox
Technical Data: Capacities
Technical Data: Miscellaneous Data
Technical Data: Special Workshop Tools
Conversion Tables
U.N.E.F., U.N.F., U.N.C. Threads
B.A., B.S.W., B.S.F. Threads
Wire Gauges Conversion Table
Drill Sizes Conversion Table
Pints to Liters Conversion Table
Gallons to Liters Conversion Table
Miles to Kilometers Conversion Table
Miles Per Gallon to Liters Per 100 Kilometers
Pounds Per Square Inch to Kilograms Per Square Centimetre Conversion Table
Pounds to Kilograms Conversion Table
Foot Pounds to Kilogrameters Conversion Table
Millimeters to Inches Conversion Table
Inches to Millimeters (Decimals Of) Conversion Table
Fractions to Decimals - Decimals of Inch to Millimetre Conversion Table
Engine and Primary Transmission
Engine and Primary Transmission: Exploded View
Engine/Primary Drive
Removing Cylinder Head
Tightening Sequence
Removal of Rockers
Valve Removal and Reassembly
Rocker Thrust Washers and Securing Plates
Extracting Rocker Spindles Using Slide Hammer 064298
Decarbonising
Valve Guide Renewal
Using Valve Guide Tool 063964 to Remove a Valve Guide
Reseating the Valves
Grinding-In the Valves
Aligning Rocker Spindle
Refitting Rockers
Refitting Cylinder Head
Guiding Pushrods into Engagement with the Rockers
Rocker Clearances
Removing Cylinder and Pistons
Checking Valve Clearances
Support Connecting Rods to Prevent Damage against Crankcases
Cylinder Reboring and Oversize Pistons
Supporting Piston Body Whilst Pushing out Gudgeon Pin
Removing Primary Chaincase
Dismantling Primary Transmission and Clutch
Removing Rotor Nut Whilist Applying Rear Brake to Prevent Movement
Diaphragm Spring Compressor Tool 060999 in Use
Removing Crankcase Assembly from Frame
Removing Engine Sprocket Clutch and Primary Chain as a Set
Using a Screwdriver Blade to Peel Circlip Away from Housing
Use of Engine Sprocket Puller 064297
Dismantling the Crankcases
Removal of the Crankcase Assembly from Mounting Plates
Showing Crankcases Supported by a Bar to Remove Sump Filter
Showing Crankcases Mounted in a Plain Jaw Vice for Ease of Handling
Removing Contact Breaker Cam Using Slide Hammer 064298
Using a Spanner to Turn the Oil Pump Drive Wheel Nut and Remove the Pump
Preventing Flywheel Turning by Use of a Bar Lodged in a Flywheel Balance Hole
Extracting Crankshaft Pinion Tool ET 2003
Parting the Crankcase Using a Wood Block against the Inner Drive Side
Crankcase Overhaul
Removing Connecting Rods
Showing Suitable Tube to Abutt to Crankshaft Shoulder yet Pass through Crankcase
Supporting the Crankcase Shoulder on a Tube Whilist Separating the Crankcase from the Crankshaft
Dismantling the Cranckshaft
Cranckshaft Inspection and Regrinding
Engine Lubrication System
Removing Roller Bearing Inner Race Using Extractor 063970
Engine Lubrication System 850 Models
Oil Pressure Relief Valve
Crankcase Breather
Servicing the Oil Pump
Oil Pump
Timing Cover
Contact Breaker Seal, Crankshaft Seal
Showing Blanking Plug in Position in Timing Cover
Positions and Lengths of Odd Timing Cover Screws
Re-Assembly of the Crankshaft
Re-Assembling Connecting Rods to Crankshaft
Showing Crankcheek to Flywheel Securing Hardware
Connecting Rods Showing both Sides of Big and Eye and Bearing Shell Tab Locations
Re-Assembling Crankshaft to Crankcases
Pushing Timing Side Crankcase over Crankshaft
Mating Crankcases
Assembling Right (Timing Side) of Engine
Assembly of Timing Chain and Sprockets
Refitting the Timing Cover
Chain Tensioner Showing Thin Inner Plate Long End Downwards
Re-Assembly of Crankcase Assembly to Frame
Inserting Front Left Gaiter Mounting Cap Group
Lifting Front Mounting into Position Using Bottom Bolt as Pivot
Refitting Pistons and Cylinder
Priming Crankshaft with Oil
Assembling Primary Transmission
Fitting Cylinder over Pistons
850 Cylinder Base Securing Torque
Using Grip Wrench to Squeeze over Tab Washers at Inner Chaincase
Winding Diaphragm Spring Circlip into Position
Clutch Operating Lever in Correct Position
Clutch Operating Lever in Wrong Position Where Lever Has Dropped down
Clutch Operating Mechanism
Clutch Plates
Clutch Adjustment
Plate Inspection
Tachometer Drive
Removing and Refitting Engine Complete
Ignition Timing
Ignition Timing Basic Procedure Prior to Checking
Ignition Timing Procedure - Engine Static
Timing Plate Visible after Removal of Inspection Cap from Chaincase
Ignition Timing Procedure - Engine Running
Auto Advance Unit
Contact Breaker Assembly
Adjusting Contact Breaker Points Gap
C50 Lucas Contact Breaker
Maintenance of the Contact Breaker
Primary Chain Adjustment
Chain Serviceability
Rear Chain Adjustment
Gearbox
Gearbox Description
Gearbox Dismantling
Removing Gearbox Outer Cover
Removing Gearbox Inner Cover
Dismantling Gear Cluster and Cam Plate
Inspection of Gearbox Parts
Removal of Gearbox Complete
Countershaft (Gearbox Final Drive) Sprocket
Changing the Countershaft Sprocket
Refitting Gear Cluster and Selectors
Mainshaft and Layshaft Fitted to Gearbox Shell
Location of Camplate to Index Plunger
Refitting Gearbox Inner Cover
Gear Layout
Showing Kickshaft Pawl Stop on Inner Cover
Dismantling and Re-Assembling Gearbox Outer Cover
Kickstart Spring Located
Order of Assembly of Clutch Withdrawal Lever
Refitting the Gearbox Outer Cover
Pawl Carrier, Spring and Pichet Plate Assembled
Carburetor
Carburetor Removal
Amal Concentric Float Carburetor
Carburetor Dismantling
Carburetor Reassembly
Examination of Carburetor Parts
Fuel Taps
Carburetor Adjustment
Twin Carburetor Adjustment
Adjustment for Altitude
Air Filter
Removing and Refitting the Elements
Cleaning the Air Filter Element
Removing Air Filter and Gauze Band
Frame and Ancillaries
Removal of Power Unit
Removing Oil Junction Block Securing Bolt
Lifting out Power Unit to Right Side
Isolastic Engine Mountings
Commando Parted to Show Isolastic Mounting Points
Frame Checking Charts
Frame Checking Dimensions
Refitting Power Unit
Gaiter/Collar Group Ready to Fit
Coil Cluster from Rear Beneath
Swinging Arm Offered into Position with End Cap Held in Place with Grease
Aligning Swinging Arm Spindle with Swinging Arm Bore
Spindle Lock Bolt Fitted
Removing and Refitting Suspension Units
Rear Suspension Units (Girling)
Changing the Spring
Rebushing the Swinging Fork
Removing and Replacing Fuel Tank
Swinging Arm Bushes Showing Order of Assembly
Removing and Refitting Oil Tank
L.H. Accessory and R.H. Covers
Shimming Engine Mountings
Checking Rear Shimming, Front Shimming
Adjusting Front Shimming
Adjusting Rear Shimming
Holding Front Mounting in a Vice for Checking
Using Service Tool 063971 to Insert Front Isolatic Rubber Bushes
Renewal of Rubbers and Buffers
Renewing Isolastic Mounting Rubbers
Isolastic Mountings Exploded View
Rear Fender
Exhaust System Removing and Refitting
750 Low Lever Exhaust Systems
S Type Exhaust
850 Exhaust Systems
Front Forks/Steering
Fork at Rest, Compressing, Extending and Almost Fully Extended
Front Fork Description
Fork at Rest
How Fork Works
Fork Extending , Fork Compresses
Removal of Front Forks
Hydraulic System Removed Complete
Shocking Main Tubes Free of Upper Yoke
Dismantling Fork Leg
Front Fork Exploded View
Reassembling Fork Leg
Hydraulic System Fitting to Fork Leg
Releasing Damper Rod from Fork Top Bolts
Renewing Steering Head Bearings
Steering Head Adjustment
Refitting Font Forks
Showing Stem Nut Tab Washer Locked to Nut
Brakes, Wheels and Tires
Removing Rear Wheel
Refitting of Rear Wheel
Complete Rear Wheel Removal
Paddles and Shock Absorbing Pads
Rear Hub Dismantling
1970 Type Rear Wheel Exploded
1971 Onwards Rear Wheel Exploded
Rear Hub Reassembly
Removing and Refitting Front Wheel
Disk Brake Front Wheel Removal
Dismantling Front Hub, Disc Type
Guiding Brake Disc between Brake Pads
Removing and Refitting Front Wheel (Drum Type Brake)
Drum Front Brake External Features
Front Wheel Bearing Overhaul (Drum Brake)
Front Brake Adjustment (Drum Brake)
Twin Leading Shoe Brake Plate Showing Link Rod
Front Brake (Disc Type)
Rear Brake Adjustment
Overhauling Drum Brakes
Setting the Link Rod
Rear Brake Dismantling
Rear Brake Reassembly
Twin Leading Shoe Brake
Front Brake
Front Brake with High Performance Modification
Twin Leading Shoe Brake with High Performance Modification
Norton Lockheed Hydraulically Operated Disc Brake
Caliper Friction Pad Removal
Exploded View of Caliper Group
Caliper Overhaul
Caliper Component Inspection
Caliper Re-Assembly
Master Cylinder Overhaul
Master Cylinder Exploded View
Master Cylinder Removal
Master Cylinder Dismantling
Inspection of Master Cylinder and Components
Master Cylinder Reassembly
Tires
Master Cylinder Refitting
Bleeding the Hydraulic Brake System
Removing Front Tire
Refitting Front Tire
Removing Rear Tire
Refitting Rear Tire
First Bead Levered into the Rim
Careful Levering of Second Bead over Wheel Rim
Lifting Cover and Engaging Security Bolt to Rim
Pressing Security Bolt Back through Rim Whilist Levering Second Bead into Position
Electrical
Charging System
Alternator - Lucas Type RM21
Alternator Maintenance
Testing the Alternator in Situ
Rectifier Type 2DS 506
Testing the DC Input to Battery
Alternator Test
Rectifier Test Connections
Testing the Rectifier
Bench Testing the Rectifier
Zener Diode
Testing the Zener Diode
Battery Maintenance
Fuse, Ignition Switch, Master Switch
Warning Light Assimilator
High Rate Discharge Check
Testing Ignition System
Ignition Coils
Ignition and Lights
Ignition System Tests
Ignition Coils Lucas Type 17M6 1971 and Later Models/Type 17M12 Certain 1972 Models
Testing an Ignition Coil (17M6 and 17M12 Types)
Connect Breaker Assembly - Lucas Type 6CA
Ballast Resistors, Capacitor Pack Testing
Changing a Capacitor
Spark Plugs - Champion N7Y
Lighting System, Stop Switches
To Change the Headlamp and Pilot Bulbs, to Change the Tail/Stomplamp Bulb
Handlebar Switch Clusters
Power Take-Off Socket
Front Brake Stop Switch
Rear Stop Switch Adjustment
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Commando 750
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