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Norton Commando 961 Service Manual

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Norton Motorcycles Service Manual
Commando 961 – All variants

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Summary of Contents for Norton Commando 961

  • Page 1 Norton Motorcycles Service Manual Commando 961 – All variants...
  • Page 2 Quick Reference Guide General Information ..............................8 Fuel System ................................28 Cooling System ................................ 43 Engine Top End ................................ 55 Clutch..................................96 Engine Lubrication System ............................ 117 Engine Removal / Installation ..........................137 Crankshaft / Transmission ............................. 143 Wheels / Tyres ............................... 170 10 Final Drive ................................
  • Page 3 Norton Motorcycles (UK) Ltd. No Liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
  • Page 4 Emission Control Information To protect the environment in which we all live, Norton motorcycles (UK) ltd has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Norton has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.
  • Page 5 Note: The phrase “remove or render inoperative any device or element of design” has been generally interpreted as follows:  Tampering does not include the temporary rendering inoperative of devices or elements of design in order to perform maintenance.  Tampering could include: ...
  • Page 6  Follow the Periodic Maintenance Chart in the Service Manual.  Be alert for problems and non-scheduled maintenance.  Use proper tools and genuine Norton Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Norton motorcycles are introduced by the Special Tool Catalog or Manual.
  • Page 7 Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operation and maintenance practices. WARNING: This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION: This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.
  • Page 8 General Information Before Servicing ..............................9 General Specification ............................13 Periodic Maintenance Chart ..........................16 Torque and Locking Agent ..........................17 Special tools and Sealant ..........................24 Cable, Wire and Hose Routing ......................... 26...
  • Page 9 Incorrect or improper modification may adversely affect the handling, stability or other aspect of the motorcycle operation, which may result in an accident causing injury or death. If the motorcycle is involved in an accident, collision or fall, it must be taken to an authorised Norton dealer for inspection and repair.
  • Page 10  Force: Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a rubber, wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads.
  • Page 11 may contain abrasive foreign particles. Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS ) in the assembly of certain engine and chassis parts.
  • Page 12 List of Abbreviations ampere (s) pounds(s) ABDC after bottom dead centre meter(s) alternating current minute(s) ATDC after top dead centre Newton(s) BBDC before bottom dead centre Pascal(s) bottom dead centre horsepower BTDC before top dead centre killer watt(s) ˚C degree(s) Celsius pound(s) per square inch direct current revolution...
  • Page 13 Displacement 79mm Compression ratio 10.1:1 Maximum / horsepower 59Kw @ 7700rpm Maximum torque 84Nm @ 6000rpm Throttle body Norton Throttle Body 38mm Starting system Electric starter Ignition system Coil Timing advance Electronically advanced Ignition timing Controlled by ECU map Spark plug...
  • Page 14 Items 961 SE/SPORT/CAFE RACER Drive Train: Primary reduction system: Type Gear Reduction ratio 1.61 Clutch type Wet multi disc Transmission: Type 5-speed, constant mesh Gear ratios: 2.688 1.969 1.433 1.181 1.000 Final drive system: Type Chain drive Reduction ratio 2.778 Overall drive ratio 4.476 @Top Frame:...

  • Page 15: Scheduled Maintenance Chart

    SCHEDULED MAINTENANCE CHART Every Odometer Reading in Miles (Kms) or time period, whichever Operation Description comes first 6,000 12,000 18,000 24,000 30,000 (800) (10,000) (20,000) (30,000) (40,000) (50,000) 1 year 2 years 3 years 4 years 5 years month Engine oil Cooler - check for leaks Engine oil - renew Engine oil filter - renew Valve clearance - check...
  • Page 16 SCHEDULED MAINTENANCE CHART Every Odometer Reading in Miles (Kms) or time period, whichever Operation Description comes first 6,000 12,000 18,000 24,000 30,000 (800) (10,000) (20,000) (30,000) (40,000) (50,000) 1 year 2 years 3 years 4 years 5 years month Steering - check for free operation Headstock bearings - check/adjust Headstock bearings - lubricate Forks - check for leaks/smooth operation...
  • Page 17 Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the “Remarks” column mean: Letters Mean Apply a non-permanent locking agent to the threads.
  • Page 18 Torque table Chassis Torq Description Component Remarks Sprocket cover SPROCKET COVER TO C/CASE BOLT, CAP HD, M8 X 30 X 1.25 Front wheel SPINDLE FOR CONVENTIONAL FORKS SPINDLE, FRONT WHEEL SPINDLE, FRONT WHEEL, USD FORKS, SPINDLE FOR USD FORKS HIGH BARS Rear wheel TO CLAMP SPROCKET TO CARRIER LOCKNUT, FLANGED, M10 X 1.25...
  • Page 19 Description Component Torque Remarks Front forks PINCH BOLT SUPPLIED WITH FORKS (for axle) BOLT, CAP HD, M8 X 25 LOWER YOKE CLAMP BOLTS BOLT, CAP HD, M8 X 20 X 1.25 SWITCH CUBE LH SCREW, M5 X 40 SWITCH CUBE LH SCREW, M5 X 30 SWITCH CUBE RH SCREW, M5 X 22...
  • Page 20 Description Component Torque Remarks Oil cooler BOLT, CAP HD, M6 X 20 x 1.0 TO CLAMP OIL COOLER TO FRAME Airbox and Exhaust TO AIR FILTER CLAMP BOLT, BUTTON HD, M5x12 TO CLAMP TRANSITION PIECE BOLT, CAP HD, M6 X 20 TO HEAD LOCKNUT, FLANGED, M8 X 1.25 LAMBDA SENSOR, EXHAUST, M10 X...