2018 961 rocker gasket repair? advice?

P- Rogers

P- Rogers

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Hi All,
I have a 2018 961 cafe mkII commando.
I'm just after any advise, went out for a 100k ride this Saturday, oil smoke started and on my return and I noticed it was coming from the rocker gasket, I think it may have a slight split in two places as it was dripping on the header- hence lots of smoke! any advice on replacing and or removing the aluminium rocker cover? 'm in Aus and parts are a challenge, I do have the capacity to draw and laser cut a new gasket myself should I need too, assuming I would with limited resources down here.
about an inch and a half back from the front, I've just noticed what appear to be two small breaks in the gasket, and it also appears to have crept out at the front as well slightly?
what are the challenges in replacing these? any advice much appreciated, I'm not much of a mechanic but happy to have a crack, I've had the tank off a lot in the time I've had it replacing all the shit that needs doing.
it's only done 900k's and it was sitting for a few years unsold until i got it 2 years ago now. with Covid and our rains I haven't been able to ride it much.
2018 961 rocker gasket repair? advice?

I
 
Hi @P- Rogers There are about 8 bolts holding it down. Making a gasket should be pretty easy, but you’ll need to get the tank off and some other stuff out of the way first. Have a look here, as it’s all explained…

961 Norton - Cylinder Head Torque

961 Norton - Cylinder Head Torque - Created by Richard Coote (many thanks Richard).
www.accessnorton.com www.accessnorton.com
 
P- Rogers said:
Hi All,
I have a 2018 961 cafe mkII commando.
I'm just after any advise, went out for a 100k ride this Saturday, oil smoke started and on my return and I noticed it was coming from the rocker gasket, I think it may have a slight split in two places as it was dripping on the header- hence lots of smoke! any advice on replacing and or removing the aluminium rocker cover? 'm in Aus and parts are a challenge, I do have the capacity to draw and laser cut a new gasket myself should I need too, assuming I would with limited resources down here.
about an inch and a half back from the front, I've just noticed what appear to be two small breaks in the gasket, and it also appears to have crept out at the front as well slightly?
what are the challenges in replacing these? any advice much appreciated, I'm not much of a mechanic but happy to have a crack, I've had the tank off a lot in the time I've had it replacing all the shit that needs doing.
it's only done 900k's and it was sitting for a few years unsold until i got it 2 years ago now. with Covid and our rains I haven't been able to ride it much.
View attachment 97114
I
Click to expand...
It's actually not that bad of a job. Once the tank is off, I find a few long straps of velcro helped lift everything out of the way while I lift the cover off.

Last year I managed to get a gasket for my rocker from AF1 Racing. If you need a scan of one, let me know. In Sydney, I'd try Quickshift Motorcycles.
 
Ollie at Thiele Motorsport has them but when I was there the cost of postage has risen dramatically for is online sales.
 
Gojuu said:
It's actually not that bad of a job. Once the tank is off, I find a few long straps of velcro helped lift everything out of the way while I lift the cover off.

Last year I managed to get a gasket for my rocker from AF1 Racing. If you need a scan of one, let me know. In Sydney, I'd try Quickshift Motorcycles.
Click to expand...
Thanks very much GoJuu, really appreciate the reply, I had grave fears it was much more than that to get the cover off! nothing so far has been strait forward!
the first 6 months of its life it sat at my work trying to get it to run and no help from the dealer at all. so I've had a lot of it apart from new anyway. I've replaced all the smaller items suggested here.
My problen turned out to be the fuel sensor, I used a Yamaha part. works great.
if you have a scan it would be fantastic to get one? I'll also follow up with Quick shift much appreciated. can i ask who you use for mechanicals here in Aus? (Sydney?) I can do bits but not able to dive in and
and do engine surgery.
I've done 900k's now and will also change the oil and filters, any idea on those part numbers? I've also noted on here that i'll need to tighten the head again around 800ml mark, so I'l do that too?
Thanks again.
 
cliffa said:
Hi @P- Rogers There are about 8 bolts holding it down. Making a gasket should be pretty easy, but you’ll need to get the tank off and some other stuff out of the way first. Have a look here, as it’s all explained…

961 Norton - Cylinder Head Torque

961 Norton - Cylinder Head Torque - Created by Richard Coote (many thanks Richard).
www.accessnorton.com www.accessnorton.com
Click to expand...
Thank you very much Cliffa, brilliant, just what the doctor ordered. thanks for taking the time to send. this definitely looks doable. I had grave fears.
I need to take the opportunity to do It's oil change as well as torque the head that you have sent. any idea what the oil filter/s details are I need to order?
i'll make another contribution to Mr Coote!
 
P- Rogers said:
Thank you very much Cliffa, brilliant, just what the doctor ordered. thanks for taking the time to send. this definitely looks doable. I had grave fears.
I need to take the opportunity to do It's oil change as well as torque the head that you have sent. any idea what the oil filter/s details are I need to order?
i'll make another contribution to Mr Coote!
Click to expand...
My pleasure Sir. Please see this (downloadable) list for oil filter reference and very many others….

Norton 961 Motorcycle Alternative Parts

Modern Norton 961 Alternative Parts lookup.
www.accessnorton.com www.accessnorton.com
 
Stu Bodycote said:
Did you see my reply to your question on the FB page chap?
Click to expand...
Hi Stu, I didn't sorry, (away on business as well.) I was also on the wrong fb for you as well, amended now! i went back and still didn't see it? but that would be me not driving fb very well.
thanks for the reply and your time, much appreciated.
I have managed to find the parts I need locally here in Sydney via Dean @ Quickshift motorcycles, extremally helpful, great prices and called me late in the evening then again on his day off to let me know he had what I needed and other parts he has left available.
Dean was also the one that helped me with the Yamaha fuel sensor i had issues with after your recommendations.
Looking forward to this weekends motogp.
 
Gojuu said:
It's actually not that bad of a job. Once the tank is off, I find a few long straps of velcro helped lift everything out of the way while I lift the cover off.

Last year I managed to get a gasket for my rocker from AF1 Racing. If you need a scan of one, let me know. In Sydney, I'd try Quickshift Motorcycles.
Click to expand...
Thanks for your advice Gojuu. I got InTouch with Dean @ quickshift, extremally helpful and had what I needed, plus some oil / air filters. in the post. really helpful and could do enough to help, called me late and on his day off.. spanners out during the week hopefully, if work doesn't get in the way.
 
Hi - FYI my late 2017 CR with 14k on the clock just had gasket go in same way - just fell apart. Got from Ollie and used blue gasket goo but Job was easier than I thought just the usual fiddly fuel quick release and fuel pump connector. Ideal opportunity to replace relays if not done, spiral cable protector where the loom can rub, tie fuses into holders and a spray around with your favourite anti rust coating. And just check the battery connector lugs - a few have come loose on the cable.
 
Clive said:
Hi - FYI my late 2017 CR with 14k on the clock just had gasket go in same way - just fell apart. Got from Ollie and used blue gasket goo but Job was easier than I thought just the usual fiddly fuel quick release and fuel pump connector. Ideal opportunity to replace relays if not done, spiral cable protector where the loom can rub, tie fuses into holders and a spray around with your favourite anti rust coating. And just check the battery connector lugs - a few have come loose on the cable.
Click to expand...
Very strange the way these gaskets fail. It almost seems like pressure is forcing them out.

According to Facebook, Thor motorcycles in Bodmin now have those and other gaskets available.
 
Bike had been standing for a while so shrunk and dried out???? (Know that feeling....)
 
Hi All,

Quick update!
Thanks again for all the great advise, just wanted to finish this off as I've successfully replaced the rocker gasket and it's all fantastic and up and on the road again without to much fuss.
2.5 hours with some help from confident like minded staff to assist.
the gasket did actually have a number of fractures to it, but only the one full spit, guess this was the weak point. it was quite hard and brittle, the comment that it had sat for a 3 years unsold (not ridden)
therefore not having oil around it may have been the correct diagnosis?
images of the fail and cleaned & repaired.
Cheers all.
 

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Last edited:
P- Rogers said:
Hi All,

Quick update!
Thanks again for all the great advise, just wanted to finish this off as I've successfully replaced the rocker gasket and it's all fantastic and up and on the road again without to much fuss.
2.5 hours with some help from confident like minded staff to assist.
images of the fail and end.
Cheers all.
Click to expand...
any advice on how I might clean clean the minor corrosion /discolouration from the cooling fins?
 
P- Rogers said:
Hi All,

Quick update!
Thanks again for all the great advise, just wanted to finish this off as I've successfully replaced the rocker gasket and it's all fantastic and up and on the road again without to much fuss.
2.5 hours with some help from confident like minded staff to assist.
the gasket did actually have a number of fractures to it, but only the one full spit, guess this was the weak point. it was quite hard and brittle, the comment that it had sat for a 3 years unsold (not ridden)
therefore not having oil around it may have been the correct diagnosis?
images of the fail and cleaned & repaired.
Cheers all.
Click to expand...
Glad too see it’s fixed. Did you end up making a gasket?

maybe try some wheel cleaner on the ally fins?
 
P- Rogers said:
any advice on how I might clean clean the minor corrosion /discolouration from the cooling fins?
Click to expand...
Stiff bristle brush with long bristles and simple green/S100 or similar cleaner . Lots of brush scrubbing and flushing with fresh water.
 
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