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961 MANUALS

Discussion in 'Norton Motorcycles (Modern)' started by richard-7, May 26, 2015.

  1. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    My dad and I have started creating some workshop manuals that accompany the NORTON Workshop Manual to help make it easier to work on the 961 Commando. It's going to take time to get to every subject matter but in time it will get there. They are in sections and some work together and some, like the Head Torque, will be in addition to the NORTON Manual for specs and patterns.

    They don't cost anything and you can share them with anyone you know, but if you feel they have saved you some cash and frustration and you would like to make a donation to my paypal account that would be fantastic. This will help me justify the time it takes to create them and give them away.

    If you would like me to email you a PDF copy, just PM me your email address until I can find a place to host them for free download.

    What I have so far;

    Fuel Tank Removal - Norton 961 (Get to battery and main fuse)
    Removing Primary Side Cover - Norton 961 (Lots of reasons to get in here)
    Removing Clutch Basket - Norton 961 (if you need to get to starter or check ring gear or replace clutch plates)
    Cylinder Head Torque - Norton 961 (Recommended at 1,000 miles - prevent a blown head gasket)
    Split Balance Gear Spring - Norton 961 (If your clutch or engine sounds noisy it's likely this)
    Transmission Vent - Norton 961 (If you are blowing starter gaskets its probably this)
    OIL CHANGE Transmission and Engine - Norton 961 (there is actually a lot to this)
    Bulb Change - Norton 961
    Cluster removal and re-install - Norton 961 (Latest update 24hr to 12hr clock)
    Ignition Coil Replacement - Norton 961
    Throttle Control - Norton 961 (there IS a trick to starting these bikes)
    Oil in the Airbox - Norton 961 (A good read for those who may not know about this yet)
    Starter Solenoid - Norton 961 (At some point in time you will need this)



    I'll keep adding to this list as more are complete. I was going to wait until they were all finished but bike season is here and the last thing we need is being off the road for something we can fix ourselves. If you have anything to add or change, post it here and just general comments post them here too. Don't be shy if you feel something is missing. This is to help everyone and your feedback is the only way they will improve.

    PS - This manual is more for people who have a general understanding of mechanics. If you don't have a good understanding of mechanics and are not generally inclined to take things apart just to see how they work, then proceed with caution and/or take your bike, the Norton Workshop Manual and my manuals to someone who does.
     
    AB2501 and Colin1980 like this.
  2. TonyA

    TonyA VIP MEMBER

    Joined:
    Jan 16, 2015
    Count me in !
     
  3. terrys

    terrys

    Joined:
    Apr 2, 2010
    Hi,

    Please email me the pdf, my head is weeping oil from the front of the gasket at about 1200 miles, the head torque section is of interest to me. I have searched the owner's manual and the factory shop manual and have not seen any mention about periodic head torqueing, am I missing something?

    regards and thanks,
    Terry Seaver
    SE USA 12 of 50

    terryseaver@yahoo.com
     
  4. richard-7

    richard-7

    Joined:
    Feb 24, 2014

    Check your email. CDN Distributor said at first service for cyl head torque. Which makes sense really. Bolts stretch and gaskets compress. :mrgreen:
     
  5. BPHORSEGUY

    BPHORSEGUY

    Joined:
    Nov 29, 2013
  6. Precisionbob

    Precisionbob

    Joined:
    May 25, 2015
    Here's my email for the pdf's. Thanks!!
    bobjones@kindacool.com
    USA SE - just took delivery May 21, 2015. Still trying to figure out SE# but VIN ends in 170
     
  7. BPHORSEGUY

    BPHORSEGUY

    Joined:
    Nov 29, 2013
    Richard, Thank-you for the pdfs, very good photos! You are a great asset to this forum! :mrgreen:
     
  8. roofus

    roofus VIP MEMBER

    Joined:
    Apr 26, 2014
    Hi Richard! Could you please send me the pdf's?

    I tried to PM you but I couldn't seem to make it work.

    Thanks for all your work on this project.

    Don aka roofus

    ********@gmail.com
     
  9. richard-7

    richard-7

    Joined:
    Feb 24, 2014
     
  10. richard-7

    richard-7

    Joined:
    Feb 24, 2014

    Thank you!
     
  11. dimitri

    dimitri

    Joined:
    Apr 4, 2013
    Hi Richard,

    If it is not to much trouble. I am interested in the head torque (head gasket sweating like others) and everything to get to the clutch. Mine is very noisy (must admit i got used to it). But now it does not disengage smoothly anymore either.

    dimitripaeleman@telenet.be

    Kind regards,

    Dimitri
     
  12. richard-7

    richard-7

    Joined:
    Feb 24, 2014

    Do you have another email address? a few bounced back because your email has a max attachment limit.
     
  13. BritTwit

    BritTwit

    Joined:
    Aug 25, 2009
    Dimitri,

    Do you have the stock exhaust in place?
     
  14. dimitri

    dimitri

    Joined:
    Apr 4, 2013
    Hi Richard,

    I got 4 of them and they are really great! Thanks for the effort.
    I don't know if you tried to send more parts, but this email should be fine:

    xxx


    @BritTwit: no, i went trough several exhaust systems. Complete open exhaust now. The clutch rattles and with hot engine it is difficult to drive away smoothly. Cars behind me must think i can't drive :)
     
  15. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    Glad they are helpful, thank you for all the replies, comments, and donations. If you posted your email on public forum, just go back and edit it out if I've sent them to you. No need for extra spam in your mail box.

    Here's some pics I took last night. Two fantastic products that go well together. A Norton and a Union Garage Robinson Jacket.
    [​IMG]Robinson Jacket & Norton 961 SE by Richard, on Flickr
    [​IMG]Robinson Jacket - Union Garage NY by Richard, on Flickr
     
  16. AcrossThePond

    AcrossThePond

    Joined:
    Dec 19, 2014
    Richard, please send me the PDF to my email address at cealawyer@aol.com. Thanks.
     
  17. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    Sent!
     
  18. richard-7

    richard-7

    Joined:
    Feb 24, 2014
    I just wanted to make a NOTE HERE:
    The transmission Venting is something we feel Norton either missed or we cannot locate, there isn't an off the shelf thing you can buy to do this. However, if you are handy, this manual will guide you in what to do and you will easily be able to make your own. From an engineering viewpoint, its the reason why starter gaskets are leaking oil. (Maybe not tho...) Also, in that manual it shows the AIRBOX TEMP. SENSOR -- If anything else, use dielectric grease on that connection because as you can see from the photo, it's in a valley with no where for water to go when washing the bike or in rain. If and when that corrodes, you will have a small nightmare on your hands.

    ALSO, make sure you remove your gas tank and make sure the MAIN FUSE has a ZIP TIE around it. Also not a bad Idea to pack with dielectric grease.
     
  19. Britfan60

    Britfan60 VIP MEMBER

    Joined:
    Jan 5, 2014
    I've already had the leaky starter gasket prior the blown gearbox. 6 weeks for a little item to arrive. Do you think the lack of venting could be why I'm blowing oil
    from the crankcase seam too? Not huge amounts. Maybe a tablespoon every 50 miles or so. My level hasn't dropped significantly over the last 400 mi. Maybe 5-6 MM on the dipstick.
     
  20. pingu-nz

    pingu-nz

    Joined:
    Jun 24, 2011
    hi Richard
    Any chance you could send a set of manuals down under .

    mclan0z@bigpond.com

    cheers
    Paul