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General| Brand | Norton Triumph |
|---|---|
| Model | 850 Commando |
| Category | Motorcycle |
| Language | English |
This manual provides technical instructions for distributors, dealer staff, and private owners for routine maintenance and overhaul.
Lists Norton Triumph International and regional distributors worldwide for parts and service.
Covers procedures for removing, servicing, and refitting the cylinder head and pistons.
Details the dismantling and servicing of the crankcase, crankshaft, connecting rods, and bearings.
Explains the lubrication system, oil pump, and starter gear train components.
Covers the procedures for timing the engine, including the timing cover and related components.
Provides information on ignition timing and auto advance contact breaker.
Provides a general overview of the gearbox and its main features.
Step-by-step instructions for removing and taking apart the gearbox.
Guidelines for examining gearbox components for wear and damage.
Instructions for reassembling the gearbox after servicing.
Details on the removal and servicing of the gearbox outer cover.
Procedure for replacing the countershaft sprocket.
Steps for removing the entire gearbox assembly from the motorcycle.
Overview of the Amal concentric carburetors used on the motorcycle.
Instructions for removing and dismantling the carburetors.
Guidance on inspecting parts and reassembling the carburetors.
Procedures for adjusting carburetor settings for optimal performance.
Information regarding the motorcycle's fuel taps.
Details on the air filter element and its maintenance.
Steps for removing and reinstalling the entire engine and gearbox assembly.
Specifications and procedures for checking frame alignment and dimensions.
Instructions for the maintenance and service of the rear suspension units.
Procedure for maintaining and servicing the motorcycle's swinging arm.
Procedure for removing and refitting the fuel tank.
Procedure for removing and refitting the oil tank.
Information on servicing and maintaining side covers and accessories.
Details on the maintenance and service of the isolastic mounting system.
Information pertaining to the rear fender of the motorcycle.
Details regarding the removal and servicing of the exhaust system.
Overview of the front fork assembly and its components.
Instructions for removing and disassembling the front forks.
Procedure for inspecting and servicing the steering head bearings.
Steps for reassembling and refitting the front fork assembly.
Procedure for removing and disassembling the rear wheel.
Steps for reassembling and refitting the rear wheel assembly.
Details on the maintenance and servicing of the disc brake system.
Explanation of the hydraulic operation of the front brake system.
Specific information regarding the Norton Lockheed disc brake.
Procedure for adjusting the rear brake pedal.
Information concerning the motorcycle's tires.
Overview of the motorcycle's electrical system and its components.
Details regarding the operation and maintenance of the charging system.
Information on the ignition system, including timing and components.
Overview of the motorcycle's lighting system and its components.
Specifications and maintenance for headlamps and tail lamps.
Details on the handlebar-mounted switch clusters.
Information related to the power take-off system.
Details concerning the operation of the flashing direction indicators.
Information on the alternating horn set, specifically for police models.
Procedure for adjusting the motorcycle's horns.
Instructions for fitting a Lucas electrical connector.
Details on the electrical starter motor and its maintenance.
Includes wiring diagrams for troubleshooting and reference.
Introduction to the routine maintenance schedule and procedures.
A table outlining service intervals and required maintenance tasks.
Procedures for servicing the engine, gearbox, and primary chaincase oil.
Instructions for lubricating the swinging arm pivot point.
Procedure for changing the oil in the front forks.
Guidance on checking the hydraulic brake fluid level.
Procedure for checking the electrolyte level in the battery.
Information on spark plug inspection, cleaning, and replacement.
Guidelines for checking and adjusting tire pressures.
Procedure for adjusting the engine's cam timing chain.
Instructions for checking and adjusting rocker arm clearances.
Procedure for setting ignition timing and adjusting contact breaker points.
Details concerning the auto clearance unit component.
Information and maintenance for the engine camshaft chain.
Procedure for adjusting the primary and rear drive chains.
Details on adjusting the governor shaft.
Procedure for adjusting the clutch mechanism.
Instructions for adjusting the steering head bearings.
Procedure for adjusting the disc brake system.
Details on adjusting the isolastic suspension mounting.
Procedure for adjusting the suspension springs.
General maintenance procedures for the disc brake system.
Guidance on troubleshooting common problems with the motorcycle.
Technical specifications for frame, engine mounts, and rear suspension.
Step-by-step method for adjusting the isolastic mountings.
Technical details regarding the rear suspension units.
Specifications and information related to the speedometer gearing.
Technical specifications related to the fuel system and components.
Technical specifications for the motorcycle's electrical system.
Technical specifications for wheels and brake systems.
Technical specifications for the various instruments on the motorcycle.
Detailed technical specifications for the front wheel assembly.
Technical specifications for both front and rear disc brake systems.
Detailed technical specifications for the rear wheel assembly.
Glossary of common engine part names and their alternatives.
Glossary of common clutch part names and their alternatives.
Glossary of common gearbox part names and their alternatives.
Glossary of common frame part names and their alternatives.
Glossary of common fork part names and their alternatives.
Technical data and specifications related to the front forks.
Technical data and specifications related to the electrical system.
Technical data and specifications related to the engine.
Technical data for the engine cylinder block.
Technical data for the engine cylinder head.
Technical data for the engine camshaft.
Technical data for the engine tappets.
Technical data for the engine rocker shaft.
Technical data for valve clearances (engine cold).
Technical data for valve lift measurements.
Technical data for the engine valves.
Technical data for the engine valve guides.
Technical data for the engine valve springs.
Technical data related to valve timing specifications.
Table of torque recommendations for various bolts.
Table of torque recommendations for various nuts.
Technical data for the camshaft chain, including size and links.
Technical data for the contact breaker assembly.
Technical data for the carburetor, including jets and settings.
Specific torque values for various engine and chassis components.
Technical data for engine mounting bolts and nuts.
Specific torque values for alternator mounting nuts.
Specific torque values for crankshaft flywheel nuts.
Specific torque values for top gearbox cover fixing bolts.
List of part numbers for engine components.
Technical data for gearbox ball journal bearings.
Gearbox reduction ratios for different gears.
Table of theoretical road speeds based on gearbox sprockets.
Detailed technical specifications for the gearbox components.
Technical specifications for the primary transmission and rear chain.
Table listing the fluid capacities for various motorcycle systems.
Miscellaneous specifications and data for the motorcycle.
A list of specialized tools required for workshop procedures.
Conversion table for millimetres to inches.
Conversion of millimetres into decimal values.
Conversion of fractional inch measurements to decimals.
Tables detailing thread specifications for various standards (UNEF, UNF, UNC, BSW, BSF).
Conversion chart for wire gauges.
Table of drill sizes in inches.
Conversion table for Imperial gallons to litres.
Conversion table for Imperial pints to litres.
Conversion for fuel economy (MPG) to kilometres.
Conversions for pressure units (PSI to kg/cm²).
Conversions for weight units (lbs to kg).
Conversions for torque units (ft-lbs to kg/m).
Introduction to the engine and primary drive systems.
Procedure for removing the engine's cylinder head.
Steps for removing the rocker arms from the cylinder head.
Procedure for removing and refitting the engine valves.
Instructions for decarbonising the engine combustion chambers.
Procedure for renewing the engine valve guides.
Instructions for reseating the engine valves in their guides.
Procedure for grinding in the engine valves for a proper seal.
Steps for correctly refitting the rocker arms.
Procedure for refitting the cylinder head assembly.
Instructions for checking and adjusting rocker clearances.
Procedure for removing the cylinder and pistons.
Details on cylinder reboring and fitting oversize pistons.
Procedure for removing the primary chaincase.
Instructions for dismantling the primary transmission and clutch.
Procedure for removing the crankcase assembly from the frame.
Instructions for dismantling the engine crankcases.
Procedures for overhauling the engine crankcases.
Procedure for removing the engine connecting rods.
Instructions for dismantling the engine crankshaft.
Procedure for inspecting and regrinding the crankshaft.
Description of the engine lubrication system.
Details on the oil pressure relief valve.
Information on the crankcase breather system.
Details on the engine oil pump.
Procedure for servicing the engine oil pump.
Details and servicing procedures for the timing cover.
Information on the contact breaker seal.
Procedure for reassembling connecting rods to the crankshaft.
Procedure for reassembling the crankshaft to the crankcases.
Instructions for assembling the right (timing) side of the engine.
Procedure for refitting the timing cover.
Procedure for reassembling the crankcase assembly to the frame.
Procedure for refitting pistons and cylinder.
Procedure for assembling the primary transmission components.
Description of the clutch operating mechanism.
Details on the tachometer drive mechanism.
Description of the electric starter mechanism.
Details and components of the starter motor assembly.
Diagram illustrating starter gear reduction and drive track.
Procedure for setting ignition timing with the engine static.
Procedure for setting ignition timing using a stroboscope.
Steps to expose the auto advance unit mechanism for inspection.
Procedure for adjusting the gaps on contact breaker points.
Details on the primary chain and its maintenance.
Procedure for adjusting the rear chain tension.
Description of the gearbox and changes specific to the Mark III model.
Procedure for dismantling the motorcycle gearbox.
Steps for removing the gearbox outer cover.
Procedure for removing the gearbox inner cover.
Instructions for dismantling the gearbox gear cluster and cam plate.
Guidance on inspecting gearbox components for wear and damage.
Procedure for removing the complete gearbox assembly.
Details regarding the countershaft (final drive) sprocket.
Procedure for refitting the gearbox gear cluster and selectors.
Procedure for refitting the gearbox inner cover.
Instructions for dismantling and reassembling the gearbox outer cover.
Procedure for refitting the gearbox outer cover.
Description of the Amal concentric carburetors.
Procedure for removing the carburetors from the motorcycle.
Instructions for dismantling the carburetors.
Guidance on examining carburetor parts for wear or damage.
Procedure for reassembling the carburetors.
Details on the fuel tap system.
Procedure for adjusting carburetor settings.
Instructions for adjusting carburetors for different altitudes.
Procedure for periodic adjustment of twin carburetors.
Procedure for removing and refitting the air filter element.
Procedure for removing the engine and gearbox power unit.
Description of the isolastic engine mounting system.
Instructions for checking frame dimensions and alignment.
Procedure for refitting the engine and gearbox power unit.
Procedure for removing and replacing the fuel tank.
Procedure for removing and refitting the oil tank.
Procedure for removing and refitting the left and right side covers.
Instructions for adjusting isolastic engine mountings.
Procedure for checking and adjusting front mounting clearance.
Procedure for reassembling the front mounting.
Notes and considerations for rear mounting.
Procedure for removing and refitting the rear fender.
Procedure for removing the exhaust system.
Description of the Commando front fork system.
Explanation of the operational principles of the front forks.
Procedure for removing the front fork assembly.
Instructions for dismantling the front fork leg.
Procedure for reassembling the front fork leg.
Procedure for renewing steering head bearings.
Procedure for adjusting the steering head.
Procedure for refitting the front fork assembly.
Procedure for removing the rear wheel.
Procedure for refitting the rear wheel.
Procedure for complete removal of the rear wheel.
Instructions for dismantling the rear hub.
Procedure for reassembling the rear hub.
Procedure for reassembling the sprocket bearing.
Instructions for dismantling the front hub.
Procedure for reassembling the front hub.
Explanation of the function of disc brakes.
Details on Norton Lockheed hydraulically operated disc brakes.
Procedure for adjusting the rear brake pedal.
Procedure for renewing front brake caliper pads.
Information on the hydraulic brake fluid system.
Procedure for overhauling the brake caliper.
Procedure for reassembling the brake caliper.
Procedure for overhauling the master cylinder.
Procedure for reassembling the master cylinder.
Procedure for bleeding and flushing the hydraulic brake system.
Procedure for flushing the hydraulic brake system.
Notes and considerations for the rear brake.
Procedure for adjusting the rear brake pedal.
Procedure for checking the brake fluid level.
Procedure for removing the front tire.
Procedure for refitting the front tire.
Procedure for removing the rear tire.
Procedure for refitting the rear tire.
Description of the Commando electrical system.
Details on the motorcycle's charging system.
Technical details of the Lucas RM23 alternator.
Technical details of the 2DV.406 rectifier.
Details on the Zener diode component.
Information on battery maintenance and charging.
Wiring diagrams and information for electrical troubleshooting.
Details on the warning light unit and its operation.
Description and operation of the master switch.
Procedures for testing the motorcycle's ignition system.
Details on the motorcycle's ignition coils.
Details on the ballast resistor used in the electrical system.
Procedure for testing the condenser (capacitor) pack.
Information on the emergency start capacitor.
Details on the motorcycle's lighting system.
Procedure for changing headlamp and pilot bulbs.
Procedure for changing tail/stop bulbs and ballast.
Details on brake stop lights and neutral indicator switch.
Overview of handlebar switch clusters.
Details on the power take-off socket.
Details on flashing direction indicators.
Details on the HC3 alternating horn set.
Procedure for adjusting single standard horns.
Procedure for fitting a Lucar connector.
Instructions for constructing a one ohm resistor.
Details on the electric starter motor.
A visual chart indicating lubrication points on the motorcycle.
Procedure and guidelines for breaking in a new motorcycle.
Information regarding the recommended fuel for the motorcycle.
Details on the complimentary service check offered for new motorcycles.
Overview of routine maintenance tasks and schedules.
Details for Service A, covering specific maintenance tasks.
Details for Service B, covering additional maintenance tasks.
Details for Service C, covering further maintenance tasks.
A table detailing maintenance tasks and intervals.
Procedure for checking the engine oil level.
Procedure for changing the engine oil.
Procedure for checking the gearbox oil level.
Procedure for changing the gearbox oil.
Procedure for checking the primary chaincase oil level.
Procedure for changing the primary chaincase oil.
Procedure for lubricating the swinging arm pivot.
Procedure for changing the oil in the front forks.
Procedure for checking the hydraulic brake fluid level.
Procedure for checking the battery electrolyte level.
Procedure for checking and replacing spark plugs.
Guidelines for checking tire pressures.
Procedure for lubricating the rear chain.
Overview of adjustments for engine and ignition systems.
Procedure for adjusting rocker clearances.
Procedure for ignition timing and contact breaker points adjustment.
Details on the auto advance unit.
Procedure for checking engine camshaft chain tension.
Procedure for adjusting the drive chains.
Procedure for adjusting carburetors.
Procedure for air filter maintenance and cleaning.
Procedure for adjusting the clutch.
Details on steering head bearings.
Procedure for adjusting disc brakes.
Procedure for adjusting isolastic suspension.
Procedure for adjusting the suspensory spring.
Procedure for disc brake maintenance.
Guidance for tracing and troubleshooting common engine and electrical issues.
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