Norton Commando 850 - Refitting the Gearbox Outer Cover; Pawl Carrier, Spring and Pichet Plate Assembled

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Contents4
Technical Data10
Technical Data: Frame, Engine Mountings and Rear Suspension Units11
Technical Data: Speedometer Gearing11
Technical Data: Wheels and Brakes12
Technical Data: Electrical13
Technical Data: Engine14
Technical Data: Torque Settings18
Technical Data: Gearbox19
Technical Data: Capacities20
Technical Data: Miscellaneous Data21
Technical Data: Special Workshop Tools22
Conversion Tables24
U.N.E.F., U.N.F., U.N.C. Threads25
B.A., B.S.W., B.S.F. Threads25
Wire Gauges Conversion Table26
Drill Sizes Conversion Table26
Pints to Liters Conversion Table27
Gallons to Liters Conversion Table27
Miles to Kilometers Conversion Table27
Miles Per Gallon to Liters Per 100 Kilometers27
Pounds Per Square Inch to Kilograms Per Square Centimetre Conversion Table28
Pounds to Kilograms Conversion Table28
Foot Pounds to Kilogrameters Conversion Table28
Millimeters to Inches Conversion Table29
Inches to Millimeters (Decimals Of) Conversion Table30
Fractions to Decimals - Decimals of Inch to Millimetre Conversion Table30
Engine and Primary Transmission31
Engine and Primary Transmission: Exploded View32
Engine/Primary Drive33
Removing Cylinder Head33
Tightening Sequence33
Removal of Rockers34
Valve Removal and Reassembly35
Rocker Thrust Washers and Securing Plates35
Extracting Rocker Spindles Using Slide Hammer 06429835
Decarbonising36
Valve Guide Renewal36
Using Valve Guide Tool 063964 to Remove a Valve Guide37
Reseating the Valves38
Grinding-In the Valves38
Aligning Rocker Spindle38
Refitting Rockers39
Refitting Cylinder Head39
Guiding Pushrods into Engagement with the Rockers39
Rocker Clearances40
Removing Cylinder and Pistons41
Checking Valve Clearances41
Support Connecting Rods to Prevent Damage against Crankcases41
Cylinder Reboring and Oversize Pistons42
Supporting Piston Body Whilst Pushing out Gudgeon Pin42
Removing Primary Chaincase43
Dismantling Primary Transmission and Clutch43
Removing Rotor Nut Whilist Applying Rear Brake to Prevent Movement43
Diaphragm Spring Compressor Tool 060999 in Use44
Removing Crankcase Assembly from Frame45
Removing Engine Sprocket Clutch and Primary Chain as a Set45
Using a Screwdriver Blade to Peel Circlip Away from Housing45
Use of Engine Sprocket Puller 06429745
Dismantling the Crankcases46
Removal of the Crankcase Assembly from Mounting Plates46
Showing Crankcases Supported by a Bar to Remove Sump Filter46
Showing Crankcases Mounted in a Plain Jaw Vice for Ease of Handling46
Removing Contact Breaker Cam Using Slide Hammer 06429847
Using a Spanner to Turn the Oil Pump Drive Wheel Nut and Remove the Pump47
Preventing Flywheel Turning by Use of a Bar Lodged in a Flywheel Balance Hole48
Extracting Crankshaft Pinion Tool ET 200348
Parting the Crankcase Using a Wood Block against the Inner Drive Side49
Crankcase Overhaul50
Removing Connecting Rods50
Showing Suitable Tube to Abutt to Crankshaft Shoulder yet Pass through Crankcase50
Supporting the Crankcase Shoulder on a Tube Whilist Separating the Crankcase from the Crankshaft50
Dismantling the Cranckshaft51
Cranckshaft Inspection and Regrinding51
Engine Lubrication System51
Removing Roller Bearing Inner Race Using Extractor 06397051
Engine Lubrication System 850 Models53
Oil Pressure Relief Valve54
Crankcase Breather54
Servicing the Oil Pump54
Oil Pump54
Timing Cover55
Contact Breaker Seal, Crankshaft Seal55
Showing Blanking Plug in Position in Timing Cover55
Positions and Lengths of Odd Timing Cover Screws55
Re-Assembly of the Crankshaft56
Re-Assembling Connecting Rods to Crankshaft56
Showing Crankcheek to Flywheel Securing Hardware56
Connecting Rods Showing both Sides of Big and Eye and Bearing Shell Tab Locations56
Re-Assembling Crankshaft to Crankcases57
Pushing Timing Side Crankcase over Crankshaft57
Mating Crankcases57
Assembling Right (Timing Side) of Engine58
Assembly of Timing Chain and Sprockets58
Refitting the Timing Cover59
Chain Tensioner Showing Thin Inner Plate Long End Downwards59
Re-Assembly of Crankcase Assembly to Frame60
Inserting Front Left Gaiter Mounting Cap Group60
Lifting Front Mounting into Position Using Bottom Bolt as Pivot60
Refitting Pistons and Cylinder61
Priming Crankshaft with Oil61
Assembling Primary Transmission62
Fitting Cylinder over Pistons62
850 Cylinder Base Securing Torque62
Using Grip Wrench to Squeeze over Tab Washers at Inner Chaincase63
Winding Diaphragm Spring Circlip into Position63
Clutch Operating Lever in Correct Position64
Clutch Operating Lever in Wrong Position Where Lever Has Dropped down64
Clutch Operating Mechanism65
Clutch Plates65
Clutch Adjustment65
Plate Inspection65
Tachometer Drive66
Removing and Refitting Engine Complete66
Ignition Timing66
Ignition Timing Basic Procedure Prior to Checking67
Ignition Timing Procedure - Engine Static67
Timing Plate Visible after Removal of Inspection Cap from Chaincase67
Ignition Timing Procedure - Engine Running68
Auto Advance Unit69
Contact Breaker Assembly69
Adjusting Contact Breaker Points Gap69
C50 Lucas Contact Breaker69
Maintenance of the Contact Breaker70
Primary Chain Adjustment70
Chain Serviceability70
Rear Chain Adjustment71
Gearbox72
Gearbox Description73
Gearbox Dismantling73
Removing Gearbox Outer Cover73
Removing Gearbox Inner Cover73
Dismantling Gear Cluster and Cam Plate74
Inspection of Gearbox Parts74
Removal of Gearbox Complete75
Countershaft (Gearbox Final Drive) Sprocket75
Changing the Countershaft Sprocket75
Refitting Gear Cluster and Selectors76
Mainshaft and Layshaft Fitted to Gearbox Shell76
Location of Camplate to Index Plunger76
Refitting Gearbox Inner Cover77
Gear Layout77
Showing Kickshaft Pawl Stop on Inner Cover77
Dismantling and Re-Assembling Gearbox Outer Cover78
Kickstart Spring Located78
Order of Assembly of Clutch Withdrawal Lever78
Refitting the Gearbox Outer Cover79
Pawl Carrier, Spring and Pichet Plate Assembled79
Carburetor80
Carburetor Removal81
Amal Concentric Float Carburetor81
Carburetor Dismantling82
Carburetor Reassembly82
Examination of Carburetor Parts82
Fuel Taps83
Carburetor Adjustment83
Twin Carburetor Adjustment84
Adjustment for Altitude84
Air Filter85
Removing and Refitting the Elements85
Cleaning the Air Filter Element85
Removing Air Filter and Gauze Band85
Frame and Ancillaries86
Removal of Power Unit87
Removing Oil Junction Block Securing Bolt87
Lifting out Power Unit to Right Side88
Isolastic Engine Mountings89
Commando Parted to Show Isolastic Mounting Points89
Frame Checking Charts90
Frame Checking Dimensions91
Refitting Power Unit91
Gaiter/Collar Group Ready to Fit91
Coil Cluster from Rear Beneath92
Swinging Arm Offered into Position with End Cap Held in Place with Grease93
Aligning Swinging Arm Spindle with Swinging Arm Bore94
Spindle Lock Bolt Fitted94
Removing and Refitting Suspension Units95
Rear Suspension Units (Girling)95
Changing the Spring95
Rebushing the Swinging Fork95
Removing and Replacing Fuel Tank96
Swinging Arm Bushes Showing Order of Assembly96
Removing and Refitting Oil Tank98
L.H. Accessory and R.H. Covers99
Shimming Engine Mountings99
Checking Rear Shimming, Front Shimming99
Adjusting Front Shimming99
Adjusting Rear Shimming101
Holding Front Mounting in a Vice for Checking101
Using Service Tool 063971 to Insert Front Isolatic Rubber Bushes102
Renewal of Rubbers and Buffers103
Renewing Isolastic Mounting Rubbers103
Isolastic Mountings Exploded View103
Rear Fender104
Exhaust System Removing and Refitting105
750 Low Lever Exhaust Systems106
S Type Exhaust107
850 Exhaust Systems108
Front Forks/Steering109
Fork at Rest, Compressing, Extending and Almost Fully Extended110
Front Fork Description112
Fork at Rest112
How Fork Works112
Fork Extending , Fork Compresses112
Removal of Front Forks113
Hydraulic System Removed Complete113
Shocking Main Tubes Free of Upper Yoke114
Dismantling Fork Leg115
Front Fork Exploded View115
Reassembling Fork Leg116
Hydraulic System Fitting to Fork Leg116
Releasing Damper Rod from Fork Top Bolts116
Renewing Steering Head Bearings117
Steering Head Adjustment117
Refitting Font Forks118
Showing Stem Nut Tab Washer Locked to Nut119
Brakes, Wheels and Tires120
Removing Rear Wheel121
Refitting of Rear Wheel122
Complete Rear Wheel Removal122
Paddles and Shock Absorbing Pads122
Rear Hub Dismantling123
1970 Type Rear Wheel Exploded123
1971 Onwards Rear Wheel Exploded124
Rear Hub Reassembly125
Removing and Refitting Front Wheel126
Disk Brake Front Wheel Removal126
Dismantling Front Hub, Disc Type127
Guiding Brake Disc between Brake Pads127
Removing and Refitting Front Wheel (Drum Type Brake)128
Drum Front Brake External Features128
Front Wheel Bearing Overhaul (Drum Brake)129
Front Brake Adjustment (Drum Brake)129
Twin Leading Shoe Brake Plate Showing Link Rod129
Front Brake (Disc Type)130
Rear Brake Adjustment130
Overhauling Drum Brakes130
Setting the Link Rod130
Rear Brake Dismantling131
Rear Brake Reassembly131
Twin Leading Shoe Brake131
Front Brake131
Front Brake with High Performance Modification132
Twin Leading Shoe Brake with High Performance Modification132
Norton Lockheed Hydraulically Operated Disc Brake133
Caliper Friction Pad Removal133
Exploded View of Caliper Group133
Caliper Overhaul134
Caliper Component Inspection134
Caliper Re-Assembly135
Master Cylinder Overhaul136
Master Cylinder Exploded View136
Master Cylinder Removal137
Master Cylinder Dismantling137
Inspection of Master Cylinder and Components137
Master Cylinder Reassembly137
Tires139
Master Cylinder Refitting139
Bleeding the Hydraulic Brake System139
Removing Front Tire140
Refitting Front Tire141
Removing Rear Tire141
Refitting Rear Tire142
First Bead Levered into the Rim142
Careful Levering of Second Bead over Wheel Rim142
Lifting Cover and Engaging Security Bolt to Rim143
Pressing Security Bolt Back through Rim Whilist Levering Second Bead into Position143
Electrical144
Charging System145
Alternator - Lucas Type RM21145
Alternator Maintenance145
Testing the Alternator in Situ145
Rectifier Type 2DS 506146
Testing the DC Input to Battery146
Alternator Test146
Rectifier Test Connections146
Testing the Rectifier147
Bench Testing the Rectifier147
Zener Diode148
Testing the Zener Diode148
Battery Maintenance148
Fuse, Ignition Switch, Master Switch149
Warning Light Assimilator149
High Rate Discharge Check149
Testing Ignition System150
Ignition Coils150
Ignition and Lights150
Ignition System Tests150
Ignition Coils Lucas Type 17M6 1971 and Later Models/Type 17M12 Certain 1972 Models151
Testing an Ignition Coil (17M6 and 17M12 Types)151
Connect Breaker Assembly - Lucas Type 6CA151
Ballast Resistors, Capacitor Pack Testing151
Changing a Capacitor152
Spark Plugs - Champion N7Y152
Lighting System, Stop Switches152
To Change the Headlamp and Pilot Bulbs, to Change the Tail/Stomplamp Bulb152
Handlebar Switch Clusters153
Power Take-Off Socket153
Front Brake Stop Switch153
Rear Stop Switch Adjustment153
Flashing Direction Indicators154
Alternator Horn Set Interpol Only Type HC3154
Bulb Replacement, Checking for Faulty Operation154
HC 3 Alternating Horn Control154
Relays155
Horn: Testing Procedure155
Returning the 9H Alternating Horns155
Contact Adjustment on Motorcycle155
Electrolytic Capacitor 2MC156
Horn Adjustment (Single Standard Horn)156
Horn in Position156
How to Make up a One Ohm Resistors157
Pre-1971 Wiring Diagram158
1971 Wiring Diagram159
1972 And 1973 Wiring Diagram160
Routine Maintenance161
Routine Maintenance: Points162
Breaking in163
Lubrication Chart164
Maintenance Table165
Engine Oil Tank Level166
Engine Oil Changing166
Oil Tank Filter and Drain Plug166
1970 S Roadster Oil Tank Unions166
Crankcase Strainer and Drain Plug167
Crankcase Gauze Strainer167
Cartridge Type Oil Filter Location167
Gearbox Oil Level, Gearbox Oil Changing168
Primary Chaincase Oil Changing, Oil Level168
Swinging Arm Pivot Lubrication168
Front Fork Oil Changing168
Checking Hydraulic Brake Fluid Level169
Refilling Fork Leg with Cap Bolt Removed169
Checking Master Cylinder Hydraulic Fluid Level169
Checking Battery Electrolyte Level170
Spark Plugs170
Tire Pressures170
Battery Electrolyte Level Mark170
Adjusting Cam Timing Chain171

Norton Commando 850 - Refitting the Gearbox Outer Cover; Pawl Carrier, Spring and Pichet Plate Assembled

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