BOLT, BUTTON HEAD, INT HEX, M10 X 20 43 DISK, PATCHLOCKED

PADS, BRAKE, REAR, SINTERED.

TO BE USED WITH 32MM REAR CALIPER

Specifications

Item Standard Service Limit

Clutch

Friction plate thickness 2.9~3.1mm 2.75 Friction and steel plate

warp 0.2mm or less 0.3mm

Clutch spring free length 54mm 52.75mm

Clutch Lever and Hose

107  Pull the lever forward and twist the adjuster [A] to move the lever forwards and backwards.

Clutch Fluid

Warning: When working the clutch, observe the precautions listed below.

 Never reuse old clutch fluid.

 Do not use fluid from a container that has been left unsealed or that has been open for a long time.

 Do not mix two types and brands of fluid for use in the clutch. It may cause the rubber brake parts to deteriorate.

 Don’t leave the reservoir cap [A] off for any length of time to avoid moisture contamination of the fluid.

 Don’t change the fluid in the rain or when a strong wind is blowing.

 Except for internal clutch parts, use only clutch fluid, isopropyl alcohol, or ethyl alcohol for cleaning clutch parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the clutch.  Clutch fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away

immediately.

 If any of the clutch line fittings or bleed valve is open at any time, the AIRMUST BE BLED FROM THE CLUTCH.

Clutch Fluid Recommendation

Recommended fluids are given below. If none of the recommended fluids are available, use extra heavy-duty brake fluid only from a container marked D.O.T. 4.

Note: Clutch fluid of D.O.T. 4 is installed in the clutch system when shipped.

Recommended Clutch Fluid Type D.O.T. 4

Brand: Fuchs Silkolene

Spec. FMVSS 116 D.O.T. 4, D.O.T. 3, ISO 4925 AND SAE J 1703, (or above)

Clutch Fluid Level Inspection

In accordance with the Periodic Maintenance Chart, inspect the clutch fluid level in the clutch fluid reservoirs.

108  Check the clutch fluid level in the reservoir.

Note: Hold the reservoir horizontal when checking clutch fluid level.

Warning: Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that is in the reservoir are unidentified

 Check the fluid in the clutch reservoir [A] is above the lower level line [B].

 If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir with the same type and brand of the fluid that already is in the reservoir.

Clutch Fluid Changing

 Remove the reservoir cap and the rubber cap on the bleed valve.

 Attach a clear plastic hose to the bleed valve on the slave, and run the other end of the hose into a container.  Fill the reservoir with new clutch fluid.

 Change the clutch fluid as follows.  Open the bleed valve [A].

 Apply the clutch level and hold it [B].  Close the bleed valve [A].

 Release the clutch lever [B].

 If the fluid in the reservoir runs completely out at any time during fluid changing, air will enter the line, and the system must be bled.

 Repeat this operation until fresh clutch fluid comes out into the plastic hose or the colour of the fluid changes.

Warning: Do not mix brands of fluid. Change the clutch fluid in the clutch line completely if the clutch fluid must be

refilled but the type and brand of the clutch fluid that is already in the reservoir are unidentified. Torque – Bleed Valve: 7 Nm

 Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings. A B A C B A B

109 Warning: If the clutch level or pedal has a soft or “spongy feeling” when it is applied, there might be air in the clutch line or the clutch line may be defective. Since it is dangerous to operate the motorcycle under such conditions, bleed the air from the brake line immediately.

Clutch Line Air Bleeding

 Bleed the air line whenever clutch parts are replaced or reassembled.

 Remove the reservoir cap and fill the reservoir with new clutch fluid.

 Slowly pump the clutch lever several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir. This bleeds the air from the master cylinder and the brake line.

 Tap the brake hose lightly going from the slave cylinder to the reservoir side and bleed the air off at the reservoir.

 Attach a clear plastic hose to the bleed valve on the slave cylinder, and run the other end of the hose into a

container.

 Bleed the brake line and the caliper as follows.  Hold the clutch lever applied [A].

 Quickly open and close the valve [B].  Release the clutch lever [A].

 The fluid level must be checked several times during bleeding operation and replenished as necessary.

 If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.

 If the brake lever or pedal action still feels soft or “spongy”, tap the clutch hose from bottom to top and air will rise up to the top part of the hose. Slowly pump the clutch in the same manner as above

Torque - Bleed Valve: 7 Nm

Torque - Reservoir Cap Screws (integral reservoir only): 1.5Nm

 Apply the clutch lever forcefully for a few seconds, and check for fluid leakage around the fittings.

Clutch Slave Cylinder

A B

110

Clutch Slave Cylinder Removal

 Remove three mounting bolts [A].

 Remove Slave cylinder, and support plate with ball bearing.

Clutch Slave Cylinder Installation

 Put Red Grease on the support plate [B] and ball bearing[C] to stop them falling out while being installed.

 Install the clutch slave cylinder.

Torque: Clutch Slave Cylinder bolts: 6NM

Clutch Slave Cylinder Inspection

 Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace slave cylinder.

Clutch Master Cylinder

Clutch Master Cylinder Removal

 Integral reservoir: Remove mounting bolts [A].  Integral reservoir: Remove brake light connection.  Integral reservoir: Remove lever assembly.

 Remote reservoir: Remove mounting bolts [B]  Remote reservoir: Remove brake light connection.  Remote reservoir: Remove lever assembly.

Clutch Master Cylinder Installation

A

B

C

B A

111  Integral reservoir: install lever assembly.

 Integral reservoir: install brake light connection.  Integral reservoir: install mounting bolts [A].

 Position level to owners preference, ensure correct operation and clearance.  Tighten top bolt.

Torque: Clutch Master Cylinder bolts: 6NM

 Tighten bottom bolt.

Torque: Clutch Master Cylinder bolts: 6NM

 Remote reservoir: install lever assembly.

 Remote reservoir: install brake light connection.  Remote reservoir: install mounting bolts [B]

 Position level to owners preference, ensure correct operation and clearance.

 Tighten top bolt.

Torque: Clutch Master Cylinder bolts: 6NM

 Tighten bottom bolt.

Torque: Clutch Master Cylinder bolts: 6NM

Clutch Master Cylinder Inspection

 Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace lever assembly.

Clutch Hose

Clutch Hose Removal

 Drain Clutch Fluid (see Clutch Fluid Changing).

 Remove clutch slave cylinder banjo bolt and drain any remained fluid into a suitable container.  Remove clutch master cylinder banjo bolt and remove clutch hose, taking note of hose routing. Clutch Hose Installation

B A

112  Install hose in reverse order to removal, ensuring hose is not, and will not be trapped or crushed

during vehicle operation.

 Install slave and master cylinder banjo bolts and tighten.

Torque: Clutch Banjo Bolts: 25Nm Clutch Hose Inspection

 Inspect surface for evidence of ware, corrosion, leakage or pitting, if any evidence exists replace hose.

Clutch Cover

Clutch Cover Removal

 Drain Gear Box oil (see Engine Lubrication System chapter).

 Remove:

 Splined gear selector arm (see Gear chapter).

 Take out the sixteen bolts [A] and remove the clutch cover [B].

Clutch Cover Installation

B

A

113  Install:

o Dowel Pins [A]

o Clutch Cover Gasket [B]  Install the clutch cover.

Torque - Clutch cover Bolts 12Nm

Clutch Release Removal

 Remove the sprocket cover bolts [A].  Remove sprocket cover.

 Remove six M6 clutch spring bolts, washers and springs.

 Remove clutch centre, friction plates and steel plates.

 Remove clutch push rods. Take note of assembly sequence.

B

B

114

Clutch release Installation

 Apply clean engine oil to all clutch parts.

 Install clutch centre, friction plates and steel plates.

 Install six M6 clutch spring bolts, washers and springs.

Torque – clutch spring bolts to 12Nm

 Install clutch push rods.

 Install sprocket cover and sprocket cover bolts.

Torque – Sprocket cover bolts to 20Nm

Clutch

Clutch Removal

 Remove six M6 clutch spring bolts, washers and springs.

 Remove clutch centre, friction plates and steel plates,

115  Using the clutch holder, hold the clutch hub to

remove the clutch hub nut [B] and hub [A]

 Remove:

o Basket [A]

o Two spacers [B] and [C]

Clutch Installation

 Install:  Spacer [A]  Spacer [B]

 Clutch Housing (with bearing)

 Install:

 Clutch hub [A] (with bearing)  Hub nut

Torque - Clutch hub nut 122Nm Threebond 1327

B A B C A A B

116  Install the friction plates and steel plates, starting with a

friction plate alternating them.

Caution: If new dry friction plate and steel plates are installed, apply engine oil to the surface of each plate and leave to soak overnight, to avoid clutch plate seizure.

 Install the last friction plate fitting the tangs in the grooves on the housing as shown.

 Apply engine oil to all bearings and clutch parts.  Install the clutch spring plate, springs and washers.

Torque – Clutch Spring Bolts: 12Nm

 Install the clutch cover.

Friction and Steel Plate Damage, Wear Inspection

 Visually inspect the friction and steel plates for signs of seizure, overheating (discoloration), or uneven wear.  Measure the thickness of the friction plates at several

points.

 If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones.

Friction Plate Thickness

Standard: 2.9 mm ~ 3.1 mm Service Limit: 2.75 mm

Friction and steel Plate Warp Inspection

 Place each friction plate or steel plate on a surface plate, and measure the gap between the surface plate and each friction plate or steel plate with a thickness gauge. The gap is the amount of friction or steel plate warp.

 If any plate is warped over the service limit, replace it with a new one.

Friction and Steel plate Warp

Standard: 0.2 mm or less Service Limit: 0.3 mm

117

Cutch Spring Free Length Measurement

 Measure the free length of the clutch springs.

 If any spring is shorter than the service limit, it must be replaced.

Clutch Spring Free Length Standard: 54 mm Service Limit: 52.75 mm

Clutch Housing Finger Damage

 Visually inspect the clutch housing fingers [A] where the friction plate tangs hit them.

 If they are badly worn or if there are groove cuts where the tangs hit, replace the housing. Also, replace the friction plates if their tangs are damaged.

Clutch Hub Spline Damage

 Visually inspect where the teeth on the steel plates wear against the clutch hub splines.

 If there are notches worn into the clutch hub splines, replace the clutch hub. Also, replace the steel plates if their teeth are damaged.

Primary Gear

Primary Gear Removal

 Remove the clutch cover (see clutch Cover Removal).  Use a gear holder or if one is not available use a copper

coin between the primary and balance gear to lock the engine rotation.

 Remove:

o Primary Gear Nut o Primary Gear Washer

118  Remove the primary gear.

 Remove woodruff key.

Primary Gear Installation

 Install:

o Woodruff key [A] (identical parts)

o Primary Gear [B]

o Primary Gear Washer [C]

 Use a gear holder or if one is not available use a copper coin between the primary and balance gear to lock the engine rotation.

 Tighten primary nut.

Torque – 122Nm Threebond 1305

 Install the clutch cover (see clutch Cover Removal).

B

C A

119

Engine Lubrication System

Exploded View ... 121 Engine Oil flow charts ... 123 Specification ... 128 Engine Oil and Oil Filter ... 129 Oil Inspection ... 129 Oil Draining ... 129 Oil Filling ... 130 Oil Filter Change ... 130 Gearbox ... Gearbox Oil Draining ... 131 Gearbox Oil Filling ... 131 Relief Valve Opening Pressure Measurement ... 131 Oil Pressure Measurement ... 132 Oil Pump ... 133 Oil Pipe Removal ... 133 Oil Pipe Installation ... 133 Oil Pipe Inspection ... 133 Relief Valve Inspection ... 133 Oil Pipe ... 134 Oil Pipe Removal ... 134 Oil Pipe Installation ... 136

120

Engine Oil Flow

Note: Oil is sucked from the back of the oil tank [1] and pumped under pressure through the engine oil feed system.

Oil is scavenged from the sump by the oil pump [2] and pumped through the radiator [3] into the oil tank [4].

The oil tank LH breather [5], vents into the back of the head. The crank case breather [6] breathes into the LH rocker cover. The RH rocker cover breather [7] breathes into the air box.

1 2 3 4 5 7 6

122 REF.

NO. PART DESCRIPTION

TORQUE

(NM) REMARKS

25 COVER ASSY, ROCKER

1 COVER, ROCKER, MACH

2 GASKET, ROCKER, COVER

3 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12

5 BANJO,M14, 9MM SPIGOT

6 WASHER, M14, OD 20.0MM X 2.5 ALUMINIUM

7 WASHER, M14, OD 20.4MM X 1.22, COPPER

8 BOLT, BANJO, M14 22

22 NUT, M14 X 1.5, THIN, STEEL

23 BOLT, BANJO, M14, MOD 22

24 BREATHER BAFFLE, ASSY

BREATHER BAFFLE, FRONT

BREATHER BAFFLE, REAR

BREATHER BAFFLE, WELD NUT

9 COVER, RH, MC/D

10 GASKET, COVER, RH

11 DOWEL, RING, 7.8MM DIA

26 COVER ASSY, OIL FILTER

12 COVER, OIL FILTER, MC/D

27 TOP HAT, OIL FILTER, COVER

28 BELLEVILLE, SPRING

29 O-RING, 14MM X 2MM, VITON

30 RING, WIRE, 18MM, PLAIN, EXTERNAL

13 O-RING, 67MM X 2 MM, VITON

14 BOLT, CAP HD, M5x0.8x14, DIN 912, A2/70 5

15 BOLT, CAP HD, M6 X 20 x 1.0, DIN 912, SS 12

16 COVER, CLUTCH, MC/D

17 GASKET, COVER, CLUTCH

11 DOWEL, RING, 7.8MM DIA

18 BOLT, CAP HD, M6 X 40, DIN 912, SS 12

19 BOLT, CAP HD, M6 X 30 X 1.0, SS 12

In document NORTON Commando 961 - Service Manual (Page 106-122)