Norton Commando 961 User manual

Norton Motorcycles Service Manual
Commando 961 –All variants

2
Quick Reference Guide
1General Information.................................................................................................................................................. 8
2Fuel System ............................................................................................................................................................. 28
3Cooling System ........................................................................................................................................................ 43
4Engine Top End........................................................................................................................................................ 55
5Clutch...................................................................................................................................................................... 96
6Engine Lubrication System .................................................................................................................................... 117
7Engine Removal / Installation ............................................................................................................................... 137
8Crankshaft / Transmission..................................................................................................................................... 143
9Wheels / Tyres....................................................................................................................................................... 170
10 Final Drive.............................................................................................................................................................. 187
11 Brakes.................................................................................................................................................................... 196
12 Suspension ............................................................................................................................................................ 219
13 Steering ................................................................................................................................................................. 256
14 Frame .................................................................................................................................................................... 271
15 Electrical System ................................................................................................................................................... 284
16 Appendix ............................................................................................................................................................... 322

3
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Norton Motorcycles (UK) Ltd.
No Liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring obligation to
make such changes to produce manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the
time of publication. Illustrations and photographs in this publication are intended for reference use only
and may not depict actual model component parts.

4
Emission Control Information
To protect the environment in which we all live, Norton motorcycles (UK) ltd has incorporated crankcase
emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the
United States Environmental Protection Agency and California Air Resources Board. Additionally, Norton
has incorporated an evaporative emission control system (3) in compliance with applicable regulations of
the California Air Resources Board on vehicles sold in California only.
Crankcase Emission Control System:
This system eliminates the release of crankcase vapours into the atmosphere. Instead, the vapours
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapours are drawn into combustion chamber, where they are burned along with the fuel and
air supplied by the injection system.
Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of
this motorcycle. The fuel and ignition systems of this motorcycle have been carefully designed and
constructed to ensure an efficient engine with low exhaust pollutant levels.
Evaporative Emission Control System
Vapours caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead,
fuel vapours are routed into the running engine to be burned, or stored in a canister when the
engine is stopped.
The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly
referred to as the Act’s “tampering provisions”.
“Sec. 203(a) the following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or element of design installed
on or in a motor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or
dealer knowingly to remove or render inoperative any such device or element of design
after such sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicles engines, or who operates a fleet of motor vehicles
knowingly to remove or render inoperative any device or element of design installed on or
in a motor vehicle or motor vehicle engine in compliance with regulations under this title
following its sale and delivery to the ultimate purchaser...”

5
Note: The phrase “remove or render inoperative any device or element of design” has been generally
interpreted as follows:
Tampering does not include the temporary rendering inoperative of devices or elements of design
in order to perform maintenance.
Tampering could include:
Maladjustment or vehicle components such that the emissions standards are exceeded.
Use of replacement parts or accessories which adversely affect the performance or durability of the
motorcycle.
Addition of components or accessories that result in the vehicle exceeding the standards.
Permanently removing, disconnecting, or rendering inoperative any component or element of
design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF
WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.
Tampering With Noise Control System Prohibited
Owners are warned that the law may prohibit:
The removal or rendering inoperative by any person other than for purposes of maintenance, repair
or replacement, of any device or element of design incorporated into any new vehicle for the
purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is use; and
The use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by
any person other than for purposes of maintenance, repair, or replacement, of any device or element of
design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design
has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with components not in compliance with
federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or intake system by cutting, drilling, or other means if such
modifications results in increased noise levels.

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Foreword
This Manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it
contains enough detail and basic information to make it useful to the owner who desires to perform his
own basic maintenance, the proper use of tools, and workshop procedures must be understood in order to
carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts
his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified
mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly
familiarize yourself with the procedures before starting work, and then do the work carefully in a clean
area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment.
Precision measurements can only be made if the proper instruments are used, and the use of substitute
tools may adversely affect safe operation.
For the duration of the warranty period, especially, we recommend that all repairs and scheduled
maintenance be performed in accordance with the service manual. Any owner maintenance or repair
procedure not preformed in accordance with this manual may void the warranty. To get the longest life
out of your Motorcycle:
Follow the Periodic Maintenance Chart in the Service Manual.
Be alert for problems and non-scheduled maintenance.
Use proper tools and genuine Norton Motorcycle parts. Special tools, gauges, and testers that are
necessary when servicing Norton motorcycles are introduced by the Special Tool Catalog or
Manual. Genuine parts provided as spare parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully don`t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new parts
installed.
How to use this Manual
In preparing this manual, we divided the product into its major systems. These systems became the
manual`s chapters. All information for a particular system from adjustment through disassembly and
inspection is located in a single chapter.
The Quick Reference Guide shows you all of the products system and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time
schedule for required maintenance; for example, go to the Periodic Maintenance Chart first. The chart tells
you how frequently to change the oil. Next, use the Quick Reference Guide to locate the Engine Lubrication
System chapter. Then, use the Table of Contents on the first page of the chapter to find the Change Engine
Oil section.

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Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe
operation and maintenance practices.
WARNING: This warning symbol identifies special instructions or procedures which, if not correctly
followed, could result in personal injury, or loss of life.
CAUTION: This caution symbol identifies special instructions or procedures which, if not strictly observed,
could result in damage to or destruction of equipment.
This Manual contains four more symbols (in addition to WARNING and CAUTION) which will help you
distinguish types of information.
Note: This note symbol indicates points of particular interest for more efficient and convenient operation.
Indicates a procedural step or work to be done.
oIndicates a procedural sub-step or how to do the work of the procedural step it follows. It
also precedes the text of a NOTE in some cases.
Indicates a conditional step or what action to take based on the results of the test or inspection
in the procedural step or sub-step it follows.
In most chapters an exploded view illustration of the system components follows the Table of Contents to
show assembly sequence.

8
General Information
Before Servicing ................................................................................................................................................. 9
General Specification ....................................................................................................................................... 13
Periodic Maintenance Chart ............................................................................................................................ 16
Torque and Locking Agent ............................................................................................................................... 17
Special tools and Sealant ................................................................................................................................. 24
Cable, Wire and Hose Routing ......................................................................................................................... 26

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Maintenance / Equipment
Consult your authorised Norton dealer whenever there is doubt as to the correct or safe operation of this
Norton motorcycle.
Remember that continued operation of an incorrectly performing motorcycle may aggravate a fault and
may also prejudice safety.
Ensure all equipment that is required by law is installed and functioning correctly.
The removal or alteration of the motorcycle’s lights, silencers, emission or noise control systems can
violate the law. Incorrect or improper modification may adversely affect the handling, stability or other
aspect of the motorcycle operation, which may result in an accident causing injury or death.
If the motorcycle is involved in an accident, collision or fall, it must be taken to an authorised Norton
dealer for inspection and repair.
Any accident can cause damage to the motorcycle that, if not correctly repaired, may cause a second
accident that may result in injury or death.
Before Servicing
Before starting to service a motorcycle, careful reading of the applicable section is recommended to
eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions
have been included wherever necessary. Nevertheless, even a detailed account has limitations; a certain
amount of basic knowledge is also required for successful work.
Especially note the following:
Dirt: Before removal and disassembly, clean the motorcycle. Any dirt entering the engine or other
parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before
installing a new part, clean off any dust or metal fillings.
Battery Ground: Remove the battery ground (-) lead from the battery before performing any
disassembly operations on the motorcycle. This Prevents:
oThe possibility of accidently turning the engine over while partially disassembled.
oSparks at electrical connections which will occur when they are disconnected.
oDamage to electrical parts.
Installation, Assembly: Generally, installation or assembly is the reverse of removal or disassembly.
But if this Service Manual has installation or assembly procedures, follow them.
Tightening Sequence: Generally, when installing a part with several bolts, nut, or screws, start them
all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is
to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the
bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws
must be tightened in the order and method indicated.
Torque: When torque values are given in this Service Manual, use them. Either too little or too
much torque may lead to serious damage. Use a good quality, reliable torque wrench.

10
Force: Common sense should dictate how much force is necessary in assembly and disassembly. If a
part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a rubber, wooden or plastic-faced mallet.
Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in
order to avoid damaging the screw heads.
Edges: Watch for sharp edges, especially during major engine disassembly and assembly. Protect
your hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
High-Flash Point Solvent: A high-flash point solvent is recommended to reduce fire danger. A
commercial solvent commonly available in the UK is Silkolene (generic name). Always follow
manufacturer and container directions regarding the use of any solvent.
Gasket, O-Ring: Do not reuse a gasket or O-ring once it has been in service. The mating surfaces
around the gasket should be free of foreign matter and perfectly smooth to avoid oil or
compression leaks.
Liquid Gasket, Non-Permanent Locking Agent: Follow manufacturer’s directions for cleaning and
preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may
block engine oil passages and cause serious damage. An example of a non-permanent locking agent
commonly available in the UK is Threebond.
Press: A part installed using a press or driver, such as a wheel bearing (hub bearing), should first be
coated with oil on its outer or inner circumference so that it will go into place smoothly.
Ball Bearing, Needle Bearing: Do not remove a ball bearing or a needle bearing unless it is
absolutely necessary. Replace any ball or needle bearings that were removed with new ones, as
removal generally damages bearings. Install bearings with the marked side facing out applying
pressure evenly with a suitable driver. Only press on the race that forms the press fit with the base
component to avoid damaging the bearings. This prevents severe stress on the balls or needles and
races, and prevents races and balls or needles from being dented. Press a ball bearing until it stops
at the stop in the hole or on the shaft.
Oil Seal and Grease Seal: Replace any oil or grease seals that were removed with new ones, as
removal generally damages seals. When pressing in a seal which has manufacturer’s marks, press it
in with the marks facing out. Seals should be pressed into place using a suitable driver, which
contacts evenly with the side of seal, until the face of the seal is even with the end of the hole.
Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce
rubber to metal friction.
Circlip, Retaining Ring: Replace any circlips and retaining rings that were removed with new ones, as
removal weakens and deforms them. When installing circlips and retaining rings, take care to
compress or expand them only enough to install them and no more.
Cotter Pin: Replace any cotter pins that were removed with new ones, as removal deforms and
breaks them.
Lubrication: Engine wear is generally at its maximum while the engine is warming up and before all
the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is
more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and

11
may contain abrasive foreign particles. Don’t use just any oil or grease. Some oils and greases in
particular should be used only in certain applications and may be harmful if used in an application
and may be harmful if used in an application for which they are not intended. This manual makes
reference to molybdenum disulfide grease (MoS2) in the assembly of certain engine and chassis
parts. Always check manufacturer recommendations before using such special lubricants.
Electrical Wires: All the electrical wires are either single-colour or two-colour and, with only a few
exceptions, must be connected to wires of the same colour. On any of the two-colour wires there is
a greater amount of one colour and a lesser amount of a second colour, so a two-colour wire is
identified by first the primary colour and then the secondary colour. For example, a red wire with
thin yellow strips is referred to as a “red/yellow” wire; it would be a “yellow/red” wire if the
colours were reversed to make red the main colour.
Replacement Parts: When there is a replacement instruction, replace these parts with new ones
every time they are removed. These replacement parts will be damaged or lose their original
function once removed.
Inspection: When parts have been disassembled, visually inspect these parts for the following
conditions or other damage. If there is any doubt as to the condition of them, replace them with
new ones.
Abrasion Crack Hardening Warp Bent Dent
Scratch Wear Colour Change Deterioration Seizure
Specifications: Specification terms are defined as follows:
“Standards” show dimensions or performances which brand-new parts or systems have.
“Service Limits” indicate the usable limits. If the measurement shows excessive wear or
deteriorated performance, replace the damaged parts
References to the left-hand or right-hand side given in this manual are made when viewing the
motorcycle from the rear.
Operations covered in this manual do not always include references to testing the motorcycle after
repair. It is essential that work is inspected and tested after completion and if necessary a road test
of the motorcycle is carried out particularly where safety related items are concerned.
Yellow
Wire Strands
Red
Yellow

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List of Abbreviations
A
ampere (s)
lb
pounds(s)
ABDC
after bottom dead centre
m
meter(s)
AC
alternating current
min
minute(s)
ATDC
after top dead centre
N
Newton(s)
BBDC
before bottom dead centre
Pa
Pascal(s)
BDC
bottom dead centre
PS
horsepower
BTDC
before top dead centre
Kw
killer watt(s)
˚C
degree(s) Celsius
psi
pound(s) per square inch
DC
direct current
r
revolution
F
farad(s)
rpm
revolution(s) per minute
˚F
degree(s) Fahrenheit
TDC
top dead centre
ft
foot, feet
TIR
total indicator reading
g
gram(s)
v
volt(s)
h
hours(s)
w
watt(s)
L
litres(s)
Ω
ohm(s)

13
Items
961 SE/SPORT/CAFE RACER
Dimensions:
Overall length
2050 mm
Overall Width
850mm
Overall Height
1110mm
Wheelbase
1430mm
Road clearance
130mm (nominal)
Seat height
810mm
Dry weight
205kg
Curb weight: Front
108kg
Rear
110kg
Fuel tank capacity
17 Litres
Performance:
Minimum turning radius
3m
Engine:
Type
4-Stroke, push-rod, 2-cylinder
Cooling System
Air/oil - cooled
Bore and stroke
88mm
Displacement
79mm
Compression ratio
10.1:1
Maximum / horsepower
59Kw @ 7700rpm
Maximum torque
84Nm @ 6000rpm
Throttle body
Norton Throttle Body 38mm
Starting system
Electric starter
Ignition system
Coil
Timing advance
Electronically advanced
Ignition timing
Controlled by ECU map
Spark plug
NGK CR9EB
Cylinder numbering method
LH:1 RH:2
Firing order
270˚
Valve timing
Inlet Open
36˚ BTDC
Close
60˚ ABDC
Duration
256˚
Exhaust Open
70˚ BBDC
Close
6˚ ATDC
Duration
256˚
Lubrication
Forced lubrication (dry sump)
Engine oil:
Grade
API SG, SH AND SJ, JASO MA
Viscosity
SAE10W-40
Capacity
3 L (from dry)

14
Items
961 SE/SPORT/CAFE RACER
Drive Train:
Primary reduction system:
Type
Gear
Reduction ratio
1.61
Clutch type
Wet multi disc
Transmission:
Type
5-speed, constant mesh
Gear ratios: 1st
2.688
2nd
1.969
3rd
1.433
4th
1.181
5th
1.000
Final drive system:
Type
Chain drive
Reduction ratio
2.778
Overall drive ratio
4.476 @Top
Frame:
Type
Tubular, steel, double cradle
Caster (rake angle)
24.5˚
Trail
99mm
Front tire: Type
Dunlop qualifier (Tube for spoked wheels-Continental
DE17)
Size
120/70 ZR17 M/C
Rear tire: Type
Dunlop qualifier (Tube for spoked wheels-Continental
G17)
Size
180/55 ZR17 M/C
Front Suspension: Type
Telescopic fork (pneumatic)
Fork
travel
110mm
Rear Suspension: Type
Swingarm, twin shock
Sus
travel
96mm
Brake type: Front
Twin floating discs
Rear
Single disc
Electrical Equipment:
Headlight: Type
Semi-sealed beam
Bulb
12 V 55/60 W
Taillight
12 V 21.5W
Alternator: Type
Three-phase AC
Rated
output
300 w
Specifications are subject to change without notice, and may not apply to every country.

15
SCHEDULED MAINTENANCE CHART
Operation Description
Every
Odometer Reading in Miles (Kms) or time period, whichever
comes first
500
(800)
1
month
6,000
(10,000)
1 year
12,000
(20,000)
2 years
18,000
(30,000)
3 years
24,000
(40,000)
4 years
30,000
(50,000)
5 years
Engine oil Cooler - check for leaks
Day
Engine oil - renew
-
Engine oil filter - renew
-
Valve clearance - check
-
Air cleaner - renew
-
Engine ECU - check for stored DTC`s
-
Spark plugs - check
-
Spark plugs - renew
-
Throttle bodies - balance
Day
Throttle cables - check/ adjust
Day
fuel system - check for leaks
Day
Lights. Instruments and elec. Systems - check
Day
SCHEDULED MAINTENANCE CHART
Operation Description
Every
Odometer Reading in Miles (Kms) or time period, whichever
comes first
500
(800)
1 month
6,000
(10,000)
1 year
12,000
(20,000)
2 years
18,000
(30,000)
3 years
24,000
(40,000)
4 years
30,000
(50,000)
5 years
Drive chain slack - check/adjust
Day
Drive chain rubbing strip - check
-
Rear wheel bearing - lubricate
-
Fasteners - inspect visually for security
Day
Wheels - inspect for damage
Day
Tyre wear/tyre damage - check
Day
Tyre pressures - check/adjust
Day
Stand - check operation
Day
Secondary exhaust clamp bolts - check/adjust
-

16
SCHEDULED MAINTENANCE CHART
Operation Description
Every
Odometer Reading in Miles (Kms) or time period, whichever
comes first
500
(800)
1
month
6,000
(10,000)
1 year
12,000
(20,000)
2 years
18,000
(30,000)
3 years
24,000
(40,000)
4 years
30,000
(50,000)
5 years
Steering - check for free operation
Day
Headstock bearings - check/adjust
-
Headstock bearings - lubricate
-
Forks - check for leaks/smooth operation
Day
Fork oil - renew
-
Brake fluid and clutch fluid levels - check
Day
Brake fluid - renew
Day
Brake pad wear - check
Day
Brake master cylinders - check for oil leaks
Day
Brake calipers - check for leaks/seized pistons
Day
Drive chain - lubricate
Every 200 miles (300kms)
Drive chain - wear check
Every 500 miles (800kms)

17
Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent
locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
Letters
Mean
L
Apply a non-permanent locking agent to the
threads.
LG
Apply liquid gasket to the threads.
Lh
Left-hand threads.
M
Apply molybdenum disulfide grease.
O
Apply oil to the threads and seating surface.
S
Tighten the fasteners following the specified
sequence.
SS
Apply silicone.
St
Stake the fasteners to prevent loosening.
R
Replacement parts.
TH05
Threebond 1305 (thread lock strong)
TH27
Threebond 1327 (thread lock medium)
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are
for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads
dia. (mm)
Torque
N-m
5
3.4~4.9
6
5.9~7.8
8
14~19
10
25~34
12
44~61
14
73~98
16
115~155
18
165~225
20
225~325

18
Torque table Chassis
Description
Component
Torq
ue
Remarks
N-m
Sprocket cover
SPROCKET COVER TO C/CASE
BOLT, CAP HD, M8 X 30 X 1.25
20
Front wheel
SPINDLE FOR CONVENTIONAL FORKS
SPINDLE, FRONT WHEEL
60
SPINDLE FOR USD FORKS
SPINDLE, FRONT WHEEL, USD FORKS,
HIGH BARS
60
Rear wheel
TO CLAMP SPROCKET TO CARRIER
LOCKNUT, FLANGED, M10 X 1.25
55
SPINDLE NUT
LOCKNUT, THIN, M24 X 2
110
Brakes
HALF CLAMP BOLTS
BOLT, M6 X 25 X 1.0, FLANGED, CP
HD,GOLD
8
BRAKE SYSTEM ONLY
BOLT, BANJO, M10 x 1.0 x 30, CHROME
25
BRAKE SYSTEM ONLY
BOLT, BANJO, M10 x 1.0 x 18, CHROME
25
BRACKET TO MASTER CYLINDER (remote)
BOLT, CAP HD, M6 X 12 X 1.0
6
LEFT HAND CALIPER BRACKET TO FORK (axial)
BOLT, CAP HD, M10x20x1.25
35
CALIPER TO BRACKET, BRACKET TO FORK
(axial)
BOLT, CAP HD, M10x30x1.25
35
6 PER SIDE, PATCH LOCKED (axial)
BOLT, BUTTON HD, INT HEX, M8 X 16
25
6 PER SIDE, PATCH LOCKED (radial)
BOLT, BUTTON HD, INT HEX, M8 X 20
25
TO CLAMP CALIPER TO FORK (radial)
BOLT, CALIPER, RADIAL
35
TO CLAMP REAR MASTER CYLINDER +
BRACKET + HEEL GUARD TO HANGER
BOLT, CAP HD, M6 X 20
10
TO CLAMP RESERVOIR TO BRACKET
BOLT, CAP HD, M6 x 10
8
BRAKE SYSTEM ONLY
BOLT, BANJO, M10x1.0x18, CHROME
25
CLAMP P CLIP TO SWINGARM
BOLT, CAP HD, M5 X 15 X 0.8
7
REAR CALIPER TO CARRIER
BOLT, CAP HD, M8 X 20 X 1.25
28
DISK, PATCHLOCKED
BOLT, BUTTON HEAD, INT HEX, M10X20
43
L

19
Description
Component
Torque
Remarks
N-m
Front forks
PINCH BOLT SUPPLIED WITH FORKS (for axle)
BOLT, CAP HD, M8 X 25
20
LOWER YOKE CLAMP BOLTS
BOLT, CAP HD, M8 X 20 X 1.25
20
SWITCH CUBE LH
SCREW, M5 X 40
3
SWITCH CUBE LH
SCREW, M5 X 30
3
SWITCH CUBE RH
SCREW, M5 X 22
3
THROTTLE ACTUATOR,TWIN CABLE
THROTTLE ACTUATOR,TWIN CABLE
4
THROTTLE ACTUATOR CLAMP
BOLT, CAP HD, M6 X 20 x 1.0
8
TOP YOKE CLAMP BOLTS
BOLT, CAP HD, M8 X 20 X 1.25
20
TOP YOKE LOCK NUT
NUT, UPPER YOKE, M25
80
ADJUSTER NUT 40NM TO SEAT BEARINGS,
BACKED OFF, THEN RE-TORQUED TO 8 NM
LOCKNUT, M25
8
LOCKED UP TO ADJUSTER NUT 40 NM STEM
INTERMEDIATE NUT, M25
40
REMOTE RESERVOIR BOLT (remote)
BOLT, CAP HD, M6 X 12 X 1.0
8
RESERVOIR TO BRACKET (axial)
LOCKNUT, FLANGED, M5 X 0.8
7
TO CLAMP SLAVE CYLINDER TO SPROCKET
COVER
BOLT, CAP HD, M6 X 16 X 1.0
12
HANDLEBAR CLAMP TO YOKE (not cafe racer)
NUT, M10 X 1.5
43
UPPER HANDLE BAR CLAMPS BOLTS (not
cafe racer)
BOLT, CAP HD, M8 X 22 X 1.25
20
Rear suspension
SWINGARM PIVOT NUT
LOCKNUT, THIN, M16 X 1.0
60
THREADED ADJUSTER, SWINGARM
THREADED ADJUSTER, SWINGARM
6
USED TO MOUNT CHAIN RUBING STRIP
BOLT BUTTON HD, INT HEX M5 X 20 X
0.8
9
RSU'S TO FRAME
BOLT, BUTTON HD, INT HEX,
FLANGED, M8 X 16 X 1.25
22
Frame
TO CLAMP ENGINE MOUNT BRACKET
LOCKNUT, M8 X 1.25
26
NUT, USED WITH ENGINE MOUNT BOLT
LOCKNUT, M12 X 1.75
85
FRAME ADJUSTER, M23
FRAME ADJUSTER, M24
15
REAR ENGINE MOUNT BOLT
BOLT, M12, ENGINE, REAR MOUNT
85
Foot controls
FOOT CONTROL FRAME TO FRAME ASSY
BOLT CAP HD, M8 X 50 X 1.25
27
TO CLAMP CLEVIS + PEG ASSY TO CONTROL
PLATE
LOCKNUT, M10 X 1.5
40
TO CLAMP TOE PEG TO PEDAL
BOLT, CAP/HD, M6 X 40
10
TO CLAMP PLATE TO PEDAL
BOLT, CSK HD, M4 X 0.7 X 12
7
USE THREE BOND 1327
PIVOT BOLT, SIDESTAND
20
GEAR CHANGE TO SELECTOR SHAFT
BOLT, CAP HD, M6 X 40
9

20
Description
Component
Torque
Remarks
N-m
Oil cooler
TO CLAMP OIL COOLER TO FRAME
BOLT, CAP HD, M6 X 20 x 1.0
6
Airbox and Exhaust
TO AIR FILTER CLAMP
BOLT, BUTTON HD, M5x12
4
TO CLAMP TRANSITION PIECE
BOLT, CAP HD, M6 X 20
8
TO HEAD
LOCKNUT, FLANGED, M8 X 1.25
19
2 REQUIRED FOR HOMOLOGATION
LAMBDA SENSOR, EXHAUST, M10 X
1.25
25
USED TO CLAMP EXHAUST SECTIONS
EXHAUST CLAMPS
10
Bodywork
TO BOLT HUGGER
BOLT, CAP HEAD, M5 X 15 X 0.8
7
Fuel tank
FUEL PUMP
BOLT, CAP HD, M5 X 12 X 0.8
9
MOULDED TANK TO FRAME
BOLT, CAP HD, M6 X 16 X 1.0
9
Electrical system
FOR ROLLOVER SWITCH
BOLT, CAP HD, M4 X 25 X 0.7
3
MOUNTED ON LOWER YOKE
BOLT, BUTTON HD, INT HEX, M8 X 16
18
TO CLAMP IGNITION COIL PACK
BOLT, CAP HD, M6 X 40 X 1.0
10
PANEL TO YOKE FIXING
BOLT, CAP HD, M8 X 20 X 1.25
20
Lighting
TO CLAMP NUMBER PLATE LIGHT
BOLT, CAP HEAD, M5 X 15 X 0.8
7