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Norton workshop repair maintenance workshop manual

The Norton bike organization is a Brit motorcycle marque, initially from Birmingham, UK. Wartime WW2 production of the armed forces design 16 H and gigantic 4 sidevalve motorcycles had been Norton's share on war effort, almost 100,000 getting made. When major investors

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/ Lubrication / Lubrication and maintenance intervals / Tune-up / Chain adjustment and inspection / Decarbonization / Winter storage * TROUBLESHOOTING Operating requirements / Starting difficulties / Poor idling / Misfiring / Flat spots / Power loss / Overheating / Engine noises / Piston seizure / Excessive vibration / Clutch / Transmission / Handling / Brakes / ELectrical / Coil ignition system / Battery charging system / 1 ohm load resistor / Zener diode charge control / Zener diode testing / Troubleshooting guide * FUEL SYSTEM Carburetor principles / Carburetor overhaul / Amal concentric / Amal monobloc / Carburetor adjsutment / Common problems / Air filter / Fuel Tank * ELECTRICAL SYSTEM Battery / Rectifier / Zener diode charge control / Ignition coil / Horn adjustment / Headlight / Turn signal lights / Taillight and stoplight / Stoplight switch / Lights / Ignition switch / Warning Rectifier / Zener diode / Battery crossbar / Starter 850 Mark III / Lights and switches / Magneto service / Wiring diagrams * FRONT WHEEL AND BRAKE Front wheel / Front drum brake / Front disc brake / Front hub * REAR WHEEL AND BRAKE Rear wheel / Rear wheel hub / Sprocket and brake assembly Rear further data

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647cc 1962 - 1968 * Mercury 647cc 1968 - 1970 * Atlas 745cc 1963 - 1968 * N15 745cc 1967 * G15 (Matchless) 745cc 1964 - 1967 * P11 745cc 1966 - 1967 * Ranger (P11A) 745cc 1967 - 1968 Contents: * Engine * Transmission (Gearbox) * Clutch * Fuel System And Carburation * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams * Conversion Factors here

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Roadster 745cc 1970 - 1973 * 750 Hi-Rider 745cc 1971 - 1973 * 750 Interstate 745cc 1972 - 1973 850 Models: * 850 Roadster 828cc 1973 - 1977 * 850 Hi-Rider 828cc 1973 - 1975 * 850 Interstate 828cc 1973 - 1977 Contents: * Maintenance * Engine * Transmission (Gearbox) * Clutch And Primary Transmission * Carburation And Lubrication * Ignition System * Frame And Forks * Wheels Brakes And Tyres * Electrical System * Wiring Diagrams extra info

The Norton bike organization is a Brit motorcycle marque, initially from Birmingham, UK. It was created in 1898 as a manufacturer of "fittings and areas the two-wheel trade". By 1902, the company started manufacturing motorbikes with bought-in motors. In 1908, a Norton-built system had been included with the product range. This started a lengthy series of production of solitary and in the end twin-cylinder motorcycles, and a lengthy reputation for racing participation.

Wartime WW2 production of the armed forces design 16 H and gigantic 4 sidevalve motorcycles had been Norton's share on war effort, almost 100,000 getting made.

When major investors started to leave Norton in 1953, the business declined and corresponding engine series bought the stocks. Although motorcycle purchases experienced a recession when you look at the 1950s, and Norton engines Ltd was only a tiny maker, Norton product sales flourished. A few Norton Dominator Twins of 500cc, then 600cc, after that 650cc after which the 750cc Norton Atlas held marketing buoyant, particularly with deals to your United States Of America.

In 1968, this new 750cc Norton Commando design showed up, with the engine/gearbox/swingarm product "isolastically" insulated from the frame with some rubber mountings. This kept the oscillations through the rider, giving a smooth luxurious ride. The Commando ended up being a best vendor, and voted #1 bike of the season numerous instances in Britain. 850cc products made an appearance for 1973, offering more torque. For 1975 an electric start arrived in the 850 Mk3.

The largest UK motorcycle producer at that time ended up being BSA-Triumph, comprising Birmingham Small Arms organization in Birmingham, and success Motorcycles in Meriden. BSA-Triumph encountered troubles brought on by poor management, outdated union tactics, antique bike design and antiquated factory circumstances. A merger with Norton motorbikes was proposed; but although Dennis Poore's Norton Motorcycles ended up being undoubtedly small companion, Poore successfully secured a take-over of BSA-Triumph, developing Norton Villiers success. The Triumph factory Meriden was the smallest amount of latest; but people involved with a "sit-in", developing a workers' co-operative. Poore had been CEO of Manganese Bronze Holdings, a business evidently considerably focused on asset-stripping than with motorcycle manufacturing. Subsequent governmental manoeuvrings led to the downfall of NVT, as taxpayer-assisted wranglings over amalgamations and sell-offs all but killed the as soon as substantial UNITED KINGDOM motorcycle industry.

In belated 2008, Stuart Garner, an UK businessman, purchased the legal rights to Norton from some US problems and relaunched Norton with its Midlands residence at Donington playground in which it'll develop the 961cc Norton Commando, and an innovative new array of Norton motorbikes.

The initial team had been created by James Lansdowne Norton at 320, Bradford Street, Birmingham in 1898. In 1902, Norton began creating motorcycles with French and Swiss motors. In 1907, a Norton ridden by Rem Fowler won the twin-cylinder class in the 1st Isle of guy TT race, start a sporting custom that continued through to the sixties. 1st Norton motors are built in 1907, with production systems offered by 1908. They certainly were the 3.5 hp together with 'larger 4', beginning a line of side-valve single-cylinder machines which continuing with couple of changes before the late 1950s.

The first Norton logo ended up being a rather simple, art nouveau design, because of the title spelled in capitals. However, a unique logo made an appearance from the front regarding the catalogue for 1914, that has been a joint efforts by James Lansdowne Norton and his daughter Ethel. They became referred to as "curly N" logo design, with only the preliminary page as a capital, and ended up being used by the business after that, first appearing on actual motorcycles in 1915. Ethel Norton additionally did some testing of the lady father's motorcycles.

In 1913 the business enterprise declined, and R.T. Shelley & Co., the primary creditors, intervened and stored they. Norton engines Ltd ended up being created immediately afterward under joint directorship of James Norton and Bob Shelley. Shelley's brother-in-law had been tuner Dan O'Donovan, in which he managed to set an important range data in the Norton by 1914 once the war smashed on - and as competition motorcycling was mainly suspended during hosilities, these data still stood whenever manufacturing restarted following the war. 1914 Dan O'Donovan records emerge April 1914 :

Under 500cc flying km 81.06 miles per hour, traveling mile 78.60 miles per hour - 490cc Norton
Under 750cc flying km and traveling mile see above
Under 500cc with sidecar flying km 65.65 mph, flying mile 62.07 mph - 490cc Norton
Under 750cc with sidecar traveling km and traveling mile see above

On 17 July 1914 O'Donovan furthermore took the traveling 5 mile record at 75.88 miles per hour, while the located start 10 mile record at 73.29 miles per hour, again on the 490cc Norton.

The CS1 had been a Norton bike between 1927 and 1939. Initially built as a TT racer, and Norton's very first design of an overhead cam system, they shown successful as a TT Replica road bike.

After the early 1930s redesign of Norton's cammy models by Arthur Carroll, the CS1 became an upmarket road-bike. The 500 cc CS1 and its smaller sibling 350 cc CJ1 continued on before outbreak of WW2 in 1939.

Numerous later on touring CS1 products were enhanced for racing, by adding and subtracting most of the optional race bits for Internationals. The Norton catalog had a long list of these types of parts offered. The distinguishing feature of 1930s CS1 products could be the stub installed carburettor - Inter products have a bolt-on TT carburettor.

The Norton Camshaft Senior design 1 system was designed by Walter Moore in 1927, based on the Norton ES2 pushrod system and re-using most areas. The framework is a fresh full cradle design with a close-ratio kickstart-less gearbox, 8 inch brake system, Amal TT carburettor, Lucas Racing magneto and a 3 gallon petrol tank. The CS1 is the standard for race Nortons for the next twenty years. The magneto is relocated to the trunk of engine together with bottom end had been a traditional Norton design, but in the medial side associated with crankcase was the oils pump housing and a pair of bevel gears to-drive the long shaft which ran in a tube within the side of the motor to a moment set of gears operating the overhead camshaft.
Sturmey-Archer was a manufacturing business initially from Nottingham, The united kingdomt. It mostly brings bicycle hub gears but has also created bike hubs.

The company is established in 1902 by Henry Sturmey and James Archer underneath the advice of Frank Bowden, the main owner of this Raleigh bike business. In 2000, the assets and trademarks of Sturmey-Archer were sold to sunshine battle of Taiwan that has been rebranded Sun battle Sturmey-Archer Inc and production moved to Taiwan.

Norton carried on production of their particular 3.5 hp and Big 4 singles better to the war duration, though in November 1916 the Ministry of Munitions granted an order that no longer focus on engine cycles or automobiles could be allowed from November 15, 1916 without an allow. By this time around most motor cycle firms had been currently either producing munitions, or devoted to the export trade. Norton are taking part in exporting and earlier that seasons had launched a brand new 'Colonial Model' of the 633cc huge 4. This featured an increase in ground clearance from 4.25" to 6.5", by changing the framework, bigger tank, better approval on mudguards, and a sturdy rear service. The engine is unaltered, and transmission was via a Sturmer-Archer 3-speed gearbox.

In February 1918 Motor Cycle reported on a call to Norton Motors. Mr Norton have stated he expected three post-war models, the 3.5 hp 490cc TT with buckle drive, and two utility supports, one with detuned TT engine, therefore the other being the major Four for really heavy solamente or sidecar services, both these with three-speed Sturmey-Archer countershaft gearbox and all string drive. It was in addition reported he have been experimenting with aluminium pistons, which Norton had created a book of driving suggestions which also included details of their army and Empire products.

In-may 1918 Norton claimed in just one of their advertisements that 'The ministry is taking the entire of our present result, but we now have a waiting checklist' - this ad furthermore uses the "Unapproachable Norton" phrase. Couple of Norton WD products come in the available column associated with the bike following the war, suggesting they were shipped abroad, evidently one purchase visiting the Russian Army . The 1913-1917 Red Book detailing UK engine, aquatic and plane production programs Norton fallen from a full range in 1916, to only the Military gigantic Four in 1917.
Inter-War Ages

Norton resumed deliveries of civil motorcycles in April 1919, with models aimed at motorcyclists just who enjoyed the reliability and gratification offered by long-stroke single-cylinder machines with split gearboxes.

Norton additionally resumed rushing and in 1924 the Isle of Man Senior TT was the initial win with a competition average rate over 60 miles per hour, rider Alec Bennett. Norton obtained this occasion ten circumstances until they withdrew from rushing in 1938.

J.L. Norton passed away in 1925 aged best 56, but he spotted his motorbikes win the Senior and sidecar TTs in 1924, specifically utilizing the 500cc design 18, Norton's first overhead-valve solitary.

Created by Walter Moore, the Norton CS1 system starred in 1927, created closely regarding the ES2 pushrod system and using lots of its parts. Moore had been hired away to NSU in 1930, and after that Arthur Carroll designed a completely brand-new OHC system destined to become the basis for many later on OHC and DOHC Norton singles. The Norton race legend began when you look at the Thirties: regarding the nine Isle of guy Senior TTs between 1931 and 1939, Norton obtained seven.

Until 1934, Norton bought Sturmey-Archer gearboxes and clutches. When Sturmey discontinued manufacturing Norton bought the design legal rights and had them made by Burman, a manufacturer of proprietary gearboxes.

Despite, or due to, the rushing success Norton was in monetary trouble. Reynolds could not render a number of the highly ideal Featherbed structures and subscribers missing interest in buying machines using the elderly structures. In 1953 Norton out of stock to corresponding Motorcycles, who owned the companies AJS, Matchless, Francis-Barnett and James. In 1962 the Norton factory in Bracebridge road, Birmingham was closed and production was moved to AMC's Woolwich factory in south-east London.

Under AMC ownership a lot enhanced version of the Norton gearbox was created, to be utilized on all of the bigger models of AJS, Matchless and Norton. Once more, the main changes had been for better gear selection. In September 1955, a 600 cc Dominator 99 was launched. The 1946 to 1953 Long Stroke Manx Norton is 79.6 mm × 100 mm in the beginning SOHC, the DOHC engine getting open to favoured racers in 1949. The Short swing model have bore and swing of 86 mm × 85.6 mm. It utilized a dry sump 499 cc single-cylinder motor, with two valves managed by bevel drive, shaft driven twin expense camshafts. Compression proportion ended up being 11:1. It had an Amal GP carburettor, and a Lucas racing magneto. The 1962 500 cc Manx Nortons produced 50 bhp at 6,780rpm, considered 142 kg, and had a top rate of 209 km/h.

In 1960, a unique type of the road-going Featherbed framework was created where the higher frame rails had been curved inwards to lessen the width between your driver's legs for better comfort. The move was also to accommodate the smaller rider once the large frame-made it difficult to achieve the floor. This frame is known as the "slimline" framework; the sooner frames then became referred to as "wideline".

The past Manx Nortons are offered in 1963. And even though Norton have drawn out of Grand Prix racing in 1954, the race-shop at Bracebridge road proceeded until 1962, plus the Manx became a mainstay of privateer race, as well as today become extremely sought-after, commanding highest prices.

On November 7, 1960 the very first newer 650cc Norton Manxman was launched when it comes to American marketplace only. By September 1961 the Norton 650SS showed up for the British marketplace, The 750cc. By April 20, 1962 the United states market because they required even more energy, but the improves to your vertical twin engine's capacity triggered a vibration problem at 5500 rpm. A 500cc vertical twin is smoother than a single-cylinder, however vertical twin's ability are enlarged vibration improves. The 750 Norton Atlas shown too expensive and costs could not be decreased. Financial trouble gathered.

There clearly was an export bike primarily to be used as a wilderness racer, offered until 1969 due to the fact Norton P11, AJS Model 33 and Matchless G15, that used the Norton Atlas engine in a changed Matchless G85CS scrambler frame with Norton rims and front forks. This bike is reputed to vibrate lower than the Featherbed framework model. AMC singles are also marketed with Norton badging within age.

Additionally during this period Norton developed a household of three comparable smaller-capacity twin-cylinder devices: first the Norton Jubilee 250 then the Navigator 350 and the Electra 400, which have an electrical beginner. These versions were Norton's first use of product construction. The system had been a totally latest design by Bert Hopwood as well as the frame and running equipment had been from the Francis-Barnett range, additionally owned by AMC. These devices had a reputation for bad reliability.

Because of the belated sixties, competition from Japanese providers and a quickly declining home market had driven the entire Brit bike business into drop. In 1966 AMC became insolvent and ended up being reformed as Norton-Villiers, element of Manganese Bronze Holdings Ltd.

The 750 Norton Atlas had been noted because of its vibration. Rather than modification engines Norton decided to change the frame, and isolastic-framed Norton Commando 750 ended up being the effect.
1973 850 Commando

In 1969, the Commando had been introduced. Its styling, innovative isolastic frame and effective motor managed to get a unique package. The Commando quickly outperformed contemporary success and BSA twins and was the absolute most effective and best-handling Uk motorcycle of its day. The isolastic frame-made they a lot smoother compared to Atlas. It put plastic bushings to isolate the engine and swing arm through the frame, forks, and rider. However, whilst the steel-shims incorporated into the Isolastic bearings wore, often from rusting, the bicycle became at risk of inferior managing - fishtailing in high-speed turns.

The "Combat" motor was released in January 1972, with a twin roller bearing crank, 10:1 compression and creating 65 bhp at 6,500 rpm. Reliability instantly suffered, with regular and early crank-shaft main-bearing problems, often ultimately causing broken crankshafts. Elderly machines had made use of one ball-bearing main bearing and something roller bearing main bearing nevertheless eliminate engine featured two roller bearings in a mistaken belief this might bolster the bottom-end to handle the bigger power-output. As an alternative the resultant crank-bending triggered the rollers to "dig-in" towards events, causing rapid failure. This fragility is particularly apparent when measured resistant to the dependability of contemporary Japanese machines. This problem had been resolved by specifying a heavier duty sort of spherical roller bearing, of 'superblend' popularity, later on in the 1972 manufacturing seasons.

The Commando is offered in a number of different kinds: the standard road model, a pseudo-scrambler with upswept pipelines plus the Interstate, packaged as a tourer. Electric begin is launched in the level III in 1974. Sales are good however the business declined economically and became insolvent in 1975. In 1976 a Norton with a US-flag motif on container might be bought for US$1,976.

In 1972, BSA has also been in financial problem. It was considering British Government help in the state that it joined with Norton-Villiers, plus 1973, the latest Norton Villiers Triumph had been formed. The success motorbikes title originated in BSA's success subsidiary. In April 1973 an 8.5:1 compression 828 cc "850" motor was launched with German FAG SuperBlend bearings. These, featuring a little barrel-shaped rollers, had been launched on late-model 750 cc engines to treat the fight engine's troubles of crank-flex together with consequent digging-in toward bearing-surface of initial cylindrical bearing rollers. This design created 51 bhp at 6,250 rpm although claimed energy cannot provide a true image of the motor overall performance because increased torque seemed to make up for the reduced horsepower.

In 1974, great britain's outgoing conventional federal government withdrew subsidies, nevertheless incoming Labour authorities restored all of them after the General Election. Rationalisation of this factory internet sites to Wolverhampton and Birmingham triggered manufacturing conflicts at success's Coventry website; Triumph would continue as a workers cooperative alone. Despite mounting losings, 1974 saw the production of the 828 Roadster, Mark 2 Hello driver, JPN Replica and Mark 2a Interstate. In 1975, the product range was right down to only two versions: the Mark 3 Interstate and also the Roadster, then again great britain national requested a repayment of their loan and declined export credits, more harming the business's capacity to sell overseas. Production of both designs however made is finished and resources dwindled.

1973 furthermore saw the beginning of developing on an innovative new device with a monocoque pressed steel framework, that also included a 500 cc twin, stepped piston engine called the 'Wulf'. However, as Norton Villiers success company is again in severe monetary problems, growth of the 'Wulf' was fallen towards the rotary Wankel means motor inherited from BSA.

A bushing or rubberized bushing is a type of vibration isolator. It offers a software between two areas, damping the vitality sent through bushing. A common application is in vehicle suspension systems, where a bushing made of rubberized separates the faces of two material things while enabling some motion. This activity enables the suspension parts to maneuver freely, for instance, when taking a trip over a large bump, while minimizing transmission of noise and tiny oscillations until the chassis of the car. A rubber bushing are often called a flexible mounting or antivibration installing.

These bushings usually take the type of an annular cylinder of versatile information inside a metallic casing or external tube. They may furthermore function an inside crush tube which protects the bushing from being crushed because of the fixings which hold they onto a threaded spigot. Various sorts of bushing styles exists. A significant difference compared with plain bearings is the fact that general movement amongst the two attached section is accommodated by stress within the rubber, in place of by shear or friction within screen. Some plastic bushings, for instance the D block for a-sway club, do allow sliding on user interface between one component and rubberized.
1st Dominator, the Model 7, have a 497 cc parallel twin engine with iron cylinders and cylinder head and a Lucas K2F magneto. The crankshaft is of 360-degree layout with two main bearings. One camshaft at the front end associated with the motor is driven by gears and chain. The rocker box was integrated with the mind, generally there were fewer gasket deals with to drip and less valve sound. The system was a lengthy stroke design with 66.0 mm × 72.6 mm bore and swing and mild tuning, causing most torque low-down. The first few ages a plunger framework ended up being made use of, in 1953 the Model 7 was upgraded with just one downtube swinging supply frame, 19-inch front-wheel and 'pear shaped' silencers, however referred to as a Model 7. The design 7 continuing in manufacturing to 1955 and ended up being often used in combination with a sidecar, which may never be fitted to the later Featherbed framework Dominators.
Model 88

The Featherbed frame had been created for Norton by the McCandless brothers making because of the Reynolds business because the Norton works did not have the required welding convenience of their make. The Featherbed framework resulted in the design 88 Dominator, also referred to as the Dominator De Luxe, that used similar 497 cc system and originated in 1951. Initially developed for export it was in love with the home market from 1953. The 88 suffered from oils leakages from the primary string case but it ended up being the outdated and inefficient Norton works that led to quality-control trouble for the 200 design 88's produced weekly.
Design 99
Design 99 Dominator

The 597cc featherbed framed design 99 Dominator was introduced in 1956, as a larger capacity variation alongside the 500 cc design 88 variation. Due to the increased engine capability, the 99 have an electrical result of 31 bhp, partly due and also to a higher compression ratio possible aided by the alloy mind introduced annually earlier. Full circumference alloy hubs with enhanced brakes had also been introduced per year previously, preparatory for the capacity boost from 500 cc to 600 cc
Model 77

The initial Model 77 had been a rigid framed telescopic forked Dominator version of 500 cc made out of 1950, and supplied to the Australian markets best. Only around 240 were made, from 1950 to 1952. This used the all metal Dominator 500 cc twin-engine, with an oil force measure within the ES2 style but flat-bottomed petrol container.

The 596 cc Model 77 Dominator ended up being introduced in late 1956. Really a moving arm, single downtube ES2 chassis with a 600 cc Dominator 99 engine, it absolutely was in manufacturing at precisely the same time due to the fact Dominator 99 as a sidecar motorcycle but is dropped from production after 1957, whenever sidecar Featherbeds were introduced.
Slimline Featherbed frames for 1960

From 1960, the featherbed frame for many Dominators had been altered so the framework pipes at the seat are narrower, for improved driver comfort. The seats and tanks and indeed the complete styling of the Dominator is redesigned to suit. A large material container badge complete the look, and some 2 toned paint schemes. Plus some optional enclosed human anatomy styling regarding the "luxurious" types of the 88 and 99, like the 'bathtub' Triumph designs.
1960 Manxman 650 and 1961 Dominator 650SS

A fresh 650 cc design ended up being put into the lineup late in 1960. The frame was altered so your top rails were closer together at the front associated with chair region generate just what became known as the 'slimline' featherbed. A 650 cc system had been installed to generate the Norton Manxman. First-built from 7 November 1960 to September 1961, these devices were a Limited Edition for the USA only, in custom-cruiser style - with high handlebars, all polychromatic blue paint and bright red seat with white piping round the edge. In September 1961 the 650SS had been launched. They had American cafe bar design and twin carburettors. The SS stood for Super activities as well as the 600 cc designs are stopped to focus on production of the 650SS, which quickly earned a reputation due to the fact "best of Dommies".
Racing
1961 Norton Domiracer

The Norton factory racing employees shortly utilized race-tuned Dominators from circa 1960, nonetheless they were still outclassed because of the Norton Manx. Doug Hele desired to understand Dominator developed and produced a 55 bhp "Domiracer" that revved to 8,000 rpm. The Domiracer weighed 35 pound lower than the Manx. Dennis Greenfield and Fred Swift won the 500 cc class in Thruxton 500 event in 1960. Within the 1961 Isle of guy TT Tom Phillis took the cycle to third room and lapped at over 100 miles per hour, a first for a pushrod motor and an initial for almost any twin. Norton abandoned the Domiracer project a-year later if the Bracebridge road battle store sealed and Domiracer and factory spares were offered to Paul Dunstall, whom carried on with development and began making Norton performance section, eventually promoting complete Dunstall Norton bicycles to users like Steve McQueen.








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