Norton Commando Workshop Manual

## Frame and Ancillaries

# F

### SECTION F18

### REAR FENDER

Removal and refitting of the rear fender is similar for all models excepting Fastback on which there is the additional problem of the tail section fairing. The separate routines are given below:
Fastback:
1 | Release the two large knurled knobs securing the seat and lift the seat straight up and clear of the frame.
2 | Remove the suspension unit top bolts to release the forward ends of the tail section.
3 | Remove the clip from beneath which secures the tail section to the rear frame loop.
4 | Disconnect the tail lamp leads and direction indicator leads where used at the snap connector terminals inside the tail section.
5 | Remove the nuts and washers at the bottom front and lift the fender away.
6 | Reassembly is a reversal of the foregoing but do not omit to reconnect the tail lamp leads. Where direction indicators are fitted, ensure that they work correctly when reconnected.
Roadster:
1 | Release the two large knurled knobs securing the seat and lift the seat straight up and clear of the frame.
2 | Release the tail lamp with fairing and number plate support as a group, by removal of six bolts and plain washers.
3 | Disconnect the tail lamp leads (and the direction indicator leads where fitted) and lift away the tail lamp and tail lamp fairing group.
4 | Remove the bottom front two self-locking nuts and plain washers securing the rear fender to the bracket from the frame gusset.
5 | Reassembly is a reversal of the foregoing but do not omit to reconnect the tail lamp leads. Where direction indicators are fitted, ensure that they work correctly when reconnected.

### SECTION F19

### EXHAUST SYSTEM

The dismantling and reassembly routine for Commando models with the various low level exhaust systems is similar but the high level system of the "S" model, upswept to the left side requires a different technique. The downswept exhaust systems are shown in Fig. F16 1 and the "S" type system in Fig. F17.
Removing and Refitting - all models except "S" type:
1 | On late models with exhaust lockring tab washers, flatten back the tabs.
2 | Using service tool 063968 unscrew the finned exhaust lockrings and allow these to hang on the exhaust pipes.
3 | Remove the nuts securing the muffler (silencer) mounting plates to the rubber mountings, so that at the next stage the mufflers are removed with plate attached.
4 | Lift each exhaust system clear.
5 | When assembling the exhaust system, fit the copper/asbestos sealing ring into the exhaust port, offer the exhaust pipe to the port and, holding in the correct position, tighten the lockring sufficiently to hold the exhaust pipe in the correct position whilst permitting it to be rotated slightly. Now assemble the muffler to the exhaust pipe and to the muffler mountings.
6 | Tighten completely the muffler mountings, forward clip and lockring.
When refitting the exhaust system, if the exhaust system is not assembled correctly to the frame, it can lie in the wrong plane. The tendency is to push the system to its lowest position during fitting so that the centre stand and other equipment can come into contact with the exhaust pipe and mufflers. Assembly as above will prevent both misilignment and strain on any of the fittings.
Removing and Refitting "S'' type Exhaust:
1 | Using service tool 063968 unscrew the finned exhaust lockrings and allow to remain loosely in place.
2 | Remove nut from rubber mount block on bracket adjacent to suspension unit.
3 | Lift off pipe and muffler complete.
4 | Repeat for other pipe and muffler.
5 | On reassembly, the use of new type tabbed washers to secure the lockrings is recommended.

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