Norton Commando Workshop Manual

## Frame and Ancillaries

# F

### SECTION F4

### REFITTING POWER UNIT

Prior to refitting the power unit, if any major mechanical attention has been given, wash the oil tank and oil pipes out very thoroughly to remove dirt and foreign matter. As with dismantling, protect the lower frame rails against damage. Proceed as follows:
1 | Pass the power unit into the frame from the right side, raising the front slightly and lowering the rear to clear the airbox.
2 | With the power unit loosely in position, move the rear end as far as possible to the right side of the frame to facilitate assembly of the rear mounting.
Engine mountings are covered in detail in Section F12-17.
However, if the mountings have merely been dismantled and are to be reassembled without varying the shimming, proceed as follows:
3 | Grease using silicone grease (such as Releasil No. 7) and place in position the shims and left side end cap (the shims should be divided equally between left and right).
4 | Grease using a silicone grease and insert as a group the left side gaiter, collar and polyurethane washer with the gaiter held back for maximum clearance. Note that the gaiter should be greased inside to slide easily over the cap and mounting. The order of assembly and method of holding the gaiter back on the edge of the polyurethane washer are seen respectively in Figs. F14 and F5.

5 | Position the spacer between the left hand alloy footrest mounting plate and battery tray bracket and slide in the mounting stud from the left side, moving the power unit as necessary to align the stud holes.
6 | Grease using a silicone grease and fit the right side shims and cap.
7 | Grease (including inside the gaiter) and fit the gaiter, spacer collar and polyurethane washer (see Figs. F14 and F5).
8 | Tap the main stud right through aligning with the right frame bracket, insert the footrest plate spacer, then fit the washer and nut. Tighten to 25 Ibs./ft. (3~456 Kg/m).
9 | Fit the front engine mounting plates to the crankcases, sliding the long end of the mounting over the lower crankcase bosses. With the stud or bolt fitted, pivot the mounting up into position to insert the second stud or bolt. Almost certainly the power unit will need to be lifted to insert the crankcase studs (or bolts).
10 | Grease the components with a silicone grease and reassemble the front mounting as in Section C32. Tighten the centre bolt to a torque of 25 Ibs./ft. (3 456 Kg/m).
11 | Refit the oil pipe junction block, using a new gasket if necessary and securing with the single bolt which must not be overtightened.
12 | Prior to refitting the carburetors and spacers, grease the manifold scrows lightly and run them into the cylinder holes to ensure that they can be tightened by finger pressure only when the carburettors and manifolds are assembled. During this operation and before attempting to fit the engine to the frame block the inlet ports with clean non-fluffy cloth to prevent a screw dropping down one of the ports. Remember to remove the cloth before fitting the carburetors.
13 | Holding the Tuffnol insulating block in place (some models use blocks with one flat edge which must fit inboard) fit the air hose to the airbox using a screwdriver blade to enter the lip, then assemble the right carburetor and manifold to the head tightening the socket screws completely.
14 | Fit the air hose to the airbox, then offer the insulatin block, carburetor and manifold to the cylinder head tightening the socket screws as far as possible with the fingers. When locking up the screws an abbreviated socket key is essential.

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