Crankcase Breather Kit

Thanks for the info.
I'll definitely discuss this with my dealer when the kit comes in.

Tony, Richard thanks again.

Fred

The new dip stick I collected this year on a service back in February at the factory,Tony & Richard 7 may correct me ,but im sure if engine is overfilled it doesn't help the wet sumping, but with these new check valves fitted u can more accurately measure the level, sure all be clear with the spec sheet etc that's comes with kit.

Hi,
Thanks for the great information. I now have an understanding of the system that I didn't have before.
TonyA, the return valve looks like it is probably the older type. It is smaller than the one in your photo, it fits completely in line, the same size as the hose.
As for wet sumping I'm not sure but the symptoms are as i said earlier.
On a good note, started the bike up this morning and took a short ride after it had been sitting for a week and no oil at all in the airbox. This has me thinking it may be the swarf problem you've identified causing an intermittent problem. I'll give cleaning it a go.
Thanks to all

Hi Tiedy , I would try the new return line check valve first . Why take apart the oil pump if you don't need to ? I know for fact that the original return line check valve leaks off oil slowly . The new version check valve has a more positive check valve internals. You will see when you get the new one and compare it to the old. You don't have a location stated in your name area. Did the factory or dealer install the kit for you ? If factory did then the oil pump shavings are probably already cleaned out . So try the return side check valve first in my opinion.

Hi TonyA,
Good advice once again. The kit was installed by the Australian importer, Fraser Motorcycles, I'll try and get hold of a newer valve, not always easy here, I'm in Newcastle, nsw, Australia for location.
Cheers

Well my ship has finally come in.

I placed my order for the Breather update kit in April, and it has finally arrived at the dealer.

$325.00 and it came in the pictured ziplock plastic bag, sans any instructions.
Not even a packing list of parts to check either. A bit underwhelming to say the least.
I’ll just be happy if the kit solves the oil use and airbox issues.
I’m going to have the dealer do the installation. However, I'll have to wait for Aug 22nd until they have an opening.
I’m posting pics/docs from Fotki since Photobucket shut me down, and I’m not too proficient with their image sharing so I not sure how the files will post.
I hope this helps others thinking about doing the breather/airbox fix.

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I was able to get the parts folks at my dealer to browse the Norton dealer website, and find/download a PDF file with the installation instructions. The 10 pages of the document are posted below. Finally, I’ll need a Power Commander and my 961 will be complete, and I’ll be happy as a pig in Sh**.

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Hello Britwit , Good you now have the breather kit. I also see that you got the newest type of return side check valve. They factory are shrink tubing their return side check valve so they won't scratch the frame downtube. Look at Richard Pearces's picture of it you will see that its covered in a rubber tubing. I used screw on hose clamps , not the factory type that require a crimper.

So would you guys say

Get this only if you have a problem
or
Get this because eventually you'll most likely encounter a problem?

Hi BritTwit,
That's great news, The install instructions are great, is it possible to email me the PDF. File for reference.
I still have issues at times but these seem to be diminishing?? No oil in airbox for last 600 kms.
Thanks,

Not being one of the 961 fraternity - but I have to comment on that crankcase joint shown in the photos on page 8 of the service bulletin.
That is one of there messiest joints I have seen. If all that goo is evident on the outside, where it could have been wiped away (but wasn't), what's on the inside, ready to be washed off into some oil gallery?
Nice tech bulletin - very poor advert for assembly quality!
I ummed & ahhed recently over a 961 vs CNW 850 - kind of glad I went CNW
Cheers
Rob

robs ss said:

Not being one of the 961 fraternity - but I have to comment on that crankcase joint shown in the photos on page 8 of the service bulletin.
That is one of there messiest joints I have seen. If all that goo is evident on the outside, where it could have been wiped away (but wasn't), what's on the inside, ready to be washed off into some oil gallery?
Nice tech bulletin - very poor advert for assembly quality!
I ummed & ahhed recently over a 961 vs CNW 850 - kind of glad I went CNW
Cheers
Rob

Click to expand...

Indeed, I noticed that too Rob!

Enjoy the cNw btw.

robs ss said:

Not being one of the 961 fraternity - but I have to comment on that crankcase joint shown in the photos on page 8 of the service bulletin.
That is one of there messiest joints I have seen. If all that goo is evident on the outside, where it could have been wiped away (but wasn't), what's on the inside, ready to be washed off into some oil gallery?
Nice tech bulletin - very poor advert for assembly quality!
I ummed & ahhed recently over a 961 vs CNW 850 - kind of glad I went CNW
Cheers
Rob

Click to expand...

I'm glad you are happy with your CNW build. I do like the CNW machines as well, and for a while entertained the thought of sending my MK3 to CNW for a makeover.

That photo of the rear crankcase joint does look untidy. Who knows the history of the engine pictured in the photos. My cases are immaculate, as the day the bike was delivered to me. In fact my 961 has never had an oil leak from the engine cases or covers. My only issue has been oil blowing from the breather into the airbox. It’s annoying, but not a reliability issue or a sloppy mess to be sure. I would say the assembly quality of the average 961 is very good from the ones I have seen. They do have niggling problems though which can sometimes infuriate an owner, like me. From talking with the mechanic at my shop, most of the problems with the 961 appear to relate to insufficient attention during assembly, and a lack of testing the final product before shipping. From a QA/QC standpoint, this bothers me. Most of the unfortunate problems owners have had, and bad publicity Norton has received could have been prevented with proper QA/QC at the factory.

I suspect that CNW restorations probably have similar issues with sub quality components that we see with the 961. Like Sparx alternators, Belt drives, Isolastics, etc. Especially if those bikes actually get ridden significant distances, and are not just for around town joy rides. They are a refinement of a 50 year old design which to a large extent still incorporates the basic design flaws of the original 750/850 Commando engines.

The 961 on the other hand has certain definite advantages, like a modern 3 main bearing crankshaft with steel rods, very strong cases built like a brick sh**house, and a modern gearbox designed to handle 80HP. Basic mechanical reliability of the 961 is a strength of the design. The niggling issues just detract from this fact.

That's not on mine or any other I've seen. Perhaps it's not finished?

Re: Rob’s comment - I guess it depends on who works on your engine. This is what I found when I decided to replace the sump oil strainer as a preventive measure on my 150,000 mile Audi. Having owned the car from new I knew the sump had only been off once, and that was when the Audi main dealer had replaced it, after they had stripped the sump plug thread. There was no excess sealant on the outside!

Doesn't mean that all Audi mechanics are like this though.

https://www.dropbox.com/s/yhh7fplkhp1lt ... 2.JPG?dl=0

https://www.dropbox.com/s/ka670s4v6tmih ... 4.JPG?dl=0

https://www.dropbox.com/s/ny9dwvf85gaka ... 0.JPG?dl=0

PS – I hope the links work.

Wow. The dealer said it just arrived. Ha! Found it searching all over for my headlight that they lost.
EDIT.....Wait a minute. I just noticed that received about half the parts listed on that service bulletin. ?!?!?!? You paid $325. for THAT?? A little bag of hardware and no banjoless valve cover? That ridiculous. I still don't have the 5 cent catch bottle on mine. Instead, a wider diameter clear plastic tubing. I may be missing something. Please post a photo of all the parts laid out.

Wow Comet - It's lucky you got that far!
It looks like the same bloke might have assembled those 961 cases.
Cheers
Rob

Tiedy said:

Hi BritTwit,
That's great news, The install instructions are great, is it possible to email me the PDF. File for reference.
I still have issues at times but these seem to be diminishing?? No oil in airbox for last 600 kms.
Thanks,

Click to expand...

Tiedy,

Sure.
Just PM me with your email address.

TonyA said:

Hello Britwit , Good you now have the breather kit. I also see that you got the newest type of return side check valve. They factory are shrink tubing their return side check valve so they won't scratch the frame downtube. Look at Richard Pearces's picture of it you will see that its covered in a rubber tubing. I used screw on hose clamps , not the factory type that require a crimper.

Click to expand...

Tony,

Have you experienced any issues with the rubber caps/clamps supplied by Norton to blank off the rocker cover banjos?
Have you had any come loose, or fall off like Paul did?
They are under pressure so it is a concern to me.

Hello,

the pressure in the rocker cover is negligibly small.
If you loose the caps you must check the clamps.
My bike runs a long time with this caps without loose them.

Regards
Panatone

BritTwit said:

TonyA said:

Hello Britwit , Good you now have the breather kit. I also see that you got the newest type of return side check valve. They factory are shrink tubing their return side check valve so they won't scratch the frame downtube. Look at Richard Pearces's picture of it you will see that its covered in a rubber tubing. I used screw on hose clamps , not the factory type that require a crimper.

Click to expand...

Tony,

Have you experienced any issues with the rubber caps/clamps supplied by Norton to blank off the rocker cover banjos?
Have you had any come loose, or fall off like Paul did?
They are under pressure so it is a concern to me.

Click to expand...

I am still running the rubber caps . They are ugly as hell but they are easy to install ! And that is why they are still on there . I like the idea of the blanking plugs , but I like the idea of the banjo - less rocker cover better. I ordered one from Norton and I have it here. I have been a little lazy this summer and it is still sitting on my desk. Right now I just want to ride the thing. BUT , when that cover comes off again it is going to be replaced !