Going under covers

Boss302 · Mar 19, 2022

So, my 2015 916 sport has between 5 and 6 thousand miles now. It has had the usual oil problems along with broken exhaust mount and chain guard mount. Also had the stator bolts come fully loose . I've checked valves once myself, and they were checked by a dealer during the stator incident. At that time gaskets were available here in the USA. It is difficult for me to distinguish the normal bucket of bolts noises from impending problems so it's time to go under cover (clutch and timing covers that is). Here are my questions of you since I know many of you have become very experienced with these procedures. 1. Am I going to be able to find clutch and timing chest gaskets in the USA if the old ones are not reusable? I have never much cared for using gasket silicone without gaskets. I suppose I can cut my own if needed using the old ones as patterns but would prefer to buy new ones if they are readily available. 2. Looks like the timing chain adjustment is the main check on the right side. Anything else of concern there? 3. I have Richard's service manual guides (thanks Richard). I am reluctant to invest in a gear lock tool and a clutch lock tool that I may only use once. Have you been able to remove the clutch for inspection using improvised methods without the locking tools? I've seen the threads about clutch rivets and springs and countershaft sprocket issues.
I'd like to be as informed as possible before I start wrenching. Thanks for sharing your experience and expertise.

cliffa · Mar 19, 2022

Open the cases carefully and the gaskets can be re-used. They are quite robust. I used a piece of aluminum 20mm x 4mm across ( not between) the gears to jam them. Worked perfectly.

TonyA · Mar 19, 2022

cliffa said:
Open the cases carefully and the gaskets can be re-used. They are quite robust. I used a piece of aluminum 20mm x 4mm across ( not between) the gears to jam them. Worked perfectly.

You should be able to reuse the gaskets on the Primary and timing covers. I seem to remember Donington Norton using a copper penny to jam the gears in the service manual !

Boss302 · Mar 19, 2022

cliffa said:
Open the cases carefully and the gaskets can be re-used. They are quite robust. I used a piece of aluminum 20mm x 4mm across ( not between) the gears to jam them. Worked perfectly.

Okay thanks.

Boss302 · Mar 19, 2022

TonyA said:
You should be able to reuse the gaskets on the Primary and timing covers. I seem to remember Donington Norton using a copper penny to jam the gears in the service manual !

I appreciate the info. Thanks

Gojuu · Mar 19, 2022

Boss302 said:
So, my 2015 916 sport has between 5 and 6 thousand miles now. It has had the usual oil problems along with broken exhaust mount and chain guard mount. Also had the stator bolts come fully loose . I've checked valves once myself, and they were checked by a dealer during the stator incident. At that time gaskets were available here in the USA. It is difficult for me to distinguish the normal bucket of bolts noises from impending problems so it's time to go under cover (clutch and timing covers that is). Here are my questions of you since I know many of you have become very experienced with these procedures. 1. Am I going to be able to find clutch and timing chest gaskets in the USA if the old ones are not reusable? I have never much cared for using gasket silicone without gaskets. I suppose I can cut my own if needed using the old ones as patterns but would prefer to buy new ones if they are readily available. 2. Looks like the timing chain adjustment is the main check on the right side. Anything else of concern there? 3. I have Richard's service manual guides (thanks Richard). I am reluctant to invest in a gear lock tool and a clutch lock tool that I may only use once. Have you been able to remove the clutch for inspection using improvised methods without the locking tools? I've seen the threads about clutch rivets and springs and countershaft sprocket issues.
I'd like to be as informed as possible before I start wrenching. Thanks for sharing your experience and expertise.

OEM Norton Clutch Cover Gasket -NO5260013

Norton Clutch Cover Gasket -NO5260013 For norton Dominator, Commando 961 SF MkII, Commando 961 Cafe Racer MkII, Commando 961 Sport MkII

www.af1racing.com

&

Norton RH Engine Cover Gasket - NO5260012

Norton RH Engine Cover Gasket - NO5260012 For norton Dominator, Commando 961 SF MkII, Commando 961 Cafe Racer MkII, Commando 961 Sport MkII

www.af1racing.com

Both in stock - I found them really good to deal with too.

Stu Bodycote · Mar 20, 2022

Checked valves?

TonyA · Mar 20, 2022

Gojuu said:
OEM Norton Clutch Cover Gasket -NO5260013

Norton Clutch Cover Gasket -NO5260013 For norton Dominator, Commando 961 SF MkII, Commando 961 Cafe Racer MkII, Commando 961 Sport MkII

www.af1racing.com

&

Norton RH Engine Cover Gasket - NO5260012

Norton RH Engine Cover Gasket - NO5260012 For norton Dominator, Commando 961 SF MkII, Commando 961 Cafe Racer MkII, Commando 961 Sport MkII

www.af1racing.com

Both in stock - I found them really good to deal with too.

Good find ! I forgot about AF1 Racing there in Austin TX .

Boss302 · Mar 20, 2022

Stu Bodycote said:
Checked valves?

I had a rocker cover leak and when I replaced the gasket I checked the valve clearances.

Boss302 · Mar 20, 2022

Gojuu said:
OEM Norton Clutch Cover Gasket -NO5260013

Norton Clutch Cover Gasket -NO5260013 For norton Dominator, Commando 961 SF MkII, Commando 961 Cafe Racer MkII, Commando 961 Sport MkII

www.af1racing.com

&

Norton RH Engine Cover Gasket - NO5260012

Norton RH Engine Cover Gasket - NO5260012 For norton Dominator, Commando 961 SF MkII, Commando 961 Cafe Racer MkII, Commando 961 Sport MkII

www.af1racing.com

Both in stock - I found them really good to deal with too.

That's what I was looking for. I ordered the gaskets from them and will use them if needed. Otherwise will be nice to have them on hand if needed later. Appreciate your help.

Stu Bodycote · Mar 21, 2022

Boss302 said:
I had a rocker cover leak and when I replaced the gasket I checked the valve clearances.

It doesn't have valve clearances to check, it has hydraulic lifters. The adjusters are set so that the lifters are roughly in the middle of their range. Never need adjusting again. If its been set with a clearance, then its wrong.

lcrken · Mar 21, 2022

I noticed that the description of the gaskets from AF1 includes the 961 Sport MkII, but not the earlier 961 Sport. Anyone know if the gaskets are the same for both? I would assume so, but it would be nice to know for sure.

Ken

Boss302 · Mar 21, 2022

Stu Bodycote said:
It doesn't have valve clearances to check, it has hydraulic lifters. The adjusters are set so that the lifters are roughly in the middle of their range. Never need adjusting again. If its been set with a clearance, then its wrong.

You are correct, there are not clearances. But the valves are adjustable and according to Richard Coote should be checked every 2 years. The procedure is available in his service manual which is what I followed.

Gojuu · Mar 21, 2022

lcrken said:
I noticed that the description of the gaskets from AF1 includes the 961 Sport MkII, but not the earlier 961 Sport. Anyone know if the gaskets are the same for both? I would assume so, but it would be nice to know for sure.

Ken

Ken - I have a full set - could you tell from a photo?

Boss302 · Mar 21, 2022

lcrken said:
I noticed that the description of the gaskets from AF1 includes the 961 Sport MkII, but not the earlier 961 Sport. Anyone know if the gaskets are the same for both? I would assume so, but it would be nice to know for sure.

Ken

I sent an email to AF1 asking that question. We'll see if they know if I get a reply. My understanding is that the differences between MK11 and pre 2015 engines were just performance related and perhaps in the casting method but not the shape of the engine cases or covers. I am sure someone else here knows the correct answer. Anyone?

Boss302 · Mar 21, 2022

lcrken said:
I noticed that the description of the gaskets from AF1 includes the 961 Sport MkII, but not the earlier 961 Sport. Anyone know if the gaskets are the same for both? I would assume so, but it would be nice to know for sure.

Ken

Ed Cook / AF1 Racing

We are not 100% sure, and all the old parts books are no longer accessible.
Pretty sure it was the same gaskets on I and II ones
The new Norton has been no help on 961 parts. We keep trying to get info and parts from them.
Ed Cook

lcrken · Mar 22, 2022

Gojuu said:
Ken - I have a full set - could you tell from a photo?

I couldn't tell anything from the pictures in the early and late service manuals. I also have all three of them, bought from AF1 a while back for spares, but didn't feel like pulling covers to check for differences. I've been assuming that they are the same for earlier and MkII, but was hoping someone else might know for certain. I'm thinking I should probably order a full gasket set from Ollie now, while they are still available. No telling what Norton will offer, or when.

cliffa · Mar 22, 2022

lcrken said:
I couldn't tell anything from the pictures in the early and late service manuals. I also have all three of them, bought from AF1 a while back for spares, but didn't feel like pulling covers to check for differences. I've been assuming that they are the same for earlier and MkII, but was hoping someone else might know for certain. I'm thinking I should probably order a full gasket set from Ollie now, while they are still available. No telling what Norton will offer, or when.

I have the cover off mine at the moment and can post a pic of the gasket tomorrow, however I'm 99% certain they are the same for all models.

lcrken · Mar 22, 2022

I just checked Ollie's site, and he only shows one gasket set for the 961s, so I think I'm also 99% certain. Let's see, between your 99% and mine, that means we're 198% certain, right?

Ken

TonyA · Mar 22, 2022

I would think they are exactly the same.