Norton 961 Alternate parts list.

luke.rogers35 said:
Hi

Does anyone know where I can get hold of a gear jam tool here in the UK, Norton part number 8900007 (6.9.1(C) in the manual ). I know I can get an aftermarket one imported from Canada but I need to source one ASAP. I can machine one if I can hold of a drawing.

Many thanks
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Welcome Luke. I had to check the calendar, as I’m not sure if you are kidding or not, but that “Special Tool” appears to be a coin. I use a 100mm long piece of aluminum about 20mm wide, by about 5mm thick, and place it perpendicular to the gears to “bridge” them rather than jamming something between them. It’s worked for me several times without damaging anything. Hope that helps.
 
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cliffa said:
Welcome Luke. I had to check the calendar, as I’m not sure if you are kidding or not, but that “Special Tool” appears to be a coin. I use a 100mm long piece of aluminum about 20mm wide, by about 5mm thick, and place it perpendicular to the gears to “bridge” them rather than jamming something between them. It’s worked for me several times without damaging anything. Hope that helps.
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Harley Davidson does the same , only they suggest using mild steel in the service manual .
 
Thanks Cliff

I don't suppose you have a photo or sketch of how you jammed the gear using your method that I could pass on to my mechanic. We are aiming to remove the clutch basket to get to (what we think) is a noisy bearing.

Thanks for your help
 
luke.rogers35 said:
Thanks Cliff

I don't suppose you have a photo or sketch of how you jammed the gear using your method that I could pass on to my mechanic. We are aiming to remove the clutch basket to get to (what we think) is a noisy bearing.

Thanks for your help
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You are in luck, as I have a spare intermediate gear….

00521D89-05F9-434F-9233-FDFC5C5A7C4F.jpeg
72AD3E24-8A83-45A0-B62B-41C4EF504062.jpeg


basically any softish flat metal bar from 20 to 50mm wide should work. When it’s time to tighten the nuts, use the same method on the other side of the gears.
Regarding the noise, it could well be the starter ring gear is loose, or the clutch basket rivets. Check both carefully. If your mechanic is not familiar with the 961, I ( and other 961 owners) can HIGHLY recommend @Stu Bodycote ( proprietor of Motorvated) who is ex Donnington Norton. Take it to him and your bike will be better than new.
 
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Cliffa, this is great. Thank you so much for all of your help. I have forward onto my mechanic so keep my fingers crossed for (hopefully) a quick solution. The contact is great, If we cannot see anything obvious I will reach out to Stu.
 
luke.rogers35 said:
Cliffa, this is great. Thank you so much for all of your help. I have forward onto my mechanic so keep my fingers crossed for (hopefully) a quick solution. The contact is great, If we cannot see anything obvious I will reach out to Stu.
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There are threads on here about the ring gear and the clutch rivets. Use the search facility (top right). By the way, what year is your bike?
 
2010, number 32 of 200. With just 1600 miles on the clock I suspect a seized bearing due to lack of use. Thanks for the kind tips and help, we can't wait to get the bike usable and put some good miles on it this year. 🤞🤞
 
My starter ring gear sheared off at around 16,500 miles so whether you have a good mileage on it or not taking a peak could be a very wise move. You don't want to hear the jingling tinkling sound I heard coming from below. 👍
 
peebee said:
My starter ring gear sheared off at around 16,500 miles so whether you have a good mileage on it or not taking a peak could be a very wise move. You don't want to hear the jingling tinkling sound I heard coming from below. 👍
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Hi Peebee , What year was your bike that this happened on ? Was the damage extensive or did you catch it soon enough ? Thanks , Tony
 
BritTwit said:
I believe his Commando is a 2015 Sport.
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Yep it was a 2015 Sport and up to that tie I had a good run with it. Luckily I pulled up at some traffic lights and heard the tinkling sound above the primary noise, so I stopped the engine then tried to restart it and just got a whiiiirrrrrrr sound and bugger all else , that's when I knew it was a recovery job and the fun started. Now apps are or can be a great idea when they work, unfortunately it couldn't find the postcode where I was so basically I was f**ked on a stinking hot day with no shelter , so the only other choice is to ring the number and wait and wait then try to explain to the girl on the other end where I was
which is difficult when she thinks that the M6 is a secret government agency. Any how on getting home I stripped the primary side and found this , so packed the whole lot off to Thor M/C to fix and they did a great job by the way, bearing in mind I didn't know at this time that Mr Bodycote even existed and Norton dealers were a little thin on the ground up here in the North to say the least.
Wil post some pics when I find them, I'm not super efficient with these damn computers.
 
peebee said:
Yep it was a 2015 Sport and up to that time I had a good run with it. Luckily I pulled up at some traffic lights and heard the tinkling sound above the primary noise, so I stopped the engine then tried to restart it and just got a whiiiirrrrrrr sound and bugger all else , that's when I knew it was a recovery job and the fun started. Now apps are or can be a great idea when they work, unfortunately it couldn't find the postcode where I was so basically I was f**ked on a stinking hot day with no shelter , so the only other choice is to ring the number and wait and wait then try to explain to the girl on the other end where I was
which is difficult when she thinks that the M6 is a secret government agency. Any how on getting home I stripped the primary side and found this , so packed the whole lot off to Thor M/C to fix and they did a great job by the way, bearing in mind I didn't know at this time that Mr Bodycote even existed and Norton dealers were a little thin on the ground up here in the North to say the least.
Wil post some pics when I find them, I'm not super efficient with these damn computers.
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Norton 961 Alternate parts list.
Norton 961 Alternate parts list.
Norton 961 Alternate parts list.
Norton 961 Alternate parts list.
Norton 961 Alternate parts list.
Norton 961 Alternate parts list.
Norton 961 Alternate parts list.
 
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As cliffa pointed out, many of us have had clutch issues, which are well described in earlier threads. The clutch rivets came loose my 2014 961 Sport at 5618 miles. Still worked, but the noise kept getting worse until I tore it down.

Ken
 
Morning all!

Does anybody know where I can get hold of a headlight shell? Basically when replacing a damaged front indicator I noticed that this shell is badly damaged, lots of plastic bits fell out when I removed the lamp. The lamp is being held on with gaffer tape for now until I can source a replacement. Thanks in advance
 
Luke, the search facility is your friend…

www.accessnorton.com

Headlight Swap

Hi All, Just a quick few photos of a headlight swap I did on my bike. I had the plastic early style headlight, with a crack on the edge (that I understand is somewhat common). I would have liked a factory one, but after some searching have gone with one from baak. Fits fairly straightforward...
www.accessnorton.com www.accessnorton.com
 
luke.rogers35 said:
Morning all!

Does anybody know where I can get hold of a headlight shell? Basically when replacing a damaged front indicator I noticed that this shell is badly damaged, lots of plastic bits fell out when I removed the lamp. The lamp is being held on with gaffer tape for now until I can source a replacement. Thanks in advance
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The other option is the factory. Doesn’t look like the headlight pattern has been changed from the later Donny unit, although the mounting bracket has. Others may know better?

Aftermarket is your only option if you want the chrome bezel though I think.
 

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