1963-79 BSA Norton Triumph Manual 500-850cc Commando Bonneville

Clymer Vintage British Street Bikes: BSA, Norton, Triumph Service, Repair, Maintenance Manual M330 Table of Contents: BSA 500 & 650cc Unit Twins 1963-1972

CHAPTER ONE / GENERAL INFORMATION Manual organization / Service hints / Safety hints / Parts replacement / Tools / Expendable supplies / Serial numbers

CHAPTER TWO / LUBRICATION AND MAINTENANCE Tools / Lubrication / Lubrication and maintenance intervals / Tune-up / Chain adjustment and inspection / Decarbonization / Winter storage

CHAPTER THREE / TROUBLESHOOTING Operating requirements / Starting difficulties / Poor idling / Misfiring / Flat spots / Power loss / Overheating / Engine noises / Piston seizure / Excessive vibration / Clutch / Transmission / Handling / Brakes / ELectrical / Coil ignition system / Battery charging system / 1 ohm load resistor / Zener diode charge control / Zener diode testing / Troubleshooting guide

CHAPTER FOUR / FUEL SYSTEM Carburetor principles / Carburetor overhaul / Amal concentric / Amal monobloc / Carburetor adjsutment / Common problems / Air filter / Fuel Tank

CHAPTER FIVE / ELECTRICAL SYSTEM Battery / Rectifier / Zener diode charge control / Ignition coil / Horn adjustment / Headlight / Turn signal lights / Taillight and stoplight / Stoplight switch / Lights / Ignition switch / Warning lights / Alternator capacitor ignition / Wiring diagrams

CHAPTER SIX / ENGINE, TRANSMISSION, AND CLUTCH Removal installation / Top end / Rocker cover and exhaust pipe / Exhaust rocker assembly / Cylinder head / Valve springs / Pushrods / Valves and guides / Valve grinding / Cylinder head assembly / Cylinder / Alternator / Clutch / Right crankcase cover / Left crankcase cover / Contact breaker / Timing gear and oil pump / Transmission / Crankcase

CHAPTER SEVEN / CHASSIS Wheels / Brake hubs / Brakes / Sprocket / Wheel inspection / Wheel balancing / Tire rim locks / Tire changing / Tire maintenance / Sidecar alignment / Handlebars / Throttle cable / Choke cable / Front brake cable / Steering head bearing / Swing arm / Shock absorbers / Seat / Side panels / Air cleaner box / Fender / Battery and mounting

SPECIFICATIONS

INDEX

Norton 750 & 850cc Commandos 1969-1975

CHAPTER ONE / GENERAL INFORMATION Precautionary measures / Parts ordering / Service hints / Tools / Expendable supplies / Safety first

CHAPTER TWO / PERIODIC MAINTENANCE AND LUBRICATION Service intervals / Tire pressure / Battery electrolyte level / Engine oil / Primary chaincase / Chain / Transmission / Swing arm / Front fork / Hydraulic disk brake / Rear chain / Control cables / Brake adjustment / Grease fittings / Air filter / Wheel bearings / Primary chain adjustment / Tune-up

CHAPTER THREE / TROUBLESHOOTING Operating requirements / Starting difficulties / Poor idling / Misfiring / Flat spots / Power loss / Overheating / Engine noises / Piston seizure / Excessive vibration / Clutch / Transmission / Handling / Brakes / Lighting problems / Troubleshooting guide

CHAPTER FOUR / ENGINE, PRIMARY DRIVE, CLUTCH Cylinder head / Valve adjustment / Cylinders and pistons / Break-in / Primary drive and clutch / Engine lower end

CHAPTER FIVE / TRANSMISSION Outer cover / Inner cover / Gearset and housing

CHAPTER SIX / FUEL SYSTEM Carburetors / Fuel tank

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS Ignition / Contact breaker / Automatic advance unit / Timing / Coils / Capacitors / Spark plugs / Charging system / Alternator / Rectifier / Zener diode / Battery crossbar / Starter 850 Mark III / Lights and switches / Magneto service / Wiring diagrams

CHAPTER EIGHT / FRONT WHEEL AND BRAKE Front wheel / Front drum brake / Front disc brake / Front hub

CHAPTER NINE / REAR WHEEL AND BRAKE Rear wheel / Rear wheel hub / Sprocket and brake assembly , Rear drum brake / Rear disc brake

CHAPTER TEN / FRAME, SUSPENSION, AND STEERING Frame / Isolastic engine mounts / Front suspension / Steering / Rear suspension / Swing arm

SPECIFICATIONS 750 Commando / 850 Commando

INDEX

Triumph 500-750cc Twins 1963-1979

CHAPTER ONE / GENERAL INFORMATION Manual organization / Service hints / Safety hints / Parts replacement / Tools / Expendable supplies / Serial numbers

CHAPTER TWO / LUBRICATION AND MAINTENANCE Maintenance lubrication intervals / Tools / Oil change / Oil pressure / Oil pressure relief valve / Contact breaker assembly / Gearbox lubrication / Primary chaincase lubrication / Rear chain lubrication / Chain / Drive chain adjustment / Front wheel bearings / Rear wheel bearings / Front forks / Lubrication fittings / Control cables / Speedometer cable / Brake lever / Checking engine for wet sump / Tune-up / Decarbonizing / Storage

CHAPTER THREE / TROUBLESHOOTING Operating requirements / Starting difficulties / Poor idling / Misfiring / Flat spots / Power loss / Overheating / Engine noises / Piston seizure / Excessive vibration / Clutch slip or drag / Transmission / Poor handling / Brake problems / Electrical problems / Ignition system / Ignition coils / Emergency starting circuit / Charging system / Rectifier / Charging circuit continuity / Zener diode / Energy transfer ignition and lighting systems Alternator output / Troubleshooting guide

CHAPTER FOUR / ENGINE Removal installation / Rocker boxes / Carburetor / Air cleaner / Cylinder / Valves / Block and tappets / Pistons, rings, and cylinders / Oil pump / Oil system / Rocker oil feed pipe / Valve timing gears / Camshafts / Crankcases / Crankshaft / Rods and main bearings / Camshaft and bushings / Tachometer drive gear

CHAPTER FIVE / CLUTCH AND TRANSMISSION Primary chain / Primary cover / Clutch / Primary drive shock absorber / Rotor and stator / Transmission outer cover / Kickstarter / Clutch and gearshift operating mechanism / Transmission / Mainshaft and countershaft bearings / Other transmission components (500cc) / Gearbox sprocket

CHAPTER SIX / FUEL SYSTEM Carburetor / Carburetor operation / Carburetor overhaul / air filter / Gas tank

CHAPTER SEVEN / ELECTRICAL SYSTEM Battery / Rectifier / Zener diode / Energy transfer ignition and lighting systems / Ignition switch / Kill switch / Capacitor ignition system / Ignition coil

CHAPTER EIGHT / FRONT BRAKE, WHEEL, AND SUSPENSION Front drum brakes / Disc brakes / Pad replacement / Brake caliper / Bleeding / Master cylinder / Wheels / Tire / Front forks / Hydraulic damper / Steering head bearings

CHAPTER NINE / REAR BRAKE, WHEEL, AND SUSPENSION Rear drum brakes / Rear disc brakes / Wheels / Rear shocks / Swing arm

CHAPTER TEN / FRAME Oil tank / Battery carrier

SPECIFICATIONS Threads per inch / 750cc models (T140V and TR7V) / 650cc models / Miscellaneous information (prior to engine No. DU.66246) / Variation among models / Variations - 1972 models / 500cc (T100S) / 500cc (T100T) / 500cc (5TA) / 500cc (TR5T) / 500cc (T100R)

SUPPLEMENT / 1978 AND LATER SERVICE INFORMATION Engine tune-up / Engine removal and installation / Carburetor / Alternator / Electronic ignition / Instruments and operating controls / Brake caliper / Front forks / Rear shocks / Swing arm

INDEX

WIRING DIAGRAMS

Models covered: BSA 500 and 650 cc Unit Twins (1963-1972) A65 Thunderbolt/Lightning/Spitfire (1964-1972) ... A65 Firebird Scrambler B25 Starfire (1968-71) ... Rocket III (1969-1972) ... BSA Fury (1970) Norton 750 & 850 cc Commando (1969-1975) Norton Commando 750- Standard Norton Commando 750- Combat Norton Commando 850 Mark II and Mark IIA Norton Commando 850 Mark III (Electric Start) includes R, S, SS, Interstate, Roadster, Hi rider and Interpol versions Triumph 500, 650 & 750 cc Twins (1963-1979) 500cc: T100C T100R Triumph Tiger 100 Daytona T100S T100T 5TA Speed Twin TR5T T6 Thunderbird. 649cc. 1963 -- 1966 TR6 Trophy. 649cc. 1963 -- 1971 TR6 R Tiger. 649cc. 1970 -- 1973 T120 Bonneville. 649cc. 1963 -- 1979 T140 V Bonneville. 744cc. 1973 -- 1979 TR7 V Tiger. 744cc. 1973 -- 1979 Clymer Manuals BSA 500cc Unit Twin Manual Clymer Manuals BSA 650cc Unit Twin Manual Clymer Manuals Norton 750cc Commando Manual Clymer Manuals Norton 850cc Commando Manual Clymer Manuals Triumph 500cc Twin Manual Clymer Manuals Triumph 650cc Twin Manual Clymer Manuals Triumph 750cc Twin Manual

Publisher ‏ : ‎ Clymer Language ‏ : ‎ English Softcover ‏ : ‎ approx 1000 pages ISBN-10 ‏ : ‎ 0892876042 ISBN-13 ‏ : ‎ 978-0892876044 Item weight ‏ : ‎ 1.2 kg Dimensions ‏ : ‎ 17.78 x 3.18 x 25.65 cm

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