Domi Mega Phone Exhaust Norton 961

Transcription

1 This section shows how to install the Domi Mega Phones IF YOU`RE A DEALER, Consider a donation as this Manual just made your life a lot easier! If you have the Standard exhaust or the Motad Shorties and want to convert to the Mega Phone, this manual will help a lot. NOTE: Mega Phone exhaust is OFF ROAD USE ONLY and extremely (insanely) loud. Also, the ECU needs to be remapped accordingly. The bike will run with whatever map you have prior to swapping and I would advise starting it to make sure you don t mind the noise before a re-map. It s not too bad when cruising but if you are on or off the gas, I hope you have ear protection. PS Get headphones to protect ears before starting for the first time! Norton 961 Engine 1 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

2 Refer to MANUAL: Domi Tail Section. Remove Tank Strap bolt. Optional: Tail Section can be removed but it is not needed to be removed to remove the tank. Remove two tank bolts (one per side) 2 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

3 ALUMINUM TANK Only one fuel tank vent line is routed over the Air Box with the aluminum tank. STANDARD TANK Two vents (really one is a water drain) for the standard tank. Pull off Spark Plug Wires Both Sides Remove two Cradle screws. Remove two Battery Connections Remove Coil Plug IGNITION UPGRADE We suggest replacing coil with BOSCH and Wires with one07 Racing Wires 3 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

4 Move cradle towards the back of the bike to expose the O2 plugs. Locate two Oxygen sensor plugs. OX1 & OX2 4 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

5 Disconnect OX1 & OX2 plugs. Fill them with Dielectric grease and tuck back under the frame as they are no longer needed. Then, carefully remove the O2 sensor cables by following them down the frame. They are usually zip tied to the frame and will require some careful cutting of the zip ties. Do not remove O2 Sensors from pipes. Loosen all exhaust connection fittings. 5 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

6 Loosen all exhaust connection fittings. Remove the muffler to frame nuts and bolts and then remove the mufflers (both sides). 6 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

7 Remove the mufflers (both sides). Remove the center section to frame nut and bolt and then remove the center section of the exhaust from the header pipes. This takes some patience! 7 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

8 Remove exhaust header nuts (3 per side) and then remove each header. Discard the exhaust crush gaskets. They are not re-useable! 8 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

9 Apply Petroleum Jelly to the NEW Crush Gaskets to hold them in place. 9 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

10 Install appropriate Hanger Brackets to each Mega Phone Exhaust using Loctite. 10 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

11 You should be looking at something like this. Next you will be removing the foot controls and A-Frame brackets that connect to the frame. Flip off spring clip. Check free play of Lever and make a note of it. This will be needed later. RIGHT HAND SIDE OF BIKE (REAR FOOT BRAKE SIDE) 11 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

12 Flip off spring clip. And remove pin to disconnect from rear brake lever. Then re-install clip and remove shaft. Do not loosen nut or adjust this length setting RIGHT HAND SIDE OF BIKE (REAR FOOT BRAKE SIDE) Flip off spring clip. And remove pin to disconnect from brake lever. Then reinstall clip and remove shaft. 12 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

13 Crack the Banjo Bolt loose and then gently tighten enough not to leak. This will be important for later. NOTE: Keep an eye on it that it does not leak as brake fluid is known to remove paint. Remove two Socket Head Cap Screws. 13 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

14 Replace two screws in the existing holes Remove two A-Frame bolts 14 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

15 Right Hand Side removed Right Hand Side removed 15 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

16 Remove Foot controls from bracket. Remove Foot controls from bracket. 16 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

17 Master Cylinder Connection Brake Lever Stop Right Hand Side Foot Control Bracket Locate right hand side replacement components. Replace rear brake to master cylinder connection. 17 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

18 18 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

19 Use a medium strength Loctite Install Right Hand Side Foot Control Assembly and use Loctite on these bolts. 19 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

20 You need to re-route the hoses as shown. This was cracked loose on pg13. Bleed brakes after completion because the lines were cracked open and could take on air. Assemble as shown. 20 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

21 Hang right side exhaust. Install header nuts and tighten. Set Brake lever stop until there is the correct amount of free play. Tighten. Make sure brake is not held on by free play stop. Free play stop. Set this to the previous noted free play. Note this is sandwiched between hanger and frame support. Exhaust hanger Right Hand Side of Bike. 21 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

22 Tighten three Header Nuts Install Cover Plate Tighten rear hanger to muffler bolts (2 bolts) The Right Hand side is now complete. Now take all your tools to the Left Hand side of the bike. Left Hand Side of the Bike. Remove A-Frame Bracket Bolts and disconnect Shifter Linkage Arm. You will need to move these foot controls to the new Foot Control Bracket. 22 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

23 Pull Pin to remove Shifter Linkage Arm Remove Linkage and replace Linkage Arm with one supplied for Mega Phone Exhaust. 23 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

24 Replace Linkage Arm with one supplied for Mega Phone Exhaust. You will need to re-use Ball joint ends. Use Loctite on the new Foot Control to Frame Bracket bolts. Install this cover Hang Left side exhaust. Install header nuts and tighten. 24 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

25 Tighten rear hanger bracket to frame nut and bolt Tighten three Header Nuts Install Shifter Linkage assembly Tighten rear hanger to muffler bolts (2 bolts) 25 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

26 Re-install the battery cradle, coil wires, the battery connections and the spark plug wires. Upgraded Bosch Coil available at Colorado Norton Works One07 Wires available at Colorado Norton Works Re-install the Fuel tank and start it up. Don t forget the ear protection! 26 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t

27 Although this guide doesn t have a price tag, it is copyrighted and formally registered. If you like what you see and this has helped you, please make a donation via PAYPAL to richard@coote1.com. Your support will help make more manuals like this available. If you haven't helped yet, please donate so I can continue to offer these guides. We are slowly developing useful tools to help make it easier for you to work on your pride and joy. Specialty hand crafted tools for your modern Norton by One07 Tools, can be purchased from places like Colorado Norton Works in the USA. If there are any tools in this manual or other manuals you would like more information on, please me at richard@coote1.com Norton Commando 961 Dual Seat SE#107 (left) and Norton Commando 961 SE#112 (right) 27 P a g e r i c h a r c o o t e 1. c o m c o p y r i g h t