Marks Norton Commando Rebuild

A sensible move on the tires. We were motor-home owners for several years and often did only about 2000 mies in a season, which is fairly typical for mainly weekend or short trip use. General consensus among the RV community is to replace tires every 7 years, regardless of wear. When we bought our final one it was 8 years old, based on its "house build" date and still had the original tires it wore when Ford drove the chassis to the RV manufacturer maybe 18 months earlier. New tires were the first things I bought when we got it home. It was a dually chassis, so 6 tires were needed. We never used the spare wheel, and I don't think the original owner had either. It was still stashed away under the propane tank, with its OEM tire, when we sold the rig 4 years later.
 
Beginning to look like a bike again - gearbox outer cover still to be polished.

Marks Norton Commando Rebuild


Marks Norton Commando Rebuild
 
Wiring going well with new loom:
Marks Norton Commando Rebuild
Marks Norton Commando Rebuild


Need some guidance with ignition wiring, my switch has three terminals:
Marks Norton Commando Rebuild


Wiring diagram for 71 shows three different wire colours to switch yet my loom has four wires:
Marks Norton Commando Rebuild


I am not sure where to connect the blue/green, I have searched the site but cannot find a similar one, any guidance would be very much appreciated.

Cheers, Mark
 
Brownymark said:
Wiring diagram for 71 shows three different wire colours to switch yet my loom has four wires:

I am not sure where to connect the blue/green, I have searched the site but cannot find a similar one,
Click to expand...


Your harness is to 1972 spec.

That "blue/green" (headlamp feed) is actually blue/yellow [UY], (see 1972-on wiring diag.], so for a '3' terminal ignition switch, connect the blue/yellow to terminal 3 along with the brown/green (other lighting) [NG] (or fit a 4 terminal switch with UY on t4) in which case you will probably have to connect UY to the headlamp switch (as '72 w/diag.) instead of NG.

Another alternative would be to leave UY completely disconnected and connect NG to the headlamp switch (as per the '71 w/diagram)
 
Hello LAB,

Thank you for the very prompt and helpful reply.

Terminal three only has a single spade connector whereas the other two are double so I guess I will need to joint them.

I want to keep the switch if I can as I have had new keys cut for it.

Many thanks again, Mark
 
Brownymark said:
Terminal three only has a single spade connector whereas the other two are double so I guess I will need to joint them.

I want to keep the switch if I can as I have had new keys cut for it.
Click to expand...



Then I suggest you do it the alternative way. Leave UY completely disconnected and connect NG to the headlamp selector switch.

If the front harness section is new and also to '72 spec. then it may have a UY headlamp switch wire that can be connected to NG?
 
Hi LAB,

Thanks again, the picture below shows how the switch was wired when I got the bike which I guess is incorrect (it has not run for many years)
Marks Norton Commando Rebuild


The following two pictures show how the headlamp was wired:
Marks Norton Commando Rebuild
Marks Norton Commando Rebuild


The final picture is the new headlamp loom which I am currently installing:
Marks Norton Commando Rebuild


Does this look correct?

Cheers, Mark
 
Brownymark said:
Thanks again, the picture below shows how the switch was wired when I got the bike which I guess is incorrect (it has not run for many years)
Click to expand...

Well, with the wires connected as they are, the lights would come on with the ignition. The number 2 terminal has broken off the switch.

Brownymark said:
The following two pictures show how the headlamp was wired:

The final picture is the new headlamp loom which I am currently installing:

Does this look correct?
Click to expand...


It's difficult to tell from the photos, however, IF the longer wire hanging straight down in that last photo is the UY (so goes to the headlamp selector switch for '72 spec.) then the other end needs to be connected to NG brown/green rather than UY in the main harness section.
 
Thanks LAB, the two long wires in the new headlamp loom are U (Blue) UY (Blue/Yellow).

i was just going to connect the blue to the switch as it was wired previously?
 
Brownymark said:
Thanks LAB, the two long wires in the new headlamp loom are U (Blue) UY (Blue/Yellow).

i was just going to connect the blue to the switch as it was wired previously?
Click to expand...

Yes, connect U as before, and UY instead of NG.
 
Thanks again LAB and apologies if I am appearing somewhat thick, so I am leaving UY disconnected at the ignition switch but connecting it to the headlamp switch?

Is it correct that only two wires are connected to the two top connectors of the headlamp switch (as my previous picture) with nothing on the two lower terminals?

Cheers again, Mark
 
Brownymark said:
so I am leaving UY disconnected at the ignition switch but connecting it to the headlamp switch?
Click to expand...

Yes, leave both ends of the main harness section UY disconnected.

Connect one end of the headlamp harness UY to the headlamp switch and the other end to NG from the main harness section.

Brownymark said:
Is it correct that only two wires are connected to the two top connectors of the headlamp switch (as my previous picture) with nothing on the two lower terminals?
Click to expand...

If that's how it was then yes, as it is a simple ON/OFF selector for the headlamp, so if desired, the other lights (pilot, tail, instruments) can be ON but the headlamp switched OFF when 'Ign. and lights' or 'Parking lights' are selected at the ignition switch.
 
Front mudguard semi fitted;
Marks Norton Commando Rebuild
Marks Norton Commando Rebuild


Need to drill for front stay.

Mountings for later centre stand arrived - need to drill out gearbox cradle which does not look easy mounted in frame without a very compact right angle drill! Busy weekend ahead...

Great progress in all the threads still learning everyday - keep up the great support network :D
 
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