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Ben's '72 Interstate Rebuild

Member's Norton Restoration Projects

Ben's '72 Interstate Rebuild

Postby Scout63 » Sat Dec 03, 2016 8:08 pm

First post for my rebuild. I did post on the new pictures thread but this seems like a better place. Here is the bike as purchased. [img][IMG]http://i1067.photobucket.com/albums/u422/bzehnderScout63/11-22-16_zpsgrvr92yq.jpg[/img][/img]

I'm photographing disassembling and bagging now and enjoying it very much. I will post pictures as things get more interesting.

Reva
Reds to all.

Ben Zehnder
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Sat Dec 03, 2016 8:10 pm

Image

Messing around with how to post pictures.
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Sat Dec 03, 2016 8:20 pm

More photos:
Image
Image
Image
Image

Initial thoughts: SAE tools work pretty well for general disassembly except for the nuts just larger than 5/16 but smaller than 3/8.

If you drop the oil tank drain bolt behind the z plate it is pretty difficult to recover while oil is dripping down your hands.

BZ
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby Danno » Sun Dec 04, 2016 5:12 am

Almost everything not holding the engine and gearbox together is SAE American bolts and nuts. You still need a few special wrenches and sockets for the holdover British stuff.
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Re: Ben's '72 Interstate Rebuild

Postby grandpaul » Sun Dec 04, 2016 7:43 am

Some of those "before" photos are going to contrast amazingly with the "after" photos!
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Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Sun Dec 04, 2016 7:13 pm

Thanks Grandpaul:

I never took enough photos in prior projects. Technology these days is great.

Investment in the project so far has been ziplock bags, sharpies and contact cleaner. I did order several disassembly tools from old britts today. The site is just what a newbie needs.

Here is what the bike looks like after a few hours each day this weekend:

Image
Image

I was glad to see that every part seems to be original and unaltered. This is helpful in documenting how to put it back together. Also, even though the rims are very rusty, most of the metal parts, plates and fasteners are not. Only the front brake system is gunky and looks like it was leaky at the top end.

I need to figure out how to support the frame when removing the wheels and drivetrain. I think I'm going to weld up a simple cart as shown on the old britts site. This way I can leave my lift available for some minor winter repairs on other bikes ( fork seal on my /5 and an exhaust fabrication and new tires on my SR).

Regards to all.
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby gortnipper » Mon Dec 05, 2016 12:34 am

Use a milk crate. If you arent going to repaint the frame, then wrap some pipe insulation or bubble wrap around the frame underneath. I some wood under there too instead of the hard edged plastic.


Image
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Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Mon Dec 05, 2016 6:12 am

Thanks - great pic. Very helpful.
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Sun Jan 29, 2017 12:21 pm

Hello all:

I'm still disassembling my bike and enjoying the process very much. Bagging, photographing and making many notes. It is very therapeutic although I wish I could spend more than two or three hours a week on the project. I've decided to build the bike back to stock save for e-ignition, excel rims, better shocks and maybe a steel tank.

I am having trouble removing the primary sprocket key. It is a tight fit in the crankshaft. I've tried gently heating with a heat gun and pulling with pliers but I am afraid of damaging the crankshaft. I assume that the key must be removed in order for the primary inner case oil seal to slide over the crankshaft. Any tricks or ideas?


Thanks and best regards to everyone.
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby grandpaul » Sun Jan 29, 2017 4:30 pm

Scout63 wrote:I am having trouble removing the primary sprocket key... Any tricks or ideas?

There is a puller that has 2 bolts that thread into the sprocket, and a third larger diameter bolt that screws down against the crank nose to extract the sprocket. Use that.

A small 2 or 3-jaw puller MIGHT be able to get in behind the primary chain, but I doubt it.
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too many bikes to list, including:
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Re: Ben's '72 Interstate Rebuild

Postby Danno » Mon Jan 30, 2017 4:21 am

grandpaul wrote:
Scout63 wrote:I am having trouble removing the primary sprocket key... Any tricks or ideas?

There is a puller that has 2 bolts that thread into the sprocket, and a third larger diameter bolt that screws down against the crank nose to extract the sprocket. Use that.

A small 2 or 3-jaw puller MIGHT be able to get in behind the primary chain, but I doubt it.


Paul, I think he means the woodruff key that locates the sprocket.

Scout, if you have a small flatblade screwdriver (narrower than the key) you can pry the key out by working the screwdriver blade in under the outer edge of the key and levering it up. A little squirt of penetrating oil won't hurt beforehand. Sometimes they get stuck from rust and running.
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Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Mon Jan 30, 2017 5:10 am

Thanks Paul and Danno. I did mean the key. The primary sprocket popped right off using the puller and a couple of taps with a bronze drift. I never thought of using penetrating oil.
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Mon Jan 30, 2017 3:35 pm

Thanks Danno. I applied some penetrating oil before I went to work, and when I came home for lunch I applied some heat and then tapped the key up and out with a thin screwdriver. Total job time about two minutes. The key material appears to be pretty soft and will need to be replaced but that makes sense as it should be softer than the keyway.

Ben
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby Scout63 » Wed Feb 08, 2017 10:01 pm

I was able to spend a few hours today dismantling the bike and have everything bagged and boxed but for the engine and gearbox. Hopefully I'll get those out tomorrrow as we are forecast to get 8-12" of snow and no work. I've been wrestling with whether to go all in and re-plate all of the fasteners. Since I will be painting or powdercoating the frame, painting the cylinders, polishing aluminum, new rims, etc, it seems logical to make everything like new. Part of me likes the idea of keeping the paint and fasteners original. I would degrease them, run them (not the tank) though my ultrasonic cleaner and chase threads. The tank I will compound and wax for now. It is a fiberglass blue/silver Interstate in good shape. I will try sealing it and watch carefully.

I realize that there as many opinions as owners, but I'm interested in your thoughts whether to keep a certain level of patina or go all the way.

Ben
Ben Zehnder
Orleans, MA
1971 BMW R75/5
1972 Norton Interstate - project bike
1978 Yamaha SR500E
1980 Honda XL500S

Scout63
Posts: 56
Joined: Thu Nov 24, 2016 1:27 pm
Location: Orleans (Cape Cod), Massachusetts USA

Re: Ben's '72 Interstate Rebuild

Postby Fast Eddie » Thu Feb 09, 2017 12:17 am

I think you have already committed yourself by having the frame done.

Any old 'scruffy' bits you bolt onto that will now look awful!

When a whole bike has age related patina, it works.

But if you use old fasteners and tin ware with (for example) powder coated frame, rebuild wheels and new seat, then all of those none restored parts will look bad, really bad!

If it has most of its original fixings, keep them as they're good quality and fit properly. Getting them bright zinc plated is usually really cheap too.

Having said all of that, I am utterly unqualified to advise on such matters... I am probably the worlds worst person for managing the 'scope creep' on my own bike projects which ALWAYS exceed my original plans!
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