72 Combat Proddy Build

Re: 72 Combat Proddy Build- It begins...

O.K. I'll try again if you look at the first picture you can see a hole second from the right on the bottom, This hole is the oil pick up hole it also shows the one Norton added to try to help with the oil pick up but it only made it worse, This is because it would start to suck air at high rpm. This Second hole from the right meets the drive side case where it is cut out and is not covered. I hope this helps, Chuck.

Re: 72 Combat Proddy Build- It begins...

So, back to the build...



I got the XS650 valve from pvisseriii today and test fit the location I was thinking about. I didn't have the right size hose (I think I might try clear here) but I did have some hose to try the other end.



A little ungainly but I'll see if it will work.

Re: 72 Combat Proddy Build- It begins...

This is basically another post telling someone how NOT to do something.

But first the good news:




And now the easy stuff:



I did have to hog out a couple of the holes. These, if you don't recognize them are the headsteady rubbers. Supposedly more robust that the oil tank ones.

And now fitting the tank strap. You gotta stretch these suckers.


Confirms I need to trim the top of the oil tank.

Now the harder stuff. That bottom one did not want to go in. And of course I forgot to buy brake fluid so can't put the pistons in yet.


If you didn't know some replacement spindles have both the MkIII slots and the single bolt hole for the earlier ones. Which means when I get Windy's clamps next week I'll see if I can take advantage of the flats.


Test fit, actually pretty snug. Which end does the threaded end go?

First challenge:

Rear iso stud. Damn that thing is long. I think I'm going to have to trim it. Also I can't figure out why the threads are longer at one end.


I know the rearset plates are thinner but surely not by that much.

And now, for those of you taking notes... why you can install the iso gaiters and keep the engine still within the frame... you don't want to. Resist any urges to install the engine until you have the gaiters. :|

Yeah, I basically had to pull everything off, suspend the engine and pull the cradle to install all the gaiters. Sucked but I got it done.

Re: 72 Combat Proddy Build- It begins...

swooshdave said:

If you didn't know some replacement spindles have both the MkIII slots and the single bolt hole for the earlier ones. Which means when I get Windy's clamps next week I'll see if I can take advantage of the flats.

Click to expand...

dave the flats facing the clamp bolts WILL NOT WORK. put the spindle in with the flats facing forward which will put the threaded end towards the primary case. i will email you the instructions on proper placement.

Re: 72 Combat Proddy Build- It begins...

Swoosh, If you put the threaded side of the spindle on the right gearbox side you dont have remove the primary to service the swinging arm Phil

Re: 72 Combat Proddy Build- It begins...

Norton-Villier said:

Swoosh, If you put the threaded side of the spindle on the right gearbox side you dont have remove the primary to service the swinging arm Phil

Click to expand...

That's what I was thinking.

More parts coming next week...

Really need to get the swingarm on so I can see what's missing on the back end.

Plan for the wheels is to put the ones I have now on to complete the build and then take them off and cut the hubs out, rebuild them and send them to Bucanans for some alloys.

Re: 72 Combat Proddy Build- It begins...

Now we're really going to see who's reading this thread. :mrgreen:

So I know ya'll are reading the headsteady thread too, right? the-keith1069-headsteady-t5862.html

Anyways, in addition to the package from McMaster-Carr with the rod ends there were also a few other bits in there. More on these later.

I also received what will probably be the last package from my brother. Which is a good thing because I think my sis-in-law is tired of having to go to the Post Office for him. :mrgreen:





First up are some side covers. I laughed as soon as I saw them in the box. I so remember these poor things. I don't remember where they came from but I remember how sad they looked. Ironically it looks like yellow paint under the thousands of other layers of paint. Half-tempted to leave them and make a rat bike. :wink:

Next is these:

Little surface rust but serviceable. I recall someone mentioning how these should be orientated. Care to refresh me?


Swingarm bushings. More on these later too.


This looks to be rear axle parts. Dummy axle and some other stuff. We'll look at this after the swingarm is on (hopefully this weekend).


No idea what these parts are. Maybe the chaincase center nut? Is that bracket to hold the alternator wires?


Lastly, just so I can confirm, this is the right order for the bushings? Best to ask now before pressing them in... I can feel the spindle snugging up just from the bushings being put in slightly. I feel a ream coming on. I'll clean up the swingarm holes better, there's some stray powdercoat in there. Take a hone to them.

Re: 72 Combat Proddy Build- It begins...

And now the stainless. Hee, hee. I do luv me the stainless. Especially buttonheads. Perhaps a sickness, I don't care. :mrgreen:


Sharp eyes may have spotted these in the previous post. 3/8 buttonheads for the side plate. Dang they look good.


And stainless 5/16-18x7/8" for the intake manifolds.



And now we have the airbox bolts. The stock ones are just so wrong. These scream for socket heads. So much easier to get to without the hex heads.

Se here's the deal. Had to buy extra of the intake manifold and airbox bolts. I want to give back to the forum just as so many have given to me.

I am going to give away two (2) sets of the airbox bolts. Just be the first two people to PM me with your address. Sorry, but US only.

I am also going to give away two (2) sets of the manifold bolts. Just be the first three people to PM me with your address. Again, US only.

The only rules are (aside from US only) is that you have to post a picture of the parts installed on your bike. For the airbox bolts you have to have to be hardcore and still have your Amals. :mrgreen: I don't know if you can use the manifold bolts on the Mukunis. If you get them and can't use them I'd ask that you post them for someone else who can. You can use this thread to post if you want. Also one set (either) per person, unless no one is interested and I'll gang them up.

(note, the side plate bolts are not available, even if they were they are so sexy I'd never let them go)

Re: 72 Combat Proddy Build- It begins...

Don't forget the seals that go behind the bushings.

Re: 72 Combat Proddy Build- It begins...

No idea what these parts are. Maybe the chaincase center nut? Is that bracket to hold the alternator wires?


Inner primary case locking tabs - three 1/4" bolts that hold the inner case to the crankcase. Clutch center nut locking tab. Bracket is for the rear brake light switch wires. Cap nut is primary case faster - the only thing holding the outer primary on.

Re: 72 Combat Proddy Build- It begins...

illf8ed said:

No idea what these parts are. Maybe the chaincase center nut? Is that bracket to hold the alternator wires?


Inner primary case locking tabs - three 1/4" bolts that hold the inner case to the crankcase. Clutch center nut locking tab. Bracket is for the rear brake light switch wires. Cap nut is primary case faster - the only thing holding the outer primary on.

Click to expand...

That is right. Thanks.

Re: 72 Combat Proddy Build- It begins...

Hortons Norton said:

Don't forget the seals that go behind the bushings.

Click to expand...

If you recall the previous page there was a bunch of parts from Old Britts. In there are the o-rings and dust covers. I'll dig them out and then mock it up again to see if I'm right. Maybe tomorrow night.



The two small o-rings go in the ends with the end caps. Does this look right now?

How do you press the bushings in and make sure they are square to each other? Pray?

Re: 72 Combat Proddy Build- It begins...



swingarm on (temporarily) until I can get some oil and lube it a little before assembly.

Re: 72 Combat Proddy Build- It begins...

swooshdave said:

Next is these:

Little surface rust but serviceable. I recall someone mentioning how these should be orientated. Care to refresh me?

Click to expand...

As shown in the photo = The one shown on the left is the left side bracket.


If you were to fit them on wrong side, then the bracket slots won't be set horizontally.
The triangular brackets are not quite symmetrical, nor are they positioned centrally on the bracket tubes, so the headlamp ends up pushed toward the instruments if the brackets are fitted on the wrong way.

In my photo, the bracket on the bike is a left side one fitted correctly, and the right hand bracket is held in the foreground to show what it would look like with a right hand bracket upside down on the left side.

Re: 72 Combat Proddy Build- It begins...

swooshdave said:

No idea what these parts are. Maybe the chaincase center nut? Is that bracket to hold the alternator wires?

Click to expand...

060395 inner primary case-to-engine-bolt tab washers,
040374 clutch centre nut tab washer.

060693 rear brake switch wire guide (with grommet) that fits onto the lowest stud of the L/H footrest hanger. http://www.nortonmotors.de/ANIL/Norton% ... 25&Part=19 - Items [19] & [20].

Re: 72 Combat Proddy Build- It begins...

L.A.B. said:

060693 rear brake switch wire guide (with grommet) that fits onto the lowest stud of the L/H footrest hanger. http://www.nortonmotors.de/ANIL/Norton% ... 25&Part=19 - Items [19] & [20].

Click to expand...

I have to figure out how it'll fit on the Norvil rearsets.

Of course that parts manual picture is COMPLETELY useless. The part is laying on what looks like a giant turd, which is probably an accurate description of a Lucas wiring harness.

Anyone have a pic of the bracket actually in place?

Re: 72 Combat Proddy Build- It begins...



These are the mufflers that will go on the bike. We this thing fires up the folks in California will think it's another earthquake and the folks in England will think their island is sinking. They are THAT loud. :mrgreen:

Re: 72 Combat Proddy Build- It begins...

SwooshDave,
nice pics, I've got to learn the digital age thing.
I'd like to do same during my gear box surgery.
I know you asked me earlier in another posting re: Norton Fashion
about a pic of my yellow Davida helemt. The only pic of the helemt is in my avatar pic.
David and Les are nominated for the new game show what's my part?
Good job on the diagnosis of them artifacts in the pic.
I remember once I got my swing arm back on and I could place it on the center stand
it was all enthusiasm to get it done after that.
It's coming to gether nicely.
I'll listen for them pipes in Penna. :wink:
Marshal

Re: 72 Combat Proddy Build- It begins...

swooshdave said:

I am going to give away two (2) sets of the airbox bolts. Just be the first two people to PM me with your address. Sorry, but US only.

Click to expand...

First set is going to Pennsylvania.

Re: 72 Combat Proddy Build- It begins...

Oil tank






Took the tank to my machinist who stripped and cleaned it. Best $20 I ever spent.

Hung it up to paint and then remembered to trim the top seam. I had bought a Harbor Freight "High Speed" Cut off air tool. Normally I luck out with most HF crap and this time I didn't. It wasn't high speed, in fact I think I could slow it down with my tongue. :| But it ground enough off I could take the rest off the bandsaw and finish it with a sanding disk on the angled die grinder (also HF but actually works).



Got it painted with hi temp paint (how hot does the tank get?). Luckily it gets a cover. I may post a picture later...