Ben's '72 Interstate Rebuild

L.A.B.

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It looks as if the factory stamper ( which is a job I would have loved for about an hour) did a poor job of stamping 1972 APR. The Japanese would have sent him out back to contemplate his family’s honor.
I have a feeling the date was possibly added on the production line after the plate was fixed to the frame which could account for the partial stamping on the curved surface and haphazard way it was done.

I ordered another fresh plate and will try again.
It is just a date stamp. Why not just overstamp the '0' with '9', the second 'P' with 'R' and add the 'A'?

After all, if it's too neat and tidy then it doesn't look authentic! :)
 

MichaelB

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Just to confuse matters more, my 2064XX has a MAR 1972 date, updside down.
 
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Scout63

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Great idea L.A.B. I really don’t want to try to get those nice shiny rivets out of my freshly painted frame. I’ll try that. I went back and sorted out which nuts and bolts I wheeled and have ordered replacements from Ella. I’ll re-plate the iso bolts.

My disk came back blasted, painted and ground from True Disk today. Great service, quick turnaround and not expensive. Tom was great and friendly and packed the disk beautifully for the return trip.


First snow here on the Cape this week. If I weren’t spending every penny on the Norton I would consider finally buying some heated gear. I installed a 450w charging system in my /5 about three years ago and should probably utilize it.
 

Richard Tool

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Another heads up Ben - make sure you put the sub harness (really just two leads) on the horn before installing it . I didn’t thinking I could put it on afterwards and now it looks like I have some disassembly to do - PM sent re:same
 

Scout63

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Thanks Richard. Wiring will come next after the engine install. Should I install the horn as well?

Forks torqued and oiled. Front wheel fitted. It was a bear since the front axle had some burring on the outer spindle. I finally realized this and lightly filed it. Then it all came together. I’ll have to recheck everything a few times.

I must say that BMW airhead forks and wheel assemblies are much simpler. Maybe I’m just used to them.

The distance between the brake disk and right fork leg seems very small - maybe 2-3mm to the naked eye. The caliper is a ways off but that installation will show me if the wheel is spaced right.

Starting to look like a motorcycle. Tank and side covers off to the paint shop tomorrow
 

Scout63

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Cradle, rear wheel, gearbox and engine in. Center and side stand on. I dinged the frame quite a bit and will have to touch it up. It’s nice to see it standing on its own.




 

gortnipper

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The locating tab on the brake plate needs to go in its slot for the brake to work!

upload_2019-11-18_17-23-11.png
 

Richard Tool

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Looking good Ben - at the rate you are going you are going to beat me to the finish line . The horn installation is tied in with battery tray & rear fender . I did manage to get my horn sub harness on by dropping the forward end of the rear fender.
 

Scout63

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Thanks for the kind words Richard. Things are slowing down and getting more expensive. Order of assembly and worry that I missed a seal or whatnot in the engine are also taking up too much brain space.

Gortnipper - many thanks for the tip. I completely missed that.

Tonight I started on headlight assembly. Of course I lost the mounting bolts. Also disassembled the right side carb and put the body and jets into the sonic cleaner.


Also lucky to have a good friend with an original 74 850 that he bought new and has never disassembled. It is a great resource
 

Scout63

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Carbs rebuilt and installed. These are the original Amal’s with gasket kits. The jets cleaned up nicely and the actions are good. I thought about getting a set of premiers but wanted to use these if possible and also I got temporarily cheap. Parts are adding up quickly.
 

Scout63

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Its been awhile since I’ve posted pictures. Since Thanksgiving I’ve finished wiring, which took a long time, rebuilt the carbs again with stay up floats, sorted the fenders, rear wheel and brake, checked the static timing on the tri spark, adjusted the valves, installed oil lines, put in gear and engine oil and started the bike for the first time in 38 years. Yesterday I polished the front caliper and installed the front brake line and connections
.

Today during lunch I attempted to bleed the front brake but instead pumped fluid out through the cover. Turns out I just placed the cover gasket inside the caliper instead of placing it on the cover. Looked that way on the parts diagram.

Towards the end of the day my paint man called and told me the tank and side covers were ready. I picked them up, re-tapped the petcock holes and installed the tank:


I also riveted in the port side side cover pocket:


The color is a flat blue that came out a tiny bit darker than the original blue. The tank is an eBay later interstate steel tank replacing this:



I still need to find someone to pin stripe it. I also need to install the side cover decals.

After that, run it, tighten head and cylinder bolts, check timing, adjust the carbs and finally shim the kick start shaft.

I’m still sitting on the 1976 NJ title and rather than deal with the MA Registry I’m going to title and register in Vermont.

Happy long weekend to all.
 

Richard Tool

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Looking good Ben - I’m a little envious . Sunny and 65 degrees a few days ago - 20 degrees today . Spring is coming.
Cheers- Rick
 

Scout63

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Where did you source the seat?
Burtons in the U.K. it looks nice but the finish on the right mounting ear is mottled. I’m going to strip and paint that part of it. Not a big deal and certainly not worth complaining to them.
 

Scout63

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Looking good Ben - I’m a little envious . Sunny and 65 degrees a few days ago - 20 degrees today . Spring is coming.
Cheers- Rick
I know Rick. I can’t wait for Spring but it is a long way away. plenty of time to finish your bike though.
 

Scout63

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I tried and tried to start the bike today with no luck. Took a walk in the woods with my wife and the dog and (tell me if you do this) just thought about the bike. I remembered that the only circuits that I didn’t clean in the carb rebuilds were the pilot jets. I dropped the float bowls and ran a guitar string through the jets with carb cleaner and compressed air. They were almost solidly blocked. Now the bike starts and runs well. Lesson learned. I feel that I understand the Amal’s now.
 

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