Commando Cafe Racer Rebuild

Re: Commando Cafe Racer Rebuild 5th August 2009

Gee you guys don't make it easy do you? I've got one chance to move this bike on before I'm well and truly lost. It'll have new Battlax's on it in week, it's getting very close to a going proposition. I've spent a fair bit of time riding around this state with my mate Ben who owns one of those dual-purpose BMWs (what Charlie and Obe-wan ride) and was really impressed with it's abilities, so thought one of the K series road bikes would be a goer. Now my line of thinking could veer into realms that may not be terribly viable in terms of domestic harmony - if you get my drift.

If I really had the $ and there was one available, my true object of desire is the Guzzi 1100 Sport from the mid-90s. Maybe they've still got some soul - and an acceptable seating position!

Re: Commando Cafe Racer Rebuild 5th August 2009

Beemers do tend to be a bit like my Goldiwng, just turn the key and they go. I have a couple friends who commute on them and they are great for that. They did make a couple of pretty hot ones but they are rare, there is a bit of an oilhead cafe type that is very quick.
It is nice to have reliable bikes to ignore while you work on your Norton though. I ride the wing to work and do errands on my Chang (BMW design), leaving the Norton for pleasant sporting use.

Re: Commando Cafe Racer Rebuild 5th August 2009

I obviously love my Nortons (and Ducati's), but have to say my R1100RS is the best all-around bike I've ever had. The 4-valve twin ain't your Grampa's airhead. The quick on/quick off hard luggage makes it great for a five or six day trip. The RS isn't as heavy and full of tupperware like its RT cousin. It's still easy to do your own maintenance and repair like the Norton. With fully adjustable, dialed in, Ohlins shocks it will stay with most sportbikes in the twisties, despite its heft. It does it all admirably, good power, good handling, good comfort, good reliability, but would not be top of the class in any one of those arenas. My biggest complaint is tire wear and that is probably due to my riding style. Unfortunately, BMW chose to discontinue this model .

That's the fun thing about motorcycles. There are so many different personalities.

Re: Commando Cafe Racer Rebuild 5th August 2009

Thanks for the thoughts guys,

I've been looking at the R1150RSs Ron and I think they're a goer. Some nice ones out there at good prices although mileages can be a bit high. Just have to see how far the budget goes and what I get for Commando and the TRX. If only I could keep them all. Sometimes life really sucks.

Anyways, progress continues on the Norton - heading towards rego now. Both wheels off (that's tricky) and down to get new rim protectors fitted. Humm that looks better doesn't it.

I've decided to fit the dual Fiamm horns that were originally on it, tucked these in under the fairing pointing forward. Have yet to wire them in, will do that one night this week. Discreet until pressed into service.

I've also decided to refit the oil cooler that was on it. Can't do any harm and I've no other use for it. Should be sorted by the end of next weekend. The return side (my thinking) of the oil circuit or the supply side - any thoughts?
Good news too from Vice Roads, I've been worried about it not passing noise limits, even though the zorsts are standard, they're pretty loud, but all vehicles before 1975 are ADR exempt, so should get through alright.
Have also found the frame/serial badge thingy amongst the junk. Can't make much of it out and will have to get a new one, punch in the details and rivet it to the frame somewhere.
Now all I need is a mirror...

Re: Commando Cafe Racer Rebuild 5th August 2009

Man, I sure like your bike. I'll never sell my Interstate tank, even if i sell the bike!

Re: Commando Cafe Racer Rebuild 5th August 2009

Cookie said:

Beemers do tend to be a bit like my Goldiwng, just turn the key and they go. I have a couple friends who commute on them and they are great for that. They did make a couple of pretty hot ones but they are rare, there is a bit of an oilhead cafe type that is very quick.
It is nice to have reliable bikes to ignore while you work on your Norton though. I ride the wing to work and do errands on my Chang (BMW design), leaving the Norton for pleasant sporting use.

Click to expand...

My brother runs a Boxer Cup replica and that is a nice bike.

Re: Commando Cafe Racer Rebuild 5th August 2009

Thanks GP, you have excellent taste , yeah it's really beginning to take shape. Don't want to sell now, but really have little choice in the matter.

By the way, I found Dunstall rep seats and fairings for sale on EB (Australia) today for anyone that's interested. Eagle screens in West Aussie will also have a mould for the screen as they made me a newy from the original.

And check out this one for sale: 1974_Mk2. Pretty big money!

Re: Commando Cafe Racer Rebuild 5th August 2009

One thing for sure, you never get out of it what you spend.
Wifey now understands that, so I am limited to one scooter at a time, and the commando just kinda grows on me.
I'll never have enough time or money to make it all I want, so now and then I entertain the thought of selling and getting a monster 1000, but hell, I got a kid in college. Then I'll go for an afternoon sprint, stop for a guiness, and the thing is like a magnet. So the norton stays.

Re: Commando Cafe Racer Rebuild 5th August 2009

I have seven bikes and a sports car, which indicates a very tolerant wife I think. She has encouraged me to get another bike whenever she sees a deal. I've stopped buying now since I'm out of room to store them, and it would have to be a tremendous deal I couldn't pass up.
My old norton is still in the mode where it breaks something that costs $100 on every ride but I'm hoping that ceases for a while soon. This is much better than the mode where you get a ride and it costs $1,000 so there is hope.

Re: Commando Cafe Racer Rebuild 5th August 2009

Look on the bright side, Cookie. At least if you drop it in your driveway, it's not going to be a write off, unlike most modern things.

Re: Commando Cafe Racer Rebuild 5th August 2009

Had a bit of spare time over the last couple of days and have had to keep myself busy. Thought I'd dig out the oil cooler and lines that came with the bike and see about refitting the whole show. The original job was just a bit too slapdash for me, I redesigned most of it, just keeping the pre-formed pipes. I decide to make it 100% removable, so have used clamps to secure the radiator to the frame. I've pushed it down as low as possible and it doesn't impede air flow to the barrel fins. Again you've got to consider this is what was done in its day, maybe not what you would do again now.
Here's the final mock-up from the side:

I haven't got the radiator exactly level here and will trim back the excess thread length. The u-bolts are stainless and covered in heat-shrink.
The cooler is mounted in grommets with about 3mm of compliant travel, there is no metal-to-metal contact.
My my, that frame could do with a repaint.

Thoughts? Like it? Don't like it? Should I keep it on, or just provide it as a complete 'kit' for the new owner when it goes up for sale?

If you have to sell it then do as little work as possible. Throw it in a box and let someone else worry about it.

Living in Victoria, as you do, I personally wouldn't bother with it. Oil coolers on these motors are really only any value if you are consistently riding in real heat, ie, 40 deg C . I've seen some test figures on oil-tank temperatures in Commandos, and in cool weather they are barely making a proper operating temperature for the oil. An oil cooler in this situation would have to be wrapped up to keep the oil warm enough. Remember these are dry-sump motors--the act of circulating via an tank vs circulating around a wet sump has an inherent cooling effect.

Well it does get rather warm over here Ranmar, had quite a few +40 days last summer, couple at 46. For probably the first time in my life I'm actually not looking forward to this summer. Couldn't go through another week like the horrors we had. Everytime we go riding it seems we end up passing through areas that were burned - no matter which way we go. Enough of that, let's just hope that it's better this time.

Over to a more positive topic. Cooler installation. Yeah but, yeah but... y'see, it was what they did in them there days to soup up their bikes. Didn't matter that it was useless or perhaps even cost power due to extra viscous drag from over-cooled oil, it was just what you used to do. Like painting the barrels black or fitting a 4:1 and bikini fairing, it was all de rigueur. Didn't have to be effective, it was all bragging rights at the pub. I'm trying to get that feeling back without it being stupid. Damn. It's hard to describe what I'm on about. You probably think I'm nuts. Well I finished it today and I'm pretty pleased with the result. Pulled the plugs and kicked it over for a few minutes to check oil circulation was ok.

Now I haven't started the bike for a month or so now and it's always been a bit of a lottery to get it running, but then it seems to run ok after it does start. I decided to investigate further and found that the eccentric cam on the points shaft has side-to-side play. About 1mm I'd say. My guess is that this is really not good as it must play havoc with the timing. Can anyone tell me what wears? Is it the cam itself or the shaft or both? I guess there's no fix other than replacement? The whole mechanism? I'd rather get this sorted and the bike running nicely before trying to refit the Rita, that might be just adding another variable to the equation - not wise.

I can see a rebuild comming up. So here's your chance to paint your frame.
You lucky devil !

GRM 450 said:

I can see a rebuild coming up. So here's your chance to paint your frame. You lucky devil !

Click to expand...

Not with you GRM? You mean I'll stiff the engine from putting the cooler on or it's already been done as a result of bad ignition timing?

I just went and pulled the points plate off and checked a bit further - I exaggerated at 1mm slop, it's only about 0.5mm. Still seems to be way too much. That must translate to many degrees of setting. I note there is only a single centrifuge weight. Sure looks like it's meant to take 2 (as shown in the diagram). I'm really going to have serious words with my engine builder. I paid good money for all these foul (insert preferred word here) ups. Bloody pathetic.

Sorry Davamb, I was trying to suggest an excuse for you to keep your Norton, not that your engine was, or will be, damaged in any way.

'salright GRM, with you now. Just don't think the missus would buy it: "you'll fix it - you always do" gets me out of a funk when I'm at work, she'll just use it for this as well. If I had my druthers, I'd pull it all down again, get the frame nickel plated, the dodgy steel rechromed, the paintjob redone, wheel bearings replaced, and so on - you name it. It would end up as one of those legendary shed finds - discovered in concourse condition (but never ridden) after I pass on from old age. I might do that with the Pantah, but this bike I've got to move on before I get too much more attached to it!
Got some shim brass, might go and have a fiddle before turning in.

I have a Boyer Micro Mk111 that was in a box of the original stuff that came with my bike. It had a new Pazon fitted when I bought it.
If the Boyer will fix your points drame you can have it.
I can only assume it works or it would have been thrown away, no warranty though.

the black box with 3 and 2 wires is there, the pick up plate, and the rotor with the fixing allen bolt.
Let me know if you want it.

Maybe it'll help get the Pantah rebuild started.

graeme

Much thanks Graeme. Depending on how I go in this tomorrow, I just might take you up on that generous offer.

I looked at the points shaft and you can definitely feel a groove worn on it, no doubt a matching one inside of the cam. Dug out the shim and cut a 3mm wide strip to just wrap around the shaft. Put the cam back on and then pressed the shim band in between cam and shaft. Ah ha, that's how it's supposed to be! Turns smoothly and easily on the advance but now no side slop. Gives you some idea of how worn it is. This may not be effective long term (the shim might move further in and the cam will seize to the shaft) but will prove my diagnosis and hopefully allow me to get it running again. Will have to dig out the junk box and see if there's another advance weight. Just can't think of why you would want to toss one away. Maybe misplaced when the Rita was put in? I haven't analysed the schematic yet (not sure I want to), but I presume the advance is electronic.

So tomorrow afternoon, got to give the neighbors some peace Sunday morning, I'll give it another go and see what transpires. Maybe the Pantah start isn't that far off after all!