Mitch's 72 Basket Case
- Thread starter htown16
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htown16
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- Apr 29, 2009
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Have been waiting on some new valve springs to get here to do the head, so I decided to work on putting the primary together. It's been a bit of a puzzle solving process since the person that disassembled the bike dumped all the hardware including the various primary shims and spacers in a large box without labling anything. Anyway, its all back together and there doesn't seem to be any clearance issue and the two sprockets are in line.
Inner cover on, engine sprocket, clutch basket and primary chain installed.
New Sparx three phase alternator, still looks strange with the rotor/stator misalignment. I'm going to check the output once its running. If I need to add shorter spacers behind the stator, It shouldn't be much of a problem.
New Sureflex clutch plates and Dyno Dave clutch seal
Pressure plate back on and everything snugged up.
Outer cover polished up and installed, need a new drain plug.
Next project is to get the clutch lever and cable installed and check its operation, also to rebuild the front brake hydraulic system. Over and out.
Inner cover on, engine sprocket, clutch basket and primary chain installed.
New Sparx three phase alternator, still looks strange with the rotor/stator misalignment. I'm going to check the output once its running. If I need to add shorter spacers behind the stator, It shouldn't be much of a problem.
New Sureflex clutch plates and Dyno Dave clutch seal
Pressure plate back on and everything snugged up.
Outer cover polished up and installed, need a new drain plug.
Next project is to get the clutch lever and cable installed and check its operation, also to rebuild the front brake hydraulic system. Over and out.
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- Oct 19, 2005
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Ugh I can fish through the bins to pick out the parts by feel now but first few times even with the parts at hand confused me to get it all right first off, as some extras snuck in or left out by those before me. Just did another commute this am - such a delight to have a holiday cruise delight work day on a Commando.
htown16
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Cranked up the a/c and spent some quallty time in the garage yesterday.
Head with new black diamond valves, springs and seals ready to install. I previously installed new bronze guides then sent the head out to have the guides reamed and valve seats recut.
Valves installed. Head was skimmed .006. Cylinder block .002. Head was a standard compression. Figure I am approaching Combat spec but not quite there as the Combat spec heads I have seen pictures of are almost flat with the fins and have the pads ground down more.
Rockers ready to be reinstalled.
Everything together and ready to go back on the bike.
Head with new black diamond valves, springs and seals ready to install. I previously installed new bronze guides then sent the head out to have the guides reamed and valve seats recut.
Valves installed. Head was skimmed .006. Cylinder block .002. Head was a standard compression. Figure I am approaching Combat spec but not quite there as the Combat spec heads I have seen pictures of are almost flat with the fins and have the pads ground down more.
Rockers ready to be reinstalled.
Everything together and ready to go back on the bike.
htown16
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Update time
Pushrods in head held in by shop towels. Ready to go back on bike. Removed the front iso bolt and tilted the engine down to give maximum room.
Head on and snugged down. Still need to torque and adjust valves but everything rotating freely.
Caliper parts layed out and ready to assemble.
Caliper on bike along with new ss line
Master cylinder bits ready to assemble.
Master cyliinder back on bike. I decided to go with a silver finish as it seems like the black is always getting chipped up and damaged by brake fluid.
I have a spare mc that I may send out to have sleeved down if I am really unhappy with the stock one.
Pushrods in head held in by shop towels. Ready to go back on bike. Removed the front iso bolt and tilted the engine down to give maximum room.
Head on and snugged down. Still need to torque and adjust valves but everything rotating freely.
Caliper parts layed out and ready to assemble.
Caliper on bike along with new ss line
Master cylinder bits ready to assemble.
Master cyliinder back on bike. I decided to go with a silver finish as it seems like the black is always getting chipped up and damaged by brake fluid.
I have a spare mc that I may send out to have sleeved down if I am really unhappy with the stock one.
htown16
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- Apr 29, 2009
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More Progress
Horn installed before I go any further.
Oil tank cleaned up and installed and plumbed.
Rear fender and tail light installed. I'm using a lot of pattern parts now and having to do a lot of fetteling to get them to fit.
Center and side stands and cleaned up hardware ready to install.
Up on the center stand. The spring was a major pia, but I got it on. Unfortunately, it put a few gouges in the powdercoat. Have installed the tank, seat and side panels, at least for the time being. Will have to get out my level to put on the side panel decals.
Horn installed before I go any further.
Oil tank cleaned up and installed and plumbed.
Rear fender and tail light installed. I'm using a lot of pattern parts now and having to do a lot of fetteling to get them to fit.
Center and side stands and cleaned up hardware ready to install.
Up on the center stand. The spring was a major pia, but I got it on. Unfortunately, it put a few gouges in the powdercoat. Have installed the tank, seat and side panels, at least for the time being. Will have to get out my level to put on the side panel decals.
htown16
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- Apr 29, 2009
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The other bikes get ridden on a regular basis, so any repairs on them always take priority over the Norton build.
Time for a bit of an update
Polished Z-plates and related hardware ready to be installed.
Headlight shell and front fender on.
Exhaust system ready to install. Commando Specialties with seamless mufflers.
When the RH muffler was installed it fouled the kick starter, so I ordered this 850 style type. Compared to the old 750 piece.
Everything together on the right side.
Left side view.
Next challenge is to install the wiring harnesses and hook up all the electrical bits including the Pazon ignition. Seeing as how I am somewhat red/green and blue/purple color blind I am going to have to have my wife help me sort the connections out. This should be interesting!
Time for a bit of an update
Polished Z-plates and related hardware ready to be installed.
Headlight shell and front fender on.
Exhaust system ready to install. Commando Specialties with seamless mufflers.
When the RH muffler was installed it fouled the kick starter, so I ordered this 850 style type. Compared to the old 750 piece.
Everything together on the right side.
Left side view.
Next challenge is to install the wiring harnesses and hook up all the electrical bits including the Pazon ignition. Seeing as how I am somewhat red/green and blue/purple color blind I am going to have to have my wife help me sort the connections out. This should be interesting!
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- Aug 8, 2005
- Messages
- 2,708
Nice built htown16.
Keep it up.
FYI. A bit of constructive criticism on the exhaust lock rings. They look pretty…. 8) But these are designed for use with the exhaust pipe collets on a cross tube exhaust system on an 850 and have a shorter thread engagement than the 750 exhaust lock ring for single pipes. By adding more corrugated exhaust seal rings is a” band aid fix”, it still does not give you the strength that a 750 type exhaust ring gives just by having more thread engagement into the aluminum head. Using this set-up has caused most exhaust port repairs that I have seen. First hand experience here as well. :cry:
Regards,
Tom
CNN
Keep it up.
FYI. A bit of constructive criticism on the exhaust lock rings. They look pretty…. 8) But these are designed for use with the exhaust pipe collets on a cross tube exhaust system on an 850 and have a shorter thread engagement than the 750 exhaust lock ring for single pipes. By adding more corrugated exhaust seal rings is a” band aid fix”, it still does not give you the strength that a 750 type exhaust ring gives just by having more thread engagement into the aluminum head. Using this set-up has caused most exhaust port repairs that I have seen. First hand experience here as well. :cry:
Regards,
Tom
CNN
htown16
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- Apr 29, 2009
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Been a while, but time for an update.
Have installed the reed valve breather from Mikes XS650 along with a breather filter.
Carbs rebuilt with new innards including stayup floats and ready to be installed.
Carbs back on the bike with K&N airfilters. Those manifold bolts are a pain. Also very little clearance for the airfilters.
New rear wiring harness going on.
New front headlight harness.
Battery in with new hardware. Sparx rectifier above airfilters
Cool Cat assimilator replacement and Pazon ignition. All the wiring is hooked up now and functional, ignition, lights, horn even the warning lights. Amazing what a new harness will do. I kept all the stock leads intact so that it could be potentially put back to standard.
Well all the bins and baggies have been emptied and every last part has been bolted on. Thank goodness no unkown pieces left over.
Just taking a break for a few weeks to sit back and admire, then try to fire it up and begin the sorting process.
Have installed the reed valve breather from Mikes XS650 along with a breather filter.
Carbs rebuilt with new innards including stayup floats and ready to be installed.
Carbs back on the bike with K&N airfilters. Those manifold bolts are a pain. Also very little clearance for the airfilters.
New rear wiring harness going on.
New front headlight harness.
Battery in with new hardware. Sparx rectifier above airfilters
Cool Cat assimilator replacement and Pazon ignition. All the wiring is hooked up now and functional, ignition, lights, horn even the warning lights. Amazing what a new harness will do. I kept all the stock leads intact so that it could be potentially put back to standard.
Well all the bins and baggies have been emptied and every last part has been bolted on. Thank goodness no unkown pieces left over.
Just taking a break for a few weeks to sit back and admire, then try to fire it up and begin the sorting process.
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