Mk3 Jigsaw Puzzel

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GRM 450

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Dec 30, 2008
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Hello to all,
Briefly, I bought a Mk3 1977 Interstate. (low miles, engine rebuilt but a bit tatty, usual story)
I found the steering head bearings faulty and the front brakes bad.
Removed seat and tank, the frames bent. Had the frame straightened.
Gear box was leaking from the kick start shaft.

So, what else is not done properley??????

I decided to do a complete rebuild and learn about Nortons along the way and be sure to the condition and fit of everything.

Luckily I caught the new cam had started to "gal" and was very soft and the lobes weren't ground flat with the shaft.
1 x "D" rod, a new rod was available at a good price.
Crank balanced, Head and cylinder surfaced, new +20th pistons, valves, etc.
Replace the bearings in the gearbox, seals, etc.
Replate all the rusty nuts and bolts, and new isos (which were stuffed) etc,etc,

So I'm onto the best bit, putting it back together. And the reason for this topic.

There doesn't seem to be enough spacers and bolts, all the major ones that hold the large things such as engine and gearbox are there. But some of the small items like the spacers for the top shock mounts and the weird brackets that hold the electrics have (according to the parts manual) spacers as well.

Is there somewhere where the size of these spacers and bolts can be viewed? then I can make them.
I have the part numbers for all these, but that would be expensive to buy and slow down the rebuild.

I'm pretty sure everything that went to the platters, came back from the platters. Maybe these bits weren't there when I pulled it apart? Considering some of the shoddy work I've found this is likley.
I do have way more washers than what I think is needed, maybe these were used as spacers?

Regards Graeme.
 
GRM 450 said:
Is there somewhere where the size of these spacers and bolts can be viewed?
Click to expand...

Fastener dimensions can be found here, using the part numbers of the items: http://stainlessbits.com/link12a.html

There's no spacer list anywhere, that I'm aware of?

If you can list the items by part number, then it should be possible to give you their dimensions?
 
GRM 450 said:
Is there somewhere where the size of these spacers and bolts can be viewed? then I can make them.
Regards Graeme.
Click to expand...

Hi Graeme, try here .....http://www.britishonly.com/estore., if it comes up page not found , click on to "e store " just above the visa card sign or below the Triumph type badge at the top. Then click onto the box where it says "parts search" on the right , shows a bearing and a magnifying glass, it will then show a box, type the part no. in, then click in the box next to it , it will say Bsa, Triumph or Norton, I typed in the part no. for rear suspension spacer, 03-3195, pressed go and it came up telling me what it was and what it's size is. I use it for bolt sizes etc., I don't know if it will give you all the sizes but it should give you some at least.
Cheers
 
Thank you L.A.B. and RBT. I'll do my homework with these 2 sites and if I get stuck I'll ask.
I do appreciate your assistance and owe you both a beer.
Regards Graeme.
 
Those spacers are cheap to buy as I had to buy some lost ones I misplaced during the rebuild of my MKIII. Start making a list of parts, then wait a week before ordering because once you order your parts, more often than not, you'll find you forgot to order a washer or something after your order has been sent. That's happned to me 3 times over the past two months! Now I can't find my rotor nut washer. :oops:
 
Please can someone explain where these bits go?

I know the piece on the left goes with the seat lock, but I can't figure out how it is supposed to fit.

Then there's a triangle shaped bit that looks like it's from a Hilman glove box, I think it goes near the battery. But does it go on the wheel side or the engine side of the gusset?

The third piece that is bent at 90 degrees and has small threaded holes on one side and larger holes on the other.
Mk3 Jigsaw Puzzel



I have the parts and workshop manuals but they only show roughly where these pieces go, and not what fastens them.

Mk3 Jigsaw Puzzel



Mk3 Jigsaw Puzzel



Thank you for your patience.

Regards Graeme.
 
Hi Graeme, great fun isn't it? :lol:
Ok going left to right in the photo,

First piece is the seat lock holder bracket, your lock fits in the teardrop hole the other hole fits over the top shock stud on the right hand side and sits against frame ,(outside), before you put the nut on ... sequence onto stud will then be ... bracket, washer, securing nut, dished washer, dished washer, finally alloy seat knob.

Second piece is the bracket that holds the capacitor in place, see pic of mine before I removed it,
Mk3 Jigsaw Puzzel

if you look at the bottom of my pic you can see the kind of "R" shaped hole that should let you see where it goes, it attaches to one of the mudguard holder bolts and one of the side panel holder bolts as in your third picture , if you are fitting a powerbox or electronic regulator/retifier, you can leave it out.

Third piece , I take it , is an "L" shaped triangle?, it is your soleniod holder which attaches to the frame at the 2 upper holes above the 2 already fitted bolts on the l/hand side of the frame cross bracket in your second picture.

As for the patience aspect.... don't worry about that, I've asked what might seem to some really simple questions, if you don't ask questions you stop learning, everyone needs a hand, remember one question asked probably helps out a few others too.
Right now go and look for the 14lb hammer and chisel!!!!!!!!!!!
Robert
 
Hi Graeme
Commandos use more nuts and bolts and spacers than any other bike I have ever known!
I have one or two left over from my re-build that I naever figured out where they went.
Have you been onto the Andover Norton web site? They have a whole bunch of exploded diagrams that if you point to items it gives you their part number. You just dial in your model.
Dunno if this helps.
Stu.
Stick this in your address line...

http://www.nortonmotors.de/ANIL/Norton% ... del=n850_2
 
Oh Graeme
Forgot to tell you the numbers relate to RGM Motors and Norvil parts distributers.
Stu
 
Thank you Robert and Stu, for the pictures and explanations, that is very helpful.
I have the parts and workshop manuals for the Mk3 but it doesn't show how the "add on" brackets fit to the frame or each other.
I've found that a photograph is worth more than the manuals, but photos are hard to find.
The bigest mistake I made with this bike was not taking pictures as I pulled it apart, I thought as I had both manuals I didn't need to. Big mistake!
I've rebuilt several Ducatis and there is no guessing with them. Things can only go in one place and one way.
Not so with the Mk3, some things don't even look like they came from a Norton in the first place, then add 30 plus years of use and various people working on it and it becomes a jigsaw puzzel with the picture rubbed off.
Very frustrating.

Regards Graeme.
 
GRM 450 said:
The bigest mistake I made with this bike was not taking pictures as I pulled it apart,
Regards Graeme.
Click to expand...

Putting bikes together years ago you just had to rely on illustrated parts books and manuals if you weren't sure, but one of the biggest bonus's of the tech era is the digital camera, instant reference!, but as you say it's remembering to take the pics. I wish they had been available when I bought my £75 Mk1 Le Mans which had been on fire , well an engine & box, frame , couple of fork legs, 2 wheels and some cycle parts, I only had manuals, ref & parts books, same for the Lightning Clubman which I also got in boxes.
Great bit of equipment ... only if you remember to use it :D
Good luck with the rest of it!
 
Robert,
A mate is re building a Mk1 Le Mans at the moment, so if you haven't finished yours I would be happy to take pictures.
It may take him a while to progress though, it's been engine, frame, forks and swing arm for 6 months now.
I'm going to help him progress on his 450 Ducati this weekend, it's been half built for 2 years. (but then a 450 only has one quarter of the pieces of a Commando)
Regards Graeme.
 
GRM 450 said:
Robert,
A mate is re building a Mk1 Le Mans at the moment, so if you haven't finished yours I would be happy to take pictures.
It may take him a while to progress though, it's been engine, frame, forks and swing arm for 6 months now.
I'm going to help him progress on his 450 Ducati this weekend, it's been half built for 2 years. (but then a 450 only has one quarter of the pieces of a Commando)
Regards Graeme.
Click to expand...

Hi Graeme , thanks for the offer but I did it years ago. I could PM you a couple of before and after pics if you like?, don't want to put on this thread as it's slightly going off thread. I got it for £75 from a guy who told me nobody could do it, well I had to replace nearly everything and managed to source a new tank and seat from Italy, (in the days before internet!). Let me know if you want a couple of pics.
Robert
 
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