Norton build sequence

Is there some inclusive resource out there which provides build sequence guidance for the re-assembly of a Norton Commando?

I have acquired a basket case 1972 Commando Combat. It appears to have all of the larger parts, at least, and I need some guidance in the assembly sequence so as to avoid installing parts that get in the way of the installation of other parts.

Also, some assistance with individual assembly details would be helpful.

I have the OEM service manual and the parts book.

I am starting to reassemble mine. Here are a few random pictures that may or may not help.

Think I mounted battery tray first ... should be info on the “rebuilds” portion of forum ....
Craig

Yep, go to the "rebuilds" section, and check on any one of many. I know all of mine have numerous pictures every step of the way...

Craig said:

Think I mounted battery tray first ... should be info on the “rebuilds” portion of forum ....
Craig

Click to expand...

BEFORE mounting the battery tray, you have to mount the horn to it, and connect the wires!

You are right! That thing is really tucked away. I am going to relocate it in a more serviceable location.

My horn is mounted to the provided threaded boss on outside front of battery tray , below carb ....it was the last thing I attached

This motorcycle is indeed built around the horn !!!

Root canal and replace horn are equivalently painful terms...

Some good info here; http://www.oldbritts.com/ob_new_bike.html

I just happen to have spent the last week disassembling my 73 Norton and I wrote down the whole sequence for reassembly, here it is.

1. Front forks (as a unit)
2. Transmission, cradle, and swing arm(as a complete unit)
3. Engine(as a complete unit)
4. Primary case and drive
5. Front fender
6. Front wheel
7. Brake caliper
8. Horn (mine is an aftermarket one that attaches to the front of the bike by the fuel tank)
9. Headlamp assembly w/ harness
10. Front signal lights
11. Tach and Speedo Cables
12. Right Hand lever assembly w/ master cylinder
13. Front brake line
14. Left Hand lever assembly
15. Clutch cable
16. Main Harness w/ ignition system, zener diode, capacitor, rectifier
17. Rear fender
18. Tail light assembly
19. Battery box (connects through isolastics so might be better to put on with that)
20. Rear wheel assembly
21. Center stand
22. Footrest support plates w/ footrests and rear brake cable & wiring
23. Passenger footrest and exhaust mounts
24. Exhaust
25. Oil tank
26. Side covers
27. Fuel tank and seat

I've probably missed some details in there, like carbs, which could probably be put in around 16-17
and the stock air filter is a real pain in the ass to get in there, still not sure the best way or which point to put that in.

You can pretty much follow this

http://www.oldbritts.com/ob_new_bike.html

Hi Brian G,
I am also the proud owner of several boxes of what was once a 75 mk 3 commando. After several years the engine, gearbox and isolostics are finally rebuilt and in place. after refitting oil tank and pipework I now find the airbox should have been the start point followed by oil tank.....hmmm. A rebuild sequence would ease some pain. Did you find any such manual ?

I rebuild the engine bottom end on the bench, Then install it in the bike after I've installed the gearbox. Then build the primary. Lock the bottom end by locking the primary chain and install the timing case bits. Then the barrel with pistons and rings. Then the head. The frame holds everything to bolt it together and it's a lot easier for one person than trying to manuever the complete engine into the frame.

Very first install the horn. That rascal is so buried you need to dismantle the whole thing to get at it. Sort of just kidding...maybe not.

I agree!

1. Install Horn

2. Put rest of bike together around it.