Norton Commando Build
It's been about 50 years since production ended, and there's still quite a few low-mileage Commandos out there. One of the main reasons for all these low-mileage examples is previously attempted repairs by less than qualified mechanics.
After sitting non-running and partially disassembled for 20+ years, this 1974 Roadster is getting a complete overhaul front to back.
Is The Bike Worth It?
The Good Stuff - The frame is straight and solid, engine and frame numbers match, it has a clear title, and it came with boxes of good original parts.
Other Good Stuff - It's a very low mileage bike, last registered 33 years ago. The speedometer and title show less than 10k miles.
The Bad Stuff - The wiring harness had multiple splices. I counted no less than a dozen! Unfortunately, this is fairly common on many old bikes.
The solution here was simple--buy a new factory harness from Andover Norton.
Other Bad Stuff - Both front forks were badly pitted, and the only solution was to remove and replace the fork tubes.
Read: Front Fork Disassembly
Read: Front Forks Overhaul
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Engine Teardown and Inspection
Although it's a low mileage bike, it's still half-a-century old and sat unused for more than a decade. So, engine teardown and inspection was in order.
More Bad Stuff - The internal exhaust threads in the cylinder head were stripped, which is not uncommon on Commandos, as the screw-in exhaust nuts often vibrate loose and damage the port threads.
Removing a Commando cylinder head is time-consuming.
Read: Timing Cover Removal and Installation
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Read: What Are Whitworth Tools?
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Brake Caliper Overhaul
Fifty-year-old brake calipers do not come apart without a struggle. Since the bike had sat for a long time, there was concern about the caliper pistons being stuck and corroded.
Before and After Caliper Overhaul
Read: Brake Caliper Overhaul
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Repair or Replace Head?
I contacted Jim Comstock, a well-known Norton specialist. After looking at the pictures, he said that the fins and the exhaust threads were repairable, but he's back-logged with work for at least six months. I emailed several other places, but unfortunately, they don't have the same expertise as Jim does.
Plan "B" was to find a good replacement head. Either way, the old head had to be taken off.
Read: Norton Commando Cylinder Head Removal
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After several weeks of sending inquiries to ebay sellers and classic bike specialists, I found a good used head on ebay.
Upon disassembly, I found that the valve guides and seats were in very good condition. All the head needed was a good cleaning.
Read: Clean Carbon Off Cylinder Head
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Cleaning Spoke Wheels
Both front and rear wheels had considerable rust built up on the rims and spokes. First, the heavy rust was removed with steel wool.
During the front forks overhaul, the front wheel was propped up on the workbench and given a thorough cleaning.
After removing the brake rotor, each spoke and nipple was scrubbed with a scuff pad soaked in full-strength degreaser.
This was followed by rinsing with water, then back up on the workbench for a second cleaning, this time with a scuff pad soaked in half-strength degreaser, followed by rinsing with water.
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Norton Commando Articles:
Cylinder Head Removal
Cracked Cooling Fin Repair
Timing Cover Removal and Installation
Brake Caliper Overhaul
Remove Fork Tubes
Front Fork Disassembly
How To Polish Motorcycle Forks
Front Fork Assembly
Norton Commando Upgrades
