Norton Commando Build
A lot of the Commando's allure is it's performance. Everything about the bike was engineered for the sole purpose of going fast.
And no-one can deny it's a fine looking machine.
Unlike most 70's bikes, very few saw major customization. Other than performance upgrades, most have been left original. How many Norton choppers have you ever seen?
Another part of it's appeal is the company's historic racing history.
During the 1930's alone, Norton accrued dozens of Isle Of Man TT wins. And many more successes followed.
In the late 1960's and early 1970's, a Norton race bike wasn't that far removed from a road bike.
Many will argue that Commandos were responsible for the term "Super Bike".
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Norton Commando Restoration
Purchased in 2024, this 1974 Roadster sat non-running and partially disassembled for 20 years.
Upon disassembly, every component was cleaned and inspected. Not only engine components, but drivetrain, front and rear brakes, and front and rear suspension as well.
This is a long-term rebuild project. There is no time schedule.
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Engine Disassembly
Cylinder Head Removal
Timing Cover Removal and Installation
Clutch Removal
Primary Chain Removal
Engine Removal
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Engine Teardown
Pinion Gear Removal
One of camshaft lobes was completely worn off! This may have been caused by lack of lubrication, lack of proper clearance, or poor quality control at the factory. Or a combination of the three.
The replacement cam looks slightly different than the original one, but will function just the same.
Engine Assembly
Sludge Trap Cleaning and Crankshaft Reassembly
Bottom End Assembly
Timing Chain Installation
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Gearbox
Remove Commando Gearbox
Gearbox gone over. New layshaft bearing, new seals and gaskets installed.
And of course, the cover was polished!
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Frame and Suspension
Both fork tubes were badly pitted and in need of replacement. Reassembly included new upper and lower neck bearings.
Remove Front End
Front Fork Disassembly
Front Forks Overhaul/Replace Seals
Swing Arm Removal
Swing Arm Overhaul
Later-style Mk3 style Isolatics were installed front and rear.
New rear Isolastics were pulled through the cross-tube with a a piece of 1-1/2" metal pipe, and a long threaded rod with nuts and washers on either end.
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Brakes
When purchased, the front brake was inoperable, and since the bike sat for so long, there was concern that the pistons were stuck inside the caliper and wouldn't come out. A combination of patience and luck resulted in success!
Before and After Brake Caliper Overhaul
Brake Caliper Overhaul
Rear brake drum overhaul consisted of removal, disassembly, cleaning and inspection, sanding the brake plate to bare metal, priming, painting, and reassembly.
Left-side 'dummy' axle removed.
Brake plate stripped and ready for primer/paint.
Note: The upper and lower inspection holes on brake plate are unique to 1974 Commando Mk2 models.
Before reinstalling, Z-plates were wet-sanded, buffed, and polished. The battery tray was sanded and painted gloss black.
I could have bought brand new fenders for about $200 each and been done with it. But by taking the time and effort to renew the originals, I saved $400 on the overall restoration budget.
Renew Stainless Steel Motorcycle Fender
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Notes and Misc
Restoring a Commando has a nice advantage over most other classic motorcycles. Not only are parts still available, they are available as factory pieces, due in large part to the existence of Andover Norton.
But, do not assume just because parts are available that they're also easy to get.
U.K. to U.S. Shipping Cost
The package in the picture below weighs three pounds and contains $150 worth of motorcycle parts.
The cost to ship it to central North Carolina was an additional $190.
On all previous packages from Andover Norton, shipping was under $50. So it wasn't always so expensive, but policies keep changing, and now it's difficult to know for sure what fees you'll be paying until the package is already on the way.
There are several Norton parts suppliers here in the US, but sadly, none that I would recommend.
Getting motorcycle parts from another continent will likely continue to be expensive and time consuming. So patience here is not only a virtue, it's a necessity!
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I have learned from experience that restoring a Norton Commando properly isn't cheap or easy. But by doing most of the work yourself, you can (hopefully) stay even with the completed bike's value.
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What Are Whitworth Tools?
How To Polish Motorcycle Forks
Norton Commando Upgrades
