Norton Commando Build
After sitting non-running and partially disassembled for 20+ years, this 1974 Roadster is getting a complete overhaul front to back.
Even after decades of neglect, this motorcycle still stands tall and proud.
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 (most of them are), it's still half-a-century old and sat unused for a long time. So, engine teardown and inspection is in order.
Upon exhaust pipe removal, I found the left-side internal exhaust thread in the cylinder head was stripped. This is not uncommon, as the screw-in exhaust nuts often vibrate loose and damage the port threads.
Read: Cylinder Head Removal
Read: Clutch Removal
Read: Primary Chain Removal
Read: Timing Cover Removal and Installation
Read: Engine Removal
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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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Brake Caliper Overhaul
Fifty-year-old brake calipers do not come apart without a struggle. Since the bike had sat for so long, there was concern about the caliper pistons being stuck and corroded.
Before and After Caliper Overhaul
Read: Brake Caliper Overhaul
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Read: What Are Whitworth Tools?
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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
Clutch Removal
Primary Chain Removal
Timing Cover Removal and Installation
Engine Removal
Brake Caliper Overhaul
Remove Fork Tubes
Front Fork Disassembly
How To Polish Motorcycle Forks
Front Fork Assembly
Norton Commando Upgrades
