650SS Rebuild

frankdamp · Dec 16, 2011

Good looking work, Sir. Brings back memories of my company hack, but I think it had flatter handlebars. I'll dig out a photo in a day or two. I have one on taken our driveway with my two young daughters sitting on it!

possm · Dec 26, 2011

After receiving some more painted parts back from my reluctant painter i have been making slow progresss, I purchased a new primary chain 78 links according to the copied factory manual but it was 2 links to long so it was shortend and rejoined as i had decided to go endless. while fitting the chain i discovered a hole in the inner primary cover which aligned with a hole in the left hand engine/gearbox plate damm back to the parts book and yes it is supposed to have a hex support in this area, during the year I had purchased an old lathe that i have been trying to learn how to use so from the small picture and guess work I made the mount, had it plated and then fitted.
Yesterday I started to fit the alternator that i had purchased from RGM,

realising i had no mounting stud studs i started searching for dimesions coming up with 1/4x20x26x1-9/16, after making these studs and fitting the stator I find the stator monting holes are 5/16 allowing in my view to much movement, so today I am going to try and make a stepped stud 1/4 at one end but with a 5/16 shaft.
Al

possm · Dec 29, 2011

stepped 5/16-1/4 studs made and fitted 8 thou airgap set and am happy with, now where is the rest of the paint?
Al

GRM 450 · Dec 29, 2011

Nice bike possum.
Why do they have inlet tract inserts ? (maybe an ignorant quention, sorry) Is that how they were made?
graeme

possm · Dec 30, 2011

Hi Grame
I was put onto these sleeves by a member of this forum Beng
http://www.facebook.com/photo.php?fbid= ... =1&theater
As the picture was the only thing we had to go by a litle guess work was used and I am happy with the result.
Al

possm · Dec 31, 2011

I HAVE THE REST OF THE PAINTWORK!
Yes i finally picked up the remainder of the paintwork and as usual it is supurb-

The tank has been finished in matalic silver, Thanks to Norton owners club info on line we were able to get BMW colour that is a close match to the Factory silver.
More to come shortly Al

possm · Jan 1, 2012

More progress,I have spent the day fitting the oil tank- making a spacer for the top mount gromett, fitting toll tray, breather line to oil tank and the starting on the main oil lines but then i realised that the hose clamps that i had purchased were not big enough so i may have to wait fo the auto shops to open after the New Year break.

All the best for the New Year
Al

possm · Jan 6, 2012

Still making slow progress fitted the oil lines and spent several days looking for suitable oil line clamps [New Years Break- shops closed] finally found some crimp ones tht i am happy with, went to fit the rocker feed pipe- Thought I had ordered a steel pipe but it turned out to be nylon and had to shorten it, went looking for my banjo bolts I had replated- strange won't screw into timing the cover "Dam" some person has helicoiled where the rocker ilne feeds from the timing cover with a whitworth helicoil so this mornings job has been making a whitworth banjo bolt, I am leaning as i go!. I have also started fitting the new wireing lome that i had made though i am nit happy with the plug for the light switch hopefully monday i can find a new one.
Al

Cheesy · Jan 6, 2012

I hope you have it strapped down well!!

A bit late now but blackwoods have a reasonably good selection of those crimp on hose clamps, although I guess they are pretty common anyway

mikegray660 · Jan 6, 2012

looking great !! can't wait to see final shot - vid of first start up??

possm · Jan 18, 2012

Found a new Lusas 88sa plug at British Spares when I called there last week, it turned out i was missing the oil tank bung so i had to modify a bolt to suit, Also I went to fit the outer primary and found the new retaining nut would not fit the primary spigot mount, 46 years of being "fkd" with by experts so i stripped the primary again and off to my engineer with the spigot to get the threads cleaned up- matched to the new nut, tonight i have reassembled the primary and fitted the outer cover so some progress has finally been made.
Al

Cheshire bloke · Jan 18, 2012

Fantastic progress so far possm, that is going to be one good looking bike!

.

This thread is why I love the site and I will be watching every stage of your speedy rebuild possm, keep posting the pics

.

possm · Feb 1, 2012

Making progress again, new throttle cables have been made and fitted along with a clutch cable evan though i brought a clutch cable from RGM I found i needed a 57" cable so a new one was made,the Brake cable also came from RGM though the inner was to short so more modifying. My biggest disapointment was the header pipes that came from the same supplier i found them to be very poor quality, poor bends, the right pipe kicked outwards and did not clear the kick start and the header bends are totaly different between left and right but as freight would be too expensive to send them back i am stuck with them.
Al

Matt Spencer · Feb 1, 2012

Crikey , look in the background . :shock: Looking Good .
The subtle application of brute force , if you can find something to screw & lock the clamp into , could well realign them adequately .

ntst8 · Feb 1, 2012

possm said:
Making progress again, new throttle cables have been made and fitted along with a clutch cable evan though i brought a clutch cable from RGM I found i needed a 57" cable so a new one was made,the Brake cable also came from RGM though the inner was to short so more modifying. My biggest disapointment was the header pipes that came from the same supplier i found them to be very poor quality, poor bends, the right pipe kicked outwards and did not clear the kick start and the header bends are totaly different between left and right but as freight would be too expensive to send them back i am stuck with them.
Al

I've had variable results from them as well, i use them as a last resort these days.
Perhaps i'm paranoid but i have wondered whether the stuff sent to the far end of the world is selected because it is too far to send it back.
Hope your trip back from Pahiatua went smoothly

cheers
Iain.

possm · Feb 1, 2012

Thanks Ian
Saw you arrive but didn't get a chance for a chat, Loaded to the gunnels plus Mrs and I the 850 didn't miss a beat, got away at 9 with John TL and Viv and Bary H, clear run down coffee in Wellington and 1-30pm ferry, all good.
Al

possm · Feb 11, 2012

Hi Guys,
I have been working away on the small things switches fuel lines etc, though i have had my share of problems- i brought a second hand seat [off an Atlas] off our local trademe site and before getting it reupholstered i decided to check the base to find it to be 2.5" short, compared to a freinds Atlas base so my panel beater is extending it along with the headlight shell as the rim did not fit correctly. The Fuel tank has been on and off a few times but to protect the new paint i will leave it off untill the last minute. the seat base etc is due back tomorrow so hopefully fireup next weekend.
Al

Matt Spencer · Feb 14, 2012

Just in case you were wondering where all those bits you had left over went .

possm · Feb 14, 2012

yep got a simular picture in my parts book, though I would love a parts book full of pictures.
Al

beng · Feb 16, 2012

Sounds like you bought an Electra 400 seat.

Two seats were sold on Atlas bikes in the early sixties to fit the two different sizes of tanks. One seat pan had it's mountings moved so it would sit further forward against the smaller "American" style fuel tank that was available the first two or three years of Atlas production. Besides the altered seat you also had to have a different rear fender with the Dzus fastner moved forwards to match.

Later on in the 1960's the Dominators were sold with a seat that had a hump on the back for a bum-stop.

The Electra seat looked just like an Atlas seat if you did not have anything for reference next to it, but it was smaller.

If I run across one in the garage somewhere I will let you know.

You did not happen to find a source for the little screws that hold the tank badges on have you? SAE fasteners can be fudged to fit okay, but nothing looks as good as the originals with their slightly rounded faces.....

Is that a ball-bearing style tach drive on the bike?

650SS Rebuild

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