John Player Special restoration project

grandpaul · Jan 19, 2016

Installing the inner primary case; need to first do a test-fit with gasket and bolt up the 3 bolts at the crankcase, while checking the gap to the stand-off stud. This is fully nipped up, and there is a 1/16" gap. While doing this step, keep checking this gap! If it closes fully before the 3 bolts are tight, you COULD crack the case by tightening further.

This washer is a little thicker than 1/16

This washer is just right

Inner case now fully tightened with zero deflection and no possibility of cracking the case when I tighten the outer cover.

grandpaul · Jan 19, 2016

I don't care for the long alternator stand-offs, they leave too much of the rotor/stator interface unused.

That's over 1/4" gap on a part that is only 1-1/4" wide; that's basically 20% inefficient.

I sorted (3) 1/4" spacers and get almost full interface between the alternator components, for maximum effect.

Plenty of chain clearance to the stator.

grandpaul · Jan 19, 2016

Primary system done after having to add 2 thin shims behind the clutch basket to properly align the primary chain with the front edge of the primary case.

Finally looking like a motorcycle instead of a pile of parts...

grandpaul · Jan 19, 2016

Assembled the brake caliper, installed & bled it; both brakes are done.

Slides are 3-1/2 cutaway

Main jets are 220s

Needle jets are 106s

grandpaul · Jan 19, 2016

Carb parts swimming in 50/50 pine oil cleaner & hot water.

Quick rattle-can spray job on the left sidecover 'till the final decision is made as to what parts the painter will deal with.

I only had 40 minutes for the carbs to soak before I had to shut down for the evening. I'll heat up the mix tomorrow and give 'em another hour with each part getting hit with a toothbrush while they soak. 40 minutes made a difference, but not as much as Berrymean's Chem-Dip does (at 3x the price).

grandpaul · Jan 20, 2016

Carbs got 4 more hours of soaking, then a soft brass wire brushing.. Nice, but not as good as Berryman's Chem-Dip. Oh well, it was worth the attempt.

Spiffy carbs ready to bolt back on.

grandpaul · Jan 20, 2016

Valve lapping time!

First the coarse, then the fine.

Hand lapping tool works great. Using a drill on the stem end is not recommended.

grandpaul · Jan 20, 2016

Exhaust valve before cleaning.

Darned if the only shot I took of the exhaust valves after cleaning didn't turn out blurry.

This Intake valve needed replacement. Seat face was badly deteriorated. Thankfully, mating seat was in great shape.

Intake valve after cleaning

grandpaul · Jan 20, 2016

Closeup of intake valve lapped face also came out blurry so hard to clearly see the thin gray band of mating face.

Done with lapping valves. I'm going to polish up the combustion chambers tomorrow.

grandpaul · Jan 21, 2016

Engine mocked up in preparation to have the bike serial numbers inspected by the local Police Dept.

Took some 0000 steel wool and Simple Green degreaser to the pipes; not too bad! There are 2 or 3 scratches, mostly covered by the bodywork.

Pipes, tank and temporary seat in place.

grandpaul · Jan 21, 2016

Bodywork in place FINALLY. It's only mocked up, but it's looking pretty close to what it will look like when it's done. Now to book the P.D. inspection.

jimbo · Jan 21, 2016

lookin good, too bad I bought an Interceptor

grandpaul · Jan 21, 2016

Headlights installed but not wired. (front lower mount installed, but you can't see it)

Tail light temporarily installed with previously installed (incorrect) license plate back, (chrome bit)). Mufflers wil be aligned after final assembly.

Right side beauty shot, front fender not drilled or mounted yet.

grandpaul · Jan 21, 2016

I need the proper original layout of the indicator lights (red, blue & amber)

Cockpit looking almost complete. Clutch pull is a little heavy, I'm going to install a stuffer plate to bring the stack height up.

gortnipper · Jan 21, 2016

Saw this one here which shows red on top left, amber on bottom - http://www.classicsportbikesforsale.com/?s=john+player

jimbo · Jan 22, 2016

Looks like you might do alright

http://www.ebay.com/itm/Norton-COMMANDO ... 1508737913

grandpaul · Jan 22, 2016

http://www.ebay.com/itm/Norton-COMMANDO ... 1508737913

"VERY, VERY NICE JOHN PLAYER SPECIAL. THESE DO NOT COME UP VERY OFTEN." Nothing else is said about the bike

There are six PARTIAL photos of the bike, and several other (admittedly decent) bike photos in the auction listing.

No way to know ANY details about the bike from the listing.

I'll be quite pleased if it fetches THAT price!

mschmitz57 · Jan 22, 2016

The seller is just using ebay as an advertisement for his business and his bike collection. Pretty clever.
He assigns a crazy price and includes his personal phone number. He doesn't mention anything about the bike.

grandpaul · Jan 25, 2016

Zener diodes, "before & after"

Spiffy clean underside; centerstand installed.

Just a mock-up. I sure love timing side shots of Commandos and Bonnevilles.

grandpaul · Jan 25, 2016

One of these two tanks will be for sale; still haven't decided which one.

"Stable mates", sans bodywork. Waiting for rings for the JPN and title for the 880 Special...

(2) Replica OEM solo seats ordered for the JPN today. I made a deal to send them my fairing and they'll send me a brand new one after they model it and start making new ones. So, I will have a FULL JPN bodywork set for sale soon (fairing, mounts, windscreen, tank shroud, tank & seat), plus one spare rough fairing.