Norton N15CS Hybrid restoration

grandpaul · Sep 29, 2009

Tank, seat & meters removed-

Sidecover, fenders and lights removed-

Pipes, handlebars, carb & controls removed-

Cookie · Sep 29, 2009

I'm glad to see that one getting some attention. They are kind of like your first girl friend to me.

grandpaul · Sep 29, 2009

After an update e-mail from Klink, it looks like shouldered aluminum rims & different mufflers are going to be the order of the day. It has been so long since we discussed details, that this stuff slipped past. It'll all be crystal clear before anything gets reworked in any way.

Cookie · Sep 29, 2009

Looks wise that red one is quite similar to my CSR. different tank, handlebars, and reversed shifter come to mind, it also looks taller. I know they used a few different fork internals and my bike would have just had the standard Norton Roadholders.
I'm occasionally tempted to build another but my featherbed is much the same with better handling.

grandpaul · Sep 29, 2009

I have a G15 frame that is raked, and want to return it to original steering angle for a Commando front end; I wonder how that will handle?

Cookie · Sep 29, 2009

Peter Williams once said that the most evil handling bike he had ever ridden was a factory G15CSR. Seems like he said he was battling constant tank slappers on the Isle of Man.
I'm sure I never rode mine at his level but she never did slap for me. Kind of chattered on the front if I recall and you knew to back off.
It seems you can't do much worse than the factory did on Peter's bike but if I were you I'd use the specs from a featherbed. I think the Commando may have had to be adjusted to compensate for the rubber mounting, for all I know perhaps the head angle is the same.
I don't know if you have ever ridden a featherbed but they sure work well. I've never ridden anything that gave me more confidence in a corner, the first time you drift both wheels feeling in perfect control it will make a believer of you.

grandpaul · Sep 29, 2009

Top yoke, headlight ears, cables & oil tank removed-

Rear wheel, footpegs & shocks removed-

Over-stressed primary adjuster resulted in bent mount plate-

Front wheel removed-

grandpaul · Sep 29, 2009

Forks removed-

Engine liberated from chassis-

Swingarm removed surprisingly easy-

Phase 1 of disassembly complete.

grandpaul · Sep 29, 2009

Lonely lump in a vice-

Primary was full of very black goo, lots of sludge, and some water (chain was loose, too)-

Primary drive removed-

Primary inner case removed, that's enough for one day...

Although I did employ my Posi-Lock puller for the crankshaft sprocket, and it did need some serious muffin, the clutch & alternator slid right off with no fuss. All in all a smooth disassembly so far with the swingarm pivot pin pushing out with an absolute minimum of persuasion.

Cookie · Sep 29, 2009

When you finally get going you really rip.

grandpaul · Sep 29, 2009

I have a helper one day a week, today was it!

In between directing the action and taking photos, I was working out the project framework, timeline, parts list with numbers, and setting up the master spreadsheet file. It helped that my phone wasn't ringing (much)...

Coincidentally, I got calls from TWO forum members with Norton-related questions.

dave M · Sep 30, 2009

Paul, It looks to me like the primary chain adjuster can only push the gearbox forward and prevent it from being pulled backwards, any rearward movement seems like it will have to be done with this adjuster loosened off and the final drive chain used to tension the primary chain and then the G/box studs tightened and the final drive readjusted, is this correct? If so it seems less than ideal and I am inclined to fit an additional adjuster on the right side mounting plate.

grandpaul · Sep 30, 2009

Dave, you are correct. I'm not sure that klink will want to do too many mods, but that would be a recommended one.

dave M · Sep 30, 2009

Paul, Thanks for the confirmation, I managed to source the right gearbox and plates and adjuster for my own project but this adjuster system seemed counter intuitive. I'm still collecting parts as they emerge on e-bay and elsewhere. I am watching this build with considerable interest.

grandpaul · Sep 30, 2009

I'm really stretching out my one mug of coffee these days...

Timing side ready to start in-

Tranny removed-

Thickened tranny mount plate on the timing side-

Primary chain adjuster is wierd, works counter-productive. You have to loosen everything off and use the rear axle adjustment to take up the slack! I think we ought to investigate modifying the existing adjuster to Commando type, and installing a second Commando adjuster on the right for better stability. Anyway, tranny mount plates removed-

grandpaul · Sep 30, 2009

Some hamfist previously working on this bike tore the oil pressure relief screen-

Timing cover off-

Timing cavity sludge buildup; at least the oil was in decent shape-

Mag chain was a bit knackered-

grandpaul · Sep 30, 2009

Oil pump seal was torn up pretty badly (sorry for the dark photo)-

Magneto removed with auto advancer unit-

Timing gear all removed (except crank pinion)-

Managed to get the crank pinion to budge about 1/4", then this-

grandpaul · Sep 30, 2009

Exhaust rockers & valve gear looks fairly clean-

Intake end looks even cleaner-

Couldn't find my 1/4" Whitworth spanner anywhere, had to grind down a 14mm Craftsman box-end to get the 3 underside head bolts undone! It must be "ruin some tools" day...

Head gasket is a conglomeration of several very thin copper sheets, some torn-

Pushrods showed some scuffing; so far it looks like someone has been inside this here engine...

grandpaul · Sep 30, 2009

Head removed-

Piston tops look typically "coked"-

.050 oversize?

The pistons are pretty sloppy in the bores, and the blemishing on the cylinders together seem to indicate .060 over pistons & rings are in order, along with a refinish hone to size.

Combustion chambers are decidely sooty, I blame the Mikuni carb!

grandpaul · Sep 30, 2009

Jugs off-

Lift your skirts!

Rear ends-

Faces-

Actually, not bad at all.

Cam lobes look good, no flat spotting at all-