Starting cafe racer restoration Commando 850 MK3 from Spain

L.A.B. said:
Not necessarily, you would have to replace the plungers as the pads are not available separately.

Also, you should have found a white nylon 'abutment' inside each plunger with the wide end to the spring.
andover-norton.co.uk

Motorcycle parts and spares for Norton motorbikes - Genuine Andover Norton Spare Parts - Andover Norton Motorcycles Parts - Original Andover Norton Parts

Motorcycle parts and spares for Andover Norton motorbikes: Andover Norton manufactures and supplies all Genuine Factory Spare Parts for Norton motorcycles built before 2002.
andover-norton.co.uk

Yes inside each plunger I see a white nylon pin but I cannot take it out. I will order two kits P/CHAIN TENSIONER PLUNGER (69.0622) ref. 06.5341
Click to expand...
andover-norton.co.uk

Andover Norton - P/CHAIN TENSIONER PLUNGER (69.0622) - 06.5341

P/CHAIN TENSIONER PLUNGER (69.0622)
andover-norton.co.uk
which includes plunger, spring and the nylon pin.
Is this the "abutment" you talk about?
Or do I also have to order this TENSIONER ABUTMENT ref. 06.5341D ???
andover-norton.co.uk

Motorcycle parts and spares for Norton motorbikes - Genuine Andover Norton Spare Parts - Andover Norton Motorcycles Parts - Original Andover Norton Parts

Motorcycle parts and spares for Andover Norton motorbikes: Andover Norton manufactures and supplies all Genuine Factory Spare Parts for Norton motorcycles built before 2002.
andover-norton.co.uk
 
I disassembled the starter motor, it is is very wasted. I cleaned it and my plan is to fit a four brush conversion kit, new shims, new STARTER MOTOR HEAD ASSEMBLY ref. 06.6312
www.rgmnorton.co.uk

STARTER MOTOR HEAD ASSEMBLY

066312 RGM NORTON STARTER MOTOR HEAD ASSEMBLY
www.rgmnorton.co.uk
New O ring.
But the bronze bearing located at the drive end cover is worn-out but I find very difficult to replace it. And I cannot find a new drive cover so I will have to install the old one.
 

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javifoto70 said:
Is this the "abutment" you talk about?
Click to expand...
Yes, that is what AN refers to as the "abutment" and what you should have found inside each plunger?
javifoto70 said:
But the bronze bearing located at the drive end cover is worn-out but I find very difficult to replace it. And I cannot find a new drive cover so I will have to install the old one.
Click to expand...

Do you mean difficult to find a replacement bearing (bush/bushing) as I believe it is possible to convert it to a ball or needle roller bearing but some machining of the armature and cap could be required.
 
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I can machine the original armature end cap to remove the worn bushing and then insert a new bronze one or a needle roller. Problem is that then the end cap will be open and dirt can eventually penetrate because it will be tough to me to made and solder an aluminium cap.
 
javifoto70 said:
I can machine the original armature end cap to remove the worn bushing and then insert a new bronze one or a needle roller. Problem is that then the end cap will be open and dirt can eventually penetrate because it will be tough to me to made and solder an aluminium cap.
Click to expand...
Ok, as you said "drive end" not the armature cap.

You could try cutting a thread in the bush and use a bolt, etc. to extract it or split the bush with a Dremel type cutter (edit link, below) or if the cap is heated enough then the bush could drop or be 'shocked' out. Surely you could machine the cap without having to bore right through it.
Edit
www.tool-shop.co.uk

Dremel 194 High Speed Cutter - Pack of 2

Extended line of high quality versatile cutters made of high speed steel.Can be used for shaping, hollowing, grooving, slotting, inletting and makingtapered holes in soft metals, plastics and woods.Shank size: 3.2mmWorking diameter: 3.2mmPack of 2.
www.tool-shop.co.uk www.tool-shop.co.uk
 
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With patient and a dremmel I have been able to remove the bushing. I will look for a new bronze one.
Regarding the drive end I will order a complete new assembly because although it is easy to extract the bushing it also has a special rubber seal and I do not see the spare at Andover neither at RGM.
 
javifoto70 said:
Regarding the drive end I will order a complete new assembly because although it is easy to extract the bushing it also has a special rubber seal and I do not see the spare at Andover neither at RGM.
Click to expand...

Both Andover Norton and RGM are out of stock.

The seal appears to be an ordinary garter spring oil seal, probably a standard (Imperial?) size and nothing special about it that I can see.
 
My problem is that your standard imperial is totally non-standard and difficult to find in my Spanish metric world. I am able to source any kind of metric component but I have no clue about where and what reference to look on imperial one. Could you give a clue or link about a place o places to find these kind of components?
 
javifoto70 said:
My problem is that your standard imperial is totally non-standard and difficult to find in my Spanish metric world. I am able to source any kind of metric component but I have no clue about where and what reference to look on imperial one. Could you give a clue or link about a place o places to find these kind of components?
Click to expand...

First I suggest you measure the shaft and housing diameters (and housing depth) and see if there's a close metric equivalent or one that would fit with a little machining of the housing. The seal only prevents primary case oil mist and splash from entering the starter motor so I doubt the actual armature shaft seal diameter is critical.

Once you know the size (assuming it is Imperial as it's a USA-manufactured Presolite starter motor) then obtaining a seal should not be too difficult, that is if the seal does actually need replacing.

Bearingboys

Online
www.bearingboys.co.uk www.bearingboys.co.uk
https://www.bearingsrus.co.uk/seali...Kd5LspPLnNY8AWFsjf3AAD6TWxcpBbSRoCGAUQAvD_BwE

Oil Seals - Imperial - WychBearings.co.uk

Wych Bearings - Buy Online. Bearing Supplier, Housed Bearings, Oil Seals, Adhesives, Lubricants, Roller Chains, Sprockets and Engineering Supplies. Service from your local Bearing Supplier, Nationwide.
www.wychbearings.co.uk www.wychbearings.co.uk
 
javifoto70 said:
My problem is that your standard imperial is totally non-standard and difficult to find in my Spanish metric world. I am able to source any kind of metric component but I have no clue about where and what reference to look on imperial one. Could you give a clue or link about a place o places to find these kind of components?
Click to expand...
With a magnifying glass, you can usually read the number off any seal and search the internet for that number. Also, I have no direct knowledge of that seal, but it could be metric even though in an imperial device and it's very unlikely to be a non-standard seal.
 
Ok doing a bit of research here while removing the cover I found the Dowel #19 at the bottom of the primary case. So it goes behind the alternator in to the Primary inner case and then peened ? Also is my alternator the wrong way around ? Nevermind most of the EStart is not there it was removed years ago
 

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