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Re: 1962 Navigator Rebuild

Submitted by anthony_wilson on Sat, 01/10/2016
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Light Twins

Hi folks, Im pretty sure I've got this in the right place, but apologies if not.

So, I just bought my first Norton, My first bike actually.

As the title says, it's a '62 Navigator, 1 owner before me, with just over 20000 on the clock. At best guess it's been ridden into a shed at some point and left.

Anyhoo, if all goes to plan, and I remember to post, I hope to keep you all updated on progress as time goes.

Needless to say, any tips or observations would be greatfully received.

This was the bike as bought.

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Submitted by anthony_wilson on Sat, 01/10/2016

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Just finished our first days work on the old girl, the engine is seized so our first aim was to remove the plugs and pour some rust treatment down the bores, one plug came out with no real issues, but the other had previously been snapped off.

We decided that as we are rebuilding it anyway, we'd strip the head down. So, the saddle came away,virtually without removing the bolt, unfortunately the seat will require major attention, found the chain under the saddle too, though i will probably renew it anyway.

With that, the tank was removed, it still had liquid in it! Not sure you could call it petrol though.... next to come off was the coils, I have to say I was surprised to find two (you'll have to forgive my ignorance).

We had a bit of fun taking the exhausts off, the pegs came away fine but the two bolts in both tailpipes were well and truly seized, one sheared and one rounded off so only two came away clean.

Nonetheless we prevailed and got the pipes off. Never seen push fit pipes before (I'm used to clamps on cars).

Once the exhausts were off, focus went to the head, didn't have any real issue getting that off, little sticky but a gentle tap with a bit of Wood soon solved that.

What I saw next made me grin though, no wear, I mean none.

There was a fair buildup of detritus on top of the piston but a bit ofa clean and the tops were shining. I haven't seen an engine that clean for a long time.

Last thing for the day, we filled the bores with some rust treatment in the hopes that it will eat though the rust and un-sieze the engine. The head will come to work with me on Monday where I'll get the spark plug remnants out and clean it up.

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Submitted by patrick_mullen on Sat, 01/10/2016

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Hi Anthony,

It's amazing to see such an original looking Navigator. As you say it looks like it was ridden into it's shed and left.

Twin Wipac coils is correct and original. Don't throw them away until you have at least tested them - Wipac coils seem to last forever. Those look like original pistons so it's probably still on standard bores. The silencers are the same as the Dominator and new ones are readily available. I hope you have the kick starter as these are hard to come by. Same goes for the tank badges - these are hard to come by as well.

Good luck with your rebuild.

Patrick

Submitted by ulrich_hoffmann on Sat, 01/10/2016

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Hi Anthony!

I am also working on a 1960 Navigator.

I already took it apart and I?ll get the frame parts back from powdercoating next week..

Make many photos during rebuild because mine was not as original as yours. E.G: I do not know how the brake pedal stop is mounted.

Will be following your rebuild!

Uli Hoffmann

Submitted by patrick_mullen on Sun, 02/10/2016

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The brake pedal stop on mine fits on the footrest bar just like Dan says. I don't think there is any other way of fitting.

Patrick

Submitted by anthony_wilson on Mon, 03/10/2016

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Hi folks, unfortunately not much progress since my last post, the engines apparently quite happy to remain seized , so it's resting in some diesel now. I have the head and carb at work, but haven't had a chance to start on them yet.

In reply to Mr mullen, unfortunately no I don't have a kickstart or tank badges ... typical, so should anyone know or hear of any supplies of the afore mentioned, it would be well appricciated.

Submitted by andrew_wibmer on Mon, 03/10/2016

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Previously anthony_wilson wrote:

Hi folks, unfortunately not much progress since my last post, the engines apparently quite happy to remain seized , so it's resting in some diesel now. I have the head and carb at work, but haven't had a chance to start on them yet.

In reply to Mr mullen, unfortunately no I don't have a kickstart or tank badges ... typical, so should anyone know or hear of any supplies of the afore mentioned, it would be well appreciated.

If it helps, the kickstart is a 5/8 36 spline I think, used on some BSA Bantams and Frances Barnets (Falcons in particular I think). I am looking for one also and have just about given up, however the gear lever has the same spline so seriously looking at getting a gear lever, cutting off the spline and welding it to any other kickstart that looks right. You will find the expression "difficult to find" comes up a lot with the Navigator, that is an understatement, throw nothing away..

Submitted by anthony_wilson on Wed, 19/10/2016

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Hi All, sorry for the distinct lack of updates, I've gotten fairly bogged down at work (you know how it is). We have managed to un-sieze the engine, but unfortunately the kickstart locks up before even starting to turn the engine. Other than that, not loads of change. One question for the better informed, with the bike I have received the original "62 logbook. An the bike is not currently registered, does anyone know the process for re-registering it?

 



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