Just looked up my invoice for the TDR crank
rebuild.
I paid £187 for the crank rebuild. This included
new main bearings(x4) and bigend bearings.
I also had the conrods replaced at £12.77 each
(x2).
Both cylinders were rebored and new pistons and
rings fitted. Cost £23.50 for each rebore and £41.13 for each piston set.
I did all the strip down and rebuild work my self.
I needed new a new gasket set which includes 2
base gaskets (£6.34) and a head gasket (£10.47).
I also replaced every bearing and seal in the
engine/gearbox too and had the engine cases bead blasted and then I sprayed
them. Next purchase should be a set of complete stainless steel exhausts.
You may not need to go to these lengths though.
Total cost for all the parts was quite high as I
replaced a lot of things.
I reckon about £500 - £550.
No special tools are really required except for a
flywheel puller.
There are a few nuts that require a little
knowledge to remove without the needed tools but they weren't any real
trouble.
The drive sproket nut can be very tight and
difficult to remove. I got the local garage to get it off with the air
compressor.
The crank (right side) drive gear nut is also
tight and this can be removed while the engine is still in the frame as it's
easier to hold.
The clutch basket nut is the other hard one. This
was again removed with the air compressor as I didn't have a socket large
enough the fit it. It is also difficult to get into and you don't want to slip
and trash the brittle aluminium clutch basket.
Once the engine is removed then it's simply a case
of splitting it by removing the 17 bolts in order.
I highly suggest giving the entire engine a really
good cleaning with Gunk grease remover and then a good spray down with either
a hose or jet wash BEFORE you start.
If you do decide to split the engine then You'd be
a fool not to replace the 2 crank oil seals at the very least.
I paid £6.04 for the left one and £11.86 for the
right.
There are 2 small rubber O-rings that keep the
water channels sealed between the 2 engine halves, these should be replaced
too (£1.20).
Engine bearings and seals.
| Bearing
93306 205760 |
£20.34 |
| Oil Seal
93105 35426 |
£4.77 |
| O-Ring
93210 22298 |
£1.22 |
| Bearing
(x2) 93311 42045 |
£8.86 |
| Bearing
93306 20585 |
£18.94 |
| 1st Gear
bearing 93310 22057 |
£4.94 |
| Oil pump
seal 93102 10002 |
£1.18 |
| Water pump
seal 93103 10168 |
£11.71 |
| Kick start
oil seal 93102 20108 |
£4.91 |
| Gear shift
oil seal 93102 12321 |
£3.11 |
| Gear shift
bush 90383 12022 |
£1.30 |
| Crank seal
LH 93103 25108 |
£6.04 |
| Crank seal
RH 93103 35149 |
£11.86 |
| Head gasket
1KT 11181 |
£10.47 |
| Base
gasket(x2) 1KT 11351 |
£6.34 |
| Clutch
cover gasket 1KT 15461 01 |
£6.49 |
| Case water
O-ring(x2) 93210 15566 |
£1.20 |
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