Boxerworks.com

Hey Gang,

After using two bikes to make one... I am left with lots of spare parts.
I have a frame and matching engine with 43k on the odometer but the previous owner somehow broke the rod inside the case.
The crank spins freely.
I tore the engine apart (though I need the proper bit to remove the rods from the crank).
I've found a few shards of metal in the case.
I want to clean and rebuild it myself as learning experiment. I've never rebuilt an engine before... by myself.
I do not want to go removing the crank or camshaft. I'd rather not replace the sprockets if I can avoid it.

I would like to rebuild the engine from it's current state without spending a TON of money on it.
I'm not in a rush.
I have a set of rods, and pistons/cyl from another R75/5
I'll need new (rebuilt) heads.


Any rebuild advice would be appreciated.
For example, How do I assess the timing chain? Should i replace it anyway?
what seals and bearings should I replace?
The rear main seal looks good but I should probably replace it anyway.

I guess I am looking for a to-do list to get me started.
Maybe a shopping list too!


Thanks in advance...
and here are some photos of my nasty engine.

First things first, I'd want to see what the crankshaft bearing surface of that broken rod looks like... Also, if you removed the flywheel, and since your crank is not blocked, it would require complete tear down.

Thanks.
What is the torx bit necessary to remove the rod? Once i have that bit, i will inspect the crank further.

And Yep, flywheel is removed. At the time, i didn't care about the engine and never blocked the crank.

Hopefully this isn't a giant boat anchor... I'm hoping to have some fun with rebuilding it.